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Locating and Estimating Sources of Toluene

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LOCATING AND ESTIMATING AIR EMISSIONS FROM SOURCES OF TOLUENE Final Report Prepared for: Dennis Beauregard Emission Inventory Branch Technical Support Division Office of Air Quality Planning and Standards U.S. Environmental Protection Agency Research Triangle Park, North Carolina 27711 Prepared by: TRC Environmental Corporation 100 Europa Drive, Suite 150 Chapel Hill, North Carolina 27514 September 1993 EPA Contract No. 68-D9-0173 Work Assignment No. 3/316 DISCLAIMER This report was furnished to the U.S. Environmental Protection Agency by TRC Environmental Corporation, 100 Europa Drive, Chapel Hill, North Carolina, 27514, in partial fulfillment of Contract No. 68-D9-0173, Work Assignment No. 3/316. This document has been reviewed by the Office of Air Quality Planning and Standards and has been approved for publication. The opinions, findings, and conclusions expressed are those of the authors and not necessarily those of the U.S. Environmental Protection Agency. Mention of company or product name is not to be considered as an endorsement by the U.S. Environmental Protection Agency. ii TABLE OF CONTENTS Section Page DISCLAIMER ..................................................... ii LIST OF FIGURES .................................................. vi LIST OF TABLES .................................................. viii 1.0 PURPOSE OF DOCUMENT ...................................... 1-1 1.1 Reference for Section 1.0 ..................................... 1-5 2.0 OVERVIEW OF DOCUMENT CONTENTS ........................... 2-1 2.1 References for Section 2.0 .................................... 2-5 3.0 BACKGROUND ............................................... 3-1 3.1 Nature of Pollutant ......................................... 3-1 3.2 Overview of Production and Use ................................ 3-4 3.3 References for Section 3.0 .................................... 3-7 4.0 EMISSIONS FROM TOLUENE PRODUCTION ........................ 4-1 4.1 Toluene Production from Petroleum Fractions ....................... 4-5 4.1.1 Hydrotreating ......................................... 4-5 4.1.2 Catalytic Reforming .................................... 4-7 4.1.3 Secondary Hydrogenation (for Pyrolysis Gasoline) .............. 4-10 4.1.4 Toluene Recovery .................................... 4-10 4.1.5 Emissions .......................................... 4-14 4.2 Toluene Production from Coal ................................ 4-18 4.2.1 Process Descriptions ................................... 4-20 4.2.2 Emissions .......................................... 4-21 4.3 Toluene Production from Styrene .............................. 4-21 4.3.1 Process Description ................................... 4-22 4.3.2 Emissions .......................................... 4-22 4.4 References for Section 4.0 .................................... 4-25 5.0 EMISSIONS FROM MAJOR USES OF TOLUENE ...................... 5-1 5.1 Benzene Production ......................................... 5-1 5.1.1 Process Description .................................... 5-2 5.1.2 Emissions ........................................... 5-5 5.2 Toluene Diisocyanate Production ................................ 5-6 5.2.1 Process Description .................................... 5-8 5.2.2 Emissions ........................................... 5-9 5.3 Trinitrotoluene Production ................................... 5-11 5.3.1 Process Description ................................... 5-11 5.3.2 Emissions .......................................... 5-13 iii TABLE OF CONTENTS (Continued) Section Page 5.4 Benzoic Acid Production .................................... 5-14 5.4.1 Process Description ................................... 5-15 5.4.2 Emissions .......................................... 5-16 5.5 Benzyl Chloride Production .................................. 5-16 5.5.1 Process Description ................................... 5-17 5.5.2 Emissions .......................................... 5-17 5.6 Other Toluene Derivatives ................................... 5-18 5.7 Paint and Ink Manufacturing .................................. 5-19 5.7.1 Process Description ................................... 5-24 5.7.2 Emissions .......................................... 5-26 5.8 Solvent Cleaning Operations .................................. 5-28 5.8.1 Process Description ................................... 5-28 5.8.2 Emissions .......................................... 5-29 5.9 Other Solvent Uses ........................................ 5-30 5.10 References for Section 5.0 ................................... 5-32 6.0 EMISSIONS FROM THE USE OF TOLUENE-CONTAINING MATERIALS .... 6-1 6.1 Surface Coating Operations ................................... 