ODOUR & ENVIRONMENTAL ENGINEERING CONSULTANTS
Unit 32 De Granville Court, Dublin Rd, Trim, Co. Meath
Tel: +353 46 9437922
Mobile: +353 86 8550401
E-mail: [email protected]
www.odourireland.com
DISPERSION MODELLING ASSESSMENT OF STACK PROCESSES LOCATED IN ALPS
ELECTRIC (IRELAND), CLARA RD, MILLSTREET, CO. CORK.
PERFORMED BY ODOUR MONITORING IRELAND ON THE BEHALF OF ALPS ELECTRIC (IRELAND) LTD, CLARA RD,
MILLSTREET, CO CORK.
REPORT PREPARED BY:
REPORT VERSION:
ATTENTION:
DATE:
REPORT NUMBER:
REVIEWERS:
Dr. Brian Sheridan
Document Ver.4
Ms. Marie Walsh
03rd Jan 2008
2007.A145(4)
Ms. Marie Walsh & Ms Margaret Stokes
Confidential Report 2007A145(4)
Alps Electric (Ireland) Ltd
TABLE OF CONTENTS
Section
Page number
TABLE OF CONTENTS
i
ii
iii
DOCUMENT AMMENDMENT RECORD
EXECUTIVE SUMMARY
1.
1.1
1.2
2.
2.1
2.1.1
2.1.2
2.1.3.
2.1.3.1
2.1.3.2
2.2
2.3
2.3.1
2.3.2
2.4
2.4.1
2.5
2.6
2.7
2.8
2.9
3.
3.1
3.2
3.3.
3.4.
3.5
3.5.1
3.5.2
3.5.2.1
3.5.2.2
3.5.2.3
3.5.2.4
4.
4.1
4.1.1
4.1.2
Introduction and scope
1
Introduction
Scope of the work
1
1
Materials and methods
3
VOC measurements and techniques
Airflow rate measurement
Flame ionisation detector (FID) measurement
Speciated VOC monitoring of exhaust emission points A2-1,
A2-2, A2-3. A2-6 and A2-7.
Sampling of VOC from exhaust emission points A2-1,
A2-2, A2-3, A2-6 and A2-7.
Sorbent tube pre-concentration
Review of historical measurement data
Dispersion modelling assessment
Atmospheric dispersion modelling of air quality:
What is dispersion modelling?
Atmospheric dispersion modelling of air quality:
dispersion model selection
Air quality impact assessment criteria
Air Quality Guidelines for classical pollutants in Ireland
and Europe
Existing Baseline Air Quality
Site location, and locations of sensitive receptors
14
Meteorological data
Terrain data
Building wake effects
Results
5
5
5
5
6
6
7
7
9
12
15
15
15
16
Volumetric airflow rate results for all emission points.
Historic and measured Total organic carbon emission concentration
results (as measured on a FID)
Measured and historical speciated VOC results from emission points
located in Alps Electric (Ireland) Ltd.
Measured and historical classical air pollutants from emission points
located in Alps Electric (Ireland) Ltd.
Dispersion modelling assessment
Results of dispersion modelling assessment for
Classical air pollutants.
Results of dispersion modelling assessment for
Volatile organic compound pollutants.
BAT Volatile organic compound abatement strategy
Review of BREF document for surface treatment
using organic solvents-treatment techniques in general.
Suggested treatment techniques applicable to Alps
Electric (Ireland) Ltd and taken from BREF.
Technical issue to be addressed in any technologies.
Discussion of results
16
18
20
23
26
26
29
35
35
36
38
40
Assessment of air quality impacts due to classical air pollutants
Carbon monoxide (CO)
Oxides of nitrogen (NO2 as NOX)
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3
3
4
i
43
43
43
Confidential Report 2007A145(4)
4.1.3
4.1.4
4.1.5
4.2
Alps Electric (Ireland) Ltd
Sulphur dioxide (SO2)
Total particulates as PM10
Particulate based Lead
Assessment of air quality impacts due to volatile organic
compound air pollutants.
5.
Conclusions
6.
Appendix VI-Air dispersion modelling contour plots.
6.1
6.2
6.3
7.
43
44
44
45
48
Classical air pollutants for Scenario 2-proposed plant operation
Total volatile organic compounds for Scenario 3-existing plant operation
Total volatile organic compounds for Scenario 4-proposed plant
operation
50
50
56
58
Appendix II-Meteorological data used within the
Dispersion modelling study.
60
Appendix III: Checklist for EPA requirements for air
dispersion modelling reporting
61
9.
Appendix IV-Proposed emission guideline/limit values for
emission points in Alps Electric (Ireland) Ltd.
62
8.
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Alps Electric (Ireland) Ltd
Document Amendment Record
Client: Alps Electric (Ireland) Ltd)
Title: Dispersion modelling assessment of stack processes located in Alps Electric (Ireland),
Clara Rd, Millstreet, Co. Cork.
Dispersion
Document
Reference:
modelling assessment of stack process
located in Alps Electric (Ireland), Clara Rd,
Millstreet, Co. Cork.
Project Number: 2007A145(4)
2007A145(1)
2007A145(2)
2007A145(3)
2007A145(4)
Revision
Document for review
Minor amendments
EPA comments
Minor edits
Purpose/Description
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B.A.S.
