AIR & EMISSIONS TESTING GROUP

Transcription

1 AIR & EMISSIONS TESTING GROUP 52 Offerton Industrial Estate Hempshaw Lane Stockport SK2 5TJ Tel: Fax: Your contact at Environmental Scientifics Group: Andrew Palliser Business Manager Tel: Fax: Stack Emissions Testing Report Operator / Company Site: Release Point: RSL Asphalt Recycler (A141) Report Date: 20th October 2010 Version: 1 Report By: Paul Adamczyk Sampling Date/s: MCERTS Number: MM MCERTS Level: MCERTS Level 2 - Team Leader Technical Endorsements: 1, 2, 3 & 4 Job Number: Report Approved By: Andrew Palliser LDO 0062 MCERTS Number: MM Business Title: MCERTS Level 2 - Business Manager Technical Endorsements: 1, 2, 3 & 4 Signature: RSL Asphalt Recycler (A141) Page 1 of 25

2 CONTENTS TITLE PAGE CONTENTS EXECUTIVE SUMMARY Stack Emissions Monitoring Objectives - Plant - Operator - Stack Emissions Monitoring - Analytical Laboratory Emissions Summary Monitoring Times Process Details Monitoring Methods - Sampling Methods with Subsequent Analysis - On-Site Testing Analytical Methods - Sampling Methods with Subsequent Analysis - On-Site Testing Sampling Location - Sampling Plane Validation Criteria - Duct Characteristics - Sampling Lines & Sample Points - Sampling Platform - Sampling Location / Platform Improvement Recommendations Sampling and Analytical Method Deviation APPENDICES RSL Asphalt Recycler (A141) Page 2 of 25

3 EXECUTIVE SUMMARY Stack Emissions Monitoring Objectives operates a Recycling of asphalt plant at. Environmental Scientifics Group Limited were commissioned by to carry out stack emissions monitoring to determine the release of prescribed pollutants from the following Plant under normal operating conditions. Plant RSL Asphalt Recycler (A141) Operator RSL Unit 1 Station Road Bagworth Leicestershire LE67 1BH Stack Emissions Monitoring Environmental Scientifics Group Limited - Stockport Laboratory 52 Offerton Industrial Estate Hempshaw Lane Stockport SK2 5TJ UKAS and MCERTS Accreditation Number: 1015 Opinions and interpretations expressed herein are outside the scope of UKAS accreditation. This test report shall not be reproduced, except in full, without written approval of Environmental Scientifics Group Limited. RSL Asphalt Recycler (A141) Page 3 of 25

4 EXECUTIVE SUMMARY Emissions Summary Parameter Units Result Uncertainty Limit Total Particulate Matter mg/m! Particulate Emission Rate g/hr Moisture % Stack Gas Temperature o C 79 Stack Gas Velocity m/s 5.2 Gas Volumetric Flow Rate (Actual) m!/hr 675 Gas Volumetric Flow Rate (STP, Wet) m!/hr 522 Gas Volumetric Flow Rate (STP, Dry) m!/hr 504 Gas Volumetric Flow Rate (@ref conditions) m!/hr 522 ND = None Detected, Results at or below the limit of detection are highlighted by bold italic text. The above volumetric flow rate is calculated using data from the preliminary survey. Mass emissions for non isokinetic tests are calculated using these values. For all isokinetic testing the mass emission is calculated using test specific values. Reference conditions are 273K, 101.3Pa, without correction for water vapour content +/- RSL Asphalt Recycler (A141) Page 4 of 25

5 EXECUTIVE SUMMARY Monitoring Times Parameter Sampling Date Sampling Times Sampling Duration Total Particulate Matter Run 1 01 October :26-12:56 30 minutes RSL Asphalt Recycler (A141) Page 5 of 25

6 EXECUTIVE SUMMARY Parameter Process Status Percentage of capacity or Tonnes / Hour Continuous or Batch Process Feedstock (if applicable) Abatement System Abatement System Running Status Fuel Plume Appearance Process Details Normal Normal Batch Asphalt None N/A Diesel Steam Plume Visible Process Details RSL Asphalt Recycler (A141) Page 6 of 25

