STACK EMISSIONS MONITORING REPORT

Transcription

1 STACK EMISSIONS MONITORING REPORT 24 Langlands Place Kelvin South Business Park East Kilbride G75 0YF Tel: Fax: Your contact at ESG David Hay Business Manager North Tel: ESG Job Number: Report Date: Operator & Address: Redmonstown,, Co. Tipperary, Ireland. Permit: Release Point: Sampling Date(s): 27 November 2015 LEK / Q4 13th Jan 2016 Version: 1 Report By: Cormac Dunne MCERTS Number: MM MCERTS Level: MCERTS Level 2 Team Leader Technical Endorsements: 1, 2, 3 & 4 Report Approved By: Matthew Green MCERTS Number: MM Business Title: MCERTS Level 2 Team Leader Technical Endorsements: 1, 2, 3 & 4 Signature: Report Template Issue 21 (Apr 2015) Page 1 of 23

2 CONTENTS EXECUTIVE SUMMARY Stack Emissions Monitoring Objectives Plant Operator Stack Emissions Monitoring Test House APPENDICES Emissions Summary Monitoring Times Process Details Monitoring Methods Analytical Methods Sampling Location Sampling Methods with Subsequent Analysis OnSite Testing Sampling Plane Validation Criteria Duct Characteristics Sampling Lines & Sample Points Sampling Platform Sampling Location / Platform Improvement Recommendations Sampling and Analytical Method Deviations APPENDIX 1 Monitoring Schedule, Calibration Checklist & Monitoring Team APPENDIX 2 Summaries, Calculations, Raw Data and Charts APPENDIX 3 Measurement Uncertainty Budget Calculations Page 2 of 23

3 EXECUTIVE SUMMARY MONITORING OBJECTIVES operates an extraction fan (press line) process at which is subject to IPPC Licence P002702, under the EPA Act ESG were commissioned by to carry out stack emissions monitoring to determine the release of prescribed pollutants from the following Plant under normal operating conditions. The results of these tests shall be used to demonstrate compliance with a set of emission limit values for prescribed pollutants as specified in the Plant's IPPC Licence, P Plant Operator Redmonstown,, Co. Tipperary, Ireland. Stack Emissions Monitoring Test House ESG East Kilbride Laboratory 24 Langlands Place Kelvin South Business Park East Kilbride G75 0YF UKAS and MCERTS Accreditation Number: 1015 Opinions and interpretations expressed herein are outside the scope of UKAS accreditation. MCERTS accredited results will only be claimed where both the sampling and analytical stages are UKAS accredited. This test report shall not be reproduced, except in full, without written approval of ESG. Page 3 of 23

4 EXECUTIVE SUMMARY EMISSIONS SUMMARY Parameter Units Result Calculated Uncertainty +/ Formaldehyde mg/m³ Formaldehyde Emission Rate g/hr Moisture % P Stack Gas Temperature o C 33.5 Stack Gas Velocity m/s Gas Volumetric Flow Rate (Actual) m³/hr Gas Volumetric Flow Rate (STP, Wet) m³/hr P Gas Volumetric Flow Rate (STP, Dry) m³/hr Gas Volumetric Flow Rate at Reference Conditions m³/hr ND = None Detected, Results at or below the limit of detection are highlighted by bold italic text. The above volumetric flow rate is calculated using data from the preliminary survey. Mass emissions for non isokinetic tests are calculated using these values. For all isokinetic testing the mass emission is calculated using test specific flow data and not the above values. Reference conditions are 273K, 101.3kPa without correction for water vapour Limit MCERTS accredited result P Page 4 of 23

5 EXECUTIVE SUMMARY Parameter MONITORING TIMES Sampling Date(s) Sampling Times Sampling Duration Formaldehyde Run 1 Stack Gas Flow Rate & Temperature Run 1 27 November :30 12:05 27 November :11 32 minutes Page 5 of 23

6 EXECUTIVE SUMMARY PROCESS DETAILS Parameter Description of process Continuous or batch Product Details Part of batch to be monitored (if applicable) Normal load, throughput or continuous rating Fuel used during monitoring Abatement Plume Appearance Process Details Extraction fan (Press Line) Continuous Wood fibre board N/A Normal N/A None None visible Page 6 of 23

