Class Project Unit 2-6 - 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 February 08, 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. 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 assessed. VOC content minus water and ES was calculated, and administrative controls were suggested. Heater and oven combustion emissions for both hourly and annual emissions were calculated. This PBR evaluation demonstrates that the paint booth would be in regulatory compliance with the state, but only with the suggested additional controls.

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 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 characterized by having a solid, 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 xylenes, which produces fuel additive, BTEX when formulated to increase the rating of Octane in unleaded gasoline (Godish et al. 2014). Aliphatic hydrocarbons differ from aromatic hydrocarbons in the way the carbon atoms are connected in the molecules, and typical aliphatic hydrocarbons are hexane, heptane, and odorless mineral spirits, which are primary reactants 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 due to hydrocarbon in the presence of oxygen (O2). For example, in methane (CH4) exposed to O2, a hydrocarbon alcohol methanol (CH3OH) is formed, known as methyl alcohol which is used as fuel in cars and ethanol as a fuel

6 additive (Godish et al. 2014). Both oxygenated and halogenated hydrocarbon pose a significant atmospheric pollution concern. 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 Hydrocarbon compounds are useful in synthetic products such as paint and interior coating materials. However, the hydrocarbon oils and solids still emit volatile organic compounds (VOCs). The air emission is natural, so the VOCs' emission rate must be forecast and quantified to determine the work system and evaluate the impact of the ambient air on humans and the environment. This will require one to calculate the emission rates. VOC/hour (in lb.) = lb VOC/unit coating x units/day = 28.0 lb VOC/unit x 2 units/day = 56.0 lb VOC/day

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7 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 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

8 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 safe air quality in the operations and to recognize the adverse effects on the agricultural system, ecological system and physical structures. Acid rain increases ultraviolent radiation (UV) and global warming, which are the ecological effect. Structures get impacted by metal, vehicle paint deteriorates, and buildings are damaged 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 effects are heavy metals, particulate matter (PM), sulfur dioxide (SO 2 ), hydrogen fluoride (HF), hydrogen chloride (HCl), nitrogen dioxide (NO 2 ), chlorine (Cl 2 ), and ammonia (NH 3 ). Other compounds, such as ozone (O 3 ), hydrogen peroxide (H2O2) and peroxyacetyl nitrate (PAN), can cause damage to vegetation through photochemical oxidation (Gurjar et al., 2010). 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 = 4240.0 ft3/min Face velocity (in ft/min) = flow rate/intake area = 4240.0 ft3/min / 28.26 ft2

9 = 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 = 4240.0 ft3/min / 40.0 ft2 = 106.0 ft/min The calculated face velocity of 150.03 ft/min was found to be over the PBR minimum limit of 100.0 ft/min. The calculated filter velocity of 106.0 ft/min was found to be below the PBR maximum limit of 250.0 ft/min. Consequently, the system was found to comply with this stage without any need for additional engineering controls. VOC Content Minus Water and Exempt Solvents Air quality monitoring comprises three aspects: sampling, sampling analysis (testing), and data analysis. Conducting samples is critical to determine toxic chemicals and must be done correctly and methodically to produce valid and best-quality air samples (Godish et al. 2014). There are different air sample types, the source sample, area sample, population, and personal. With the source sample, the samples are collected at the emission source and used when conducting emission control, monitoring, permitting, studies, modelling, and specific control technology requirements (Phalen & Phalen, 2013). This sampling is conducted mainly on waste gas streams that flow to the atmosphere through stacks. These source sampling can also be conducted on local exhaust ventilation systems like the painted boat (Phalen & Phalen, 2013). Secondly, area sampling is used when attempting to identify and characterize sources within a

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10 specific area and nearby that are being monitored for their emission control effectiveness (Phalen & Phalen, 2013); Thirdly, population sampling is typical for epidemiological research. It is conducted randomly and collected as a predetermined number within a specified air community in order to effectively represent the air quality of an identified population in order to evaluate ultimate acute or chronic health risks for humans or other ecological life (Phalen & Phalen, 2013). Next is the most unique and unique sample, the personal sampling. This sample is collected within the breathing zone of willing human test subjects. This sample is common with personal risk assessments, including at-risk populations and other susceptible individuals within a given environment (Phalen & Phalen, 2013). After the samples are collected, they are sent for analysis to a specialized laboratory to analyze the data for the quantitative chemical and physical analysis results which is then sent out as a report to determine what action needs to be taken by the engineer. Gallons of water/gal of coating = lb/gal of coating x 1.0 gallon of water/density in lb = (1.0 lb/gal) x (1.0 gallon of water/8.34 lb) = 0.11 gallons of water/gal of coating A gallon of exempt solvent/gallon of coating = lb/gal of coating x 1.0 gallon of ES/density in lb = (0.5 lb/gal) x (1.0 gallon of ES/6.64 lb) = (0.07 gallons of ES/gal of coating) lb of VOC/gal of coating (less water and ES) per day = Wv / 1.0 gal of coating volume – gal of water volume – gal of ES

