birkenhead annual stack monitoring report oct 2015 … · 2017. 2. 15. · monitoring of stacks 4a...

BIRKENHEAD ANNUAL STACK

MONITORING REPORT

Oct 2015 – Sept 2016

Version: 1

Submitted: 31st October 2016

[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

[Adelaide Brighton Cement Birkenhead Works. License Number: 1126

2 Annual Stack Monitoring Report

Annual Report Oct 2015 –Sept 2016

Monitoring Objective The aim of the Annual 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 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 under schedule 6

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

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 Schedule 6

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 below detail, the hourly averages of 10 minute averages of stack emissions

from 4A and 4B stacks. For each month there is a graph for 4A stack and 4B stack. The

thin red line indicates the ABC Birkenhead license reporting level and the heavy red line

indicated the Air Quality Policy Schedule 1 limit. The tables below each chart show the

results of RCA (root cause analysis) that was undertaken for hourly average particulate

emissions above the Air Quality Policy Schedule 1 limit or the ABC Birkenhead license

reporting levels. RCA on particulate emissions above the ABC Birkenhead license

reporting levels are also conducted.

Tag RCA Number Description

0

50

100

150

200

250

300

1/10

3/10

5/10

7/10

9/10

11/10

13/10

15/10

17/10

19/10

21/10

23/10

25/10

27/10

29/10

31/10

Stac

k Em

issi

on

Co

nce

ntr

atio

n (m

g/N

m3 )

4A Stack Emissions for October 2015

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




0

50

100

150

200

250

300

1/11

3/11

5/11

7/11

9/11

11/11

13/11

15/11

17/11

19/11

21/11

23/11

25/11

27/11

29/11

Stac

k Em

issi

on

Co

nce

ntr

atio

n (m

g/N

m3)

4A Stack Emissions for November 2015





0

50

100

150

200

250

300

1/12

3/12

5/12

7/12

9/12

11/12

13/12

15/12

17/12

19/12

21/12

23/12

25/12

27/12

29/12

31/12

Stac

k Em

issi

on

Co

nce

ntr

atio

n (m

g/N

m3 )

4A Stack Emissions for December 2015





0

50

100

150

200

250

300

1/10

3/10

5/10

7/10

9/10

11/10

13/10

15/10

17/10

19/10

21/10

23/10

25/10

27/10

29/10

31/10

Stac

k Em

issi

on

Co

nce

ntr

atio

n (m

g/N

m3 )

4B Stack Emissions for October2015

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




0

50

100

150

200

250

300

1/11

3/11

5/11

7/11

9/11

11/11

13/11

15/11

17/11

19/11

21/11

23/11

25/11

27/11

29/11

Stac

k Em

issi

on

Co

nce

ntr

atio

n (m

g/N

m3)

4B Stack Emissions for November 2015





0

50

100

150

200

250

300

1/12

3/12

5/12

7/12

9/12

11/12

13/12

15/12

17/12

19/12

21/12

23/12

25/12

27/12

29/12

31/12

Stac

k Em

issi

on

Co

nce

ntr

atio

n (m

g/N

m3)

4B Stack Emissions for December 2015





0

50

100

150

200

250

300

1/1

3/1

5/1

7/1

9/1

11/1

13/1

15/1

17/1

19/1

21/1

23/1

25/1

27/1

29/1

31/1

Stac

k Em

issi

on

Co

nce

ntr

atio

n (m

g/N

m3 )

4A Stack Emissions for Jan 2016





0

50

100

150

200

250

300

1/2

3/2

5/2

7/2

9/2

11/2

13/2

15/2

17/2

19/2

21/2

23/2

25/2

27/2

29/2

Stac

k Em

issi

on

Co

nce

ntr

atio

n (m

g/N

m3)

4A Stack Emissions for Feb 2016





0

50

100

150

200

250

300

1/3

3/3

5/3

7/3

9/3

11/3

13/3

15/3

17/3

19/3

21/3

23/3

25/3

27/3

29/3

31/3

Stac

k Em

issi

on

Co

nce

ntr

atio

n (m

g/N

m3 )

4A Stack Emissions for Mar 2016





0

50

100

150

200

250

300

1/1

3/1

5/1

7/1

9/1

11/1

13/1

15/1

17/1

19/1

21/1

23/1

25/1

27/1

29/1

31/1

Stac

k Em

issi

on

Co

nce

ntr

atio

n (m

g/N

m3 )

4B Stack Emissions for Jan 2016





0

50

100

150

200

250

300

1/2

3/2

5/2

7/2

9/2

11/2

13/2

15/2

17/2

19/2

21/2

23/2

25/2

27/2

29/2

Stac

k Em

issi

on

Co

nce

ntr

atio

n (m

g/N

m3)

4B Stack Emissions for Feb 2016





0

50

100

150

200

250

300

1/3

3/3

5/3

7/3

9/3

11/3

13/3

15/3

17/3

19/3

21/3

23/3

25/3

27/3

29/3

31/3

Stac

k Em

issi

on

Co

nce

ntr

atio

n (m

g/N

m3)

4B Stack Emissions for Mar 2016





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 2016




Tag Description

A1 4A field failure – kiln taken offline.

