voc control devices
TRANSCRIPT
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VOLATILE ORGANIC COMPOUNDS
CONTROLS
CUSTOMIZED ENVIRONMENTAL
TRAINING
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INSTRUCTOR
Insert Instructor Name Here
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Define Ground Level Ozone.
Define VOCs.
Discuss VOC Content.
Discuss Transfer Efficiency (TE).
Discuss Different Types of Sprayers.
Discuss Operator Training.
Discuss Capturing Fugitive Emissions.
Discuss Destroying Fugitive Emissions.
Recommend Handling, Storage, and Disposal Procedures for
VOCs.
OBJECTIVES
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GOALS
Understand the Definition Ground Level Ozone.
Understand the Definition of VOCs.
Understand What VOC content is. Understand Transfer Efficiency.
Be Familiar With The Different Types of Sprayers.
Understand the Importance of Operator Training.
Understand the Importance of Capturing Fugitive Emissions. Understand the Importance of Destroying Fugitive Emissions.
Be Familiar With Recommend Handling, Storage, and
Disposal Procedures for VOCs.
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BACKGROUND In 1998, 61,234 industries reported a total of 7.3 billion
pounds of hazardous chemicals released to the air, land and
water in the United States.
EPA estimates that 85,300 tons of toxic emissions from
solvents are released to the atmosphere annually
Solvents contain Volatile Organic Compounds (VOCs) that
have been found to contribute to the formation of smog and
ozone
Fugitive Air Emissions Containing VOCs can have a
Detrimental Impact on Human Health and the Environment.
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Supervisors
Facility Engineers
Maintenance Personnel
Department Managers
Building Occupants
Process Specialists Environmental and Safety Committees
LEARNERS
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The goal of this course is to provide supervisors
with the tools needed to help control Volatile
Organic Compounds (VOCs) from becoming fugitiveemissions. It recommends practical, actions that can
be carried out by facility management, maintenance
personnel and building occupants. The course will
help you to integrate good VOC control management
activities into your existing organization and identify
which of your staff have the necessary skills to carry
out those activities.
OVERVIEW
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WHAT THIS COURSE DOES NOT DO
The course is not intended to provide information to
install, repair, calibrate equipment or remove VOC
control devices. Nor is it intended to providealternative technologies or products that do not
contain VOCs. These specialties required training
beyond the intended scope of this course. Where
this expertise is needed, outside assistance should
be solicited.
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CLEAN AIR ACT AMENDMENTS
(CAAA)
CAAA of 1990 - One of the 189 hazardous air pollutants that has been identified is Volatile OrganicCompounds (VOCs).
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FEDERAL REGULATIONS
Pertinent Regulations:
40 CFR 59²National Volatile Organic Compound Emission
Standards For Consumer and Commercial Products
40 CFR 63 Subpart D²National Volatile Organic CompoundEmission Standards for Architectural Coatings
40 CFR 63 Subpart KK - National Emission Standards for thePrinting and Publishing Industry
40 CFR 60 Subpart RR - Standards of Performance for PressureSensitive Tape and Label Surface Coating Operations
40 CFR 60 Subpart FFF - Standards of Performance for FlexibleVinyl and Urethane Coating and Printing
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GROUND LEVEL OZONE
Ground level ozone, commonlyreferred to as "smog," is the singlemost serious air quality challenge for
most urban areas
In 1990, six out of every ten Americans were living in an areaswhere ozone levels exceeded EPA'sair quality standards
This was the number 1 urbanpollutant
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GROUND LEVEL OZONE
Ground level ozone is a complex problem that is difficultto control in part because it is not emitted directly byspecific sources
It forms in the air when there are chemical reactionsbetween two other pollutants nitrogen oxides (NOx) andvolatile organic compounds (VOCs) -- in the presence of heat and sunlight
Hotter temperatures accelerate ozone formation
Ozone at ground level is a major health andenvironmental problem
Ozone is beneficial substance in the stratosphere whereit shields the earth from the sun's harmful ultravioletradiation
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WHAT ARE VOCs?
VOCs* (volatile organic compounds); smog-formers
VOCs are released from burning fuel solvents, paints
glues and other products used at work or at home
VOCs, in addition to ozone (smog) effects, can causeserious health problems such as cancer and other effects
In addition to ozone (smog) effects, some VOCs suchas formaldehyde and ethylene may harm plants andanimals
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WHAT ARE VOCs?
