Assured Monitoring Group

Transcription

1 ABN: Assured Monitoring Group SOURCE EMISSIONS MONITORING BORAL WYEE BORAL ROOFING NSW Project ID R_0 DATE OF RELEASE: 24/08/2017 Unit 7, 142 Tennyson Memorial Avenue Tennyson Queensland 4105

2 Table 1: Document approval Name Position Title Signature Date Author Curtis Profke Senior Consultant Reviewer Adam Dixon Senior Consultant Approved Adam Dixon Senior Consultant Table 2: Revision register Revision Date Issued By Comment R_ Adam Dixon Initial release R_ Aaron Dobson Updated licence conditions DISCLAIMER Assured Monitoring Group acts in all professional matters as a faithful advisor to the Client and exercises all reasonable skill and care in the provision of its professional services. Reports are commissioned by and prepared for the exclusive use of the Client. They are subject to and issued in accordance with the agreement between the Client and Assured Monitoring Group. Assured Monitoring Group is not responsible for any liability and accepts no responsibility whatsoever arising from the misapplication or misinterpretation by third parties of the contents of its reports. Except where expressly stated, Assured Monitoring Group does not attempt to verify the accuracy, validity or comprehensiveness of any information supplied to Assured Monitoring Group for its reports. Reports cannot be copied or reproduced in whole or part for any purpose without the prior written agreement of Assured Monitoring Group. Where site inspections, testing or fieldwork have taken place, the report is based on the information made available by the client or their nominees during the visit, visual observations and any subsequent discussions with regulatory authorities. The validity and comprehensiveness of supplied information has not been independently verified and, for the purposes of this report, it is assumed that the information provided to Assured Monitoring Group is both complete and accurate. It is further assumed that normal activities were being undertaken at the site on the day of the site visit(s), unless explicitly stated otherwise. ACCREDITED FOR COMPLIANCE TO ISO/IEC The results of the tests, calibrations and/or measurements included in this document are traceable to Australian/national standards. Accreditation ID: Project ID R_0 ii

3 EXECUTIVE SUMMARY Assured Monitoring Group (AMG) conducted source emissions monitoring at the Boral Roofing facility located at Wyee, NSW on the 18 th & 19 th July A summary of results is presented below, for further details please refer to the body of this report. No licence limit breaches were recorded. Table 3: Summary of results Kiln stack (EPA Point 4) Release Point Parameter Unit of Measure Kiln Stack - EPA Point 4 Date of testing dd-mm-yy 18/07/ Average exhaust Velocity m/sec Average stack temperature C Moisture % Dry standard stack flow rate Nm 3 /sec Total solid particulates mg/nm emission rate g/sec PM 10 mg/nm emission rate g/sec Sulphur dioxide mg/nm emission rate g/sec Sulphur trioxide (as H 2SO 4) mg/nm emission rate g/sec Carbon monoxide mg/nm emission rate g/sec Licence Limit Oxides of nitrogen (NO 2) mg/nm emission rate g/sec Total Fluorides mg/nm emission rate g/sec Project ID R_0 iii

4 Table 4: Summary of results Dryer stack (EPA Point 6) Release Point Parameter Unit of Measure Dryer stack - EPA Point 6 (VE2) Date of testing dd-mm-yy 19/07/ Average exhaust Velocity m/sec Average stack temperature C Moisture % Dry standard stack flow rate Nm 3 /sec Total solid particulates mg/nm 3 < emission rate g/sec < PM 10 mg/nm 3 < emission rate g/sec < Sulphur dioxide mg/nm emission rate g/sec Sulphur trioxide (as H 2SO 4) mg/nm emission rate g/sec Carbon monoxide mg/nm 3 < emission rate g/sec < Oxides of nitrogen (NO 2) mg/nm 3 < emission rate g/sec < Total Fluorides mg/nm 3 < emission rate g/sec < Licence Limit Project ID R_0 iv