7 EXECUTIVE SUMMARY Monitoring Methods The selection of standard methods employed by Scientifics is determined, wherever possible by the hierarchy of method selection outlined in Environment Agency Technical Guidance Document (Monitoring) M2. i.e. CEN, ISO, BS, US EPA etc. The tables below summarise the monitoring methods, techniques and technical procedures employed, and details any deviations from the aforementioned hierarchy: Sampling Methods with Subsequent Analysis Species Standard Method Scientifics UKAS Lab MCERTS Limit of MU of MU Technical Number Accredited Detection Method +/- % Procedure Method (LOD) +/- % TPM BS EN AE Yes 0.25 mg/m! 30% 2.8 % On-Site Testing Species Standard Method Scientifics UKAS Lab MCERTS Limit of MU of MU Technical Number Accredited Detection Method +/- % Procedure Method (LOD) +/- % H 2 O BS EN AE Yes % 10% 3.1% RSL Asphalt Recycler (A141) Page 7 of 25

8 EXECUTIVE SUMMARY Analytical Methods The following tables list the analytical methods employed together with the custody and archiving details: Sampling Methods with Subsequent Analysis Species Analytical Technique Analytical UKAS Lab UKAS Laboratory Sample Archive Procedure Number Accredited Archive Period Analysis Location TPM Gravimetric AE Yes Stockport Stockport 3 months On-Site Testing Species Analytical Technique Analytical UKAS Lab MCERTS Laboratory Sample Span Procedure Number Accredited Archive Gas Analysis Location H 2 O Gravimetric AE Yes Stockport N/A N/A BS EN has been validated over a range of 4-40%. It is however the prefered method of the Environment Agency for concentrations below 4% RSL Asphalt Recycler (A141) Page 8 of 25

9 EXECUTIVE SUMMARY Sampling Location Sampling Plane Validation Criteria Value Units Requirement Compliance Method Lowest Differential Pressure 21 Pa >= 5 Pa Yes BS EN Lowest Gas Velocity 5.19 m/s - Highest Gas Velocity 5.19 m/s - Ratio of Above 1.00 : 1 < 3 : 1 Yes BS EN Mean Velocity 5.19 m/s - Angle of flow with regard to duct axis 0 o < 15 o Yes BS EN No local negative flow - Yes BS EN Duct Characteristics Sampling Lines & Sample Points Value Units Isokinetic Isokinetic Non-Iso & Type Square - (CEN Methods) (ISO Methods) Gases Depth 0.19 m Sample Port Size 4 inch hole Width 0.19 m Number Used 1 Area 0.04 m 2 Orientation Horizontal Port Depth 0 mm Number Points / Line 1 Filtration for TPM In stack Sampling Platform General Platform Information Permanent / Temporary Platform Inside / Outside Temporary Outside M1 Platform requirements Minimum Platform Area 5 m 2 Platform has 2 levels of handrails (approximately 0.5 m & 1.0 m high) Platform has vertical base boards (approximately 0.25 m high) Platform has removable chains / self closing gates at the top of ladders Handrail / obstructions do not hamper insertion of sampling equipment Depth of Platform = Minimum of 2m or Probe Length + 1m No No No No Yes Yes Sampling Location / Platform Improvement Recommendations Ideally a platform that complies with EA guidance note M1 should be installed. RSL Asphalt Recycler (A141) Page 9 of 25

10 EXECUTIVE SUMMARY Sampling & Analytical Method Deviations Traverse data A preliminary flow traverse could not be performed as plant operations restricted the measurement of flows prior to our particulates test. RSL Asphalt Recycler (A141) Page 10 of 25

11 APPENDICES CONTENTS CONTENTS APPENDIX 1 - Stack Emissions Monitoring Team APPENDIX 2 - Summaries, Calculations, Raw Data and Charts APPENDIX 3 - Calibrateable Equipment Checklist and Calibration Gases APPENDIX 4 - Measurement Uncertainty Budget Calculations RSL Asphalt Recycler (A141) Page 11 of 25

12 APPENDICES STACK EMISSIONS MONITORING TEAM Team Leader Paul Adamczyk MCERTS Level 2, Technical Endorsements 1, 2, 3 & 4 MM Technician Victor Johnson MCERTS trainee MM RSL Asphalt Recycler (A141) Page 12 of 25

13 Test APPENDIX 2 - Summaries, Calculations, Raw Data and Charts TOTAL PARTICULATE MATTER SUMMARY Sampling Times Concentration mg/m³ LOD Limit Emission mg/m³ mg/m³ Rate g/hr Run 1 12:26-12:56 01 October Blank Reference conditions are 273K, 101.3Pa, without correction for water vapour content Acetone Blank Value mg/l 5.0 Acceptable Value mg/l 10 RSL Asphalt Recycler (A141) Page 13 of 25