MW/MS
AMD
MW
Originated
iii
JMC
BAS
BAS
BAS
Checked
B.A.S
B.A.S
B.A.S
B.A.S
Authorised
20/06/2007
15/08/2007
12/12/2007
03/01/2008
Date
Confidential Report 2007A145(4)
Alps Electric (Ireland) Ltd
EXECUTIVE SUMMARY
Odour Monitoring Ireland was commissioned by Alps Electric (Ireland) Ltd, to perform a review
of previous air quality data collected onsite, an air quality measurement and dispersion
modelling assessment of emissions from ten emission points located within Alps Electric
(Ireland) manufacturing facility, Clara, Rd, Millstreet, Co. Cork. The operation of processes
within Alps Electric (Ireland) can lead to emissions of air pollutants and by using atmospheric
dispersion modelling, the potential impact of these pollutants are assessed and compared to
relevant ambient air quality objectives and limits including SI 271 of 2002, TA Luft 2002 and H1
Horizontal Guidance notes limit values. Background air quality data was obtained from
available baseline air quality data generated by the Irish EPA.
Data used within the air dispersion model was collated from previous monitoring reports
generated by an environmental consultancy company while additional measurements were
performed upon 5 emission points by staff from Odour Monitoring Ireland. All measurements
performed by Odour Monitoring Ireland on the 27th April 2007 were performed in accordance
with European standards where possible. These included:
•
•
•
•
ISO10780:1994- Stationary source emissions-Measurement of velocity and volume
flowrate of gas streams in ducts.
IS EN13526:2002-Stationary source emissions-Determination of the mass
concentration of total gaseous organic carbon in flue gases from solvent using
processes-Continuous flame ionisation detector method.
IS EN12619:1999-Stationary source emissions-Determination of the mass
concentration of total gaseous organic carbon at low concentrations in flue gasesContinuous flame ionisation detector method.
I.S. EN13649:2002-Stationary source emissions-Determination of the mass
concentration of individual gaseous organic compounds-Activated carbon and solvent
desorption method.
The main compounds emissions from processes operating within Alps Electric (Ireland) include
Oxides of nitrogen (NOX as NO2), Carbon monoxide (CO), Sulphur dioxide (SO2) and
Particulate matter (PM as PM10) from boiler and Electric generator (process emission points
A1-1 and A1-2) while various volatile organic compounds are emitted from the other eight
emission points. Average modelling scenarios were performed to allow for comparison with
relevant air quality criteria. These included 1-hour mean, 8-hour mean, 24-hour mean, Annual
mean and maximum number of exceedence expressed as percentiles (see Table 2.1 and 2.2).
All processes and source characteristics are outlined within the emission tables. Five years
worth of meteorological was selected (Cork Airport 1993 to 1997) in order to ascertain average
ground level concentrations of pollutants in accordance with the regulatory assessment
criterion. Two scenarios were assessed to take account of percentile values and ground level
concentrations (GLC’s) during routine operation and following the implementation of proposed
mitigation techniques. This allowed for the assessment of the effectiveness of proposed
mitigation techniques on predicted GLC’s.
The following conclusions are drawn from the air quality impact assessment of process vents
located in Alps Electric (Ireland) Ltd:
1. Twelve emission points are located within the Alps Electric (Ireland) Ltd boundary. In
terms of emission characteristics, emission points A1-1 and A1-2 are combustion
based for the production of steam and electricity while Emission points A2-1, A2-2, A23, A2-4, A2-6 and A2-7 are scheduled emission points from process operations
located within the production building. Emission points A2-5, A4-1, A4-2 and A4-3 are
considered fugitive emission points ventilated storage rooms located within the facility
operations. In terms of significant emissions of VOC’s, vents A2-2, A2-6 and A2-7
would be considered highest with all other VOC emission points negligible in terms of
mass emission. It proposed during future operations to operate emission point A1-2
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Confidential Report 2007A145(4)
Alps Electric (Ireland) Ltd
during the time period 16.45PM to 19.15PM Monday to Friday October to March on
the winter demand scheme.
2. The existing and proposed boiler and generator (i.e. emission points A1-1 and A1-2)
operations will not cause any significant classical air pollutant impact with all predicted
ground level concentrations of Carbon monoxide, Oxides of nitrogen, Sulphur dioxide
and Particulate matter within the regulatory guideline and limit values. In order to
ensure compliance with statutory limit values, emission point A1-2 (generator) stack
will require increasing up to a final height of 16.50 metres above ground level.
3. Following a review of historical particulate based lead emissions and dispersion
modelling it was concluded that lead emissions are insignificant from process vents
A2-2, A2-3 and A2-4. Particulate-based emission from these process vents is also
insignificant.
4. Following a review of measured and historical emission profile data on speciated
VOC’s (over two years), all maximum emission concentration of VOC’s are within their
respective environmental assessment concentration level for the protection of human
health. A screening mechanism was used to ascertain the maximum potential
speciated VOC concentrations impact. Advanced dispersion modelling was used to
predict maximum ground level and downwind concentration in order to allow for
comparison with the assessment criteria. Isopropyl alcohol, Xylene isomers, Toluene,
Butyl acetate, Ethyl benzene and Methyl isobutyl ketone were used for the screening
exercise.
