EMISSION SURVEY FOR SONAE NOVOBORD: WHITE RIVER. Report No. 565/12 FR.1. March 2013 C & M CONSULTING ENGINEERS PO BOX LYNNWOOD RIDGE 0040

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1 EMISSION SURVEY FOR SONAE NOVOBORD: WHITE RIVER Report No. 565/12 FR.1 BY C & M CONSULTING ENGINEERS PO BOX LYNNWOOD RIDGE 0040 PRETORIA SOUTH AFRICA SONAE NOVOBORD 1

2 SUMMARY C&M Consulting Engineers (C&M) conducted an emission survey on the following stacks: -Boiler/Konus Stack -Maxxtec Oil Stack -MDF Cyclone -WR3 Dryer (Recalor Dryer) -Scrubber Stack -MDF Pre-steam Stack -Sawmill Cyclones 1 to 6 (as per C&M Map Layout, see Appendix) -Flaker Cyclones 1 to 4 (as per C&M Map Layout, see Appendix) The objective of the measurement programme was to quantify the emissions of Particulate Matter (PM), Combustion Gases (CG) and Aldehydes (A) for the following stacks: Stack Type of Test Date Boiler/Konus Stack PM, CG and A 04/02/2013 Maxxtec Oil Stack PM, CG and A 11/02/2013 MDF Cyclone PM, CG and A 07/02/2013 WR3 Dryer Stack PM, CG and A 13/02/2013 Scrubber Stack PM, CG and A 14/02/2013 Sawmill Cyclones 1 to 4 PM and CG 05/02/2013 Sawmill Cyclones 5 to 6 PM and CG 08/02/2013 Flaker Cyclone 1 to 4 PM and CG 06/02/2013 MDF Pre-Steam Stack PM and CG 11/02/2013 The average emission results obtained at the time of the measurements are given in the Tables below. SONAE NOVOBORD 2

3 Table A: Isokinetic Sampling of Various Point Sources; Average Stack Parameters, Particulate Concentrations and Stack Name Formaldehyde Concentrations Boiler/Konus Stack Maxxtec Oil Stack MDF Cyclone WR3 Dryer Stack Scrubber Stack STACK PARAMETERS UNITS AVERAGE AVERAGE AVERAGE AVERAGE AVERAGE Barometric pressure kpa Duct static pressure kpa Gas temperature ºC Gas velocity ms (Actual) m 3 h * (NTP) Nm 3 h * Total particulate matter (Actual) mgm Total particulate matter (NTP) mgnm (250) # 75.1 (100) # 40.1 (120) # 119 (100) # 279 Total solids emission rate kgh Water content (% Vol/Vol) % Formaldehyde (Actual) mgm Formaldehyde (NTP) mgnm *Due to cyclonic flow, the cross sectional area was estimated with the help of the point velocities profile to eliminate dead area. # Values in brackets are Permit Conditions SONAE NOVOBORD 3

4 Table B: Isokinetic Sampling of Various Point Sources; Average Component Concentrations Stack Name Boiler/Konus Stack Maxxtec Oil Stack MDF Cyclone WR3 Dryer Stack Scrubber Stack COMBUSTION GAS UNITS AVERAGE AVERAGE AVERAGE AVERAGE AVERAGE O 2 % CO Actual NTP, dry NO Actual NTP, dry NO 2 Actual NTP, dry NO x Actual NTP, dry SO 2 Actual NTP, dry ppm 798 mgnm ppm 90.1 mgnm ppm mgnm -3 ppm 90.1 mgnm ppm mgnm PERMIT CONDITION SONAE NOVOBORD 4

5 Table C: Non-Isokinetic Sampling of Flaker Cyclones; Average Stack Parameters and Particulate Concentrations Stack Name Flaker Cyclone 1 Flaker Cyclone 2 Flaker Cyclone 3 Flaker Cyclone 4 STACK PARAMETERS UNITS AVERAGE AVERAGE AVERAGE AVERAGE PERMIT CONDITION Barometric pressure kpa Gas temperature ºC Gas velocity ms (Actual) m 3 h -1 * * *9 590 * (NTP) Nm 3 h -1 * * *7 980 * Total particulate matter (Actual) mgm Total particulate matter (NTP) mgnm Total solids emission rate kgh Water content (% Vol/Vol) % *Due to cyclonic flow, the cross sectional area was estimated with the help of the point velocities profile to eliminate dead area. SONAE NOVOBORD 5

6 Table D: Non-Isokinetic Sampling of Flaker Cyclones; Average Component Concentrations Stack Name Flaker Cyclone 1 Flaker Cyclone 2 Flaker Cyclone 3 Flaker Cyclone 4 COMBUSTION GAS UNITS AVERAGE AVERAGE AVERAGE AVERAGE O 2 % CO Actual NTP, dry NO Actual NTP, dry NO 2 Actual NTP, dry NO x Actual NTP, dry SO 2 Actual NTP, dry ppm mgnm -3 ppm mgnm -3 ppm mgnm -3 ppm mgnm -3 ppm mgnm -3 SONAE NOVOBORD 6

