Interim Report of the Committee on Changes in New Source Review Programs for Stationary Sources of Air Pollutants (2005) / Chapter Skim
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4 Emission Sources and Technology Options
4 Emission Sources and Technology Options
Pages 84-133
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From page 84... ...
4 Emission Sources and Technology Options INTRODUCTION The purpose of this chapter is to address the following key questions: · What source categories account for the greatest permitting activity pertaining to modifications under New Source Review (NSR)
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However, because technology changes over time, explicit consideration is given to the process of technology change and the implications for technology change in the future. Furthermore, we consider both pollution control and pollution prevention technologies.
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containing case-specific information on best available control technology (BACT) /lowest achievable emission rate (LAER)
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; and SIC type 49, electric, gas, and sanitary services (primarily electric utilities)
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88 for cafi 6 3 9 s) odi Review M onsit (tonsn 693, 3 66,3 25 -- 16 952, 87,8 24 -- 697, g Source issio at Em istin cation 1 6 0 9 6 New New Ex Lo 831, -- 281, 022, 027, 7 19,6 79 18 -- 891, 1977-1999 tedit rm Under Pe ieldf 7 During NSR Green -- -- 043, 5 5 -- 13 0 21 15 - ssionsi Em of yb erb its itted Num Perm SIC Modifications, 2 2 9 4 14 9 18 1 17 Perm and and cafi ons, odi CO M onsit 0 2 3 0 b6 6 b7 0 5 Permits Locati of g erbm at Existing itsmr istin cation b New Ex Lo 2 0 3 4 7 3 10 0 12 Nu at Pe tedam of erb ieldf Esti Facilities Num Green 0 0 3 0 1 0 1 1 0 of New pt s ci d uct exce tscu Summary pe gasd allet edrdnkid s an od alliedd s andsl odrp Facilities, Ty 4-1 ngniimlate ngniim an erb ica E SIC M aloC anl traction nm od ducto prdo anre ducto dnagnitn nghisibl Oi ex No minerals fuels Fo pr Lum wo Pap pr Pri pu Chem allied TABL Greenfield SIC 10 12 13 14 20 24 62 27 28
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From page 89... ...
89 3 032, 10,0 48,0 09,8 5388, 4 5 18 17 15 -- -- -- 10 0 50 0 0 202, 0 071, 65,4 78,9 56,3 0 5362, 1 4 19 16 51 55 17 NA 12 35 0 45 31 172, 89,1 0 -- 15 883, 34,7 3321, 3 88 -- -- -- 11 0 0 42 0 41 8 1 9 25 30 24 1 1 1 39 1 3 4 4 21 PM b 5 6 17 38 0 0 0 95 0 3 0 0 8 b 1 b 4 16 11 96 1 1 1 17 1 0 2 4 12 4 5 0 3 2 11 0 0 0 12 0 0 2 0 1 and dna, s dna, ices e -- d sd ytri pt tra goo ci mueolr products aycl, ducto ltaem gas serv le secu affairs exce edrdnkid s pr ab onali ary stries ur onali ngniim gasd allet an one Pet coal St assgl Prim duin itary nm Electric, san Wholesale ondn ucat tl.ind ngniimlate Ed services Nat an nsotla M aloC anl traction od ducto Oi ex No minerals fuels Fo pr 29 32 33 49 51 82 96 Tot 10 12 13 14 20
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From page 90... ...
90 cafi 1 7 2 9 7 s) odi M onsit (tonsn 101, 0 043, 0 403, 4 45 6 562, 431, g issio at Em istin cation 1 2 9 3 4 New Ex Lo 83 11 122, 0 001, 4 26 0 894, 491, tedit rm Pe ieldf 8 NSR Green 9 0 46 14 14 0 0 271, 2 35 of yb erb its Num Perm SIC 19 1 24 1 31 11 1 34 42 d)
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From page 91... ...
91 0 5 6 8 8 7 17 582, 74,3 0 18 17 764, 501, 60 0 022, 161, 12,0 10 9 1 6 6 8 0 0 659, 52,9 97,1 77 0 22 26 0 863, 131, 706, 0 51 397, 84,5 72,7 9 0 0 17 0 2 19 0 0 955, 9 0 75 0 12 2 3 1 2 19 1 1 39 3 2 9 4 14 9 20 x 8 NO 1 2 30 0 1 11 1 0 3 0 7b 6 8 b 8 0 0 67 1 0 16 2 2 3 4 9 3 12 7 0 0 95 0 0 10 0 0 3 0 1 0 1 talem noita dna, ices ytri pt doowd s gas secu ci exce ort ent serv onali affairs gasd allet edrdnkid s an s alliedd s ducto sp pm itary ucat onali tl.ind ngniimlate ngniim an erb Fabricated pr Tran equi Electric, san Ed services Nat an nsotla M aloC anl traction nm od ducto ducto anre ducto Oi ex No minerals fuels Fo pr Lum pr Pap pr 34 37 49 51 97 Tot 10 12 13 14 20 24 62
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From page 92... ...