All VOCs contain carbon (C), the basic chemicalelement found in living beings
Carbon-containing chemicals are called organic
Volatile chemicals escape into the air easily
Many VOCs are also hazardous air pollutants, whichcan cause very serious illnesses
EPA does not list VOCs as criteria air pollutants, butthey are included in this list of pollutants because effortsto control smog target VOCs for reduction
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REDUCING VOCs
Non-attainment areas must reduceVOC emissions by 3% per year, untilthe standard is attained
The base year of measuring is 1990.
All but Marginal areas must reduceVOC emissions by 15% by 1996
After that point, the areas must
continue to reduce VOC emissions by3% annually
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REDUCING VOCs
Purchase products with the lowest VOCconcentrations
Ensure there are high transfer efficiencies of theproduct to reduce waste and fugitive emissions
Collect and destroy fugitive VOC emissions
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VOC CONTENT
Coatings consist of solids and solvents
Solvents lower the viscosity and act as the carrier for
the solids
Solvents also are used to dissolve the solid resin
Solvents evaporate from the coating before, duringand after application
Solvents include VOCs, water, and exempt solvents
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VOC CONTENT
The VOC concentration does not change if youincrease the volume of mixed paint used, however, theVOC concentration does increase when adding VOC
solvents such as thinners or reducers
Manufacturers are currently being required by federalregulations to formulate paint to certain VOCspecifications, that when used, according to themanufacturer¶s recommendations, will meet VOCcontent limits
The VOC content is generally stated on the label or on the manufacturer¶s paint specification sheet
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CALCULATING VOC CONTENT
Information is from a Material Safety Data Sheet for thiscoating:
If the coating weighs 10.4 pounds/gallon, and it contains
the following VOCs:Xylene 2% x 10.4 lb/gal = .21 lb/gal
Toulene 2% x 10.4 lb/gal = .21 lb/gal
MEK 6% x 10.4 lb/gal = .63 lb/gal
Mixed Aliphatics 10% x 10.4 lb/gal = 1.04 lb/galTOTAL 20% x 10.4 lb/gal = 2.09 lb/gal
2.09 lb/gal x 119.8 (g/L) (gal/lb) = 250 grams/Liter
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TRANSFER EFFICIENCY
Transfer efficiency rates the ability of sprayequipment to put a coating on the parts being coatedrather than allowing it to escape as overspray or in
other forms of waste
If you spray 10 pounds of coating on uncoated partsand those parts gain two pounds as the result of beingcoated, you've achieved 20% transfer efficiency (TE)
In selecting new spray-painting equipment, 85% of industrial consumers rated transfer efficiency as
extremely or moderately important
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SPRAYING
The major types of spray equipment in use today are asfollows:
Conventional Air-Atomize Guns
Airless and Air-Assisted Airless Guns
High-Volume, Low-Pressure Spray Equipment
Electrostatic Spray Equipment
Plural-Component Spray Equipment
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CONVENTIONAL SPRAY GUNS
They have been around sincethe early part of this century
They emit a stream of coating
from a small opening in a fluidnozzle
The coating is broken up intotiny droplets by compressed air emerging from jets adjacent to the
fluid nozzle Relatively high air pressures atlow volumes will quickly atomizelarge amounts of coating
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CONVENTIONAL SPRAY GUNS
Advantages
In the hands of a skilled operator, produces smooth,reflective finishes
Can be used to coat almost any shape
Can apply paint at high production rates on partshanging from fast-moving conveyors
Are "user friendly." Most spray painters areexperienced in using them
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CONVENTIONAL SPRAY GUNS
Disadvantages
Very poor transfer efficiency
Wastes paint, increases cleanup costs, emitsmore VOCs
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AIRLESS SPRAY GUNS
Similar to a garden hose
Airless paint guns pressurize coatings to 900-1200psi (or higher) and forces it through a nozzle
Unlike conventional air spray, there are no jets of atomizing air to break up the paint and propel it to thesurface
Atomization is dependent upon high fluid pressure
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AIRLESS SPRAY GUNS
Advantages
In the absence of atomizing air, less overspray andbetter transfer efficiency
Can apply paint at high flow rates, resulting in abilityto meet high-production speeds
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AIRLESS SPRAY GUNS
Disadvantages
Inability to break up paint into very fine droplets, thusproducing a coarser spray and a rougher finish
Nozzle wear from high velocities cause abrasivepigments in paints to wear nozzle openings morerapidly as they travel through the nozzle.