7 Stack Name Table E: Non-Isokinetic Sampling of Sawmill Cyclones; Average Stack Parameters and Particulate Concentrations Sawmill Cyclone 1 Sawmill Cyclone 2 Sawmill Cyclone 3 Sawmill Cyclone 4 Sawmill Cyclone 5 Sawmill Cyclone 6 STACK PARAMETERS UNITS AVERAGE AVERAGE AVERAGE AVERAGE AVERAGE AVERAGE Barometric pressure kpa Gas temperature ºC Gas velocity ms (Actual) m 3 h -1 * * * * * * (NTP) Nm 3 h -1 * * * * * * Total particulate matter (Actual) Total particulate matter (NTP) mgm mgnm Total solids emission rate kgh Water content (% Vol/Vol) % *Due to cyclonic flow, the cross sectional area was estimated with the help of the point velocities profile to eliminate dead area. SONAE NOVOBORD 7

8 Table F: Non-Isokinetic Sampling of Sawmill Cyclones; Average Component Concentrations Stack Name Sawmill Cyclone 1 Sawmill Cyclone 2 Sawmill Cyclone 3 Sawmill Cyclone 4 Sawmill Cyclone 5 Sawmill Cyclone 6 COMBUSTION GAS UNITS AVERAGE AVERAGE AVERAGE AVERAGE AVERAGE AVERAGE O 2 % CO Actual NTP, dry NO Actual NTP, dry NO 2 Actual NTP, dry NO x Actual NTP, dry SO 2 Actual NTP, dry ppm mgnm -3 ppm mgnm -3 ppm mgnm -3 ppm mgnm -3 ppm mgnm -3 SONAE NOVOBORD 8

9 TABLE OF CONTENTS SUMMARY INTRODUCTION METHOD OF MEASUREMENTS TOTAL PARTICULATE EMISSION RATE STACK GAS VELOCITY STACK GAS TEMPERATURE WATER VAPOUR CONTENT COMBUSTION GASES FORMALDEHYDE EMISSIONS RESULTS TABLE 3.1: BOILER / KONUS STACK; STACK CONDITIONS AND PARTICULATE EMISSIONS;04 FEBRUARY TABLE 3.2: BOILER / KONUS; COMBUSTION GASES (NTP, DRY); 04 FEBRUARY TABLE 3.2 (CONT D): BOILER / KONUS; COMBUSTION GASES (NTP, DRY); 04 FEBRUARY TABLE 3.3: MAXXTEC OIL STACK; STACK CONDITIONS AND PARTICULATE EMISSIONS;11 FEBRUARY TABLE 3.4: MAXXTEC OIL STACK; COMBUSTION GASES (NTP, DRY); 11 FEBRUARY TABLE 3.5: MDF CYCLONE OUTLET; STACK CONDITIONS AND PARTICULATE EMISSIONS; 07 FEBRUARY TABLE 3.6: MDF CYCLONE OUTLET; COMBUSTION GASES (NTP, DRY); 07 FEBRUARY TABLE 3.7: WR3 DRYER STACK; STACK CONDITIONS AND PARTICULATE EMISSIONS; 13 FEBRUARY TABLE 3.8: WR3 DRYER STACK; COMBUSTION GASES (NTP, DRY); 13 FEBRUARY TABLE 3.9: SCRUBBER STACK; STACK CONDITIONS AND PARTICULATE EMISSIONS; 14 FEBRUARY TABLE 3.10: SCRUBBER STACK; COMBUSTION GASES (NTP, DRY); 14 FEBRUARY TABLE 3.11: FLAKER CYCLONE 1; STACK CONDITIONS AND PARTICULATE EMISSIONS; 06 FEBRUARY TABLE 3.12: FLAKER CYCLONE 1; COMBUSTION GASES (NTP, DRY); 06 FEBRUARY TABLE 3.13: FLAKER CYCLONE 2; STACK CONDITIONS AND PARTICULATE EMISSIONS; 06 FEBRUARY TABLE 3.14: FLAKER CYCLONE 2; COMBUSTION GASES (NTP, DRY); 06 FEBRUARY TABLE 3.15: FLAKER CYCLONE 3; STACK CONDITIONS AND PARTICULATE EMISSIONS; 06 FEBRUARY TABLE 3.16: FLAKER CYCLONE 3; COMBUSTION GASES (NTP, DRY); 06 FEBRUARY TABLE 3.17: FLAKER CYCLONE 4; STACK CONDITIONS AND PARTICULATE EMISSIONS; 06 FEBRUARY TABLE 3.18: FLAKER CYCLONE 4; COMBUSTION GASES (NTP, DRY); 06 FEBRUARY TABLE 3.20: SAWMILL CYCLONE 1; COMBUSTION GASES (NTP, DRY); 05 FEBRUARY TABLE 3.21: SAWMILL CYCLONE 2; STACK CONDITIONS AND PARTICULATE EMISSIONS; 05 FEBRUARY TABLE 3.22: SAWMILL CYCLONE 2; COMBUSTION GASES (NTP, DRY); 05 FEBRUARY TABLE 3.23: SAWMILL CYCLONE 3; STACK CONDITIONS AND PARTICULATE EMISSIONS; 05 FEBRUARY SONAE NOVOBORD 9

