ENVIRONMENTAL MONITORING OF EMISSIONS FROM PAINT MANUFACTURING PROCESS

Transcription

1 ODOUR & ENVIRONMENTAL ENGINEERING CONSULTANTS Unit 32 De Granville Court, Dublin Rd, Trim, Co. Meath Tel: Mobile: ENVIRONMENTAL MONITORING OF EMISSIONS FROM PAINT MANUFACTURING PROCESS EXHAUST POINT LOCATED IN CASTLE PAINTS, TULLAMORE, CO OFFALY. PERFORMED BY ODOUR MONITORING IRELAND ON THE BEHALF OF ENVIROCO MANAGEMENT LTD. REPORT PREPARED BY: Dr. Brian Sheridan REPORT VERSION: Document Ver.2 ATTENTION: Mr. Niall Nally DATE: 19 th Feb 2008 REPORT NUMBER: 2008A34(2) REVIEWERS: Mr. Niall Nally

2 TABLE OF CONTENTS Section TABLE OF CONTENTS DOCUMENT AMMENDMENT RECORD Page number i ii 1. Introduction Scope of the work 1 2. Materials and methods Airflow rate measurement Flame ionisation detector (FID) measurement 3 3. Results Airflow rate measurements FID concentration results 4 4. Conclusions 7 info@odourireland.com i

3 Document Amendment Record Client: PROJECT: Environmental monitoring of emissions from paint manufacturing process exhaust point located in Castle Paints Ltd, Tullamore, Co. Offaly. Document Reference: Environmental monitoring of emissions from paint Project Number: 2008.A35(2) manufacturing process exhaust point located in Castle Paints Ltd, Tullamore, Co. Offaly. 2008A34(1) Document for review B.A.S. JMC B.A.S 28/01/ A34(2) Minor edits NN JMC B.A.S 19/02/2008 Revision Purpose/Description Originated Checked Authorised Date ii

4 1. Introduction Odour Monitoring Ireland were commissioned by to perform Total Volatile Organic Compound (TVOC) of the exhaust emission point of an extraction and particulates filtration system located on a paint mixing process located in Castle Paints Ltd, Tullamore, Co. Offaly. Traditional Flame ionisation detector monitoring in accordance with EN13526:2002 in order to determine the average emissions from the exhaust point over the batch paint making process. Values were recorded every 5 minutes over the process in order to ascertain any cyclic emissions associated with the emission profile. The addition of various liquids and solids were also recorded in order to ascertain any effect on the overall emission profile. The paint making process consists of a batch mixing tank whereby solvent (mainly Xylene) and various other powders (Titanium dioxide, pigment, etc) and liquid additives (resin, driers and antiskin) are added in batch mode and allow to mix in order to generate a final paint product. The batch mixer is connected to a negative ventilation system whereby air is filtered with a reverse flow dust filter and exhaust to atmosphere. As part of a request from the Environmental Protection Agency, monitoring was performed in accordance with the European Standard in order to allow for the quantification of TVOC emissions. In addition, airflow rate was measured from the exhaust point in accordance with ISO10780:1994 in order to allow for quantification of total flow and mass emission rate of VOC s from the emission point. The results of this monitoring are presented within this report for review. 1.1 Scope of the work The main aims of the study included: Assessment of airflow rate and volumetric airflow rate of extraction system installed upon the batch paint production process, Assessment of Total Volatile Organic compound concentration (as Carbon) (TVOC as C) mass loading and emission concentration from the exhaust point of the batch paint production process, Report the findings of the emission survey. info@odourireland.com 1

