t s environment · PDF file(SOP), each SOP has a ... Balance Scales M-S-E-13-1 On Site Eccentricity check Temperature, K Pressure, kPa Oxygen % Moisture %

Phone: +353-1-4626710

Fax: +353-1-4626714

Web: www.tmsenv.ie

TMS Environment Ltd

53 Broomhill Drive

Tallaght

Dublin 24

t m s environment ltd

CONFIDENTIAL REPORT

AIR EMISSIONS SURVEY

AT

GALCO STEEL LTD

FOR

KEVIN LYNCHEHAUN

Licence Reg. P0385-01

TMS Environment Ref. 22801

Commencement Date: 09 December 2015 Completion Date: 08 February 2016

Reporting Site Personnel Analysts Graham Adams Graham Adams

Enda Flood

Lee Martin

Approved by:

Date: 08 February 2016

Dr Imelda Shanahan

Technical Manager

Terms and conditions:

1. Reports shall not be reproduced except in full, without prior approval of TMS Environment Ltd

2. This report relates only to the items tested

3. Complaints should be addressed in writing to the Quality Manager

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 05-05-2016:00:49:27

___________________________________________________________________________

Galco Steel LTD (P0385-01) Emissions Survey Annual 2015

Ref. 22801, Page 2 of 8

EXECUTIVE SUMMARY

This report presents results of a survey of emissions to atmosphere from the Pot Enclosure

Exhaust 1 at the Galco Steel, Facility Gracedieu Road, Co. Waterford to satisfy the

requirements of IPPC Licence Register No. 0385-01. The licence requirements satisfied are

the Annual monitoring requirements for 2015 in respect of the following parameters:

Pot Enclosure Exhaust 1

• Ammonia

• HCL

• Metals (Pb, Zn, Cd)

• Velocity & Temperature

Measurements were completed on the 9th

December 2015. Details of the monitoring methods

employed, Standard Methods referenced and Guidance Notes consulted are presented in the

report together with information on the equipment used.

The results for all of the measurement parameters reported are compared with the licence

Limit Values specified in Licence PO P0385-01 and all results are in compliance with the

licence limits.

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 05-05-2016:00:49:27

___________________________________________________________________________


Ref. 22801, Page 3 of 8

1.0 Scope .................................................................................................................. 4

2.0 Survey protocol .................................................................................................. 4

2.1 Protocol .............................................................................................................. 4

3.0 Monitoring Results ............................................................................................ 5

3.1 Results for Pot Enclosure Exhaust 1 09 December 2015, 10:22-10:52 ............. 5



3.4 Reference Conditions for Pot Enclosure Exhaust 1 ......................................... 6

4.0 Supporting Information .................................................................................... 6

4.1 Monitoring team information ........................................................................... 6

4.2 Substance(s) monitored, SOP’s, Standard Methods and Accreditation Status6

4.3 Equipment used and Quality checks ................................................................. 6

4.4 Reporting results ............................................................................................... 7

4.4.1 Expression of test results ................................................................................... 7

4.4.2 Reporting results less than the detection limit .................................................. 7

4.4.3 Uncertainty calculation ..................................................................................... 7

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 05-05-2016:00:49:27

___________________________________________________________________________


Ref. 22801, Page 4 of 8

1.0 Scope

This report deals with a survey of emissions to the atmosphere from the Pot Enclosure

Exhaust 1 at the Galco Steel facility at Gracedieu Road, Co. Waterford. The survey

was completed to satisfy the requirements of the IPPC Licence Register No. 0385-01.

The licence requirements satisfied are as follows:

Reporting period Annual 2015

EMISSION

POINT PARAMETER

SAMPLING METHOD AND

MEDIUM & ANALYSIS

METHODOLOGY

STANDARD REFERENCE

METHOD

Pot

Enclosure

Exhaust 1

TEMPERATURE

PRESSURE

VELOCITY,

FLOW

Pitot tube coupled with

pressure measurement device

or anemometer, and

temperature measurement

device

EN/ISO 16911-1:2013

Ammonia**

Isokinetic/Non-isokinetic

0.1N H₂SO₄ /

Analysis by IC

EN 14791:2005

HCl*

Isokinetic/Non-isokinetic

Reagent grade water /

Analysis by ISE

EN 1911:2010

Metals**

Isokinetic

Nitric peroxide solution /

Analysis by ICP-MS, ICP-OES

or ICP-AAS

EN 14385:2005

* Monitoring and analysis currently covered by ISO 17025 Accreditation

** Monitoring currently covered by ISO 17025 Accreditation, with analysis

Subcontracted to ISO 17025 Accredited Lab

2.0 Survey protocol

2.1 Protocol

TMS Environment Ltd personnel conducted the survey on the 09th

December 2015.