10 TABLE 3.24: SAWMILL CYCLONE 3; COMBUSTION GASES (NTP, DRY); 05 FEBRUARY TABLE 3.25: SAWMILL CYCLONE 4; STACK CONDITIONS AND PARTICULATE EMISSIONS; 05 FEBRUARY TABLE 3.26: SAWMILL CYCLONE 4; COMBUSTION GASES (NTP, DRY); 05 FEBRUARY TABLE 3.27: SAWMILL CYCLONE 5; STACK CONDITIONS AND PARTICULATE EMISSIONS; 08 FEBRUARY TABLE 3.28: SAWMILL CYCLONE 5; COMBUSTION GASES (NTP, DRY); 08 FEBRUARY TABLE 3.29: SAWMILL CYCLONE 6; STACK CONDITIONS AND PARTICULATE EMISSIONS; 08 FEBRUARY TABLE 3.30: SAWMILL CYCLONE 6; COMBUSTION GASES (NTP, DRY); 08 FEBRUARY DISCUSSION BOILER/KONUS STACK MAXXTEC OIL STACK MDF CYCLONE OUTLET WR3 DRYER STACK (RECALOR DRYER STACK) SCRUBBER STACK MDF PRE-STEAM STACK FLAKER CYCLONES 1 TO SAWMILL CYCLONES 1 TO CONCLUSIONS APPENDIX A SONAE NOVOBORD 10

11 1 INTRODUCTION C&M Consulting Engineers (C&M) conducted an emission survey on the following stacks: -Boiler/Konus Stack -Maxxtec Oil Stack -MDF Cyclone -WR3 Dryer (Recalor Dryer) -Scrubber Stack -MDF Pre-steam Stack -Sawmill Cyclones 1 to 6 (as per C&M Map Layout, see Appendix) -Flaker Cyclones 1 to 4 (as per C&M Map Layout, see Appendix) The objective of the measurement programme was to quantify the emissions of Particulate Matter (PM), Combustion Gases (CG) and Aldehydes (A) for the following stacks: Stack Type of Test Date Boiler/Konus Stack PM, CG and A 04/02/2013 Maxxtec Oil Stack PM, CG and A 11/02/2013 MDF Cyclone PM, CG and A 07/02/2013 WR3 Dryer Stack PM, CG and A 13/02/2013 Scrubber Stack PM, CG and A 14/02/2013 Sawmill Cyclones 1 to 4 PM and CG 05/02/2013 Sawmill Cyclones 5 to 6 PM and CG 08/02/2013 Flaker Cyclone 1 to 4 PM and CG 06/02/2013 MDF Pre-Steam Stack PM and CG 11/02/2013 SONAE NOVOBORD 11

12 2 METHOD OF MEASUREMENTS All isokinetic sampling techniques employed were carried out according to internationally accepted reference methods, which comply with the National Environmental Management: Air Quality Act of 2004 (Act 39 of 2004), as scheduled in the Minimum Emissions Listed Activities as prescribed in Government Notice TOTAL PARTICULATE EMISSION RATE Isokinetic sampling techniques were used to collect flue gas samples for particulate concentrations in the various flue gas streams, in compliance with the specifications of the following internationally accepted sampling methods: USEPA Method 17 Determination of Particulate Matter Emissions from Stationary Sources. ISO 9096 Stationary Source Emissions Determination of Concentration and Mass Flow Rate of Particulate Material in Gas-carrying Manual Gravimetric Method. The reference method entails in-stack filtration with the filter at stack temperature. The isokinetic sampling train for particulates consisted of the following components: - Sampling probe, nozzle and filter holder with high efficiency filter (thimble) - Impinger set for the removal of water vapour - Dry gas meter - Control unit fitted with calibrated orifice, thermocouple and vacuum gauge - Vacuum pump SONAE NOVOBORD 12

13 2.2 STACK GAS VELOCITY The gas velocity was calculated from data obtained from multi-point velocity pressure measurements. The location of the sampling points was based on the assumption that the distribution of gas velocity in sections of the stack crosssectional area adjacent to the wall will approximate the 1 / th 7 power law curve. Velocity pressure measurements were taken by means of an S-type Pitot tube and inclined gauge manometer. Stack gas volumes were calculated from the individual point velocities and internal dimensions of the stack. 2.3 STACK GAS TEMPERATURE The gas temperature was measured by means of a Type-K thermocouple connected to a digital thermometer. 2.4 WATER VAPOUR CONTENT The water vapour content of the gas stream was calculated from the temperature of the gas leaving the condenser unit and the mass of water condensed during each test. 2.5 COMBUSTION GASES A Teledyne PEM9004 portable emissions analyser was used to measure the concentrations of O 2, CO, NO x and SO 2 in the flue gas streams on a volume/volume basis, in accordance with EN : Specification for portable electrical apparatus designed to measure combustion flue gas parameters of heating appliances. The analyser utilises electro-chemical sensors to detect the concentrations of the various gases. SONAE NOVOBORD 13

14 2.6 FORMALDEHYDE EMISSIONS Gaseous and particulate pollutants are withdrawn isokinetically from an emission source and are collected in aqueous acidic 2,4-dinitrophenylhydrazine. Formaldehyde present in the emissions reacts with the 2,4-dinitrophenylhydrazine to form the formaldehyde dinitrophenylhydrazone derivative. The dinitrophenylhydrazone derivative is extracted, solventexchanged, concentrated, and then analyzed by high performance liquid chromatography (HPLC) according to Method 8315 or other appropriate technique. These analyses were conducted by Chemtech (SANAS Accreditation Certificate Number T0361). SONAE NOVOBORD 14