14 APPENDIX 2 - Summaries, Calculations, Raw Data and Charts ISOKINETIC SAMPLING EQUATIONS- RUN 1 TPM Absolute pressure of stack gas, P s Molecular weight of dry gas, M d Barometric pressure, P b mm Hg CO 2 % Stack static pressure, P static mm H 2 O 2.04 O 2 % P s = P b + (P static ) mm Hg Total % N 2 (100 -Total) % Vol. of water vapour collected, V wstd M d = 0.44(%CO 2 )+0.32(%O 2 )+0.28(%N 2 ) Moisture trap weight increase,vlc g 16.2 Molecular weight of wet gas, M s V wstd = ( )(V lc ) m M s = M d (1 - B wo ) + 18(B wo ) g/gmol Volume of gas metered dry, V mstd Actual flow of stack gas, Q a Volume of gas sample through gas meter, V m Area of stack, A s m Gas meter correction factor, Y d Q a = (60)(A s )(V s ) m!/min 11.1 Mean dry gas meter temperature, T m Total flow of stack gas, Q Mean pressure drop across orifice, H mmh 2 O Conversion factor (K/mm.Hg) V mstd = (0.3592)(V m )(P b +( H/13.6))(Y d ) Q std = (Q a )P s (0.3592)(1-B wo ) Dry 8.3 T m (T s ) +273 Volume of gas metered wet, V mstw Q stdo2 = (Q a )P s (0.3592)(1-B wo )(O 2 No O2 Ref V mstw = V mstd + V wstd m (T s ) +273 Q stw = (Q a )P s (0.3592) Wet 8.58 No Percent isokinetic, %I (T s ) +273 Nozzle diameter, D n mm % oxygen measured in gas stream, act%o Nozzle area, A n mm % oxygen reference condition 21 Total sampling time, min 30 O 2 Reference Factor 13.6 Vol. of gas metered at O 2 Ref. Cond., V mstd@x%o2 Is the process burning hazardous waste? (If yes, no favourable oxygen correction) O2 Ref = act%o2 No O2 Ref %I = (4.6398E6)(T s +273)(V mstd ) % ref%o2 (P s )(V s )(A n )( )(1-B wo ) V mstd@x%oxygen = (V mstd ) (O 2 Ref ) m 3 No O2 Ref Acceptable isokinetic range 95% to 115% Yes Moisture content, B wo Particulate Concentration, C B wo = V wstd Mass collected on filter, M f g V mstd + V wstd % 3.46 Mass collected in probe, M p g Moisture by FTIR % - Total mass collected, M n g Velocity of stack gas, V s C wet = M n mg/m! Pitot tube velocity constant, K p V mstw Velocity pressure coefficient, C p 0.84 C dry = M n mg/m! Mean of velocity heads, P avg mm H 2 O 2.04 V mstd Mean square root of velocity heads, P 1.43 C dry@x%o2 = M n mg/m! No O2 Ref Mean stack gas temperature, T o s C 79 V mstd@x%oxygen V s = (K p )(C p )( P)( T s + 273)) m/s 5.13 Particulate Emission Rates, E (M s )(P s ) E = [(C wet )(Q stw )(60)] / RSL Asphalt Recycler (A141) Page 14 of 25

15 APPENDIX 2 - Summaries, Calculations, Raw Data and Charts TOTAL PARTICULATE MATTER QUALITY ASSURANCE CHECKLIST Leak Rate Run Mean Sampling Rate Pre-sampling Leak Rate Post-sampling Leak Rate Maximum Vacuum Acceptable Leak Rate litre/min litre/min litre/min mm Hg litre/min Leak Tests Acceptable? Run Yes Isokineticity Run Isokinetic Variation % Run Yes Acceptable Isokinetic rate % Acceptable Isokineticity Blank Value Run Overall Blank Value Daily Emission Limit Value Acceptable Blank Value Overall Blank Acceptable mg/m 3 mg/m 3 mg/m 3 mg/m 3 Blank Yes Filters Run mm C Run 1 QF GF = Glass Fibre QF = Quartz Fibre Filter Material Filter Size Max Filtration Temperature Pre-conditioning Filter Temperature C 180 Post conditioning Filtration Temperature C 160 RSL Asphalt Recycler (A141) Page 15 of 25

16 APPENDIX 2 - Summaries, Calculations, Raw Data and Charts PRELIMINARY STACK SURVEY Stack Diameter / Depth, D 0.19 m Stack Width, W 0.19 m Stack Area, A 0.04 m 2 Average stack gas temperature 79 o C Pitot static pressure 0.02 kpa Barometric Pressure 101 kpa Pitot tube calibration coefficient, K pt Stack Gas Composition & Molecular Weights Component Molar Density Conc Dry Volume Dry Conc Conc Wet Volume Wet Conc Mass kg/m 3 Dry Fraction kg/m 3 Wet Fraction kg/m 3 M p % Vol r pi % Vol r pi CO O N H 2 O Where: p = M / pi = r x p 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 Result Units kg/m 3 kg/m 3 3 kg/m kg/m 3 RSL Asphalt Recycler (A141) Page 16 of 25

