Analysis of Multi-Pollutant Emissions Inventories for Key ......2007 Acid Rain SO 11 11 11 9 2...

1

April 16, 2009

Analysis of Multi-Pollutant Emissions Inventories for Key Industrial Sectors

Anne Pope, U.S. EPA, [email protected] Chappell, U.S. EPA, [email protected]

Tina Ndoh, U.S. EPA, [email protected]

2

Multi-Pollutant Inventories Are Needed to Support Development of Multi-Pollutant Sector Strategies

EPA has initiated multi-pollutant analyses to explore the development of multi-pollutant sector-based approaches for managing emissions and air quality.

NAS report “Air Quality Management in the United States”, recommends: EPA take an integrated multi-pollutant approach to controlling emissions of pollutants posing the most significant risks

A “Sector” is a logical grouping of processes, emissions sources, and pollutants in a manner that maximizes environmental benefit while reducing costs and regulatory burden

The Approach:Considers multi-pollutant interactions and emission reduction options Relies on replicable and consistent emissions inventories and numerical metricsIncludes measurable environmental improvement

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Benefits of Multi-Pollutant Sector Strategies

Benefits to PublicFocus on reducing emissions of greatest public health interestOptimization of tax $ spentAbility to address local concerns better

Benefits to IndustryMaximization of capital and operating environmental expendituresReduction in costs of control or over-control in the wrong areasAvoidance of “stranded” costs associated with piecemeal investment in control equipment for individual pollutantsIncreased flexibility Consolidated monitoring, recordkeeping and reporting

Benefits to RegulatorsDevelopment of better emissions data and compilation tools for characterizing individual sectorsReduction in existing regulatory barriers to improve environmental performanceConsolidated requirements to reduce overall administrative burden

4

Emission Inventory Data Used in This Analysis

CAPs:Includes CO, NOx, PM10, PM2.5, SO2 and VOC Data source - 2005 NEI v2

HAPsIncludes 382 individual pollutantsData source - 2005 NEI v2

GHGs:Includes CO2, CH4, and N20Data sources:

Electric Utilities - CAMD Acid Rain Program & EGRID databasesIron and Steel Mills, Lime Manufacturing, Petroleum Refineries, and Portland Cement - GHG Reporting Rule Other categories - Inventory of U.S. Greenhouse Gas Emissions and Sinks

5

Industrial GHG Emissions and Facility Count

0

50

100

150

200

250

Petr

oleu

m R

efin

erie

s

Lan

dfill

sC

emen

t

Iron

and

Ste

el

NG

Tra

nsm

issi

on C

ompr

esso

rsPu

lp a

nd P

aper

Petr

oche

mic

als

Nat

ural

Gas

Pro

cess

ing

Und

ergr

ound

Coa

l Min

esL

ime

Nitr

ic A

cid

Hyd

roge

n

Am

mon

ia

HC

FC-2

2 Pr

oduc

tion

SF6

from

Ele

ctri

cal E

quip

men

t

Und

ergr

ound

Gas

Sto

rage

O

ther

Che

mic

als

Off

shor

e O

il an

d G

asA

dipi

c A

cid

Oth

er M

etal

sA

lum

inum

Ele

ctro

nics

Fluo

rina

ted

Gas

Pro

d. (F

ugiti

ves)

Gla

ss

LN

G T

erm

inal

s and

Sto

rage

MM

TCO

2 e

02505007501,0001,2501,5001,7502,0002,2502,5002,7503,000

Num

ber o

f Fac

ilitie

s

7,800

EG

Us

2,661

6

Stationary Sources of CO, NOx, SO2*

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

CO Emissions NOx Emissions SO2 Emissions

Residential Energy andCombustion

Pulp and Paper

Petroleum Refining

Other

Oil & GasProducttion/Distribution

Non-Ferrous Metals

Iron and Steel

Electric Utilities

Crop Production

Chemical Manufacturing

Cement Manufacturing

Boilers & Process Heaters

*excludes fires, open burning and road dust.

