Fugitive Emissions Assessment - EPA · 2017. 8. 20. · Fugitive emissions are unintentional emissions of gases or vapours from facilities or industry activities. Fugitive emissions

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Fugitive Emissions Assessment

(For the year 2016)

Magh nAla

Document No.: 1914-01

Version 5.00

Licence No. P1OOO-01.

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http://www.enviro-consult.com/

Magh nAla Fugitive Emissions Assessment 2016

Environmental Efficiency Page 2 of 15 Document No.: 1914-01 v5.00

Document Lead Sheet C

lien

t

Organisation Magh Nala

Site Building 3

Permit/Lic No. (if applic) P1000-01 Magh nAla

Client contact Pacelli Donegan

Order Proposal number N/A

Client PO or other reference 20170001363

Del

iver

able

Report title Fugitive Emissions Assessment

Document number 1914-01

Report template Std template to be defined

Type of document Report

Method Statement N/A Date written N/A

Format for issue PDF

Ap

pro

val &

Issu

e Site visit by N/A Date last site visit N/A

Document author RD Date written 20/06/2017

Approved by RBS Date approved 20/06/2017

Report version nr 5.00

Issued by RBS Date report issued 20/06/2017

Doc issued to As per client info

Method issue Email

Act

ion

All results satisfactory Yes

If not satisfactory, further testing required N/A

If satisfactory, when is next test due? N/A

Key to personnel

RBS Bob Sutcliffe, Director, CEng, MIMechE, MIEI,CEM

RTS Ronan Sutcliffe, Director, Dip. Environmental Protection

GB George Byrne, MSc Biosystems Engineering

RD Richard Deeney, B.Sc. AIEMA

JC John Cullen, BAgSc, P.Grad.Dip Environmental Engineering

VB Valerie Browne, BSc Environmental and Earth System Science

Conditions relating to the issue of this report: 1. No alteration to this report by third parties is permitted 2. Where this report is reproduced, it shall only be reproduced in full. 3. Reports remain the property of Environmental & Efficiency Consultants (Ireland) Limited until paid for in full.

Report History 1.0 Issued 2.0 Re-issued with word errors amended 3.0 Re-issued taking into account new solvent streams 4.0 Amending incorrect input 5.0 Updating product names

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Table of Contents

1 INTRODUCTION......................................................................................................................... 5

2 METHODOLOGY ........................................................................................................................ 6

3 CALCULATION OF INPUTS AND OUTPUTS.................................................................................. 6

4 CALCULATION OF SMP PARAMETERS ........................................................................................ 7

5 DISCUSSION AND CONCLUSION ................................................................................................ 7

Table 3-1 Mass Balance Equations for SMP Parameters .......................................................................... 6 Table 4-1 Solvent Input/Output figures .................................................................................................... 6 Table 5-1 Calculated Results for SMP Parameters ................................................................................... 7

Appendix 1 Solvent Inputs and Outputs: Definitions and how figures were determined ........................ 8 Appendix 2 Solvent Use Inventory ......................................................................................................... 10 Appendix 3 O1 for the study period ....................................................................................................... 11 Appendix 4 Calculating 06 for the study period ..................................................................................... 12 Appendix 5 Calculation of Solvent Output in Product ............................................................................ 13 Appendix 6 Calculation of SMP Parameters for the study period .......................................................... 15

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Executive Summary This report details a Fugitive Emissions Assessment/Solvent Management Plan (SMP)

for Magh nAla considering manufacturing operations which take place at their facility

in Quartertown Industrial Estate, Mallow, Co. Cork. A mass balance analysis of

solvent input/output associated with these operations took place to inform this SMP

- which was carried out in accordance with statutory requirements pertaining to

installations using organic solvent stipulated S.I. No. 565/2012 - European Union

(Installations and Activities Using Organic Solvents) Regulations 2012 – and,

specifically, to calculate solvent consumption, fugitive emissions, solvent input, the

fugitive emissions value (as a % of input) and total solvent emissions.

