For inspection purposes only.

Transcription

1 ISO/IEC Accredited Legal Entity, UKAS Accredited Testing Laboratory No Exova (UK) Ltd trading as Exova Catalyst & Exova Catalyst Ireland Unit C5, Emery Court, The Embankment Business Park, Stockport, SK4 3GL Exova Catalyst Ireland, Unit D8 North City Business Park, North Road, Finglas, Dublin 11 T: E: Your Exova Catalyst Ireland Contact: Nick Kenny ( ) Stack Emissions Testing Report Commissioned by Installation Name & Address Cork Road Industrial Park Ireland Irish EPA IPPC Licence: P Stack Reference A29 Wet Scrubber Dates of the Monitoring Campaign 19th January 2016 Job Reference Number CDU0583 Report Written by John Glennon Team Leader MCERTS Level 2 MM TE1 TE2 TE3 TE4 Report Approved by Patrick O'Brien Team Leader MCERTS Level 2 MM TE1 TE2 TE3 TE4 Report Date 9th February 2016 Version Version 1 Signature of Report Approver CATRT (Version BK) CDU0583 Honeywell Int Technology, A29 Wet Scrubber (HF) Report EPA Export :01:55:36

2 CONTENTS TITLE PAGE CONTENTS Summary of Sampling Deviations 2 EXECUTIVE SUMMARY Monitoring Objectives Monitoring Results Monitoring Dates & Times Process Details Monitoring & Analytical Methods Sampling Location Plant Photos / Sample Points APPENDIX 1 Monitoring Personnel & List of Equipment APPENDIX 2 Raw Data, Sampling Equations & Charts Opinions and interpretations expressed herein are outside the scope of Exova Catalyst Ireland's ISO accreditation. This test report shall not be reproduced, except in full, without the written approval of Exova Catalyst Ireland. The testing performed fully meets the technical requirements in Irish EPA Guidance Note, AG2. SUMMARY OF SAMPLING DEVIATIONS All Run All Deviation There are no deviations associated with the sampling employed. A29 Wet Scrubber CATRT (Version BK) Page 2 of 18 Job Number: CDU0583, Version 1 Irish EPA IPPC Licence: P EPA Export :01:55:36

3 Executive Summary (Page 1 of 7) MONITORING OBJECTIVES, A29 Wet Scrubber 19th January 2016 Overall Aim of the Monitoring Campaign Exova Catalyst Ireland were commissioned by to carry out stack emissions testing on the A29 Wet Scrubber at. The aim of the monitoring campaign was to demonstrate compliance with a set of emission limit values (ELVs) as specified in the Site's Permit. Special Requirements There were no special requirements. Target s Hydrogen Fluoride A29 Wet Scrubber CATRT (Version BK) Page 3 of 18 Job Number: CDU0583, Version 1 Irish EPA IPPC Licence: P EPA Export :01:55:36

4 Executive Summary (Page 2 of 7) MONITORING RESULTS, A29 Wet Scrubber 19th January 2016 where MU = Measurement Uncertainty associated with the Result Concentration Mass Emission Hydrogen Fluoride ¹ mg/m³ < g/hr < 0.28 Water Vapour Stack Gas Temperature Stack Gas Velocity Volumetric Flow Rate (ACTUAL) Volumetric Flow Rate (REF) ¹ % v/v NOTE: VOLUMETRIC FLOW RATE & VELOCITY DATA TAKEN FROM THE PRELIMINARY VELOCITY TRAVERSE. ¹ Reference Conditions (REF) are: 273K, 101.3kPa, without correction for water vapour content. C m/s m³/hr m³/hr Result MU +/ +/ Limit Limit Result MU Limit A29 Wet Scrubber CATRT (Version BK) Page 4 of 18 Job Number: CDU0583, Version 1 Irish EPA IPPC Licence: P EPA Export :01:55:36

5 Executive Summary (Page 3 of 7) MONITORING DATE(S) & TIMES, A29 Wet Scrubber 19th January 2016 Concentration Mass Emission Sampling Date(s) Sampling Times Duration mins Hydrogen Fluoride Velocity & Volumetric Flow Rate R1 mg/m³ < g/hr < R1 19/01/ :52 13: /01/ :30 10:40 All results are expressed at the respective reference conditions. A29 Wet Scrubber CATRT (Version BK) Page 5 of 18 Job Number: CDU0583, Version 1 Irish EPA IPPC Licence: P EPA Export :01:55:36