17 APPENDIX 2 - Summaries, Calculations, Raw Data and Charts PRELIMINARY STACK SURVEY TRAVERSE 1 Date of Survey Time of Survey Velocity Measurement Device: 01 October :10 S Type Pitot Sampling Line A Traverse Distance P pt P pt Temp Velocity O 2 Angle Point into mmh 2 O Pa o C m/s % of Swirl duct (m) Vol o Mean Sampling Line B Traverse Distance P pt P pt Temp Velocity O 2 Angle Point into mmh 2 O Pa o C m/s % of Swirl duct (m) Vol o Mean - - *Flow data in the above table is based on readings taken during the isokinetc testing and not a preliminary survey. RSL Asphalt Recycler (A141) Page 17 of 25

18 APPENDIX 2 - Summaries, Calculations, Raw Data and Charts PRELIMINARY STACK SURVEY (CONTINUED) TRAVERSE 1 CONTINUED Sampling Line C Traverse Distance P pt P pt Temp Velocity O 2 Angle Point into mmh 2 O Pa o C m/s % of Swirl duct (m) Vol Mean - - o Sampling Line D Traverse Distance P pt P pt Temp Velocity O 2 Angle Point into mmh 2 O Pa o C m/s % of Swirl duct (m) Vol Mean - - o RSL Asphalt Recycler (A141) Page 18 of 25

19 APPENDIX 2 - Summaries, Calculations, Raw Data and Charts PRELIMINARY STACK SURVEY (CONTINUED) Sampling Plane Validation Criteria EA Technical Guidance Document (Monitoring) M1 Result Units Requirement Compliant Lowest Differential Pressure Pa >= 5 Pa Yes Lowest Gas Velocity 5.19 m/s Highest Gas Velocity 5.19 m/s Ratio of Above < 3 : 1 Yes Angle of flow with regard to duct axis 0 o < 15 o Yes No local negative flow - Yes Other Sampling Method Criteria Result Units Requirement Compliant Mean Velocity 5.19 m/s Standard Deviation of Velocity from Mean 0.00 % < 10% Yes Mean Oxygen - % Standard Deviation of Oxygen from Mean - % < 15% - Homogeneous flow stream / gas velocity - Yes Where: P STD = sum of component concentrations, kg/m 3 (not including water vapour) P STW = (P STD + pi of H 2 O) / (1 + (pi of H 2 O / )) P Actual = P STD x (Ts / Ps) x (Pa / Ta) P ActualW (at each sampling point) = P STW x (Ts / Ps) x (Pa / Ta) Calculation of Stack Gas Velocity, V Velocity at Traverse Point, V = K pt x (1- ) * 2 * P pt / P ActualW ) Calculation based on BS 1042:Section 2.1:1983 (Section 7 - Velocity Computation) Where: K pt = Pitot tube calibration coefficient (1- ) = Compressibility correction factor, assumed at a constant Average Stack Gas Velocity, Va 5.19 m/s RSL Asphalt Recycler (A141) Page 19 of 25

20 APPENDIX 2 - Summaries, Calculations, Raw Data and Charts PRELIMINARY STACK SURVEY (CONTINUED) Calculation of Stack Gas Volumetric Flowrate, Q Sampling plane reference conditions Duct gas flow conditions Actual Reference Units Temperature 79 0 o C Total Pressure kpa Oxygen % Moisture % Gas Volumetric Flowrate Gas Volumetric Flowrate (Actual), Q Actual Gas Volumetric Flowrate (STP, Wet), Q STP Gas Volumetric Flowrate (STP, Dry), Q STP,Dry Gas Volumetric Flowrate (REF), Q Ref Result Units m 3 /hr m 3 /hr m 3 /hr m 3 /hr Where: Q Actual = Va x A x 3600 Q STP = Q (Actual) x (Ts / Ta) x (Pa / Ps) x 3600 Q STP,Dry = Q (STP) / (100 - (100 / Ma)) x 3600 Q Ref = Q (STP) x ((100 - Ma) / (100 - Ms)) x (( O 2 a) / ( O 2 s)) Nomenclature: Ts = Absolute Temperature, Standard Conditions, 273 K Ps = Absolute Pressure, Standard Conditions, kpa Ta = Absolute Temperature, Actual Conditions, K Pa = Absolute Pressure, Actual Conditions, kpa Ma = Water vapour, Actual Conditions, % Vol Ms = Water vapour, Reference Conditions, % Vol O 2 a = Oxygen, Actual Conditions, % Vol O 2 s = Oxygen, Reference Conditions, % Vol RSL Asphalt Recycler (A141) Page 20 of 25

