EMISSION SURVEY FOR SONAE NOVOBORD: WHITE RIVER Report No. 565/12 FR.1 BY C & M CONSULTING ENGINEERS PO BOX 74936 LYNNWOOD RIDGE 0040 PRETORIA SOUTH AFRICA SONAE NOVOBORD 1
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
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 89.41 92.25 91.59 91.90 89.33 Duct static pressure kpa -0.079-0.085-0.48-0.135-0.142 Gas temperature ºC 207 258 55.6 123 32.6 Gas velocity ms -1 8.22 8.29 19.3 15.5 14.5 (Actual) m 3 h -1 83 100 35 500 *260 400 142 000 92 300 (NTP) Nm 3 h -1 41 700 16 600 *194 600 88 600 72 600 Total particulate matter (Actual) mgm -3 65.2 35.2 30.0 74.5 219 Total particulate matter (NTP) mgnm -3 130 (250) # 75.1 (100) # 40.1 (120) # 119 (100) # 279 Total solids emission rate kgh -1 5.39 1.23 7.80 10.1 20.3 Water content (% Vol/Vol) % 9.15 12.1 5.54 23.6 4.86 Formaldehyde (Actual) mgm -3 3.22 0.402 104 1.02 6.42 Formaldehyde (NTP) mgnm -3 6.42 0.972 148 1.64 8.13 *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
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 % 14.2 12.9 21.0 16.9 21.0 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 -3 998 ppm 90.1 mgnm -3 194 ppm mgnm -3 ppm 90.1 mgnm -3 185 ppm mgnm -3 56.9 71.1 185 248 2.80 5.75 188 386 103 128 103 138 3.55 7.29 107 219 PERMIT CONDITION - 500-350 SONAE NOVOBORD 4
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 92.12 92.29 92.21 92.51 Gas temperature ºC 29.5 28.8 26.9 26.8 Gas velocity ms -1 8.72 10.4 7.67 10.4 (Actual) m 3 h -1 *13 930 *16 660 *9 590 *13 160 (NTP) Nm 3 h -1 *11 410 *13 720 *7 980 *10 920 Total particulate matter (Actual) mgm -3 5.26 5.59 9.31 10.9 Total particulate matter (NTP) mgnm -3 6.49 6.78 11.5 13.1 100 Total solids emission rate kgh -1 0.0741 0.0930 0.0918 0.143 Water content (% Vol/Vol) % 3.43 5.23 3.27 3.44 *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
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 % 21 21 21 21 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
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 90.24 92.57 90.32 92.64 92.59 91.92 Gas temperature ºC 37.7 37.4 35.3 35.3 39.3 39.4 Gas velocity ms -1 7.54 8.02 8.99 7.77 8.92 9.98 (Actual) m 3 h -1 *13 440 *13 440 *16 100 *13 020 *14 910 *16 730 (NTP) Nm 3 h -1 *10 570 *10 780 *12 670 *10 570 *11 550 *13 320 Total particulate matter (Actual) Total particulate matter (NTP) mgm -3 83.6 65.7 77.1 196 99.3 104 mgnm -3 107 81.8 97.6 242 129 131 Total solids emission rate kgh -1 1.13 0.882 1.24 2.56 1.49 1.73 Water content (% Vol/Vol) % 2.36 2.65 1.55 1.72 3.22 2.30 *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
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 % 21 21 21 21 21 21 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
TABLE OF CONTENTS SUMMARY... 2 1 INTRODUCTION... 11 2 METHOD OF MEASUREMENTS... 12 2.1 TOTAL PARTICULATE EMISSION RATE... 12 2.2 STACK GAS VELOCITY... 13 2.3 STACK GAS TEMPERATURE... 13 2.4 WATER VAPOUR CONTENT... 13 2.5 COMBUSTION GASES... 13 2.6 FORMALDEHYDE EMISSIONS... 14 3 RESULTS... 15 TABLE 3.1: BOILER / KONUS STACK; STACK CONDITIONS AND PARTICULATE EMISSIONS;04 FEBRUARY 2013... 17 TABLE 3.2: BOILER / KONUS; COMBUSTION GASES (NTP, DRY); 04 FEBRUARY 2013... 18 TABLE 3.2 (CONT D): BOILER / KONUS; COMBUSTION GASES (NTP, DRY); 04 FEBRUARY 2013... 