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3、f the entire set to gain a complete understanding of fugitive emissions from refinery process drains. I STD=API/PETRO PUBL 4bBL-ENGL 1994 U7322qU 0626785 983 E ABSTRACT Emissions from refinery process drains are under increasing regulatory scrutiny, particularly with respect to volatile organic comp
4、ounds (VOCs) and hazardous air pollutants (HAPS). Drain emissions are currently estimated using EPAs AP-42 factor for non-methane hydrocarbons. The factor is now considered obsolete because it does not reflect design modifications that have resulted in significant reductions in emissions. As a resul
5、t, the AP-42 factor over-predicts emission rates in many cases. API has recently sponsored projects that investigate emissions from process drains and that develop mechanistic models to predict VOC and HAP emission rates based on mass transfer fundamentals and conservation of mass. In this project,
6、API has funded the development of a user-friendly model called APIDRAIN that incorporates a suite of procedures for estimating emission rates from refinery process drains. In addition to the mass transfer model, APIDRAIN also provides an option to estimate emission rates using emission factors, corr
7、elation equations, and a stripping efficiency estimation procedure. Users may create process units, and within each process unit, specify the drain estimation procedure used. The level of detail in reports generated ranges from a simple facility overview to a detailed categorization of emission rate
8、s of specific chemical compounds from individual drains within each process unit. The APIDRAIN model will enable users to easily categorize drains and report drain emission rates in various process units based on the quality of collected analytical data of contaminants in process liquid or gas phase
9、 streams. Previous page is blank. STDmAPIIPETRO PUBL 461-ENGL 1999 I 0732290 06267b BIT = TABLE OF CONTENTS Section Page I INTRODUCTION 1-1 1 . 1 I . 2 I . 3 1.4 I . 5 1.6 2 2 .I BACKGROUND . 1-1 PRINCIPLES OF USE AND SYSTEM REQUIREMENTS . 1-2 INSTALLATION . 1-3 SAVING APIDRAIN FILES 1-4 BITING FROM
10、 APIDRAIN . 1-4 TECHNICAL SUPPORT 1-4 USING APIDRAIN 2-1 START-UP . 2-1 2.2 FACILITY DESCRIPTION 2-3 2.3 APIDRAIN TOOLBAR ICONS 2-5 2.4 PROCESS DATA ENTRY 2-7 2.4.1 Creating Process Units and Drains . 2-7 2.4.2 Use of AP-42 Zero/Pegged Factors 2-11 2.4.3 2.4.4 Use of Stripping Efficiency Factor Esti
11、mation Method . 2-14 2.4.5 Use of the UT Drain Model 2-19 REPORT SET-UP AND PRINTING . 2-24 Use of OVA Screening Values 2-13 2.5 3 3.1 3.2 MODEL EQUATIONS . 3- 1 USE OF STRIPPING EFFICIENCY FACTORS . 3-1 MODELING EQUATIONS FOR THE UT DRAIN MODEL . 3-5 3.2.1 Sealed Drain . 3-5 3.2.2 Unsealed (Open) D
12、rain . 3-10 Previous page is blank . STD-APIIPETRO PUBL 4681-ENCL 1999 m 0732290 0626787 75b = 3.3 TEMPERATURE-CORRECTED FACTORS . . 3-1 3 3.3. I 3.3.2 Diffusion Coefficients . . . . . . . . . . . . . . 3-1 3 Viscosities . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 5 3.3.3 Phase Densiti
13、es 3-16 4 4.1 4.2 MODEL “WORK-AROUNDS” FOR EXCELm 97 . 4-1 WARNING DISPLAY FOR CHE-NAMELIST FORMULA REFERENCE . 4-1 INITIATION OF STRIPPING EFFICIENCY MODEL 4-1 5 REFERENCES 5-1 Appendix A COMPARISON OF METHODS FOR CALCULATING HENRYS LAW COEFFICIENTS A-I Appendix B ESTIMATION OF DIFFUSION COEFFICIEN
14、TS BY DIFFERENT CORRELATIONS . . . B-1 Appendix C CONVERSION FACTORS . C-I STD-API/PETRO PUBL 468L-ENGL 1999 0 0732270 Ohtb7BB b92 Fiaure Figure 2.1 Figure 2.2 Figure 2.3 Figure 2.4 Figure 2.5 Figure 2.6 Figure 2.7 Figure 2.8 Figure 2.9 LIST OF FIGURES Page Enable Macro Dialog Box 2-1 APIDRAIN Start
15、-up Dialog Box. . 2-2 New Facility Worksheet . 2-2 Author Information . 2-3 General Facility Information Sheet 2-4 Facility Operation Sheet 2.5 Contact Information Sheet . 2-5 Add Process Unit Dialog 1 . 2-7 Process Unit Worksheet Prior to Drain Entry . 2-8 Figure 2.1 O Add New Drain Dialog Box . 2-
16、9 Figure 2.1 I Example of Drain I.D. After Use of Arrow Key to Edit Name 2-9 Figure 2.12 Process Unit Worksheet After Drain Emission (Zero Default Value) 2-10 Figure 2.13 Process Unit Characterized by 3 AP-42 Zero/Pegged Factors . 2-12 Figure 2.14 Facility Sheet After a Drain Has Been Added . 2-13 F
17、igure 2.1 5 Drain Emissions from AP-42 and OVA Methods 2-14 Figure 2-16 Facility Worksheet Summary with OVA Correlation Method Added . 2-15 Figure 2.1 7 Stripping Efficiency Model Data Entry Screen 2-16 Figure 2.1 8 Drain Worksheet Displaying Scroll List of Chemicals . 2-18 Figure 2.19 Drain Workshe
18、et Showing Summary of Emission Rates from Each Influent . 2-19 Figure 2.20 UT Model Drain Characterization Worksheet . 2-21 Figure 2.21 UT Drain Worksheet Showing Emission Summary for Each Chemical Compound 2-23 Figure 2.22 UT Model Worksheet with Unhidden Chemical Properties . 2-24 Figure 2.23 Dial
