BACKGROUND REPORT

AP-42 SECTION 8.6

HYDROCHLORIC ACID PRODUCTION

Prepared for

U.S. Environmental Protection Agency

OAQPS/TSD/EIB
Research Triangle Park, NC 27711

1-96

Pacific Environmental Services, Inc.

P.O. Box 12077
Research Triangle Park, NC 27709
919/941-0333

i
 1-96
AP-42 Background Report

TECHNICAL SUPPORT DIVISION

U.S. ENVIRONMENTAL PROTECTION AGENCY

Office of Air Quality Planning and Standards
Research Triangle Park, North Carolina 27711

ii
This report has been reviewed by the Technical Support Division of the Office of Air Quality
Planning and Standards, EPA. Mention of trade names or commercial products is not intended to
constitute endorsement or recommendation for use. Copies of this report are available through
the Library Services Office (MD-35), U.S. Environmental Protection Agency, Research Triangle
Park, NC 27711.

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 TABLE OF CONTENTS

1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.0 INDUSTRY DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 PROCESS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 EMISSIONS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.4 REVIEW OF SPECIFIC DATA SETS . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5 REFERENCES FOR CHAPTER 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.0 GENERAL EMISSION DATA REVIEW AND ANALYSIS

PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 LITERATURE SEARCH AND SCREENING SOURCE
TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 EMISSION DATA QUALITY RATING SYSTEM . . . . . . . . . . . . . . 9
3.3 EMISSION FACTOR QUALITY RATING SYSTEM . . . . . . . . . . . 10
3.4 REFERENCES FOR CHAPTER 3 . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.0 POLLUTANT EMISSION FACTOR DEVELOPMENT . . . . . . . . . . . . . . . . . . . 13

4.1 REVIEW OF SPECIFIC DATA SETS . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 CRITERIA POLLUTANT EMISSIONS DATA . . . . . . . . . . . . . . . . 14
4.3 NONCRITERIA POLLUTANT EMISSIONS DATA . . . . . . . . . . . . 15
4.4 DATA GAP ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.5 REFERENCES FOR CHAPTER 4 . . . . . . . . . . . . . . . . . . . . . . . . . . 21

APPENDIX A: AP-42 SECTION 8.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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 LIST OF TABLES

TABLE 4.3-1 (METRIC): HAZARDOUS AIR POLLUTANTS:

HYDROCHLORIC ACID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
TABLE 4.3-1 (ENGLISH): HAZARDOUS AIR POLLUTANTS:
HYDROCHLORIC ACID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TABLE 4.4-1: LIST OF CONVERSION FACTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

LIST OF FIGURES

FIGURE 2.2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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1.0 INTRODUCTION
The document "Compilation of Air Pollutant Emission Factors" (AP-42) has been
published by the U.S. Environmental Protection Agency (the EPA) since 1972. Supplements to
AP-42 have been routinely published to add new emission source categories and to update
existing emission factors. AP-42 is routinely updated by the EPA to respond to new emission
factor needs of the EPA, State, and local air pollution control programs and industry.
An emission factor relates the quantity (weight) of pollutants emitted to a unit of activity
of the source. The uses for the emission factors reported in AP-42 include:
1. Estimates of area-wide emissions;
2. Emission estimates for a specific facility; and
3. Evaluation of emissions relative to ambient air quality.
The purpose of this report is to provide background information from process information
obtained from industry comment and hydrochloric acid production test reports to support
revision of the process description and/or emission factors for hydrochloric acid production.
Including the introduction (Chapter 1), this report contains four chapters. Chapter 2 gives a
description of the hydrochloric acid production industry. It includes a characterization of the
industry, an overview of the different process types, a description of emissions, a description of
the technology used to control emissions resulting from hydrochloric acid production, and a
review of specific data sets.
Chapter 3 is a review of emissions data collection and analysis procedures. It describes the
literature search, the screening of emission data reports, and the quality rating system for both
emission data and emission factors. Chapter 4 details criteria and noncriteria pollutant emission
factor development. It includes the review of specific data sets and the results of data analysis.
Particle size determination and particle size data analysis methodology are described when
applicable. Appendix A presents a copy of the revised AP-42 Section 8.6.