15 3 RESULTS The average results of the emission measurements conducted on the Boiler/Konus Stack, Maxxtec Oil Stack, MDF Cyclone Stack, WR3 Dryer Stack, Scrubber Stack and MDF Pre-steam Bin Cyclone as well as Flaker Cyclones 1 to 4 and Sawmill Cyclones 1 to 6 are presented in Tables A to F in the Summary of this report. The results of the measurements on the Boiler/Konus Stack, Maxxtec Oil Stack, MDF Cyclone Outlet, WR3 Dryer and Scrubber stack are presented in Tables 3.1 to The results of the measurements on the Flaker Cyclones 1 to 4 are presented in Tables 3.11 to The results of the measurements on the Sawmill Cyclones 1 to 6 are presented in Tables 3.19 to 3.30 Where concentrations are reported at NTP or mgnm -3 it refers to the conversion of concentrations to normal conditions of 0 ºC (273 K) and kpa. A map showing the locations and arrangement of the different cyclones as sampled by C&M can be found in Appendix A of this report. It must be noted that this report has been compiled using this map as reference. Normal temperature and pressure: This condition is also referred to as NTP and imply concentrations recalculated from actual conditions to gas volumes at 0ºC ( K) and kpa. As these conditions imply a reduction in the sampled gas volume due to the effect of reduced temperature and increased SONAE NOVOBORD 15

16 pressure, the resulting calculated concentration is higher than at actual flue gas conditions. NTP, dry: Current emission limits imposed by the Department of Environmental Affairs require results to be reported at NTP on a dry basis, i.e. based on the gas volume with water vapour removed. The removal of the water vapour content from the flue gas implies a further reduction in gas volume, resulting in even higher calculated concentrations. SONAE NOVOBORD 16

17 Table 3.1: Boiler / Konus Stack; Stack Conditions and Particulate Emissions; PARAMETER UNITS 04 February 2013 TEST NUMBER Time of day 11h11 13h24 14h55 Barometric pressure Duct static pressure kpa kpa Gas Temperature (Average) o C Stack diameter m 1.89 Gas velocity m.s Volumetric flow rate (Actual) Volumetric flow rate (NTP) Total solids (Actual) m 3 h Nm 3 h mgm PERMIT CONDITION Total solids (NTP) mgnm Total solids emission rate Water content (% Vol/Vol) Formaldehyde (Actual) Formaldehyde (NTP) kgh % mgm mgnm SONAE NOVOBORD 17

18 Table 3.2: Boiler / Konus; Combustion Gases (NTP, dry); 04 February 2013 Time O 2 CO NO NO 2 NOx as NO 2 SO 2 % mgnm -3 Test 1 11h h h h h h h h h h Average Test 2 13h h h h h h h h h h Average SONAE NOVOBORD 18

19 Table 3.2 (cont d): Boiler / Konus; Combustion Gases (NTP, dry); 04 February 2013 Test 3 15h h h h h h h h h h Average SONAE NOVOBORD 19

20 Table 3.3: Maxxtec Oil Stack; Stack Conditions and Particulate Emissions; 11 February 2013 PARAMETER Barometric pressure UNITS TEST NUMBER 1 2 Time of day 08h50 10h39 kpa Duct static pressure kpa Gas Temperature o C (Average) Stack diameter m 1.23 Gas velocity m.s (Actual) m 3 h (NTP) Nm 3 h Total solids (Actual) mgm PERMIT CONDITION Total solids (NTP) mgnm Total solids emission rate Water content (% Vol/Vol) Formaldehyde (Actual) Formaldehyde (NTP) kgh % mgm mgnm SONAE NOVOBORD 20

21 Table 3.4: Maxxtec Oil Stack; Combustion Gases (NTP, dry); 11 February 2013 Time O 2 CO NO NO 2 NOx as NO 2 SO 2 % mgnm -3 Test 1 08h h h h h h h h h h Average Test 2 10h h h h h h h h h h Average SONAE NOVOBORD 21

22 Table 3.5: MDF Cyclone Outlet; Stack Conditions and Particulate Emissions; PARAMETER UNITS 07 February 2013 TEST NUMBER 1 2 Time of day 10h10 12h05 Barometric pressure kpa Duct static pressure kpa Gas Temperature o C (Average) Stack diameter m 2.64 Gas velocity m.s (Actual) m 3 h -1 * * (NTP) Nm 3 h -1 * * Total solids (Actual) mgm PERMIT CONDITION Total solids (NTP) mgnm Total solids emission rate Water content (% Vol/Vol) Formaldehyde (Actual) Formaldehyde (NTP) kgh % mgm mgnm mgnm -3 * Due to cyclonic flow, the cross sectional area was estimated with the help of the point velocities profile to eliminate dead area. The cross sectional area of the cyclone outlet thus has been reduced to a theoretical value to compensate for the noflow area caused by cyclonic flow. This has no influence on the concentration of the particulates measured; it influences the volumetric flow rate and mass emission rate only. SONAE NOVOBORD 22

23 Table 3.6: MDF Cyclone Outlet; Combustion Gases (NTP, dry); 07 February 2013 Time O 2 CO NO NO 2 NOx as NO 2 SO 2 % mgnm -3 Test 1 10h h h h h h h h h h Average Test 2 12h h h h h h h h h h Average SONAE NOVOBORD 23

24 Table 3.7: WR3 Dryer Stack; Stack Conditions and Particulate Emissions; 13 February 2013 PARAMETER UNITS TEST NUMBER 1 2 Time of day 12h06 13h30 Barometric pressure kpa Duct static pressure kpa Gas Temperature o C (Average) Stack diameter m 1.8 Gas velocity m.s (Actual) m 3 h (NTP) Nm 3 h Total solids (Actual) mgm PERMIT CONDITION Total solids (NTP) mgnm Total solids emission rate Water content (% Vol/Vol) Formaldehyde (Actual) Formaldehyde (NTP) kgh % mgm mgnm SONAE NOVOBORD 24