6 Executive Summary (Page 4 of 7) PROCESS DETAILS, A29 Wet Scrubber 19th January 2016 Standard Operating Conditions Process Status Continuous or Batch Process Abatement System Abatement System Running Status Plume Appearance Value Wet Scrubber Continuous Wet Scrubber On None visible A29 Wet Scrubber CATRT (Version BK) Page 6 of 18 Job Number: CDU0583, Version 1 Irish EPA IPPC Licence: P EPA Export :01:55:36

7 Executive Summary (Page 5 of 7) MONITORING & ANALYTICAL METHODS, A29 Wet Scrubber 19th January 2016 Monitoring Analysis Standard Technical Procedure ISO Testing Testing Lab Analytical Procedure Analytical Technique ISO Analysis MCERTS Lab Testing Analysis LOD (Average) Hydrogen Fluoride ISO CATTP10 CAT CATAP01 IC Water Vapour EN CATTP05 CAT CATTP05 Gravimetric Velocity & Vol. Flow Rate EN (MID) CATTP41 CAT Pitot Tube and Thermocouple CAT CAT mg/m³ 0.1 % v/v 1.2 m/s ANALYSIS LABORATORIES (with short name reference as appears in the table above) Exova Catalyst (CAT) ISO Accreditation Number: 4279 A29 Wet Scrubber CATRT (Version BK) Page 7 of 18 Job Number: CDU0583, Version 1 Irish EPA IPPC Licence: P EPA Export :01:55:36

8 Executive Summary (Page 6 of 7) SUITABILITY OF SAMPLING LOCATION Duct Characteristics Location of Sampling Platform Value General Platform Information Value Type Depth Width Area Port Depth Orientation of Duct Sample Port Size m m m² cm Circular Vertical 4" BSP Permanent / Temporary Platform Inside / Outside Permanent Outside Platform Details Irish EPA Technical Guidance Note AG1 / EN Platform Requirements Value Sufficient working area to manipulate probe and operate the measuring instruments Platform has 2 levels of handrails (approx. 0.5m & 1.0m high) Platform has vertical base boards (approx. 0.25m high) Platform has chains / self closing gates at top of ladders There are no obstructions present which hamper insertion of sampling equipment Safe Access Available Easy Access Available Sampling Location / Platform Improvement Recommendations The sampling location meets all the requirements specified in Irish EPA Guidance Note AG1 and EN 15259, and therefore there are no improvement recommendations. EN Homogeneity Test Requirements There is no requirement to perform a EN Homogeneity Test on this Stack. No No Sampling Plane Validation Criteria (from EN 15259) Criteria in EN Traverse 1 Required Compliant Lowest Differential Pressure Pa Mean Velocity m/s Lowest Gas Velocity m/s Highest Gas Velocity m/s Ratio of Above : 1 Maximum Angle of Swirl No Local Negative Flow > 5 Pa < 3 : 1 < 15 A29 Wet Scrubber CATRT (Version BK) Page 8 of 18 Job Number: CDU0583, Version 1 Irish EPA IPPC Licence: P EPA Export :01:55:36

9 Executive Summary (Page 7 of 7) PLANT PHOTOS Photo 1 Photo 3 SAMPLE POINTS Photo 4 Line B A2 Line A where = isokinetic point sampled at = isokinetic point not sampled at = combustion gases sample point = nonisokinetic sample point A29 Wet Scrubber CATRT (Version BK) Page 9 of 18 Job Number: CDU0583, Version 1 Irish EPA IPPC Licence: P EPA Export :01:55:36

10 APPENDICES APPENDIX CONTENTS APPENDIX 1 Stack Emissions Monitoring Personnel, List of Equipment & Methods and Technical Procedures Used APPENDIX 2 Summaries, Calculations, Raw Data and Charts A29 Wet Scrubber CATRT (Version BK) Page 10 of 18 Job Number: CDU0583, Version 1 Irish EPA IPPC Licence: P EPA Export :01:55:36