Danger of airless-injection injury
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AIR-ASSISTED AIRLESS SPRAY
A hybrid of airless spray and conventional air-atomizespray, this kind of gun uses fluid pressures higher thanthose used in conventional air-atomize guns but lower
than those employed in normal airless spray Unlike normal airless guns, these guns do havecompressed air jets that supply atomizing air, but the air pressure is far lower than that used in conventional air-atomize guns
In operation, air-assisted airless guns provideatomization much better than is normal with airless
spray
Danger of airless injection is lessened, as is wear of fluid nozzles
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AIR-ASSISTED AIRLESS SPRAY
The main reason for considering use of air-assistedairless spray is better transfer efficiency
Its softer spray also makes it easier to spray intorecesses
Both air-assisted and pure airless spray operate athigh fluid pressures and thus can use smaller-diameter fluid lines
This translates into paint and solvent savings
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HVLP SPRAY
High-Volume Low-Pressure (HVLP) Spray is avariation of conventional air-atomize spray
The difference is that these guns are designed toatomize coatings using a high volume of air delivered at
low pressure
The lower pressure results in far less overspray and"bounce-back"
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HVLP SPRAY
Advantages
Better transfer efficiency results in less coating wasteand lower cleanup costs
The exact TE depends upon the circumstances inyour installation the booth design, spray techniques, themix of parts, etc.
Operators used to conventional guns generally find it
easy to learn how to use HVLP
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HVLP SPRAY
Disadvantages
Atomization may be insufficient to meet the strictestrequirements for smooth, fine finishes
May be difficult to atomize coating at sufficiently highrates to meet very high-production requirements
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HVLP SPRAY
Disadvantages continued
Some problems in achieving proper atomization withHVLP may be caused by "starving" the spray gun for air
Causes of this problem include use of air hoses thatare too long or too small in diameter; use of too many"quick-disconnect" fittings; and use of low-performanceair compressors and air regulators
Any one of these factors may result in too little air being delivered to the air cap, causing poor atomizationfrom the gun
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ELECTROSTATIC PAINTING
Electrostatic painting begins with a spray gun or other device to atomize a coating
The atomizing principle could be any of those
previously discussed conventional air-atomize, HVLP,or airless
The difference is that an electrostatic applicationdevice is equipped with a means of electrically chargingthe particles of a coating
A common method is to build in an electrode near thepoint where a coating is atomized
Parts are grounded, usually by hanging them on aconveyor securely connected to a ground
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ELECTROSTATIC PAINTING
The result is that fewer of the coating particles arepropelled into space as overspray and more areelectrostatically guided to the surfaces of the parts
being coated Sprayed particles will even turn the corner and beattracted to the back side of a part if the velocity of theparticles causes them to initially travel past the partsbeing painted
Transfer efficiency is greatly improved withelectrostatic spray
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ELECTROSTATIC PAINTING
Advantages
Higher transfer efficiency
Coverage of edgesUniformity of film thickness
Productivity - Electrostatic guns mounted onreciprocators are widely used to paint long runs of partsin high-production installations producing lower labor
costs
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ELECTROSTATIC PAINTING
Disadvantages
Electrostatically charged particles seek out the
nearest grounded surface, if that happens to be theridge area of a sculptured part, the valley may bedifficult to reach
For this reason, manual touchup with non-electrostatic guns may be necessary
Changes appearance of metallics that areelectrostatically charged
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ELECTROSTATIC PAINTING
Disadvantages continued
Fire hazard - there is danger that a spark can occur,
igniting paints containing flammable solvents Safety - If operators are not careful to follow set-updirections, they can be electrically shocked
Ergonomics - Operators may find some guns moredifficult and more tiring to handle
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ELECTROSTATIC PAINTING
Disadvantages continued
Cleanliness - It's mandatory in order to achieve thebenefits of electrostatic application
Some coatings may require reformulation becausesome solvents are more conductive than others
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ELECTROSTATIC ROTATIONAL
ATOMIZERS Rotary atomizers utilize centrifugal force rather thancompressed air or fluid pressure to atomize coatings
Discs
It is a spinning flat round disc with a hole in the center Feed coating through a hose so that it overflows throughthe hole and onto the spinning disc
Centrifugal force propels coating over the surface of thespinning disc until it flies off the edge
The coating atomizes as it is propelled through theatmosphere
Parts on hangers travel around the periphery of the discin an "omega loop," housed by a circular spray booth
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ELECTROSTATIC ROTATIONAL
ATOMIZERSBells
Electrostatic bells are similar in principle, except thatin this case the paint is fed through a hole at the closedend of the spinning bell-shaped atomizer
Centrifugal force propels paint from the edges of thebell
Bells may be mounted on reciprocators or on hand-
held guns.