Emissions to atmosphere from the Pot Enclosure Exhaust 1, at Galco Steel, Gracedieu

Road, Co. Waterford were monitored during the visit.

The survey was completed in order to meet the requirements of the company’s IPPC

Licence (Reg 0385-01).

Relevant Process conditions during the survey are summarized below.

Operational information during testing

Emission monitoring

point Date Time

Details

Pot Enclosure Exhaust 1 09 December 2015

10:22 – 10:52

11:01 – 11:31

11:42 – 12:12

Normal operation

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 05-05-2016:00:49:27

___________________________________________________________________________


Ref. 22801, Page 5 of 8

A Site Specific Protocol was prepared in accordance with EPA Air Guidance Note

AG1 and CEN/TS 15675:2007 after a site review has been conducted with site

personnel. A site risk assessment was completed prior to commencement of any

monitoring to confirm that the monitoring could be carried out in a safe manner. All

necessary PPE was worn at all times on site.

3.0 Monitoring Results

The results of the air emission monitoring reported in this document are presented in

tables below. The methods used are defined by Standard Operating Procedures

(SOP), each SOP has a unique number, and details regarding each SOP are given in

Section 4.0 of this report.

3.1 Results for Pot Enclosure Exhaust 1 09 December 2015, 10:22-10:52



Parameter Emission

limit value

Emission

results Uncertainty Units

Mass

Emission

(kg/hr)

Compliance

Chloride

(as HCl) 30 < 0.1 ±0.02 mg/m3 < 6.90 x 10-4 Yes

Volume

Flow Rate 10,500 5,498 ± 319 Nm

3/hr - Yes

Parameter Emission

limit value

Emission


Mass

Emission

(kg/hr)

Compliance

Ammonia N/S < 0.3 ± 0.04 mg/m3 1.70 x 10-3 Yes

Volume

Flow Rate 10,500 5,345 ± 311 Nm

3/hr - Yes

Parameter Emission

limit value

Emission


Mass

Emission

(kg/hr)

Compliance

Cadmium 0.5 2.3 x10-4 ± 3.15 x 10-5 mg/m3 1.19 x 10-6 Yes

Lead 2 5.6 x10-3 ± 5.07 x 10-4 mg/m3 1.92 x 10-5 Yes

Zinc 5 7.0 x10-2 ± 9.89 x 10-3 mg/m3 3.74 x 10-4 Yes

Volume

Flow Rate 10,500 5,228 ± 304 Nm

3/hr - Yes

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 05-05-2016:00:49:27

___________________________________________________________________________


Ref. 22801, Page 6 of 8

3.4 Reference Conditions for Pot Enclosure Exhaust 1

Reference Conditions for concentrations and volume flow as expressed as:

4.0 Supporting Information

4.1 Monitoring team information

Name Function Qualification

Graham Adams Environmental Engineer

• Bachelor of Engineering (Hons.) in

Manufacturing Engineering.(2006) ITT Dublin

• National Diploma in Mechanical Engineering

(2004), ITT Dublin

Enda Flood Environmental Scientist

• PgC (Hons) in Green Technologies (2010),

UCD

• BAgSc (Hons) in Agricultural and

Environmental Science. (2008), UCD

4.2 Substance(s) monitored, SOP’s, Standard Methods and Accreditation Status

Substance

Monitored SOP

Standard

Method

Analysis

by

Accreditation

Range mg/m3

ISO 17025

Accreditation

Status

Analysis

Date

Heavy Metals QP-SITE-

2017 EN 14358 ESG 0.005-50 B

22 Jan

2016

HCl QP-SITE-

2014 EN 1911 TMS 0.05-5,000 A

11 Jan

2016

Ammonia QP-SITE-

2013

EN

14791:2005/

US EPA 26A

ESG N/A B 18 Jan

2016

Moisture QP-SITE-

2020

EN

14790:2005 TMS 2-40% A

09 Dec

2015

Velocity &

Temp

QP-SITE-

2006

QP-

SITE2027

EN 13284-

1:2002/

EN/ISO 16911-

1:2013

TMS

2.8-25m/s

0.13-40m/s

0-1,200oC

A 09 Dec

2015

Note 1: ISO 17025 Accreditation Status: A – TMS accredited for Monitoring and Analysis, B – TMS accredited for

Monitoring, Subcontract Lab accredited for Analysis.