19 TABLE 3.3: MAXXTEC OIL STACK; STACK CONDITIONS AND PARTICULATE EMISSIONS;11 FEBRUARY 2013... 20 TABLE 3.4: MAXXTEC OIL STACK; COMBUSTION GASES (NTP, DRY); 11 FEBRUARY 2013... 21 TABLE 3.5: MDF CYCLONE OUTLET; STACK CONDITIONS AND PARTICULATE EMISSIONS; 07 FEBRUARY 2013... 22 TABLE 3.6: MDF CYCLONE OUTLET; COMBUSTION GASES (NTP, DRY); 07 FEBRUARY 2013... 23 TABLE 3.7: WR3 DRYER STACK; STACK CONDITIONS AND PARTICULATE EMISSIONS; 13 FEBRUARY 2013... 24 TABLE 3.8: WR3 DRYER STACK; COMBUSTION GASES (NTP, DRY); 13 FEBRUARY 2013... 25 TABLE 3.9: SCRUBBER STACK; STACK CONDITIONS AND PARTICULATE EMISSIONS; 14 FEBRUARY 2013... 26 TABLE 3.10: SCRUBBER STACK; COMBUSTION GASES (NTP, DRY); 14 FEBRUARY 2013... 27 TABLE 3.11: FLAKER CYCLONE 1; STACK CONDITIONS AND PARTICULATE EMISSIONS; 06 FEBRUARY 2013... 28 TABLE 3.12: FLAKER CYCLONE 1; COMBUSTION GASES (NTP, DRY); 06 FEBRUARY 2013... 29 TABLE 3.13: FLAKER CYCLONE 2; STACK CONDITIONS AND PARTICULATE EMISSIONS; 06 FEBRUARY 2013... 30 TABLE 3.14: FLAKER CYCLONE 2; COMBUSTION GASES (NTP, DRY); 06 FEBRUARY 2013... 31 TABLE 3.15: FLAKER CYCLONE 3; STACK CONDITIONS AND PARTICULATE EMISSIONS; 06 FEBRUARY 2013... 32 TABLE 3.16: FLAKER CYCLONE 3; COMBUSTION GASES (NTP, DRY); 06 FEBRUARY 2013... 33 TABLE 3.17: FLAKER CYCLONE 4; STACK CONDITIONS AND PARTICULATE EMISSIONS; 06 FEBRUARY 2013... 34 TABLE 3.18: FLAKER CYCLONE 4; COMBUSTION GASES (NTP, DRY); 06 FEBRUARY 2013... 36 TABLE 3.20: SAWMILL CYCLONE 1; COMBUSTION GASES (NTP, DRY); 05 FEBRUARY 2013... 37 TABLE 3.21: SAWMILL CYCLONE 2; STACK CONDITIONS AND PARTICULATE EMISSIONS; 05 FEBRUARY 2013... 38 TABLE 3.22: SAWMILL CYCLONE 2; COMBUSTION GASES (NTP, DRY); 05 FEBRUARY 2013... 39 TABLE 3.23: SAWMILL CYCLONE 3; STACK CONDITIONS AND PARTICULATE EMISSIONS; 05 FEBRUARY 2013... 40 SONAE NOVOBORD 9
TABLE 3.24: SAWMILL CYCLONE 3; COMBUSTION GASES (NTP, DRY); 05 FEBRUARY 2013... 41 TABLE 3.25: SAWMILL CYCLONE 4; STACK CONDITIONS AND PARTICULATE EMISSIONS; 05 FEBRUARY 2013... 42 TABLE 3.26: SAWMILL CYCLONE 4; COMBUSTION GASES (NTP, DRY); 05 FEBRUARY 2013... 43 TABLE 3.27: SAWMILL CYCLONE 5; STACK CONDITIONS AND PARTICULATE EMISSIONS; 08 FEBRUARY 2013... 44 TABLE 3.28: SAWMILL CYCLONE 5; COMBUSTION GASES (NTP, DRY); 08 FEBRUARY 2013... 45 TABLE 3.29: SAWMILL CYCLONE 6; STACK CONDITIONS AND PARTICULATE EMISSIONS; 08 FEBRUARY 2013... 46 TABLE 3.30: SAWMILL CYCLONE 6; COMBUSTION GASES (NTP, DRY); 08 FEBRUARY 2013... 47 4 DISCUSSION... 48 4.1 BOILER/KONUS STACK... 48 4.2 MAXXTEC OIL STACK... 48 4.3 MDF CYCLONE OUTLET... 49 4.4 WR3 DRYER STACK (RECALOR DRYER STACK)... 50 4.5 SCRUBBER STACK... 50 4.6 MDF PRE-STEAM STACK... 51 4.7 FLAKER CYCLONES 1 TO 4... 52 4.8 SAWMILL CYCLONES 1 TO 6... 53 5 CONCLUSIONS... 54 APPENDIX A... 55 2.1 SONAE NOVOBORD 10
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
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 33064. 2.1 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
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 50379-2:2004 - 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
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
