40 CFR 98 Tier 4 Greenhouse Gas Reporting with Stack
Emissions Flow MeterBrian Fieser, DP Flow Director of Operations
Joel Lemke, DP Flow Marketing Manager
Emerson Process ManagementRosemount Measurement Division
Agenda
Overview of Mandatory Reporting Rule DP Flow for Stack Measurements Applying DP Flow to Tier 4 GHG Measurements
Purpose of the GHG MRR Rule
U.S. GHG Emissions (CO2e)
by Economic Sector (2007)
Source: http://www.epa.gov/climatechange/emissions/ghgrulemaking.html
Rule overview
“Kyoto Six” must be reported– Combustion Products
• CO2
• CH4
• N2O– Fluorinated Gases
• SF6
• Perfluorocarbons (PFCs)• Hydrofluorocarbons (HFCs)
Converted to CO2 equivalents using Global Warming Potentials (GWP)– CO2 = 1– CH4 = 21– N2O = 310– Fluorinated gases ~1000’s
Example Emissions Calculation*
*Rule contains standard estimates for amounts of GHG produced for each fuel
burned; 1 metric ton = 1000 kg
Greenhouse Gas
Annual emissions
(metric tons)
Global Warming Potential
Emissions total (CO2e)
CO2 100,000 1 100,000
CH4 1000 21 21,000
N2O 100 310 31,000
Total Annual Emissions (metric tons CO2e) 152,000
Applicability to different types of facilities
Facilities can have multiple source categories Must evaluate each source category separately to
assess applicability to the rule– “All-in” categories– Threshold categories– Stationary combustion
If rule applies, report emissions for all source categories for which methods are provided in the rule
Source: http://www.epa.gov/climatechange/emissions/ghgrulemaking.html
Does it apply to me?
Source: http://www.epa.gov/climatechange/emissions/ghgrulemaking.html
Refineries/Petrochem
Aluminum
Ammonia
Refrigerants
Iron/Steel
Glass
Hydrogen
Pulp & PaperBoilers/Process Heaters
Combustion Turbines
Stationary Engines
Incinerators
Reporting Status
CY 2010 Report must be uploaded to EPA website by March 31st 2011
Initial deadline for active reporting system was March 31st 2010
Many facilities received extensions up to December 31st 2010
EPA has suggested possibility of mandatory CO2e reductions starting in CY 2011
CY 2011 first year for Oil & Gas and some other facilities
When to use each “Reporting Tier”Reporting
TierConditions
of use:How to
Use Notes
1
Any fuel in Table C-1 (including biomass)
Unit < 250 mmBtu/hr
HHV NOT routinely sampled or supplied
“Company records” for fuel use
Default HHV & EF from Table C-1
Also for MSW units of any size not making steam and not required to use Tier 4
2
Any fuel in Table C-1 (including biomass)
Unit < 250 mmBtu/hr
Unit > 250 mmBtu/hr burning pipeline NG or distillate fuel oil
“Company records” for fuel use
Supplied or sampled HHV & default EF from Table C-1
Also for MSW units of any size making steam and not required to use Tier 4
3
May be used for any size unit & any fuel
Required for units > 250 mmBtu/hr unless Tier 2 applies
Required for fuels not in Table C-1
Direct fuel flow meters
4Existing CEMS system Combine hourly CO2
concentration readings w/ stack volumetric flow meter
O2 monitor may substitute for CO2 monitor
Advantages to Tier 4 Reporting
Aggregates all fuel types Direct measurement of CO2
Simplicity – may only require single metering system Mandatory if CEMS system already in place
Agenda
Overview of Mandatory Reporting Rule DP Flow for Stack Measurements Applying DP Flow to Tier 4 GHG Measurements
Annubar Averaging Pitot Tube
Explain the Annubar
How an Annubar Works
Theory of operation
FLOW
PH PL
PL
PL
Flow
Impa
ct
Pre
ssu
re
Suc
t.
Pre
ss
Suc
t.
Pre
ss
DP(hw) = PH(avg.) - PL(avg.)