7 EXECUTIVE SUMMARY Monitoring Methods The selection of standard reference / alternative methods employed by ESG is determined, wherever possible by the hierarchy of method selection outlined in Environment Agency Technical Guidance Note (Monitoring) AG2. i.e. CEN, ISO, BS, US EPA etc. MONITORING METHODS Species Method ESG UKAS Lab MCERTS Limit of Calculated Standard Reference Method / Technical Number Accredited Detection MU Alternative Method Procedure Method (LOD) +/ % Formaldehyde USEPA M316 AE Yes 0.09 mg/m³ 11.2 % H 2 O SRM BS EN AE Yes 0.02% 9.60% Velocity SRM EN ISO AE Yes 5 Pa 2.5 % Volumetric Flow Rate SRM EN ISO AE Yes 5.2 % BS EN has been validated over a range of 4 40%. It is however the prefered method of the Environment Agency for concentrations below 4% Page 7 of 23

8 EXECUTIVE SUMMARY Analytical Methods The following tables list the analytical methods employed together with the custody and archiving details: SAMPLING METHODS WITH SUBSEQUENT ANALYSIS Species Analytical Technique Analytical UKAS Lab Analysis Lab Sample Archive UKAS Accredited Procedure Number (ESG or Archive Period Lab Analysis Subcontract) Location Formaldehyde Spectrophotometry M Yes RPS RPS 3 months ONSITE TESTING Species Analytical Technique Analytical UKAS Lab MCERTS Laboratory Data Archive Procedure Number Accredited Archive Period Analysis Location H 2 O Gravimetric AE Yes ESG East Kilbride Page 8 of 23

9 EXECUTIVE SUMMARY SAMPLING LOCATION Sampling Plane Validation Criteria Value Units Requirement Compliant Method Lowest Differential Pressure 88 Pa >= 5 Pa Yes BS EN Lowest Gas Velocity m/s Highest Gas Velocity m/s Ratio of Gas Velocities 1.11 : 1 < 3 : 1 Yes BS EN Mean Velocity m/s Maximum angle of flow with regard to duct axis <15 o < 15 o Yes BS EN No local negative flow Yes Yes BS EN Highly homogeneous flow stream / gas velocity Yes Yes BS EN Value Units Isokinetic Isokinetic Shape Circular (CEN Methods) (ISO Methods) Depth 1.00 m Sample port size 4" BSP Width m Number of lines used 2 Area 0.79 m 2 Number of points / line 2 Port Depth 90 mm Duct orientation Vertical General Platform Information Permanent / Temporary Platform / Ground level / Floor Level / Roof Inside / Outside DUCT CHARACTERISTICS AG1 Platform requirements Is there a sufficient working area so work can be performed in a compliant manner Platform has 2 levels of handrails (approximately 0.5 m & 1.0 m high) Platform has vertical base boards (approximately 0.25 m high) Platform has removable chains / self closing gates at the top of ladders Handrail / obstructions do not hamper insertion of sampling equipment Depth of Platform = >Stack depth / diameter + wall and port thickness + 1.5m Filtration In Stack SAMPLING PLATFORM SAMPLING LINES & POINTS Roof Outside Yes Yes Yes Yes Yes Yes NonIso & Gases Sampling Platform Improvement Recommendations (if applicable) As far as is reasonably practical the sampling location meets all the requirements as specified in EA Guidance Note M1. Page 9 of 23

10 EXECUTIVE SUMMARY Sampling & Analytical Method Deviations USEPA M316 Formaldehyde samples were filtered at the request of Medite therefore the monitoring does not completely adhere to US EPA Method 316. Page 10 of 23

11 APPENDICES CONTENTS APPENDIX 1 Monitoring Schedule, Calibration Checklist & Monitoring Team APPENDIX 2 Summaries, Calculations, Raw Data and Charts APPENDIX 3 Measurement Uncertainty Budget Calculations Page 11 of 23

12 APPENDIX 1 Monitoring Schedule, Calibration Checklist & Monitoring Team MONITORING SCHEDULE Species Method ESG UKAS Lab MCERTS Standard Reference Method / Alternative Method Technical Number Accredited Procedure Method Number of Samples Formaldehyde USEPA M316 AE Yes 1 H 2 O SRM BS EN AE Yes 1 Velocity SRM EN ISO AE Yes 1 Page 12 of 23