5 2. Materials and methods This section describes the materials and methods used throughout the survey. The following standards were used for reference and adhered to where possible: ISO10780:1994- Stationary source emissions-measurement of velocity and volume flowrate of gas streams in ducts. IS EN13526:2002-Stationary source emissions-determination of the mass concentration of total gaseous organic carbon in flue gases from solvent using processes-continuous flame ionisation detector method. 2.1 Airflow rate measurement An initial assessment of the airflow rate sampling ports resulted in mechanical works on site before commencement of measurement sequence. The airflow sampling ports were positioned to ensure that approximately 5 duct diameters were achieved between the nearest obstruction to airflow and the measurement location. In addition, a general survey of airflow rate through the duct confirmed the absence of swirling flow. Airflow rate measurement was performed in accordance with ISO10780:1994-Stationary source emissions-measurement of velocity and volume flowrate of gas streams in ducts. The following equipment was used through the airflow rate assessment. These included: Testo 400 and 350/454 MXL handheld and differential pressure sensors, L type pitot probe, PT100 temperature probe, The following control procedure was used through the measurement sequence: 1. Measurement was performed at two diameters at right angles to each other, 2. The internal diameter of the ductwork was measured and verified to be 200 mm inner diameter, 3. Approximately 5 duct diameters were available between the measurement point and the nearest obstruction, 4. The temperature profile across the stack was verified and did not differ by more than 5% from the average absolute temperature of the duct cross section, 5. Six individual samples points excluding the duct centre point was used to determine the average flow at specified locations across the duct diameter. No sample point was located within 20 mm of the duct wall. 6. The difference in the average airflow velocity across each diameter did not exceed 5% of the mean for all the diameters (2 in total). 7. The number of sample points across the 2 diameters were determined in accordance with Table of ISO10780:1994. The sample locations were marked upon the L type pitot using a water resistant marker. 8. The L type pitot was checked for any burrs and obstructions in the pitot orifices, 9. The absence of swirling flow was determined in accordance with Section 7.2 and Annex C-ISO10780: The measurement sequence was performed in accordance with the procedure described in Section 7.2-ISO10780:1994. The airflow rate measurement was used to ascertain the exhaust volumetric airflow rate, VOC and VOC emission rate from the exhaust point. info@odourireland.com 2

6 2.2 Flame ionisation detector (FID) measurement A heated portable FID (Signal 3010 PM) (MCERT and TUV certified to 15 and 500 mg/nm 3 ), heated line, controller and data logger was used to analyse the duct air stream for total hydrocarbon concentration as propane. An FID operates on the principle where influent contaminated gas is mixed with hydrogen and the mixture is burned at the tip of a jet with air or oxygen. Ions and free electrons are formed in the flame and enter a gap between two electrodes, the flame jet and a collector, mounted centimetres above the flame tip. A potential (400 volts) is applied across the two electrodes and with the help of produced ions, a very small current flows between the two electrodes. When an organic substance is introduced this is burned in the flame; a complex process takes place in which positively charged carbon species and electrons are formed. The current is greatly increased and therefore the sample is detected. The FID is a mass flow detector, its response depending directly on the flow rate of the carrier gas. Its response also varies with applied voltage and the temperature of the flame. The following procedure was used for operating the FID: 1. The FID was switched on and the oven temperature and sample line temperature were allowed to stabilise. The set-point temperatures were C sample line temperature and C oven temperature. This took approximately 45 minutes. 2. The Hydrogen/He and Propane calibration gases (500 ppm) were attached to the instrument. 3. Once temperatures had stabilised, the instrument was started and the ignition procedure was commenced. 4. Once ignited, the sample procedure was commenced and any VOC upon the sample line was baked off. 5. The analyser was zero calibrated and span calibrated. Zero air is supplied via the clean air filter. There is less than 1% of range or 1.6 mg/m 3 in eight hours whichever is greater (see Section 6.1 of EN12619:1999 and Section EN13526: The analyser calibration procedure was rechecked and recorded, 7. The sample line was checked by presenting calibration gas in the sample line. The value was confirmed to be the value and recorded. This reading must be less than 5% difference from the span/zero reading. 8. The probe was inserted into the stack. 9. The datalogger was commenced (10 second intervals) and manual readings were taking and recorded (every 10 minutes). 10. The instrument was re-spanned every approximately 60 minutes to confirm calibration reading and to isolate any drift. 11. The recorded concentrations were converted for ppm TVOC propane to mg/m 3 TVOC using the equation contained in Annex E and F of EN12619:1999 and EN13526:2001, respectively. The analyser is MCERT and TUV approved. The MCERTS certification covers EN12619:1999 and EN13526:2001 (see Appendix I) The FID remained analysing continuously in the duct air stream. Results were presented as mg [TVOC] m -3 as propane. This was used to assess the VOC emission from the exhaust point and to ascertain the affects of cyclic loading. Data generated from the testing resulted in results for the full production run. info@odourireland.com 3

