Attachment L
EMISSIONS UNIT DATA SHEET
CHEMICAL PROCESS
For chemical processes please fill out this sheet and all supplementary forms (see below) that apply. Please check all
supplementary forms that have been completed.
Emergency Vent Summary Sheet
Leak Sources Data Sheet
Toxicology Data Sheet
Reactor Data Sheet
Distillation Column Data Sheet
1. Chemical process area name and equipment ID number (as shown in Equipment List Form)
2. Standard Industrial Classification Codes (SICs) for process(es)
3. List raw materials and
attach MSDSs
4. List Products and Maximum Production and
Description and CAS Number
attach MSDSs
Maximum Hourly (lb/hr)
Maximum Annual (ton/year)
5. Complete the Emergency Vent Summary Sheet for all emergency relief devices.
6. Complete the Leak Source Data Sheet and describe below or attach to application the leak detection or
maintenance program to minimize fugitive emissions. Include detection instruments, calibration gases or methods,
planned inspection frequency, and record-keeping, and similar pertinent information. If subject to a rule
requirement (e.g. 40CFR60, Subpart VV), please list those here.
7. Clearly describe below or attach to application Accident Procedures to be followed in the event of an accidental
spill or release.
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8A. Complete the Toxicology Data Sheet or attach to application a toxicology report (an up-to-date material safety data
sheets (MSDS) may be used) outlining the currently known acute and chronic health effects of each compound or
chemical entity emitted to the air. If these compounds have already been listed in Item 3, then a duplicate MSDS
sheet is not required. Include data such as the OSHA time weighted average (TWA) or mutagenicity,
teratogenicity, irritation, and other known or suspected effects should be addressed. Indicate where these are
unknown, and provide references.
8B. Describe any health effects testing or epidemiological studies on these compounds that are being or may be
conducted by the company or required under TSCA, RCRA or other federal regulations. Discuss the persistence
in the environment of any emission (e.g. pesticides, etc.).
9. Waste Products - Waste products status: (If source is subject to RCRA or 45CSR25, please contact the
Hazardous Waste Section of WVDEP, OAQ at (304) 926-3647.)
9A. Types and amounts of wastes to be disposed:
9B. Method of disposal and location of waste disposal facilities:
Carrier:
Phone:
9C. Check here if approved USEPA/State Hazardous Waste Landfill will be used
10. Maximum and Projected Typical Operating Schedule for process or project as a whole (circle appropriate units).
circle units:
10A.
Maximum
10B.
Typical
(hrs/day) (hr/batch)
(days), (batches/day), (batches/week)
(days/yr), (weeks/year)
11. Complete a Reactor Data Sheet for each reactor in this chemical process.
12. Complete a Distillation Column Data Sheet for each distillation column in this chemical process.
13. Proposed Monitoring, Recordkeeping, Reporting, and Testing
Please propose monitoring, recordkeeping, and reporting in order to demonstrate compliance with the proposed
operating parameters. Please propose testing in order to demonstrate compliance with the proposed emissions
limits.
MONITORING
RECORDKEEPING
REPORTING
TESTING
MONITORING. Please list and describe the process parameters and ranges that are proposed to be monitored in order
to demonstrate compliance with the operation of this process equipment operation or air pollution control device.
RECORDKEEPING. Please describe the proposed recordkeeping that will accompany the monitoring.
REPORTING. Please describe the proposed frequency of reporting of the recordkeeping.
TESTING. Please describe any proposed emissions testing for this process equipment or air pollution control device.
14. Describe all operating ranges and maintenance procedures required by Manufacturer to maintain warranty
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INFORMATION REQUIRED FOR CHEMICAL PROCESSES
The notes listed below for chemical processes are intended to help the applicant submit a complete application to the
OAQ; these notes are not intended to be all inclusive. The requirements for a complete application for a permit issued
under 45CSR13 are designed to provided enough information for a permit reviewer to begin a technical review.
Additional information beyond that identified may be required to complete the technical review of any individual
application.