4.3 Equipment used and Quality checks

Equipment Equipment ID Quality Check

Tecora G4 Isokinetic sampler M-S-E-1-1 Annual Calibration

Balance Scales M-S-E-13-1 On Site Eccentricity check

Temperature, K Pressure, kPa Oxygen % Moisture %

273 101.3 N/A Dry

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 05-05-2016:00:49:27

___________________________________________________________________________


Ref. 22801, Page 7 of 8

4.4 Reporting results

4.4.1 Expression of test results

All test results are expressed to one decimal place lower than the Emission Limit Value

(ELV), while uncertainty of measurement results are expressed to two decimal places lower

than the ELV, e.g. where an ELV of 50mg/m3 applies, the reported result shall be reported to

the first decimal place e.g. 6.6mg/m3

with the uncertainty of measurement reported to two

decimal places, e.g. ±0.12mg/m3.

4.4.2 Reporting results less than the detection limit

If a single result is reported as being less than the limit of detection, the measurement result is

expressed using a less than “<” sign, e.g. <0.005 mg/Nm3. Where a number of parameter

results, found to be less than the limit of detection, are expressed as an overall parameter,

these results are calculated as per Section 3.3, Method 3 (Half the Limit of Detection) of the

EPA BREF Guidance on the General Principles of Monitoring. This percentage method

provides an estimation of the value of the measurement. It is reported without the less than

“<” sign, e.g. 0.05 mg/Nm3.

4.4.3 Uncertainty calculation

An estimation of the uncertainty of measurement is attached to all measurements.

Measurement uncertainties are based on calibration data and laboratory repeatability

experiments. All uncertainties are given at a 95% confidence, based on applying a coverage

factor of k=2 to the combined uncertainties for each measurement. The uncertainty of

measurement associated with emissions monitoring are provided in the Table below.

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 05-05-2016:00:49:27

___________________________________________________________________________


Ref. 22801, Page 8 of 8

Table 4-1: Uncertainty of Measurement

Parameter Source of uncertainty

Estimated

uncertainty

%

Combined

uncertainty

%

Expanded

uncertainty %

(95% confidence level)

