TECHNICAL ARTICLE
Dixon Bellows Sealed Globe Valves: F8-Series, J-Series, and G8-Series used in the production of plastics, resins, and synthetic fibers. When VOCs leak into the atmosphere, they can form ground-level ozone, a major component of smog, negatively impacting air quality and human health.
GHGs, such as carbon dioxide and methane, are critical drivers of climate change. While carbon dioxide is the more prevalent GHG, methane is at least 28 times more potent. Even small amounts of methane can have a significant impact on global warming due its potency as a GHG.
HAPs are toxic chemicals that pose a threat to human health and the environment, even at low levels. A notable example is formaldehyde, which is used in various industrial processes, including the production of building materials and household products. Fugitive emissions of HAPs can cause long-term health problems, including cancer, reproductive issues, and damage to the nervous system.
Although the leaks are small, across a large facility the amount of lost product adds up to a very large volume, especially for constant, around-theclock operations. Some fugitive emissions consist of hazardous chemicals that can cause health problems upon inhalation or skin contact. Other gasses are highly flammable such that even small leaks can result in explosions, especially in confined spaces or in areas where other ignition sources are present. Benzene leaks are a prime example of both toxicity and flammability concerns. Additionally, acids and other caustic substances can corrode metal surfaces to eventually cause equipment failures leading to larger leaks, malfunctions, or safety hazards.
Regulations
Beyond immediate safety hazards, fugitive emissions have broad environmental implications. Given the significant environmental impact, governments around the world have enacted strict regulations to limit and reduce the occurrence of fugitive emissions. In the U. S., the Environmental Protection Agency( EPA) has established several rules under the Clean Air Act( CAA) to curb emissions from various industrial sources, including those from equipment leaks. The EPA’ s Clean Water Act( CWA) also addresses fugitive emissions indirectly by controlling the pollution that may contribute to stormwater runoff. The European Union has comprehensive regulations under its Industrial Emissions Directive( IED) to address fugitive emissions. Violating these regulations is not only detrimental to the environment, but can also lead to monetary damages.
In the U. S., the EPA uses consent decrees as a penalty to cease or correct certain actions or processes that are polluting the environment. Many major refineries and chemical plants operate under consent decrees that require the installation of equipment to help reduce fugitive emissions. Consent decrees include payments of penalties, which have been as much as $ 40 million in the past.
Regulatory compliance is driving industries to adopt more effective leak detection and repair programs. These programs involve regular monitoring of equipment and facilities to help identify and quantify fugitive emissions. This allows facilities to address leaks before they cause significant environmental harm or lead to costly fines.
The cost of environmental compliance is just one component of the economic consequences of fugitive emissions. Operating costs should be considered, as well. Making steam requires energy, which comes at a price. A boiler fired with natural gas producing 450 PSI saturated steam and supplied with 230 ° F feedwater will yield a steam cost of $ 2.89 per 1,000 lb. A small valve leak can be estimated by comparing it to leakage through an orifice. A 1 / 32” orifice at 450 PSIG will yield a flow of about 10 lbs per hour. Even with these conservative estimates, the cost of the leakage comes to $ 253.16 per valve, per year. The EPA estimates that there are an average of 7,400 valves at a typical refinery or chemical plant, which brings the average cost of leakage from valves per year for a typical refinery or plant around $ 1.87 million. A leak-free steam valve not only saves product to benefit the bottom line, but also pays for itself over a short amount of time in terms of energy savings.
26 FUGITIVE EMISSIONS JOURNAL • APRIL 2025