25 Table 3.8: WR3 Dryer Stack; Combustion Gases (NTP, dry); 13 February 2013 Time O 2 CO NO NO 2 NOx as NO 2 SO 2 % mgnm -3 Test 1 12h h h h h h h h h h Average Test 2 13h h h h h h h h h h Average SONAE NOVOBORD 25

26 Table 3.9: Scrubber Stack; Stack Conditions and Particulate Emissions; 14 February 2013 PARAMETER UNITS TEST NUMBER 1 2 Time of day 09h41 10h54 Barometric pressure kpa Duct static pressure kpa Gas Temperature o C (Average) Stack diameter m 1.5 Gas velocity m.s (Actual) m 3 h (NTP) Nm 3 h Total solids (Actual) mgm PERMIT CONDITION Total solids (NTP) mgnm Total solids emission rate Water content (% Vol/Vol) Formaldehyde (Actual) Formaldehyde (NTP) kgh % mgm mgnm SONAE NOVOBORD 26

27 Table 3.10: Scrubber Stack; Combustion Gases (NTP, dry); 14 February 2013 Time O 2 CO NO NO 2 NOx as NO 2 SO 2 % mgnm -3 Test 1 09h h h h h h h h h h Average Test 2 10h h h h h h h h h h Average SONAE NOVOBORD 27

28 Table 3.11: Flaker Cyclone 1; Stack Conditions and Particulate Emissions; 06 February 2013 PERMIT TEST NUMBER PARAMETER UNITS CONDITION 1 2 Time of day 12h26 13h38 Barometric pressure kpa Gas Temperature (Average) o C Stack diameter m 0.9 Gas velocity m.s (Actual) m 3 h -1 * * (NTP) Nm 3 h -1 * * Total solids (Actual) mgm Total solids (NTP) mgnm Total solids emission rate kgh Water content (% Vol/Vol) % * Due to cyclonic flow, the cross sectional area was estimated with the help of the point velocities profile to eliminate dead area. The cross sectional area of the cyclone outlet thus has been reduced to a theoretical value to compensate for the noflow area caused by cyclonic flow. This has no influence on the concentration of the particulates measured; it influences the volumetric flow rate and mass emission rate only. SONAE NOVOBORD 28

29 Table 3.12: Flaker Cyclone 1; Combustion Gases (NTP, dry); 06 February 2013 Time O 2 CO NO NO 2 NOx as NO 2 SO 2 % mgnm -3 Test 1 12h h h h h h h h h h Average Test 2 13h h h h h h h h h h Average SONAE NOVOBORD 29

30 Table 3.13: Flaker Cyclone 2; Stack Conditions and Particulate Emissions; 06 February 2013 PERMIT TEST NUMBER PARAMETER UNITS CONDITION 1 2 Time of day 12h26 13h39 Barometric pressure kpa Gas Temperature (Average) o C Stack diameter m 0.9 Gas velocity m.s (Actual) m 3 h -1 * * (NTP) Nm 3 h -1 * * Total solids (Actual) mgm Total solids (NTP) mgnm Total solids emission rate kgh Water content (% Vol/Vol) % * Due to cyclonic flow, the cross sectional area was estimated with the help of the point velocities profile to eliminate dead area. The cross sectional area of the cyclone outlet thus has been reduced to a theoretical value to compensate for the noflow area caused by cyclonic flow. This has no influence on the concentration of the particulates measured; it influences the volumetric flow rate and mass emission rate only. SONAE NOVOBORD 30

31 Table 3.14: Flaker Cyclone 2; Combustion Gases (NTP, dry); 06 February 2013 Time O 2 CO NO NO 2 NOx as NO 2 SO 2 % mgnm -3 Test 1 12h h h h h h h h h h Average Test 2 13h h h h h h h h h h Average SONAE NOVOBORD 31

32 Table 3.15: Flaker Cyclone 3; Stack Conditions and Particulate Emissions; 06 February 2013 PERMIT TEST NUMBER PARAMETER UNITS CONDITION 1 2 Time of day 09h46 10h55 Barometric pressure kpa Gas Temperature (Average) o C Stack diameter m 0.8 Gas velocity m.s (Actual) m 3 h -1 *8 960 * (NTP) Nm 3 h -1 *7 420 *8 540 Total solids (Actual) mgm Total solids (NTP) mgnm Total solids emission rate kgh Water content (% Vol/Vol) % * Due to cyclonic flow, the cross sectional area was estimated with the help of the point velocities profile to eliminate dead area. The cross sectional area of the cyclone outlet thus has been reduced to a theoretical value to compensate for the noflow area caused by cyclonic flow. This has no influence on the concentration of the particulates measured; it influences the volumetric flow rate and mass emission rate only. SONAE NOVOBORD 32

33 Table 3.16: Flaker Cyclone 3; Combustion Gases (NTP, dry); 06 February 2013 Time O 2 CO NO NO 2 NOx as NO 2 SO 2 % mgnm -3 Test 1 09h h h h h h h h h h Average Test 2 10h h h h h h h h h h Average SONAE NOVOBORD 33

