1. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge 30 th Environmental and Energy Symposium & Exhibition San Diego, CA April 7, 2004 Gregory D. Holland John N. Veenstra Arland H. Johannes Gary L. Foutch Freddie Hall

2. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge Background The Oklahoma City Air Logistics Center (OC-ALC) conducts surface coating as regulated by 40 CFR 63.741 in maintenance paint booths at the facility. Volatile Organic Compounds (VOCs) are emitted as a result. While the emissions rate is currently well below the stationary major source threshold of 10 tons per year, these low emissions are the result of using low-VOC/low-solids paints.

3. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge Background The low-VOC/low-solids paint has performed and weathered poorly, and as a result, the planes require more frequent painting as well as constant touch-ups. An efficient method of emission treatment is desired to enable renewed use of the better performing high- VOC/high-solids paints.

4. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge Background The typical emissions control technique for surface coating spray booths is carbon absorption (average control efficiency = 90%). Carbon absorption has a fire potential in the carbon bed when high concentrations of ketones and alcohols are present as at TAFB. Furthermore, the painting operations at TAFB are not continuous but are of short duration. Due to this operational pattern, a technology with an “instant-on”, ”instant off” capability without a concurrent step-up in emissions would be the most efficient treatment for TAFB.

5. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge Background TAFB has commissioned the investigation of an innovative technology to meet plant and regulatory requirements. A Gas Phase Corona Reactor (GPCR), also known as a dielectric barrier discharge (DBD) or non-thermal plasma (NTP) reactor, is being designed to reduce VOC emissions from painting operations.

6. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge Project Goals Establish optimum operating conditions using bench-scale studies. Test capacity limits for design and cost of full-scale equipment. Collect statistically significant data to verify VOC destruction and determine operating costs. Two week operation test at Tinker AFB with greater than 90% removal of VOCs from stack exhaust.

7. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge Project Phases Phase I: Investigate operation of different reactor geometries. Verify destruction capabilities. Investigate operating variables using single-tube, bench-scale reactors. Phase II: Design pilot-scale reactor for 1,000 scfm (multi-tube design) and demonstrate unit at TAFB. Develop technology demonstration plan. Phase III: Test 1,000 scfm unit. Determine economic and scale- up factors for the plasma unit. Design full-scale reactor for 20,000 cfm.

8. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge Plasma Discharge Process High electric fields are used to generate high energy electrons (up to 10 eV) which collide with the gas molecules to create highly reactive ions and/or free-radicals. The dielectric barrier prevents the direct flow of current and prevents excess heating. Essentially no warm-up period required, allowing “instant on” capability. “On-the-fly” adjustment of power to handle variation in VOC loading

9. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge Dielectric Barrier Discharge

10. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge Phase I Investigate operation of different reactor geometries. Verify destruction capabilities. Investigate operating variables using single plasma zone, bench- scale reactors.

11. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge Target components: –Toluene –Methyl Isobutyl Ketone –Butyl Acetate –Sec-Butyl Alcohol –Methyl Propyl Ketone –Ethyl 3-Ethoxypropionate –1,6-Hexamethylene Diisocyanate –Gas Mixture –Actual Stack Gas Operating variables: –Reactor geometry Round, square, plate –Electric field strength 16-18 kV –Discharge frequency 200-400 Hz –Residence time 0.05-0.2 seconds –VOC concentration 35-250 ppm –Humidity 0-80% relative humidity

12. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge

13. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge

14. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge Flat Plate Reactor

15. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge Square Tube Reactor

16. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge Single Tube Reactor

17. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge Single Tube Reactor

18. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge

19. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge Figure 3. Plot of destruction data (as concentration) for V” = 17 kV rms, f = 300 Hz, t res = 0.1 second, and rh = 0% (Run #04).

20. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge Figure 4. Plot of destruction data (as a fraction of inlet conc.) for V” = 17 kV rms, f = 300 Hz, t res = 0.2 second, and rh = 70-80% (Run #40).

21. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge Phase I Results Reactor geometry: Single dielectric barrier, annular gap. Electric field strength: Greater destruction at higher electric field strengths. Discharge frequency: Greater destruction at higher discharge frequencies. Residence time: Greater destruction efficiency at higher residence times. VOC concentration: Greater destruction efficiency at higher concentrations. Humidity: Improves destruction efficiency of some components, reduces destruction efficiency of others. Humid conditions improve overall destruction efficiency. May increase energy requirements.

22. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge Phase II Design pilot-scale reactor for treating 1,000 cfm (multi-tube design) and demonstrate unit at TAFB. Determine economic and scale-up factors for the plasma unit. Develop technology demonstration plan.

23. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge Phase II – Current Status Comparing energy consumption parameters of different size reactors to determine scaling factors: –Single-tube reactor with a 1 to 50 cm plasma zone. –10-tube reactors with 1-cm or 5-cm plasma zones in each tube. Difficulties measuring the secondary current – require customized circuitry. Economics will depend on energy requirements and final size.

24. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge 10-Tube Reactor

25. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge

26. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge Acknowledgments Oklahoma City – Air Logistics Center Center for Aircraft and Systems/Support Infrastructure

27. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge Acknowledgments Vijay Kalpathi – Ph.D. student, Chemical Engineering Visalakshi Annamalai – M.S. student, Electrical Engineering Rajbarath.P – M.S. student, Environmental Engineering Elangovan Karuppasamy – M.S. student, Environmental Engineering

28. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge Questions

29. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge Table 1. Summary of destruction data for residence time comparisons.

30. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge Table 2. Summary of destruction data for line operating frequency comparisons.

31. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge Table 3. Summary of destruction data for applied electric potential comparisons.

32. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge Table 4. Summary of destruction data for VOC concentration comparisons.

33. Reduction of VOC Emissions from Paint-Booth Operations Using Dielectric Barrier Discharge Table 5. Summary of destruction data for relative humidity comparisons.