2010 voc workshop session 1d: fugitive emissions definitions, measurement and verification david...

2010 VOC WorkshopSession 1D: Fugitive emissions – definitions, measurement and verification

David Knight

Belgium - Flemish Government Environment, Nature and Energy departmentAir, Nuisance, Risk Management, Environment and Health DivisionKoning Albert II-laan 20, bus 8, 1000 BrusselTel. 02 553 11 34 – Fax. 02 553 11 [email protected]

mailto:[email protected]



2010 VOC WORKSHOP: SESSION 1D 17-18/06/2010

Mass balance of solvent based printing Mass balance of solvent based printing with incinerationwith incineration

I = Input Solvent consuming Installation

OUTPUTO1 = waste gases (stack)O2 = solvents in waste waterO3 = residual solvent in productO4 = fugitive emissionsO5 = destroyed/capturedO6 = solvent in wasteO7 = solvent in products (e.g. paints)O8 = recovered solvents for reuseO9 = other

Simplified exampleSolvent based printing: O4 = fugitive emissionsO5 = destroyed/captured O1, O2, O3, O6, O7, O8 = marginal

Fugitive emission = O4 = I – O5

ELV and BATAELELV: 100 mg C / Nm3 20% of solvent input Reduction scheme: 25% * (4*solids) BREF: 7,5 – 12,5 % * (4*solids)


Solvent based printing:Solvent based printing:flexography, rotogravure, laminating, flexography, rotogravure, laminating, varnishing (> 200 ton/year)varnishing (> 200 ton/year)

I = 100% O4 = 10%

O5 = 90 %

BREF BATAEL: 7,5 - 12,5 % In IPPC permits: 10% of reference emission Solvent based printing => incineratorFloor extraction + cleaning machines => incinerator

Solvent based flexography, rotogravure, laminating, varnishing


[O4 = I – O5] in practice

Unit Value Deviation

Min. Max.

Flowrate m3/h 50.000

Concentration g/m3 5

Operation Hours 3400

O5 Ton/year 850 10% 765 935

Input Ton/year 1000

O4 Ton/year 150 235 65

O4 % of solvent input

15 23,5 6,5

POSSIBLE SOLUTION = MEASURE O4 INSTEAD OF O5


[O4 = I – O5] in practice

Possibility 1Printing room with negative pressure due to extraction, all extraction to incinerator

Possibility 3Printing room under pressure / no pressure

NO PROBLEMCan be tested with e.g. smoke

PROBLEMATICEmissions through doors, windows

Possibility 2Printing room with negative pressure due to extraction, not all extraction to incinerotor

Emission through ventitlation shaftsCan be tested with e.g. smokeVentilation shafts can be measured


Possibility 3: several methods tested Possibility 3: several methods tested during 1 production day (VITO during 1 production day (VITO

Method 1: input + passive sampling Method 2: input + portable FIDMethod 3: FID for O5 and passive sampling for O4Method 4: FID for O5 and portable FID for O4 Method 5: portable FID for O4 and O5Method 6: theoretical estimation based on specifics of printing machines and used solvents


Method 1: Method 1: solvent input + passive sampling solvent input + passive sampling

I O4 Solvent based flexography, rotogravure, laminating, varnishing

O5

Solvent input measured O4 measured with passive sampling O4 = 11% of solvent input


Method 1: Method 1: solvent input + passive sampling solvent input + passive sampling


Method 5: Method 5: Portable FID Portable FID

Input O4 Solvent based flexography, rotogravure, laminating, varnishing

O5

O4 and O5 with portable FID 2 measurements for each source O4 + O5 = 100% O4 = 14,9 %


Method 6: Method 6: Theoretical estimation Theoretical estimation

Theoretical percentages based on the following assumptions: Completely covered ink fountain = 0% Adequate coverage of ink fountains = 2,5% Chamber doctor blades = 2,5% Open ink fountain = 5% Disfunctioning of incinerator = 0,29% Cleaning machine not connected = 5% Residual solvent in products = 2,5% ect.

Estimation of solvent use for every machine

Combination of this information leads to emission estimate of 9,6 %


Method 2: Method 2: solvent input + FID solvent input + FID


O5

solvent input measured O4 measured with portable FID


Method 3: Method 3: Passive sampling + FID Passive sampling + FID


O5

O4 with passive sampling O5 with FID continuous measurement Solvent input = O4 + O5


Method 4: Method 4: FID + portable FID FID + portable FID


O5

O4 with portable FID: 4 measurements O5 with FID: continuous measurement Solvent input = O4 + O5


Method % 95% confidence

%

Cost

1 input + passive 13 26 ++++2 input + port FID 31 10 Not representative for

entire period+++

3 passive + FID 9 260 Not useful ++++

4 FID + port FID 20 107 Not useful +++

5 port FID 15 - ++6 theoretical 10 - +


Conclusions solvent based printing Conclusions solvent based printing

O4 = I – O5 does not always work in practice

Measuring O4 is in some cases a robust and feasible solution

Measuring O4 can however be expensive and labour intensive

For extrapolation from 1 day measurement to an entire year stable ventilation and printing specifics are needed

Measuring does not reduce emissions

Alternative approach: estimation based on reduction measures applied?


Mass balance of paint/ink production Mass balance of paint/ink production with incinerationwith incineration

I = Input Solvent consuming installation

OUTPUTO1 = waste gases (stack)O2 = solvents in waste waterO3 = residual solvent in productO4 = fugitive emissionsO5 = destroyed/capturedO6 = solvent in wasteO7 = solvent in products (e.g. paints)O8 = recovered solvents for reuseO9 = other

Simplified examplePaint/ink production : 01 = waste gasesO4 = fugitive emissionsO5 = destroyed/capturedO7 = solvent in product O2, O3, O6, O8, O9 = marginal

Emission = O1 + O4 = I – O5 – O7

ELV 150 mg C / Nm3 AND 3% of solvent input 3% of solvent input


O1 + O4 = I – O5 – O7

Unit Value Deviation

Min. Max.

I = INPUT Ton/year 10.000 1% 10.100 9.900

O7 = PRODUCT Ton/year 9.700 1% 9.603 9.797

O5 = INCINERATOR Ton/year 100 10% 90 110

O1 + O4 Ton/year 200 >100% 407 23

O1 + O4 % of input 4% 0%

POSSIBLE SOLUTION = MEASURE O4 INSTEAD OF O1 AND O7


Paint and ink production: estimation of Paint and ink production: estimation of emissions at 3 plants in Belgium emissions at 3 plants in Belgium

Plant 1 O1 + O4 = I – O5 – O7

Plant 2 Uses results of monitoring of working environment Twice a year employees wear passive sampling badges For every production area, the ventilation frequency is known (e.g. air is refreshed 6 times per hour) Concentration and ventilation combined give an estimate of mass flux for every area

Plant 3 All emissions are lead through ventilation shafts All emissions are measured at least once a year Continuous paint production Difference between mass balance and measurement = 85%

2010 voc workshop session 1d: fugitive emissions definitions, measurement and verification david...

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