Measurement Report LIFE10 ENV/FI/059

Transcription

1 Measurement Report LIFE10 ENV/FI/059 Air pollution control measurement of the workplace atmosphere and testing of emission-reducing prototypes from the project partners Nederman Filtration GmbH and Reinluft Umwelttechnik Ing. GmbH at the steel foundry Foundry: Pilot steel foundry, Germany Prepared by: IfG Measurement centre for hazardous substances at the workplace Dr. Guido Furth Tobias Spenner Alexander Gieselmann Thomas Wohlers Düsseldorf, IfG Sohnstraße Düsseldorf Postfach Düsseldorf Sitz der Gesellschaft: Düsseldorf, Sohnstr. 70 Dresdner Bank AG, Düsseldorf (BLZ ) Geschäftsführer: Dr.-Ing. Wolfram Stets; Registergericht Düsseldorf HRB Steuernummer: 105/5890/1324 Dr.-Ing. Horst Wolff Telefon (0211) Telefax (0211) Umsatzsteuer-Ident-Nr. DE

2 IfG Measurement Report Life10 ENV/FI/059 Page 2 IfG Measurement Report Life10 ENV/FI/059 Date: Air pollution control measurement of the workplace atmosphere and testing of emission-reducing prototypes at the pilot steel foundry Owner-operator: Steel foundry, Germany Type of measurement: Date of the measurement: to Scope of the report: Measurement of odours and pollutant emissions at selected contained and diffuse sources 18 pages Task: The contained sources of the exhaust air systems from sand conditioning and of the pilot plants of the project partners are to be investigated with regard to their odours and pollutant emissions. The odour and pollutant concentrations in the indoor air in the immediate vicinity of five selected manufacturing processes are additionally to be determined.

3 IfG Measurement Report Life10 ENV/FI/059 Page 3 1 Formulation of the task 1.1 Customer 1.2 Owner-operator 1.3 Location 1.4 Plant The measurements were undertaken in the following foundry as part of the EU project Odourless Casting LIFE ENV/FI/059. Steel foundry, Germany See above Steel foundry: Machine moulding shop Hand moulding shop Pouring and cooling line Sand conditioning 1.5 Measurement period (dates) Date of last measurement Date of next measurement No recurrent measurements 1.6 Reason for the measurement Emissions by seven European pilot foundries are to be investigated as part of the Odourless Casting project (LIFE ENV/FI/059). In addition to a general assessment of the emissions situation, manufacturing processes with major odour and pollutant emissions are to be identified in particular. In conjunction with the tests to be undertaken by IfG ggmbh as project partner, hazardous substances are also to be measured in various departments of the steel foundry. These measurements will serve as controls and provide a quantitative overview of the odour levels and gaseous pollutant levels. A feature specific to this foundry is that only a few emissions are contained and the majority emitted diffusely. For this reason, many samples were taken locally in the direct vicinity of the manufacturing processes and not at the stacks as usual. In addition to a cadastral assessment of the situation regarding emissions, the efficiency of the pilot plants installed by the project partners Nederman Filtration GmbH and Reinluft Umwelttechnik Ing. GmbH for treating foundry emissions is

4 IfG Measurement Report Life10 ENV/FI/059 Page also to be established. Task Both contained and diffuse sources were included and assessed with regard to their odour and pollutant emissions. 1.8 Measurement components Odour as an olfactometric cumulative parameter, TVOC, hydrocarbons carbon monoxide, sulphur dioxide, and volume flow rates at the contained sources 1.9 Persons with whom the measurement plan was coordinated The measurement plan was agreed and coordinated with the owner-operator of the foundry and the project partners Names of all persons involved in sampling on site and number of auxiliaries Mr. Gieselmann (IfG), Dr. Furth (IfG), Mr. Spenner (IfG), Mr. Wohlers (IfG) 1.11 Other institutes involved Not applicable 1.12 Person technically responsible Dr. rer. nat. Guido Furth Telephone 0211/

