Class Project Unit 2-5 - weekly Submission_ENV 6302...

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ENV 6302

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Oct 30, 2023

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1 A Permit by Rule (PBR) Evaluation for a Painting Operation Facility Ernest Mungong Columbia Southern University MEE 6501: Advanced Air Quality Control Dr. Paul Baumgardner, Professor January 22, 2023

2 Abstract Mazin Motors is conducting a Permit by Rule (PBR) evaluation for a future vehicle exterior coating facility that will be located in Canada. Throughout this PBR evaluation process, volatile organic compounds (VOC) will be an important area of consideration while working with Environment Canada: Alberta (EC) for permit authorization. Volatile organic compounds and exempt solvent (ES) values were determined, and VOC and exempt solvent (ES) values were calculated. Operational air emission rates were considered and calculated, and engineering controls were suggested. Operational face and filter velocities were considered before calculating the engineering specification and ensuring regulatory compliance for non-human threats.

3 A Permit by Rule (PBR) Evaluation for a Painting Operation Facility General Considerations for Operation Mazin Motors is conducting a Permit by Rule (PBR) evaluation for a future vehicle exterior coating facility that will be located in Canada. Throughout this PBR evaluation process, volatile organic compounds (VOC) will be an important area of consideration while working with Environment Canada: Alberta (EC) for permit authorization. Mazin Motors is a vehicle exterior coating paint booth designed with an interior coating spray painting system that allows the exterior of each unit to be coated. The shop is constructed with steel and finished with concrete floors, and there is a paint booth for each unit with a stripped-down unit placed in the spray booth. During operation, vehicles will have to pass through the booths, which are opened at one end of the booth for makeup air. The fate of the airflow and proper ventilation matters in the facility's safe operation process. An exhaust is located at the other end of the unit for airflow through the exhaust chamber. Once the liner application operations are completed for each unit, the forced curing (drying) operations will immediately commence. Aerosol is particulate material that can be liquid or solid emitted directly from an anthropogenic source suspended in the air, which ends up being the most visible and apparent form of air pollution (Godish et al., 2014, Phalen & Phalen, 2013). Aerosol is droplets of liquids and so get deposited on the surface. Aerosols may result from different sources, for example, mobile, natural, area secondary and stationary suspended in the air in the form of fumes, fogs, hazes, mists, smogs, and smokes, referred to as aerodisperse systems (Phalen & Phalen, 2013). Mazin Motors have tabulated the following information from the appropriate SDS and Equipment Technical Data Sheets Plan, as shown in Table 1.

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4 Table 1. SDS Documents & Equipment Technical Data Sheets Plan Interior Liner Coating Material 10 gallons coating/unit 2 gallons of solvent/unit Unit Lining Application Apply interior liners to two (2) units per day Work five (5) hours/day and four (4) days/week Unit Lining Curing Cure interior liners of two (2) units/day Work five (5) hours/day and four (4) days/week Interior Liner Cure The heater fuel source is a natural gas-fired drying oven The heater generates 2.1 million (MM) Btu/hr at a maximum of 2,500 hrs/year Unit Lining Design Cross-draft air plenum Unit interior is the spray area Exhaust Fan 10,000 ft3/min (CFM) 1 exhaust fan Air Makeup Unit 5760 ft3/min (CFM) 1 air makeup system Filter Openings 20.0 ft2 each Two (2) filter openings Coating WV VOC content 2.8 lb/gal coating Coating VM Coating volume 1.0 gal Water Content Per gal/coating 1.0 lb/gal Water Density Per gal/water 8.34 lb/gal Coating VW Water volume Calculation Exempt-solvent Content Per gal/coating 0.5 lb/gal Exempt-solvent Density Per gal/exempt solvent 6.64 lb/gal Coating Ves Exempt solvent volume Calculation Table 2: PBR Limits Potential to Emit (PTE) 100 tons VOC/year Face Velocity 100 ft/min Filter Velocity 250 ft/min VOC/5-hour period 6.0 lbs/hr Short term Emissions 1.0 lbs/hr Long term Emissions 1.0 tons/yr Figure 1. Process Flow Diagram (PFD) for the Vehicle Exterior Coating Process AIRFLOW EXHAUST Light Air Flow

5 Supply air Front VOC and ES Content per Unit VOC is a type of hydrocarbon (HC) that is broken down into four categories of (HC) such as aliphatic, aromatic, halogenated, and oxygenated, which can be a threat to the indoor quality and impact the environment (Godish et al. (2014). Similarly, hydrocarbons are organic compounds with only two elements of carbon and hydrogen (Hill & Feigl, 1987). The VOCs found in indoor air are either mutagenic or carcinogenic. Aromatic hydrocarbons like benzene (C6H6) are simply characterized by having an unusually strong, stable ring of electrons as the base structure (Hill & Feigl, 1987; Godish et al. 2014). Other groups of aromatic hydrocarbon other than C6H6 include ethylbenzene, toluene, and the xylenes which produces fuel additive, BTEX, when formulated to increases the rating of Octane in unleaded gasolines (Godish et al. 2014). Aliphatic hydrocarbons differ from aromatic hydrocarbons in the way the carbon atoms are connected in the molecules and a typical aliphatic hydrocarbons are hexane, heptane, and odorless mineral spirits which are primary reactant in the photochemical processes and are readily available in an extensive range of solvent strength (Godish et al. 2014). Halogenated hydrocarbon is some of the most readily recognized VOCs in indoor air pollution with a characterized bonding with other elements like chlorine fluorine iodine (Hill & Feigl, 1987; Godish et al. 2014). Oxygenated hydrocarbons are formed as a result of hydrocarbon in the presence of oxygen (O2). For example, methane (CH4) exposed to O2 a hydrocarbon alcohol methanol (CH3OH) is formed know as methyl alcohol which is used as fuel in cars and ethanol