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Stationary Sources of PM*

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

PM 10 Emissions PM2.5 Emissions

Residential Energy andCombustion

Pulp and Paper

Petroleum Refining

Other

Mining

Livestock Production

Iron and Steel

Electric Utilities

Crop Production

Construction




8

Stationary Sources of VOC*


3%

18%

3%

2%

3%

7%

14%10%1%

3%

2%

15%

18%

1%


Consumer/ Commercial Products Use

Crop Production

Cutback Asphalt

Furniture Manufacturing

Oil & Gas Production/Distribution

Organic Products Distribution

Other

Petroleum Refining

POTWs

Printing

Pulp and Paper

Residential Energy and Combustion

Solvent Use

9

Stationary Sources of HAPs*

0%

20%

40%

60%

80%

100%

Emissions Cancer Noncancer

Residential Energy andCombustionPulp and Paper

Other

Organic ProductsDistributionOil and Gas Production &DistributionNon-Ferrous Metals

Iron and Steel

Halogenated Solvent Use

Electric Utilities

Dry Cleaning Facilities

Crop Production

Consumer/CommercialProducts UseChemical Manufacturing


*excludes fires, open burning and road dust

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Ranking of Sectors across Pollutant Emissions

27215051131411101610Mineral Processing33425853265315269Mining

108896910898Chemical Manufacturing

712512389677Pulp and Paper

1220145121925356Oil & Gas Production & Distribution

433738912141145Iron and Steel

31334449817137104Cement Manufacturing

2519152435272320203Solid Waste Landfills

30273015411159122Petroleum Refining21126124131Electric Utilities

Rank Non CancerTox Wt

Rank CancerTox Wt

Rank 188

HAP

Rank VOC

Rank SO2

Rank PM25

Rank PM10

Rank NOx

Rank CO

Rank GHG

Source Category

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Correlation Matrix of HAPs & CAPs with GHGs

1-0.02134-0.171580.00668-0.05832-0.029840.282330.07782Lime Manufacturing

10.223800.631460.6150430.692550.644170.563660.72917Iron and Steel

10.382060.188410.382600.331090.288050.591790.09715Portland Cement

10.555320.581440.288900.646970.602400.705120.26306Petroleum refining

10.689560.056210.724680.695420.722120.862160.23756Electric Utilities

CO2Equivalent188 HAPsVOCSO2PM2.5PM10NOxCO

INDUSTRY

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Electric Utility Summary

acetaldehyde, hexane, HCl, HF, methanol

HAPs with highest emissions

acrolein, As, HCl, HF, Mn, Ni

HAPs with highest Non-Cancer effect

As, Be, Cd, Cr VI, Ni

HAPs with highest Cancer risk

238 # HAPs (individual) reported

91111112007 Acid Rain SO2Nonattainment areas

302332340365# Facilities in PM2.5Nonattainment areas

591010# Facilities in CO Nonattainment areas

405478495524# Facilities in Ozone Nonattainment areas (8 hr standard)

48494949# U.S. States1111# Tribes

735769781799# U.S. Counties1194132813801440# Unique Facilities

HAPsCAPsGHGTotalParameter

15122810528469595265435666188 HAP

3329710827735380127155VOC

502072921231143731291687710722071SO2

242568114423825157008556963PM2.5

289407127114262188115687284PM10

122652619719370968201993887315NOx

5390166283816727831NH3

28838928392107309179924223CO

83953512317755617118963336591273312661336595GHG

PM2.5SO2COOzone

Nonattainment Area Emissions (tpy)Total Emissions

(tpy)

Pollutant

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Electric Utility: Correlation of GHG Emissions to CAP and HAP Emissions

EGUs - HAPs & GHGs

y = 2822.9x + 1E+06R2 = 0.4755

0

5,000,000

10,000,000

15,000,000

20,000,000

25,000,000

30,000,000

0 2,000 4,000 6,000 8,000 10,000

HAPs (tpy)

CO

2 Eq

. (tp

y)

HAPs Linear (HAPs)

EGUs - SO2 and GHGs

y = 134.1x + 956806R2 = 0.5252

0

5,000,000

10,000,000

15,000,000

20,000,000

25,000,000

30,000,000

0 50,000 100,000 150,000 200,000

SO2 (tpy)

CO

2 Eq

. (tp

y)

SO2 Linear (SO2)