5 IfG Measurement Report Life10 ENV/FI/059 Page 5 2 Description of the plant, substances handled 2.1 Type of plant Steel foundry in accordance with No. 3.7 column 1, Annex to the 4th Federal Pollution Control Act (BImSchG) 2.2 Description of the plants Steel is melted in two MF dual-hearth induction furnaces and poured in a hand moulding process (cold-setting resin-bonded) or in a machine moulding shop (bentonite-bonded). The heat treatment is a major element of the process and knowhow. The foundry is located in an industrial district. Production is > 20 t steel cast per day, 4th Federal Pollution Control Act (BImSchG) No. 3.7 column 1 Machine moulding shop, bentonite-bonded, with sand conditioning Hand moulding shop with moulding by means of the resol ester process (alpha set method) with sand regeneration Core-making shop for furan resin bonded cores Water-based zircon coating, magnesite coating and Arkofluid coating based on alcohol Cleaning room, heat treatment, quenching baths 2x poly-quench and 1x water, quality control Operating hours: 2-shift as a matter of principle, heat treatment in 3 shifts 2.3 Location of the plant and description of the emission sources Location (geographical) Germany

6 IfG Measurement Report Life10 ENV/FI/059 Page Emission sources, heights, exit areas, description of the source Measuring point Contained sources Designation Inclusion Height above ground Exit area [m 2 ] Easting / northing [m] Execution MP 1 MP 2 MP 3 MP 7 Before the pilot plants Pilot plant A (Nederman) Pilot plant B (Reinluft) Sand conditioning - Knock-out grate - Sand transfer -2 TEKA mixing stations - Weighing station - Jet mixer - Bentonite silo [m] Steel tube Steel tube Steel tube / Steel tube Diffuse sources (in the hall) Measuring point Designation Inclusion Height above ground Exit area [m 2 ] Easting/northing [m] [m] MP 4 Casting MP 5 Start of the cooling line MP 6 End of the cooling line MP 8 Core making MP 9 Hand moulding shop Indicates that (at least) one odour sample was taken here The contained sources operated in accordance with their specifications.

7 IfG Measurement Report Life10 ENV/FI/059 Page National correlation Possible charge materials according to the permit Not specified 2.5 Operating hours Total operating hours 6.00 h h (2-shift) Emission period (in conjunction with the measurements) Two-shift 2.6 Equipment for detecting and reducing emissions Equipment for detecting emissions Casings, piping and fans are part of the exhaust gas routing for sand conditioning The cooling line is not encased Equipment for reducing emissions Each contained source is equipped with at least one filtering purification stage which operates in dry mode.

8 IfG Measurement Report Life10 ENV/FI/059 Page 8 3 Description of the sampling points 3.1 Position of the sampling sections In the case of contained sources, the measurements were undertaken in the vertical purified gas stack at the openings provided for this purpose. Inflow and outflow sections met with the requirements of VDI regulation 2066 sheet 1 > 3 x pipe diameter. 3.2 Diameter of the exhaust gas pipe at the sampling point or dimensions of the sampling point In the case of contained sources, the stated cross-sectional area is always also the measurement plane and can be found in Table Number of axes and position of the measuring points in the sampling area Not applicable.

9 IfG Measurement Report Life10 ENV/FI/059 Page 9 4 Measurement and analysis methods, equipment 4.1 Determination of basic exhaust gas conditions Flow speed Equipment type: Make: Theoretical calculation - operating data: -- Vane anemometer, Testoterm combination instrument type 445 Measuring range: 0-60 m/s Testo, Lenzkirch Air pressure at the sampling point Equipment type: Make: Last inspection: Exhaust gas temperature Equipment type: Make: Registration of measured values: Representative nature of the measuring point: Vapour content of the exhaust gas (exhaust gas humidity) Method: Equipment type: Make: Precision aneroid barometer Lufft, Stuttgart Annual comparison with mercury barometer Vane anemometer with built-in NiCrNi temperature sensor, Testoterm combination instrument 445 Measuring range: C Testo, Lenzkirch Manual The influence of the measuring point over the cross-section equalled 1 C, the measuring point represents the mean value. Capacitive change NTC moisture sensor, Testoterm 445 combination instrument Measuring range: 2-98% relative humidity Testo, Lenzkirch