11 = (2.8 lb VOC) / 1.0 gal of coating volume – 0.12 gal of water volume – 0.075 gals of ES volume = 2.8 / 0.805 = 3.48 lb of VOC/gal of coating (less water and ES) per day Vm = 1.0 gal x 2 units/5-hours day) Vm = (3.48lb/gal x 1.0 gal/unit x 2 unit/5 hour day) Vm = 6.96 lb VOC/5 hour day The calculated 6.96 lbs VOC/gal/unit for two units exceeds the 6.0 lbs VOC/5-hr PBR limit. As such, administrative controls are suggested. Appropriate administrative controls are to either decrease the number of days the booth is active during the week, or to reduce the number of hours the booth is operating during the day. Heater and Oven Combustion Emissions There are many methods for statistically modeling air quality mathematically and with modeling software options. It is important to understand the different types of models and how they are best utilized for different atmospheric and structural consideration with or without software options. There are a number of dispersion models to be considered as best option due to their characteristics. These models include box model, Gaussian plume model, Gaussian puff model, Lagrangian model, Eulerian model, CFD model…. these models are also supported with commercial software option to help make the modeling easier (Godish et al., 2014; Gurjar et al., 2010; Phalen & Phalen, 2013). The data from air quality differ by mathematical theory…... and can be analyzed using one of four approaches: artificial neural network, fuzzy logic, ranking, and time series (Gurjar et al., 2010).

12 The artificial neural network is utilized when known variables are available to calibrate regression analysis tools; the fuzzy logic approach is utilized when ranking multiple air quality models in order to normalize and subsequently formalize limits; the ranking approach is utilized when ranking the air models by known variables of concern and finally approach is the time series which is utilized when attempting to accurately forecast pollutant concentrations in areas of high pollutant susceptibility as a function of time (Gurjar et al., 2010). Lbs of air contaminants/hr = lbs air contaminants/MMscf x 1.0 scf/1,020Btu x 2.1 MMBtu/1.0 hr = 100.0 lb/MMscf x1.0/1,020Btu x 2.1 tu/1.0 hr = 0.206 lb of NOx/hr Lbs of air contaminants/hr = lbs air contaminants/MMscf x 1.0 scf/1,020Btu x2.1 MMBtu/1.0 hr = 84.0 lb/MMscf x1.0/1,020Btu x 2.1 tu/1.0 hr = 0.173 lb of CO/hr Lbs of air contaminants/hr = lbs air contaminants/MMscf x 1.0 scf/1,020Btu x2.1 MMBtu/1.0 hr = 7.6 lb/MMscf x1.0/1,020Btu x 2.1 tu/1.0 hr = 0.016 lb of PM/hr Lbs of air contaminants/hr = lbs air contaminants/MMscf x 1.0 scf/1,020Btu x2.1 MMBtu/1.0 hr = 5.5 lb/MMscf x1.0/1,020Btu x 2.1 tu/1.0 hr = 0.011 lb of VOC/hr Lbs of air contaminants/hr = lbs air contaminants/MMscf x 1.0 scf/1,020Btu x2.1 MMBtu/1.0 hr = 0.6 lb/MMscf x1.0/1,020Btu x 2.1 tu/1.0 hr = 0.001 lb of SO2/hr Tons of air contaminant/yr = lbs air contaminant/1.0 x 2,500 hr/1.0 yr x 1.0 ton/2,000 lb = 0.206 lb of NOx/1.0 hr x 2,500 hr/1.0 yr x1.0 ton/2,000 lb

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13 = 0.257 ton of NOx/yr Tons of air contaminant/yr = lbs air contaminant/1.0 x 2,500 hr/1.0 yr x 1.0 ton/2,000 lb = 0.173 lb of CO/1.0 hr x 2,500 hr/1.0 yr x1.0 ton/2,000 lb = 0.216 ton of CO/yr Tons of air contaminant/yr = lbs air contaminant/1.0 x 2,500 hr/1.0 yr x 1.0 ton/2,000 lb = 0.016 lb of PM/1.0 hr x 2,500 hr/1.0 yr x1.0 ton/2,000 lb = 0.02 ton of PM/yr Tons of air contaminant/yr = lbs air contaminant/1.0 x 2,500 hr/1.0 yr x 1.0 ton/2,000 lb = 0.011 lb of VOC/1.0 hr x 2,500 hr/1.0 yr x1.0 ton/2,000 lb = 0.014 ton of VOC/yr Tons of air contaminant/yr = lbs air contaminant/1.0 x 2,500 hr/1.0 yr x 1.0 ton/2,000 lb = 0.001 lb of SO2/1.0 hr x 2,500 hr/1.0 yr x1.0 ton/2,000 lb = 0.00125 ton of SO2/yr The analysis from the calculated contaminant categories (emission) generated in the hourly and yearly from the booth heater was derived by using the units for million British thermal units/hr (MMBtu/hr) thousands British thermal units/hr (MBtu/hr), and standard cubic feet/hr (SCF/hr). In working through the different steps in the calculation, one had to effectively forecast emissions during operation from interior of the booth using statistics to mathematically model the air emissions in order to mitigate air pollution risk to human and the environment as regulatory compliance . References Godish, T., Davis, W. T., & Fu, J. S. (2014). Air quality (5th ed.). Boca Raton, FL: CRC Press.

14 Gurjar, B., Molina, L., & Ojha, C. (2010). Air pollution: Health and environmental impacts. 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