Escolar Documentos
Profissional Documentos
Cultura Documentos
Process Heaters
.................................................................................
combustion controls, to over 90 percent for radiant burners and selective catalytic reduction. Cost effectiveness
varies with fuel and heater size. In 200-MMBtu/hr
process heaters, control costs typically range from $500
to $2500 per ton of NO X removed, although these costs
may be as high as $6000/ton in some cases.
SUMMARY
DESCRIPTION OF SOURCE
PROCESS HEATERS
STAPPA/ALAPCO
Recommendation
10,- Process heaters are currently meeting
limits similar to those for mid-sized
industrial boilers, including 0.10, 0.12
and 0.30 lb/MMBtu for gas-, distillateoil- and residual-oil-fired units, respectively. Agencies seeking additional
reductions could require limits similar
to those set by several California local
districts, including 0.036 Ib/MMBtu for
gas and 0.05 lb/MMBtu for other liquid
fuels.
residual-oil-fired heaters, typical uncontrolled emissions
are 0.2-0.4 and 0.4-0.6 lb/MMBtu, respectively.
NATIONAL EMISSIONS ESTIMATE
Table 2 details how the 169,000 tons of estimated annual
process heater NO,, emissions are broken down by fuel
use.
GEOGRAPHIC DISTRIBUTION OF SOURCES AND
EMISSIONS
45
CONTROLLING NITROGEN OXIDES UNDER THE CLEAN AIR ACT: A MENU OF OPTIONS
PROCESS HEATERS
CONTROLLING NITROGEN OXIDES UNDER THE CLEAN AIR ACT: A MENU OF OPTIONS
Figure 1
,CONVECTIVELY
.. I HEATED TUBES
.
.
BURNER
REFERENCES
Table 1
Fuel
Residual Oil
Distillate Oil
Natural Gas
Natural Draft
Mechanical Draft
0.42
0.20
0.14
0.54
0.32
0.26
Table 2
Fuel
Number of
Process Heaters
National Emissions
(tons/year)
Oil
Gas
390
4,270
18,000
152,000
Total
4,660
170,000
48
PROCESS HEATERS
Table 3
Residual Oil
Distillate Oil
5-20
30-50
30-60
N/A
75-90
30-60
5-20
30-50
30-60
N/A
80-90
30-60
Table 4
Technology
LNB
RB3
FGR 2
SNCR 2
SCR 5
Unit Size
25 MMBtu/hr
75 MMBtu/hr
200 MMBtu/hr
25 MMBtu/hr
75 MMBtu/hr
200 MMBtu/hr
25 MMBtu/hr
75 MMBtu/hr
200 MMBtu/hr
25 MMBtu/hr
75 MMBtu/hr
200 MMBtu/hr
25 MMBtu/hr
75 MMBtu/hr
200 MMBtu/hr
Total Capital
Cost ($)
82,000
210,000
350,000
230,000
440,000
790,000
Natural Draft
Annual Cost
($/year)
14,000
36,000
61,000
See note 4 below
See note 4 below
See note 4 below
See note 4 below
See note 4 below
See note 4 below
45,000
97,000
200,000
See note 4 below
See note 4 below
See note 4 below
49
5-20
50-60
30-60
90+
80-90
20-50
Cost Effectiveness
Total Capital
2050-2560
1720-2160
1100-1370
120,000
310,000
530,000
180,000
500,000
1,300,000
91,000
180,000
320,000
230,000
440,000
790,000
380,000
740,000
1,330,000
($/ton)
8190-10,920
5870-7820
4500-6000
'Costs are estimated for process heaters with a capacity factor of 0.9 and are in 1993 dollars.
Source: EPA, February 1993.
3
Source: Santa Barbara County APCD, 1991.
4
Requires conversion of heater to mechanical draft for application.
5
Source: Environex, 1991.