5. The overall individual impact of screened compounds Isopropyl alcohol, Xylene
isomers, Toluene, Butyl acetate, Ethyl benzene and Methyl isobutyl ketone is within
proposed Environmental Assessment Levels (EALs), and therefore in accordance with
the requirements of H1 Guidance will not cause any significant impact.
6. Total volatile organic compounds as carbon as measured over a two-year period were
used in conjunction with dispersion modelling to ascertain the maximum GLC’s of total
VOC in the vicinity of the facility. This was compared to the regulatory assessment
criteria contained within the Ta Luft guidance document. During existing operations,
the overall plume spread and maximum GLC values are above the regulatory
guideline values. Predictive modelling was used to ascertain the emission sources that
contributed greatest to overall plume spread. Emission points A2-2, A2-6, A2-7 and to
a lesser extent emission point A2-1 were found to contribute most while all other
emission points contributing negligibly to ground level impact.
7. This was used to construct the basis of a predictive mitigation strategy where
investigation of VOC emission minimisation (process optimisation and end of pipe
abatement). Due to the air stream characteristics, three technologies may be suitable
including regenerative thermal oxidation and non-thermal plasma technology. It was
assumed for the dispersion modelling assessment that an exhaust gas concentration
of less than or equal to 50 mg/Nm3 would be achieved (i.e. this is achievable on such
technologies). Following implementation upon emission points A2-2, A2-6 and A2-7,
the overall Total VOC impact will be less than 233 and 351 μg/m3 for the 98th and 99th
percentile isopleths for 5 years of meteorological data utilising Aermod Prime
dispersion model.
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Document No. 2007A145(1)
1.
Introduction and scope
1.1
Introduction
Alps Electric (Ireland) Ltd
Following a conversation with Ms. Marie Walsh, Alps Electric (Ireland) Ltd, Odour Monitoring
Ireland was requested to perform:
• Volatile Organic Compound (VOC’s) monitoring assessment of five exhaust stacks
ventilating five separate processes and projection of mass emission rates of VOC and
classical air pollutant to atmosphere,
• Review of historic monitoring data performed by an environmental consultancy
company and projection of mass emission rates of VOC and classical air pollutant to
atmosphere,
• Dispersion modelling assessment of existing plant operation and comparison with
relevant air quality criterion,
• Dispersion modelling of proposed plant operation following the implementation of
process optimisation, mitigation techniques and comparison with relevant air quality
criterion.
This allowed for the robust presentation of existing and proposed GLC’s of pollutants in the
vicinity of the operating plant. Dispersion modelling was performed in accordance with
recommended methodologies using three years of hourly sequential meteorological data in
order to provide a statistical significant GLC profile of pollutants in the vicinity of the facility.
Predicted dispersion modelling data was compared to National and European regulatory
ground level guideline values. The proposed process optimisation and implementation of
mitigation on a number of emission points will lead to the achievements of regulatory ground
level guideline value for all assessed pollutants.
1.2
Scope of the work
The main aims of the study included:
• Volatile Organic Compound (VOC’s) monitoring assessment of five exhaust stacks
ventilating five separate processes and projection of mass emission rates of VOC and
classical air pollutant to atmosphere,
• Review of historic monitoring data performed by an environmental consultancy
company and projection of mass emission rates of VOC and classical air pollutant to
atmosphere,
• Dispersion modelling assessment of existing plant operation and comparison with
relevant air quality criterion,
• Development of VOC and classical air pollutant mitigation strategy to be implemented
within the operating facility.
• Dispersion modelling of proposed plant operation following the implementation of
mitigation techniques and comparison with relevant air quality criterion.
The approach adopted in this assessment is considered a worst-case investigation in respect
of emissions to the atmosphere from the facility for the outlined scheduled emission sources.
These predictions are therefore most likely to slightly over estimate the GLC’s that may
actually occur for each modelled scenario. These assumptions are summarised and include:
• Emissions to the atmosphere from the Boiler A1-1 process operation were assumed to
occur 24 hours each day over a standard year;
• Emissions to the atmosphere from the Electric Generator A1-2 process operation were
assumed to occur between the hours 16.45PM to 19.15PM over the period October to
March;
• The Particulate matter is treated as an ideal gas and therefore no removal due to
deposition (wet or dry) is accounted for in modelling scenarios,
• The total particulate matter emitted from the stack sources is assumed to be all PM10.
This is unlikely since varying particulate fraction size may be emitted.
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•
•
•
•
•
Alps Electric (Ireland) Ltd
All emissions were assumed to occur at maximum potential emission concentration
and mass emission rates for each scenario.
All emission points were assumed to emit simultaneously.
All emissions of total VOC’s were assumed to occur simultaneously 24/7 365 days per
year. This provides a conservative approach to the assessment of Total VOC’s.
Maximum GLC’s + Background were compared with relevant air quality guidelines and
limits.
Worst-case available meteorological input data was assumed in the study with five
years of hourly sequential met data used to provide more statistical significant results.
This is in keeping with current national and international recommendations. AERMOD
Prime dispersion modelling was utilised throughout the assessment.