34 Table 3.17: Flaker Cyclone 4; Stack Conditions and Particulate Emissions; 06 February 2013 PERMIT TEST NUMBER PARAMETER UNITS CONDITION 1 2 Time of day 09h36 10h59 Barometric pressure kpa Gas Temperature (Average) o C Stack diameter m 0.8 Gas velocity m.s (Actual) m 3 h -1 * * (NTP) Nm 3 h -1 * * Total solids (Actual) mgm Total solids (NTP) mgnm Total solids emission rate kgh Water content (% Vol/Vol) % * Due to cyclonic flow, the cross sectional area was estimated with the help of the point velocities profile to eliminate dead area. The cross sectional area of the cyclone outlet thus has been reduced to a theoretical value to compensate for the noflow area caused by cyclonic flow. This has no influence on the concentration of the particulates measured; it influences the volumetric flow rate and mass emission rate only. SONAE NOVOBORD 34

35 Table 3.18: Flaker Cyclone 4; Combustion Gases (NTP, dry); 06 February 2013 Time O 2 CO NO NO 2 NOx as NO 2 SO 2 % mgnm -3 Test 1 09h h h h h h h h h h Average Test 2 11h h h h h h h h h h Average SONAE NOVOBORD 35

36 Table 3.19: Sawmill Cyclone 1; Stack Conditions and Particulate Emissions; 05 February 2013 PARAMETER UNITS TEST NUMBER 1 2 Time of day 12h05 13h15 Barometric pressure kpa Gas Temperature (Average) o C Stack diameter m 0.92 Gas velocity m.s (Actual) m 3 h -1 * * (NTP) Nm 3 h -1 * * Total solids (Actual) mgm Total solids (NTP) mgnm Total solids emission rate kgh Water content (% Vol/Vol) % * Due to cyclonic flow, the cross sectional area was estimated with the help of the point velocities profile to eliminate dead area. The cross sectional area of the cyclone outlet thus has been reduced to a theoretical value to compensate for the noflow area caused by cyclonic flow. This has no influence on the concentration of the particulates measured; it influences the volumetric flow rate and mass emission rate only. SONAE NOVOBORD 36

37 Table 3.20: Sawmill Cyclone 1; Combustion Gases (NTP, dry); 05 February 2013 Time O 2 CO NO NO 2 NOx as NO 2 SO 2 % mgnm -3 Test 1 12h h h h h h h h h h Average Test 2 13h h h h h h h h h h Average SONAE NOVOBORD 37

38 Table 3.21: Sawmill Cyclone 2; Stack Conditions and Particulate Emissions; 05 February 2013 PARAMETER UNITS TEST NUMBER 1 2 Time of day 12h05 13h15 Barometric pressure kpa Gas Temperature (Average) o C Stack diameter m 0.92 Gas velocity m.s (Actual) m 3 h -1 * * (NTP) Nm 3 h -1 * * Total solids (Actual) mgm Total solids (NTP) mgnm Total solids emission rate kgh Water content (% Vol/Vol) % * Due to cyclonic flow, the cross sectional area was estimated with the help of the point velocities profile to eliminate dead area. The cross sectional area of the cyclone outlet thus has been reduced to a theoretical value to compensate for the noflow area caused by cyclonic flow. This has no influence on the concentration of the particulates measured; it influences the volumetric flow rate and mass emission rate only. SONAE NOVOBORD 38

39 Table 3.22: Sawmill Cyclone 2; Combustion Gases (NTP, dry); 05 February 2013 Time O 2 CO NO NO 2 NOx as NO 2 SO 2 % mgnm -3 Test 1 12h h h h h h h h h h Average Test 2 13h h h h h h h h h h Average SONAE NOVOBORD 39

40 Table 3.23: Sawmill Cyclone 3; Stack Conditions and Particulate Emissions; 05 February 2013 PARAMETER UNITS TEST NUMBER 1 2 Time of day 09h40 10h50 Barometric pressure kpa Gas Temperature (Average) o C Stack diameter m 0.92 Gas velocity m.s (Actual) m 3 h -1 * * (NTP) Nm 3 h -1 * * Total solids (Actual) mgm Total solids (NTP) mgnm Total solids emission rate kgh Water content (% Vol/Vol) % * Due to cyclonic flow, the cross sectional area was estimated with the help of the point velocities profile to eliminate dead area. The cross sectional area of the cyclone outlet thus has been reduced to a theoretical value to compensate for the noflow area caused by cyclonic flow. This has no influence on the concentration of the particulates measured; it influences the volumetric flow rate and mass emission rate only. SONAE NOVOBORD 40

41 Table 3.24: Sawmill Cyclone 3; Combustion Gases (NTP, dry); 05 February 2013 Time O 2 CO NO NO 2 NOx as NO 2 SO 2 % mgnm -3 Test 1 09h h h h h h h h h h Average Test 2 10h h h h h h h h h h Average SONAE NOVOBORD 41

42 Table 3.25: Sawmill Cyclone 4; Stack Conditions and Particulate Emissions; 05 February 2013 PARAMETER UNITS TEST NUMBER 1 2 Time of day 09h40 10h50 Barometric pressure kpa Gas Temperature (Average) o C Stack diameter m 0.92 Gas velocity m.s (Actual) m 3 h -1 * * (NTP) Nm 3 h -1 * * Total solids (Actual) mgm Total solids (NTP) mgnm Total solids emission rate kgh Water content (% Vol/Vol) % * Due to cyclonic flow, the cross sectional area was estimated with the help of the point velocities profile to eliminate dead area. The cross sectional area of the cyclone outlet thus has been reduced to a theoretical value to compensate for the noflow area caused by cyclonic flow. This has no influence on the concentration of the particulates measured; it influences the volumetric flow rate and mass emission rate only. SONAE NOVOBORD 42