11 APPENDIX 1 STACK EMISSIONS MONITORING PERSONNEL Position Name MCERTS Accreditation MCERTS Number Technical Endorsements Team Leader John Glennon MCERTS Level 2 MM TE1 TE2 TE3 TE4 Technician Kate NiDhuill MCERTS Level 1 MM TE1 LIST OF EQUIPMENT Extractive Sampling Instrumental Analysers Miscellaneous Items Equipment Type Equipment I.D. Equipment Type Equipment I.D. Equipment Type Equipment I.D. Control Box DGM (1) SELECT Horiba Model (1) Digital Manometer (1) CAT Control Box DGM (2) SELECT Horiba Model (2) Digital Manometer (2) Box Thermocouples (1) Servomex 4900 Digital Temperature Meter CAT Box Thermocouples (2) Eco Physics CLD 822Mh Stopwatch CAT Umbilical (1) ABB AO2020URAS26 Barometer CAT Umbilical (2) Servomex 5200MP Stack Thermocouple (1) CAT Oven Box (1) SELECT Gas Conditioning Stack Thermocouple (2) Oven Box (2) SELECT FTIR Stack Thermocouple (3) Heated Probe (1) CAT 5.52 Gasmet Sampling System 1m Heated Line (1) Heated Probe (2) Bernath 3006 FID 1m Heated Line (2) Heated Probe (3) SELECT Heated Head 1m Heated Line (3) SPitot (1) SPitot (2) CAT 21S.42 CAT 21P.59 Mass Flow Controller (1) Mass Flow Controller (2) 5m Heated Line (1) 15m Heated Line (1) LPitot Mass View (1) CAT m Heated Line (1) 500g Check Weight CAT Mass View (2) 20m Heated Line (2) 1Kg Check Weight CAT SELECT Logger 1 Dual Channel Heater Controller Last Impinger Arm CAT SELECT Logger 2 Single Channel Heater Controller Callipers Bioaerosols Temperature Logger Laboratory Balance CAT 1.18 / 1.18a Tubes Kit Thermocouple Electronic Refrigerator Tape Measure CAT Hydrogen Fluoride Water Vapour Velocity & Vol. Flow Rate METHODS & TECHNICAL PROCEDURES USED Standard ISO EN EN (MID) Technical Procedure CATTP10 CATTP05 CATTP41 A29 Wet Scrubber CATRT (Version BK) Page 11 of 18 Job Number: CDU0583, Version 1 Irish EPA IPPC Licence: P EPA Export :01:55:36

12 APPENDIX 2 PRELIMINARY STACK SURVEY: CALCULATIONS General Stack Details Stack Details (from Traverse) Stack Diameter / Depth, D Stack Width, W Stack Area, A Average Stack Gas Temperature, T a Average Stack Gas Pressure Average Stack Static Pressure, P static Average Barometric Pressure, P b Average Pitot Tube Calibration Coefficient, C p m m m² C Pa kpa kpa Value Stack Gas Composition & Molecular Weights Component Conc ppm Conc Dry % v/v Conc Wet % v/v Volume Fraction r Molar Mass M Density kg/m³ p Conc kg/m³ p i CO₂ (Estimated) O₂ (Estimated) N₂ Moisture (H₂O) Where: p = M / p i = r x p 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 kg/m³ Result kg/m³ kg/m³ kg/m³ Where: P STD = sum of component concentrations, kg/m³ (not including water vapour) P STW = sum of all wet concentrations / 100 x density, kg/m³ (including water vapour) P Actual = P STD x (T STP / (P STP )) x ((P static + P b ) / T a ) P ActualW (at each sampling point) = P STW x (T s / P s ) x (P a / T a ) Calculation of Stack Gas Volumetric Flowrate, Q Duct gas flow conditions Temperature Total Pressure Moisture C kpa % Actual REF ¹ Gas Volumetric Flowrate (from Traverse) Result Gas Volumetric Flowrate (Actual) Gas Volumetric Flowrate (STP, Wet) Gas Volumetric Flowrate (STP, Dry) Gas Volumetric Flowrate REF ¹ m³/hr m³/hr m³/hr m³/hr A29 Wet Scrubber CATRT (Version BK) Page 12 of 18 Job Number: CDU0583, Version 1 Irish EPA IPPC Licence: P EPA Export :01:55:37

13 APPENDIX 2 PRELIMINARY STACK SURVEY: VELOCITY TRAVERSE TO EN (MID) (1 of 1) Value Value Date of Survey 19/01/2016 Initial Pitot Leak Check Pass Time of Survey 10:30 10:40 Final Pitot Leak Check Pass Atmospheric Pressure kpa Orientation of Duct Vertical Average Stack Static Pressure Pa 17 Pitot Tube, C p 0.84 Result of Pitot Stagnation Test Pass Number of Lines Available 2 Are Water Droplets Present? No Number of Lines Used 1 Device Used SType Pitot with KIMO MP 200 (500Pa) Sampling Line A Sampling Line B Restricted Access Traverse Depth P Temp Wet Density Velocity Swirl P Temp Wet Density Velocity Swirl Point m Pa C kg/m³ m/s C kg/m³ m/s STATIC (: Pa) 16.7 Mean A29 Wet Scrubber CATRT (Version BK) Page 13 of 18 Job Number: CDU0583, Version 1 Irish EPA IPPC Licence: P EPA Export :01:55:37