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Document No. 2007A145(1)
2.
Alps Electric (Ireland) Ltd
Materials and methods
This section describes the materials and methods used throughout the survey and dispersion
modelling assessment.
2.1
VOC measurements and techniques.
The following measurement methods were used by Odour Monitoring Ireland within Alps
Electric (Ireland) Ltd to perform VOC emission rate calculation on 27th April 2007 on the
specified emission points A2-1, A2-2, A2-3, A2-6 and A2-7. These included:
• ISO10780:1994- Stationary source emissions-Measurement of velocity and volume
flowrate of gas streams in ducts.
• IS EN13526:2002-Stationary source emissions-Determination of the mass
concentration of total gaseous organic carbon in flue gases from solvent using
processes-Continuous flame ionisation detector method.
• IS EN12619:1999-Stationary source emissions-Determination of the mass
concentration of total gaseous organic carbon at low concentrations in flue gasesContinuous flame ionisation detector method.
• I.S. EN13649:2002-Stationary source emissions-Determination of the mass
concentration of individual gaseous organic compounds-Activated carbon and solvent
desorption method.
2.1.1
Airflow rate measurement
Airflow rate measurement was performed in accordance with ISO10780:1994-Stationary
source emissions-Measurement of velocity and volume flowrate of gas streams in ducts. The
following equipment was used through the airflow rate assessment. These included:
• Testo 400 and 350/454 MXL handheld and differential pressure sensors,
• L type pitot probe,
• PT100 temperature probe,
The following control procedure was used through the measurement sequence:
1.
Measurement was performed at two diameters where possible at right angles to each
other where possible,
2.
The internal diameter of the ductwork was measured and verified using a SS rod,
3.
Approximately, 5 duct diameters were available between the measurement point and
the nearest obstruction for emission points A2-2 and A2-3. This was not available for
emission point A2-1, Two methods were used on Points A2-2 and A2-3. Five duct
diameters were available for A2-6 and A2-7.
4.
The temperature profile across the stack was verified and did not differ by more than
5% from the average absolute temperature of the duct cross section,
5.
Eight individual samples points excluding the duct centre point was used to determine
the average flow at specified locations across the duct diameter. No sample point was
located within 20 mm of the duct wall.
6.
The difference in the average airflow velocity across each diameter did not exceed 5%
of the mean for all the diameters (2 in total).
7.
The number of sample points across the 2 diameters were determined in accordance
with Table 7.1.4 of ISO10780:1994. The sample locations were marked upon the L type
pitot using a water resistant marker.
8.
The L type pitot was checked for any burrs and obstructions in the pitot orifices,
9.
The absence of swirling flow was determined in accordance with Section 7.2 and Annex
C-ISO10780:1994.
10.
The measurement sequence was performed in accordance with the procedure
described in Section 7.2-ISO10780:1994.
The airflow rate measurement was used to ascertain the volumetric airflow from each emission
points in order to determine the mass emission rate of VOC from each emission point.
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Document No. 2007A145(1)
2.1.2
Alps Electric (Ireland) Ltd
Flame ionisation detector (FID) measurement
A heated portable FID (Signal 3030PM) (MCERT certified to 15 & 500 mg/Nm3), heated line,
controller and data logger was used to analyse the duct air stream for total hydrocarbon
concentration as propane.
An FID operates on the principle where influent contaminated gas is mixed with hydrogen and
the mixture is burned at the tip of a jet with air or oxygen. Ions and free electrons are formed in
the flame and enter a gap between two electrodes, the flame jet and a collector, mounted 0.51.0 centimetres above the flame tip. A potential (400 volts) is applied across the two electrodes
and with the help of produced ions, a very small current flows between the two electrodes.
When an organic substance is introduced this is burned in the flame; a complex process takes
place in which positively charged carbon species and electrons are formed. The current is
greatly increased and therefore the sample is detected. The FID is a mass flow detector, its
response depending directly on the flow rate of the carrier gas. Its response also varies with
applied voltage and the temperature of the flame.
The following procedure was used for operating the FID:
1. The FID was switched on and the oven temperature and sample line temperature were
allowed to stabilise. The set-point temperatures were 180 0C sample line temperature
and 2000C oven temperature. This took approximately 45 minutes.
2. The Hydrogen/He fuel, and Propane calibration gases (50 and 500 ppm) were
individually attached to the instrument.
3. Once temperatures had stabilised, the instrument was started and the ignition
procedure was commenced.
4. Once ignited, the sample procedure was commenced and any VOC upon the sample
line was baked off.
5. The analyser was zero calibrated and span calibrated. Zero air is supplied via the
clean air supply catalytic oxidiser. There is less than 1% of range or 1.6 mg/m3 drift in
eight hours whichever is greater (see Section 6.1 of EN12619:1999 and Section 6.2.1
EN13526:2001.
6. The analyser calibration procedure was rechecked and recorded,
7. The sample line was checked by presenting calibration gas in the sample line. The
value was confirmed to be the value and recorded. This reading must be less than 5%
difference from the span/zero reading.
8. The probe was inserted into the stack.
9. The datalogger was commenced (10 second intervals) and manual readings were
taking and recorded (every 10 minutes).