43 Table 3.26: Sawmill Cyclone 4; Combustion Gases (NTP, dry); 05 February 2013 Time O 2 CO NO NO 2 NOx as NO 2 SO 2 % mgnm -3 Test 1 09h h h h h h h h h h Average Test 2 10h h h h h h h h h h Average SONAE NOVOBORD 43

44 Table 3.27: Sawmill Cyclone 5; Stack Conditions and Particulate Emissions; 08 February 2013 PARAMETER UNITS TEST NUMBER 1 2 Time of day 12h00 13h22 Barometric pressure kpa Gas Temperature (Average) o C Stack diameter m 0.92 Gas velocity m.s (Actual) m 3 h -1 * * (NTP) Nm 3 h -1 * * Total solids (Actual) mgm Total solids (NTP) mgnm Total solids emission rate kgh Water content (% Vol/Vol) % * Due to cyclonic flow, the cross sectional area was estimated with the help of the point velocities profile to eliminate dead area. The cross sectional area of the cyclone outlet thus has been reduced to a theoretical value to compensate for the noflow area caused by cyclonic flow. This has no influence on the concentration of the particulates measured; it influences the volumetric flow rate and mass emission rate only. SONAE NOVOBORD 44

45 Table 3.28: Sawmill Cyclone 5; Combustion Gases (NTP, dry); 08 February 2013 Time O 2 CO NO NO 2 NOx as NO 2 SO 2 % mgnm -3 Test 1 12h h h h h h h h h h Average Test 2 13h h h h h h h h h h Average SONAE NOVOBORD 45

46 Table 3.29: Sawmill Cyclone 6; Stack Conditions and Particulate Emissions; 08 February 2013 PARAMETER UNITS TEST NUMBER 1 2 Time of day 11h30 13h00 Barometric pressure kpa Gas Temperature (Average) o C Stack diameter m 0.92 Gas velocity m.s (Actual) m 3 h -1 * * (NTP) Nm 3 h -1 * * Total solids (Actual) mgm Total solids (NTP) mgnm Total solids emission rate kgh Water content (% Vol/Vol) % * Due to cyclonic flow, the cross sectional area was estimated with the help of the point velocities profile to eliminate dead area. The cross sectional area of the cyclone outlet thus has been reduced to a theoretical value to compensate for the noflow area caused by cyclonic flow. This has no influence on the concentration of the particulates measured; it influences the volumetric flow rate and mass emission rate only. SONAE NOVOBORD 46

47 Table 3.30: Sawmill Cyclone 6; Combustion Gases (NTP, dry); 08 February 2013 Time O 2 CO NO NO 2 NOx as NO 2 SO 2 % mgnm -3 Test 1 14h h h h h h h h h h Average Test 2 14h h h h h h h h h h Average SONAE NOVOBORD 47

48 4 DISCUSSION 4.1 Boiler/Konus Stack Table 3.1 provides the stack conditions as well as the particulate concentrations found during the sampling period on 04 February From the table it can be seen that stack parameters which prevailed during the testing period, remained essentially stable. Some variance was noted in the volumetric flow rate however. It is noted that the volumetric flow rate is significantly higher when compared to previous sampling programmes. The static pressure was recorded to be more negative than for previous sampling programmes and is in theory a result of the higher volumetric flow rates recorded as there exists a direct relationship between the linear velocity of a fluid and the static pressure exerted by the fluid. Three tests were conducted due to info received that a plant upset took place during Test 1 after it was finished already. It was decided to do a third test as well to err on the conservative side if an operational upset did take place. The values for Test 1 are still reported as no significant difference could be noted between the three tests. It was possible to apply the principles of isokinetic sampling on the Boiler/Konus Stack and Formaldehyde sampling was conducted as well. The formaldehyde found in the boiler stack can only be attributed to the feed material s formaldehyde content. 4.2 Maxxtec Oil Stack Table 3.3 provides the stack conditions as well as the particulate concentrations found during the sampling period on 11 February A substantial increase in the volumetric flow rate was noted, as well as an SONAE NOVOBORD 48

49 increase in the average stack gas temperature when comparing results from both tests conducted. This increase in stack temperature for Test 2 combined with a process variable change which could influence the variable speed drive of the ID fan could explain the increase in volumetric flow rate of Test 2. It was possible to apply the principles of isokinetic sampling on the Maxxtec Oil Stack and Formaldehyde sampling was conducted as well. 4.3 MDF Cyclone Outlet Table 3.5 provides the stack conditions as well as the particulate concentrations found during the sampling period on 07 February From the table it can be seen that stack parameters which prevailed during the testing period remained essentially stable. A slight increase in stack temperature was noted for Test 2 but this could be due to the increase in atmospheric temperature. No combustion gas components were detected in the flue gas during the sample duration. Due to the flow through the outlet of the cyclone not being uniform throughout the cross sectional area of the outlet, but following a distinctive spiral flow as is expected, the repeatability of results cannot be guaranteed or even justified. C&M personnel tried to compensate for the spiral flow as to best practice. Formaldehyde sampling was conducted on the MDF Cyclone Outlet and the results for the Formaldehyde samples were determined to be 42.7 and 254 mg.nm -3 for Test 1 and Test 2, respectively. The SANAS accredited laboratory analysed the submitted samples twice to verify this high concentration and confirmed the results. A field blank of the DNPH solution used to capture the formaldehyde compound did not yield any significant amount of pre-existing formaldehyde. SONAE NOVOBORD 49

