REPORT ON REVISIONS TO 5TH EDITION AP-42 Section 1.3 Fuel Oil Combustion Prepared for: Contract No. EPA 68-D7-0068, WA-005 EPA Work Assignment Officer: Roy Huntley Office of Air Quality Planning and Standards Office of Air And Radiation U. S. Environmental Protection Agency Research Triangle Park, North Carolina 27711 Prepared by: Eastern Research Group Post Office Box 2010 Morrisville, North Carolina 27560 September 1998 7997\92\04\Suplemnt.B\Reports\Chptr01\01-03.002 (6-26-3) Table of Contents Page 1.0 INTRODUCTION ..................................................... 1-1 2.0 REVISIONS.......................................................... 2-1 2.1 General Text Changes............................................ 2-1 2.2 Sulfur Oxides, SOx ............................................... 2-1 2.3 Sulfur Trioxide, SO3 ............................................. 2-1 2.4 Nitrogen Oxides, Nox ............................................. 2-1 2.4.1 Mid-Sized Fuel Oil Fired Boilers ............................. 2-2 2.4.2 Utility Boilers ............................................ 2-4 2.5 Carbon Monoxide, CO ............................................ 2-6 2.6 Filterable Particulate Matter, PM ................................... 2-6 2.7 Condensable Particulate Matter, CPM ................................ 2-8 2.7.1 Description of Documents Evaluated .......................... 2-8 2.7.2 Emission Factor Development ................................ 2-9 2.8 Total Organic Compounds (TOC) and Non-Methane TOC (NMTOC) ..... 2-12 2.9 Particle Size Distribution......................................... 2-12 2.10 Polycyclic Organic Matter (POM) and Formaldehyde (HCOH) ........... 2-12 2.11 Trace Elements ................................................. 2-12 2.12 Greenhouse Gases .............................................. 2-14 2.12.1 Carbon Dioxide, CO2 ...................................... 2-14 2.12.2 Methane ................................................ 2-16 2.12.3 Nitrous Oxide, N2O ....................................... 2-16 2.13 Speciated Organic Compounds .................................... 2-18 3.0 REFERENCES ....................................................... 3-1 4.0 REVISED SECTION 1.3................................................ 4-1 5.0 EMISSION FACTOR DOCUMENTATION, APRIL 1993 ..................... 5-1 APPENDIX A SUPPORTING DOCUMENTATION.................................. A Supporting Data for Supplements E .................................... B.1 Data Used for Average Emission Factors Development in Supplements A and B .......................................................... B.2 Source Test Report Summary Data for Supplements A and B ................ 7997\92\04\Suplemnt.B\Reports\Chptr01\01-03.002 (6-26-3) iii 1.0 INTRODUCTION This report supplements the Emission Factor (EMF) Documentation for AP-42 Section 1.3, Fuel Oil Combustion, dated April, 1993. The EMF provides technical documentation for updates to Section 1.3 that have been made through the 4th Edition of AP-42. This report provides documentation for the most recent updates to the 5th edition of AP-42 contained in Supplements A (February, 1996), B (October, 1996), and E (September, 1998). The 5th edition of AP-42 and its supplements have greatly expanded information concerning toxics, revised emission factors for nitrogen oxides (NOx), and added information and emission factors for condensable particulate matter. For Supplements A, B, and E to the 5th Edition, Section 1.3 of AP-42 was reviewed by internal peer reviewers to identify technical inadequacies and areas where state-of-the-art technological advances need to be incorporated. Based on these review, tables and text have been updated or modified to address any technical inadequacies or provide clarification. For Supplements A and B to the 5th Edition, emission factors in AP-42 were checked for accuracy with information in the EMF Document and recent test data. New emission factors were generated if recent test data the available test data indicated that new factors were needed. If discrepancies were found when checking the factors, the appropriate reference materials were then checked. For Supplement E to the 5th Edition, emission factors for condensable particulate matter were included. Changes were made to the text and in table headings as applicable to identify data as either filterable or condensable particulate matter. Emission factors for nitrogen oxides (NOx) were updated. To accommodate the NOx update, new categories are used to describe boilers. Boiler categories were originally based on the ownership of the unit: utility, industrial and commercial/ institutional. Evaluation of boiler data indicated that emissions from boilers are most affected by design. Boilers with capacities less than 100 million Btu per hour are “shop 7997\92\04\Suplemnt.B\Reports\Chptr01\01-03.002 (6-26-3) 1-1 fabricated” or “packaged” and exhibit different NOx emissions than boilers with capacities greater than 100 million Btu per hour which are generally “field erected” boilers. Based on a 1996 EPA report, text and emission factors were added pertaining to Number 6 oil/water emulsion mix. Emission factors for trace metals in distillate oil were updated using more current data. Four sections follow this introduction. Section 2 of this report documents revisions made in Supplements A, B, and E to the 5th edition of Section 1.3 of AP-42 and the basis for the changes. Section 3 presents the references for the changes documented in this report. Sections 4 and 5 present the web page addresses of the revised AP-42 Section 1.3 and the EMF documentation dated April, 1993, respectively. 