10. The instrument was re-spanned every approximately 60 minutes to confirm calibration
reading and to isolate any drift.
11. The recorded concentrations were converted for ppm TOC propane to mg/m3 TOC
using the equation contained in Annex E and F of EN12619:1999 and EN13526:2001,
respectively.
The analyser is MCERT approved for both low and medium range VOC concentration levels.
The MCERTS certification covers EN12619:1999.
The FID remained analysing continuously in the duct air stream. Results were presented as
mg [TOC] m-3 as propane. This was used to assess the VOC emission from each emission
point and allowed the determination of cyclic emissions.
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Alps Electric (Ireland) Ltd
2.1.3. Speciated VOC monitoring of exhaust emission points A2-1, A2-2, A2-3. A2-6
and A2-7.
2.1.3.1 Sampling of VOC from exhaust emission points A2-1, A2-2, A2-3, A2-6 and A2-7.
In order to obtain air samples for speciated VOC assessment, a static sampling method was
used where air samples were collected in 10 litre pre-conditioned Tedlar sampling bags using
a vacuum sampling device over a 20-minute period. The sampler operates on the 'lung
principle', whereby the air is removed from a rigid container around the bag by a battery
powered SKC vacuum pump at a rate of 0.50 l min-1. This caused the bag to fill through a
stainless steel and PTFE tube whose inlet is placed in the air stream, with the volume of
sample equal to the volume of air evacuated from the rigid container.
Three Tedlar sample bags were taken from each exhaust stack process. All sample bags were
pre-flushed with sample air in order to prevent any reductions in the actual VOC due to sample
bag surface binding. A leak check was performed on the sample set-up by placing a Primary
flow calibrator inline after the carbon/anasorb sorption tube (SKC 226-09). Once sample
acquisition was completed, the sample bag was transferred to another location and connected
to the sample pump, sorption tube and Primary flow calibrator. A charcoal/anasorb sorbent
was chosen to efficiently bind and pre-concentrate speciated VOC for analysis by
GCFID/GCMS in accordance with established and accredited methodologies. Sealed SKC
sorbent tubes (SKC 226-09) were used throughout the study to maintain repeatability and
integrity. In addition, the sorbent tube has a second plug to detect any breakthrough. Each
tube contained a minimum of 200 mg of sorbent. All sampling for speciated VOC’s was
performed in accordance with EN13649:2002.
2.1.3.2 Sorbent tube pre-concentration
In order to pre-concentrate speciated VOC upon each sorbent, a pre-calibrated controlled
volume of sample air was drawn through each tube by a SKC pump for a period range of 90
minutes depending on recorded results from the onsite FID analysis (Active sampling/pumped
sampling). Each SKC pump was pre-calibrated with their specific sorbent using a Bios
Primary flow calibrator (NIST traceable certified). Each pump was calibrated to a flow rate of
approximately 111 ml min-1 depending on the sample, sample pump and sorbent tube as
recommended by the sorbent manufacturer, analysing laboratory and sampling/test
methodology. When sampling was completed all tubes were sealed and stored in flexible air
tight containers and transported to the gas chromatography laboratory and analysed by
means of thermal desorption/solvent extraction GCFID/GCMS in a UKAS accredited
laboratory (RPS Laboratories, Manchester). All sample blanks were handled in the same
manner to the sample tubes with the exception of being exposed to the flue gas.
2.2
Review of historical measurement data
Over the past 2 years Alps Electric (Ireland) have performed through another Environmental
consultancy company various measurements on emission points A1-1, A1-2, A2-1, A2-2, A2-3,
A2-4 and A2-5.
Measurements for classical air pollutants were performed upon A1-1 and A1-2 (i.e. boiler and
Electric generator emission points (see Table 3.4) using standard techniques. Concentrations
of Carbon monoxide (CO), Oxides of nitrogen (NOX as NO2), SO2, Total particulates, airflow
rate and temperature were used to develop mass emission rates for use in conjunction with
dispersion modelling to ascertain the ground level impacts of such pollutants and to allow for
comparison with regulatory guidelines and limits.
Measurements of Speciated Volatile organic compounds (SVOC’s), Total volatile organic
compounds (TVOC’s), airflow rate and temperature were performed upon emission points A21, A2-2, A2-3, A2-4, and A2-5 (see Table 3.2 and 3.3). Mass emission rates of these
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Document No. 2007A145(1)
Alps Electric (Ireland) Ltd
compounds were used in conjunction with dispersion modelling in order to allow for the
assessment of ground level impact of such compounds and to allow for comparison with
regulatory guidelines and limits.
Particulate based lead and total particulates were also assessed from emission points A1-1,
A1-2, A2-2, A2-3 and A2-4. Mass emission rates of these compounds were used in
conjunction with dispersion modelling in order to allow for the assessment of ground level
impact of such compounds and to allow for comparison with regulatory guidelines and limits.
All emission data and assumptions used in the dispersion modelling assessment are contained
in Tables 3.1, 3.4 to 3.8.
2.3
Dispersion modelling assessment
2.3.1
Atmospheric dispersion modelling of air quality: What is dispersion modelling?
