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MONITORING REPORT

Petrotemex Energy Integration Project

1

Grupo Petrotemex S.A. de C.V.

Verification Plus

Monitoring Report

of

Petrotemex Energy Integration Project UNFCCC Number: 1453

Version 04

22/12/2008

Monitoring period 20/11/2007 to 4/05/2008

Project location Grupo Petrotemex, S.A. de C.V.

Belisario Domínguez 2002, Colonia Obispado

Nuevo León, Mexico

http://www.alfa.com.mx

Prepared by MGM International Group LLC

501 Brickell Key Dr, Suite 202

Miami, FL 33131

http://www.mgminter.com

2

TABLE OF CONTENTS

TABLE OF CONTENTS ........................................................................................ 2

1 INTRODUCTION ........................................................................................... 3

2 REFERENCE .................................................................................................. 3

3 GENERAL DESCRIPTION OF THE PROJECT ACTIVITY ..................... 3

3.1 OBJECTIVES OF THE PROJECT............................................................ 3

3.2 PROJECT PARTICIPANTS ...................................................................... 4

3.3 TECHNICAL DESCRIPTION OF THE PROJECT ................................. 5

4 PROJECT LOCATION .................................................................................. 6

5 CURRENT STATUS OF THE PROJECT ..................................................... 6

6 MONITORING PLAN .................................................................................... 6

6.1 DATA MONITORED .................................................................................. 6

6.2 QUALITY CONTROL (QC) AND QUALITY ASSURANCE (QA) ........12

6.3 FIXED PARAMETERS .............................................................................12

6.4 OPERATIONAL AND MANAGEMENT STRUCTURE .........................12

6.5 MEASURING INSTRUMENTS ................................................................14

6.6 CALIBRATION EQUIPMENT .................................................................15

6.7 MAINTENANCE PROCEDURES ............................................................17

6.8 SPREADSHEET MODELS .......................................................................17

7 ENVIRONMENTAL IMPACT .....................................................................19

8 EQUATIONS USED FOR CALCULATION OF EMISSION

REDUCTIONS .......................................................................................................19

9 EMISSION REDUCTION CALCULATION................................................23

MONITORING REPORT


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1 INTRODUCTION

The objective of this Monitoring Report is to show the calculation of the emission reductions

achieved by the project activity under the Voluntary Market and verified by a Designated

Operational Entity.

The monitoring period is from 20/11/2007 to 4/05/2008 (both days included).

The report also shows the Monitoring and Verification Plan for data collection and auditing

followed by the project developer in order to determine real and credible emission reductions.

2 REFERENCE

The monitoring plan is in accordance with the registered project design document of

Petrotemex Energy Integration Project, Version 10 of 08/02/20081, that uses existing baseline

and monitoring methodologies (AM0018/Version01.1 of 06/12/2004 and

ACM0004/Version02 of 03/03/2006), which have been approved and made publicly available

by the CDM Executive Board. The methodologies are designated “Methodology for steam

optimization systems” and “Consolidated methodology for waste gas and/or heat and/or

pressure for power generation”.

According to the methodology ACM0004/Version02, the emission factor of the grid is

determined using the methodology ACM0002/Version06 of 19/05/2006.

3 GENERAL DESCRIPTION OF THE PROJECT ACTIVITY

3.1 OBJECTIVES OF THE PROJECT

The project activity aims at reducing GHG emissions (mainly carbon dioxide and, to a lesser

extent, methane and nitrous oxide) through the implementation of a series of mitigation

measures that involve fuel and electricity savings as well as the installation of new electricity

self-generation equipment.

These goals will be achieved through a process of energy integration, leading to lower

consumption of steam from boilers and lower electricity demand to the national grid, thus

reducing overall fuel usage. Besides, additional power will be generated using remaining low-

quality steam produced from waste heat of the production process.

Petrotemex will lead this project activity that involves its production plants of Pure

Terephthalic Acid (PTA), located at Cosoleacaque and Altamira, in Mexico.

Petrotemex is a business of Alpek Group, subsidiary of Alfa, oriented to the production of

raw materials for polyester yarn, Polyethylene terephthalate (PET) and other products.

The project activity generates the inherent benefits of fuel and electricity savings, and clean

self-generation:

� Petrotemex technical staff has carried out studies in order to design the best option for

energy saving for each plant, which involves adaptation and transference of efficient

and clean technology to the productive sector.

1 http://cdm.unfccc.int/UserManagement/FileStorage/TYH8ELFNEMX7K4OBCQ93I48HVDE078

MONITORING REPORT


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� As a result of the project activity, there is an improvement in plant efficiency in a

thermodynamic sense, reducing fuel burning at the plant site, and reducing electricity

purchases, thus decreasing electricity generation outside the industrial facility.

� The energy savings obtained through the project activity contributes to the sustainable

use of natural resources, and to improve the environment by reducing emission of

pollutants and particulate matter in the air.

� The project activity generates economic benefits related to CDM and Voluntary

Market revenues. The benefit obtained by selling CERs and VERs will allow

Petrotemex to invest in further research and development and to cover part of the

initial investment and the unexpected costs of project implementation and operation.

� The project activity improves de air quality and the cleanliness of the work site, thus,

improving the labor and health conditions of the employees.

� The project activity provides job opportunities during the construction phase of the

project. About 100 new work positions are needed during this phase.

Thus, the project activity involves social, environmental, and economic benefits, contributing

to the sustainable development objectives of Mexican Federal and State authorities, in

accordance with the development plans of:

� Mexico (Plan Nacional de Desarrollo 2001-20062),

� Veracruz State (Plan Veracruzano de Desarrollo 2005-20103), and

� Tamaulipas State (Plan Estatal de Desarrollo 2005- 20104).

The project proponent has obtained the written approval of the Mexican DNA, confirming

that the project supports sustainable development.

3.2 PROJECT PARTICIPANTS

Organization: Grupo Petrotemex, S.A. de C.V.