The facility had a solvent fugitive emission value (as a % of input) of 4.61%. Therefore

it is compliant with the applicable fugitive emission limit value for the activity

concerned of 5% as specified in Condition 5.4 of the licence for the facility (P1OOO-

01).

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1 Introduction

Magh nAla carries out manufacturing operations at its site in Mallow which have a

capacity to use significant quantities of solvent per annum. They carry out these

operations in accordance with an IPC licence (P1000-01) administered by the EPA.

Condition 5.4.1 of the licence requires that Magh nAla calculate annual fugitive mass

emissions of Volatile Organic Compounds from solvent.

Fugitive emissions are unintentional emissions of gases or vapours from facilities or

industry activities. Fugitive emissions can often comprise polluting material and can

be released into air from leaks in equipment, pipe lines, seals, valves, open

containers etc., and not from the usual sources such chimneys, stacks, and vents. It is

important to control the release of these unintentional releases to minimize

pollution to air.

Condition 5.4.2 requires that fugitive emissions from the Manufacturing of coating

mixtures, varnishes, inks and adhesives (Activity 17 of Annex VII part 2 of

2010/75/EU) shall not exceed 5% of total solvent input, where solvent consumption

is greater than 100 tonnes and less than 1000 tonnes per annum. The total solvent

use by Magh nAla at this installation was ca. 596 tonnes per annum for 2016 and

therefore this 5% limit applies.

Environmental Efficiency Consultants (EEC) were commissioned by Magh nAla to

develop a Fugitive Emissions Assessment, taking into consideration solvent inputs

and outputs associated with its manufacturing process at its installation in Mallow.

The relevant study period is the year 2016. EEC conducted this assessment in

accordance with provisions stipulated in Part of 7 of Annex 7 of the industrial

Emissions Directive 2010/75/EU.

For the relevant study period, the assessment comprises a determination of the

following parameters:

Solvent consumption

Fugitive emissions

Solvent Input

Fugitive emission value (as % of Input)

Solvent emissions

Subsequently, EEC verified whether Magh nAla complied with condition 5.4.2 of its

IPC licence.

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2 Methodology

A mass balance analysis of solvent inputs and outputs associated with the process

took place to inform the assessment. Table 3-1 below details mass balance equations

which were used to calculate fugitive emissions assessment parameters. The

definition for the terms used in these equations, as well as how figures were

determined, are shown in Appendix 1.

Table 2-1 Mass Balance Equations for SMP Parameters

Parameter Equation

Solvent consumption C = I1 – O8

Fugitive emissions F = I1 – O1 – O5 – O6 – O7 – O8

Solvent Input I = I1 + I2

Fugitive emission value (as % of input) FEV = F / I1 + 12

Solvent emissions E = F + O1

3 Calculation of Inputs and Outputs

The table below details the solvent input/output figures recorded. Details as regards

the calculation of figures are shown in the Appendices.

Table 3-1 Solvent Input/Output figures

Term Value Appendices Ref.

I1 596,658 Appendix 2

I2 0 N/A

O1 937.10 Appendix 3

05 0 N/A

06 11,364 Appendix 4

07 551,139 Appendix 5

08 5,694 Appendix 6

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4 Calculation of SMP Parameters

The calculated results relating to Fugitive Emissions at Magh nAla, taking into

consideration the solvent inputs and outputs associated with the installations

manufacturing process, are shown in Table 5-1 below. Details as regards the

calculation of these parameters are shown in Appendix 6.

Table 4-1 Calculated Results for SMP Parameters

Parameter Term Unit Value

Solvent Consumption C kg 590,964.24

Fugitive emissions F kg 27,523.70

Solvent Input I kg 596,658.24

Fugitive Emission Value (as % of Input) FEV % 4.61%

Solvent emissions E kg 28,460.80

5 Discussion and Conclusion

The solvent fugitive emission limit value, as defined by the licence, is 5% of total

solvent input. The fugitive emission value for the study period is 4.61% of total

solvent input. Magh nAla therefore complies with the applicable fugitive emission

limit value.