21 APPENDIX 2 - Summaries, Calculations, Raw Data and Charts STACK DIAGRAM Value Units Non-Isokinetic Sampling Stack Depth 0.19 m Sampling Distance Distance into Units Stack Width 0.19 m Point (% of Depth) Stack Area 0.04 m 2 Sampling Line Isokinetic Sampling CEN Methods Sampling Distance Distance into Swirl Point (% of Depth) Stack (m) o RSL Asphalt Recycler (A141) Page 21 of 25

22 APPENDIX 3 - Calibrateable Equipment Checklist & Calibration Gases CALIBRATEABLE EQUIPMENT CHECKLIST Extractive Sampling Instrumental Analyser/s Miscellaneous Equipment Equipment I.D. Equipment Equipment I.D. Equipment Equipment I.D. Control Box DGM LAB 1259 Horiba PG-250 Analyser - Laboratory Balance LAB 0001/0652 Box Thermocouples LAB 1260 JCT JCC P-1 Cooler - Tape Measure LAB 1369 Meter In Thermocouple LAB 1262 MAK 10 Cooler - Stopwatch LAB 1528 Meter Out Thermocouple LAB 1263 FT-IR - Protractor LAB 1386 Control Box Timer LAB 1261 FT-IR Oven Box - Barometer LAB 1147 Oven Box LAB 0738 Bernath 3006 FID - Digital Micromanometer LAB 1187 Probe - Signal 3030 FID - Digital Temperature Meter LAB 0737 Probe Thermocouple LAB 0826 Servomex - Stack Thermocouple LAB 1597 Probe LAB 0953 JCT Heated Head Filter - Mass Flow Controller - Probe Thermocouple LAB 1306 Thermo FID - Mass Flow Control Box - S-Pitot LAB 1615 Stackmaster - 1m Heated Line (1) - L-Pitot - FTIR Heater Box for Heated Line - 1m Heated Line (2) - Site Balance LAB m Heated Line (3) - Last Impinger Arm 5m Heated Line (1) - Dioxins Cond. Thermocouple 10m Heated Line (1) - Callipers 10m Heated Line (2) - Small DGM 15m Heated Line (1) - Heater Controller 20m Heated Line (1) m Heated Line (2) - NOTE: If the equipment I.D is represented by a dash (-), then this piece of equipment has not been used for this test. CALIBRATION GASES Gas Cylinder Supplier ppm % Analytical I.D. Number Tolerance +/- % - - RSL Asphalt Recycler (A141) Page 22 of 25

23 APPENDIX 4 - Measurement Uncertainty Budget Calculations MEASUREMENT UNCERTAINTY BUDGET - TOTAL PARTICULATE MATTER Run Sampled Volume Sampled Gas Temp Sampled Gas Pressure Sampled Gas Humidity Oxygen Content Limit of Detection Leak Uncollected Mass m! K kpa % by volume % by volume % by mass % mg MU required < 2% < 2% < 1% < 1% < 10% < 5% of ELV < 2% < 10% of ELV Run N/A as a % N/A compliant? Yes Yes Yes Yes N/A Yes Yes Yes Run Volume (STP) Mass of particulate O2 Correction Uncollected Mass m! mg - mg/m! mg Combined uncertainty Run MU as mg/m MU as % Leak R1 - Uncertainty expressed at a 95% confidence level (where k = 2) (k is a coverage factor which gives a 95% confidence in the quoted figures) Developed for the STA by R Robinson, NPL 1.82 mg/m³ 2.82 % RSL Asphalt Recycler (A141) Page 23 of 25

24 Run Sampled Volume Sampled Gas Temp Sampled Gas Pressure Sampled Gas Humidity Oxygen Content m! K kpa % by volume % by volume % MU required < 2% < 2% < 1% < 1% < 10% < 2% Run N/A - as a % N/A 0.50 compliant? Yes Yes Yes Yes N/A Yes Run Volume (STP) Mass Gained APPENDIX 4 - Measurement Uncertainty Budget Calculations MEASUREMENT UNCERTAINTY BUDGET - MOISTURE O2 Correction Uncollected Mass m! mg - mg/m! mg Run MU as % v/v MU as % Leak Leak Combined uncertainty R1 - Uncertainty expressed at a 95% confidence level (where k = 2) 0.11 % v/v 3.06 % RSL Asphalt Recycler (A141) Page 24 of 25

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