6 as a fuel additive (Godish et al. 2014). Both oxygenated and halogenated hydrocarbon pose a major atmospheric pollution concerns. To calculate the number of pounds of VOC in the mixed coating/thinner that will be used for the internal liner coating material, one can use the formula: VOC/unit (in lb.) = Coating Wv (lb. gal coating) x interior Liner Coating Material (gal coating/unit) = 2.8 lbs VOC/gal x 10 gal = 28.0 lbs VOC/unit To calculate how many pounds of exempt solvent (ES) per gallon are in the coating/thinner mixture, one can use the formula: Exempt Solvent (ES)/unit (in lb.) =Exempt solvent Content (lb./gal) x interior Liner Coating Material solvent requirement (gal solvent/unit) = 2 gals/unit x 0.5 lbs/gal = 1.0 lbs ES/unit Operational Air Emission Rates The operational air emission rate is the calculated rates in “units per day”, “hours per day” as well as days per week” that will be processed for each process in the painting operation. The entire process painting process will comprise of coating, lining, and curing process. The calculated values (28.0 lb VOC/unit coating and 1.0 lb ES/unit) will be multiplied by the number of units/day to derive a value for lb VOC/day. Then, our lb VOC/day will be multiplied by the 1 day/hours to derive a value for lb VOC/hour. These calculated values will collectively serve as our operational air emission rates for our PBR evaluation document VOC/hour (in lb.) = lb VOC/unit coating x units/day

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7 = 28.0 lb VOC/unit x 2 units/day = 56.0 lb VOC/day 56.0 lb VOC/day x 1 day/5 hours = 11.2 lb VOC/hour ES/hour (in lb.) = lb ES/unit coating x units/day = 1.0 lb. ES/unit 2 units/day = 2.0 lb. ES/day 2.0 lb ES/day x 1 day/5 hours = 0.4 lb ES/hour VOC/year (in tons) = lb VOC/day coating x days/week = 56.0 lb VOC/day x 4 days/week = 224.0 lb VOC/week 224.0 lb VOC/week x 52 weeks/year = 11,648.0 lb VOC/year = 11,648.0 lb VOC/year x 1 ton/2,000 lb = 5.824 tons VOC/year ES/year (in tons) = lb ES/day x days/week = 2.0 lb ES/day x 4 days/week = 8.0 lb ES/week 8.0 lb ES/Week x 52 week/year = 416 lb ES/year = 416 lb ES/year x 1 ton/2,000 lb = 0.208 tons ES/year

8 The calculated potential to emit (PTE) of 5.824 tons VOC/yr does not exceed the PBR limit of 100 tons VOC/yr. However, the calculated hourly VOC of 11.2 lbs VOC/hr is over the PBR limit of 6.0 lbs VOC/5-hr. Consequently, engineering controls are suggested at this point in the process. Operational Face and Filter Velocities It is important to calculate the airflow rates and filter velocities for Mazin Motors work system designs to ensure a safe air quality in the operations and to recognize the adverse effects on agricultural system, ecological system and physical structures. Acid rain, increased ultraviolent radiation (UV), and global warming are the ecological effects, while structures get impacted by metal, vehicle paint deteriorate and building get damage due to acid rain. Chemicals generate odors when being used during processes. According to Godish et al., (2014) some of the recognized and significant phytotoxins causing adverse effect are heavy metals, particulate matter (PM), sulfur dioxide (SO2), hydrogen fluoride (HF), hydrogen chloride (HCl), nitrogen dioxide (NO2), chlorine (Cl2), and ammonia (NH3). To successfully calculate airflow velocity, firstly, one has to consider the engineering specifications for the air makeup unit and the spray booth equipment’s air makeup unit and exhaust fan. Then, to check the regulatory face velocity minimum of 100 ft/min. Calculating the operational face velocity is to ensure enough air circulation at a sufficient speed to capture the particulate matter (PM) and the solvents emissions (SE) and direct them through the filters and out of the exhaust fan. Secondly, is to consider the engineering specification for the filter openings and check our regulatory filter velocity maximum of 250 ft/min. The filter-velocity ensure that air is moving slowly enough to capture the particulate matter while maintaining acceptable pressure

9 drop across the filters. This will ensure that Mazin Motors is within regulatory compliance of 250 ft/min for the permit. Air Intake (in ft2) = (ft opening radius)2 x 3.14 = (3.0 ft)2 x 3.14 = 9.0 ft2 x 3.14 = 28.26 ft2 Flowrate (in ft3/min) = exhaust fan flow rate – air makeup unit flow = 10,000 ft3/min - 5,760 ft3/min = 4,240 ft3/min Face velocity (in ft/min) = flow rate / intake area = 4,240 ft3/min / 28.26 ft2 = 150.03 ft Total filter area (in ft2) = ∑ (filter area per filter) = 20.0 ft2 + 20.0 ft2 = 40.0 ft2 Filter velocity (in ft/min) = flow rate / total filter area = 4,240 ft3/min / 40.0 ft2 = 106 ft/min After calculating the face and filter velocity of Mazin Motors operations, it is determined that the spray booth was designed as per the required regulations. Considering the fact that the filter velocity in the facility is 106.0 ft./min, one can conclude that the facility will continue with the Permit by Rule (PBR) process to ensure a safe operation.

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10 References Godish, T., Davis, W. T., & Fu, J. S. (2014). Air quality (5th ed.). Boca Raton, FL: CRC Press. Hill, J., & Feigl, D. (1987). Chemistry and life: An introduction to general, organic, and biological life (3rd ed.). Macmillan Phalen, R. F., & Phalen, R. N. (2013). Introduction to air pollution science: A public health perspective. Jones & Bartlett Learning