14 APPENDIX 2 PRELIMINARY STACK SURVEY: VELOCITY TRAVERSE TO EN (MID) MEASUREMENT UNCERTAINTY (1 of 1) Performance characteristics (Uncertainty Components) Standard Uncertainty on the coefficient of the Pitot Tube Standard Uncertainty associated with the mean local dynamic pressures Resolution Calibration Drift Lack of Fit Overall corrections to dynamic measurements Standard uncertainty associated with the molar mass of the gas φo₂,w φco₂,w Oxygen, dry Carbon Dioxide, dry Water Vapour Oxygen, wet Carbon Dioxide, wet Standard uncertainty associated with the stack temperature Standard uncertainty associated with the absolute pressure in the duct Atmospheric Pressure Static Pressure Standard uncertainty associated with the density in the duct Standard uncertainty associated with the local velocities Standard uncertainty associated with the mean velocity Standard uncertainty associated with the mean velocity (95% Confidence) Standard uncertainty associated with the mean velocity (95% Confidence), relative Standard uncertainty associated with the volume flow rate (95% Confidence) u²(a)/a² u²(qv,w)/q²v,w u²(qv,w) u(qv,w) Standard uncertainty associated with the volume flow rate (95% Confidence), relative Uncertainty Value u(k) u( pi) u(res) Pa u(cal) u(drift) u(fit) u(cf) u(m) u(φo₂,d) u(φco₂,d) u(φh₂o) u(φo₂,w) u(φco₂,w) u(tc) K u(pc) Pa u(patm) u(pstat) u(ρ) u(vi) Pa u(v) m/s Uc(v) Uc,rel(v) m/s % Uc(qV,w) m³/hr Uc,rel(qV,w) 4.83 % A29 Wet Scrubber CATRT (Version BK) Page 14 of 18 Job Number: CDU0583, Version 1 Irish EPA IPPC Licence: P EPA Export :01:55:37

15 APPENDIX 2 HYDROGEN FLUORIDE: RESULTS SUMMARY, A29 Wet Scrubber Sample Runs Run 1 Mean Concentration Uncertainty mg/m³ ±mg/m³ < < Mass Emission g/hr < < Uncertainty ±g/hr Water Vapour % v/v Run 1 Mean Uncertainty ±% v/v Blank Runs Concentration mg/m³ General Sampling Information Standard Technical Procedure Blank 1 Maximum < < Value ISO CATTP10 Name of Analytical Laboratory CAT Analytical Laboratory's Procedure CATAP01 ISO Accredited Analysis? Date of Sample Analysis 01/02/2016 Probe Material Filter Housing Material Impinger Material Absorption Solution Positioning of Filter Filter Size and Material Number of Sampling Lines Used Number of Sampling Points Used Sample Point I.D.'s Monel Monel Polyethylene 0.1 mol/l Sodium Hydroxide In Stack 47mm Quartz Fibre 1 / 1 1 / 1 A2 FORMAT: Number Used / Number Required FORMAT: Number Used / Number Required Reference Conditions Reference Conditions are: 273K, 101.3kPa, without correction for water vapour content. A29 Wet Scrubber CATRT (Version BK) Page 15 of 18 Job Number: CDU0583, Version 1 Irish EPA IPPC Licence: P EPA Export :01:55:37