PH(avg.) = High Pressure
PH(avg.) = Low Pressure
How It WorksT-Shape Design Features
Location of Low pressure
sensing ports
maximizes DP Signal
How an Annubar Works Low Pressure Measured in Stagnation Zones
Blunt obstruction leads to higher DP
• T-Shape results in high DP Signal
• Stagnation zones reduce noise/increase repeatability
• Impact zone deflects particles to resist plugging
Low pressure sensing ports on downstream side of Annubar in less turbulent zones
Stagnation pressure exerted on front of sensor deflects particulates front slotted opening
Less turbulent region on backside of Annubar® prevents particulates from entering sensing ports
How It Works“T-Shape” Design Helps Eliminate Pluggage
Annubar Flowmeters
1.5% Accuracy
Extreme Velocity / Pressure /
Temperature
Highest Performance
0.75% Accuracy
Agenda
Overview of Mandatory Reporting Rule DP Flow for Stack Measurements Applying DP Flow to Tier 4 GHG Measurements
Agenda
Overview of Mandatory Reporting Rule Tier 4 Measurement Methods
Measurement Options
Stack Annubar– Custom designed Annubar unit with special connections and
mounting to install into exhaust-point applications– Full or partial span
S-Type Pitot– Partial span pitot tube measurement– Single point calculation per CFR Part 60, Appendix A,
Method 2
Measurement Options
Stack Annubar – Full spanning– Custom designed Annubar unit with special connections and
mounting to install into exhaust-point applications
Stack Annubar – Partial spanning– Designed to insert only partially into stack instead of
crossing its whole diameter
Severe Service Annubar– Heavy-duty Annubar designed for corrosive measurements
or those having extreme pressure or temperature
Rosemount Stack Annubar for Tier 4 (CEMS) GHG Reporting
Flexible mounting hardware– Standard ANSI flanges– Customer or Factory supplied
Captive opposite support design Large diameters: up to 15 feet
Stack Annubar – Full span
Spans full pipe, integrating measurement signal from entire flow profile
Firmly supported at both ends Best solution for accuracy and strength
Stack Annubar – Partial Span
Spans approximately 1/3 of stack Flange mounting at top end Cost effective, very large pipe, single side access
Stack Annubar – Hardware
Oversized & additional porting– Blockage prevention– Rod-out ready– Purge-system ready
Opposite side packing gland– Through ported
– Ensures proper support
– Simplifies installation
Stack Annubar Drawing
“Stub” 1/3 pipe ID length available at ±3% accuracy
Severe Service Annubar PrimaryWetted Materials to Suit Application
Machined Sensor Extremely high structural strength Can be made from variety of materials
– 316 Stainless Steel– Alloy C-276 (Hastelloy)– Alloy 800H (Incoloy)– PVDF (KYNAR)– Titanium– Other
S-Type Pitot
Conforms to CFR Part 60, Appendix A, Method 2, providing industry standard flow coefficient
Requires properly developed flow profile and steady flow
Cost effective, easy to install
Limits
SolutionLow Flow
Max Flow
Accuracy Cost
Stack Annubar, Full-span Best High Best $$$
Stack Annubar, Partial-span Better Low Medium $$
S-Type Pitot Good High Lowest $
Limits
SolutionLow Flow
Max Flow
Accuracy Cost
Stack Annubar, Full-span Best High Best $$
Stack Annubar, Partial-span Better Low Least $
Severe Service Annubar Good High Medium $$$
Stack Annubar Performance
Annubar accuracy 0.75 – 1.5% of rate Above assumes fully developed flow profile “Good” profile often not found in stacks In situ calibration performed to meet high
measurement accuracy requirements
In-Line Flow Calibration
At or near the location of an existing Annubar®, the pitot tube is used to determine the actual flow rate, compensating for any special conditions.
The actual pitot traverse is done following the guidelines of Code of Federal Regulations (CFR) number 40, part 60
Preferred Flow Testing Location
To D.P. Transmitter
HI Pressure Sensing Port
RTD
Low Pressure Sensing Port
Stausscheibe Pitot
(aka: “S-type” or open face)
In-Line Flow Calibration
Inline Calibration Example
Locale: USA 14 fps stack velocity 42” diameter Method: In-line pitot traverse Result: Successful inline
calibration at customer running load
Application Example
Locale: Europe 45 fps stack velocity 98” diameter Dirty flow Purge capability
required
Accurate measurement No plugging issues
40 CFR 98 ApplicationCorrosive Flue Gases
Chemical Industry Stacks– Incinerators– Halogen Acid Furnace– Thermal Oxidizer
Titanium Sensor Material (for chlorides)
30 to 42-inch lines In situ calibrations planned for
November
CEMS Compatibility
Annubars regularly integrated into CEMS
Stack Annubars have connections for automatic blow-down
Roddable, Plug-resistant design
Combined with CO2 or O2 Concentration
Other Resources Workshop # 06-425: “Get Your Ducts in a Row For Better Flow
Measurement”, Amy Johnson & Dave Winters– Tue 10:00-11:30am, 202A– Wed 8:00-9:30am 002B
Greenhouse Gas Solutions Booth at Technology Exhibits EPA Web
http://www.epa.gov/climatechange/emissions/ghgrulemaking.html Rosemount Web
http://www2.emersonprocess.com/en-US/brands/rosemount/Rosemount-Site-Map/Greenhouse-Gas-Compliance/Pages/index.aspx Micro Motion Web
http://www2.emersonprocess.com/en-US/brands/micromotion/industries/Chemical/ghg/Pages/index.aspx 40 CFR 60 – Standards of Performance for New Stationary Sources