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2.0 INDUSTRY DESCRIPTION
2.1 GENERAL1,4
Hydrochloric acid (HCl) is a versatile chemical that has a number of different industrial
uses. Some examples are hydrometallurgical processing (e.g., production of alumina and/or
titanium dioxide), chlorine dioxide synthesis, hydrogen production, activation of petroleum
wells, and miscellaneous cleaning/etching operations including metal cleaning (e.g., steel
pickling). Also known as muriatic acid, HCl is used by masons to clean finished brick work.
Hydrochloric acid is also a common ingredient in many reactions and is the preferred acid for
catalyzing organic processes. One example is a carbohydrate reaction promoted by hydrochloric
acid, analogous to those in the digestive tracts of mammals.
Hydrochloric acid may be manufactured by several different processes, however, over 90
percent of the HCl produced in the U.S. is a byproduct of the chlorination reaction. Some
examples of chlorination reactions are the production of dichloromethane, trichloroethylene,
perchloroethylene, and vinyl chloride.
The 1990 Directory of Chemical Producers lists 80 facilities in the U.S. that produce HCl.
These facilities produce approximately 2.3 million megagrams (2.5 million tons) of HCl
annually, a slight decrease from the 2.5 million megagrams (2.8 million tons) produced in 1985.
The majority of these facilities are located in the Gulf Coast and Northeast portions of the
country. Fourteen of the facilities are located in Louisiana, the most of any State. Texas has the
second highest total with nine, followed by West Virginia with seven and New Jersey with five
facilities each.

2.2 PROCESS DESCRIPTION1-3,5

Hydrochloric acid can be produced by one of the five following processes:

1) Synthesis from elements:

H2
Cl2
2HCl (1)

2) Reaction of metallic chlorides, particularly sodium chloride (NaCl), with sulfuric

acid (H2SO4) or a hydrogen sulfate:
NaCl
H2SO4
NaHSO4
HCl (2)

NaCl
NaHSO4
Na2SO4
HCl (3)

2
 2NaCl
H2SO4
Na2SO4
2HCl (4)

3) As a byproduct of chlorination, e.g. in the production of dichloromethane,

trichloroethylene, perchloroethylene, or vinyl chloride:
C2H4
Cl2
C2H4Cl2 (5)

C2H4Cl2
C2H3Cl
HCl (6)

4) By thermal decomposition of the hydrated heavy-metal chlorides from spent pickle

liquor in metal treatment:
2FeCl3
6H2O
Fe2O3
3H2O
6HCl (7)

5) From incineration of chlorinated organic waste:

C4H6Cl2
5O2
4CO2
2H2O
2HCl (8)

CHLORINATION GASES VENT GAS

Ethelene Dichloride SCC = 3-01-125-04

Perchloroethelene SCC = 3-01-125-22
HCl
CHLORINATION HCl SCRUBBER
PROCESS ABSORPTION CHLORINE
1.1.1 Trichloroethane SCC = 3-01-125-26
Vinyl Chloride SCC = 3-01-125-42
DILUTE HCl
CONCENTRATED
LIQUID HCl

Figure 2.2-1 HCl production from chlorination process

Figure 2.2-1 is a simplified diagram of the steps used for the production of byproduct HCl
from the chlorination process.
After leaving the chlorination process, the HCl-containing gas stream proceeds to the
absorption column, where concentrated liquid HCl is produced by absorption of HCl vapors into
a weak solution of hydrochloric acid. The HCl-free chlorination gases are removed for further

3
processing. The liquid acid is then either sold or used elsewhere in the plant. The final gas stream
is sent to a scrubber to remove the remaining HCl prior to venting.

2.3 EMISSIONS AND CONTROLS5,6

Hydrochloric acid is listed as a Title III Hazardous Air Pollutant (HAP) as defined in the
1990 Clean Air Act Amendments. Emissions from hydrogen chloride production result primarily
from gas that exits the HCl purification system. The contaminants are HCl gas and chlorine (both
HAPs), and chlorinated organic compounds. The type of chlorinated organic compounds emitted
are dependent on the type process that produces the HCl as a byproduct.
According to a 1985 emission inventory, over 89 percent of all HCl emitted to the
atmosphere resulted from the combustion of coal. Less than one percent of the HCl emissions
came from the direct production of HCl.
Tailgas concentrations of the various contaminants emitted from typical byproduct acid
plants are often reduced by being scrubbed with water in a packed tower located after the final
process tower. Venturi scrubbers are also used. These systems are usually designed for reducing
a single contaminant but may often remove other gases. For instance, a phosgene decomposition
tower which allows the phosgene to contact water or a caustic solution will at the same time
absorb traces of hydrogen chloride which are present. Another method of preventing atmospheric
emissions is to use a closed system. The materials are then never emitted to the atmosphere, but
are simply recycled.
The removal of organics is a specific design problem for each tailgas compound. In some
cases, a decomposition system is necessary; in others, an absorption system properly sized and
designed is needed. If needed, the absorption medium can be changed and the efficiency will be
increased so that all the organics are removed. The use of a properly designed gas scrubber will
also remove organics.
2.4 REVIEW OF SPECIFIC DATA SETS
Pacific Environmental Services (PES) contacted the following sources to obtain the most
up-to-date information on process descriptions and emissions for this industry:

