20 June 2013Prague, Czech Republic
Russell KempAtlanta, Georgia [email protected]
Advances in US Lead ProducerEmission Controls
2
Overview and Update
• New rules in US spurring substantial spending on additional emission controls
• 2008 revision to National Ambient Air Quality Standard for Lead– Ten-fold reduction to 0.15 ug/m3 three-month rolling avg.– Currently in implementation phase
• 2012 revision to National Emission Standard for Hazardous Air Pollutants for both primary and secondary lead smelting– Secondary Lead compliance Deadline January 2014
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Fugitive Emission Controls
• Key element in achieving low ambient fenceline concentrations is reduction of fugitive emissions – driven by the lowered ambient standard
• New Emission Standard includes requirement to place all furnace operations, battery breakers, and feed storage rooms within negative pressure enclosures– To 0.007 inches water (0.013 mmHg, 1.7 Pa)– Continuously monitored
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New, large full process enclosures being constructed (Battery Wrecker Enclosure)
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A “before” view
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An “after” view
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Ambient monitoring network
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Ambient Monitor Results
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Stack Emission Progress
• New Secondary Lead Emission Standard– Cuts allowed stack exhaust concentration from
2 mg/dscm Pb to 1 mg/dscm for any one stack• Facility-wide, airflow-weighted average limited to 0.2
mg/dscm
• Growing deployment of secondary (post-baghouse) HEPA filtration– For both goals, the new ambient standard and the new
emission standard
• Lowest metals emission rates being achieved by Wet Electrostatic Precipitators downstream of baghouses
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Wet Electrostatic Precipitator (WESP)
• WESP installation completed at two US facilities, with third unit in final design phase followed by construction. WESP utilized to remove unfilterable sub-micron particles, including arsenic, and condensable gases.
• WESP downstream of conventional baghouses for all process emissions from dryer, furnaces & refinery kettles. Total Pb emissions from WESP < 2.3 kg/yr (<5 lb/yr).
• Balance of facility ventilation systems provide negative pressure for all total enclosures housing processes and equipped with HEPA secondary filtration.
• WESP and HEPAs support potential of < 11.3 kg/yr (25 lb/yr) facility-wide lead emissions from large capacity facilities.
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WESP Installation 1, nominal 100,000 cfm (170,000 m3/hr)
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WESP Installation 2, nominal 130,000 cfm (220,000 m3/hr)
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WESP Performance (Installation 1)
Note: Installation 2 exhibits comparable results
614.95
8.58 0.81 1.22 3.59 1.800
100
200
300
400
500
600
700
pre-WESP Nov-08 Jun-09 Nov-09 Nov-10 Oct-12 (Est.)
Lead (Pb) Emissions
Lead (Pb) lbs/yr
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WESP Performance (Installation 1)Note: Installation 2 exhibits comparable results
96.01
8.67 4.56 1.59 2.89 5.630
20
40
60
80
100
120
pre-WESP Nov-08 Jun-09 Nov-09 Nov-10 Oct12 (Est.)
Arsenic (As) Emissions
Arsenic (As) lbs/yr
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US EPA Moving to Retain Ambient Lead Standard
• National Ambient Air Quality Standards (NAAQS) must be reviewed every five years
• EPA is in midst of review of the 2008 lowered standard
• On 05 May 2013, EPA’s full Clean Air Scientific Advisory Committee approved its Lead Review Panel’s conclusion that the available scientific evidence does not support revising the Pb NAAQS.
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Dry scrubbing
To close with a cross-media development:
Facility required to eliminateSalt discharges to surface water
Eliminated up-front feed desulfurization, which generated sulfate water discharge
Installed dry lime scrubber downstream of primary metal emission control baghouse to control SO2
All while EPA’s new 1-hour SO2 NAAQS being implemented