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 3.10. The results of the measurements on the Flaker Cyclones 1 to 4 are presented in Tables 3.11 to 3.18. 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 101.325 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 (273.15 K) and 101.325 kpa. As these conditions imply a reduction in the sampled gas volume due to the effect of reduced temperature and increased SONAE NOVOBORD 15
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
Table 3.1: Boiler / Konus Stack; Stack Conditions and Particulate Emissions; PARAMETER UNITS 04 February 2013 TEST NUMBER 1 2 3 Time of day 11h11 13h24 14h55 Barometric pressure Duct static pressure kpa 89.44 89.39 89.39 kpa -0.085-0.076-0.076 Gas Temperature (Average) o C 207 207 207 Stack diameter m 1.89 Gas velocity m.s -1 9.32 7.15 8.21 Volumetric flow rate (Actual) Volumetric flow rate (NTP) Total solids (Actual) m 3 h -1 94 100 72 200 82 900 Nm 3 h -1 47 200 36 300 41 500 mgm -3 60.2 67.4 68.2 PERMIT CONDITION Total solids (NTP) mgnm -3 120 134 136 250 Total solids emission rate Water content (% Vol/Vol) Formaldehyde (Actual) Formaldehyde (NTP) kgh -1 5.66 4.87 5.65 % 9.69 8.75 9.00 mgm -3 1.80 3.89 3.97 mgnm -3 3.59 7.76 7.92 SONAE NOVOBORD 17
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 11h18 14.6 1 140 106 0.0 162 0.0 11h20 14.8 1270 108 0.0 166 0.0 11h22 13.8 838 119 0.0 183 0.0 11h24 14.1 945 115 0.0 177 0.0 11h26 14 784 121 0.0 185 0.0 11h38 14.3 888 122 0.0 187 0.0 11h40 14.3 929 116 0.0 179 0.0 11h42 13.7 795 126 0.0 193 0.0 11h44 14 943 122 0.0 187 0.0 11h47 13.6 715 122 0.0 187 0.0 Average 14.1 924 118 0.0 181 0.0 Test 2 13h30 14.4 948 107 0.0 164 0.0 13h32 15.1 1 310 102 0.0 156 0.0 13h34 14 746 125 0.0 191 0.0 13h36 14.7 1 160 107 0.0 164 0.0 13h38 14 935 110 0.0 168 0.0 13h40 14.3 791 114 0.0 175 0.0 13h42 14.5 996 110 0.0 168 0.0 13h44 14.6 1 090 110 0.0 168 0.0 13h46 14.1 826 112 0.0 173 0.0 13h48 14.1 884 125 0.0 191 0.0 Average 14.4 968 112 0.0 172 0.0 SONAE NOVOBORD 18
Table 3.2 (cont d): Boiler / Konus; Combustion Gases (NTP, dry); 04 February 2013 Test 3 15h10 13.6 748 150 0.0 230 0.0 15h12 13.3 503 175 0.0 269 0.0 15h17 13.6 851 142 0.0 218 0.0 15h20 14.5 1 170 122 0.0 187 0.0 15h24 14.6 1 500 118 0.0 181 0.0 15h27 13.5 661 146 0.0 224 0.0 15h30 16 2 320 88.4 0.0 136 0.0 15h36 13.8 1 200 133 0.0 203 0.0 15h38 14.1 1 300 125 0.0 191 0.0 15h41 13.3 778 127 0.0 195 0.0 Average 14 1 100 133 0.0 203 0.0 SONAE NOVOBORD 19
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 92.26 92.23 Duct static pressure kpa -0.066-0.103 Gas Temperature o C 253 262 (Average) Stack diameter m 1.23 Gas velocity m.s -1 6.76 9.82 (Actual) m 3 h -1 28 900 42 000 (NTP) Nm 3 h -1 13 600 19 500 Total solids (Actual) mgm -3 38.4 31.9 PERMIT CONDITION Total solids (NTP) mgnm -3 81.4 68.7 100 Total solids emission rate Water content (% Vol/Vol) Formaldehyde (Actual) Formaldehyde (NTP) kgh -1 1.11 1.34 % 13.7 10.5 mgm -3 0.561 0.243 mgnm -3 1.19 0.754 SONAE NOVOBORD 20
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 08h56 17.4 204 111 0.0 170 0.0 09h01 17.6 143 103 0.0 158 0.0 09h04 15.5 345 162 0.0 249 0.0 09h09 12.7 77.5 256 0.0 392 0.0 09h12 14.8 229 175 0.0 269 0.0 09h21 12.2 47.5 232 0.0 355 0.0 09h39 13.4 48.8 208 0.0 318 0.0 09h44 12.7 11.3 221 0.0 339 0.0 09h48 13.3 17.5 233 6.16 364 0.0 09h52 12 7.5 234 0.0 359 0.0 Average 14.2 113 193 0.616 297 0.0 Test 2 10h41 11.4 17.5 276 8.22 431 0.0 10h44 9.5 45 362 10.3 565 0.0 10h48 12.5 25 295 8.22 460 0.0 10h52 12.8 18.8 280 8.22 438 0.0 10h57 10.5 36.3 341 10.3 534 0.0 11h01 11.5 36.3 291 10.3 456 0.0 11h04 12.9 15 269 10.3 423 0.0 11h11 13.2 33.8 280 14.4 444 0.0 11h16 10.3 43.8 332 14.4 524 0.0 11h20 11.7 20 299 14.4 472 0.0 Average 11.6 29.1 302 10.9 475 0.0 SONAE NOVOBORD 21
