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Table 6-4. Estimated Energy Use in Manufacture of Sodium Carbonate (Soda Ash) From Trona Ore - 1997 Average Specificd Energy Total Industry Use e Energy (Btu/lb) (1012 Btu) Electricitya 127 3.0 Fuel Oil and LPGb 98 2.3 Natural Gas 2,515 59.6 Coal and Coke 327 7.7 Otherc 327 7.7 NET PROCESS ENERGY 3,393 80.4 Electricity Losses 264 6.3 Energy Export 0 0.0 TOTAL PROCESS ENERGY 3,657 86.7 a Does not Include losses incurred during the generation and transmission of electricity. b Includes ethane, ethylene, propane, propylene, normal butane, butylenes, and mixtures of these gases. c Includes net purchased steam, and any other energy source not listed (e.g., renewables). d Steam/fuel use estimated based on current distribution of fuels in chemical plants (CMA 1998). Values are based on published fuel use and electricity requirements for process based on trona ore (Brown 1996). e Calculated by multiplying average energy use (Btu/lb) by1997 production values for sodium carbonate (23.7 billion lbs) (CMA 1998). 6.4 Air Emissions Chlorine Gas and Freon Are Primary Air Emissions from Brine Electrolysis Air emissions from brine electrolysis include chlorine gas and freon emissions (both fugitive and point source) and other vapors. Fugitive emissions arise from cells, scrubbers, and vents throughout the system. While individual leaks may be minor, the combination of fugitive emissions from various sources can be substantial. In 1995, nearly 3 million pounds of chlorine fugitive and point source emissions were reportedly released by the inorganic chemical industry (EPA 1997c). These emissions are controlled through leak-resistant equipment modifications, source reduction, and programs to monitor such leaks. Table 6-5 lists emission factors for mercury emissions from chlor-alkali production (EPA 1992b). Diaphragm cells and membrane cells release chlorine as fugitive emissions from the cell itself and in process tail gases, which are wet-scrubbed with soda ash or caustic soda to remove chlorine. The spent caustic solution from this wash is neutralized and then discharged to water treatment facilities (EPA 1992b, EPA 1995a). Mercury cells release small amounts of mercury vapor and chlorine gas from the cell itself. Process tail gases from chlorine processing, caustic soda processing, and hydrogen processing also release small amounts. Mercury is removed from the hydrogen gas stream by cooling followed by absorption with activated carbon. (EPA 1992b, Orica 1999). 193PDF Image | The Chlor-Alkali Industry
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