6-1 6.1.1 Process Description .................................... 6-2 6.1.2 Emissions ........................................... 6-2 6.2 Printing and Publishing ...................................... 6-5 6.2.1 Process Description .................................... 6-6 6.2.2 Emissions ........................................... 6-8 6.3 Gasoline and Automotive Emissions ............................ 6-11 6.4 Gasoline Marketing ........................................ 6-12 6.4.1 Toluene Emissions from Loading Marine Vessels .............. 6-15 6.4.2 Toluene Emissions from Bulk Gasoline Plants, Bulk Gasoline Terminals and Service Stations ........................... 6-17 6.4.3 Control Technology for Gasoline Transfer .................... 6-22 6.4.4 Control Technology for Gasoline Storage .................... 6-26 6.4.5 Control Technology for Vehicle Refueling Emissions ............ 6-26 6.5 Other Sources of Residual Toluene Emissions ...................... 6-28 6.6 References for Section 6.0 ................................... 6-30 7.0 BY-PRODUCT EMISSIONS: PROCESSES UNRELATED TO PRODUCTION OR USE OF TOLUENE ......................................... 7-1 7.1 Coal Combustion ........................................... 7-1 7.2 Hazardous and Solid Waste Incineration ........................... 7-3 7.3 Wastewater Treatment Processes ................................ 7-4 7.4 References for Section 7.0 .................................... 7-7 iv TABLE OF CONTENTS (Continued) Section Page 8.0 AMBIENT AIR AND STATIONARY SOURCE TEST PROCEDURES ........ 8-1 8.1 EPA Method TO-1 ......................................... 8-2 8.2 EPA Method TO-2 ......................................... 8-2 8.3 EPA Method TO-3 ......................................... 8-5 8.4 EPA Method TO-14 ........................................ 8-8 8.5 EPA Method 0030 .......................................... 8-8 8.6 EPA Method 5040 ......................................... 8-10 8.7 EPA Reference Method 18 ................................... 8-12 8.8 EPA Method 0010 ......................................... 8-16 8.9 EPA Method 8270 ......................................... 8-16 8.10 NIOSH Method 1501 ....................................... 8-18 8.11 References for Section 8.0 ................................... 8-20 APPENDIX A POTENTIAL SOURCE CATEGORIES OF TOLUENE EMISSIONS .................................A-1 APPENDIX B LISTS OF PAINT, INK, AND PRINTING FACILITIES WITH ANNUAL SALES GREATER THAN $1 MILLION ..............B-1 APPENDIX C TOLUENE SOURCE CATEGORIES IN SURFACE COATING OPERATIONS ......................................C-1 APPENDIX D SUMMARY OF EMISSION FACTORS LISTED IN THIS DOCUMENT .....................................D-1 v LIST OF FIGURES Number Page 3-1 Chemical Use Tree for Toluene .................................. 3-6 4-1 Process Flow Diagram for Hydrotreating ............................ 4-6 4-2 Typical Reforming Unit ........................................ 4-8 4-3 Generalized Toluene Recovery Process Flow Diagram .................. 4-12 4-4 Process Flow Diagram for Styrene Production by Ethylbenzene Dehydrogenation ............................................ 4-23 5-1 Process Flow Diagram of a Toluene Dealkylation Unit .................. 5-4 5-2 Basic Operations That May Be Used in Toluene Diisocyanate Production .... 5-10 5-3 TNT Production ............................................ 5-12 5-4 Usage of Toluene in the Paint and Coatings Industry ................... 5-20 5-5 Flow Diagram of the Paint and Ink Manufacturing Process .............. 5-25 6-1 Flow Diagram of a Surface Coating Operation ........................ 6-3 6-2 The Gasoline Marketing Distribution System in the United States .......... 6-14 6-3 Bulk Plant Vapor Balance System ................................ 6-24 6-4 Service Station Vapor Balance System ............................. 6-25 8-1 EPA Method TO-1 Sampling System .............................. 8-3 8-2 Tenax® Cartridge Design ....................................... 8-4 8-3 Carbon Molecular Sieve Trap (CMS) Construction ..................... 8-6 8-4 Automated Sampling and Analysis System for Cryogenic Trapping .......... 8-7 8-5 Canister Sampling System ...................................... 8-9 8-6 Schematic of Volatile Organic Sampling Train (VOST) ................. 8-11 8-7 Schematic Diagram of Trap Desorption/Analysis System ................ 8-13 vi LIST OF FIGURES (Continued) Number Page 8-8 Direct Interface Sampling System ................................ 8-14 8-9 Integrated Bag Sampling Train .................................. 8-15 8-10 Modified Method 5 Sampling Train ............................... 8-17 8-11 Method 1501 Sampling System .................................. 8-19 vii LIST OF TABLES Number Page 3-1 Chemical Identification of Toluene ...............................
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