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 91.65 91.52 Duct static pressure kpa -0.52-0.44 Gas Temperature o C 55.2 56.1 (Average) Stack diameter m 2.64 Gas velocity m.s -1 19.4 19.4 (Actual) m 3 h -1 *261 800 * 262 500 (NTP) Nm 3 h -1 *196 000 *196 000 Total solids (Actual) mgm -3 33.5 24.5 PERMIT CONDITION Total solids (NTP) mgnm -3 44.8 32.9 120 Total solids emission rate Water content (% Vol/Vol) Formaldehyde (Actual) Formaldehyde (NTP) kgh -1 8.78 6.45 % 8.15 9.81 mgm -3 31.9 176 mgnm -3 42.7 254 26.8 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
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 10h45 21 0.0 0.0 0.0 0.0 0.0 10h48 21 0.0 0.0 0.0 0.0 0.0 10h51 21 0.0 0.0 0.0 0.0 0.0 10h54 21 0.0 0.0 0.0 0.0 0.0 10h57 21 0.0 0.0 0.0 0.0 0.0 11h02 21 0.0 0.0 0.0 0.0 0.0 11h05 21 0.0 0.0 0.0 0.0 0.0 11h08 21 0.0 0.0 0.0 0.0 0.0 11h11 21 0.0 0.0 0.0 0.0 0.0 11h13 21 0.0 0.0 0.0 0.0 0.0 Average 21 0.0 0.0 0.0 0.0 0.0 Test 2 12h17 21 0.0 0.0 0.0 0.0 0.0 12h20 21 0.0 0.0 0.0 0.0 0.0 12h23 21 0.0 0.0 0.0 0.0 0.0 12h25 21 0.0 0.0 0.0 0.0 0.0 12h28 21 0.0 0.0 0.0 0.0 0.0 12h30 21 0.0 0.0 0.0 0.0 0.0 12h33 21 0.0 0.0 0.0 0.0 0.0 12h36 21 0.0 0.0 0.0 0.0 0.0 12h39 21 0.0 0.0 0.0 0.0 0.0 12h41 21 0.0 0.0 0.0 0.0 0.0 Average 21 0.0 0.0 0.0 0.0 0.0 SONAE NOVOBORD 23
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 91.95 91.85 Duct static pressure kpa -0.112-0.158 Gas Temperature o C 122 125 (Average) Stack diameter m 1.8 Gas velocity m.s -1 13.1 17.9 (Actual) m 3 h -1 120 000 164 000 (NTP) Nm 3 h -1 102 000 75 200 Total solids (Actual) mgm -3 96.4 52.6 PERMIT CONDITION Total solids (NTP) mgnm -3 154 84.7 100 Total solids emission rate Water content (% Vol/Vol) Formaldehyde (Actual) Formaldehyde (NTP) kgh -1 11.6 8.64 % 26.2 21 mgm -3 1.12 0.924 mgnm -3 1.78 1.49 SONAE NOVOBORD 24
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 12h12 17.3 150 114 12.3 187 0.0 12h14 17 136 131 16.4 218 0.0 12h16 16.4 111 198 16.4 320 0.0 12h18 16 106 208 16.4 335 0.0 12h20 15.7 101 229 12.3 364 0.0 12h22 15.5 128 241 14.4 384 0.0 12h24 15.9 118 209 14.4 335 0.0 12h26 15.6 124 230 14.4 368 0.0 12h28 16 135 208 14.4 333 0.0 12h30 16 140 209 14.4 335 0.0 Average 16.1 125 198 14.6 318 0.0 Test 2 13h30 16.8 133 126 0.0 193 0.0 13h32 16.9 135 121 0.0 185 0.0 13h34 17.4 140 97.7 0.0 150 0.0 13h36 17.6 153 76.3 0.0 117 0.0 13h38 17.9 153 65.6 0.0 101 0.0 13h41 18 136 57.6 0.0 88.3 0.0 13h43 18.2 119 56.2 0.0 86.3 0.0 13h45 18.1 121 57.6 0.0 88.3 0.0 13h47 17.9 134 64.3 0.0 98.6 0.0 13h50 18.1 95 62.9 0.0 96.5 0.0 Average 17.7 132 78.5 0.0 120 0.0 SONAE NOVOBORD 25
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 89.37 89.28 Duct static pressure kpa -0.132-0.152 Gas Temperature o C 33.2 32.0 (Average) Stack diameter m 1.5 Gas velocity m.s -1 14.1 14.9 (Actual) m 3 h -1 89 600 95 000 (NTP) Nm 3 h -1 70 300 74 800 Total solids (Actual) mgm -3 200 239 PERMIT CONDITION Total solids (NTP) mgnm -3 255 303 100 Total solids emission rate Water content (% Vol/Vol) Formaldehyde (Actual) Formaldehyde (NTP) kgh -1 17.9 22.7 % 4.57 5.15 mgm -3 6.82 6.01 mgnm -3 8.66 7.60 SONAE NOVOBORD 26
