Course Textbook
Godish, T., Davis, W. T., & Fu, J. S. (2015). Air quality (5th ed.). Boca Raton, FL: CRC Press.
Our course project will be to develop a document titled A Permit By Rule (PBR) Application for an Interior Surface Coating Facility that will serve as a simulation of our work as a contract environmental engineer to a small vehicle body shop located in the state of Texas.
The Scenario:
You have been contracted with a vehicle body repair shop named Texas Car Body Repairs, USA to engineer and write a state (Texas) air permit application for a carefully designed interior lining (painting) facility. According to Texas state laws and EPA laws, the facility must have an air permit before construction begins. Once the facility is completed, the construction air permit will then become the operational air permit for the facility. As a result, your client wants the air permit application to automatically align the interior surface coating facility into operational compliance with state and federal air quality laws. Consequently, it is extremely important for you to write the air permit application to meet the air permit criteria using the state guidance document and considering the equipment and chemicals already planned for the facility operations.
Your client has presented you with the following specifications regarding the facility operations plan:
Interior Liner Coating Material 10 gallons coating/vehicle 2 gallons of solvent/vehicle
Vehicle Lining Application Apply interior liners to two (2) vehicles/day Work five (5) hours/day and four (4) days/week Vehicle Lining Curing
Vehicle Lining Curing Cure interior liners of two (2) vehicles/day Work five (5) hours/day and four (4) days/week
Interior Liner Cure Heater fuel source is natural gas-fired drying oven Heater generates 2.1 million (MM) Btu/hr at maximum 2,500 hrs/year
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Interior Liner Coating Material
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10 gallons coating/vehicle
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2 gallons of solvent/vehicle
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Vehicle Lining Application
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Apply interior liners to two (2) vehicles/day
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Work five (5) hours/day and four (4) days/week Vehicle Lining Curing
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Vehicle Lining Curing
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Cure interior liners of two (2) vehicles/day
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Work five (5) hours/day and four (4) days/week
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Interior Liner Cure
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Heater fuel source is natural gas-fired drying oven
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Heater generates 2.1 million (MM) Btu/hr at maximum 2,500 hrs/year
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Vehicle Lining Design
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Cross-draft air plenum
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Vehicle interior is the spray area
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Exhaust Fan
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10,000 ft3/min (CFM)
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1 exhaust fan
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Air Makeup Unit
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5760 ft3/min (CFM)
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1 air makeup
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Filter Openings
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20.0 ft2 each
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Two (2) filter openings
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Coating WV
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VOC content
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2.8 lb/gal coating Coating VM
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Water Content
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Per gal/coating
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1.0 lb/gal
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Water Density
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Per gal/water
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8.34 lb/gal
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Coating VW
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Water volume
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Calculation
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Exempt-solvent Content
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Per gal/coating
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0.5 lb/gal
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Exempt-solvent Density
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Per gal/exempt solvent
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6.64 lb/gal
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Coating Ves
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Exempt solvent volume
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Calculation
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The client has designed an interior coating spray painting system that allows the interior of a vehicle to be coated (such as for new vehicles, or vehicles being restored after fire damage or other catastrophic interior damage). The operations will involve a stripped-down vehicle body being brought into the facility's shop. The shop is a steel building with a finished concrete floor and a paint booth for each vehicle. The vehicle will be placed in the spray booth. The booth will be opened at one end of the booth for makeup air. The exhaust air will flow through an exhaust chamber at the other end of the vehicle (see Cross-Draft Automotive Spray Booth in Appendix F of the TCEQ Regulatory Guidance Document). For each vehicle, once the liner application operations are completed the forced curing (drying) operations will immediately commence.
Instructions:
1. Closely read the Required Reading assignment from your textbook, the TCEQ (2011) document, and the Unit Lesson in the Study Guide.
2. Open the Unit VII Study Guide, read the Unit VII Unit Lesson, then review the calculations demonstrated and explained regarding calculations for emissions of products of combustion from heaters and ovens for our scenario.
3. Make your Unit VII work your sixth level 1 heading titled "Heater and Oven Combustion Emissions." Describe and demonstrate (illustrate) the calculations for the following for this section of your project: (a) nitrous oxides (NOx), (b) carbon monoxide (CO), (c) particulate matter (PM), (d) volatile organic compounds (VOC), and (e) sulfur dioxide (SO2) for BOTH hourly emissions (short-term) in lbs./hr. AND annual (long-term) emissions in tons/year. Your response should be in a minimum one-page, double-spaced document.