1) Allied-Signal, Inc., Baton Rouge, Louisiana and Danville, Illinois.

2) BASF Chemicals Corp., Geismar, Louisiana.

3) Borden Chemicals and Plastics, Geismar, Louisiana.

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 4) Dow Chemical, Midland, Michigan.

5) Elf-Atochem N.A., Inc., Calvert City, Kentucky and King of Prussia, Pennsylvania.

6) Formosa Plastics Corp., Baton Rouge, Louisiana.

7) Hanlin Group (LCP Chemicals), Orrington, Maine and Reigelwood, North Carolina.

8) Pioneer Chlor-Alkali, Henderson, Nevada.

9) PPG Industries, Lake Charles, Louisiana.

10) Rubicon Inc., Geismar, Louisiana.

11) Vulcan Inc., Geismar, Louisiana.

No source tests or emissions data related to hydrochloric acid production were received
from any of the companies contacted. The general discussion, process description, and emissions
chapters of Section 8.6 were updated utilizing the following references PES obtained through a
literature search for information on HCl manufacturing.

Reference 1: Encyclopedia of Chemical Technology

Reference 2: Ullmann's Encyclopedia of Industrial Chemistry
Reference 3: Encyclopedia of Chemical Processing and Design
Process descriptions and the block flow diagram were updated using information from
these three references.
Reference 4: 1990 Directory of Chemical Producers
Reference 4 was used to determine industrial capacity and regional statistics for the
general industry description section.

Reference 5: Hydrogen Chloride and Hydrogen Fluoride Emission Factors for the NAPAP
Emission Inventory
The quote related to HCl emissions from the combustion of coal found in the Emissions
chapter was obtained from Reference 5.

Reference 6: Atmospheric Emissions from Hydrochloric Acid Manufacturing Processes

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 The information from Reference 6 in the emissions chapter was left unchanged from the
previous Section 8.6 update (February 1972).

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2.5 REFERENCES FOR CHAPTER 2

1. Encyclopedia of Chemical Technology, Third Edition, Volume 12, John Wiley and Sons,
New York, 1978.

2. Ullmann's Encyclopedia of Industrial Chemistry, Volume A, VCH Publishers, New York,

1989.

3. Encyclopedia of Chemical Processing and Design, Marcel Dekker, Inc., New York, 1987.

4. 1990 Directory of Chemical Producers. United States of America. Menlo Park, California:
Chemical Information Services, Stanford Research Institute, 1990.

5. Hydrogen Chloride and Hydrogen Fluoride Emission Factors for the NAPAP (National
Acid Precipitation Assessment Program) Emission Inventory, U.S. EPA, PB86-134040.
October 1985.

6. Atmospheric Emissions from Hydrochloric Acid Manufacturing Processes. U.S. DHEW,

PHS, CPEHS, National Air Polluting Control Administration. Durham, N.C. Publication
Number AP-54. September 1969.

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3.0 GENERAL EMISSION DATA REVIEW AND ANALYSIS PROCEDURES
3.1 LITERATURE SEARCH AND SCREENING SOURCE TESTS
The first step in the investigative process involved a search of available literature relating
to criteria and noncriteria pollutant emissions associated with hydrochloric acid production. This
search included, but was not limited to the following references:
1) AP-42 background files maintained by the Emission Factor and Methodologies
Section.
2) Files maintained by the Emission Standards Division.
3) Handbook of Emission Factors, Parts I and II, Ministry of Health and Environmental
Protection, The Netherlands, 1980/1983.
4) The EPA databases, including but not limited to the VOC/Particulate Matter (PM)
Speciation Database Management System (SPECIATE), the Crosswalk/Air Toxic
Emission Factor Data Base Management System (XATEF), and the Emission
Measurement Technical Information Center's Test Methods Storage and Retrieval
System (TSAR).