13 APPENDIX 1 Monitoring Schedule, Calibration Checklist & Monitoring Team Extractive Sampling CALIBRATEABLE EQUIPMENT CHECKLIST Instrumental Analyser/s Miscellaneous Equipment Equipment I.D. Equipment Equipment I.D. Equipment Equipment I.D. Control Box DGM Box Thermocouples Meter In Thermocouple Meter Out Thermocouple Control Box Timer Oven Box Probe Probe Thermocouple Probe Probe Thermocouple SPitot LPitot Site Balance Last Impinger Arm LEK 9.29 Horiba PG250 Analyser Laboratory Balance LEK LNO 0302 FTIR Tape Measure LEK 20.2 FTIR Oven Box Stopwatch LEK 17.6 Bernath 3006 FID Protractor LNO 1702 Signal 3030 FID Barometer LEK 16.5 LNO 0916 Servomex Digital Micromanometer LEK 15.7 LNO 1101 JCT Heated Head Filter Digital Temperature Meter LNO 03CD LNO 1001 Thermo FID Stack Thermocouple LEK LNO 1161 Stackmaster Mass Flow Controller LNO 1061 FTIR Heater Box for Heated Line MFC Display module 6.46 Anemometer 1m Heated Line (1) Ecophysics NOx Analyser 1m Heated Line (2) LEK Chiller (JCT/MAK 10) 1m Heated Line (3) Heated Line Controller (1) 5m Heated Line (1) Dioxins Cond. Thermocouple Heated Line Controller (2) 10m Heated Line (1) Callipers Small DGM Heater Controller Inclinometer (Swirl Device) LEK 151F 0 10m Heated Line (2) 15m Heated Line (1) LEK m Heated Line (1) LNO 23IH 20m Heated Line (2) NOTE: If the equipment I.D is represented by a dash (), then this piece of equipment has not been used for this test. Personnel Gas (traceable to ISO 17025) MCERTS Number Cylinder I.D Number CALIBRATION GASES Supplier ppm % Analytical Tolerance +/ % STACK EMISSIONS MONITORING TEAM MCERTS Qualification MONITORING TEAM TE / H&S Qualifications and Expiry Date TE1 TE2 TE3 TE4 H&S Cormac Dunne MM MCERTS Level 2 Team Leader Sep16 Mar17 Dec16 Dec16 Nov18 Hugh McMahon MM MCERTS Trainee Sep20 Page 13 of 23

14 APPENDIX 2 Summaries, Calculations, Raw Data and Charts Test Run 1 Sampling Times 11:30 12:05 27 November 2015 LOD Limit Emission mg/m³ mg/m³ Rate g/hr Field Blank 0.07 Please note figures in bold italic font are at the limit of detection FORMALDEHYDE SUMMARY Reference conditions are 273K, 101.3kPa without correction for water vapour Concentration mg/m³ 0.09 FORMALDEHYDE QUALITY ASSURANCE CHECKLIST Leak Test Results Mean Sampling Rate Pre sampling leak rate Post sampling leak rate Acceptable leak rate Leak Tests Acceptable? l/min l/min l/min l/min Run Yes Filter Material Filter Size mm C C Run 1 GF Glass GF = Glass Fibre QF = Quartz Fibre Max. Filtration Temp. Max. Storage / Transit Temp. Type of Absorbers Absorption Solutions HPLC Water Page 14 of 23