0

50

100

150

200

250

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 2016


A1




0

50

100

150

200

250

300

1/6

3/6

5/6

7/6

9/6

11/6

13/6

15/6

17/6

19/6

21/6

23/6

25/6

27/6

29/6

Stac

k Em

issi

on

Co

nce

ntr

atio

n (m

g/N

m3 )

4A Stack Emissions for June 2016




Tag Description

B1 Kiln/calciner trip

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 )

4B Stack Emissions for April 2016


B1




0

50

100

150

200

250

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)

4B Stack Emissions for May 2016





0

50

100

150

200

250

300

1/6

3/6

5/6

7/6

9/6

11/6

13/6

15/6

17/6

19/6

21/6

23/6

25/6

27/6

29/6

Stac

k Em

issi

on

Co

nce

ntr

atio

n (m

g/N

m3)

4B Stack Emissions for June 2016





0

50

100

150

200

250

300

1/7

3/7

5/7

7/7

9/7

11/7

13/7

15/7

17/7

19/7

21/7

23/7

25/7

27/7

29/7

31/7

Stac

k Em

issi

on

Co

nce

ntr

atio

n (m

g/N

m3 )

4A Stack Emissions for July 2016





0

50

100

150

200

250

300

1/8

3/8

5/8

7/8

9/8

11/8

13/8

15/8

17/8

19/8

21/8

23/8

25/8

27/8

29/8

31/8

Stac

k Em

issi

on

Co

nce

ntr

atio

n (m

g/N

m3)

4A Stack Emissions for August 2016





0

50

100

150

200

250

300

1/9

3/9

5/9

7/9

9/9

11/9

13/9

15/9

17/9

19/9

21/9

23/9

25/9

27/9

29/9

Stac

k Em

issi

on

Co

nce

ntr

atio

n (m

g/N

m3 )

4A Stack Emissions for September 2016





0

50

100

150

200

250

300

1/7

3/7

5/7

7/7

9/7

11/7

13/7

15/7

17/7

19/7

21/7

23/7

25/7

27/7

29/7

31/7

Stac

k Em

issi

on

Co

nce

ntr

atio

n (m

g/N

m3 )

4B Stack Emissions for July 2016





0

50

100

150

200

250

300

1/8

3/8

5/8

7/8

9/8

11/8

13/8

15/8

17/8

19/8

21/8

23/8

25/8

27/8

29/8

31/8

Stac

k Em

issi

on

Co

nce

ntr

atio

n (m

g/N

m3)

4B Stack Emissions for August 2016





0

50

100

150

200

250

300

1/9

3/9

5/9

7/9

9/9

11/9

13/9

15/9

17/9

19/9

21/9

23/9

25/9

27/9

29/9

Stac

k Em

issi

on

Co

nce

ntr

atio

n (m

g/N

m3)

4B Stack Emissions for September 2016


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 as per the suppliers

standard.

Key Process Improvements for the period

(for more detailed analysis of improvement initiatives refer to the quarterly reports)

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:

Plant Stack Emissions Improvement Team

Following an FLSmidth Airtech specialist site visit in November 2015 to review the

operability of the site electrostatic precipitators and fabric filter bag house,

improvements were trialed and implemented on all of the electrostatic precipitator field

controllers. Changes were made to improve the collecting efficiency during process

upsets (e.g. Raw mill starts) and during normal operation to reduce the emissions. The

change lowered baseline emissions on 4A and 4B electrostatic precipitator during both

normal and unstable operating conditions.

Annual shutdown improvements

Installation of kiln ventilation fan which allowed for extensive bypass ESP

maintenance. The new ventilation infrastructure allowed much greater scope in

the bypass ESP, and a significant amount of mechanical work and optimization

was performed.

4B ESP major maintenance, with regular mechanical maintenance along with

major outlet dampening wall replacement.

Installation of build-up inhibiting kiln ‘blasters’ to prevent process instability

from affecting the bypass system. This instability was a major cause of 4A stack

excursions.

New bypass dust handling system installed to eliminate dust blockages and

potential excursions in the handling system.



Bypass Operation Optimisation

The Birkenhead technical and operations team have been analyzing the operation of the

bypass system over the past 12 months to investigate how the environment footprint

can be minimized as much as possible. The outcome of this investigation was an

improvement on the gas conditioning bypass system, which was intended to increase

the collection efficiency of the bypass electrostatic precipitator.

The graph above shows the dramatic improvement from the changes made on 5/8/16.

The blue line represents the particulate emissions measured on 4A stack, while the red

line indicates the bypass temperature control (high resolution version in Q3 quarterly

report). The emissions on 4A stack have dropped considerably, and the process is more

resilient to disturbances. The change observed has greatly contributed to future project

plans for emissions reduction on site.

Cooler Bag Filter trials

New cooler filter bags were trialled in cell 4 of the kiln 4 cooler bag filter during the

annual shutdown. This area showed the greatest wear rates in the previous campaign,

and so it was determined to be the best location for a trial. The trial bags were made

from a higher durability weave, as well as additional designed reinforcement around the

cuffs of the bags.



Conclusion

This is the ninth annual report generated as a result of a new license. There were no

incidents with an hourly average particulate concentration above 250mg/Nm3 on 4B or

4B stack. There was one incidents based on a one hourly average over the reporting

limit of 150mg/Nm3 on 4A stack where the 4A ESP experienced a field failure. The kiln

was taken offline to repair. There was one incident above the reporting limit of

80mg/Nm3 on 4B stack, which was occurred during a combustibles trip on the

kiln/calciner.

birkenhead annual stack monitoring report oct 2015 … · 2017. 2. 15. · monitoring of stacks 4a...

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