EMISSION FACTOR DOCUMENTATION FOR AP-42 SECTION 1.1 BITUMINOUS AND SUBBITUMINOUS COAL COMBUSTION By: Acurex Environmental Corporation Research Triangle Park, North Carolina 27709 Edward Aul & Associates, Inc. Chapel Hill, North Carolina 27514 E. H. Pechan and Associates, Inc. Rancho Cordova, California 95742 Contract No. 68-DO-00120 Work Assignment No. II-68 EPA Project Officer: Alice C. Gagnon Office of Air Quality Planning and Standards Office Of Air And Radiation U.S. Environmental Protection Agency Research Triangle Park, NC 27711 April 1993 DISCLAIMER This report has been reviewed by the Office of Air Quality Planning and Standards, U. S. Environmental Protection Agency, and approved for publication. Mention of trade names or commercial products does not constitute endorsement or recommendation for use. ii TABLE OF CONTENTS Page LIST OF TABLES............................................................................................. v LIST OF FIGURES............................................................................................ vi CHAPTER 1. INTRODUCTION........................................................................ 1-1 CHAPTER 2. SOURCE DESCRIPTION.......................................................... 2-1 2.1 CHARACTERIZATION OF BITUMINOUS AND SUBBITUMINOUS APPLICATIONS....................................2-1 2.2 PROCESS DESCRIPTIONS..................... .........................2-2 2.2.1 Suspension Firing............................ .........................2-3 2.2.2 Stoker Firing..............................................................2-4 2.2.3 Fluidized Bed Combustion.........................................2-5 2.2.4 Handfeed Units..........................................................2-6 2.3 EMISSIONS.........................................................................2-7 2.3.1 Particulate Matter Emissions.....................................2-8 2.3.2 Sulfur Oxide Emissions.............................................2-9 2.3.3 Nitrogen Oxide Emissions.........................................2-9 2.3.4 Carbon Monoxide Emissions.................................... 2-11 2.3.5 Organic Compound Emissions..................................2-12 2.3.6 Trace Element Emissions..........................................2-14 2.3.7 Fugitive Emissions.....................................................2-15 2.4 CONTROL TECHNOLOGIES.................................................2-16 2.4.1 Fuel Treatment/Substitution......................................2-16 2.4.2 Combustion Modification...........................................2-18 2.4.3 Post-Combustion Control..........................................2-22 REFERENCES............................................................................ 2-47 CHAPTER 3. GENERAL EMISSION DATA REVIEW AND ANALYSIS PROCEDURE........................................................... 3-1 3.1 CRITERIA POLLUTANTS.......................................................3-1 3.1.1 Literature Search.......................................................3-1 3.1.2 Literature Evaluation..................................................3-1 3.1.3 Emission Factor Quality Rating 3.2 SPECIATED VOCs..................................................................3-5 3.2.1 Literature Search.......................................................3-5 3.2.2 Literature Evaluation 3.2.3 Data and Emission Factor Quality Rating..................3-5 3.3 AIR TOXICS............................................................................3-6 3.3.1 Literature Search.......................................................3-6 3.3.2 Literature Evaluation for Air Toxics............................3-7 iii TABLE OF CONTENTS (continued) Page 3.3.3 Data and Emission Factor Quality Rating Criteria.....3-7 3.4 N2O..........................................................................................3-8 3.4.1 Literature Search.......................................................3-8 3.4.2 Literature Evaluation..................................................3-8 3.4.3 Data and Emission Factor Quality Rating..................3-9 3.5 FUGITIVES.............................................................................3-9 3.6 PARTICLE SIZE DISTRIBUTION...........................................3-10 3.6.1 Literature Search.......................................................3-10 3.6.2 Literature Evaluation..................................................3-11 3.6.3 Data Quality Ranking.................................................3-12 REFERENCES................................................................................. 3-18 CHAPTER 4. EMISSION FACTOR DEVELOPMENT...................................... 4-1 4.1 CRITERIA POLLUTANTS.......................................................4-1 4.1.1 Review of Previous AP-42 Data................................4-1 4.1.2 Review of New Baseline Data...................................4-2 4.1.3 Compilation of Baseline Emission Factors................4-5 4.1.4 Compilation of Controlled Emission Factors.............4-13 4.2 SPECIATED VOCs.................................................................4-13 4.3 AIR TOXICS............................................................................4-14 4.3.1 Review of New Data..................................................4-14 4.3.2 Baseline Emission Factors........................................4-17 4.3.3 Controlled Emission Factors......................................4-19 4.4 N2O..........................................................................................4-20 4.5 PARTICLE SIZE DISTRIBUTION..............................................................................4-22 4.5.1 Review of Previous AP-42 Data................................4-22 4.5.2 Review of New Data..................................................4-23 4.6.3 Compilation of Uncontrolled Emission Factors......... 4-25 4.6.4 Control Technology Emission Factors...................... 4-26 REFERENCES............................................................................. 4-57 CHAPTER 5. AP-42 SECTION 1.1: BITUMINOUS AND SUBBITUMINOUS COAL COMBUSTION.................................................................... 5-1 APPENDIX A. BACKGROUND FILE SPOT CHECK SUMMARY..................... A-1 APPENDIX B. CONVERSION FACTORS..........................................................B-1 APPENDIX C. MARKED-UP 1988 AP-42 SECTION 1.1................................. C-1 iv LIST OF TABLES Table Page 2-1 U.S. Coal Consumption by Sector, 1990..................................................2-30 2-2 Boiler Usage by Sector.............................................................................2-31 2-3 Total 1985 U.S. Emissions from Coal Combustion by Use Sector...........2-32 2-4 NSPS Summary for Fossil Fuel-fired Boilers............................................2-33 2-5 Commercially Available NOx Control Techniques for Pulverized Coal-fired Boilers.................................................................. 2-34 2-6 Commercially Available NOx Control Techniques for Stoker Coal-fired Boilers......................................................................... 2-36 2-7 Post Combustion SO2 Controls for Combustion Sources.........................2-37 3-1 Speciated VOC Literature Search Results................................................3-14 3-2 Literature Search Checklist.......................................................................3-15 3-3 Evaluation of Air Toxics References.........................................................3-16 3-4 N2O Literature Search Checklist...............................................................3-17 4-1 Background Document Check..................................................................4-29 4-2 New SO2 Baseline Data For Bituminous Coal...........................................4-30 4-3 New NOx Baseline Data For Bituminous Coal...........................................4-32 4-4 New CO Baseline Data..............................................................................4-35 4-5 New PM Baseline Data For Bituminous Coal............................................4-38 4-6 New CH4 Baseline Data For Bituminous Coal...........................................4-39 4-7 Controlled Particulate Emissions...............................................................4-40 4-8 Controlled SOx Emissions.........................................................................4-42 4-9 Controlled NOx Emissions.........................................................................4-43 4-10 Metal Enrichment Behaviors.....................................................................4-45 4-11 Enrichment Ratios for Classes of Elements..............................................4-45 4-12 Enrichment Ratios for Boilers and ESP.....................................................4-46 4-13 HAP Emission Factors (English Units) for Uncontrolled Bituminous Coal-fired Boilers.................................................................. 4-47 4-14 HAP Emission Factors (Metric Units) for Uncontrolled Bituminous Coal-fired Boilers.................................................................. 4-48 4-15 HAP Emission Factors (English Units) for Controlled Bituminous Coal-fired Boilers.................................................................. 4-49 4-16 HAP Emission Factors (Metric Units) for Controlled Bituminous Coal-fired Boilers.................................................................. 4-50 4-17 Average Trace Element Removal Efficiency For Control Devices............4-51