92 cafi 6 9 2 s) odi M onsit (tonsn 0 771, 982, 97,4 0 20 842, 0 0 0 g issio at Em istin cation 1 1 1 0 New Ex Lo 0 843, 382, 24,8 33 27 035, 18 081, 0 tedit Prem ieldf 8 6 NSR Green 90 18 0 0 389, 6 3 40 0 2 35 of yb erb its Num Perm SIC 1 26 13 1 31 26 1 3 1 d)
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From page 93... ...
93 82,2 0 21,5 1 4 26 0 0 65 74 0 222, 0 0 495, 43,6 20 12 0 69,4 4 3405, 4 8 28 43 88 0 11 37 0 291, 0 27,2 64 26 0 973, 0 08,2 6887, 2 91 0 0 0 10 0 0 232, 0 80 0 0 5 9 7 29 1 1 1 43 1 2 6 2 16 1 18 1 2 7 SO 46 0 0 1 10 0 2 0 0 6 1 9 0 b 3 97 1 1 0 19 1 0 3 2 8 0 9 0 5 7 12 0 0 0 13 0 0 3 0 2 0 0 1 dna, ices e -- d sd ytri pt tra goo gas serv le doowd secu ci exce ab onali affairs ur gasd allet edrdnkid s an s alliedd s itary ucat onali ngniim an anl traction nm od ducto erb ducto anre dnagnitn Electric, san Wholesale ondn tl.ind Ed services Nat an ) sno(tla ngniimlate M aloC ducto nghisibl Oi ex No minerals fuels Fo pr Lum pr Pap pr Pri pu 49 51 82 97 Tot 10 12 13 14 20 24 62 27
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94 cafi 8 4 s) odi M onsit 60,2 (tonsn 22 362, 09,2 20 221, 14,5 2 02,1 0 24 0 12 0 91 g issio at Em istin cation 99,2 4 0 2 8 New Ex Lo 12 92 108, 583, 40 014, 7 80,0 78 37 0 62 tedit rm Pe ieldf 5 NSR Green 0 0 153, 1 61,1 97,3 79 0 29 0 0 0 35 of yb erb its 3 8 Num Perm SIC 15 6 27 16 1 12 1 1 1 23 d)
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95 0 1 2 0 7 9 0 161, 37 0 194, 053, 0 646, 0 572, 24 391, 4 1 4 2 8 3 9 351, 0 95 513, 707, 222, 1 97 154, 7 51 021, 1 16 222, 6 0 0 211, 7 0 0 0 0 63 88 12 0 0 2 2 4 3 16 26 2 28 7 21 5 11 VOC b 0 2 2 0 7 13 0 10 0 10 2 4 2 0 1 3 8 13 2 17 6 10 3 7 0 0 1 0 1 0 0 1 1 1 0 0 pt ngniimlate ngniim ci and ucts gasd allet exce edrdnkid s d uct tscu sc.imd s an dna od alliedd s andsl an an anl erb odrp esr ica odrp products M aloC traction nm od ducto prdo reutin anre ducto dnagnitn nghisibl mueolr Oi ex No minerals fuels Fo pr Lum wo Fur fixtu Pap pr Pri pu Chem allied Pet coal erbbuR asticlp 10 12 13 14 20 24 25 62 27 28 29 30
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96 cafi 2 3 2 6 s) odi M onsit (tonsn 071, 222, 2 14 0 381, 0 0 021, 0 g issio at Em istin cation 5 4 7 5 6 New Ex Lo 76 16 44 30 744, 1 46 20 954, 41 tedit rm Pe ieldf 8 0 68,8 NSR Green 76 0 0 0 60 0 0 10 0 of yb erb its 5 Num Perm SIC 18 26 2 1 13 1 1 18 1 cafi ued)
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97 52,9 0 24 0 701, 41,9 36 70,2 0 14 usly.oi .s evrp unit w ne isted and 6 1 37 exdah 7 facilityon odificationsm 0 10 and both iltub had its is 0 ty 1 17 facili wena permemos . 04 20 st gu Au 0 99 because where ytri total sitea ta,adde to secu affairs to mus lishb onali tl.ind not npuu refers do Nat an nsotla ieldf ersb EPA, ce:r 87 Tot Green Num a b Sou
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From page 98... ...
The key inferences from the available data suggest that the following industries have significant NSR permitting activity for modifications, whether measured in terms of the number of permits or the permitted emissions: electric utilities; stone, clay, and glass products; paper and allied products; chemicals and allied products; and food and kindred products. The reported tons of permitted emissions for modifications composed 25-48% of the reported total of permitted emissions for all NSR permits, including greenfield, new facilities at existing locations, and modifications, depending on the pollutant.