Street/P.O.Box: Belisario Domínguez 2002, Colonia

Obispado

City: Nuevo León

Postfix/ZIP: 64060

Country: Mexico

Telephone: 52 81 8748-1355

FAX: 52 81 8748-2525

2 http://www.economia.gob.mx/pics/p/p1376/PLAN1.pdf

3 http://portal.veracruz.gob.mx/portal/page?_pageid=273,3913793&_dad=portal&_schema=PORTAL 4 http://www.tamaulipas.gob.mx/gobierno/plan_estatal/plan%20estatal%20de%20desarrollo.pdf)

MONITORING REPORT


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URL: http://www.alfa.com.mx

Name of the person in

charge Roberto Blanco Sánchez

Personal E-Mail: [email protected]

3.3 TECHNICAL DESCRIPTION OF THE PROJECT

The project activity involves the two PTA production plants of Petrotemex, one located in

Cosoleacaque and the other one in Altamira.

Cosoleacaque Plant

The project activity involves the reduction of overheated steam generation in boilers by

switching from the existing turbo-compressors to a new high-efficiency turbo-compressor.

The new turbine of such compressor will utilize surplus low-pressure steam from PTA

production process, instead of the overheated steam used by the existing compressors.

The project also involves the reduction of low-pressure steam consumption from the PTA

production process by increasing of low-pressure steam generation using waste heat from

such process. In order to achieve that, the following mitigation measures were carried out:

• Switching from binary distillation to azeotropic distillation in dehydration columns.

• Incorporation of a new process of thermo-compression of the steam used in the

reboiler of the dehydration tower.

• Switching the current dehydration columns’ condensers to new condensers that

generate low-pressure steam.

• Installation of new systems generating low-pressure steam using the heat released by

the oxidation reaction of p-xylene.

In addition, steam consumption is reduced by shutting down the low-pressure steam turbine

connected to turbo-compressor.

Due to the availability of the low-pressure steam flows mentioned above, the generated

energy surpasses the requirements of the new turbo-compressor. Thus, the project also

involves the installation of an electricity generator integrated to the new compression train to

obtain the complete use of energy.

Additionally, the project activity also involves changes in electricity consumption due to the

shutting down of the condenser fans of the dehydration towers, the moto-compressor, among

other equipment, and the installation of more-efficient new equipment like motors and pumps

(actually, there are electricity savings due to the project activity, but they are not considered

in the calculation of emission reductions as a conservative assumption).

Altamira Plant

The project activity involves the reduction of low-pressure steam consumption used as means

of heating the reboilers in dehydration column, by switching from binary to azeotropic

distillation. The more-efficient low- pressure steam generated by azeotropic distillation will

be used to generate electricity in a new turbo-generator, in order to obtain the complete use of

energy resulting from the availability of low-pressure steam flow mentioned above.

MONITORING REPORT


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The project activity also involves taking advantage of the additional energy benefits obtained

when expanding plant capacity to 900,000 tPTA/year in 2007, generating more steam that can

be used in the turbo-generator to produce additional power output. The proposed project

activity already considers such an expansion so as to capture these future benefits with no

additional investment.

4 PROJECT LOCATION

The project activity was implemented at the production facilities of Petrotemex, located in

Cosoleacaque and Altamira, in the States of Veracruz and Tamaulipas, respectively.

The exact coordinates of the project sites are 18° 1’ 56” North and 94° 35’ 43” West for

Cosoleacaque plant, and 22° 22’ 44’’ North and 97° 53’ 32’’ West for Altamira plant.

5 CURRENT STATUS OF THE PROJECT

In Cosoleacaque plant, the project activity started operating in the lately months of 2005 and

reach its stable operation on March 2006, while in Altamira plant, the project activity started

operating on January 2008.

The Petrotemex Energy Integration Project started operating in the lately months of 2005. A

first VER verification was done on 19/11/2007 under the VSC version 1.

The first voluntary crediting period started on 01/11/2005.

The CERs generation began on 05/05/2008, when the project was registered as a CDM

project activity.

6 MONITORING PLAN

6.1 DATA MONITORED

Since the monitoring plan of the proposed CDM project was not completely implemented

until the project was registered as CDM, the data used to determine the emission reductions

obtained from 20/11/2007 to 4/5/2008 was collected by Petrotemex’ staff following a

monitoring plan with some differences, comparing to the requirement of the methodologies

applied to the CDM project. In order to explain these minor differences, the registered

monitoring plan and the monitoring plan used in this monitoring period are shown in the

following tables.

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Cosoleacaque Plant

# Data

variable Data unit

Recording frequency

(registered

PDD)

Comment

(registered PDD)

Monitoring plan used in the monitoring period from

20/11/2007 to 4/5/2008

1 PTA

production tonne

every shift

PTA production in

Cosoleacaque plant.

Value determined by

mass balance based on

solids concentration and

flow rate feed to the purification reactors

(CR-202-A/B) of

Cosoleacaque plant.

Each reactor feed

pipeline have one Micro

Motion flow meter

(CWT-110 and CWT-

112A2). A third Micro

Motion (CWIC-201)

measures the solid

concentration in the

slurry drum (CD-101).

Value determined by mass

balance based on solids concentration and flow rate feed

to the purification reactors (CR-

202-A/B) of Cosoleacaque

plant.

Recording frequency: daily

2 Steam

consumption tonne every shift

Steam consumption by the compression room of

Cosoleacaque plant.

It is measured by orifice

plates (AFE-131, AFE-

4131, and AFE-1103)

and transmitters (AFT-

131, AFT-4131, and AFT-1103) installed at

the turbine inlet 42

kg/cm2 steam pipelines

of each turbo-compressor

(ACT-101, ACT-103,

and ACT-104) of

Cosoleacaque plant.

For the new turbo-compressor,

the steam flow meters are BFI-

1140, BFIR-960B, and

AFIR_360 (BFE-1140 turbine

inlet, BFE-960B second

pressure reduction valve, and AFIR-360 first pressure

reduction valve).

