1. 2010 VOC Workshop Session 1D: Fugitive emissions – definitions, measurement and verification David Knight Belgium - Flemish Government Environment, Nature and Energy department Air, Nuisance, Risk Management, Environment and Health Division Koning Albert II-laan 20, bus 8, 1000 Brussel Tel. 02 553 11 34 – Fax. 02 553 11 45 david.knight@lne.vlaanderen.be

2. 2010 VOC WORKSHOP: SESSION 1D17-18/06/2010 Mass balance of solvent based printing with incineration I = Input Solvent consuming Installation OUTPUT O1 = waste gases (stack) O2 = solvents in waste water O3 = residual solvent in product O4 = fugitive emissions O5 = destroyed/captured O6 = solvent in waste O7 = solvent in products (e.g. paints) O8 = recovered solvents for reuse O9 = other Simplified example Solvent based printing: O4 = fugitive emissions O5 = destroyed/captured O1, O2, O3, O6, O7, O8 = marginal Fugitive emission = O4 = I – O5 ELV and BATAEL  ELV: 100 mg C / Nm 3 20% of solvent input  Reduction scheme: 25% * (4*solids)  BREF: 7,5 – 12,5 % * (4*solids)

3. 2010 VOC WORKSHOP: SESSION 1D17-18/06/2010 Solvent based printing: flexography, rotogravure, laminating, 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 => incinerator  Floor extraction + cleaning machines => incinerator Solvent based flexography, rotogravure, laminating, varnishing

4. 2010 VOC WORKSHOP: SESSION 1D17-18/06/2010

5. 2010 VOC WORKSHOP: SESSION 1D17-18/06/2010 [O4 = I – O5] in practice UnitValueDevia tion Min.Max. Flowratem 3 /h50.000 Concentrationg/m 3 5 OperationHours3400 O5Ton/year85010%765935 InputTon/year1000 O4Ton/year15023565 O4% of solvent input 1523,56,5 POSSIBLE SOLUTION = MEASURE O4 INSTEAD OF O5

6. 2010 VOC WORKSHOP: SESSION 1D17-18/06/2010 [O4 = I – O5] in practice Possibility 1 Printing room with negative pressure due to extraction, all extraction to incinerator Possibility 3 Printing room under pressure / no pressure NO PROBLEM Can be tested with e.g. smoke PROBLEMATIC Emissions through doors, windows Possibility 2 Printing room with negative pressure due to extraction, not all extraction to incinerotor Emission through ventitlation shafts Can be tested with e.g. smoke Ventilation shafts can be measured

7. 2010 VOC WORKSHOP: SESSION 1D17-18/06/2010 Possibility 3: several methods tested during 1 production day (VITO  Method 1: input + passive sampling  Method 2: input + portable FID  Method 3: FID for O5 and passive sampling for O4  Method 4: FID for O5 and portable FID for O4  Method 5: portable FID for O4 and O5  Method 6: theoretical estimation based on specifics of printing machines and used solvents

8. 2010 VOC WORKSHOP: SESSION 1D17-18/06/2010 Method 1: 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

9. 2010 VOC WORKSHOP: SESSION 1D17-18/06/2010 Method 1: solvent input + passive sampling

10. 2010 VOC WORKSHOP: SESSION 1D17-18/06/2010 Method 5: 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 %

11. 2010 VOC WORKSHOP: SESSION 1D17-18/06/2010 Method 6: 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 %

12. 2010 VOC WORKSHOP: SESSION 1D17-18/06/2010 Method 2: solvent input + FID I O4 Solvent based flexography, rotogravure, laminating, varnishing O5  solvent input measured  O4 measured with portable FID

13. 2010 VOC WORKSHOP: SESSION 1D17-18/06/2010 Method 3: Passive sampling + FID I O4 Solvent based flexography, rotogravure, laminating, varnishing O5  O4 with passive sampling  O5 with FID continuous measurement  Solvent input = O4 + O5

14. 2010 VOC WORKSHOP: SESSION 1D17-18/06/2010 Method 4: FID + portable FID I O4 Solvent based flexography, rotogravure, laminating, varnishing O5  O4 with portable FID: 4 measurements  O5 with FID: continuous measurement  Solvent input = O4 + O5

15. 2010 VOC WORKSHOP: SESSION 1D17-18/06/2010 Method%95% confidence % Cost 1 input + passive1326++++ 2 input + port FID3110Not representative for entire period +++ 3 passive + FID9260Not useful++++ 4 FID + port FID20107Not useful+++ 5 port FID15-++ 6 theoretical10-+

16. 2010 VOC WORKSHOP: SESSION 1D17-18/06/2010 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?

17. 2010 VOC WORKSHOP: SESSION 1D17-18/06/2010 Mass balance of paint/ink production with incineration I = Input Solvent consuming installation OUTPUT O1 = waste gases (stack) O2 = solvents in waste water O3 = residual solvent in product O4 = fugitive emissions O5 = destroyed/captured O6 = solvent in waste O7 = solvent in products (e.g. paints) O8 = recovered solvents for reuse O9 = other Simplified example Paint/ink production : 01 = waste gases O4 = fugitive emissions O5 = destroyed/captured O7 = solvent in product O2, O3, O6, O8, O9 = marginal Emission = O1 + O4 = I – O5 – O7 ELV  150 mg C / Nm 3 AND 3% of solvent input  3% of solvent input

18. 2010 VOC WORKSHOP: SESSION 1D17-18/06/2010 O1 + O4 = I – O5 – O7 UnitValueDeviat ion Min.Max. I = INPUTTon/year10.0001%10.1009.900 O7 = PRODUCTTon/year9.7001%9.6039.797 O5 = INCINERATORTon/year10010%90110 O1 + O4Ton/year200>100%40723 O1 + O4% of input4%0% POSSIBLE SOLUTION = MEASURE O4 INSTEAD OF O1 AND O7

19. 2010 VOC WORKSHOP: SESSION 1D17-18/06/2010 Paint and ink production: estimation of 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%