a case study: tomago aluminium smelter

1
Sources of SO 2 2 oven stacks (BO1 & BO2) constant emissions average emission rate Fugitive emissions from bake oven buildings several volume sources with hourly emissions file with constant emissions and modelled 10°C above ambient 7 Gas treatment stacks constant emissions average emission rate Overview A review of the monitoring data found: 21 exceedances of 24-hr SO 2 at School Drive 9 exceedances of 24-hr SO 2 at the Farm No exceedances of 1-hr SO 2 standard at any site during these periods Exceedances occurred during extended periods of strong westerly winds (prevalent in winter months) Previous air dispersion modelling of the site did not highlight these meteorological conditions as a potential issue Measured SO 2 concentrations at the Highway, Laverick Avenue and at the Met station comply with 1-hr and 24-hr SO 2 NEPM standard of 570 μg/m 3 and 228 μg/m 3 , respectively A CASE STUDY: TOMAGO ALUMINIUM SMELTER Further information Katestone has been a leading provider of expert air quality and meteorology services since 1989. It now assists clients with sustainability, climate change and energy. Located in Brisbane, our team of 20 professionals have established an enviable reputation for high quality advice to clients in the mining, energy, heavy industry, government and agricultural sectors. Our long list of loyal clients is a testament to the principled way in which we conduct our business. P (07) 3369 3699 Donnelly, Sarah-Jane 1 , Shaw, Natalie 2 , Killip, Christine 3 , Roser, Neil 4 1 Senior Consultant, Katestone Environmental, Brisbane 2 Principal Consultant, Katestone Environmental, Brisbane 3 Managing Director, Katestone Environmental, Brisbane 4 Environment Services Team Leader, Tomago Aluminium Company, Newcastle Dispersion modelling Objective: Determine the source of 24-hour exceedances of SO 2 TAC ambient monitoring for SO 2 consists of five sites within 1.1 km of the site, with monitoring Analysis of measured data 30 May 2 Aug 12 Aug 16 Aug 24 Aug 26 Aug 27 Aug 16 Sep 22 Jun 9 Jul 11 Jul 12 Jul Carbon Bake Fugitive 59.9 42.8 46.4 61.8 65.6 37.4 56.9 45.1 39.0 44.9 62.5 40.4 Gas Treatment Stacks 13.2 20.4 18.4 19.9 20.9 23.0 19.3 26.3 7.8 11.8 12.3 19.9 Bake Oven Stacks 51.1 51.3 51.2 68.3 75.3 35.4 64.6 46.0 54.6 63.3 77.9 69.6 0 20 40 60 80 100 120 140 160 180 Concentration of SO 2 (μg/m 3 ) Modelled source contribution of 24-hour average SO 2 at the School monitoring station The analysis of monitoring data suggests: A wake effected stack source Direction of source consistent with bake ovens Wind tunnel modelling Emissions Sources of SO 2 2 Bake oven stacks (BO1 & BO2) constant emissions average emission rate Fugitive emissions from bake oven buildings several volume sources with hourly emissions file with constant emissions and modelled 10°C above ambient 7 Gas treatment stacks constant emissions average emission rate Risk Assessment Modelled met file Building wakes Source configuration Stack tip downwash Shut down of bake ovens Met file representative of site Important to local dispersion Roof vents modelled as several volume sources May be important Residual emissions occur 1- Hazard identification Recognise that there are exceedances and therefore a hazard 4- Risk characterisation The risk assessment was expressed as a hazard index for each sulphur dioxide air quality criteria and averaging period The hazard index was calculated as follows: Where: HI is the hazard index Max C i is the maximum concentration measured (or predicted by dispersion model) in a zone for a particular pollutant averaging period i AQCi is the air quality criteria for the pollutant Max C i for averaging period i Conclusions: TAC should consider options for mitigating potential impacts at residences within 1 km to the east of the smelter. TAC should consider undertaking further investigation of sulfur dioxide levels at the Detention Centre. 2- Assessment of exposure Identification of sensitive receptor locations 3- Dose response assessment Evaluate the qualitative and quantitative toxicity information to estimate the incidence of adverse effects occurring in humans at different exposure levels 0 2 4 6 8 10 12 0 45 90 135 180 225 270 315 360 Wind Speed (m/s) Wind Direction (°) Hour Wind direction Wind speed 0 100 200 300 400 500 600 Concentration (μg/m³) Hour School Drive Farm Contour of scaled up predicted maximum 24- hour average SO 2 ground-level concentrations to match measurements. Shows the area of potential exceedance or the areas ‘at risk’ Results showed a number of receptors in zone 1 were at risk Sources of SO 2 2 Bake oven stacks (BO1 & BO2) Fugitive emissions from bake oven buildings 7 Gas treatment stacks Fugitive emissions: Investigated side and roof vents Side vents not a source of emissions during event days Emissions measurement: BO1, roof vents and gas treatment stacks 0 5 10 15 20 25 30 35 40 0 100 200 300 400 500 600 700 800 Emission rate (g/s) Concentration (mg/m³) SO2 concentration (mg/m3) Emission rate (g/s) Bake oven 1 emissions variability Side vents on bake oven building Sarah-Jane Donnelly Outcome: Main source is the gas treatment stacks (290° to 310°) Bake oven stacks resulted in lowest concentrations Fugitive sources impact at wind speeds of < 5 m/s Outcome: Modelling replicated the general trend but concentrations were underestimated Major sources were the bake oven stacks and roof vents Investigated: Outcome: Five SO 2 monitors and met station School Drive The Farm Evaluation of hazard index

