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 – Fax
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)
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
2010 VOC WORKSHOP: SESSION 1D17-18/06/2010
2010 VOC WORKSHOP: SESSION 1D17-18/06/2010 [O4 = I – O5] in practice UnitValueDevia tion Min.Max. Flowratem 3 /h Concentrationg/m 3 5 OperationHours3400 O5Ton/year85010% InputTon/year1000 O4Ton/year O4% of solvent input 1523,56,5 POSSIBLE SOLUTION = MEASURE O4 INSTEAD OF O5
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
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
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
2010 VOC WORKSHOP: SESSION 1D17-18/06/2010 Method 1: solvent input + passive sampling
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 %
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 %
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
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
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
2010 VOC WORKSHOP: SESSION 1D17-18/06/2010 Method%95% confidence % Cost 1 input + passive input + port FID3110Not representative for entire period passive + FID9260Not useful FID + port FID20107Not useful+++ 5 port FID theoretical10-+
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?
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
2010 VOC WORKSHOP: SESSION 1D17-18/06/2010 O1 + O4 = I – O5 – O7 UnitValueDeviat ion Min.Max. I = INPUTTon/year % O7 = PRODUCTTon/year9.7001% O5 = INCINERATORTon/year10010%90110 O1 + O4Ton/year200>100%40723 O1 + O4% of input4%0% POSSIBLE SOLUTION = MEASURE O4 INSTEAD OF O1 AND O7
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%