15 APPENDIX 2 Summaries, Calculations, Raw Data and Charts ISOKINETIC SAMPLING EQUATIONS 1 Formaldehyde Absolute pressure of stack gas, P s Velocity of stack gas, V s Barometric pressure, P b mm Hg 753 Pitot tube velocity constant, K p Stack static pressure, P static mm H 2 O 12 Velocity pressure coefficient, C p 0.81 P s = P b + (P static ) mm Hg 752 Mean of velocity heads, DP avg mm H 2 O Mean square root of velocity heads, ÖDP 3.20 Vol. of water vapour collected, V wstd Mean stack gas temperature, T o s C 34 Moisture trap weight increase,vlc g H₂0 by Non Iso V wstd = ( )(V lc ) m 3 V s = (K p )(C p )(ÖDP)(Ö(T s + 273)) m/s 10.8 (M s )(P s ) Volume of gas metered dry, V mstd Actual flow of stack gas, Q a Volume of gas sample through gas meter, V m Area of stack, A s m Gas meter correction factor, Y d Q a = (60)(A s )(V s ) m³/min 507 Mean dry gas meter temperature, T m 9.56 Dry total flow of stack gas, Q std Mean pressure drop across orifice, DH mmh 2 O Conversion factor (K/mm.Hg) V mstd = (0.3592)(V m )(P b +(DH/13.6))(Y d ) 0.55 Q std = (Q a )P s (0.3592)(1B wo ) m³/min 444 T m (T s ) +273 Volume of gas metered wet, V mstw Wet total flow of stack gas, Q stw V mstw = V mstd + V wstd m Q stw = (Q a )P s (0.3592) m³/min 446 Vol. of gas metered at O 2 Ref. Cond., V mstd@x%o2 Is the process burning hazardous waste? (If yes, no favourable oxygen correction) No (T s ) +273 % oxygen measured in gas stream, act%o (T s ) +273 % oxygen reference condition 21 Percent isokinetic, %I O 2 Reference Factor m³/min No O2 Ref O2 Ref = 21.0 act%o2 No O2 Ref Nozzle diameter, D n mm ref%o2 Nozzle area, A n mm V mstd@x%oxygen = (V mstd ) (O 2 Ref ) m 3 No O2 Ref Total sampling time, q min 32 Moisture content, B wo %I = (4.6398E6)(T s +273)(V mstd ) % 111 B wo = V wstd (P s )(V s )(A n )(q)(1b wo ) V mstd + V wstd % 0.54 Acceptable isokinetic range 95% to 115% Yes Moisture by FTIR % Formaldehyde Concentration, C Molecular weight of dry gas, M d Mass collected, M ug 48 CO C wet = M n mg/m³ O V mstw Total C dry = M n mg/m³ N 2 (100 Total) V mstd C dry@x%o2 = M n mg/m³ No O2 Ref M d = 0.44(%CO 2 )+0.32(%O 2 )+0.28(%N 2 ) Dry total flow of stack gas at X% O 2, Q stdo2 Q stdo2 = (Q a )P s (0.3592)(1B wo )(O 2 REF) V mstd@x%oxygen Molecular weight of wet gas, M s Formaldehyde Emission Rates, E M s = M d (1 B wo ) + 18(B wo ) g/gmol 28.8 E = [(C wet )(Q stw )(60)] / kg/hr 0.00 Page 15 of 23

16 APPENDIX 2 Summaries, Calculations, Raw Data and Charts MOISTURE CALCULATIONS Moisture Determination Non Isokinetic Test Number Sampling Time and Date Start Weight End Weight Total gain Concentration LOD Uncertainty kg kg kg % % % Run 1 11:30 12:05 27 November Test Number Sampling Duration Total Volume Sampled Moisture Quality Assurance Sampling Rate Start Leak Rate End Leak Rate Acceptable Leak Rate mins l l/min l/min l/min l/min Leak Tests Acceptable? Run Yes Stack Characteristics Stack Diameter / Depth, D 1.00 m Stack Width, W m Stack Area, A 0.79 m 2 Average stack gas temperature 34 PRELIMINARY STACK SURVEY Stack static pressure kpa Barometric Pressure kpa Pitot tube calibration coefficient, K pt 0.81 Stack Gas Composition & Molecular Weights Component Molar Density Conc Dry Volume Dry Conc Conc Wet Volume Wet Conc Mass kg/m 3 Dry Fraction kg/m 3 Wet Fraction kg/m 3 M p % Vol r pi % Vol r pi CO O N H 2 O Where: p = M / pi = r x p o C Calculation of Stack Gas Densities Determinand Dry Density (STP), P STD Wet Density (STP), P STW Dry Density (Actual), P Actual Average Wet Density (Actual), P ActualW Where: P STD = sum of component concentrations, kg/m 3 (not including water vapour) P STW = (P STD + pi of H 2 O) / (1 + (pi of H 2 O / )) Result Units 1.29 kg/m kg/m kg/m kg/m 3 P Actual = P STD x (Ts / Ps) x (Pa / Ta) P ActualW = P STW x (Ts / Ps) x (Pa / Ta) Page 16 of 23