50 It is a possibility that at the time of measurement, a release of formaldehyde might have taken place due to unforeseen circumstances. A process history check is strongly advised and might validate this finding. C&M does not believe that this spike results are indicative of the typical operation of the MDF Cyclone as previous sampling programmes yielded much lower formaldehyde concentrations. 4.4 WR3 Dryer Stack (Recalor Dryer Stack) Table 3.7 provides the stack conditions as well as the particulate concentrations found during the sampling period on 13 February Some variance is noted in the volumetric flow rate when comparing Test 1 to Test 2. The particulate matter concentration was found to be lower during Test 2 when the average stack temperature was slightly higher coupled with the increased volumetric flow rate measured for Test 2. The oxygen and carbon monoxide concentrations were found to be slightly lower during Test 2 when compared to Test 1 which indicates improved combustion during Test 2. It was possible to apply the principles of isokinetic sampling on the WR3 Dryer Stack and Formaldehyde sampling was conducted as well. The results for the Formaldehyde samples were 1.78 and 1.49 mg.nm -3 for Test 1 and Test 2, respectively. 4.5 Scrubber Stack Table 3.9 provides the stack conditions as well as the particulate concentrations found during the sampling period on 14 February All parameters measured remained essentially stable throughout the sampling period. SONAE NOVOBORD 50

51 The outlet of the stack was altered from the last visit as the stack flap/hood part was removed since the last sampling programme was conducted on the scrubber outlet. This influenced the average volumetric flow rate as the stack area for the gas to escape was enlarged as the stack flap/hood was removed from the outlet. Due to this larger area the volumetric flow rate was determined to be lower when compared to the previous sampling programme conducted on the scrubber outlet. The higher particulate matter concentration should be interpreted with care as it is suspected that the droplets emitted from the scrubber might have been trapped by the filters. These droplets are suspected to be consisting of a resin/organic like material which were deflected by the flap/hood during the previous sampling programme and the removal of this flap/hood from the stack outlet might have caused these resin-like droplets to be caught by the sample probe. The sample site and scaffolding were covered with this specific substance at the time of sampling. No ports were installed on the stack and C&M personnel took the sample at the top of the stack outlet. This did not comply with the isokinetic sampling method employed by C&M and the results obtained must be interpreted with care. 4.6 MDF Pre-Steam Stack No ports were installed on the stack and C&M personnel attempted to take the sample at the top of the stack outlet. This did not comply with the isokinetic sampling method employed by C&M. The MDF Pre-steam stack outlet could not be sampled isokinetically however. This was due to varying steam loads caused by a change in the input material used in the process. The steam emission at the outlet did not allow for isokinetic sampling as the sampling condenser was not capable to remove enough heat from the steam to completely condense all the water out of the SONAE NOVOBORD 51

52 gas stream. After 10 minutes of sampling the entire sample train were wet and the testing was abandoned to prevent damage to the sample train. 4.7 Flaker Cyclones 1 to 4 Isokinetic sampling on the Flaker Cyclones was attempted by C&M to try and quantify the particulate matter concentration. Due to the flow through the outlet of the cyclones not being uniform throughout the cross sectional area of the outlets, instead, following a distinctive spiral flow as is expected of the design, the repeatability of results cannot be guaranteed or even justified. C&M personnel tried to compensate for the spiral flow as to best practice. Due to cyclonic flow, the cross sectional area was estimated with the help of the point velocities profile to eliminate dead area or the area of the outlet where no or negligible flow was measured. The cross sectional area of the cyclone outlet thus has been theoretically reduced to compensate for the noflow area caused by cyclonic flow. This, however, has no influence on the concentration of the particulates measured; it influences the volumetric flow rate and mass emission rate only. The concentration of particulates are calculated by taking the mass difference of the glass fibre thimble (filter) for each test and dividing by the total volume of gas sampled (using a dry gas meter that quantifies the volume of gas sampled). The results of all four Flaker Cyclones 1 to 4 are given in Table 3.11 to 3.18 and should be interpreted with care although all the particulate concentrations are well below the limit according to the permit conditions. The combustion gas analysis of all four Flaker Cyclones shows that the gas sampled is predominantly dust laden ambient air. SONAE NOVOBORD 52

53 4.8 Sawmill Cyclones 1 to 6 Isokinetic sampling on the Sawmill Cyclones was attempted by C&M to try and quantify the particulate matter concentration. Due to the flow through the outlet of the cyclones not being uniform throughout the cross sectional area of the outlets, instead, following a distinctive spiral flow as is expected of the design, the repeatability of results cannot be guaranteed or even justified. C&M personnel tried to compensate for the spiral flow as to best practice. Due to cyclonic flow, the cross sectional area was estimated with the help of the point velocities profile to eliminate dead area or the area of the outlet where no or negligible flow was measured. The cross sectional area of the cyclone outlet thus has been theoretically reduced to compensate for the noflow area caused by cyclonic flow. This, however, has no influence on the concentration of the particulates measured; it influences the volumetric flow rate and mass emission rate only. The concentration of particulates are calculated by taking the mass difference of the glass fibre thimble (filter) for each test and dividing by the total volume of gas sampled (using a dry gas meter that quantifies the volume of gas sampled). The results of the Sawmill Cyclones 1 to 6 are given in Table 3.19 to 3.30 and should be interpreted with care. The combustion gas analysis of all eight Sawmill Cyclones shows that the gas sampled is predominantly dust laden ambient air. SONAE NOVOBORD 53