40 cfr 98 tier 4 greenhouse gas reporting with stack emissions flow meter

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