To reduce the amount of literature collected to a final group of references pertinent to this
report, the following general criteria were used:
1. Emissions data must be from a primary reference, i.e. the document must constitute
the original source of test data. For example, a technical paper was not included if
the original study was contained in the previous document.
2. The referenced study must contain test results based on more than one test run.
3. The report must contain sufficient data to evaluate the testing procedures and source
operating conditions (e.g., one-page reports were generally rejected).

If no primary data was found and the previous update utilized secondary data, this
secondary data was still used and the Emission Factor Rating lowered, if needed. A final set of
reference materials was compiled after a thorough review of the pertinent reports, documents,
and information according to these criteria. The final set of reference materials is given in
Chapter 4.0.

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3.2 EMISSION DATA QUALITY RATING SYSTEM
As part of Pacific Environmental Services' analysis of the emission data, the quantity and
quality of the information contained in the final set of reference documents were evaluated. The
following data were always excluded from consideration:
1. Test series averages reported in units that cannot be converted to the selected
reporting units;
2. Test series representing incompatible test methods (i.e., comparison of the EPA
Method 5 front-half with the EPA Method 5 front- and back-half);
3. Test series of controlled emissions for which the control device is not specified;
4. Test series in which the source process is not clearly identified and described; and
5. Test series in which it is not clear whether the emissions were measured before or
after the control device.
Data sets that were not excluded were assigned a quality rating. The rating system used
was that specified by the OAQPS for the preparation of AP-42 sections. The data were rated as
follows:
A Rating
Multiple tests performed on the same source using sound methodology and reported in
enough detail for adequate validation. These tests do not necessarily conform to the
methodology specified in either the inhalable particulate (IP) protocol documents or the
EPA reference test methods, although these documents and methods were certainly used as
a guide for the methodology actually used.
B Rating
Tests that were performed by a generally sound methodology but lack enough detail for
adequate validation.
C Rating
Tests that were based on an untested or new methodology or that lacked a significant
amount of background data.
D Rating
Tests that were based on a generally unacceptable method but may provide an order-of-
magnitude value for the source.

9
 The following criteria were used to evaluate source test reports for sound methodology
and adequate detail:
1. Source operation. The manner in which the source was operated is well documented
In the report. The source was operating within typical parameters during the test.
2. Sampling procedures. The sampling procedures conformed to a generally acceptable
methodology. If actual procedures deviated from accepted methods, the deviations
are well documented. When this occurred, an evaluation was made of the extent
such alternative procedures could influence the test results.
3. Sampling and process data. Adequate sampling and process data are documented in
the report. Many variations can occur unnoticed and without warning during testing.
Such variations can induce wide deviations in sampling results. If a large spread
between test results cannot be explained by information contained in the test report,
the data are suspect and were given a lower rating.
4. Analysis and calculations. The test reports contain original raw data sheets. The
nomenclature and equations used were compared to those (if any) specified by the
EPA to establish equivalency. The depth of review of the calculations was dictated
by the reviewer's confidence in the ability and conscientiousness of the tester, which
in turn was based on factors such as consistency of results and completeness of
other areas of the test report.

3.3 EMISSION FACTOR QUALITY RATING SYSTEM

The quality of the emission factors developed from analysis of the test data was rated
utilizing the following general criteria:
A (Excellent)
Developed only from A-rated test data taken from many randomly chosen facilities in the
industry population. The source category is specific enough so that variability within the
source category population may be minimized.
B (Above average)
Developed only from A-rated test data from a reasonable number of facilities. Although no
specific bias is evident, it is not clear if the facilities tested represent a random sample of
the industries. As in the A-rating, the source category is specific enough so that variability
within the source category population may be minimized.

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 C (Average)
Developed only from A- and B-rated test data from a reasonable number of facilities.
Although no specific bias is evident, it is not clear if the facilities tested represent a
random sample of the industry. As in the A-rating, the source category is specific enough
so that variability within the source category population may be minimized.
D (Below average)
The emission factor was developed only from A- and B-rated test data from a small
number of facilities, and there is reason to suspect that these facilities do not represent a
random sample of the industry. There also may be evidence of variability within the source
category population. Limitations on the use of the emission factor are noted in the
emission factor table.
E (Poor)
The emission factor was developed from C- and D-rated test data, and there is reason to
suspect that the facilities tested do not represent a random sample of the industry. There
also may be evidence of variability within the source category population. Limitations on
the use of these factors are always noted.

The use of these criteria is somewhat subjective and depends to an extent on the individual
reviewer.