7 3. Results This section describes the results obtained during the survey. 3.1 Airflow rate measurements Table 3.1 illustrates the average airflow rates and volumetric airflow rates from the exhaust vent of the extraction and particulate removal system as measured onsite on the 16 th Jan Table 3.1. Airflow velocity and volumetric airflow rate of sample locations during two different operating modes. Measurement location Run 1 - Transverse 1 Run 1 - Transverse 2 Run 1 - Average Run 2 - Transverse 1 Run 2 - Transverse 2 Run 2 - Average Airflow rate (m s -1 ) Area of stack (m 2 ) Temperature (K) Normalised Volumetric airflow rate (Nm 3 h -1 ) Notes: 1 denotes that the average static pressure on the duct work run on measurement Run 1 was mm WG. 2 denotes that the average static pressure on the ductwork run on measurement Run 2 was mm WG. As can be observed in Table 3.1, the average normalised volumetric airflow rate from the exhaust emission point was 732 Nm 3 /hr. 3.2 FID concentrations Table 3.2 illustrates the average TVOC concentration and emission rates from the exhaust point as measured onsite between the hours of 09:50AM and 12:00 noon on the 16 th January The instrument remained monitoring over the process period. Data was logged every 5 minutes. During the measurement sequence intermittent instrument span checks were performed. VOC hang-up in the sample line was also assessed to ensure no bias in results in the outlet stack. This was performed by removing the sample probe from the inlet stack and checking displayed VOC readings and comparing to initial start-up reading. Figure 3.1 illustrates the profile of emissions over the manufacturing run for the batch paint process. As can be observed in Table 3.2 and Figure 3.1, overall emissions of VOC s decreased initially until additive addition to the Xylene solvent was completed. This occurred for a period of 1.50 hrs approximately. Then over a period of 30 minutes, VOC emissions increased sharply. This may have been due to lower viscosity and better mixing of the added resin, which resulted in a less viscous solution and therefore greater potential for volatilisation. The process was stopped for a period of 15 to 20 minutes to allow for the addition of additional resin. When mixing recommenced, the overall VOC emissions from the process were significantly lower. info@odourireland.com 4

8 Table 3.2 presents the overall mass emission rate of VOC from the batch paint process. Minimum, maximum and average concentrations of VOC measured in the exhaust point ranged from 803, 3,615 and 2,491 mg/nm 3, respectively. The average mass emission rate of VOC was 0.51 g/s. Table 3.2. Tabular profile of air stream concentration of VOC and mass emission rate of VOC from the exhaust point located in Castle Paints Ltd. Sample FID conc Average volumetric Mass emission Time (mg/nm 3 ) airflow rate (Nm 3 /hr) rate (g/s) Notes 9:50 3, Xylene addition 9:55 3, Powder addition 10:00 3, Powder addition , Powder addition 10:10 3, Powder addition 10:15 2, Powder addition 10:20 2, Powder addition 10:25 2, Powder addition 10:30 2, Powder addition 10:35 2, Powder addition 10:40 2, Powder addition 10:45 2, Powder addition 10:50 2, Powder addition 10:55 2, Mixing 11:00 2, Mixing , Mixing 11:10 3, Mixing 11:15 3, Mixing 11: Resting before addition of resin, drier and antiskin 11: Resting before addition of resin, drier and antiskin 11: Resting before addition of resin, drier and antiskin 11: Resting before addition of resin, drier and antiskin 11:40 1, Addition of resin, drier and antiskin 11:45 1, Addition of resin, drier and antiskin 11:50 1, Mixing 11: Mixing 12: Mixing Average conc - - 2,491 - (mg/nm 3 ) Standard deviation (mg/nm 3 ) Minimum conc (mg/nm 3 ) Maximum conc. (mg/nm 3 ) - - 3,615 - info@odourireland.com 5

9 Total Volatile Organic Compound (TVOC) profile Castle Paints Ltd (16 th Jan 2008) Process shut off for addition of resin, drier and antiskin 3000 TVOC (mg/nm 3 ) Mixing re-started FID mg/nm :50 9:55 10: :10 10:15 10:20 10:25 10:30 10:35 10:40 10:45 10:50 10:55 11: :10 11:15 11:20 11:25 11:30 11:35 11:40 11:45 11:50 11:55 12:00 Time (hr:min) Figure 3.1. Emission profile of VOC s from Castle Paints Ltd batch paint production process. info@odourireland.com 6

10 4. Conclusions The following conclusions are drawn for this monitoring assessment. These included: 1. Monitoring of Total Volatile Organic compounds was performed in accordance with EN13526: Monitoring of airflow rate was performed in accordance with ISO10780: The average normalised volumetric airflow rate from the emission point was 732 m 3 /hr. 4. Minimum, maximum and average concentrations of VOC measured in the exhaust point ranged from 803, 3,615 and 2,491 mg/nm 3, respectively. The average mass emission rate of VOC was 0.51 g/s. 5. Based on a 250 days per year, 732 m3/hr per day and an average conc of emission of 2419 mg/nm3 and a total run time of 3.5 hrs per day the total mass emission rate of VOC per year would be = kg/yr. info@odourireland.com 7