Any material discharged into the atmosphere is carried along by the wind and diluted by wind
turbulence, which is always present in the atmosphere. This process has the effect of
producing a plume of air that is roughly cone shaped with the apex towards the source and can
be mathematically described by the Gaussian equation. Atmospheric dispersion modelling has
been applied to the assessment and control of emissions for many years, originally using
Gaussian form ISCST 3. Once the compound emission rate from the source is known, (g s-1),
the impact on the vicinity can be estimated. These models can effectively be used in three
different ways:
• Firstly, to assess the dispersion of compounds;
• Secondly, in a “reverse” mode, to estimate the maximum compound emissions which
can be permitted from a site in order to prevent air quality impact occurring;
• And thirdly, to determine which process is contributing greatest to the compound
impact and estimate the amount of required abatement to reduce this impact within
acceptable levels (McIntyre et al. 2000).
In this latter mode, models have been employed for imposing emission limits on industrial
processes, control systems and proposed facilities and processes (Sheridan et al., 2002).
Any dispersion modelling approach will exhibit variability between the predicted values and
the measured or observed values due to the natural randomness of atmospheric
environment. A model prediction can, at best, represent only the most likely outcome given
the apparent environmental conditions at the time. Uncertainty depends on the completeness
of the information used as input to the model as well as the knowledge of the atmospheric
environment and the ability to represent that process mathematically. Good input information
(emission rates, source parameters, meteorological data and land use characteristics)
entered into a dispersion model that treats the atmospheric environment simplistically will
produce equally uncertain results as poor information entered into a dispersion model that
seeks to simulate the atmospheric environment in a robust manner. It is assumed in this
discussion that pollutant emission rates are representative of maximum emission events,
source parameters accurately define the point of release and surrounding structures,
meteorological conditions define the local atmospheric environment and land use
characteristics describe the surrounding natural environment. These conditions are employed
within the dispersion modelling assessment therefore providing good confidence in the
generated predicted exposure concentration values.
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Document No. 2007A145(1)
2.3.2
Alps Electric (Ireland) Ltd
Atmospheric dispersion modelling of air quality: dispersion model selection
The AERMOD model was developed through a formal collaboration between the American
Meteorological Society (AMS) and U.S. Environmental Protection Agency (U.S. EPA).
AERMOD is a Gaussian plume model and replaced the ISC3 model in demonstrating
compliance with the National Ambient Air Quality Standards (Porter et al., 2003) AERMIC
(USEPA and AMS working group) is emphasizing development of a platform that includes air
turbulence structure, scaling, and concepts; treatment of both surface and elevated sources;
and simple and complex terrain. The modelling platform system has three main components:
AERMOD, which is the air dispersion model; AERMET, a meteorological data pre-processor;
and AERMAP, a terrain data pre-processor (Cora and Hung, 2003).
AERMOD is a Gaussian steady-state model which was developed with the main intention of
superseding ISCST3 (NZME, 2002). The AERMOD modeling system is a significant departure
from ISCST3 in that it is based on a theoretical understanding of the atmosphere rather than
depend on empirical derived values. The dispersion environment is characterized by
turbulence theory that defines convective (daytime) and stable (nocturnal) boundary layers
instead of the stability categories in ISCST3. Dispersion coefficients derived from turbulence
theories are not based on sampling data or a specific averaging period. AERMOD was
especially designed to support the U.S. EPA’s regulatory modeling programs (Porter at al.,
2003)
Special features of AERMOD include its ability to treat the vertical in-homogeneity of the
planetary boundary layer, special treatment of surface releases, irregularly-shaped area
sources, a three plume model for the convective boundary layer, limitation of vertical mixing in
the stable boundary layer, and fixing the reflecting surface at the stack base (Curran et al.,
2006). A treatment of dispersion in the presence of intermediate and complex terrain is used
that improves on that currently in use in ISCST3 and other models, yet without the complexity
of the Complex Terrain Dispersion Model-Plus (CTDMPLUS) (Diosey et al., 2002).
Input data from stack emissions, and source characteristics will be used to construct the basis
of the modelling scenarios.
2.4
Air quality impact assessment criteria
The predicted air quality impact from the proposed operation located in Alps Electric (Ireland)
Ltd is compared to relevant air quality objectives and limits. Air quality standards and
guidelines referenced in this report include:
•
•
•
•
•
•
SI 271 of 2002 Air Quality legislation,
EU limit values laid out in the EU Daughter directives on Air Quality 99/30/EC,
Ta Luft of 2002 Air Quality Regulations,
SI543 of 2002-Emissions of Volatile organic compounds from organic solvents
regulations, 2002.
Environmental Guidelines No.1 of 2002,-Guidelines for air emission regulation, Danish
EPA.
Horizontal guidance Note, IPPC H1, Environmental assessment and appraisal of BAT,
UK Environment Agency.
Air quality is judged relative to the relevant Air Quality Standards, which are concentrations of
pollutants in the atmosphere, which achieve a certain standard of environmental quality. Air
quality Standards are formulated on the basis of an assessment of the effects of the pollutant
on public health and ecosystems.
In general terms, air quality standards have been framed in two categories, limit values and
guideline values. Limit values are concentrations that cannot be exceeded and are based on
WHO guidelines for the protection of human health. Guideline values have been established
for long-term precautionary measures for the protection of human health and the environment.