Volume

Flow

Velocity 2

2.8 6%

Stack Temperature 0.5

Stack Pressure 0.5

O2 1

CSA 2

Metals

Flow/ADM Manometer 3

7.24 14%

Oxygen/Lancom

Analyser 6

Temperature/Lancom

Analyser 0.5

Leak check 2

Moisture 1

Isokinetic uncertainty 0.2

Analytical/Lab 12

HCl

Volume Flow 3

6.52

13%

Oxygen/Lancom

Analyser 1

Temperature/Lancom

Analyser 0.5

Leak check 0

Moisture 1

Isokinetic uncertainty 0

Analytical/Lab 10

Ammonia

Volume Flow 3

5.94 12%

Oxygen/Lancom

Analyser 1

Temperature/Lancom

Analyser 0.5

Leak check 0

Moisture 1 Isokinetic uncertainty 0

Analytical/Lab 10

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 05-05-2016:00:49:27

___________________________________________________________________________


Ref. 22801, Appendix I

APPENDIX I


GALCO STEEL LTD WATERFROD

DECEMBER 2015

EMISSION POINT DETIALS


For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 05-05-2016:00:49:27

___________________________________________________________________________



Appendix 1: Emission Point Pot Enclosure Exhaust 1

Appendix1:1 – Stack Diagram

Appendix1:2 - Stack Information

Emission Point Pot Enclosure Exhaust 1

Stack Diameter 0.55 m

Stack Cross Sectional Area 0.238 m2

Number of Ports 2

Number of sampling planes 2

Number of Sampling points per line 4

Power supply available Yes

Shelter at platform Yes

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 05-05-2016:00:49:27

___________________________________________________________________________



Appendix1:3 - Stack Measurements Pot Enclosure Exhaust 1 HCL Monitoring

Reference method HCl - EN 1911

Sampling date 09 December 2015

Sampling time 10:22 – 10:52

Sampling technique

Flue gas sampling system Isokinetic sampling with heated probe

Oxygen measurement technique FGA

Material

Sampling probe material Titanium

Filter material Titanium

Sampling conditions

Probe temperature [oC] 150

Filtration temperature [oC] 150

Total sampling time [min] 30

Sampled volume of the dry gas at STP [m3] 0.32

Average flue gas velocity [m/s] 6.91

Nozzle diameter [mm] 6.00

Ratio of highest to lowest velocity <3:1

Swirl test result Pass

Initial leak test result [% of expected sampling

flow rate]

0.00

Final leak test result [% of average sampling

flow rate]

0.0

Average flue gas temp temperature [oC] 18.1

Reference conditions Actual conditions

Moisture [%] 0 Moisture [%] 0.4

Temperature [K] 273 Temperature [K] 291.1

Pressure [kPa] 101.3 Pressure [kPa] 100.9

Oxygen [%] N/A Oxygen [%] N/A

Deviation from isokinetic conditions [%] 0.0

Deviation from reference method There was no deviation from reference

method.

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 05-05-2016:00:49:27

___________________________________________________________________________



Appendix1:4 - Stack Measurements A1 Ammonia Monitoring

Reference method US EPA Method 26



Sampling technique

Flue gas sampling system Isokinetic in stack filtration system

Oxygen measurement technique Electrochemical

Material

Sampling probe material SS

Filter material Quartz

Sampling conditions



Average sampling nozzle flow rate [l/min] 10.69

Deviation from isokinetic conditions [%] 0



Absorption temperature [oC] <30


Nozzle diameter [mm] 6

Ratio of highest to lowest velocity < 1:3



flow rate]

0


flow rate]

0



Moisture [%] Dry Moisture [%] 1.2



Deviation from reference method

There was no deviation reference method

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 05-05-2016:00:49:27

___________________________________________________________________________



Appendix1:5 - Stack Measurements A1 Metals Monitoring

Reference method EN 14385, I.S. EN 13211



Sampling technique

Flue gas sampling system Isokinetic out stack filtration system

Oxygen measurement technique Electrochemical

Material

Sampling probe material Quartz

Filter material Quartz

Trapping solution for metals 3.3%HNO3 @ 1.5%H2O2 @ DI H2O

Sampling conditions


oC


oC

Average sampling flow rate [l/min] 10.74




Nozzle diameter [mm] 6.00

Ratio of highest to lowest velocity < 1:3



flow rate]

< 2


flow rate]

< 2



Moisture Dry Moisture [%] 2.29



Oxygen [%] N/A Oxygen [%] N/A

Deviation from isokinetic conditions [%] 0

Deviation from reference method There was no deviation from reference

method

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 05-05-2016:00:49:27

___________________________________________________________________________



Appendix1:6 – Manual method results Pot Enclosure Exhaust 1

Parameter Result mg/m3 Normalised Result mg/Nm

3

HCL < 0.12 < 0.13

Ammonia < 0.31 < 0.32

Cadmium 0.0002 0.0002

Lead 0.0035 0.0036

Zinc 0.0683 0.0699

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 05-05-2016:00:49:28

___________________________________________________________________________


Ref. 22801, Appendix II

APPENDIX I


GALCO STEEL LTD WATERFROD

DECEMBER 2015

EQUIPMENT CALIBRATION

CERTIFICATES


For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 05-05-2016:00:49:28

___________________________________________________________________________



For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 05-05-2016:00:49:28

___________________________________________________________________________



For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 05-05-2016:00:49:28

___________________________________________________________________________



For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 05-05-2016:00:49:28

___________________________________________________________________________



For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 05-05-2016:00:49:28

___________________________________________________________________________



For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 05-05-2016:00:49:28

Documents

t s environment · PDF file(SOP), each SOP has a ... Balance Scales M-S-E-13-1 On Site Eccentricity check Temperature, K Pressure, kPa Oxygen % Moisture %