MONITORING REPORT April June 2017 Version: 1 Submitted: …Presentation of Results ... Conditioning tower spray project As part of the kiln shutdown, the cut-in work was completed

Adelaide Brighton Cement Birkenhead Works. Licence Number: 1126

1

QUARTERLY STACK

MONITORING REPORT

April – June 2017

Version: 1

Submitted: 31st July 2017

[Pick the date]

EPA LICENCE NO: 1126

Report Prepared By: Daniel Mellor

Certified By: Tim Radimissis

[Adelaide Brighton Cement Birkenhead Works. License Number:

Authored by: Lloyd Felicity


2

Quarterly Report April – June 2017

Monitoring Objective The aim of the Quarterly Stack Monitoring Report is to identify and report on emissions

to compare actual emissions from Adelaide Brighton Cement Birkenhead Works against

the Environment Protection (Air Quality) Policy 1994, Authorisation 1126 and Exemption

Authorisation 12368. Furthermore the aim of the report is to continuously monitor and

provide reasons for the particulate emissions exceeding reporting limits in order to

establish key areas where opportunities lie for process and mechanical improvements to

reduce the level of stack dust emissions from the site.

Monitoring Plan Monitoring of stacks 4A and 4B on the Birkenhead site is performed using Durag Dust and

Opacity Meters. These meters provide a continuous % opacity and this is converted to

mg/Nm3 using a calibration curve. The results are then summarized as one hourly

averages based on 10 minute averages for the purpose of this report.

The license that Adelaide Brighton Cement operates under in regard to stack emissions is

summarized below.

Environment Protection (Air Quality) Policy

o Schedule 1 (1) - limit of 250mg/Nm3 stack 4A and 4B

o Exemptions License

Kiln or calciner light up &/or purge – max 10 minutes

Level 3 combustibles trip – max 5 minutes

Power failure – duration of emergency situation

Stack emissions testing for calibration of opacity meter – provided

that an EPA authorised officer is on site


3

Reporting Levels

o All emissions in excess of 80 mg/m3 (Stack 4B) and 150 mg/m3 (Stack 4A)

The Environmental Protection Authority (EPA) must be notified as soon as practicably

possible of all emissions in excess of the Schedule 1 (1) limit or reporting limit and cause

as well as remedial actions must be communicated. Where particulate emissions exceed

the Schedule 1(1) limit and the cause is not explicitly covered by the exemptions an

investigation will be carried out by the EPA to ensure that ABC Birkenhead has taken all

reasonable and practicable measures to reduce the emissions.

Monitoring Results

Presentation of Results

The graphs on the following pages detail the hourly averages of 10 minute averages of

stack emissions from 4A and 4B stacks by month. The tables below each chart show the

results of RCA (root cause analysis) that was undertaken for plant stoppages resulting in

emissions above either the reporting limit or the Air Quality Policy Schedule 1 (1) limit on

an hourly average.


4

Tag RCA Number Description

0

50

100

150

200

250

300

1/4

3/4

5/4

7/4

9/4

11/4

13/4

15/4

17/4

19/4

21/4

23/4

25/4

27/4

29/4

Stac

k Em

issi

on

Co

nce

ntr

atio

n (m

g/N

m3 )

4A Stack Emissions for April 2017

4A Stack Emission Hourly Average (mg/Nm3) 4A Reporting Limit (150 mg/Nm3) State (Schedule) Limit (250 mg/Nm3)


5


0

50

100

150

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300

1/5

3/5

5/5

7/5

9/5

11/5

13/5

15/5

17/5

19/5

21/5

23/5

25/5

27/5

29/5

31/5

Stac

k Em

issi

on

Co

nce

ntr

atio

n (m

g/N

m3)

4A Stack Emissions for May 2017



6


0

50

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300

1/6

3/6

5/6

7/6

9/6

11/6

13/6

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23/6

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27/6

29/6

Stac

k Em

issi

on

Co

nce

ntr

atio

n (m

g/N

m3 )

4A Stack Emissions for June 2017



7


0

50

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300

1/4

3/4

5/4

7/4

9/4

11/4

13/4

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19/4

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23/4

25/4

27/4

29/4

Stac

k Em

issi

on

Co

nce

ntr

atio

n (m

g/N

m3)

4B Stack Emissions for April 2017

4B Stack Emission Hourly Average (mg/Nm3) 4B Reporting Limit (80 mg/Nm3) State (Schedule) Limit (250 mg/Nm3)


8

Tag Description

B1 &

B2

Field instability in 4B Electrostatic Precipitator. Repaired 8/2.

0

50

100

150

200

250

300

1/5

3/5

5/5

7/5

9/5

11/5

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27/5

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31/5

Stac

k Em

issi

on

Co

nce

ntr

atio

n (m

g/N

m3)

4B Stack Emissions for May 2017



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Tag Description

0

50

100

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250

300

1/6

3/6

5/6

7/6

9/6

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13/6

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29/6

Stac

k Em

issi

on

Co

nce

ntr

atio

n (m

g/N

m3)

4B Stack Emissions for June 2017



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Short Term Report Summary

1. Short Term Excursions above 250mg/Nm3

In addition to hourly averages shown earlier in the report short term excursions above

250mg/Nm3 are reported during the period to the EPA. Below is a pie chart of the causes on

both 4A and 4B stack.