16 APPENDIX 2 HYDROGEN FLUORIDE: SAMPLING DETAILS Sample Runs Run 1 Sampling Times 10:52 13:12 Sampling Dates 19/01/2016 Sampling Device MFC / MV Duration mins 140 Volume Sampled (STP, Dry) m³ Volume Sampled (STP, Wet) m³ Volume Sampled (REF) m³ Sample Flow Rate l/min Laboratory Result for Front Impingers Laboratory Result for Back Impinger Volume in Front Impingers Volume in Back Impinger Mass in Front Impingers Mass in Back Impinger Total Mass Collected Calculated Concentration µg/ml µg/ml ml ml µg µg µg mg/m³ < 0.05 < < 12.8 < 6.0 < 18.8 < 0.01 Liquid Trap Start Mass g Liquid Trap End Mass g Silica Trap Start Mass g Silica Trap End Mass g Total Mass Of Water Vapour g 14.4 Calculated Water Vapour % v/v 1.24 Where: MFC stands for Mass Flow Controller, MV stands for Mass View Flowmeter Blank Runs Blank 1 Blank Dates 19/01/2016 Average Volume Sampled (REF) m³ Laboratory Result for Impingers Volume in Impingers Total Mass Collected Calculated Concentration µg/ml ml µg mg/m³ < < 16.3 < 0.01 A29 Wet Scrubber CATRT (Version BK) Page 16 of 18 Job Number: CDU0583, Version 1 Irish EPA IPPC Licence: P EPA Export :01:55:37

17 APPENDIX 2 HYDROGEN FLUORIDE: QUALITY ASSURANCE Sample Runs Leak Test Results Run 1 Mean Sampling Rate l/min PreSampling Leak Rate l/min 0.16 PostSampling Leak Rate l/min 0.12 Allowable Leak Rate l/min 0.20 Leak Test Acceptable Absorption Efficiency Run 1 Absorption Efficiency % Allowable Absorption Efficiency % N/A ² Absorption Efficiency Acceptable N/A ² ² The concentration is less than 30% of the ELV, therefore no assessment against an allowable efficiency is required Water Droplets Run 1 Are Water Droplets Present No MU (Concurrent Water Vapour) Run 1 Measurement Uncertainty (MU) % 4.5 Allowable MU % 20 MU Acceptable % Silica Gel (Concurrent Water Vapour) Run 1 Less than 50% Faded % No Test Conditions Run 1 Ambient Temperature Recorded? Blank Runs Leak Test Results Expected Sampling Rate l/min PreSampling Leak Rate l/min 0.14 PostSampling Leak Rate l/min 0.14 Allowable Leak Rate l/min 0.20 Leak Test Acceptable Blank 1 Validity of Blank vs ELV Allowable Blank Blank Acceptable mg/m³ Blank Method Deviations Nature of Deviation (x = deviation applies to the associated run, wx = deviation also applies to the concurrent water vapour run) 1 Run Number There are no deviations associated with the sampling employed. wx A29 Wet Scrubber CATRT (Version BK) Page 17 of 18 Job Number: CDU0583, Version 1 Irish EPA IPPC Licence: P EPA Export :01:55:37

18 APPENDIX 2 HYDROGEN FLUORIDE: MEASUREMENT UNCERTAINTY CALCULATIONS Measured Quantities Symbol Value Run 1 Symbol Run 1 Standard uncertainty Sampled Volume (STP) Leak Laboratory Result V m uv m m³ L 1.17 ul L r 2.65 ul r % % Measured Quantities Run 1 Uncertainty as a Percentage Requirement of Standard Sampled Volume (STP) Leak Laboratory Result % % % % % 2.65 No Requirement Uncertainty in Measurement Measured Quantities Symbol Run 1 Sampled Volume (STP) Leak Laboratory Result V m Measured Quantities Run 1 Sampled Volume (STP) Leak Laboratory Result mg/m³ mg/m³ mg/m³ L L r m³ mg/m³ mg/m³ Uncertainty in Result Oxygen Correction Part of MU Budget Measured Quantities Run 1 O₂ Correction Factor Stack Gas O₂ Content MU for O₂ Correction % v/v N/A N/A N/A Overall MU For O₂ Measurement % N/A Run Sensitivity Coefficient Run 1 Combined uncertainty mg/m³ Expanded uncertainty (95% confidence), without Oxygen Correction Expanded uncertainty (95% confidence), with Oxygen Correction Expanded uncertainty (95% confidence), estimated with Method Deviations Reported Uncertainty Expanded uncertainty (95% confidence), without Oxygen Correction Expanded uncertainty (95% confidence), with Oxygen Correction Expanded uncertainty (95% confidence), estimated with Method Deviations Reported Uncertainty mg/m³ mg/m³ N/A mg/m³ mg/m³ % 6.6 % N/A % 6.6 % 6.6 A29 Wet Scrubber CATRT (Version BK) Page 18 of 18 Job Number: CDU0583, Version 1 Irish EPA IPPC Licence: P EPA Export :01:55:37