17 APPENDIX 2 Summaries, Calculations, Raw Data and Charts PRELIMINARY STACK SURVEY TRAVERSE 1 Date of Survey Time of Survey Velocity Measurement Device: 27 November :11 SType Pitot Sampling Line A Traverse Distance DP pt DP pt Temp Velocity Volumetric O 2 Angle Point into mmh 2 O Pa o C m/s Flow Rate (actual) % of Swirl duct (m) (average of 3) (average of 3) m³/s Vol o < < < < < < < < < <15 Mean Sampling Line B Traverse Distance DP pt DP pt Temp Velocity Volumetric O 2 Angle Point into mmh 2 O Pa o C m/s Flow Rate (actual) % of Swirl duct (m) (average of 3) (average of 3) m³/s Vol o < < < < < < < < < <15 Mean PRELIMINARY STACK SURVEY QUALITY ASSURANCE CHECKLIST PITOT LEAK CHECK Pre Traverse Leak Rate Post Traverse Leak Rate Run Start Value End Value Difference Outcome Start Value End Value Difference Outcome mmh₂o mmh₂o % mmh₂o mmh₂o % Run Pass Pass To complete a compliant pitot leak check a pressure of over 80 mmh₂o (or 800 Pa) is applied and the pressure drop monitored over 5 mins. A drop of less than 5% must be observed. Run SType Pitot Stagnation Check Stagnation (Pa) Reference (Pa) Difference (Pa) Outcome (Permitted +/ 10 Pa) Run Pass Page 17 of 23

18 APPENDIX 2 Summaries, Calculations, Raw Data and Charts PRELIMINARY STACK SURVEY (CONTINUED) Sampling Plane Validation Criteria EA Technical Guidance Note (Monitoring) M1 Result Units Requirement Compliant Lowest Differential Pressure 88 Pa >= 5 Pa Yes Lowest Gas Velocity m/s Highest Gas Velocity m/s Ratio of Gas Velocities 1.11 < 3 : 1 Yes Maximum angle of flow with regard to duct axis >15 o < 15 o Yes No local negative flow Yes Yes Calculation of Stack Gas Velocity, V Velocity at Traverse Point, V = K pt x (1e) * Ö(2 * DP pt / P ActualW ) Where: K pt = Pitot tube calibration coefficient (1e) = Compressibility correction factor, assumed at a constant Average Stack Gas Velocity, Va m/s Calculation of Stack Gas Volumetric Flowrate, Q Duct gas flow conditions Actual Reference Units Temperature 34 0 o C Total Pressure kpa Oxygen % Moisture % Gas Volumetric Flowrate Result Units Average Stack Gas Velocity (Va) m/s Stack Area (A) 0.79 m 2 Gas Volumetric Flowrate (Actual), Q Actual m 3 /hr Gas Volumetric Flowrate (STP, Wet), Q STP m 3 /hr Gas Volumetric Flowrate (STP, Dry), Q STP,Dry m 3 /hr Gas Volumetric Flowrate (REF), Q Ref m 3 /hr Where: Q Actual = Va x A x 3600 Q STP = Q (Actual) x (Ts / Ta) x (Pa / Ps) x 3600 Q STP,Dry = Q (STP) / (100 (100 / Ma)) x 3600 Q Ref = Q (STP) x ((100 Ma) / (100 Ms)) x ((20.9 O 2 a) / (20.9 O 2 s)) Nomenclature: Ts = Absolute Temperature, Standard Conditions, 273 K Ps = Absolute Pressure, Standard Conditions, kpa Ta = Absolute Temperature, Actual Conditions, K Pa = Absolute Pressure, Actual Conditions, kpa Ma = Water vapour, Actual Conditions, % Vol Ms = Water vapour, Reference Conditions, % Vol O 2 a = Oxygen, Actual Conditions, % Vol O 2 s = Oxygen, Reference Conditions, % Vol Page 18 of 23