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Poster presentation delivered at the 2013 CASANZ conference by Katestone Senior air quality consultant Sarah Jane Donnelly. The poster presents a case study for the Tomago Aluminium Smelter to investigate the cause of exceedances of the 24-hour average air quality standard for sulfur dioxide.

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Page 1: A Case Study: Tomago Aluminium Smelter

Sources of SO2

2 oven stacks (BO1 & BO2) – constant emissions average emission rate Fugitive emissions from bake oven buildings – several volume sources with hourly emissions file with constant emissions and modelled 10°C above ambient 7 Gas treatment stacks – constant emissions average emission rate

Overview

A review of the monitoring data found:

• 21 exceedances of 24-hr SO2 at School Drive

• 9 exceedances of 24-hr SO2 at the Farm

• No exceedances of 1-hr SO2 standard at any site during these periods

• Exceedances occurred during extended periods of strong westerly winds (prevalent in winter months)

• Previous air dispersion modelling of the site did not highlight these meteorological conditions as a potential issue

• Measured SO2 concentrations at the Highway, Laverick Avenue and at the Met station comply with 1-hr and 24-hr SO2 NEPM standard of 570 µg/m3 and 228 µg/m3, respectively

A CASE STUDY: TOMAGO ALUMINIUM SMELTER

Further information Katestone has been a leading provider of expert

air quality and meteorology services since 1989.

It now assists clients with sustainability, climate

change and energy. Located in Brisbane, our

team of 20 professionals have established an

enviable reputation for high quality advice to

clients in the mining, energy, heavy industry,

government and agricultural sectors. Our long

list of loyal clients is a testament to the

principled way in which we conduct our

business.