EGUs - NOx and GHGs

y = 553.7x + 387213R2 = 0.7433

0

5,000,000

10,000,000

15,000,000

20,000,000

25,000,000

30,000,000

0 5,000 10,000 15,000 20,000 25,000 30,000 35,000 40,000 45,000

NOx (tpy)

CO

2 Eq

. (tp

y)

NOx Linear (NOx)

EGUs - PM2.5, VOCs, and GHGs

y = 2535x + 985357R2 = 0.4836

y = 488.86x + 2E+06R2 = 0.0032

0

5,000,000

10,000,000

15,000,000

20,000,000

25,000,000

30,000,000

0 2,000 4,000 6,000 8,000 10,000 12,000

PM2.5 or VOCs (tpy)

CO

2 Eq

. (tp

y)

PM2.5 VOC Linear (PM2.5) Linear (VOC)

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8Taconite2EAF and DRI

94EAF2Integrated Iron and Steel &EAF

11Integrated Iron and Steel6Coke Ovens & Integrated Iron and Steel

12Coke OvenNumber of FacilitiesType of Operations

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Iron and Steel Summary

benzene, coke oven emissions, Cl2, HCl, Mn


acrolein, As, Cl2, Mn, Ni

HAPs with highest Non-Cancer risk

As, Cr VI, coke oven emissions,

Ni, POM


185# HAPs individual reported






99899799# U.S. Counties 135119128135# Unique Facilities


210014004410188 HAP

11213927517548VOC

583485622085551SO2

186971476427607PM2.5

252672077142039PM10

5219049787111566NOx

449113414523554502CO

652288515407518793862647GHG

PM2.5SO2COOzoneNonattainment Area Emissions (tpy)Total

Emissions (tpy)

Pollutant

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Iron and Steel: Correlation of GHG Emissions to CAP and HAP Emissions

Iron and Steel - CAPs & GHG

y = 1774.9x + 267824R2 = 0.4796

y = 358.15x + 345031R2 = 0.3177

y = 328.78x + 450790R2 = 0.3783

y = 2093.9x + 373532R2 = 0.3987

0

1,000,000

2,000,000

3,000,000

4,000,000

5,000,000

6,000,000

7,000,000

0 5,000 10,000 15,000 20,000

CAPs (tpy)

CO

2 Eq

. (tp

y)

NOx PM2.5 SO2 VOCLinear (PM2.5) Linear (NOx) Linear (SO2) Linear (VOC)

Iron and Steel - HAPs and GHG

y = 2496.7x + 580132R2 = 0.0501

0

2,000,000

4,000,000

6,000,000

8,000,000

10,000,000

12,000,000

14,000,000

0 1,000 2,000 3,000 4,000 5,000

HAPs (tpy)

CO

2 Eq

. (tp

y)

HAPs Linear (HAPs)

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Lime Summary

acetaldehyde, HCl, HF, methanol


acrolein, As, HCl, Mn, Ni


acetaldehyde, As, Cd, Cr VI, Ni










48339132762204188 HAP

259739913125VOC

6689132228272751526SO2

381641803969013PM2.5

91210823375115165PM10

10270751566597453151NOx

3041227814269338638CO

8475660116845417775517975328020714GHG

PM2.5SO2COOzone


(tpy)

Pollutant

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Lime: Correlation of GHG Emissions to CAP and HAP Emissions

Lime Manufacturing - NOx, PM2.5, SO2 and GHGs

y = 114.35x + 246146R2 = 0.0797

y = -129.52x + 319055R2 = 0.0085

y = 1.6893x + 329042R2 = 4E-05

0200,000400,000600,000800,000

1,000,0001,200,0001,400,0001,600,0001,800,0002,000,000

0 2,000 4,000 6,000 8,000 10,000 12,000

CAPs (tpy)

CO

2 Eq

. (tp

y)

NOx PM2.5 SO2 Linear (NOx) Linear (PM2.5) Linear (SO2)

Lime Manufacturing - VOCs, HAPs and GHG

y = -480.49x + 335876R2 = 0.0294

y = -105.52x + 300736R2 = 0.0005

-500,000

0

500,000

1,000,000

1,500,000

2,000,000

0 200 400 600 800 1,000 1,200

VOC or HAPs (tpy)