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 09h49 21 0.0 0.0 0.0 0.0 0.0 09h51 21 0.0 0.0 0.0 0.0 0.0 09h54 21 0.0 0.0 0.0 0.0 0.0 09h56 21 0.0 0.0 0.0 0.0 0.0 09h58 21 0.0 0.0 0.0 0.0 0.0 10h03 21 0.0 0.0 0.0 0.0 0.0 10h07 21 0.0 0.0 0.0 0.0 0.0 10h12 21 0.0 0.0 0.0 0.0 0.0 10h15 21 0.0 0.0 0.0 0.0 0.0 10h18 21 0.0 0.0 0.0 0.0 0.0 Average 21.0 0.0 0.0 0.0 0.0 0.0 Test 2 10h56 21 0.0 0.0 0.0 0.0 0.0 10h59 21 0.0 0.0 0.0 0.0 0.0 11h04 21 0.0 0.0 0.0 0.0 0.0 11h08 21 0.0 0.0 0.0 0.0 0.0 11h12 21 0.0 0.0 0.0 0.0 0.0 11h16 21 0.0 0.0 0.0 0.0 0.0 11h20 21 0.0 0.0 0.0 0.0 0.0 11h24 21 0.0 0.0 0.0 0.0 0.0 11h28 21 0.0 0.0 0.0 0.0 0.0 11h31 21 0.0 0.0 0.0 0.0 0.0 Average 21.0 0.0 0.0 0.0 0.0 0.0 SONAE NOVOBORD 27
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 92.37 91.86 Gas Temperature (Average) o C 30.0 29.0 Stack diameter m 0.9 Gas velocity m.s -1 9.07 8.37 (Actual) m 3 h -1 *14 560 *13 300 (NTP) Nm 3 h -1 *11 970 *10 850 Total solids (Actual) mgm -3 4.86 5.66 Total solids (NTP) mgnm -3 5.92 7.06 100 Total solids emission rate kgh -1 0.0709 0.0766 Water content (% Vol/Vol) % 2.74 4.12 * 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
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 12h27 21 0.0 0.0 0.0 0.0 0.0 12h30 21 0.0 0.0 0.0 0.0 0.0 12h33 21 0.0 0.0 0.0 0.0 0.0 12h36 21 0.0 0.0 0.0 0.0 0.0 12h39 21 0.0 0.0 0.0 0.0 0.0 12h42 21 0.0 0.0 0.0 0.0 0.0 12h45 21 0.0 0.0 0.0 0.0 0.0 12h48 21 0.0 0.0 0.0 0.0 0.0 12h51 21 0.0 0.0 0.0 0.0 0.0 12h54 21 0.0 0.0 0.0 0.0 0.0 Average 21.0 0.0 0.0 0.0 0.0 0.0 Test 2 13h30 21 0.0 0.0 0.0 0.0 0.0 13h33 21 0.0 0.0 0.0 0.0 0.0 13h36 21 0.0 0.0 0.0 0.0 0.0 13h39 21 0.0 0.0 0.0 0.0 0.0 13h42 21 0.0 0.0 0.0 0.0 0.0 13h45 21 0.0 0.0 0.0 0.0 0.0 13h48 21 0.0 0.0 0.0 0.0 0.0 13h51 21 0.0 0.0 0.0 0.0 0.0 13h54 21 0.0 0.0 0.0 0.0 0.0 13h59 21 0.0 0.0 0.0 0.0 0.0 Average 21.0 0.0 0.0 0.0 0.0 0.0 SONAE NOVOBORD 29
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 92.37 82.21 Gas Temperature (Average) o C 28.7 28.8 Stack diameter m 0.9 Gas velocity m.s -1 9.51 11.3 (Actual) m 3 h -1 *15 260 *18 130 (NTP) Nm 3 h -1 *12 600 *14 910 Total solids (Actual) mgm -3 5.54 5.63 Total solids (NTP) mgnm -3 6.72 6.84 100 Total solids emission rate kgh -1 0.0847 0.102 Water content (% Vol/Vol) % 4.64 5.82 * 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
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 12h27 21 0.0 0.0 0.0 0.0 0.0 12h30 21 0.0 0.0 0.0 0.0 0.0 12h33 21 0.0 0.0 0.0 0.0 0.0 12h36 21 0.0 0.0 0.0 0.0 0.0 12h39 21 0.0 0.0 0.0 0.0 0.0 12h42 21 0.0 0.0 0.0 0.0 0.0 12h45 21 0.0 0.0 0.0 0.0 0.0 12h48 21 0.0 0.0 0.0 0.0 0.0 12h51 21 0.0 0.0 0.0 0.0 0.0 12h54 21 0.0 0.0 0.0 0.0 0.0 Average 21.0 0.0 0.0 0.0 0.0 0.0 Test 2 13h39 21 0.0 0.0 0.0 0.0 0.0 13h42 21 0.0 0.0 0.0 0.0 0.0 13h45 21 0.0 0.0 0.0 0.0 0.0 13h48 21 0.0 0.0 0.0 0.0 0.0 13h51 21 0.0 0.0 0.0 0.0 0.0 13h54 21 0.0 0.0 0.0 0.0 0.0 13h59 21 0.0 0.0 0.0 0.0 0.0 14h01 21 0.0 0.0 0.0 0.0 0.0 14h04 21 0.0 0.0 0.0 0.0 0.0 14h09 21 0.0 0.0 0.0 0.0 0.0 Average 21.0 0.0 0.0 0.0 0.0 0.0 SONAE NOVOBORD 31