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ELECTROSTATIC ROTATIONAL
ATOMIZERSHigher-Speed Rotational Devices
The latest bells and discs utilize higher rotationalspeeds, producing finer atomization, the ability to apply
higher-solids and waterborne coatings, and high transfer efficiency
These devices are often mounted on reciprocators invery-high-production installations
Less operator time is required in the disc application
But high-speed discs and bells also may have problemsin reaching into deep recesses
Some of the labor conserved by their use may berequired to hand-spray reinforce the areas of parts notproperly covered by the automatic spray
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VOLTAGE-BLOCK SYSTEMS
Voltage-Block Systems
Waterborne coatings are widely used to lessen theVOC content of coating materials
To oversimplify, if water replaces some or all of theorganic solvents used in paints, the resultant coatingmaterial contains less VOC
Electrostatically applying waterborne coatings can bea problem
To circumvent this, manufacturers have developedincreasingly sophisticated "voltage-block" systems
Switching to waterbornes is now easier because of the new technologies available in voltage-isolatingsystems
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PLURAL-COMPONENT GUNS
Plural-Component Guns continued
If the two components are mixed before entering apaint pump or pressure pot, the mixed material must besprayed promptly
It is said to have limited "pot life"
For this reason, spray guns have been developedthat bring each of the two components into the spray
gun through separate feed lines This remedies the "pot-life" problem, since mixingoccurs only at the moment before application
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CO2 SPRAY
CO2 Spray
The most recent development in spray applicationequipment is built to spray coatings formulated withheated, compressed carbon dioxide
Carbon dioxide is a liquid and can be used as acoating thinner
Since carbon dioxide is naturally present in the
atmosphere and is not considered hazardous The system was developed and patented by UnionCarbide under the trade name "Unicarb"
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HYBRIDS
Hybrids
There are numerous combinations of thetechnologies for spray painting
Such technologies as HVLP and air-assisted airless,already more efficient in raising TE, can be equippedwith electrostatics to further improve TE and lessenVOCs
But you have to test any system that appears to meetyour requirements in YOUR plant, while painting YOURmix of parts
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PAINT HEATERS
Paint Heaters
Heat reduces the viscosity of paint
Heating paint before it is atomized makes it possibleto spray more viscous paint
Paint heaters are a well-established, viable means of lowering VOCs
If the coating formulation permits use of a paint
heater, it will keep viscosity more constant, improve TE,lower wear of equipment and improve finish quality andconsistency
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CONVERTIBLE AIR-SPRAY GUNS
Convertible Air-Spray Guns
Some conventional air-sprayguns can be converted to HVLP
By inexpensively changing a fewcomponents of these guns, one canmove to HVLP without buying awhole new gun
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OPERATOR TRAINING
Training operators of sprayequipment has always beenimportant, but it becomes evenmore so when one considers howoperators' techniques caninfluence TE
Operator training and annual re-training may be the bestinvestment you can make
Knowledgeable operators withgood spray techniques canmeasurably improve TE withoutchanging equipment
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OPERATOR TRAINING
Pressures
Operators sometimes perceive that they can increaseair and fluid pressures to improve speed or reduce
orange peel Had they used the right air caps and fluid tips theymight have applied a smoother finish at lower fluid andair pressures
As much as 20% of a coating applied can be wasted
by too-high fluid and air pressures Use the lowest pressures consistent with finishquality and productivity
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OPERATOR TRAINING
Exhaust Rates
In trying to improve transfer efficiency plant engineersmust set air-exhaust rates in spray booths to the lowest
consistent with operator safety and comfort
Too-high rates can pull more coating onto air-exhaustfilters than is being applied on parts being coated
OSHA regulations specify minimum flow rates and
you should aim to be close to these rates
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OPERATOR TRAINING
Gun Handling
A well-trained operator holds the gun perpendicular tothe surface being coated, at a distance of six to eight
inches
Avoid "arcing" (holding the gun at less than a 90-degree angle to the surface)
Good operators move the spray gun toward the
surface to be coated before triggering As they reach the end of the surface being coated,they release the trigger to stop coating flow
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OPERATOR TRAINING
Gun Handling continued
Manufacturers of equipment have been paying muchmore attention to ergonomic design
Companies using ergonomically designed gunsreport not only greater worker satisfaction and higher-quality finishes, but actual improvements in TE
A competent operator learns how to overlap hisstrokes to apply a smooth finish without excessive
thickness Your equipment and coating suppliers can help youwith operator training and tell you where to find trainingcourses for your operators
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FUGITIVE VOC EMISSIONS
State permits will often dictate either "capture efficiency,""overall VOC reduction efficiency," or both
VOC Reduction can be expressed in the following way:
VOC Reduction = VOC Capture x VOC DestructionVOC Capture = % of the VOC emissions that is exhaustedto the VOC control
VOC Destruction = % of the VOC emissions that isexhausted to VOC control that is destroyed
Example:VOC Destruction for Control Device = 95%VOC Capture Rate = 90%VOC Reduction = 0.95 x 0.90 = 0.855 or 85.5%
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TOTAL ENCLOSURE
EPA Guidelines for "TOTAL ENCLOSURE"