Process Description
Please keep these points in mind when completing your process description as part of this permit application.
1. Provide a general process overview. This brief, but complete, process description should include chemical or
registered trademark names of chemical products, intermediates, and/or raw materials to be produced or
consumed, and the ultimate use(s) of the product(s). A list of the various chemical compounds is helpful.
2. Describe each process step. Include the process chemistry and stoichiometrically balanced reaction equation or
material mass balance on all components.
3. Describe the methods and equipment used to receive, store, handle, and charge raw materials.
4. Describe the methods and equipment used to handle, store, or package final products and intermediates.
5. Provide process flow diagrams or equipment layout drawings which clearly show the process flow relationships
among all pieces of process and control equipment. Identify all air emission discharge points. Discuss
instrumentation and controls for the process.
6. Discuss the possibilities of process upsets, the duration and frequency of upsets, and consequences (including air
emissions) of these upsets. Include a description of rupture discs, pressure relief valves, and secondary
containment systems.
7. Discuss any fugitive emissions and the methods used to minimize them.
8. Include the following plans for the process if available:
a. preventative maintenance and malfunction abatement plan (recommended for all control equipment).
b. continuous emissions (in-stack) monitoring plan
c. ambient monitoring plan
d. emergency response plan
Regulatory Discussion
The following state and federal air pollution control regulations may be applicable to your chemical process. You
should review these regulations carefully to determine if they apply to your process. Please summarize the results of
your review in your permit application along with any other regulations you believe are applicable.
• Title 45 Legislative Rule Division of Environmental Protection, Office of Air Quality contains West Virginia’s air
pollution control regulations, including the following promulgated rules which may require emissions reductions or
control technologies for your chemical process:
a. 45CSR27 - Best Available Technology (BAT) for Toxic Air Pollutants (TAPs)
b. 45CSR21 - VOC emissions controls for ozone maintenance in Kanawha, Cabell, Putnam, Wayne, and Wood
counties.
c. 45CSR13 (Table 45-13A) - plantwide emission thresholds for permitting for certain pollutants.
• Federal Guidelines for case-by-case MACT determinations under section 112(g) of the 1990 CAAA for individual
and total HAPs greater than 10 and 25 tons per year, respectively.
• There are also subparts of the federal Standards of Performance for New Stationary Sources (NSPS), 40CFR60
60, and the National Emission Standards for Hazardous Air Pollutants (NESHAP) at 40CFR61 and 40CFR63,
which apply to various chemical and nonchemical processes. These subparts are too numerous to list here, but
these areas of the federal regulations should be consulted carefully to determine applicability to your process.
Emissions Summary and Calculations
Please keep these points in mind when submitting your emissions calculations as part of this permit application.
1. For each pollutant, provide the basis for the emissions estimate and for all emission reduction(s) or control
efficiency(ies) claimed.
2. For all batch processes provide the following
a. Emissions of each pollutant in pound(s) per batch, from each process step
b. Annual emissions based on number of batches requested per year
c. The total time for each process step and the duration of the emissions during the process step
d. Total batch time, total emissions per batch (or per day), and annual emissions based on the number of
batches requested per year.
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EMERGENCY VENT SUMMARY SHEET
List below all emergency relief devices, rupture disks, safety relief valves, and similar openings that will vent only under
abnormal conditions.
Emission Point ID1
Equipment to Relief
Vent (type, ID if
available)2
Relief Vents (type) &
Set Pressure (psig)
Name of Chemical(s)
or Pollutants
Controlled
Worst Case
Emission per
Release Event (lbs)
All routine vents (non-emergency) should be listed on the Emission Points Data Summary Sheet.
1
Indicate the emission point, if any, to which source equipment normally vents. Do not assign emission point ID
numbers to each emergency relief vent or device.
2
List all emergency relief devices next to the piece of equipment from which they control releases.