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From page 99... ...
For example, in Louisiana, the largest share of all permits was issued for chemical manufacturing, power generation, refining, paper and allied products, and inorganic chemical industries. The industrial mix in Louisiana is somewhat unique because of the large industrial presence in areas such as those around the lower Mississippi River and Lake Charles and others.
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From page 100... ...
PROCESS TECHNOLOGIES OF EMISSION SOURCES: PROCESS DESCRIPTION, REPAIRS AND REPLACEMENT, AND POLLUTION PREVENTION AND CONTROL APPROACHES The purpose of this section is to describe the major components of emission sources that are most relevant to NSR permitting decisions pertaining to repair and replacement. An understanding of the typical facilities in several key industries is needed to assess the impact of changes of NSR on emissions and energy use from these sectors.
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. Most utility NOx emissions are from coal-fired plants, including bituminous and subbituminous coals, and naturalgas-fired plants.
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The choice of furnace design can influence baseline emission rates. For example, tangentially fired furnaces promote the formation of a rotating fireball inside the furnace, leading to different NOx emissions than a wall-fired boiler.
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If a power plant is equipped with a flue gas desulfurization (FGD) system, also commonly referred to as a "scrubber," the FGD system is typically located downstream of the fly ash collection device.
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. The compressor increases the pressure of ambient air for delivery into the combustor, where pressurized gaseous fuel (typically natural gas)
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Repair and Replacement Considerations at Electric Power Plants This section reviews the typical repair and replacement considerations for electric power plants, with a primary focus on coal-based power plants and secondary consideration of natural-gas-fired combined cycle systems. The types of activities reviewed here are with respect to typical industry practice but are not evaluated here with respect to implications for NSR.
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· Repairs · Care of idle equipment. Specific areas of a typical coal-fired power plant that require repair and replacement can include the following (ERCC 2002)
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Many of the common repair and replacement requirements at coalfired power plants are attributable to exposure of key components to the erosive effects of ash or other solids during fuel handling or in the flue gas stream; the corrosive effects of acid gases in the flue gas stream; or impurities, such as in steam. Wear and tear on turbine blades, heat transfer surfaces, and other components can lead to a loss of system efficiency, reliability, capacity, or some combination of the three.
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From page 108... ...
Typical Air Pollution Prevention and Control Approaches for Electric Power Plants Air pollution prevention and control options for coal-fired power plants typically focus on emissions of PM, NOx, and SO2. For natural-gas-fired gas turbine-based systems, NOx emissions are usually of primary concern, whereas emissions of other pollutants, such as CO and VOCs, are of secondary concern.
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From page 109... ...
, no boilers of the wet-bottom wall-fired, cell, or cyclone designs have been built since promulgation of applicable NSPS. Table 4-2 is useful in providing a baseline for uncontrolled emission rates that can be used to assess the overall effectiveness of pollution prevention and pollution control strategies that reduce emissions.
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From page 110... ...
Source: EPA 1994e. TABLE 4-3 Example of Cost-Effectiveness Estimates for Utility Boiler NOx Control for a Generic Tangentially Fired Furnace: Comparison of Cost Effectiveness for Different Sizes and Capacity Factors Cost Effectiveness, $/ton Emission Rate, 100 MW Boiler at 600 MW Boiler at Control lb of NO2/106 30% Capacity 75% Capacity Optiona Btu Factor Factor Uncontrolled 0.70 -- -LNC1 0.40 4,600 260 LNC2 0.37 3,100 240 LNC3 0.33 3,700 280 SCR 0.14 16,800 780 LNC1+SNCR 0.24 9,500 620 LNC2+SNCR 0.22 8,400 590 LNC3+SNCR 0.20 8,700 610 LNC1+SCR 0.12 17,200 810 LNC2+SCR 0.11 16,300 790 LNC3+SCR 0.10 16,560 820 a LNC1, LNC2, and LNC3 are various types of low-NOx burner designs.
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only to combinations of LNB, overfire air, and postcombustion methods of either SCR or SNCR. Typical capital costs for selected pollution control equipment for coal-fired power plants are reported by EPA (2002e)
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. Costing algorithms for the capital, annual, and levelized costs of a variety of pollution control systems are available in EPA's Air Pollution Control Cost Manual (EPA 2002e)
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Ozone is not directly produced by fossil fuel combustion, although NOx emissions and fugitive hydrocarbon emissions from fuel storage and supply components, among other sources, contribute to ozone formation (see Chapter
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, utilizing combustion best practices (e.g., lean combustion, air staging, flue gas recirculation, steam injection) , low-NOx burners.