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 92.23 92.18 Gas Temperature (Average) o C 26.8 27 Stack diameter m 0.8 Gas velocity m.s -1 7.14 8.20 (Actual) m 3 h -1 *8 960 *10 290 (NTP) Nm 3 h -1 *7 420 *8 540 Total solids (Actual) mgm -3 8.03 10.6 Total solids (NTP) mgnm -3 9.90 13.1 100 Total solids emission rate kgh -1 0.0735 0.112 Water content (% Vol/Vol) % 3.34 3.20 * 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
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 09h46 21 0.0 0.0 0.0 0.0 0.0 09h49 21 0.0 0.0 0.0 0.0 0.0 09h53 21 0.0 0.0 0.0 0.0 0.0 09h56 21 0.0 0.0 0.0 0.0 0.0 09h59 21 0.0 0.0 0.0 0.0 0.0 10h03 21 0.0 0.0 0.0 0.0 0.0 10h06 21 0.0 0.0 0.0 0.0 0.0 10h09 21 0.0 0.0 0.0 0.0 0.0 10h13 21 0.0 0.0 0.0 0.0 0.0 10h15 21 0.0 0.0 0.0 0.0 0.0 Average 21.0 0.0 0.0 0.0 0.0 0.0 Test 2 10h55 21 0.0 0.0 0.0 0.0 0.0 11h00 21 0.0 0.0 0.0 0.0 0.0 11h05 21 0.0 0.0 0.0 0.0 0.0 11h10 21 0.0 0.0 0.0 0.0 0.0 11h15 21 0.0 0.0 0.0 0.0 0.0 10h20 21 0.0 0.0 0.0 0.0 0.0 10h25 21 0.0 0.0 0.0 0.0 0.0 10h30 21 0.0 0.0 0.0 0.0 0.0 10h35 21 0.0 0.0 0.0 0.0 0.0 10h40 21 0.0 0.0 0.0 0.0 0.0 Average 21.0 0.0 0.0 0.0 0.0 0.0 SONAE NOVOBORD 33
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 92.56 92.45 Gas Temperature (Average) o C 26.7 27.0 Stack diameter m 0.8 Gas velocity m.s -1 10.5 10.3 (Actual) m 3 h -1 *13 300 *13 020 (NTP) Nm 3 h -1 *11 060 *10 850 Total solids (Actual) mgm -3 8.93 12.8 Total solids (NTP) mgnm -3 10.7 15.5 100 Total solids emission rate kgh -1 0.118 0.168 Water content (% Vol/Vol) % 2.79 4.09 * 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
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 09h38 21 0.0 0.0 0.0 0.0 0.0 09h41 21 0.0 0.0 0.0 0.0 0.0 09h44 21 0.0 0.0 0.0 0.0 0.0 09h48 21 0.0 0.0 0.0 0.0 0.0 09h51 21 0.0 0.0 0.0 0.0 0.0 09h55 21 0.0 0.0 0.0 0.0 0.0 09h58 21 0.0 0.0 0.0 0.0 0.0 10h02 21 0.0 0.0 0.0 0.0 0.0 10h05 21 0.0 0.0 0.0 0.0 0.0 10h09 21 0.0 0.0 0.0 0.0 0.0 Average 21 0.0 0.0 0.0 0.0 0.0 Test 2 11h00 21 0.0 0.0 0.0 0.0 0.0 11h04 21 0.0 0.0 0.0 0.0 0.0 11h08 21 0.0 0.0 0.0 0.0 0.0 11h11 21 0.0 0.0 0.0 0.0 0.0 11h13 21 0.0 0.0 0.0 0.0 0.0 11h17 21 0.0 0.0 0.0 0.0 0.0 11h20 21 0.0 0.0 0.0 0.0 0.0 11h23 21 0.0 0.0 0.0 0.0 0.0 11h26 21 0.0 0.0 0.0 0.0 0.0 11h29 21 0.0 0.0 0.0 0.0 0.0 Average 21 0.0 0.0 0.0 0.0 0.0 SONAE NOVOBORD 35
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 90.26 90.21 Gas Temperature (Average) o C 36.8 38.5 Stack diameter m 0.92 Gas velocity m.s -1 9.4 10.0 (Actual) m 3 h -1 *13 020 *13 930 (NTP) Nm 3 h -1 *10 220 *10 850 Total solids (Actual) mgm -3 79.4 87.9 Total solids (NTP) mgnm -3 103 116 Total solids emission rate kgh -1 1.05 1.26 Water content (% Vol/Vol) % 2.13 2.59 * 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
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 12h06 21 0.0 0.0 0.0 0.0 0.0 12h09 21 0.0 0.0 0.0 0.0 0.0 12h12 21 0.0 0.0 0.0 0.0 0.0 12h16 21 0.0 0.0 0.0 0.0 0.0 12h19 21 0.0 0.0 0.0 0.0 0.0 12h22 21 0.0 0.0 0.0 0.0 0.0 12h26 21 0.0 0.0 0.0 0.0 0.0 12h29 21 0.0 0.0 0.0 0.0 0.0 12h33 21 0.0 0.0 0.0 0.0 0.0 12h37 21 0.0 0.0 0.0 0.0 0.0 Average 21 0.0 0.0 0.0 0.0 0.0 Test 2 13h15 21 0.0 0.0 0.0 0.0 0.0 13h18 21 0.0 0.0 0.0 0.0 0.0 13h22 21 0.0 0.0 0.0 0.0 0.0 13h26 21 0.0 0.0 0.0 0.0 0.0 13h29 21 0.0 0.0 0.0 0.0 0.0 13h32 21 0.0 0.0 0.0 0.0 0.0 13h36 21 0.0 0.0 0.0 0.0 0.0 13h40 21 0.0 0.0 0.0 0.0 0.0 13h43 21 0.0 0.0 0.0 0.0 0.0 13h46 21 0.0 0.0 0.0 0.0 0.0 Average 21 0.0 0.0 0.0 0.0 0.0 SONAE NOVOBORD 37