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Document No. 2007A145(1)
Alps Electric (Ireland) Ltd
European legislation has also considered standards for the protection of vegetation and
ecosystems.
Where ambient air quality criteria do not exist as in the case for some of the speciated
substances of interest, it is usual to use
• 1/100th of the 8-hour time weighted average occupational exposure limit (OEL)-Long
term EAL as an annual average.
• 1/500th of the 8 hour MEL time weighted average occupational exposure limit (OEL) Long term EAL as an annual average.
• 1/10th of the 15-minute time weighted average occupational exposure limit (OEL)-Short
term EAL as an hourly average.
• 1/50th of the 15 minute MEL time weighted average occupational exposure limit (OEL)
–short term EAL as an hourly average.
Occupational exposure limits are published by the Occupational Safety and Heath Authority
EH 40 notes and subsequent reviews.
The relevant air quality standards for the Alps Electric (Ireland) Ltd facility are presented in
Tables 2.1 and Table 2.2.
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Document No. 2007A145(1)
2.4.1
Alps Electric (Ireland) Ltd
Air Quality Guidelines for classical pollutants in Ireland and Europe
Table 2.1 illustrates the guideline and limit values for classical air quality pollutants in Ireland.
1
Table 2.1. EU and Irish Limit values laid out in the EU Daughter directive on Air Quality 99/30/EC and SI 271 of 2002
Objective
Pollutant
Exceedence expressed as
Maximum
No.
Of
2
Concentration
Measured as
percentile3
exceedence allowed3
-3
300 μg m NO2
Nitrogen
1 hour mean
18 times in a year
99.79th percentile
200 μg m-3 NO2
dioxide and
1 hour mean
th
18 times in a year
99.79 percentile
-3
oxides of
Annual mean
40 μg m NO2
---3
nitrogen
Annual mean (vegetation)
30 μg m NO2
-3
th
50 μg m
7 times in a year
98.08 percentile
24 hour mean
Particulates
-3
(PM10)
40 μg m
Annual mean
--20 μg m-3
Carbon
10 mg m-3
None
100th percentile
Running 8 hour mean
monoxide (CO)
To be
4
achieved by
19 Jul 19994
1 Jan 2010
1 Jan 2010
---1 Jan 20106
1 Jan 2005
1 Jan 20106
31st Dec 2003
1st Jan 2005
1 hour mean
24 hour mean
1st Jan 2005
Sulphur
Annual mean and winter
dioxide (SO2)
19th Jul 20015
mean (1st Oct to 31st
March
0.50 μg m-3
01st Jan 2005
-Annual limit
-3
th
2.50 μg m
98 percentile
175 times in a year
TA Luft 2002
1 hour mean
Lead
87 times in a year
C Value
Annual limit
0.50 μg m-3
-Danish EPA
1 hour mean
99th percentile
0.40 μg m-3
1/100th EH40
Annual mean
1.50 μg m-3
Notes: 1 denotes Directive 99/30/EC: Council Directive 1999/30/EC of 22nd April 1999 relating to limit values for sulphur dioxide, nitrogen dioxide and oxides of
nitrogen and particulate matter in ambient air;
2
denotes conversions of ppb and ppm to μg m-3 and mg m-3 at 293.15 Kelvin and 101.3 Kpa;
3
denotes Number of exceedence are quoted in the directive, exceedence or percentiles are used in AMDS;
4
A margin of tolerance is accepted while limit value is phased in; this will reduce progressively every year;
5
denotes limit value for the protection of vegetation/ecosystem;
6
denotes Stage 2 values to be achieved by EU following the implementation of Stage 1.
350 μg m-3
125 μg m-3
20 μg m-3
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99.73th percentile
99.18th percentile
--
24 times in a year
3 times in a year
--
9
Document No. 2007A145(1)
Alps Electric (Ireland) Ltd
Table 2.2 illustrates the guideline and limit values for VOC based pollutants as taken from specified references. Both a limit for total VOC and individual
identified VOC’s are presented to allow comparison of impact with guideline values.
Table 2.2. EU regulatory limit and guideline values for Total VOC and Speciated VOC compounds as laid out in the Ta Luft of 2002, Danish EPA Notes, 2002,
Horizontal H1 guidance documents and fractional exposure from EH40 values.
Pollutant
Concentration
2
Objective
Maximum No. Of
exceedence allowed3
Exceedence expressed
as percentile3
Measured as
Class III
Class II
Class I
Total VOC as Carbon
1000 μg m-3
-3
200 μg m
-3
50 μg m
100 μg m-3
175 times in a year
175 times in a year
175 times in a year
175 times in a year
98 percentile
th
98 percentile
98th percentile
98th percentile
1 hour mean Class III
1 hour mean Class II
1 hour mean Class I
1 hour mean
Class I
Class II
Class III
≤10 μg m-3
> 10 ≤ 200 μg m-3
> 200 μg m-3
87.60 times in a year
87.60 times in a year
87.60 times in a year
99th percentile
th
99 percentile
99th percentile
1 hour mean
1 hour mean
1 hour mean
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10
th
Source
Ta Luft of
1986
Ta Luft 2002 &
1996
Industrial Air
Pollution
Control
Guidelines No.