19、og Box for Selection of OVA Correlation in Report Output . 2-25 Figure 2.24 Example of Emission Report Screen in APIDRAIN 2-26 Figure 2.25 Printer Options Toolbar 2-27 Figure 2.26 Page Set-up Options 2-27 STD-APIIPETRO PUBL 4681-ENGL 1999 0732290 Ob26787 529 m Figure 2.27 Figure 2.28 Figure 2.29 Fig
20、ure 3.1 Figure 3.2 Figure 4.1 Figure 4.2 Figure 4.3 Example of Facility Emission Summary Report 2.28 Process Unit Emission Report 2.28 Drain Emission Summary Report . 2.29 Schematic Representations of Unsealed and Sealed Drains 3-2 Modeled Density of Water by Non-Linear Least Squares Regression Tech
21、nique 3-17 Dialog Box with Che-Namelist Formula Reference 4.1 Stripping Efficiency Model Worksheet with “#NAME? Notation 4.2 Stripping Efficiency Model Worksheet After Saving Procedure 4-3 sTD.API/PETRO PUBL 468L-ENGL 1999 = 0732290 Ob26790 240 LIST OF TABLES Paqe Table 1-1 Applicability of Drain Em
22、ission Estimation Procedures in APIDRAIN Model . 1-2 Table 2-1 AP-42 Zero and Pegged Emission Factors .2-1 I Table 3-1 Table 3-2 Stripping Efficiency Factors for High Volatility Compounds .3-4 Table 3-3 Table 34 Table A-I Comparison of Henrys Law Coefficient Estimation Methods with Measured Data . A
23、-3 Table B-I Comparison of Diffusion Coefficients by Gilliland and Wilke-Chang Correlations Using Molar Volume at Compound Boiling Point and at 20 OC . B-3 Examples of Compound Volatility in Stripping Efficiency Model 3-3 Stripping Efficiency Factors for Moderate Volatility Compounds . 34 Stripping
24、Efficiency Factors for Low Volatility Compounds 3-5 STD.API/PETRO PUBL 4b82-ENGL 1777 m 0732270 Ob2b79L 287 m Section 1 INTRODUCTION 1.1 BACKGROUND Emissions from refinery process drains are under increased regulatory scrutiny, particularly with respect to volatile organic compounds (VOCs) and hazar
25、dous air pollutants (HAPS), pursuant to the Clean Air Act Amendments of 1990. Emissions from refinery process drains are currently estimated in the industry using EPAs AP-42 factor of 0.070 Ib/hr of total non-methane hydrocarbons. There have been significant design modifications to refinery process
26、drains over the years since the AP-42 factor was first developed. The design changes have resulted in significant emission reductions from process drains, and the AP-42 factor is now considered obsolete because it over-predicts emission rates in many cases. The American Petroleum Institute (API) fun
27、ded a project to develop a mathematical model that predicts acceptably accurate emissions from refinery process drains. A mechanistic model was developed to predict VOC and HAP emission rates from process drains based on mass transfer fundamentals and conservation of mass. The mechanistic model acco
28、unts for emissions that may occur as the process wastewater is discharged from a pipe nozzle to the drain hub, emissions from the surface of a water seal, if present, and emissions from wastewater falling from the leg of the process drain into water conveyed in the underlying collection channel. API
29、 initiated a project to incorporate the mechanistic model for refinery process drains into a suite of procedures for estimating emissions from refinery process drains resulting in a user- friendly software tool called APIDRAIN. In addition to the mass transfer mechanistic model, APIDRAIN also offers
30、 two other options for estimating emissions from process drains. They include (I) emission factors, and (2) correlation equations. Each calculation option requires considerably different input information. Thus, the user can choose the appropriate estimation method based on the level of detailed inf
31、ormation available. APIDRAIN enables the user to sum up the emissions from drains within a refinery process unit, or from the entire refinery. The model user can quickly and easily predict the contribution of process drain emissions to the total emission inventory of a refinery. 1-1 Previous page is
32、 blank. - STD=API/PETRO PUBL 468L-ENGL 1999 = 0732290 062b792 013 = Estimation Procedure The estimation procedures provided by APIDRAIN are generally applicable across the petroleum industry (exploration and production, refining and marketing terminals), as indicated in Table 1-1. The screening valu
33、e correlation developed for the South Coast Air Quality Management District (SCAQMD) applies only to petroleum refineries in southern California, and only to inactive drains in those refineries. The stripping efficiency procedure and University of Texas model may be used to estimate process drain em
34、issions in other industrial sectors. The stripping efficiency procedure applies only to sealed drains, while the UT model can be used to estimate emission rates from both sealed and unsealed drains. Applicable to South. California Petroleum Other Petroleum Refineries Industry Industries Table 1-1 Ap