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LEAK SOURCE DATA SHEET
Source Category
Pollutant
Pumps5
Number of Source
Components1
Number of Components
Monitored by Frequency2
Average Time to
Repair (days)3
Estimated Annual
Emission Rate (lb/yr)4
light liquid VOC6,7
heavy liquid VOC8
Non-VOC9
Valves10
Gas VOC
Light Liquid VOC
Heavy Liquid VOC
Non-VOC
Safety Relief Valves
11
Gas VOC
Non VOC
Open-ended Lines
12
VOC
Non-VOC
Sampling
Connections13
VOC
Non-VOC
Compressors
VOC
Non-VOC
Flanges
VOC
Non-VOC
Other
VOC
Non-VOC
1 - 13
See notes on the following page.
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Notes for Leak Source Data Sheet
1. For VOC sources include components on streams and equipment that contain greater than 10% w/w VOC,
including feed streams, reaction/separation facilities, and product/by-product delivery lines. Do not include certain
leakless equipment as defined below by category.
2. By monitoring frequency, give the number of sources routinely monitored for leaks, using a portable detection
device that measures concentration in ppm. Do not include monitoring by visual or soap-bubble leak detection
methods. "M/Q(M)/Q/SA/A/O" means the time period between inspections as follows:
Monthly/Quarterly, with Monthly follow-up of repaired leakers/Quarterly/Semi-annual/Annually/Other (specify time
period)
If source category is not monitored, a single zero in the space will suffice. For example, if 50 gas-service valves
are monitored quarterly, with monthly follow-up of those repaired, 75 are monitored semi-annually, and 50 are
checked bimonthly (alternate months), with non checked at any other frequency, you would put in the category
“valves, gas service:” 0/50/0/75/0/50 (bimonthly).
3. Give the average number of days, after a leak is discovered, that an attempt will be made to repair the leak.
4. Note the method used: MB - material balance; EE - engineering estimate; EPA - emission factors established by
EPA (cite document used); O - other method, such as in-house emission factor (specify).
5. Do not include in the equipment count sealless pumps (canned motor or diaphragm) or those with enclosed
venting to a control device. (Emissions from vented equipment should be included in the estimates given in the
Emission Points Data Sheet.)
6. Volatile organic compounds (VOC) means the term as defined in 40 CFR 51.100 (s).
7. A light liquid is defined as a fluid with vapor pressure equal to or greater than 0.04 psi (0.3 Kpa) at 20°C. For
mixtures, if 20% w/w or more of the stream is composed of fluids with vapor pressures greater than 0.04 psi (0.3
Kpa) at 20 °C, then the fluid is defined as a light liquid.
8. A heavy liquid is defined as a fluid with a vapor pressure less than 0.04 psi (0.3 Kpa) at 20°C. For mixtures, if less
than 20% w/w of the stream is composed of fluids with vapor pressures greater than 0.04 psi (0.3 Kpa) at 20 °C,
then the fluid is defined as a heavy liquid.
9. LIST CO, H2S, mineral acids, NO, NO2, SO3, etc. DO NOT LIST CO2, H2, H2O, N2, O2, and Noble Gases.
10. Include all process valves whether in-line or on an open-ended line such as sample, drain and purge valves. Do
not include safety-relief valves, or leakless valves such as check, diaphragm, and bellows seal valves.
11. Do not include a safety-relief valve if there is a rupture disk in place upstream of the valve, or if the valve vents to a
control device.
12 Open-ended lines include purge, drain and vent lines. Do not include sampling connections, or lines sealed by
plugs, caps, blinds or second valves.
13. Do not include closed-purge sampling connections.
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TOXICOLOGY DATA SHEET1
Descriptor Name/CAS
Number
OSHA Limits2
TWA
CL
Acute3
TCLO - Animal
LCLO - Animal
LC50 - Animal
Chronic4
Irritation5
References
1
Indicate by "ND" where no data exists, in company's knowledge.
Time Weighted Average, Ceiling Limit, or other, with units.
3
If inhalation data is not available, provide other data as available.
4
Relying on animal or human studies, indicate if any data suggests: C = carcinogenicity, M = mutagenicity, T = teratogenecity, O = oncogenicity.
