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6.10 3 Benzene Emissions from Maleic Anhydride Industry

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6.10 3 Benzene Emissions from Maleic Anhydride Industry AP42 Section 6.10 Background Ref: 3 Title: Benzene Emissions from Maleic Anhydride Industry - Background Information for Proposed Standards EPA 45013-80-001 a February 1980 United Sfatas Office of Air Quality EPA-450/3-80-001 a Environmental Protection Planning and Standards February 1980 4ww Research Triangle Park NC 2771 1 ~ Air ~~~ GEPA Benzene Emissions Draft from Maleic EIS Anhydride Industry - Background Information for Proposed Standards I k I i I 1 f i ! EPA-450/3-80-001 a Benzene Emissions from Maleic Anhydride Industry - Background Information for'Proposed Standards Emission Standards and Engineering Division USENVIRONMENTAL PROTECTION AGENCY Office of Air, Noise, and Radiation Office of Air Quality Planning and Standards Research Triangle Park, North Carolina 2771 1 February 1980 This report has been reviewed by the Emission St.andards and Engi- neering Division of the Office of Air Quality Planning and Stand- ards, U.S. Environmental Protection Agency, and approved for publication. Mention of trade names or commercial products is not intended to constitute endorsement or recommendation for use. Copies of this report are available through the Library Services Office (MD-35), U. S. Environmental Protection Agency, Research Triangle Park, N.C. 27711, or from National Technical Information Services, 5285 Port Royal Road, Springfield, Va. 22161. PUBLICATION NO. EPA-450/3-80-001a ~ ~~~ ~ . ~~~ ii Background Information and Draft Environmental Impact Statement for Benzene Emissions from Maleic Anhydride Plants Type of Action: Administrative Prepared by: L , L. .e .I ,/..I 5 !.>,..',' ; ,. L < ,,;/.(,,,/,): Don R. Goodwip /' Date Director, Emission Standards and Engineering Division Environmental Protection Agency Research Triangle Park, N.C. 27711 Approved by: / ---? DavidZAHZL!mL G. Hawkins Assistant Administrator, Air, Noise, and Radiation Environmental Protection Agency Washington, D.C. 20460 Draft Statement Submitted to EPA's Office of Federal Activities for Review on This document may be reviewed at: Central Docket Section Room 29036, Waterside Mall Environmental Protection Agency 401 M Street, S.W. Washington, D.C. 20460 Additional copies may be obtained at: Environmental Protection Agency Library (MD-35) Research Triangle Park, N.C. 27711 National Technical Information Service 5285 Port Royal Road Springfield, Va. 22161 iii TABLE OF CONTENTS % INTRODUCTION ............................. 1-1 SUMMARY ............................... 5-1 1. THE MALEIC ANHYDRIDE INDUSTRY ................... 1-1 1.1 General .......................... 1-1 1.2 Process Descriptions and Emissions ............. 1-5 1.2.1 Benzene Oxidation Process .............. 1-6 1.2.2 n-Butane Oxidation Process ............. 1-11 1.2.3 Byproduct of Phthalic Anhydride Production .....1-16 1.2.4 Foreign Process ................... 1-16 1.3 Summary ........................... 1-17 1.4 References ......................... 1-17 2 . EMISSION CONTROL TECHNIQUES ................... 2-1 2.1 Alternative Emission Control Techniques ..........2-1 2.1.1 Carbon Adsorption .................. 2-1 2.1.2 Thermal Incineration ................ 2-3 2.1.3 Catalytic Incineration ............... 2-4 2.1.4 n-Butane Process Conversion ............. 2-4 2.2 Performance of Emission Control Techniques ......... 2-5 2.2.1 Carbon Adsorption .................. 2-5 2.2.2 Thermal Incineration ................ 2-10 2.2.3 Catalytic Incineration ............... 2-15 2.3 References ......................... 2-15 3 . REGULATORY OPTIONS ........................ 3-1 I 4 . ENVIRONMENTAL AND ENERGY IMPACT ................. 4-1 4.1 Air Pollution Impact .................... 4-1 4.1.1 Carbon Adsorption (99 Percent Control of Benzene) ................ 4-17 4.1.2 Carbon Adsorption (97 Percent Control of Benzene) ................ 4-19 4.1.3 Thermal Incineration (99 Percent Control of Benzene) ................ 4-20 4.1.4 Thermal Incineration (97 Percent Control of Benzene) ................ 4-20 4.1.5 n-Butane Process Conversion (100 Percent Control of Benzene) ............ 4-21 TABLE OF CONTENTS (continued) & 4.2 Water Pollution Impact ......... .......... 4-22 4.3 Solid Waste Disposal Impact ...... .......... 4-23 4.4 Energy Impact ............. ..........4-23 ! 4.4.1 Carbon Adsorption (99 Percent Control of Benzene) ...... ..........4-24 4.4.2 Carbon Adsorption (97 Percent Control of Benzene) ...... ..........4-24 4.4.3 Thermal Incineration (99 Percent Control of Benzene) ...... .......... 4-24 4.4.4 Thermal Incineration (97 Percent Control of Benzene) ...... .......... 4-24 4.4.5 n-Butane Process Conversion ... ..........4-25 4.4.6 Summary ............. .......... 4-25 4.5 Other Environmental Impacts ................ 