For the existing turbo-compressors, it is measured by

orifice plates (AFE-131, AFE-

4131, and AFE-1103) and

transmitters (AFT-131, AFT-

4131, and AFT-1103) installed

at the turbine inlet 42 kg/cm2

steam pipelines of each turbo-

compressor (ACT-101, ACT-

103, and ACT-104) of

Cosoleacaque plant.

Recording frequency: every

shift

MONITORING REPORT


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# Data

variable Data unit

Recording frequency

(registered

PDD)

Comment

(registered PDD)

Monitoring plan used in the

monitoring period from

20/11/2007 to 4/5/2008

3 Steam

temperature ºC

every shift

Temperature of the steam generated at the boiler

room of Cosoleacaque

plant.

This value is used to

determine the steam

enthalpy.

It is measured by thermo

couples installed at each

boiler exit pipeline

(ATE-336-A/B/D and

ATE-309-C) of

Cosoleacaque plant.

In this case, a unique value of

steam enthalpy is used, which is obtained according to design

conditions provided by AMOCO

(temperature and pressure) of

the generated steam. These

conditions are significantly

constant during the operation of

the plant.

Recording frequency: unique

value

4 Steam

pressure kg/cm

2

every shift

Pressure of the steam generated at the boiler


plant.


determine the steam

enthalpy.

It is measured by

pressure transmitters

installed at each boiler

exit pipeline (APT-311-

A and APT-310-B/C/D)

of Cosoleacaque plant.

In this case, a unique value of steam enthalpy is used, which is

obtained according to design

conditions provided by AMOCO

(temperature and pressure) of

the generated steam. These

conditions are significantly

constant during the operation of

the plant.


value

5 Feed water

temperature ºC

every shift

Temperature of the water

feed to the boiler room of

Cosoleacaque plant.


determine the feed water

enthalpy.

It is measured by

temperature indicators

(before de-aerator and

economizer) at the end of

each shift in

Cosoleacaque plant.

In this case, a unique value of

feed water enthalpy is used,

which is obtained according to

design conditions provided by

AMOCO (temperature) of the

feed water. This condition is

significantly constant during the

operation of the plant.


value

MONITORING REPORT


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# Data

variable Data unit

Recording frequency

(registered

PDD)

Comment

(registered PDD)



20/11/2007 to 4/5/2008

6 Steam

generation tonne daily

Steam generation by the boiler room of

Cosoleacaque plant.


plates and transmitters

installed at each boiler

exit pipeline (AFE-309-

A/B/C/D and AFT-309-

A/B/C/D) of Cosoleacaque plant, and

the total steam generated

is determined by an

algorithms configured in

the DCS (AFQI-

301ABC).

It is measured by orifice plates

and transmitters installed at each

boiler exit pipeline (AFE-309-

A/B/C/D and AFT-309-A/B/C/D) of Cosoleacaque

plant, and the total steam

generated is determined by an

algorithms configured in the

DCS (AFQI-301ABC).


7 Fuel

consumption m

3 daily

Consumption of each

fuel in the boiler room of

Cosoleacaque plant.


plates and transmitters installed at each boiler

natural gas pipeline

(AFE-306-A/B/C/D and

AFT-306-A/B/C/D) and

Micro Motion flow

meters installed at each

boiler fuel oil pipeline

(AFT-306-A2/B2 and

AFT-305).

The natural gas consumption is measured by flow meters

installed at each boiler natural

gas pipeline (AFIR-306A.SQR

in boiler AB-301A, AFIR-

306B.SQR in boiler AB-301B,

AFR-306C.SQR in boiler AB-

301C, and AFR-306D in boiler

AB-301D).

The fuel oil consumption is

measured by flow meters

installed at each boiler fuel oil

pipeline (AFIR-306A2 in boiler

AB-301A, AFIR-306B2 in

boiler AB-301B, and AFR-305D

in boiler AB-301D).


8

Lower heating

value of

fuels

MMBtu/m3

with every delivery of

fuel

Lower heating value of

each fuel consumed at

the boiler room of

Cosoleacaque plant.

Determined by fuel oil

analysis made by the

supplier laboratory for

each delivery and by an

external laboratory as

required.

For the natural gas, this

analysis results can be

consulted as needed in

supplier’s Web site and

can be validated by an external laboratory as

required.

A unique value of lower heating value obtained through

laboratory analysis of each fuel

is considered.


value

MONITORING REPORT


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# Data

variable Data unit

Recording frequency

(registered

PDD)

Comment

(registered PDD)



20/11/2007 to 4/5/2008

9 Fuel

composition %

with every

delivery of

fuel

Composition of each fuel consumed at the boiler


plant, on weight basis.

Determined by fuel oil

analysis made by the

supplier laboratory for

each delivery and by an


required.

For the natural gas, this

analysis results can be

consulted as needed in

supplier’s Web site and

can be validated by an


required.

Composition of each fuel

consumed at the boiler room of

Cosoleacaque plant, on weight

basis.

Determined by fuel oil analysis

made by the supplier laboratory for each delivery and by an

external laboratory as required.

For the natural gas, this analysis results can be consulted as

needed in supplier’s Web site

and can be validated by an

external laboratory as required.


value

10 Retrofit NA when occurs

Future retrofitting within

the project boundary, at

Cosoleacaque plant.

The enhanced steam

saving due to the impact of a retrofit should be

estimated and deducted

from claimed emission

reductions.

N/A

11 Electricity

generation MWh monthly

Electricity generation at

Cosoleacaque plant.

Value measured. Using

the generated voltage and

the current signals from the electric generator, a

transducer converts

continuously to power

signal (BXI-124)

Value measured. Using the

generated voltage and the

current signals from the electric

generator, a transducer converts

continuously to power signal

(BXI-124).

Recording frequency: monthly

12

Auxiliary

electricity

consumption

MWh monthly

Auxiliary electricity used

by power generating

equipment at

Cosoleacaque plant.