CO

2 Eq

. (tp

y)

VOC HAPs Linear (VOC) Linear (HAPs)

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Petroleum Refinery Summary

benzene, hexane, methanol,

toluene, xylenes


acrolein, 1,3-butadiene, Cl2,

Mn, Ni


benzene, POM1,3-butadiene, Cr VI, naphthalene,






53515353# Facilities in Ozone Nonattainment areas(8 hr standard)

34303535# U.S. States*000# Tribes

98879999# U.S. Counties*

151137151152# Unique Facilities*


*includes territories

1162256400010423188 HAP

15133347237158101823VOC

961419069121961242175SO2

61084831388630566PM2.5

67666811509834842PM10

38277123067750149426NOx

27509185662082134050CO

552650723624657122535731233117905GHG

PM2.5SO2COOzone


(tpy)

Pollutant

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Petroleum Refinery: Correlation of GHG Emissions to CAP and HAP Emissions

Petroleum Refining -CAPs & GHG

y = 807.46x + 586469R2 = 0.4972

y = 3043.1x + 802971R2 = 0.4186

y = 116.07x + 1E+06R2 = 0.0835

y = 912.75x + 791841R2 = 0.3381

0

1,000,000

2,000,000

3,000,000

4,000,000

5,000,000

6,000,000

7,000,000

8,000,000

9,000,000

0 5,000 10,000 15,000 20,000 25,000 30,000

CAPs (tpy)

CO

2 Eq

(tpy

)

NOx PM2.5 SO2 VOCLinear (NOx) Linear (PM2.5) Linear (SO2) Linear (VOC)

Petroleum Refining - HAPs & GHG

y = 6532.4x + 955473R2 = 0.3084

01,000,0002,000,0003,000,0004,000,0005,000,0006,000,0007,000,0008,000,0009,000,000

0 200 400 600 800 1000 1200

HAPs (tpy)

CO

2 Eq

. (tp

y)

HAPs Linear (HAPs)

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Portland Cement Plant Locations

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Portland Cement Summary

benzene, Cl2, formaldehyde, HCl, toluene


acrolein, Cl2,HCl, Mn


benzene, Be, Cr VI, POM










91110526167188 HAP

257629638830VOC

2362341955155917SO2

5374441616804PM2.5

127481007938009PM10

5266851678217681NOx

1648819093154375CO

2601451127337283101412500GHG

PM2.5SO2COOzone


(tpy)

Pollutant

26

Portland Cement: Correlation of GHG Emissions to CAP and HAP Emissions

Portland Cement CAPs & GHG

y = 63.549x + 670541R2 = 0.0292

y = 1250.8x + 642510R2 = 0.1096

y = 69.802x + 739173R2 = 0.1464

y = 366.13x + 812033R2 = 0.0355

0

500,000

1,000,000

1,500,000

2,000,000

2,500,000

3,000,000

3,500,000

0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000CAPs (tpy)

CO

2 Eq

. (tp

y)

NOx PM2.5 SO2 VOCLinear (NOx) Linear (PM2.5) Linear (SO2) Linear (VOC)

Portland Cement - HAPs & GHGs

y = 1749.4x + 736149R2 = 0.146

0

500,000

1,000,000

1,500,0002,000,000

2,500,000

3,000,000

3,500,000

0 100 200 300 400 500 600 700 800

HAPs (tpy)

CO

2 Eq

. (tp

y)Haps Linear (Haps)

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High GHG Emitters Also Contribute to Poor Air Quality

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Example Sector: Refinery

Large source of industrial emissions

152 refineries in all, refining 25% of the world’s oil production

Lots of emission points, some difficult to characterize

Lots of regs NSPS, NESHAP, ACTs, CTGs)

Many are located in SIP nonattainment areas

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LandFarm

Transfer Racks

MarineVessel Loading

Tank Farm

WastewaterTreatmentProcess

Equipment Area

NearestResidences

Storm WaterLandfill

Land Farm

CoolingTowers

AdministrativeOffices

Plant’s Property Boundary Line

Parking Area

River

32

Petroleum Refineries RegsOriginal

Date Rule

1977Refinery Vacuum Producing Systems, Wastewater Separators, and Process Unit Turnarounds (ACT/CTG)