2
Natural Gas
Cost ($)
Mechanical Draft
Annual Cost
Cost Effectiveness
21,000
54,000
91,000
57,000
160,000
420,000
20,000
40,000
77,000
47,000
100,000
220,000
77,000
170,000
340,000
1650-2070
1390-1740
890-1110
2340-2610
2210-2470
2170-2420
1300-1550
870-1050
630-750
4620-6170
3370-4500
2640-3510
3300-3800
2600-3500
2000-2700
($/year)
($/ton)
CONTROLLING NITROGEN OXIDES UNDER THE CLEAN AIR ACT: A MENU OF OPTIONS
Table 5
Technology
LNB
FGR 2
SNCR 2
SCR 4
Unit Size
25 MMBtu/hr
75 MMBtu/hr
200 MMBtu/hr
25 MMBtu/hr
75 MMBtu/hr
200 MMBtu/hr
25 MMBtu/hr
75 MMBtu/hr
200 MMBtu/hr
25 MMBtu/hr
75 MMBtu/hr
200 MMBtu/hr
Total Capital
Cost ($)
82,000
210,000
350,000
230,000
440,000
790,000
Natural Draft
Annual Cost
($/year)
Cost Effectiveness
14,000
36,000
61,000
See note 3 below
See note 3 below
See note 3 below
48,000
110,000
220,000
See note 3 below
See note 3 below
See note 3 below
($/ton)
1430-1790
1200-1510
770-960
4880-6100
3580-4470
2810-3510
Costs are estimated for process heaters with a capacity factor of 0.9 and are in 1993 dollars.
Source: EPA, February 1993.
3
Requires conversion of heater to mechanical draft for application.
4
Source: Environex, 1991.
}
Total Capital
Cost ($)
120,000
310,000
530,000
91,000
180,000
320,000
230,000
440,000
790,000
380,000
740,000
1,330,000
Mechanical Draft
Annual Cost
Cost Effectiveness
21,000
54,000
91,000
20,000
40,000
77,000
50,000
110,000
240,000
83,000
180,000
390,000
1340-1680
1130-1410
720-900
1580-2100
1070-1420
770-1020
3190-3980
2370-2970
1900-2370
2920-3280
2160-2430
1710-1930
($/year)
($tton)
Table 6
Technology
LNB
FG R 2
SNCR2
SCR4
Unit Size
25 MMBtu/hr
75 MMBtu/hr
200 MMBtu/hr
25 MMBtu/hr
75 MMBtu/hr
200 MMBtu/hr
25 MMBtu/hr
75 MMBtu/hr
200 MMBtu/hr
25 MMBtu/hr
75 MMBtu/hr
200 MMBtu/hr
($)
82,000
210,000
350,000
230,000
440,000
790,000
Natural Draft
Annual Cost
($/year)
Cost Effectiveness
14,000
36,000
61,000
See note 3 below
See note 3 below
See note 3 below
50,000
110,000
240,000
See note 3 below
See note 3 below
See note 3 below
($/ton)
680-850
580-720
370-460
2410-3010
1790-2230
1420-1780
l Costs are estimated for process heaters with a capacity factor of 0.9 and are in 1993 dollars
EPA, February 1993.
3Requires conversion of heater to mechanical draft for application.
2Source:
4
50
($)
120,000
310,000
350,000
91,000
180,000
320,000
230,000
440,000
790,000
380,000
740,000
1,330,000
Mechanical Draft
Annual Cost
Cost Effectiveness
21,000
54,000
61,000
20,000
40,000
77,000
52,000
120,000
250,000
78,000
170,000
350,000
800-1000
670-840
290-360
930-1250
630-840
450-600
1950-2440
1470-1840
1190-1490
1630-1830
1180-1330
910-1030
($/year)
($/ton)
PROCESS HEATERS
Table 7
Selected Process Heater Retrofit NO x Emission Limits
State
Illinois
Louisiana
Michigan
Texas
Virginia
Gas-Fired
0.10-0.18
0.10-0.18
0.20
0.10-0.18
0.20
Distillate Oil-Fired
0.10-0.12
0.30
0.30
0.30
0.25
Residual Oil-Fired
0.23-0.30
0.30
0.40
0.30
0.25
Table 8
Bay Area
Emission Limit
(lb/MMBtu)
gas
0.036
other
0.052
San Joaquin
gas
0.036
li quid
0.052
South Coast
gas
0.037
li quid
0.050
other
0.037
Ventura
unspecified
0.050
California Air Resources Board: RACT Guidance
gas
0.084
other
0.150
California Air Resources Board: BARCT Guidance
0.036
gas
other
0.052
BARCT = Best Available Retrofit Control Technology
Boiler Size
( MMBtu/lir)
>10
>_10
>_10
>_10
?2, <5
>_5
>40
>_5
>_5
>_5
?5
?5
51