4-28 4.6 Other Environmental Concerns ...... .......... 4-28 4.6.1 Irreversible and Irretrievable Commitment of Resources .... .......... 4-28 4.6.2 Safety Issues .................... 4-28 4.7 References ............... .......... 4-28 5 . ECONOMIC IMPACT ......................... 5-1 5.1 Summary of Economic Impacts of the Maleic Anhydride Benzene NESHAP ....................... 5-1 5.1.1 Capital Budget Impacts................ 5-1 5.1.2 Shifts in Competitive Position ............ 5-1 5.1.3 Price Impacts on Products that Use MA ........5-1 5.1.4 Employment and Balance of Trade Impacts ....... 5-2 ~ ~- 5.1.5~ AnnuaJized Costs in Fifth-Year and Energy ~- -~ ~ ~ ~- ~ Tmpacts .......................-~ ~ ~~5-2 5.1.6 Impact of Requiring n-Butane (100 Percent Control) at New MA Facilities ............ 5-2 5.2 Industrial Economic Profile ................. 5-2 5.2.1 Maleic Anhydride Supply and Capacity ......... 5-2 5.2.1.1 General ................... 5-2 5.2.1.2 The Individual MA-Producing. Companies ....5-4 5.2.2 MA Usage and Demand .................5-7 5.2.3 Prices ........................ 5-9 5.2.3.1 Price of MA ................. 5-9 5.2.3.2 Feedstock Costs ............... 5-11 5.2.3.3 Transportation Costs ............5-11 5.2.4 Briquettes vs . Mol ten MA ............... 5-11 5.2.4.1 Imports of Maleic Anhydride ......... 5-12 5.3 Cost Analysis of Alternative Emission Control Systems ....5-15 5.3.1 Introduction..................... 5-15 5.3.2 Summary of Technical Parameters Used as the Basis in Cost Analysis ...................5-16 5.3.3 Control Costs for Maleic Anhydride Facilities ....5-20 vi TABLE OF CONTENTS (continued) 5.3.3.1 Costs to Achieve the 97-Percent Regula- tory Option................ 5-20 5.3.3.2 Costs to Achieve the 99-Percent Regula- I tory Option................ 5-20 5.3.3.3 Comparison of Control Levels ....... 5-25 5.3.3.4 Monitoring ................ 5-26 5.3.4 Cost-Effectiveness of the Alternative Emissions Limits ....................... 5-26 5.3.5 Control Cost Comparison .............. 5-33 5.4 Economic Impact of Regulatory Options ........... 5-34 5.4.1 Introduction.................... 5-34 5.4.2 Impact on Manufacturers .............. 5-37 5.4.2.1 Capital Budget Requirements ........ 5-37 5.4.2.2 Intraindustry Competition......... 5-41 5.4.2.3 Effect of Cost Pass-Through on Market Com- petition Due to Benzene Emissions Control . 5-41 5.4.2.3.1 Price Differentials in a Low-Demand MA Market ............... 5-46 5.4.2.3.2 Price Differentials and the Future MAMarket .............. 5-50 5.4.2.3.3 Effect of Transportation on Intra- industry Impacts ........... 5-51 5.4.2.4 Effect of Imports ............. 5-55 5.4.2.5 Summary of Impact on Manufacturers .... 5-56 5.4.3 Effect on Product Prices .............. 5-56 5.4.3.1 Cost Pass-Through to the Final Customer . 5-56 5.4.4 Employzent and Balance of Trade .......... 5-62 5.4.5 Fifth-Year Impacts ................. 5-63 5.5 Economic Impacts of Using n-Butane as the Feedstock at New Maleic Anhydride Plants .............. 5-63 5.5.1 Introduction.................... 5-63 5.5.2 Impact on Licensors ................ 5-64 5.5.3 Impact on the Price and Availability of Feedstocks . 5-64 5.5.4 Impact on the Economic Life of Existing Plants... 5-66 6 5.6 References ........................ 5-66 Appendix A.. Evolution of the BID ................... A-1 Appendix 6.. Index to Environmental Impact Considerations ....... 6-1 Appendix C.. Emission Source Test Data ................. C-1 Appendix 0.. Emission Measurement and Continuous Monitoring ...... 0-1 Appendix E.. Methodology for Estimating Mortality and Lifetime Risk from Exposure to Benzene Emissions from Maleic Anhydride Plants ..................... E-1 vii k LIST OF TABLES I Summary s- 1 Environmental and Economic Impacts of Regulatory A1 ternatives . 5-2 Chapter 1. 1- 1 Maleic Anhydride Usage and Growth . 1-2 1- 2 Maleic Anhydride Capacity . 1-3 1- 3 Benzene and Total VOC Emissions from Model Uncontrolled Maleic Anhydride Plant . 1-10 1-4 Waste Gas Composition--Product Recovery Absorber . 1-12 1-5 Benzene Emissions From Maleic Anhydride Plants . 1-13 Chapter 2. 2-1 Technical Data--Carbon Adsorption System (99 Percent Control) . 2-9 2- 2 Technical Data--Carbon Adsorption System (85 Percent Control) . 2-9 2-3 Technical Data--Carbon Adsorption System (98 Percent Control at Design) . 2-11 !1 2-4 Design Criteria--Thermal Incineration (99 Percent Control) . 2-14 1 2-5 Technical Data--Thermal Incineration (97 Percent Control. 2-14 1 ~ ~~ . ~~~~ ~ ~~ ~~ ~~~~ ~~.~ Chapter 4; ~ ~~ - - 1 4-1 Maximum Annual Average Benzene Concentrations . 4-2 ~ 1 4- 2 Mean Annual Average Benzene Concentrations Produced by Emissions from the Combined Sources . : . 4- 3 Mean Annual Benzene Concentrations Produced by Emissions From Individual Sources . 4-4 Maximum 1-hr, 3-hr, 8-hr, 24-hr, and Annual Average Benzene Concentrations
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