5 TABLE OF CONTENTS 1 INTRODUCTION METHODOLGY & EQUIPMENT SAMPLING METHODOLOGY SAMPLE LOCATION PLANT OPERATIONAL DATA TEST EQUIPMENT QUALITY ASSURANCE & QUALITY CONTROL (QA/QC) DEFINITIONS RESULTS LIST OF TABLES TABLE 1: DOCUMENT APPROVAL... II TABLE 2: REVISION REGISTER... II TABLE 3: SUMMARY OF RESULTS KILN STACK (EPA POINT 4)... III TABLE 4: SUMMARY OF RESULTS DRYER STACK (EPA POINT 6)... IV TABLE 5: SAMPLING SCHEDULE... 6 TABLE 6: TEST METHODS... 7 TABLE 7: SAMPLING NOTES... 7 TABLE 8: ANALYSIS NOTES... 7 TABLE 9: SAMPLE LOCATION SUMMARY... 9 TABLE 10: PRODUCTION DETAILS... 9 TABLE 11: SAMPLING DATA QA/QC CHECKLIST TABLE 12: LABORATORY DATA QA/QC CHECKLIST TABLE 13: DEFINITIONS TABLE 14: TEST RESULTS KILN STACK MANUAL SAMPLES TABLE 15: TEST RESULTS KILN STACK GASES TABLE 16: TEST RESULTS DRYER STACK MANUAL SAMPLES TABLE 17: TEST RESULTS DRYER STACK GASES LIST OF FIGURES FIGURE 1: KILN STACK RELEASE POINT (LEFT) AND DRYER STACK RELEASE POINT (RIGHT)... 8 FIGURE 2: BORAL WYEE SITE LOCATION... 8 FIGURE 3: FULL ISOKINETIC SAMPLING ASSEMBLY...10 FIGURE 4: KILN STACK GAS TRENDS Project ID R_0 v

6 1 INTRODUCTION Assured Monitoring Group (AMG) was appointed by Boral Roofing NSW to sample and analyse source emissions from the Wyee facility. The sources sampled included a kiln stack emission point and dryer release point. Sampling was conducted by AMG on the 18 th & 19 th July 2017 during typical site operations. AMG was responsible for the collection and analysis of samples, unless otherwise indicated. The samples were recovered and stored in the appropriate manner until their return to the laboratory where the samples were prepared and analysed according to the methodologies listed below in this report. This test program was conducted to satisfy the conditions detailed in the recent Wyee Environment Protection Licence (#2702 March 2017) issued to Boral Montoro Pty Limited for their facility located at Toomey s Road East, Bushels Ridge. The table below details the sampling program as conducted on this occasion. Table 5: Sampling schedule Parameter Kiln stack - EPA Point 4 Dryer Stack - EPA Point 6 Particulate matter total 1 1 Sulphur dioxide SO Oxides of nitrogen (as NO2) 1 1 Sulphuric acid mist SO Fluoride - total 1 1 Particulate matter PM Project ID R_0 6

7 2 METHODOLGY & EQUIPMENT 2.1 Sampling methodology All sampling and analysis was carried in accordance to the listed requirements in Table 6. Any specific method comments have been documented where required. Table 6: Test methods Parameter Reference Test Method NSW EPA TM Notes Analysis Sample plane criteria AS TM-1 A 1 Flow rate, temperature and velocity USEPA Method 2 TM-2 nil 1 Stack gas molecular weight USEPA Method 3 TM-23 B 1 Oxygen (O 2) USEPA Method 3A TM-25 B 1 Carbon dioxide (CO 2) USEPA Method 3A TM-24 B 1 Moisture content USEPA Method 4 TM-22 nil 1 Total solid particulates AS TM-15 nil 1 Sulphur dioxide SO 2 USEPA Method 6 TM-4 nil 1 Oxides of nitrogen (as NO2) USEPA Method 7E TM-11 B 1 Sulfuric acid mist SO 3 USEPA Method 8 TM-3 nil 1 Fluoride total USEPA Method 13B TM-9 nil 2 Particulate matter PM 10 USEPA Method 201A OM-5 nil 3 Table 7: Sampling notes Note A Comment Sample location on the dryer release point is compliant but non-ideal as per AS The sample location is greater than two, but less than six diameters downstream from a disturbance. The temperature and velocity survey showed that the sample position was in compliance to items (a) to (f) as per AS B Analyser calibration pre and post field work in our laboratory. Table 8: Analysis notes Note Company Work performed NATA ID Report Number 1 Assured Monitoring Group Sampling & analysis EnviroLab Services Fluoride analysis R00 3 Particulate & surface sciences Analysis a / a A particulate sample was collected isokinetically from the stack, with the particulate catch then being analysed by particle counting instruments for determination of particle size distribution. The percentage of particles less than 10μm in size was then applied to the total particle matter result to determine the PM10 fraction of the total catch. Project ID R_0 7

8 2.2 Sample Location The figures below show the site and sample location. Figure 1: Kiln stack release point (left) and dryer stack release point (right) Figure 2: Boral Wyee site location Project ID R_0 8