Electricity consumption

is measured continuously

by power meters.

Only the control panel of the

generation equipment consumes

electricity. In this case, the electricity consumption is not

measured, but estimated

according to data from the

provider of the control panel.


MONITORING REPORT


11

Altamira Plant

# Data

variable Data unit

Recording

frequency

(registered

PDD)

Comment

(registered PDD)

Monitoring plan used in the monitoring period from

20/11/2007 to 4/5/2008

13 Electricity

generation MWh monthly

Electricity generation at

Altamira plant.

Value measured. Using the generated voltage and

the current signals from

the electric generator, a

transducer converts

continuously to power

signal (AXI-310).

Value measured. Using the

generated voltage and the

current signals from the electric

generator, a transducer converts

continuously to power signal

(AXI-310).


14

Auxiliary electricity

consumption

MWh monthly

Auxiliary electricity used by power generating

equipment at Altamira

plant.

Electricity consumption

is measured continuously

by power meters.

Electricity consumption is estimated in a conservative

manner using equipment

specifications.


In addition, emissions of NOx, COx, SOx, and particulate matter will be measured in order to

detect environmental impacts of the project and to ensure compliance with environmental

regulations.

As part of the routine of Petrotemex, perimeter noise measurements and medical

examinations to all the personnel are carried out in Cosoleacaque and Altamira plants.

In Altamira plant, the perimeter noise is monitored in an annual basis and control measures

are established in accordance with the results. Complete medical examinations of the

personnel are carried out on an annual basis, including the administrative personnel.

Additionally, the Altamira plant has a continue communication with the local community,

through meetings that are included within the annual training program for the community

schools about preventing contamination. Mini-Olympics activities are included as a part of

this activity and, through answer addressing exercises, Altamira plant can get close to the

authorities and organize meetings with them.

In Cosoleacaque plant, the medical examinations (clinical analysis, radiographies, ocular

analysis, and audiometry) are carried out annually to all the personnel, and the perimeter noise

is monitored according to the Mexican norms.

All the monitored data, including data related to sustainability indicators, will be registered

and stored according to the procedures developed by the company.

Additionally, all the data monitored will be filed until two years after finishing the crediting

period.

MONITORING REPORT


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6.2 QUALITY CONTROL (QC) AND QUALITY ASSURANCE (QA)

All the measuring instrument signals are connected to the Distributed Control System (DCS)

and their data are exported and stored in the database of the PI system.

Additionally, the value of PTA production determined by mass balance is verified daily by

silos inventories and the product shipment.

6.3 FIXED PARAMETERS

The following table shows the fixed parameters that will not be monitored and that will be

used in calculation of emission reductions.

Parameter Value Source

Emission factor of residual fuel

oil

0.08166 tCO2/MMBtu

and 77.40 tCO2/TJ

2006 IPCC Guidelines for National Greenhouse

Gas Inventories, Chapter 1, Table 1.4, Page 1.23

Emission factor of natural gas 0.05919 tCO2/MMBtu

and 56.10 tCO2/TJ

2006 IPCC Guidelines for National Greenhouse


Emission factor of diesel 74.10 tCO2/TJ 2006 IPCC Guidelines for National Greenhouse


Emission factor of coal 94.60 tCO2/TJ 2006 IPCC Guidelines for National Greenhouse


Oxidation factor of residual fuel

oil 0.990 IPCC Guidelines for National Greenhouse Gas

Inventories, Reference Manual, Volume 3 (1996),

Table 1-6, Page 1.29. Oil and Oil Products: 0.99.

Oxidation factor of natural gas 0.995 IPCC Guidelines for National Greenhouse Gas

Inventories, Reference Manual, Volume 3 (1996), Table 1-6, Page 1.29. Gas: 0.995.

Oxidation factor of diesel 0.990

IPCC Guidelines for National Greenhouse Gas

Inventories, Reference Manual, Volume 3 (1996),

Table 1-6, Page 1.29. Oil and Oil Products: 0.99.

Oxidation factor of coal 0.980 IPCC Guidelines for National Greenhouse Gas Inventories, Reference Manual, Volume 3 (1996),

Table 1-6, Page 1.29. Coal: 0.98.

Global Warming Potential (CH4) GWP (CH4)

21 IPCC, Climate Change 1995: The Science of Climate Change (Cambridge, UK: Cambridge

University Press, 1996).

Global Warming Potencial GWP (N2O)

310 IPCC, Climate Change 1995: The Science of Climate Change (Cambridge, UK: Cambridge

University Press, 1996).

6.4 OPERATIONAL AND MANAGEMENT STRUCTURE

Measurements in the levels of fuel and steam consumption as well as electricity and steam

generation after the project implementation is made by the production departments of the respective plants. The structure that the company will implement for the monitoring process is

showed through the following tables:

MONITORING REPORT


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Cosoleacaque Plant

Department Responsibility Monitoring Methodology

Raw Material Fernando Vásquez Daily Inventory consumption Physical tanks level measurement and

balance in-out

TA/PTA production

José Luis Sosa Valencia

PTA production Mass balance based on solids concentration

and flow rate feed to the purification

reactors (DCS, PI, and meter calibration)

OSBL

production

(utilities)

Fredy

Valenzuela

Zarrabal Steam consumption

Orifice plates and transmitters installed at

the turbine inlet 42 kg/cm2 steam pipelines

of each turbo-compressors (DCS, PI, and

meter calibration)

OSBL

production

(utilities)

Fredy

Valenzuela

Zarrabal Steam generation


each boiler exit pipeline (DCS, PI, and

meter calibration)

OSBL

production (utilities)

Fredy

Valenzuela Zarrabal

Fuel flow measurement on line to the boilers


each boiler natural gas pipeline and Micro

Motion flow meters installed at each boiler fuel oil pipeline (DCS, PI, and meter

calibration)

OSBL production

(utilities)