1. VOC sources not close to indraft openings.
2. Minimum openings in room of less that 5% of total
enclosure surface area.3. Minimum indraft air velocity of 200 fpm.
4. Access doors and windows closed during routineoperation.
5. All exhaust points must be directed to a controldevice.
With "total enclosure," EPA will assume 100% of totalcapture under these guidelines.
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CAPTURING FUGITIVE VOC
EMISSIONSThe kinds of equipment needed to capture and conveythe waste gas to a control device are:
(1) hoods - used to capture the emissions at the source
(2) ductwork- to convey them to the control device
(3) stacks - to disperse them after they leave the controldevice
(4) fans - to provide the energy for moving them through
the control system
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CONTROL DEVICES
The principle devices are:
Thermal Oxidation
Catalytic Oxidation
Condensation
Carbon Adsorption
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THERMAL OXIDATION
Thermal oxidizers are control devices in whichsolvent-laden air is preheated and then passed to acombustion chamber
In the combustion chamber, volatile organics in theinlet air stream are ignited and combusted to carbondioxide and water
The two main types of thermal oxidizers arerecuperative and regenerative
Thermal oxidizers device efficiencies range from 98to 99 percent
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CATALYTIC OXIDATION
Catalytic oxidizers, like thermal oxidizers, are controldevices in which solvent-laden air is preheated and thenpassed to a combustion chamber
In the combustion chamber, volatile organics in theinlet air stream are ignited and combusted to carbondioxide and water
In the presence of a catalyst, combustion will takeplace at a lower temperature than that required for thermal oxidizers
The catalysts, supported on ceramic or metallicsubstrates, are metal oxides or precious metals
Catalytic oxidizers can achieve control deviceefficiencies of 95 to 99 percent
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CONDENSATION
Condensation is a control technique in which one or more volatile components of a solvent-laden air streamare separated from the remaining vapor throughsaturation followed by a gas-to-liquid phase conversion(i.e., condensation)
The recovered organic components can be reused or sold
Refrigeration is often employed to obtain the lowtemperatures required for acceptable removalefficiencies
Removal efficiencies obtained by condensers usuallyrange from 50 to 90 percent.
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ADSORPTION
Adsorbers typically use activated carbon as theadsorptive material
Adsorber beds are typically operated in parallel sothat when the adsorption capacity of one bed isexhausted, it can be removed from service and asecond adsorber bed can be put into service
Carbon adsorption systems can achieve control
device efficiencies between 95 and 99 percent.
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HANDLING, STORAGE AND
DISPOSAL OF VOCsHandling ±
Reduce spills and clean up spills immediately
During atomized cleaning of a spray gun, the
cleaning solvent must be directed into a waste container fitted with a capture device
Storage -
Store all VOCs and materials impregnated with VOCsin closed containers
Disposal -
Handle used VOCs as hazardous waste and alwayskeep waste VOCs in closed containers
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Remember, You Control Your Facility or Area!
Review Procedures W ith Them Before Starting the Job!
Ensure They Are Properly Trained!
Determine Their Environmental Compliance Record!
Determine Who Is in Charge of Their People!
Determine How They Will Affect Your Facility¶s
Environmental Compliance!
TIPS FOR USING CONTRACTORS
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THE IMPORTANCE OF A
CLEAN ENVIRONMENT
³I would ask all of us to remember
that protecting our environment is
about protecting where we live andhow we live. Let us join together to
protect our health, our economy,
and our communities -- so all of us
and our children and our
grandchildren can enjoy a healthyand a prosperous life.´
Carol Browner
Former EPAAdministrator