19 Value Units Stack Depth 1.00 m Sampling Distance Distance into Units Stack Width m Point (% of Depth) Stack Area 0.79 m Sampling Line A APPENDIX 2 Summaries, Calculations, Raw Data and Charts 3 Sampling Line B STACK DIAGRAM NonIsokinetic/Gases Sampling Sampling Distance Distance into Swirl Point (% of Depth) Stack (m) o < < < < 15 Isokinetic sampling point Isokinetic sampling points not used Non Isokinetic/Gases sampling point SAMPLING LOCATION Isokinetic Sampling CEN Methods Page 19 of 23

20 APPENDIX 3 Measurement Uncertainty Budget Calculations MEASUREMENT UNCERTAINTY BUDGET ISOKINETIC FORMALDEHYDE Run Sampled Volume Sampled Gas Temp Sampled Gas Pressure Sampled Gas Humidity Oxygen Content Concentration in impinger Limit of Detection Leak m³ K kpa % by volume % by volume mg % by mass % MU required <=2% <2.5 k <=1% <=1% <=5% <5% < 5% of ELV <=2% Run as a % compliant? Yes Yes Yes Yes N/A Yes Yes Yes Run Volume (STP) Mass of Formaldehyde O2 Correction Leak Lab Uncertainty Combined uncertainty m³ mg mg/m³ mg Run MU as mg/m MU as % R1 Uncertainty expressed at a 95% confidence level (where k = 2) (k is a coverage factor which gives a 95% confidence in the quoted figures) Developed for the STA by R Robinson, NPL 0.01 mg/m³ % Page 20 of 23

21 APPENDIX 3 Measurement Uncertainty Budget Calculations MEASUREMENT UNCERTAINTY BUDGET MOISTURE Run Sampled Volume Sampled Gas Temp Sampled Gas Pressure Sampled Gas Humidity Oxygen Content Leak m³ K kpa % by volume % by volume % MU required < 2% < 2% < 1% < 1% < 10% < 2% Run N/A as a % N/A 0.11 compliant? Yes Yes Yes Yes N/A Yes Run Volume (STP) Mass Gained O2 Correction Uncollected Mass m³ mg mg/m³ mg Run MU as % v/v MU as % Leak Combined uncertainty R1 Uncertainty expressed at a 95% confidence level (where k = 2) Developed for the STA by R Robinson, NPL 0.05 % v/v 9.60 % Page 21 of 23

22 APPENDIX 3 Measurement Uncertainty Budget Calculations MEASUREMENT UNCERTAINTY BUDGET VELOCITY & VOLUMETRIC FLOW RATE Measured Velocity at Actual Conditions Measured Volumetric Flow rate at Actual Conditions 10.8 m/s m³/hr Performance Characteristics & Source of Value Units Values Requirement Compliant Uncertainty of pitot tube coefficient Uncertainty of mean local dynamic pressures 0.36 Factor loading, function of the number of measurements. 3 readings minimum 3 Yes Range of measurment device pa 1000 Resolution pa 1.00 Calibration uncertainty pa 3.44 Drift % range 0.10 <1% of Value or 20 Pa whichever is Linearity % range 0.06 <2% of value Yes Uncertainty of molar mass determination kg/mol Uncertainty of temperature measurement K 1.56 <1% of value Yes Uncertainty of absolute pressure in the duct pa 512 Uncertainty associated with the estimate of density Uncertainty associated with the measurement of local velocity Uncertainty associated with the measurement of mean velocity Measurement Uncertainty Velocity Combined uncertainty Expanded uncertainty at a 95% Confidence Interval Note The expanded uncertainty uses a coverage factor of k = 2. Expanded Measurement Uncertainty of Velocity at a 95% Confidence Interval Expressed as a % of the Measured Concentration Expanded uncertainty at a 95% Confidence Interval greater m/s % Yes Measurement Uncertainty Volumetric Flow Rate Combined uncertainty Expanded uncertainty at a 95% Confidence Interval Note The expanded uncertainty uses a coverage factor of k = 2. Expanded Measurement Uncertainty of Volumetric Flow Rate at a 95% Confidence Interval Expressed as a % of the Measured Concentration Expanded uncertainty at a 95% Confidence Interval m³/hr % Page 22 of 23

23 END OF REPORT Page 23 of 23