5
Indicate if there are dermal or eye irritation effects and whether they are considered to be low, moderate, or severe.
2
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REACTOR DATA SHEET
Provide the following information for each piece of equipment that is a potential or actual source of emissions as shown
on the Equipment List Form and other parts of application.
Identification Number (as shown on Equipment List Form):
1. Name and type of equipment (e.g. CSTR, plug flow, batch, etc.)
2. Type of operation
Batch
Continuous
Semi-batch
3. Projected Actual Equipment Operating Schedule (complete appropriate lines):
hrs/day
days/week
weeks/year
hrs/batch
batches/day, weeks
(Circle one)
day,weeks/yr
(Circle one)
4. Feed Data
Material Name &
CAS No.
Flow In =
Phasea
gal/hr, or gal/batch
Specific Gravity
Vapor
Pressureb
Charge Rate
Normal
Max
Units
Fill Time
(min/batch, run)c
a. S = Solid, L = Liquid, G = gas or vapor
b. At feed conditions
c. Total time that equipment is filling per batch or run (start-up), for tank or vessel-type equipment.
5. Provide all chemical reactions that will be involved (if applicable), including the residence time and any side
reactions that may occur as well as gases that may be generated during these reactions. Indicate if the reaction(s)
are exothermic or endothermic.
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6. Maximum Temperature
8. Output Data
7A. Maximum Pressure
7B. Max. Set Pressure for venting
°C
mmHg
mmHg
°F
psig
psig
Flow Out =
Material Name and CAS
Phase
No.
gal/hr or gal/batch
Specific
Gravity
Vapor
Pressure
Normal
Hourly or Batch Output Rate
Maximum
Units
9. Complete the following emission data for equipment connected to a header exhaust system, giving emissions
levels before entering header system (i.e. before control equipment).
Check here if not applicable
Emission Point ID (exhaust point of header system):
Material Name and CAS No.
Maximum Potential Emission Rate (lb/hr)
Method **
** MB - material balance: EE - Engineering Estimate: TM - Test Measurement (submit test data): O - other (Explain)
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10. Provide the following information pertaining to each condenser that may be attached to this reactor. Attach
additional pages as necessary if more than one condenser is used for this reactor. Complete the Condenser Air
Pollution Control Device Sheet if necessary.
Check here if not applicable
10A.
Cooling material
10B.
Minimum and Maximum flowrate of cooling material (gal/hr)
10C.
Inlet temperature of cooling material (°F)
10D.
Outlet temperature of cooling material (°F)
10E.
Pressure drop of gas to be condensed from inlet to outlet (psig)
10F.
Inlet temperature of gas stream (°F)
10G.
Outlet temperature of gas stream (°F)
10H.
Number of passes
10I.
Cooling surface area
11. Provide the following pertaining to auxiliary equipment that burns fuel (heaters, dryers, etc.):
Check here if not applicable
11A.
Type of fuel and maximum fuel burn rate, per hour:
11B.
Provide maximum percent sulfur (S), ash content of fuel, and the energy content using appropriate units:
%S
BTU/lb, std. ft3/day, gal
% Ash
(circle one)
11C.
Theoretical combustion air requirement in SCFD per unit of fuel (circle appropriate unit) @ 70°F and 14.7
PSIA:
SCFD/lb, SCFD, gal (circle one)
11D.
Percent excess air:
%
11E.
Type, amount, and BTU rating of burners and all other firing equipment that are planned to be used:
11F.
Total maximum design heat input:
×106 BTU/hr.
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12. Proposed Monitoring, Recordkeeping, Reporting, and Testing
Please propose monitoring, recordkeeping, and reporting in order to demonstrate compliance with the proposed
operating parameters. Please propose testing in order to demonstrate compliance with the proposed emissions
limits.
MONITORING
RECORDKEEPING
REPORTING
TESTING
MONITORING. PLEASE LIST AND DESCRIBE THE PROCESS PARAMETERS AND RANGES THAT ARE PROPOSED TO BE
MONITORED IN ORDER TO DEMONSTRATE COMPLIANCE WITH THE OPERATION OF THIS PROCESS EQUIPMENT OPERATION OR
AIR POLLUTION CONTROL DEVICE.
