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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
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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)
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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
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2010 VOC WORKSHOP: SESSION 1D17-18/06/2010
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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
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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
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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
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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
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2010 VOC WORKSHOP: SESSION 1D17-18/06/2010 Method 1: solvent input + passive sampling
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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 %
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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 %
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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
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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
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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
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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-+
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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?
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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
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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
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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%
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