10 IfG Measurement Report Life10 ENV/FI/059 Page Gaseous and vapour emissions BTXE emissions Test object BTX, ethylbenzene, naphthalene, VOC, formaldehyde, phenol, cresol Measurement method / VDI regulation, methodological basis A part-stream is extracted from the exhaust gas via a probe and drawn through a tube containing pollutant-specific adsorbents with the aid of a vacuum device. These samples are analysed by a test laboratory accredited in accordance with DIN EN ISO/IEC 17025: Sampling equipment Mechanical design (sampling Probe / short Teflon hose / tube / pump train) Specification of major parts - Sampling probe: Stainless steel probe - Ab-/adsorption device: Dräger activated charcoal tubes type BIA, Supelco DNPH tubes, Dräger silica tubes - Sorption agents: Activated carbon, dinitrophenylhydrazine, silica gel - Distance between sampling probe and sorbent: 150 mm - Pump: Electronic pump Type Gas sampler type GS 312 (diaphragm pump with gas drying, digital indication of temperature and volume) Manufacturer DESAGA, Heidelberg Delivery capacity - External laboratories involved: 0.3 l/min to approx. 5 l/min RAG Ruhranalytik Laboratorium für Kohle und Umwelt GmbH, Henkel AG & Co. KGaA, ANECO Institut für Umweltschutz GmbH & Co Analytical determination The Dräger activated carbon tubes were assayed by gas chromatography in accordance with VDI regulation "3865 sheet 3". The DNPH tubes were eluted with acetonitrile/hcl and subsequently assayed by liquid chromatography (DIN ISO 16000). The Dräger silica tubes were assayed by gas chromatography (DIN EN 12673).

11 IfG Measurement Report Life10 ENV/FI/059 Page Process characteristics The measurement uncertainties remained within the limits specified for the indicated test methods. 4.3 Particulate emissions Not applicable 4.4 Odour emissions Measurement method / VDI regulation Test object: Olfactometric units. A part-stream is extracted from the exhaust gas via a probe and drawn into nalophan bags with the aid of a vacuum device. The bags are sealed and transported to the measuring room, where they are assayed by a group of test persons on a dynamic dilution olfactometer in accordance with DIN EN ISO (dilution based on the gas flow principle). The odorant samples are gradually diluted with neutral air and offered to the group of test persons via breathing masks Sampling equipment Mechanical design (sampling train) Probe / short PS hose / sample bag / vacuum container / pump Specification of major parts - Sampling probe: Stainless steel probe - Sample bag: Nalophan NA - Pre-filter: Not required - Pump: - Type - Manufacturer - Delivery capacity Electronic pump Gas sampler type GS 312 DESAGA, Heidelberg 0.3 l/min to approx. 5 l/min Analyser / olfactometer Manufacturer: Ecoma Mannebeck Type: TO 7 Details see Attachment: Equipment specification Group of test persons One group of four people Evaluation of the samples At IfG, in a separate measuring room

12 IfG Measurement Report Life10 ENV/FI/059 Page Number of measurement series Three series per bag Presentation time 2.2 s Breaks for the group of test persons Individual 4.5 Toxic dust constituents (and substances passing through the filter) Not applicable 5 Status of the plants during the measurements 5.1 Production plants Mode of operation: Quasi-continuous Throughput/capacity: Care was taken to ensure typical production conditions during the measurements. Charge materials/fuels: Standard situation Characteristic parameters: Cannot be presented, the amount of liquid iron cast plays a predominant role. 5.2 Exhaust gas purification plants Sand conditioning includes a dust collection plant with filtration.