4A Greater Than 250mg/Nm³ Emissions Qtr 2 2017

4A Stack Pie Chart of causes over 250 mg/Nm3 in terms of number of occurrences and total

time

Total number of occurrences =12; total time 8 minutes 50 seconds


11

4B Greater Than 250mg/Nm³ Emissions Qtr 2 2017

4B Stack Pie Chart of causes over 250 mg/Nm3 in terms of number of occurrences and total

time

Total number of occurrences = 40; total time 67 minutes 0 seconds


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2. Causes of reporting limit excursions

Stack emissions greater than 150 mg/Nm3 (4A Stack) and 80 mg/Nm3 (4B Stack) are reported to

the EPA on a weekly basis. A pie chart and the total time are presented. Below are pie charts

for 4A and 4B stack for the three-month period; and also the total time charts up until the end

of September 2016.

4A Greater Than 150mg/Nm³ Emissions Qtr 2 2017

4A Stack Pie Chart of causes over 150 mg/Nm3 in terms of number of occurrences and total

time

Total number of occurrences = 87; total time 0 hours 54 minutes 30 seconds


13

4B Greater Than 80mg/Nm³ Emissions Qtr 2 2017

4B Stack Pie Chart of causes over 80mg/Nm3 in terms of number of occurrences and total time

Total number of occurrences = 210; total time 4 hours 02 minutes 30 seconds


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Tracking total time for stack emissions greater than the reporting levels of 150mg/Nm3 on 4A

stack and 80mg/Nm3 on 4B stack.

Monitoring Results – Quality Assurance / Quality Control Evaluation

The data shown in the graphs above was calculated using an opacity curve generated by a

number of iterations of spot testing by Axiom Air whom are accredited for compliance with

ISO/IEC 17025. The opacity meters are also calibrated daily and via regular planned

maintenance as per the suppliers’ standard.

0

2000

4000

6000

8000

10000

12000

14000

16000

18000

20000

3/0

8/2

014

31/0

8/2

014

28/0

9/2

014

26/1

0/2

014

23/1

1/2

014

21/1

2/2

014

18/0

1/2

015

15/0

2/2

015

15/0

3/2

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12/0

4/2

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10/0

5/2

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7/0

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2/0

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30/0

8/2

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27/0

9/2

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25/1

0/2

015

22/1

1/2

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20/1

2/2

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17/0

1/2

016

14/0

2/2

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13/0

3/2

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10/0

4/2

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8/0

5/2

016

5/0

6/2

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3/0

7/2

016

31/0

7/2

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28/0

8/2

016

25/0

9/2

016

23/1

0/2

016

20/1

1/2

016

18/1

2/2

016

15/0

1/2

017

12/0

2/2

017

12/0

3/2

017

9/0

4/2

017

7/0

5/2

017

4/0

6/2

017

2/0

7/2

017

Tim

e (se

co

nd

s)

Date (End of week)

4A Stack 4B Stack Linear (4A Stack) Linear (4B Stack)


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Process Improvement for the Quarter

As part of our continuous improvement commitment the emissions reduction team formed last

year has continued to work on new and existing projects to mitigate emissions, including:

Cooler bagfilter improvement project

During the kiln shutdown, a new control system was installed on the clinker cooler bag filter. The

clinker cooler bag filter takes hot gas from the kiln cooler and dedusts it before being exhausted

in 4A stack. The new control system allows for much higher degree of process optimization on

the pulsation frequency and pressure for the cleaning of the bags. This will greatly increase bag

life and performance over the campaign.

New bag types were used in the cooler bag filter this campaign based on data from the previous

bag samples. This is also expected to increase performance and campaign life of the bags. So far

in the campaign, this has been very effective in reducing emissions from the cooler baghouse.

The increased feedback has allowed for easier and more frequent maintenance of the bags

which has resulted in lower emissions.

Conditioning tower spray project

As part of the kiln shutdown, the cut-in work was completed for the conditioning tower upgrades

on 4A conditioning tower and the bypass system conditioning tower. This upgrade will increase

the response rate and effectiveness of the water sprays in the conditioning tower which will

increase the performance of the electrostatic precipitators.

Conclusions and Recommendations

There were no incidents above 250mg/Nm3 for a one hour average on 4A or 4B stack in the

quarter. There were no incidents above 150 mg/Nm3 on 4A stack and no incidents above 80

mg/Nm3 on 4B stack for a one-hour average in the quarter. A process of review and improvement

(including root cause analysis) is utilized to reduce these situations, thereby reducing the number

of occurrences of emissions greater than 250 mg/Nm3. Ongoing emission reductions have

continued for the quarter because of improvements made to the process.


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Appendix A See attached PDF files.

2017Q2.zip

MONITORING REPORT April June 2017 Version: 1 Submitted: …Presentation of Results ... Conditioning tower spray project As part of the kiln shutdown, the cut-in work was completed

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