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 92.60 92.54 Gas Temperature (Average) o C 36.8 38.0 Stack diameter m 0.92 Gas velocity m.s -1 8.12 7.91 (Actual) m 3 h -1 *13 580 *13 230 (NTP) Nm 3 h -1 *10 990 *10 640 Total solids (Actual) mgm -3 51.0 80.4 Total solids (NTP) mgnm -3 63.3 100 Total solids emission rate kgh -1 0.696 1.06 Water content (% Vol/Vol) % 2.92 2.38 * 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
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 12h06 21 0.0 0.0 0.0 0.0 0.0 12h08 21 0.0 0.0 0.0 0.0 0.0 12h10 21 0.0 0.0 0.0 0.0 0.0 12h12 21 0.0 0.0 0.0 0.0 0.0 12h14 21 0.0 0.0 0.0 0.0 0.0 12h16 21 0.0 0.0 0.0 0.0 0.0 12h18 21 0.0 0.0 0.0 0.0 0.0 12h20 21 0.0 0.0 0.0 0.0 0.0 12h22 21 0.0 0.0 0.0 0.0 0.0 12h24 21 0.0 0.0 0.0 0.0 0.0 Average 21 0.0 0.0 0.0 0.0 0.0 Test 2 13h15 21 0.0 0.0 0.0 0.0 0.0 13h17 21 0.0 0.0 0.0 0.0 0.0 13h19 21 0.0 0.0 0.0 0.0 0.0 13h21 21 0.0 0.0 0.0 0.0 0.0 13h23 21 0.0 0.0 0.0 0.0 0.0 13h25 21 0.0 0.0 0.0 0.0 0.0 13h27 21 0.0 0.0 0.0 0.0 0.0 13h29 21 0.0 0.0 0.0 0.0 0.0 13h31 21 0.0 0.0 0.0 0.0 0.0 13h33 21 0.0 0.0 0.0 0.0 0.0 Average 21 0.0 0.0 0.0 0.0 0.0 SONAE NOVOBORD 39
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 90.31 90.32 Gas Temperature (Average) o C 34.2 36.3 Stack diameter m 0.92 Gas velocity m.s -1 9.33 8.65 (Actual) m 3 h -1 *16 660 *15 470 (NTP) Nm 3 h -1 *13 230 *12 180 Total solids (Actual) mgm -3 82.3 71.9 Total solids (NTP) mgnm -3 104 91.4 Total solids emission rate kgh -1 1.38 1.11 Water content (% Vol/Vol) % 1.54 1.55 * 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
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 09h44 21 0.0 0.0 0.0 0.0 0.0 09h46 21 0.0 0.0 0.0 0.0 0.0 09h49 21 0.0 0.0 0.0 0.0 0.0 09h53 21 0.0 0.0 0.0 0.0 0.0 09h56 21 0.0 0.0 0.0 0.0 0.0 09h59 21 0.0 0.0 0.0 0.0 0.0 10h03 21 0.0 0.0 0.0 0.0 0.0 10h06 21 0.0 0.0 0.0 0.0 0.0 10h09 21 0.0 0.0 0.0 0.0 0.0 10h13 21 0.0 0.0 0.0 0.0 0.0 Average 21 0.0 0.0 0.0 0.0 0.0 Test 2 10h52 21 0.0 0.0 0.0 0.0 0.0 10h56 21 0.0 0.0 0.0 0.0 0.0 10h59 21 0.0 0.0 0.0 0.0 0.0 11h03 21 0.0 0.0 0.0 0.0 0.0 11h06 21 0.0 0.0 0.0 0.0 0.0 11h09 21 0.0 0.0 0.0 0.0 0.0 11h12 21 0.0 0.0 0.0 0.0 0.0 11h15 21 0.0 0.0 0.0 0.0 0.0 11h18 21 0.0 0.0 0.0 0.0 0.0 11h22 21 0.0 0.0 0.0 0.0 0.0 Average 21 0.0 0.0 0.0 0.0 0.0 SONAE NOVOBORD 41
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 92.63 92.65 Gas Temperature (Average) o C 34.2 36.3 Stack diameter m 0.92 Gas velocity m.s -1 7.67 7.87 (Actual) m 3 h -1 *12 880 *13 160 (NTP) Nm 3 h -1 *10 430 *10 640 Total solids (Actual) mgm -3 163 229 Total solids (NTP) mgnm -3 201 284 Total solids emission rate kgh -1 2.10 3.02 Water content (% Vol/Vol) % 1.68 1.76 * 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
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 09h42 21 0.0 0.0 0.0 0.0 0.0 09h46 21 0.0 0.0 0.0 0.0 0.0 10h00 21 0.0 0.0 0.0 0.0 0.0 10h04 21 0.0 0.0 0.0 0.0 0.0 10h09 21 0.0 0.0 0.0 0.0 0.0 10h13 21 0.0 0.0 0.0 0.0 0.0 10h16 21 0.0 0.0 0.0 0.0 0.0 10h19 21 0.0 0.0 0.0 0.0 0.0 10h24 21 0.0 0.0 0.0 0.0 0.0 10h27 21 0.0 0.0 0.0 0.0 0.0 Average 21 0.0 0.0 0.0 0.0 0.0 Test 2 10h56 21 0.0 0.0 0.0 0.0 0.0 11h00 21 0.0 0.0 0.0 0.0 0.0 11h03 21 0.0 0.0 0.0 0.0 0.0 11h06 21 0.0 0.0 0.0 0.0 0.0 11h09 21 0.0 0.0 0.0 0.0 0.0 11h12 21 0.0 0.0 0.0 0.0 0.0 11h16 21 0.0 0.0 0.0 0.0 0.0 11h19 21 0.0 0.0 0.0 0.0 0.0 11h22 21 0.0 0.0 0.0 0.0 0.0 11h25 21 0.0 0.0 0.0 0.0 0.0 Average 21 0.0 0.0 0.0 0.0 0.0 SONAE NOVOBORD 43