13 IfG Measurement Report Life10 ENV/FI/059 Page 13 6 Explanation of the Nederman plant 6.1 Description The adsorption system is based on the adsorption of odorous with a suitable additive. The additive is recirculated for a better utilization. The material is dosed by a feeding system where dusty type additives are sprayed in the exhaust flow. The dust is deposited on the filter bags and is collected below the filter in a hopper. From there, most of the additive is fed back into the raw gas and only a small part is discharged as a residue. P r o c e s s T h e adsorption materials applied are typical ones e.g. activated carbon and coke as a fine dust with a high specific surface. Also zeolite can be used. The adsorption reaction takes place in the pipework during the flight of the gas dust mixture. and at the additive layer on the filter bag material. The cleaning system is a pulse jet system that works online during the continuous filtration process. The filter loading factor is about 1 m / min corresponding 17 mm / s. The pulses should be timed that there is a filter cake of about 2mm before the bag is cleaned. The ratio of the recirculation could be varied between 5/1 up to 20/1. In the flow chart is a middle recirculation rate of 1/10 shown. 6.2 test parameters Flow Rate: 4000m³/h Additive: 4 kg/h Minsorb DX (Rheinkalk) 1g/m³ Recirculation ratio: 1 : 10 (fresh additive : recirculated additive) Difference pressure filter: 800 Pa Cleaning system: pulse jet at 6 Bar; difference pressure controlled.

14 IfG Measurement Report Life10 ENV/FI/059 Page Filter and description Additive dosing electrical components fabric filter exhauster

15 IfG Measurement Report Life10 ENV/FI/059 Page 15 7 Summary of results and discussion 7.1 Evaluation of operating conditions during the measurements Only the results are presented below. 7.2 Results Concentration, contained sources Odour threshold Source : MP 1 Before the pilot plants Component : Odour threshold Date Time Concentration Z 50 Odour level Odorant mass from - to [GE/m 3 ] [db] flow [MGE/h] :00 8: ± :00 9: ± :33 10: ± Mean value :34 8: ± :08 8: ± :42 9: ± Mean value 121 < :50 9: ± :30 10: ± :04 10: ± Mean value :30 8: ± :04 8: ± :37 9: ± Mean value The concentrations stated refer to dry exhaust air in normal condition (273 K and 1013 hpa).

16 IfG Measurement Report Life10 ENV/FI/059 Page 16 Source : MP 2 Pilot plant A (Nederman) Component : Odour threshold Date Time Concentration Z 50 Odour level Odorant mass from - to [GE/m 3 ] [db] flow [MGE/h] No measurement No result :00 9: ± :33 10: ± Mean value :34 8: ± :08 8: ± :42 9: ± Mean value :50 9: ± :30 10: ± :04 10: ± Mean value :30 8: ± :04 8: ± :37 9: ± Mean value The concentrations stated refer to dry exhaust air in normal condition (273 K and 1013 hpa). Source : MP 3 Pilot plant B (Reinluft) Component : Odour threshold Designation Time Concentration Z 50 Odour level Odorant mass from - to [GE/m 3 ] [db] flow [MGE/h] :00 8:46 < 20 - < :00 9:32 < 20 - < :33 10:06 < 20 - <0.06 Mean value :34 8: ± :08 8: ± :42 9: ± Mean value

17 IfG Measurement Report Life10 ENV/FI/059 Page 17 The concentrations stated refer to dry exhaust air in normal condition (273 K and 1013 hpa). Source : MP 7 Sand regeneration Component : Odour threshold Date Time Concentration Z 50 Odour level Odorant mass from - to [GE/m 3 ] [db] flow [MGE/h] :15 12: ± Mean value The concentrations stated refer to dry exhaust air in normal condition (273 K and 1013 hpa) Concentration, diffuse sources Odour threshold Source : MP 4 Pouring station Component : Odour threshold Date Time Concentration Z 50 Odour level Odorant mass from - to [GE/m 3 ] [db] flow [MGE/h] :04 11: ± Mean value The concentrations stated refer to dry exhaust air in normal condition (273 K and 1013 hpa). Source : MP 5 Start of the cooling line Component : Odour threshold Date Time Concentration Z 50 Odour level Odorant mass from - to [GE/m 3 ] [db] flow [MGE/h] :04 11: ± Mean value The concentrations stated refer to dry exhaust air in normal condition (273 K and 1013 hpa).