3.4 REFERENCES FOR CHAPTER 3

1. Technical Procedures for Developing AP-42 Emission Factors and Preparing AP-42
Sections. U.S. Environmental Protection Agency, Emissions Inventory Branch, Office of
Air Quality Planning and Standards, Research Triangle Park, NC, 27711, April, 1992.
[Note: this document is currently being revised at the time of this printing.]

2. AP-42, Supplement A, Appendix C.2, "Generalized Particle Size Distributions." U.S.

Environmental Protection Agency, October, 1986.

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4.0 POLLUTANT EMISSION FACTOR DEVELOPMENT

4.1 REVIEW OF SPECIFIC DATA SETS

Reference 1
Reference 1 is a comprehensive study undertaken in 1969 to determine emissions from the
manufacture of HCl. Although the test procedures are well documented in Reference 1, no
individual source tests were available to confirm the test results. The data is also over 20 years
old and may not be representative of the industry today. The rating of the study was therefore
dropped from "A," in the previous AP-42 update (February 1972), to "C."

The study contains data from 21 facilities that were tested, of which two utilized closed
systems, nine had uncontrolled emission sources, and the remaining 10 were controlled. The data
is very questionable, however, since the average uncontrolled emission factor is 0.15 kg/Mg
(0.30 lb/ton), but the average controlled emission factor is 0.675 kg/Mg (1.35 lb/ton), a higher
value.

PES feels that the average of the tests is not representative of actual HCl emissions since
any reading of 0.5 percent HCl or less in the exit gases was considered negligible and reported as
zero. This was the case for 16 of the 21 facilities tested. No further information was found in
the study to indicate the minimum detectable level of HCl so that the "zero" data could be
utilized. Consequently, the data reported as zero emissions could not be used.

If all of the tests reported as zero emissions are ignored and the remaining five non-zero
test results are utilized, this technique results in a more reasonable uncontrolled emission factor
of 0.90 kg/Mg (1.8 lb/ton) and a controlled emission factor of 0.08 kg/Mg (0.15 lb/ton). Since
this is the only data available for hydrochloric acid production, this technique was used to update
the emission factors for Section 8.6. The specific calculations utilizing the data in Table 4.3-1
are shown below:

Uncontrolled Emission Factor Calculation

[(0.5 + 1.3)/2] = 0.9 kg/Mg

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 Controlled Emission Factor Calculation
[(0.004 + 0.2 + 0.025)/3] = 0.08 kg/Mg

Note that the new emission factors are lower than those quoted in the previous update and
that the quality ratings have been lowered as well. The previous emission factors appear to have
been based on the results of a single test. This update utilizes the average of several tests to
develop the emission factors. The emission factor ratings were lowered to provide a more
realistic appraisal of the quality of the data. Both of the changes made for this update are a result
of more closely following the emission factor development procedures outlined in Chapter 3.0 of
this background report.

4.2 CRITERIA POLLUTANT EMISSIONS DATA

Volatile organic compounds.

No data on emissions of these pollutants were found for the hydrochloric acid production
process. The presence and quantity of these pollutants is entirely dependent on the specific
process used to produce the byproduct HCl.

Lead.
No data on emissions of these pollutants were found for the hydrochloric acid production
process. The presence and quantity of these pollutants is entirely dependent on the specific
process used to produce the byproduct HCl.

Sulfur dioxide.
No data on emissions of these pollutants were found for the hydrochloric acid production
process. The presence and quantity of these pollutants is entirely dependent on the specific
process used to produce the byproduct HCl.

13
 Nitrogen oxides.
No data on emissions of these pollutants were found for the hydrochloric acid production
process. The presence and quantity of these pollutants is entirely dependent on the specific
process used to produce the byproduct HCl.

Carbon monoxide.
No data on emissions of these pollutants were found for the hydrochloric acid production
process. The presence and quantity of these pollutants is entirely dependent on the specific
process used to produce the byproduct HCl.

Total Suspended Particulate.

No data on emissions of these pollutants were found for the hydrochloric acid production
process. The presence and quantity of these pollutants is entirely dependent on the specific
process used to produce the byproduct HCl.