1977 Storage of Petroleum Liquids in Fixed Roof Tanks (ACT/CTG)1978 Leaks from Petroleum Refinery Equipment (ACT/CTG)1978 Petroleum Liquid Storage in External Floating Roof Tanks (ACT/CTG)1984 Refineries: Equip. Leaks (NSPS)1988 Refineries: Wastewater (NSPS)2008 Petroleum Refineries (NSPS)1984 Benzene Equipment Leaks (NESHAP)1989 Benzene Storage Vessels (NESHAP)1990 Benzene Transfer Operations (NESHAP)1990 Benzene Waste Operations (NESHAP)1995 Petroleum Refineries I (MACT)2002 Petroleum Refineries II (MACT)

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Refinery Fired Source Requirements

Maybe UUU

Maybe UUU

250 ppmv for >20 ltpd

98% control of TOC;92/97% control of HCl or to 30/10 ppmv

500 ppmv (suurogate for organic HAP)

<=1.0 lb/1000 lb coke burn + PM for CO boiler – or-Ni<= .029 lb/hr –or-Ni<= 0.001 lb/1000 lb coke burn

2002

NESHAPUUU (MACT)HAP

Catalytic Reformer

OtherHAP

NSPS JaCAP

NSPS J CAP

CAPEmission Source

500 ppmv500 ppmvCO

Flare minimization

See fuel gas combustion above

40/60 ppmv for >40 MMBTU/hr

-20 ppmv (3-hour); 162 ppmv H2S (3-hou avg)-60 ppmv H2S long term limit

250 ppmv for >20 ltpd99% control < 20 ltpd

25 ppmv

0.5 lb/1000 lb coke burn

80 ppmv

25 ppmv

<=0.5 lb/1000 lb coke burn (new) and <=1.0 lb/1000 lb coke burn (M/R)

2008/2009

None

See Fuel gas combustion above

None

-20 ppmv (3-hour); 162 ppmvH2S (3-hou avg)

250 ppmv for >20 ltpd

None

None

None

50 ppmv

<=1.0 lb/1000 lb coke burn + PM for CO boiler

1978

Subpart CC

MACT for Boilers and Heaters;NSPS Db

MACT for Boilers and Heaters

AllFlares

SO2Boilers

NOxProcess Heaters

SO2Fuel Gas Combustion

SO2SRP

SO2

PMFluid Coker

NOx

SO2

PMFCCU

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Refinery Non-Fired Source Requirements

References Subpart R

GasolineLoading

Gasoline Racks

Marine Vessels

Leak Detection and Repair

TOC/HAPCooling Towers

BWONReferences Benzene Waste Rule (BWON)

BenzeneWastewater

NSPS GGGa (more stringent leak definitions than VV/GGG)

NSPS QQQ VOC

Other Regs that ApplyNESHAP CCPollutantEmission Source

NSPS GGG

NSPS Kb

NSPS Kb

References NSPS VV or NESHAP H for components in HAP service

References NESHAP YGroup 1 controls for >10/25 TPY terminals

None

Group 1 Tank Controls

98% for VOC>33 kg/day (existing); >6.8 kg/day (new)

1995/2009

HAP/VOCEquipment Leaks

HAP

VOC

HAPStorage

VOC/HAPProcess Vents

36

Wastewater Systems

Collection Systems

API Separator DAF Activated Sludge

ClarifierSlop Oil Tank

Sludge to coker

37

CONCLUSIONS

Current GHG, CAP and HAP emission inventories are not sufficient to support development of multi-pollutant sector strategies

Data providers are strongly encouraged to integrate inventories across all pollutants at the unit/process level and to develop multi-pollutant sector strategies

Multi-pollutant sector strategies can result in a number of benefits including:

Focus on reducing emissions of greatest public health interestMaximization of capital and operating environmental expendituresReduction in costs of control or over-control in the wrong areasDevelopment of better emissions data and compilation tools for characterizing individual sectorsConsolidated monitoring, recordkeeping and reporting

Analysis of Multi-Pollutant Emissions Inventories for Key ......2007 Acid Rain SO 11 11 11 9 2...

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