RECORDKEEPING. PLEASE DESCRIBE THE PROPOSED RECORDKEEPING THAT WILL ACCOMPANY THE MONITORING.
REPORTING. PLEASE DESCRIBE THE PROPOSED FREQUENCY OF REPORTING OF THE RECORDKEEPING.
TESTING. PLEASE DESCRIBE ANY PROPOSED EMISSIONS TESTING FOR THIS PROCESS EQUIPMENT OR AIR POLLUTION
CONTROL DEVICE.
13. Describe all operating ranges and maintenance procedures required by Manufacturer to maintain warranty
NOTE: An AIR POLLUTION CONTROL DEVICE SHEET must be completed for any air pollution device(s) (except
emergency relief devices) used to control emissions from this reactor.
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DISTILLATION COLUMN DATA SHEET
Identification Number (as assigned on Equipment List Form):
1. Name and type of equipment
#. Projected actual equipment operating schedule (complete appropriate lines):
hrs/day
hrs/batch
days/week
weeks/year
batches/day, batches/week
(circle one)
days/yr, weeks/yr
(circle one)
2. Number of stages (plates), excluding condenser
3. Number of feed plates and stage location
4. Specify details of any reheating, recycling, or stage conditioning along with the stage locations
5. Specify reflux ratio, R (where R is defined as the ratio of the reflux to the overhead product, given symbolically as
R=L/D, where L = liquid down column, D = distillation product)
6. Specify the fraction of feed which is vaporized, f (where f is the molal fraction of the feed that leaves the feed plate
continuously as vapor).
7A. Type of condenser used:
total
partial
multiple
other
7B. For each condenser provide process operating details including all inlet and outlet temperatures, pressures, and
compositions.
8. Feed Characteristics
A. Molar composition
B. Individual vapor pressure of each component
C. Total feed stage pressure
D. Total feed stage temperature
E. Total mass flow rate of each stream into the system
9. Overhead Product
A. Molar composition of components
B. Vapor pressure of components
C. Total mass flow rate of all streams leaving the system as overhead products
10. Bottom Product
A. Molar composition of all components
B. Total mass flow rate of all steams leaving the system as bottom products
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11. General Information
A. Distillation column diameter
B. Distillation column height
C. Type of plates
D. Plate spacing
E. Murphree plate efficiency
F. Any other information necessary of describe the operation of this distillation column.
12. Proposed Monitoring, Recordkeeping, Reporting, and Testing
Please propose monitoring, recordkeeping, and reporting in order to demonstrate compliance with the proposed
operating parameters. Please propose testing in order to demonstrate compliance with the proposed emissions
limits.
MONITORING
RECORDKEEPING
REPORTING
TESTING
MONITORING. PLEASE LIST AND DESCRIBE THE PROCESS PARAMETERS AND RANGES THAT ARE PROPOSED TO BE
MONITORED IN ORDER TO DEMONSTRATE COMPLIANCE WITH THE OPERATION OF THIS PROCESS EQUIPMENT OPERATION OR
AIR POLLUTION CONTROL DEVICE.
RECORDKEEPING. PLEASE DESCRIBE THE PROPOSED RECORDKEEPING THAT WILL ACCOMPANY THE MONITORING.
REPORTING. PLEASE DESCRIBE THE PROPOSED FREQUENCY OF REPORTING OF THE RECORDKEEPING.
TESTING. PLEASE DESCRIBE ANY PROPOSED EMISSIONS TESTING FOR THIS PROCESS EQUIPMENT OR AIR POLLUTION
CONTROL DEVICE.
13. Describe all operating ranges and maintenance procedures required by Manufacturer to maintain warranty
NOTE: An AIR POLLUTION CONTROL DEVICE SHEET must be completed for any air pollution device(s) (except
emergency relief devices) used to control emissions from this distillation column.
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