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 92.70 92.47 Gas Temperature (Average) o C 38.3 40.2 Stack diameter m 0.92 Gas velocity m.s -1 8.91 8.93 (Actual) m 3 h -1 *14 910 *14 980 (NTP) Nm 3 h -1 *11 620 *11 550 Total solids (Actual) mgm -3 93.0 106 Total solids (NTP) mgnm -3 120 137 Total solids emission rate kgh -1 1.39 1.58 Water content (% Vol/Vol) % 3.80 2.64 * 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
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 12h02 21 0.0 0.0 0.0 0.0 0.0 12h05 21 0.0 0.0 0.0 0.0 0.0 12h08 21 0.0 0.0 0.0 0.0 0.0 12h11 21 0.0 0.0 0.0 0.0 0.0 12h14 21 0.0 0.0 0.0 0.0 0.0 12h17 21 0.0 0.0 0.0 0.0 0.0 12h20 21 0.0 0.0 0.0 0.0 0.0 12h23 21 0.0 0.0 0.0 0.0 0.0 12h25 21 0.0 0.0 0.0 0.0 0.0 12h28 21 0.0 0.0 0.0 0.0 0.0 Average 21 0.0 0.0 0.0 0.0 0.0 Test 2 13h22 21 0.0 0.0 0.0 0.0 0.0 13h25 21 0.0 0.0 0.0 0.0 0.0 13h28 21 0.0 0.0 0.0 0.0 0.0 13h31 21 0.0 0.0 0.0 0.0 0.0 13h34 21 0.0 0.0 0.0 0.0 0.0 13h38 21 0.0 0.0 0.0 0.0 0.0 13h41 21 0.0 0.0 0.0 0.0 0.0 13h44 21 0.0 0.0 0.0 0.0 0.0 13h47 21 0.0 0.0 0.0 0.0 0.0 13h50 21 0.0 0.0 0.0 0.0 0.0 Average 21 0.0 0.0 0.0 0.0 0.0 SONAE NOVOBORD 45
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 92.02 91.82 Gas Temperature (Average) o C 38.7 40.2 Stack diameter m 0.92 Gas velocity m.s -1 9.97 10.0 (Actual) m 3 h -1 *16 730 *16 730 (NTP) Nm 3 h -1 *13 300 *13 320 Total solids (Actual) mgm -3 101 106 Total solids (NTP) mgnm -3 131 137 Total solids emission rate kgh -1 1.74 1.82 Water content (% Vol/Vol) % 2.58 2.03 * 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
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 14h01 21 0.0 0.0 0.0 0.0 0.0 14h03 21 0.0 0.0 0.0 0.0 0.0 14h05 21 0.0 0.0 0.0 0.0 0.0 14h07 21 0.0 0.0 0.0 0.0 0.0 14h09 21 0.0 0.0 0.0 0.0 0.0 14h11 21 0.0 0.0 0.0 0.0 0.0 14h13 21 0.0 0.0 0.0 0.0 0.0 14h15 21 0.0 0.0 0.0 0.0 0.0 14h17 21 0.0 0.0 0.0 0.0 0.0 14h19 21 0.0 0.0 0.0 0.0 0.0 Average 21 0.0 0.0 0.0 0.0 0.0 Test 2 14h42 21 0.0 0.0 0.0 0.0 0.0 14h44 21 0.0 0.0 0.0 0.0 0.0 14h46 21 0.0 0.0 0.0 0.0 0.0 14h48 21 0.0 0.0 0.0 0.0 0.0 14h50 21 0.0 0.0 0.0 0.0 0.0 14h52 21 0.0 0.0 0.0 0.0 0.0 14h54 21 0.0 0.0 0.0 0.0 0.0 14h56 21 0.0 0.0 0.0 0.0 0.0 14h58 21 0.0 0.0 0.0 0.0 0.0 15h00 21 0.0 0.0 0.0 0.0 0.0 Average 21 0.0 0.0 0.0 0.0 0.0 SONAE NOVOBORD 47
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 2013. 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 2013. A substantial increase in the volumetric flow rate was noted, as well as an SONAE NOVOBORD 48
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 2013. 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
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 2013. 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 2013. All parameters measured remained essentially stable throughout the sampling period. SONAE NOVOBORD 50
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
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
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