P (07) 3369

3699

Donnelly, Sarah-Jane1, Shaw, Natalie2, Killip, Christine3, Roser, Neil4

1 Senior Consultant, Katestone Environmental, Brisbane 2 Principal Consultant, Katestone Environmental, Brisbane 3 Managing Director, Katestone Environmental, Brisbane 4Environment Services Team Leader, Tomago Aluminium Company, Newcastle

Dispersion modelling

Objective: Determine the source of 24-hour exceedances of SO2

TAC ambient monitoring for SO2 consists of five sites within 1.1 km of the site, with monitoring

Analysis of measured data

30 May 2 Aug 12 Aug 16 Aug 24 Aug 26 Aug 27 Aug 16 Sep 22 Jun 9 Jul 11 Jul 12 Jul

Carbon Bake Fugitive 59.9 42.8 46.4 61.8 65.6 37.4 56.9 45.1 39.0 44.9 62.5 40.4

Gas Treatment Stacks 13.2 20.4 18.4 19.9 20.9 23.0 19.3 26.3 7.8 11.8 12.3 19.9

Bake Oven Stacks 51.1 51.3 51.2 68.3 75.3 35.4 64.6 46.0 54.6 63.3 77.9 69.6

0

20

40

60

80

100

120

140

160

180

Co

nce

ntr

ati

on

of SO

2(µ

g/m

3)

Modelled source contribution of 24-hour average SO2 at the School monitoring station

The analysis of monitoring data suggests:

• A wake effected stack source

•Direction of source consistent with bake ovens

Wind tunnel modelling

Emissions

Sources of SO2

2 Bake oven stacks (BO1 & BO2) – constant emissions average emission rate Fugitive emissions from bake oven buildings – several volume sources with hourly emissions file with constant emissions and modelled 10°C above ambient 7 Gas treatment stacks – constant emissions average emission rate

Risk Assessment

Modelled met file Building wakes Source configuration Stack tip downwash Shut down of bake ovens

Met file representative of site Important to local dispersion Roof vents modelled as several volume sources May be important Residual emissions occur

1- Hazard identification Recognise that there are exceedances and therefore a hazard

4- Risk characterisation The risk assessment was expressed as a hazard index for each sulphur dioxide air quality criteria and averaging period The hazard index was calculated as follows: Where: HI is the hazard index Max Ci is the maximum concentration measured (or predicted by dispersion model) in a zone for a particular pollutant averaging period i AQCi is the air quality criteria for the pollutant Max Ci for averaging period i

Conclusions: TAC should consider options for mitigating potential impacts at residences within 1 km to the east of the smelter. TAC should consider undertaking further investigation of sulfur dioxide levels at the Detention Centre.

2- Assessment of exposure Identification of sensitive receptor locations

3- Dose response assessment Evaluate the qualitative and quantitative toxicity information to estimate the incidence of adverse effects occurring in humans at different exposure levels

0

2

4

6

8

10

12

0

45

90

135

180

225

270

315

360

Win

d S

pe

ed

(m/s)W

ind

Dir

ect

ion

(°)

Hour

Wind direction Wind speed

0

100

200

300

400

500

600

Co

nce

ntr

ati

on

g/m

³)

Hour

School Drive Farm

Contour of scaled up predicted maximum 24-hour average SO2 ground-level concentrations to match measurements. Shows the area of potential exceedance or the areas ‘at risk’

Results showed a number of receptors in zone 1 were at risk

Sources of SO2

•2 Bake oven stacks (BO1 & BO2) •Fugitive emissions from bake oven buildings •7 Gas treatment stacks

Fugitive emissions: Investigated side and roof vents Side vents not a source of emissions during event days

Emissions measurement: BO1, roof vents and gas treatment stacks

0

5

10

15

20

25

30

35

40

0

100

200

300

400

500

600

700

800

Emissio

n rate

(g/s)

Co

nce

ntr

ati

on

(m

g/m

³)

SO2 concentration (mg/m3) Emission rate (g/s)

Bake oven 1 emissions variability

Side vents on bake oven building

Sarah-Jane Donnelly

Outcome: •Main source is the gas treatment stacks (290° to 310°) •Bake oven stacks resulted in lowest concentrations •Fugitive sources impact at wind speeds of < 5 m/s

Outcome: •Modelling replicated the

general trend but concentrations were

underestimated •Major sources were the bake

oven stacks and roof vents

Investigated: Outcome:

Five SO2 monitors and met station

School Drive

The Farm

Evaluation of hazard index