4.3 NONCRITERIA POLLUTANT EMISSIONS DATA

Hazardous Air Pollutants.
Hydrochloric acid is listed as a Title III Hazardous Air Pollutant (HAP) as defined in the
1990 Clean Air Act Amendments. Emissions data for both controlled and uncontrolled
manufacturing environments are based solely on the results of the emissions study found in
Reference 1. No additional data were found.
Table 4.3-1 contains a listing of the five tests from Reference 1 used to develop emission
factors. The controlled emission factor of 0.08 kg/Mg (0.15 lb/ton) and 0.90 kg/Mg (1.8 lb/ton)
uncontrolled quoted in the revised AP-42 section are based on this "C" rated data and are
therefore rated "E." See Section 4.1 for a more detailed discussion of Reference 1.
Some processes that create byproduct HCl may also produce other HAP emissions.
Although both chlorine (a HAP) and chlorinated organic compounds (e.g., dichloromethane,
vinyl chloride, etc.) may be emitted during the byproduct production of HCl, the emissions are
dependent on the specific processes used to create the byproduct HCl. Emissions data for these
compounds should be available within each specific AP-42 section that produces HCl as a
byproduct.

14
 Global Warming Gases.
Pollutants such as methane, carbon dioxide, and N2O have been found to contribute to
overall global warming. No data on emissions of these pollutants were found for the hydrochloric
acid production process. Although Reference 1 contained HCl emissions data, no corresponding
carbon dioxide emissions data were reported.

15
 TABLE 4.3-1 (METRIC UNITS)
HAZARDOUS AIR POLLUTANTS: HYDROCHLORIC ACID

Control Test Test Run Production Emission Emission

Equipment Rating Method # Ratea Rateb Factorc

Facility #BP-13d
None C Average 27 13.5 0.5
Facility #BP-18d
Caustic Scrubber C Average 81.6 0.33 0.004
Facility #BP-19d
Water Scrubber C 1 54.4 2.7 0.05
2 54.4 19 0.35
Average 54.4 10.9 0.2
Facility #BP-20d
Water Scrubber C 1 127 0.28 0.0022
2 127 0.24 0.0019
3 127 8.9 0.07
Average 127 3.18 0.025
Facility #BP-21d
None C Average 204 265 1.3

a
Units are in Mg per day.
b
Units are in kg per day.
c
Units are in kg per Mg.
d
Reference 1.

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 TABLE 4.3-1 (ENGLISH UNITS)
HAZARDOUS AIR POLLUTANTS: HYDROCHLORIC ACID

Control Test Test Run Production Emission Emission

Equipment Rating Method # Ratea Rateb Factorc

Facility #BP-13d
None C Average 30 30 1
Facility #BP-18d
Caustic Scrubber C Average 90 0.72 0.008
Facility #BP-19d
Water Scrubber C 1 60 6 0.1
2 60 42 0.7
Average 60 24 0.4
Facility #BP-20d
Water Scrubber C 1 140 0.616 0.0044
2 140 0.518 0.0037
3 140 19.6 0.14
Average 140 6.91 0.049
Facility #BP-21d
None C Average 225 585 2.6

a
Units are in tons per day.
b
Units are in lbs per day.
c
Units are in lbs per ton.
d
Reference 1.

17
 Ozone Depletion Gases.
Chlorofluorocarbons have been found to contribute to ozone depletion. No data on
emissions of these pollutants were found for the hydrochloric acid production process.

4.4 DATA GAP ANALYSIS

The emissions data for hydrochloric acid manufacturing is weak, at best, and provides only
an estimate of emissions from this industry. Although several HCl facilities were contacted, none
provided any source test data, only generalizations about emissions. A comprehensive source
testing program or access to existing industry data is needed to better define emissions from this
industry. The study should begin with emissions from the production of byproduct HCl, the most
common production method.

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 TABLE 4.4-1

LIST OF CONVERSION FACTORS

Multiply: by: To obtain:

mg/dscm 4.37 x 10-4 gr/dscf
m2 10.764 ft2
acm/min 35.31 acfm
m/s 3.281 ft/s
kg/hr 2.205 lb/hr
kPa 1.45 x 10-1 psia
kg/Mg 2.0 lb/ton
Mg 1.1023 ton

Temperature conversion equations:

Fahrenheit to Celsius:

C  (F32)
1.8

Celsius to Fahrenheit:

F  1.8(C)
32

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4.5 REFERENCES FOR CHAPTER 4

1. Atmospheric Emissions from Hydrochloric Acid Manufacturing Processes. U.S. DHEW,

PHS, CPEHS, National Air Polluting Control Administration. Durham, N.C. Publication
Number AP-54. September 1969.

20
 APPENDIX A.

AP-42 SECTION 8.6

[Not presented here. See instead current AP-42 Section 8.6]

21