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Petroleum refineries have a substantial impact on environmental quality of all sorts, not just air quality. For example, of all industries operating in California, petroleum refining is the largest source of hazardous wastes (CalEPA 2004)
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116 CHANGES IN NEW SOURCE REVIEW PROGRAMS TABLE 4-4 Natural Emissions Inventory (Tons/Year) for Typical Petroleum-Refining Processes Process (no.
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The national emissions inventory for petroleum refineries presented in Table 4-4 notably aggregates a number of the smaller-volume refining processes under several "miscellaneous" categories. Also notable in Table 4-4 is the predominance of combustion sources (internal and external)
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118 CHANGES IN NEW SOURCE REVIEW PROGRAMS bustion sources are associated with the operation of one of the refining processes listed. To understand the air emissions attributed to each process, a basic understanding of each process is necessary: Distillation Distillation is the process of coarsely separating the components of the petroleum feed by boiling-temperature differences.
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From page 119... ...
EMISSION SOURCES AND TECHNOLOGY OPTIONS 119 Catalytic Cracking The catalytic cracking process involves breaking down larger hydrocarbon molecules and re-forming the fragments into smaller hydrocarbon molecules. It occurs at high temperatures and involves vaporizing the hydrocarbon feed and introducing a granulated or powdered catalyst.
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From page 120... ...
, fuel scrubbers, flares, incineration, fuel-sulfur content limits, and leak detection and prevention. · NOx: Source, internal and external combustion, sulfurrecovery unit; abatement, SCR, SNCR, utilizing combustion best practices (e.g., lean combustion, air staging, flue gas recirculation, steam injection)
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From page 121... ...
exempts changes from triggering NSR activities that are considered "routine maintenance and repair." Thus, any assessment of the impacts of procedural changes to the NSR program must consider the type of repair and replacement activities typical of petroleum refineries. Table D-2 in Appendix D presents the aggregated responses to a National Petrochemical and Refiners Association member survey initiated in response to an information request from the committee.
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From page 122... ...
122 CHANGES IN NEW SOURCE REVIEW PROGRAMS White liquor (Na2S and Digester NaOH) Evaporators Wood chips Black liquor & pulp Concentrated black liquor Blow Tanks Condensate Chemical Recovery Boilers Na(SO4)
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EMISSION SOURCES AND TECHNOLOGY OPTIONS 123 chips to a soluble phase containing the lignin and an insoluble phase (the brown pulp) that is further processed into paper.
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. Table 4-5 provides data on the types of compounds emanating from the major sections of a typical kraft mill as well as the typical air pollution control devices that are used to reduce emissions (Someshwar 2003; NCASI in press; Witkowski and Wyles 2004; Springer 2000; Davis 2000)
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From page 125... ...
Technological advances can lead to lower costs of installing pollution control devices, lower costs of operating those devices, improved emission reduction performance, or some combination of those improvements. Understanding the relationship between regulation and technological change is important to accurately assess the costs and, in some cases, the benefits of environmental regulations into the future, including the changes to NSR rules being considered in this report.
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From page 126... ...
included agreements to install FGD scrubbers at one or more coal-fired units. FGD units were also an important part of utility compliance strategies with the SO2 cap-and-trade provisions of Title IV of the 1990 Clean Air Act Amendments.
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From page 127... ...
(2003) found that patents relevant to SO2 control technology grew dramatically in the early 1970s and have remained high through the mid-1990s relative to earlier time periods.
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. Selective Catalytic Reduction SCR technology is of interest because it is a very effective means of reducing NOx emissions at utility boilers that has the potential to reduce emissions by between 70% and 90%.
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From page 129... ...
German coal-fired boilers adopted SCR in the late 1980s and early 1990s in combination with environmental regulations. During the 1980s, improvements in catalyst formulation, as well as injection grids and control systems, enabled achievement of the 80-90% removal efficiencies with less ammonia slip for a wider variety of flue gas compositions.
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From page 130... ...
The dearth of literature on NSR and technological change makes it difficult to offer much in the way of informed judgment about how the recent NSR rule changes are likely to affect innovation, let alone any direct evidence on the issue. To the extent that the regulation reduces applicability of NSPS, BACT, and LAER to existing sources, it could reduce demand for pollution control retrofits and thereby reduce innovation by technology developers.
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From page 131... ...
Those favoring the NSR rule changes have asserted that concerns over triggering NSR reduced investments at existing plants and, at the same time, reduced markets for new technologies (see Box 4-1)
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Gasification can be the cornerstone of a "polygeneration" system or "coal refinery" that creates a mix of multiple products. For power-generation applications, NOx emissions can be prevented or minimized via saturation of the syngas with moisture and/or injection of nitrogen from the air-separation plant.
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· Emission sources, pollution prevention techniques, and pollution control technology are expected to change over time, and regulations such as the ones considered here can be part of the motivating factors for such change. However, the effects of regulations can vary greatly, depending on the specifics of the programs.
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