2012 wm-awma spring conference (caudell and mcquiston)
TRANSCRIPT
1. West Michigan Air & WasteManagement AssociationSpring Conference GVSU Eberhard CenterApril 26, 2012 2. Scott McQuiston, P.E. John Caudell, P.E.Lansing Board of Water & Light Fishbeck, Thompson, Carr, & [email protected] [email protected] 3. Boiler MACT Compliance OptionsSmall & Hardly-Used Leadsto Expensive Solutions Scott McQuiston, P.E. 4. Limited-Use Category1. Rated capacity of greater than 10 MMBtu/hr2. No more than 876 hours per year of operation 5. Why Not A Hardly Used Category? Actual operation is less than 10% of: Emissions (PTE) Fuel Usage Capacity Factor 3-year average of hours of operation 6. Emission Limits Emissions Must Not Exceed, exceptPollutantduring startup and shutdown CO 10 ppmvd @ 3% O2 PM0.0075 lb/MMBtu HCl0.00033 lb/MMBtu Hg 3.6 10-6 lb/MMBtu D/F 4 ng/dscm (corrected to 7% O2) 7. Carbon Monoxide EPA Database Results range from 1.67 ppm to 700+ ppm 58 Stack Tests 8 Below 10 ppm 27 reported at 100 ppm (Detection Limit?) 8. Control Options Low Emissions Retrofit Kit Catalytic Oxidizer $150,000 Solution $350,000 Solution Expected CO = 10 ppm 95% Removal Expected PM = 0.025 ppm PM Controls = $320,000 9. Control Options Gas is King! Only Requirement is an Annual Tune-Up No Emission Limits for Gas No Annual Stack Tests or Fuel Analyses No Requirement for an Energy Assessment Conversion Costs Only $300,000 Future Gas will be Cheap, Right? 10. Questions?Scott McQuiston, P.E.Lansing Board of Water & [email protected] 11. Equipment Maintenance We Dont Need No Stinkin Equipment MaintenanceJohn Caudell, P.E. 12. New Equipment 13. 5 Years Later Good Maintenance 14. 5 Years Later Poor Maintenance 15. Malfunction Abatement Plan Preventative Maintenance Malfunction Response 16. Malfunction Abatement Plan Focus on Detailed Summary Tables Less on Lengthy Narratives ThatMost Will Probably Not Read Summary Tables Simplifies MAPRequirements for Plant Staff andAQD Personnel 17. Preventive Maintenance (Baghouse) Control Device Spare Parts on PM Activity DailyWeeklyAnnually (Emission Unit)HandCE004 (baghouse)VisibleCheck photohelicReplacementEmissions,gauge for proper belts, Bearings,CE008 (baghouse)VisualNon-certified Check oil / operation and and Filter bags Inspections,VE readings replace bags pressure drop for each Maintenance rangeBaghouse model ActivitiesCE010 (baghouse) 18. Malfunction Response (Baghouse) Possible Corrective Steps toControl Device Operating Parameter MalfunctionPossible MalfunctionsReturn Unit to Proper(Emission Unit) Parameters RangeDetection Operation Unit will be brought off- 0 - 20%Visible Emission Bag(s) may have failed or Baghouses Opacity line and the bagsmax.exceed 20% are not properly seated checkedUnit will be brought off- One or more bags may CE004line and the bags be plugged or blindedcheckedUnit will be brought off- Air to the cleaning jets line and air pulse CE008Differential 0.5 - 5"Pressure drop maybe pluggedcleaning system will be Pressure waterabove 5"inspectedMaintain spare Magnehelic unit may CE010magnehelic gauge for have failedpossible replacement 19. Preventive Maintenance (Scrubber) Control Device Spare Parts onPM Activity DailyWeekly Monthly (Emission Unit)Hand Visible Emissions, Level Check site gaugesFermentation VisualNon-certified Pump oil transmitter,for liquid flowScrubberInspections,VE readingsreservoir fullPump rebuildand liquid levelMaintenance kit, ValveActivities Visible Emissions, Pressure Check site gauges VisualNon-certified Pump oil transmitter,Vent Gas Scrubber for liquid flowInspections,VE readingsreservoir fullPump rebuildand liquid levelMaintenancekitActivities 20. Malfunction Response (Scrubber)Possible Corrective Steps toControl Device Operating ParameterMalfunctionPossible MalfunctionsReturn Unit to Proper(Emission Unit) Parameters Range Detection OperationWater flow loopPressure less Water flow to scrubber instrumentation will beVent Gas Differential 50 -150"than 50 repairedScrubberPressure water Pressure greaterPlugged packingUnit will be cleanedthan 150 Visible EmissionsOpacity 0 - 20%Loss of water flowexceed 20%Pressure less Water flow to scrubber Differential 50 -150"than 50 Water flow loopFermentationPressure waterinstrumentation will beScrubber Pressure greaterrepairedPlugged packingthan 150 Water50 - 100Flow rate