Fredy Valenzuela

Zarrabal Electricity generation

Transducer that converts the generated voltage and the current signals to power

signal (DCS, PI, and meter calibration)

Instruments

Maintenance Juan Alonso Iparrea

Medellín

Quality assurance for low uncertainties in the measurement

instruments ISO-9001 Instructions, procedures, and

planning maintenance

Environmental Carlos Roberto Vergara Herrera

Emissions of NOx, COx, SOx, and particulate matter

For third party inspection (external company)

Altamira Plant

Department Responsibility Monitoring Methodology

Operations Eduardo Anaya

Núñez de

Cáceres

Electricity generation Transducer that converts the generated

voltage and the current signals to power

signal (DCS, PI, and meter calibration)

Maintenance

Manuel

Vázquez

Zúñiga

Quality assurance for low

uncertainties in the measurement

instruments ISO-9001 Instructions, procedures, and

planning maintenance

Security and

Ecology Ernesto Flores

Emissions of NOx, COx, SOx,

and particulate matter For third party inspection (external

company)

MONITORING REPORT


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6.5 MEASURING INSTRUMENTS

The following tables show principal characteristics of measuring instruments to be used by

the company:

Cosoleacaque Plant

Instruction

number

Identification

number5

Variable Instrument Manufacturer Model Accuracy Range

CWIC-201* Solid

concentration

Controller

indicator

ABB MOD-

300

+/- 0.1 % 0-35 %

GMT-I-061 CWT-112A2 Solid

concentration

Flow

transmitter

MICROMOTION RFT9712 +/- 0.2 % 0-35 %

GMT-I-061 CWT-110 Solid

concentration

Flow

transmitter

MICROMOTION 9739 +/- 0.2 % 0-35 %

GMT-I-004 AFT-131 Steam

consumption

Flow

transmitter

YOKOGAWA EJA110 +/- 0.2 % 0-8,000

m3/hr


consumption

Flow

transmitter YOKOGAWA EJA110 +/- 0.2 % tonne/hr


consumption

Flow

transmitter YOKOGAWA EJA110 +/- 0.2 % tonne/hr

GMT-I-062 ATE-336A Steam

temperature

Temperature

element

MINCO +/- 0.2 %

GMT-I-062 ATE-336B Steam

temperature Temperature

element MINCO +/- 0.2 %

GMT-I-062 ATE-336D Steam



GMT-I-062 ATE-309C Steam



GMT-I-004 APT-311A Steam

pressure

Pressure

transmitter

YOKOGAWA EJA530A +/- 0.2 %

GMT-I-004 APT-310B Steam

pressure Pressure

transmitter YOKOGAWA EJA530A +/- 0.2 %

GMT-I-004 APT-310C Steam

pressure Pressure

transmitter YOKOGAWA EJA430A +/- 0.2 %

GMT-I-004 APT-310D Steam

pressure Pressure

transmitter YOKOGAWA YA43F +/- 0.2 %

GMT-I-004 AFT-309A Steam

generation

Flow

transmitter

YOKOGAWA EJA110 +/- 0.2 % 0-100

tonne/hr

GMT-I-004 AFT-309B Steam

generation Flow

transmitter YOKOGAWA EJA110 +/- 0.2 % 0-100

tonne/hr

GMT-I-004 AFT-309C Steam

generation Flow

transmitter YOKOGAWA EJA110 +/- 0.2 % 0-85

tonne/hr

5 The differences between the identification numbers shown in the registered monitoring plan and the

monitoring plan used from 20/11/2007 to 4/5/2008 are detailed in Section 6.1.

MONITORING REPORT


15

Instruction

number

Identification

number5


GMT-I-004 AFT-309D Steam

generation Flow

transmitter YOKOGAWA YA11F +/- 0.2 % 0-115

tonne/hr

GMT-I-004 AFT-306A Natural gas

consumption

Flow

transmitter

YOKOGAWA EJA110 +/- 0.2 % 0-8,000

m3/hr

GMT-I-004 AFT-306B Natural gas

consumption

Flow

transmitter YOKOGAWA EJA110 +/- 0.2 % 0-8,500

m3/hr

GMT-I-004 AFT-306C Natural gas consumption

Flow


m3/hr

GMT-I-004 AFT-306D Natural gas

consumption

Flow


m3/hr

GMT-I-061 AFT-306A2 Fuel oil consumption

Flow transmitter

MICROMOTION +/- 0.2 % 0-8,500 lt/hr

GMT-I-061 AFT-306B2 Fuel oil

consumption

Flow

transmitter

MICROMOTION +/- 0.2 % 0-8,500

lt/hr

GMT-I-061 AFT-305 Fuel oil consumption

Flow transmitter

MICROMOTION +/- 0.2 % 0-8,500 lt/hr

BXI-124 Power

generation

Transducer 0-11.6

MWh

Altamira Plant

Instruction

number

Identification

number6


AXI-310 Power

generation Multifunction ABB

MGE

144

+/- 0.25

%

0-14.3

MWh

6.6 CALIBRATION EQUIPMENT

The calibration procedures implemented for the project are similar to those currently

implemented in Cosoleacaque and Altamira plants, because despite the project is an innovate

technological development, the equipment, recipients and instruments are of the same type

than those currently installed in the plants.

Petrotemex developed a specific Calibration Program for the equipment that is involved in the

CDM project. The maintenance management is in charge of the follow up of this program

through instruments department.