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Appendix 1 Solvent Inputs and Outputs: Definitions and how figures were determined

Term used in the mass balance analysis

Definition as per regulations How was the figure used in the SMP determined?

I1

The quantity of organic solvents or their quantity in mixtures purchased which are used as input into the process in the time frame over which the mass balance is being calculated.

Opening Stock + Purchases during the period – Closing Stock

I2

The quantity of organic solvents or their quantity in mixtures recovered and reused as solvent input into the process. The recycled solvent is counted every time it is used to carry out the activity.

N/A – No solvent recovery and reuse.

O1

Emissions in waste gases. The emissions in wastes gases were calculated using results from air monitoring carried out by an accredited air monitoring consultancy at a stack emission point during a period of representative processing. The concentration of Total Organic Carbon as Carbon (TOC as C) obtained from this monitoring will be multiplied by volume flow and operating hours for the study period to obtain TOC as C mass flow figures.

O2 Organic solvents lost in water, taking into account waste water treatment when calculating O5.

N/A – No solvent releases via water

O3 The quantity of organic solvents which remains as contamination or residue in products output from the process.

N/A – See 07 for releases in product

04 Uncaptured emissions of organic solvents into air. This includes the general ventilation of rooms, where air is

N/A – Not used in any equation in this report

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Term used in the mass balance analysis

Definition as per regulations How was the figure used in the SMP determined?

released to the outside environment via windows, doors, vents and similar openings.

O5

Organic solvents and/or organic compounds lost due to chemical or physical reactions (including those which are destroyed, by incineration or other waste gas or waste water treatments, or captured, as long as they are not counted under O6, O7 or O8).

N/A – No solvent lost due to chemical/physical reactions

O6 Organic solvents contained in collected waste. The quantity of waste solvent is recorded by Magh nAla ’s

waste contractor.

O7 Organic solvents, or organic solvents contained in mixtures, which are sold or are intended to be sold as a commercially valuable product.

Sold as part of the product

O8 Organic solvents contained in mixtures recovered for reuse but not as input into the process, as long as not counted under O7.

Zinc Milling tailings comprising solvent materials

O9 Organic solvents released in other ways. N/A – No solvent released in other ways

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Appendix 2 I1 Solvent Use Inventory

Product Usage 2016 (kg) CAS No. EC No. % Solvent Solvent Usage (kg)

EHTAA 244117.70 - - 75.00% 183,088.28

Aromatic 150 ND Fluid 2908.00 64742-94-5 918-811-1 100.00% 2,908.00

Aromatic Fluid 150 (SC 150) 9,294.700 64742-94-5 918-811-1 100.00% 9,294.70

Mineral Spirits 73604.00 64742-82-1 919-446-0 100.00% 73,604.00

Epoxy Resin 88747.87 - - 68.00% 60,348.55

Butanol 2289.70 71-36-3 200-751-6 100.00% 2,289.70

Methyl Ethyl Ketone (Lab) 24.00 78-93-3 201-159-0 100.00% 24.00

DBE 35,465.316 - 906-170-0 100.00% 35,465.32

DER 732 Epoxy 2,496.100 - - 100.00% 2,496.10

P.M. Acetate 135,573.784 Various Various 100.00% 135,573.78

IPA (Lab) 150.00 67-63-0 200-661-7 100.00% 150.00

ALUMINUM PASTE 48325.987 Various Various 32.50% 15,705.95

Acetone (Lab) 2.00 67-64-1 200-662-2 100.00% 2.00

Phenolic Resin 144568 Various Various 50.55% 73,079.12

PBT 148019 162303-51-7 500-687-1 0.50% 740.10

Liquid Defoamer 3678 Various Various 51.35% 1,888.65

Total Solvent Usage 2016 596,658.24

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Appendix 3 O1 for the study period

Parameter Figure (kg) Comment

Air Emissions (annual TOC)

937.1 Calculated with reference to TOC as C Results from quarterly air monitoring report for licensed emission point A2-1 at the facility for 2016.