9 Table 9: Sample location summary Sample location Kiln Stack Dryer Stack Stack Shape CIRCULAR CIRCULAR Stack Diameter (m) Stack Cross Section Area (m 2 ) Distance to upstream disturbance (m) Diameters (D) Distance to downstream disturbance (m) Diameters (D) Total traverse point factors 1, 1, 1, , 1, 1.1, 16 Port size (mm) Port Thread Type BSP BSP Number of traverses 2 2 Number of points per traverse 6 8 Total number of traverse points Flow & temperature compliance check YES YES 2.3 Plant operational data The table below summarises the plant operation data at the time of sampling. Table 10: Production details Item Cars per shift 15 Project ID R_0 9

10 2.4 Test equipment The sampling equipment was transported to site and specifically setup at the test location. Sampling was performed using one complete isokinetic sampling train with an out-of-stack heated filter. All equipment used during the course of the testing is sourced from Apex Instruments, an industry leader in the supply of source testing equipment. Figure 3: Full isokinetic sampling assembly Project ID R_0 10

11 3 QUALITY ASSURANCE & QUALITY CONTROL (QA/QC) AMG operates within a quality system based upon the requirements of ISO Our quality system defines specific procedures and methodologies to ensure any project undertaken by AMG is conducted with the highest level of quality given the specific confines of each project. The overall objective of our QA/QC procedures is to representatively sample and accurately analyse components in the gas streams and therefore report valid measurements of emission concentrations. To ensure representativeness of field work, our quality procedures target: 1. Correct sampling locations 2. Sample time 3. Frequency of samples and 4. Method selection & adherence To ensure representativeness of lab work, our quality procedures target: 1. Sample preservation 2. Chain of custody (COC) 3. Sample preparation and 4. Analytical techniques AMG maintains strict quality assurance throughout all its sampling programs, covering on-site field work and the analytical phase of our projects. Our QA program covers the calibration of all sampling and analytical apparatus where applicable and the use of spikes, replicate sample and reference standards. The test methodologies used for this project are outlined in section 2 of this document. Field test data has been recorded and calculated using direct entry into Microsoft Excel spreadsheets following the procedures of the appropriate test methods. Determination of emission concentrations has been performed using the same Microsoft Excel spreadsheets which are partially supplied as an attachment to this report. More detailed information can be supplied upon request. QA/QC checks for this project will use validation techniques and criteria appropriate to the type of data and the purpose of the measurement to approve the test report. Records of all data will be maintained. Complete chain of custody (COC) procedures has been followed to document the entire custodial history of each sample. The COC forms also served as a laboratory sheet detailing sample ID and analysis requirements. Table 11: Sampling data QA/QC checklist Sampling Data QA/QC Checklist Use of appropriate test methods Normal operation of the process being tested Use of properly operating and calibrated test equipment Use of high purity reagents Performance of leak checks post sample (at least) Table 12: Laboratory data QA/QC checklist Laboratory Data QA/QC Checklist Use of appropriate analytical methods Use of properly operating and calibrated analytical equipment Precision and accuracy comparable to that achieved in similar projects Accurate reporting Comment Yes Yes as instructed by client Yes Yes Yes Comment Yes Yes Yes Yes Project ID R_0 11

12 4 DEFINITIONS The following terms and abbreviations may be used in this report: Table 13: Definitions Symbol Definition < The analytes tested for was not detected; the value stated is the reportable limit of detection Am 3 AS BH o C CARB dscm FH f/ml g kg m m 3 mbar mg min ml mmh 2O Mole N/A ng NATO NIOSH Nm 3 NMI NM VOC NR OSHA ou PCDD PCDF PM ppb ppm sec Sm 3 STP TO TWA USEPA Gas volume in cubic metres at measured conditions Australian Standard Back half of sample train (filter holder and impingers) (referred to during sample recovery) Degrees Celsius California Air Resources Board methods dry standard cubic meters Front half of sample train (probe and filter holder) (referred to during sample recovery) Fibres per millilitre Grams Kilograms Metres actual gas volume in cubic metres as measured Millibars Milligrams (10-3 grams) Minute Millilitres Millimetres of water SI unit that measures the amount of substance Not applicable Nanograms (10-9 grams) North Atlantic Treaty Organisation National institute for occupational safety and health (USA) Gas volume in dry cubic metres at standard temperature and pressure (0 C and kpa) National Measurement Institute Non methane volatile organic compound Not required on this occasion Occupational Safety and Health Act Odour unit Polychlorinated dibenzo-p-dioxin Polychlorinated dibenzofuran Particulate matter Parts per billion Parts per million Second Gas volume in dry cubic metres at standard temperature and pressure (0 C and kpa) and corrected to a standardised value (e.g. 15% O 2) Standard temperature and pressure (0 C and kpa) USEPA air toxics method Time weighted average United States Environmental Protection Authority Project ID R_0 12