35、plicability of Drain Emission Estimation Procedures in APIDRAIN Model AP42Zero/Pegged Factors OVA Screening (EPA) OVA Screening (SCAQMD)“ Stripping Efficiency Factorst University of Texas Model X X X X X X X I I I I I * for inactive drains for sealed drains only 1.2 PRINCIPLES OF USE AND SYSTEM REQU
36、IREMENTS APIDRAIN operates as a workbook under the PC-based MicrosoftR Excel“ for WindowsTM environment, and therefore requires a PC system with the capacity to run ExcelTM and the Windowsm operating system. (At a minimum, a 486DX2 Windowsm 3.1 I platorm with 8 Mbyte RAM is needed to operate the API
37、DRAIN workbook.) The user must complete independent installations of Windowsm and Excelm to begin using the software. The APIDRAIN workbook is enhanced with automatic functions that enable the user to summarize easily important reporting information and to generate tabular emission totals for both s
38、pecific refinery process units and for the entire refinery. Therefore, it is not necessary for the user to possess a rigorous understanding of Excel“ to use APIDRAIN; only a few common principles of the WindowsTM 1-2 STD*API/PETRO PUBL 4bBL-ENGL 1999 073Z270 0626773 TST operating environment are nee
39、ded (such as point-and-click, and navigation of tab and arrow keys). APIDRAIN is also designed such that the user has a great deal of discretion in the selection of emission estimation procedures. 1.3 INSTALLATION APIDRAIN comes with an installation program to assist a user in transferring the model
40、 to the users computer hard drive. Users must employ the SETUP.DE program to install APIDRAIN. To begin the installation program from MS-WindowsTM 95, the user first clicks with the mouse pointer on the WindowsTM Explorer icon, and then on the floppy disk drive (usually A:). From WindowsTM 3.1 , use
41、 the file manager to access the floppy drive (usually A:). The floppy disk contains four files: apid.OO1 apidc.inf disk.id 0 setup-exe Double-click on the setup.exe file to activate the installation program. A dialog box appears with development information, with a prompt to continue; click OK to pr
42、oceed. A second dialog box next appears offering the user two choices, either to proceed with the installation or to exit the installation. The user should click on the install option and OK to proceed. The installation next prompts the user to declare the drive on which to install the model; this w
43、ill usually be the local hard drive root directory (C:). Click on OK to accept the selected drive. The installation program then prompts the user to define the directory name for the APIDRAIN files. By default, the installation will create a directory called “APIDRAIN“ at the root directory. The use
44、r may accept this by clicking on the OK box, or if desired, modify the name of the directory, using up to eight characters, prior to accepting. At the completion of the installation, a dialog box appears with address and contact information about the developer (Enviromega Inc.) regarding technical a
45、ssistance or bug reporting. The user will now have a program group box with an icon on the computer screen. The icon is: 0 APIDrain 1 .O 1-3 STD-APIIPETRO PUBL 4bBL-ENGL L397 1.4 SAVING APIDRAIN FILES 0732270 0b2b794 976 m To ensure the model runs properly, it is recommended tha, users retain the or
46、igin open an existing facility workbook; 2- 1 STD.API/PETRO PUBL 4b81-ENGL 1999 O732290 0626796 b9 Figure 2.2 APIDRAIN Start-up Dialog When the user clicks on the Create New FaciMy Workb-ok button, the summary facility p ge will appear (Figure 2.3). At this point in the program, the faciMy summary i
47、s empty, showing no process units or facility total emissions. All estimation methods are shown on this summary, so that emissions from different units may be characterized by different estimation methods (AP42 factors, OVA screening correlations, stripping efficiency factors or the UT drain model).
48、 Figure 2.3 New Facility Worksheet If the user has previously created a facility workbook, by clicking on the Open Existing FaciMy Workbook button, a dialog box appears that allows the user to select the directory and file name of the previously created facility. 2-2 STD-API/PETRO PUBL 4bBL-ENGL 199
49、9 0732290 0626797 bT5 RI 2.2 FA CIL1 N DESCRIPTION The next step for a user starting to work with the spreadsheet will be to characterize the facility (refinery, distribution terminal, other). Point the mouse to the menu at the top of the screen to the item Facility and click. A dropdown box will appear with the following items: Add New Process Unif Edit Selecfed Process Unif Delefe Selected Process Unif Auf