MONITORING REPORT


16

The calibration of the equipment is done as it is established in the tables below:

Cosoleacaque Plant

Instruction number

Identification number7

Variable Instrument Calibration

CWIC-201* Solid concentration

Controller indicator Internal calibration twice a year

GMT-I-061 CWT-112A2 Solid concentration

Flow transmitter Internal calibration twice a year

GMT-I-061 CWT-110 Solid concentration

Flow transmitter Internal calibration twice a year

GMT-I-004 AFT-131 Steam consumption

Flow transmitter Internal calibration once a year





GMT-I-062 ATE-336A Steam temperature Temperature element Internal calibration once a year

GMT-I-062 ATE-336B Steam temperature Temperature element Internal calibration once a year

GMT-I-062 ATE-336D Steam temperature Temperature element Internal calibration once a year

GMT-I-062 ATE-309C Steam temperature Temperature element Internal calibration once a year

GMT-I-004 APT-311A Steam pressure Pressure transmitter Internal calibration once a year

GMT-I-004 APT-310B Steam pressure Pressure transmitter Internal calibration once a year

GMT-I-004 APT-310C Steam pressure Pressure transmitter Internal calibration once a year

GMT-I-004 APT-310D Steam pressure Pressure transmitter Internal calibration once a year

GMT-I-004 AFT-309A Steam generation Flow transmitter Internal calibration once a year

GMT-I-004 AFT-309B Steam generation Flow transmitter Internal calibration once a year

GMT-I-004 AFT-309C Steam generation Flow transmitter Internal calibration once a year

GMT-I-004 AFT-309D Steam generation Flow transmitter Internal calibration once a year

GMT-I-004 AFT-306A Natural gas consumption


GMT-I-004 AFT-306B Natural gas consumption


GMT-I-004 AFT-306C Natural gas consumption




MONITORING REPORT


17

Instruction

number

Identification

number7


GMT-I-004 AFT-306D Natural gas

consumption


GMT-I-061 AFT-306A2 Fuel oil

consumption


GMT-I-061 AFT-306B2 Fuel oil

consumption


GMT-I-061 AFT-305 Fuel oil consumption


BXI-124 Power generation Transducer Internal calibration once a year

Altamira Plant

Instruction

number

Identification

number8


AXI-310 Power generation Multifunction Calibration once a year

Petrotemex developed specific Calibration Procedures that are follow up by the specialized

personal to secure that the equipment of inspection, measurement and test stays calibrated,

controlled and in conditions of operation to demonstrate the product conformity according to

their requirements, as well as, to assure that the calibration of the instrument is within the rank

of exactitude specified by the manufacturer.

6.7 MAINTENANCE PROCEDURES

The maintenance procedures implemented for the project are similar to those currently

implemented in Cosoleacaque and Altamira plants, because despite the project is an innovate

technological development, the equipment, recipients and instruments are of the same type

than those currently installed in the plants.

These procedures were available during the verification.

6.8 SPREADSHEET MODELS

For this project, the monitoring methodology is applied through spreadsheet models. The

spreadsheets automatically provide the total GHG emission reductions achieved through the

project.



MONITORING REPORT


18

The models contain a series of worksheets with different functions, as follows:

Data entry sheets Function

Cosoleacaque Plant

The input data is entered in these sheets to

estimate parameters used in the emissions

reduction calculations.

PTA production

Steam Consumption

Steam Generation

Fuel Consumption

Lower Heating Value

Steam Enthalpy

Feed Water Enthalpy

Electricity Generation

Altamira Plant

Electricity Generation

Calculation sheets Function

Cosoleacaque Plant

These sheets use the data entered in the data entry

sheets.

Fuel Proportion

Net Enthalpy

Representative PTA Production

Representative Steam Consumption

Project SSCR

Efficiency

ER Steam Savings

ER Electricity Generation

Result sheet Function

Cosoleacaque Plant

This final sheet shows the emissions reductions calculated on an annual basis.

Total Emission Reductions

Altamira Plant

Emission Reductions

Additionally, there are some cells that show fixed parameters required for the calculations and

references for these parameters.

A color-coded key is used to facilitate data input. The key for the code is as follows:

• Input Fields: Pale yellow fields indicate cells where project operators are required to

supply data input, as is needed to run the model;

MONITORING REPORT


19

• Result Fields: Green fields display key result lines as calculated by the model.

7 ENVIRONMENTAL IMPACT

The activities involved in this energy integration project have positive environmental impacts

on several grounds.

As a consequence of steam saving, the project activity will reduce emissions of particulate

matter and pollutant gases like SO2 and NOx from combustion of petroleum fuels in boilers,

reducing local negative environmental impact and improving air quality in the regions.

In addition, by reducing electricity demand from the Electricity Federal Commission

(Commission Federal de Electricidad – CFE), the project will reduce emissions from

electricity generation of the power plants connected to the grid. Thus there will be a reduction

of the local negative effects of such emissions.

In the case of this project activity, it is not necessary to modify the environmental impact

study required by the Environmental and Natural Resources Secretariat of Mexico, due to the

modifications that will be carried out by Petrotemex will not change the PTA production

process.

In addition, it is considered that the construction process will not have any negative

environmental impact.

8 EQUATIONS USED FOR CALCULATION OF EMISSION REDUCTIONS

Baseline emissions BEEG related to

avoided grid electricity generation due to

the waste heat recovery for power self-

generation in Cosoleacaque and Altamira

plants

BEEG = EG × EFgrid

where

EG Net quantity of electricity generated (MWh/year). It is

obtaining by subtracting the quantity of electricity

required by the power generation equipment to the

total electricity generation.

EFgrid CO2 baseline emission factor for the electricity

displaced due to the project activity (tCO2/MWh). It

is determined using the methodology

ACM0002/Version06 as a combined margin emission

factor, consisting of the combination of the operating

margin and the build margin factors. It is calculated

ex-ante and considered fixed along the crediting

period.

CO2 baseline emission factor for the

electricity displaced due to the project

activity

EFgrid = wOM × EFOM + wBM × EFBM

where

EFOM Operating margin emission factor (tCO2/MWh).

EFBM Build margin emission factor (tCO2/MWh).

wOM and

wBM

Relative weights assumed to be equal to 0.5,

according to the default value provided by the

methodology ACM0002/Version06.