18 IfG Measurement Report Life10 ENV/FI/059 Page 18 Source : MP 6 End of the cooling line Component : Odour threshold Date Time Concentration Z 50 Odour level Odorant mass from - to [GE/m 3 ] [db] flow [MGE/h] :54 9: ± Mean value The concentrations stated refer to dry exhaust air in normal condition (273 K and 1013 hpa). Source : MP 8 Core making Component : Odour threshold Date Time Concentration Z 50 Odour level Odorant mass from - to [GE/m 3 ] [db] flow [MGE/h] :15 12: ± Mean value The concentrations stated refer to dry exhaust air in normal condition (273 K and 1013 hpa). Source : MP 9 Hand forming shop Component : Odour threshold Date Time Concentration Z 50 Odour level Odorant mass from - to [GE/m 3 ] [db] flow [MGE/h] :34 9: ± Mean value The concentrations stated refer to dry exhaust air in normal condition (273 K and 1013 hpa).

19 IfG Measurement Report Life10 ENV/FI/059 Page Concentration, contained sources Pollutants Source Date Before the pilot plants Behind pilot plant (A) Behind pilot plant (B) Sand regeneration MP1*) MP2*) MP3*) MP7 27. and 27. and 27. and TVOC [ppm] Benzene [mg/m 3 ] Toluene [mg/m3] Ethylbenzene [mg/m 3 ] <0.04 <0.04 <0.04 <0.04 o-xylene [mg/m 3 ] <0.04 <0.04 <0.04 <0.04 m-xylene [mg/m 3 ] 0.07 <0.04 <0.04 <0.04 p-xylene [mg/m 3 ] <0.04 <0.04 <0.04 <0.04 Naphthalene [mg/m 3 ] <0.04 <0.04 <0.04 <0.04 Source Date Before the pilot plants Behind pilot plant (A) Behind pilot plant (B) Sand regeneration MP1*) MP2*) MP3*) MP7 27. and 27. and 27. and CO [ppm] SO2 [ppm] Formaldehyde [µg/m 3 ] 59 Acetaldehyde [µg/m 3 ] 170 Phenol [µg/m 3 ] <0.02 Cresol [µg/m 3 ] *): Mean values of the measurements on 27 and

20 IfG Measurement Report Life10 ENV/FI/059 Page Concentration, diffuse sources Pollutants Source Casting Start of the cooling line End of the cooling line Core making Hand forming shop MP4 MP5 MP6 MP8 MP9 Date TVOC [ppm] Benzene [mg/m 3 ] Toluene [mg/m3] Ethylbenzene [mg/m 3 ] <0.04 <0.01 <0.01 <0.01 <0.04 o-xylene [mg/m 3 ] <0.04 <0.01 <0.01 <0.01 <0.04 m-xylene [mg/m 3 ] < <0.04 p-xylene [mg/m 3 ] < <0.01 <0.01 <0.04 Naphthalene [mg/m 3 ] <0.04 <0.01 <0.01 <0.01 <0.04 CO [ppm] SO2 [ppm] Formaldehyde [µg/m 3 ] 150 <10 <10 62 Acetaldehyde [µg/m 3 ] 650 <10 <10 73 Phenol [µg/m 3 ] <0.02 <0.02 <0.02 <0.02 Cresol [µg/m 3 ] 0.14 <0.02 <0.02 <0.02 Düsseldorf, /Fu IfG - - Measurement Centre - Dr. G. Furth (Head of Measurement Centre)