7997\92\04\Suplemnt.B\Reports\Chptr01\01-03.002 (6-26-3) 1-2 2.0 REVISIONS 2.1 General Text Changes Supplements A and B Information in the EMF Document was used to enhance text concerning fuel oil firing practices. Also, at the request of EPA, the metric units were removed. Supplement E Text was updated to describe condensate particulate matter. Additional text changes were minimal and served to identify specific changes in emission factors. 2.2 Sulfur Oxides, SOx Supplements A and B The uncontrolled SOx factors were checked against information in Table 4-3 of the EMF Document and the 10/86 version of Section 1.3 and no changes were required. 2.3 Sulfur Trioxide, SO3 Supplements A and B The SO3 factors were checked against information in Table 4-4 of the EMF Document and the 10/86 version of Section 1.3 and no changes were required. 2.4 Nitrogen Oxides, NOx Supplements A and B The uncontrolled NOx factors were checked against information in Table 4-6 of the EMF Document and the 10/86 version of Section 1.3 and no changes were required. 7997\92\04\Suplemnt.B\Reports\Chptr01\01-03.002 (6-26-3) 2-1 2.4.1 Mid-Sized Fuel Oil Fired Boilers Supplement E Based on new NOx data collected, revised emission factors are presented for oil fired boilers (>100 MMBtu/hr) equipped with Low NOx burners and flue gas recirculation. All of the data used in this analysis originated from four sources; 1) a search of the STIRS and STIRS II databases, 2) data compiled by EPA for use in regulatory development activities, 3) data found in the 1990 Ozone Transport Commission (OTC) baseline NOx emissions inventory, and 4) data reported to the EPA as part of the acid rain program. In addition, test data collected in 1993 to update the current AP-42 emission factors have been considered in this analysis where appropriate. In order to provide a complete data set for use in updating AP-42, additional information was needed to supplement the raw data contained in the individual test reports. In most cases, this information was obtained by contacting the appropriate regulatory agency, from the source itself, or from Energy Information Administration (EIA) publications. In particular, the following information was sought for inclusion prior to analysis of the data: C Oil Type (No. 2 and No. 6) C Boiler Firing Configuration; and C Boiler size and age. In order to convert the supplied emission factors (in most cases lb/MMBtu) to units consistent with those already found in AP-42 (lb/ton for coal and lb/103 gallons for oil), the following fuel heat contents, taken from Appendix A of AP-42, were used: C No. 6 Oil = (150,000 Btu/gal); and C No. 2 Oil = (140,000 Btu/gal). 7997\92\04\Suplemnt.B\Reports\Chptr01\01-03.002 (6-26-3) 2-2 Once the boiler data were entered into a spreadsheet, each individual “record” (consisting of the NOx emission rate, fuel type, and boiler firing type) was assigned (or sorted) to a unique boiler grouping based on the following set of parameters: C Firing Type (i.e.,. wall fired, tangentially fired); C Control Status; and C Fuel Type (No. 2 and No. 6 Fuel Oil). A summary of the results for each fuel type and firing configuration follows. No. 2 Fuel Oil - For boilers over 100 (MMBtu/HR), the only change is the addition of a NOx emission factor for No. 2 fired boilers equipped with Low-NOx burners and FGR. Two data points were found with an average emission factor of 10 (lb/103 gallons).21,22 This compares to the previously developed emission factor of 24 (lb/103 gallons) for No. 2 fired boilers (over 100 MMBtu/HR) with no control equipment. For boilers under 100 (MMBtu/HR), there are no changes to the current emission factors. Two additional data points were obtained which had an average emission factor of 13 (lb/103 gallons). However, the current AP-42 emission factor of 20 (lb/103 gallons) was obtained from 19 individual data points and is considered more appropriate. No. 6 Fuel Oil - Three new data points were obtained for No. 6 oil fired boilers under 100 (MMBtu/HR). The average of these three data points is 58 (lb/103 gallons), which compares favorably with the current factor of 55 (lb/103 gallons), which is based on 28 data points. Therefore, there is no update to the emission factor for No. 6 fired boilers rated less than 100 (MMBtu/HR). 7997\92\04\Suplemnt.B\Reports\Chptr01\01-03.002 (6-26-3) 2-3 Table 1 provides a summary of the AP-42 source category classifications and emission factors for oil.