MONITORING REPORT


20

Operating margin emission factor EFOM = (Σkp Fkp × COEFkp) / (Σp GENp)

where the sum over k extends to all the fuels used by the power sources p, and the sum over p extends to all power sources

delivering electricity to the grid, not including low-operating cost

and must-run power plants, and including imports to the grid, and:

Fkp Quantity of fuel k consumed by the power source p

(TJ).

COEFkp CO2 emission coefficient of fuel k (tCO2 /TJ).

GENp Electricity generation delivered to the grid by the

power source p (MWh).

CO2 emission coefficient of fuel k COEFkp = CEFk × OXIDk

where

CEFk Carbon dioxide emission factor per unit energy of

fuel k (tCO2/TJ). IPCC default values are used.

OXIDk Oxidation factor of fuel k. IPCC default values are

used.

Build margin emission factor EFBM EFBM = (Σkq Fkq × COEFkq) / (Σq GENq)

where the sum over k extends to all the fuels used by the power

sources q, and:

Fkq Quantity of fuel k consumed by the power source q

(TJ).

COEFkq CO2 emission coefficient of fuel k (tCO2 /TJ). It is

obtained through equation showed above.

GENq Electricity generation delivered to the grid by the

power source q (MWh).

Project emissions PEEG and leakage

LEEG related to avoided grid electricity

generation due to the waste heat

recovery for power self-generation in

Cosoleacaque and Altamira plants

According to the methodology ACM0004/Version02, no leakage is

considered. In addition, no project emissions are considered, since

there are not fuels fired in the project scenario for electricity

generation start-up, in emergencies, or to provide additional heat

gain. Thus, PEEG = 0 and LEEG = 0.

Emission reductions EREG related to

avoided grid electricity generation due to the waste heat recovery for power self-

generation in Cosoleacaque and Altamira

plants

EREG = BEEG – PEEG – LEEG = BEEG

Emission reductions ERFS related to

boiler steam optimization

ERFS = Σ Cernet = Σ [Cer – (Cer1 + Cer2)] = Σ Cer

where the sum extends to all the days in a given year, and

Cernet Emission reductions per day (tCO2e/day).

Cer Emission reductions per day related to fuel savings due

to the boiler steam optimization in Casoleacaque plant

(tCO2e/day).

Cer1 Emissions related to captive generation (tCO2e/day).

Cer2 Emissions related to external grid supply (tCO2e/day).

According to the methodology AM0018/Version01.1, no leakage is

considered. There are not additional electrical load that may result

from the project activity (actually, there are electricity savings due to

the project activity, but they are not considered in the calculation of

emission reductions as a conservative assumption). Thus, Cer1 = 0

and Cer2 = 0.

MONITORING REPORT


21

Emission reductions per day related to

fuel savings due to the boiler steam

optimization in Cosoleacaque plant

Cer = Ein × Σ(Ffuel × %Hfuel)

where the sum extends to all fuels consumed in the boiler room, and:

Ein Energy input in the boiler room during the day

(MMBtu/day).

Ffuel Carbon dioxide emission factor per unit of energy of

fuel (tCO2/MMBtu).

%Hfuel % of hours per day for each type of fuel. It is

obtained from the actual consumption of fuels by the

boiler room9. Thus, the % of hours per day for each

type of fuel is equivalent to the proportion of fuel

consumed in the boiler room during the day (%).

Energy input in the boiler room during

the day Ein = Enet / ηb

where

Enet Net reduction in steam energy consumption during the

day (MMBtu/day).

ηb Efficiency of the boiler room (%).

Efficiency of the boiler room ηb = Eo / Ei

where

Eo Output energy of steam (MMBtu/month).

Ei Input energy of fuel (MMBtu/month).

Output energy of steam Eo = Es × S

where

Es Net enthalpy of steam (MMBtu/tonne).

S Steam generation by the boiler room (tonnes/month).

Net enthalpy of steam Es = Etot – Efw

where

Etot Enthalpy of steam at the boiler room outlet

(MMBtu/tonne).

Efw Enthalpy of feed water (MMBtu/tonne).

The steam enthalpy is obtained by using steam tables for enthalpy at

given pressures and temperatures.

The enthalpy of feed water is estimated by multiplying the feed

water temperature by the water specific heat (1 kcal/kg ºC).

NOTE: for this verification period, design values provided by

AMOCO for pressure and temperature of the steam and feed water temperature were used.

Input energy of fuel Ei = NCVfuel × F

where

NCVfuel Net calorific value of fuel (MMBtu/m3).

F Quantity of fuel consumed at the boiler room

(m3/month).

9 According to the methodology, under direct method of boiler efficiency estimation, fuel

metering/measurement facility is available. Thus, the % of fuel is derived by actual consumption of

respective fuel.

MONITORING REPORT


22

Net reduction in steam energy

consumption during the day Enet = Snet × Es

where

Snet Net reduction in steam consumption during the day

(tonnes/day).

Es Net enthalpy of steam (MMBtu/tonne). It is estimated

through equation showed above.

Net reduction in steam consumption

during the day Snet = SSCRdiff ×××× Pact

where

SSCRdiff Difference in SSCR (Specific Steam Consumption

Ratio) of baseline and project scenarios during the day (tonne steam/tonne PTA).

Pact Actual PTA production during the day (tonne

PTA/day).

Difference in SSCR SSCRdiff = SSCR – SSCR1

where

SSCR SSCR of baseline scenario (tonne steam/tonne PTA).

SSCR1 SSCR of project scenario during the day (tonne steam/tonne PTA).

The SSCR of baseline scenario is calculated ex-ante and considered

fixed along the crediting period. It is determined using the same

formulae than the SSCR of project scenario.

SSCR of project scenario during the day SSCR1 = S1 / P1

where

S1 Representative steam consumption during the day

(tonne steam/day).

P1 Representative PTA production during the day (tonne

PTA/day).

Representative PTA production during

the day Prep1 = (P1 + P2…..+ Pm) × A / m

where

P1, P2,….Pm PTA production during the shift 1, 2,….m (tonne

PTA/shift).

A Total number of shifts per day.