13 5 RESULTS Table present a summary of the isokinetic and gases analyser sample runs. Table 14: Test results Kiln stack manual samples Unit sampled Kiln Scrubber Stack Sampling date 18/07/ /07/ /07/ /07/ /07/2017 Begin sampling time 10:30 12:25 10:30 10:30 10:30 Units End sampling time 11:30 13:25 11:30 11:30 11:30 Equipment rated capacity Not specified Equipment load during sampling 41 cars per shift Sampling plane diameter 970 mm Sampling plane area 0.74 m 2 Sampling port size, number and depth 100, 2, 130 mm, -, mm Duct orientation and shape Vertical, Circular - No. of traverse points sampled 12 - Parameters Units PM total F total SO 2 SO 3 (as H 2SO 4) PM 10 Average results Temperature C Carbon dioxide vol-% Oxygen vol-% Stack gas water vapour vol-% Gas molecular weight - dry g/g mole Gas density - dry kg/m Average velocity m/s Volumetric flow rate - actual, wet m 3 /min Volumetric flow rate - dry & STP dsm 3/ min Total sampling time min Isokinetic rate (90%-110%) % Isokinetic rate (80%-120%) % Cut point µm Results mg/nm Release limit mg/nm Emission rate Project ID R_0 13

14 Table 15: Test results Kiln stack gases Unit sampled Kiln Scrubber Stack Sampling date Begin sampling time 12:19:17 End sampling time 14:23:31 Equipment rated capacity Not specified Equipment load during sampling 41 cars per shift Parameters Units Temperature C 150 Carbon dioxide vol-% 2.0 Oxygen vol-% 17.7 Stack gas water vapour vol-% 5.9 Gas molecular weight - dry g/g mole 29.0 Gas density - dry kg/m Average velocity m/s 14 Volumetric flow rate - wet m 3 /min 639 Volumetric flow rate - dry dsm 3/ min 389 Sampling time min 2:04:14 Sample result Release Limit Carbon monoxide (CO) mg/nm Emission rate g/s Sample result Release Limit Nitrogen Oxides (NOx as NO 2) mg/nm ,500 Emission rate g/s Project ID R_0 14

15 Table 16: Test results Dryer stack manual samples Unit sampled Dryer (EF-VE-2) Sampling date 19/07/ /07/ /07/ /07/ /07/2017 Begin sampling time 9:10 10:30 9:10 9:10 9:10 Units End sampling time 10:10 11:30 10:10 10:10 10:10 Equipment rated capacity Not specified Equipment load during sampling Normal operation Sampling plane diameter 890 mm Sampling plane area 0.62 m 2 Sampling port size, number and depth 100, 2, 90 mm, -, mm Duct orientation and shape Vertical, Circular - No. of traverse points sampled 16 - Parameters Units PM total F total SO 2 SO 3 (as H 2SO 4) PM 10 Average results Temperature C Carbon dioxide vol-% Oxygen vol-% Stack gas water vapour vol-% Gas molecular weight - dry g/g mole Gas density - dry kg/m Average velocity m/s Volumetric flow rate - wet m 3 /min Volumetric flow rate - dry dsm 3/ min Sampling time min Isokinetic rate (90%-110%) % Isokinetic rate (80%-120%) % Cut point µm Results mg/nm 3 < < < Release limit mg/nm Emission rate g/s < < < Project ID R_0 15

16 Table 17: Test results Dryer stack gases Unit sampled Dryer (EF-VE-2) Sampling date Begin sampling time 9:04:50 End sampling time 9:56:50 Equipment rated capacity Not specified Equipment load during sampling Normal operation Parameters Units Temperature C 22 Carbon dioxide vol-% 0.00 Oxygen vol-% 21.0 Stack gas water vapour vol-% 4.0 Gas molecular weight - dry g/g mole 28.8 Gas density - dry kg/m Average velocity m/s 7.1 Volumetric flow rate - wet m 3 /min 265 Volumetric flow rate - dry dsm 3/ min 235 Sampling time min 0:52:00 Concentration Release Limit Carbon monoxide (CO) mg/nm 3 < Emission rate g/s < Concentration Release Limit Nitrogen Oxides (NOx as NO 2) mg/nm 3 < Emission rate g/s < Project ID R_0 16

17 CO2 & O2 - % CO & NOx - ppm Source Emissions Monitoring Boral Wyee Figure 4: Kiln stack gas trends 25 Gases Trend CO2 O2 CO NOx Project ID R_0 17