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Appendix 4 Calculating 06 for the study period

Waste Out

Waste Type Weight (kg) Solvent % Solvent Output (kg)

Waste solvent 902 90.00% 811.8

Mineral spirit/water/zinc waste, 7.918 T 7918 80.00% 6334.4

Rejected Zinc Pigment (RM02905), 1936 8.50% 164.56

Zinc Pigment/Mineral Spirit + Water contamination 1082 80.00% 865.6

Zinc pigment/Mineral Spirit/Trace Iron & other metals (magnetic separator)

1092 5.00% 54.6

Waste IPA (Lab) 150 100.00% 150

Output in Solvent Waste Streams

8380.96

Loss in Packaging

Solvent Type Usage % Loss in Packaging

Loss in Packaging Waste

EHTAA 183,088.28 0.50% 915.44

Aromatic 150 ND Fluid 2,908.00 0.50% 14.54

Aromatic Fluid 150 (SC 150) 9,294.70 0.50% 46.47

Mineral Spirits 73,604.00 0.50% 368.02

Epoxy Resin 60,348.55 0.50% 301.74

Butanol 2,289.70 0.50% 11.45

Methyl Ethyl Ketone (Lab) 24.00 0.50% 0.12

DBE 35,465.32 0.50% 177.33

DER 732 Epoxy 2,496.10 0.50% 12.48

P.M. Acetate 135,573.78 0.50% 677.87

IPA (Lab) 150.00 0.50% 0.75

ALUMINUM PASTE 15,705.95 0.50% 78.53

Acetone (Lab) 2.00 0.50% 0.01

Phenolic Resin 73,079.12 0.50% 365.40

PBT 740.10 0.50% 3.70

Liquid Defoamer 1,888.65 0.50% 9.44

Total Output in Packaging Waste kg

2,983.29

Total Waste Output kg

11,364.25

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Appendix 5 07 Calculation of Solvent Output in Product

Description Solvent Output in Product kg

EHTAA 184,809.49

Aromatic 150 ND Fluid 2,908.00

Aromatic Fluid 150 (SC 150) 9,294.70

Mineral Spirits 26,717.20

Epoxy Resin 60,348.55

Butanol 2,289.70

Methyl Ethyl Ketone (Lab) 0.00

DBE 35,465.32

DER 732 Epoxy 2,496.10

P.M. Acetate 135,573.78

IPA (Lab) 0.00

ALUMINUM PASTE 15,705.95

Acetone (Lab) 0.00

Phenolic Resin 73,079.12

PBT 562.63

Liquid Defoamer 1,888.65

Total 551,139.19

Note: The percentage of Material in each finished product has not been included in this

report due to the commercially sensitive nature of this information however this data can be made available upon request.

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Appendix 6 O8 Calculation of Solvent Reuse

Parameter Total Solvent (kg) Comment

Tails 5,694 Oversized zinc particles containing solvent

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Appendix 7 Calculation of SMP Parameters for the study period

Parameter Equation Calculation: Step 1 (kg) Calculation: Step 2 & Result (kg)

Solvent consumption C = I1 - O8 C = 596,658 – 5,694 590,964

Fugitive emissions F = I1 - O1 - O5 - O6 - O7 - O8 F = 596,659 - 937 – 0 – 11,364 – 551,139 – 5,694 27,523.70

Solvent Input I = I1 + I2 I = 596,658 + 0 596,658.24

Fugitive emission value (as % of input)

FEV = F / I1 + 12 FEV = 27,523.70/596,659 + 0 4.61%

Solvent emissions E = F + O1 E = 27,523.70 + 937 28,460.80

*All units are in kg

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Fugitive Emissions Assessment - EPA · 2017. 8. 20. · Fugitive emissions are unintentional emissions of gases or vapours from facilities or industry activities. Fugitive emissions

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