The representative PTA production for the day is determined by

selecting and averaging the representative PTA production values

(i.e. within the normal production range). A “normal” production

range can be defined based on the relationship between production

rates and energy consumption. Based on general experience the

energy consumption per unit of production is not significantly

sensitive up to +/- 5% of the normal production. The normal

production range can be defined as the range in which production

levels are 5% above or below the normal production. If production

fluctuates beyond this normal production range, these specific values

can be excluded to derive a representative production level of the day.

NOTE: for this verification period there is only one data per day.

MONITORING REPORT


23

Representative steam consumption

during the day Srep1 = (S1 + S2…..+ Sm) × A / m

where

S1, S2,….Sm Steam consumption corresponding to the PTA

production during the shift 1, 2,….m (tonne

steam/shift).

A Total number of shifts per day.

The representative steam consumption for the day is determined by

selecting and averaging the steam consumption values corresponding

to the PTA production values included in the calculation of the

representative PTA production for this day.

NOTE: for this verification period there is only one data per day.

Total emission reduction ER of the

project activity ER = EREG + ERFS = BEEG + Σ Cer

where BEEG and Cer are determined as explained above.

There are not identified sources of project emissions PE and leakage

LE associated to the proposed project activity. Then, PE = 0 and LE

= 0.

Thus, the total annual emission reductions ER of the project activity

result to be:

ER = BE – PE – LE = BE

Thus, emission reductions are equal to baseline emissions that

include (i) CO2 emission from fuels that would have been used at the

boiler room of Cosoleacaque plant in order to generate the quantity

of steam saved by the proposed project activity, and (ii) CO2

emissions from fuels that would have been used by the operation of

grid-connected power plants and by the addition of new generation

sources, in order to generate the quantity of electricity self-generated by Cosoleacaque and Altamira plants following project

implementation. Then:

ER = BE = BEEG + Σ Cer

9 EMISSION REDUCTION CALCULATION

The total emission reductions achieved by the project activity through the monitoring period is equal to 59,13458,065 tCO2e.

The following tables summarize the values measured during the monitoring period.

Cosoleacaque Plant

Period

Total PTA

production

(tonnes)

Total Steam

Consumption

(tonnes)

Total Steam

Generation

(tonnes)

Total Residual Fuel

Oil

Consumption

(m3)

Total Natural Gas

Consumption

(m3)

From November 20th

, 2007

15,913 10,474 25,096 23.28 2,144,950

December 2007 51,998 20,689 61,308 63.85 5.023,765

January 2008 52,032 22,067 65,311 62.45 5,471,830

February 2008 43,325 21,262 65,002 59.42 5,501,642

MONITORING REPORT


24

March 2008 49,450 24,330 79,535 63.80 6,958,237

April 2008 47,963 22,767 66,737 22.58 5,884,496

To May 4th

, 2008 4,634 4,562 11,094 0.10 995,494

TOTAL 265,314 126,151 374,083 295.48 31,980,415

Cosoleacaque Plant

Period

LHV of Residual Fuel

Oil

(MMBtu/m3)

LHV of Natural Gas

(MMBtu/m3)

Steam Enthalpy

(MMBtu/tonne)

Feed Water Enthalpy

(MMBtu/tonne)

From November 20th

, 2007 to May 4

th, 2008

38,89 0.0352 3.0376 0.4808

MONITORING REPORT


25

Cosoleacaque Plant

Period

Total Electricity

Generation

(MWh)

Total Auxiliary

Electricity Used

(MWh)

From November 20th, 2007 265 0.02385

December 2007 1,045 0.06727

January 2008 1,063 0.06727

February 2008 665 .06290

March 2008 1,060 0.06724

April 2008 1,040 0.06501

To May 4th, 2008 97 0.00868

TOTAL 5,234 0.36222

Altamira Plant

Period

Total Electricity

Generation

(MWh)

Total Auxiliary Electricity Used

(MWh)

From November 20th,

2007

December 2007

January 2008 1,968 194.00

February 2008 1,272 108.00

March 2008 2,914 194.00

April 2008 4,573 280.00

To May 4th

, 2008 401 33.00

TOTAL 11,128 809

MONITORING REPORT


26

In addition, the following table shows the parameters calculated ex-ante and considered fixed

along the crediting period.

Baseline SSCR 1.5242 tsteam/tPTA For further information please see the registered

PDD of Petrotemex Energy Integration Project,

Version 10 of 08/02/2008. Grid Emission Factor 0.5133 tCO2/MWh

Finally, the following tables show the emission reductions obtained during the monitoring

period.

Period

Cosoleacaque Plant

Total Emission

Reduction from

Steam Savings

(tCO2e)

Emission Reduction from

Electricity

Generation

(tCO2e)

From November 20th, 2007 2,497 136 2,632

December 2007 10,193 536 10,729

January 2008 10,168 545 10,713

February 2008 8,028 341 8,368

March 2008 9,435 544 9,978

April 2008 9,301 534 9,834

To May 4th, 2008 467 50 517

TOTAL 50,089 2,686 52,771

Period

Altamira Plant

Emission Reduction

from Electricity

Generation

(tCO2e)

From November 20th

, 2007

December 2007

January 2008 910

February 2008 597

March 2008 1,396

April 2008 2,203

To May 4th, 2008 188

TOTAL 5,294

MONITORING REPORT


27

Total Emission Reductions during the monitoring period for Cosoleacaque Plant (tCO2e)

52,771

Total Emission Reductions during the monitoring period for Altamira plant (tCO2e)

5,294

Total Emission Reductions during the monitoring period for Cosoleacaque and Altamira plants

(tCO2e)

58,065

For further details see the monitoring spreadsheets “MGM_MVP_Altamira_ VERs_1Jan08

to 4May08” and “MGM_MVP_Cosoleacaque_VERs_20Nov07 to 4May08”.

petrotemex energy integration project grupo … · 6.2 quality control ... petrotemex energy...

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