9/1992,
Danish EPA
Document No. 2007A145(1)
Alps Electric (Ireland) Ltd
Table 2.2 continued. EU regulatory limit and guideline values for Total VOC and Speciated VOC compounds as laid out in the Ta Luft of 2002, Danish EPA
Notes, 2002, Horizontal H1 guidance documents and fractional exposure from EH40 values
Speciated VOC identified
in air stream in Alps
Electric over 2 year
period
EAL-Long
termannual
mean
EAL-short
term- 1
hour
mean
Isopropyl alcohol
Xylene isomers
Cyclo pentane
2 propanol 1 ethoxy
2 hexanone 5 methyl
1-methoxy-2 propyl acetate
Methyl isobutyl ketone
Methyl ethyl ketone
Ethyl benzene
Butyl acetate
Ethyl acetate
Methyl cyclopentane
Cyclohexane
1,3,5 Trimethylbenzene
Toluene
Ethanol
Acetone
Tetrahydrofuran
Hexane
Heptane
Cyclohexanone
1-Pentene
2,710
4,410
---3,750
--4,410
7,240
14,600
-3,500
1,250
1,910
19,200
18,100
3000
720
-1020
--
81,300
66,200
---112,000
--55,200
96,600
420,000
-105,000
37,500
8,000
576,000
362,000
59,900
21,600
-40,800
--
Source:
Fractional
OEL 8 hourAnnual
mean
9800
2210
1720
-950
-830
6000
1000
7100
14000
-3400
1000
500
19000
12100
1180
18000
16000
408
--
Fractional
OEL 15
minute-1
hour mean
122500
44200
----20800
90000
-95000
--103000
----29500
360000
200000
8,160
--
Maximum No. Of
3
exceedence allowed
Annual limit for Long
term exposure data
Exceedence
expressed as
3
percentile
100th percentile
1 hour mean for short
term exposure data
Ta Luft of 2002 Air Quality Regulations,
Environmental Guidelines No.1 of 2002,-guidelines for air emission regulation, Danish EPA.
Horizontal guidance Note, IPPC H1, Environmental assessment and appraisal of BAT, UK Environment Agency.
EH40 notes, National Authority for Occupational Safety and Health (2002).
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11
Measured as
Annual mean
1 hour mean
Source
H1 Guidance
notes.
EH40
exposure data
and fractional
analysis
Document No. 2007A145(4)
2.5
Alps Electric (Ireland) Ltd
Existing Baseline Air Quality
The EPA has been monitoring national Air quality from a number of sites around the country.
This information is available from the EPA’s website. The values presented for PM10, SO2,
NO2, CO and Lead give an indication of expected urban and suburban emissions of the
compounds listed in Table 2.1. Table 2.3 illustrates the baseline data expected to be obtained
from Zone C/D sites. Since Alps Electric (Ireland) Ltd site is located in a suburban area of a
small town, it would be considered located in a Zone C area according to the EPA’s
classification of zones for air quality. Traffic and industrial related emissions would be
medium.
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12
Document No. 2007A145(4)
Alps Electric (Ireland) Ltd
Table 2.3. Baseline air quality data used to assess air quality impact criterion in Zone C/D regions.
Nitrogen dioxideParticulate matter-PM10
Reference air quality data-Source
NO2 (μg m-3) hourly
-3
(μg m )-Daily/Annual
identity
max and annual
mean
mean
Naas (Zone C)
Mountrath (Zone C/D)
Kilkenny (Zone D)
Tralee (Zone C)
Notes:
1
Maximum 2.30
Mean hourly value
28.30
Maximum 2.60
Annual mean 13.0
Annual mean 9.0
---
Mean daily value 16.90
Mean hourly value
9.60
Mean daily value 22.50
13
Sulphur dioxideLead (μg m-3)
SO2 (μg m-3)
maximum
Maximum 24 hour
mean 23.60
Mean hourly value
25.90
Mean daily value 17.30
denotes EPA monitoring reports 2003, 2004 to 2005,
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Carbon monoxide-CO
-3
(mg m ) 8 hour running
max
Maximum hourly
value 64.60
Maximum 24 hour
mean 12
Maximum hourly
value 28.20
Maximum 1.90
Annual mean 5.0
Details
Annual mean Measured 2004
0.006
to 2005
Annual mean Measured 2004
0.03
to 2005
Annual mean Measured 2004
0.01
to 2005
Maximum 24 hour
Annual mean Measured 2003
17.70
0.01
to 2004
Maximum 1 hour
63.60
Document No. 2007A145(4)
2.6
Alps Electric (Ireland) Ltd
Site location, and locations of sensitive receptors
Figure 2.1. Site location map for Alps Electric (Ireland) Ltd illustrating relative location of sensitive receptors and boundary (
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14
).
Document No. 2007A145(4)
Alps Electric (Ireland) Ltd
Figures 2.1 illustrate Alps Electric (Ireland) Ltd site and the relative location of boundary and
receiving environment. Approximately 10 residential properties are located 25 metres from the
northwest and northeastern boundary of the facility. The dispersion modelling assessment
accounts for all sensitive receptors approximately 1.04 Km radius inside and outside the
boundary of the facility with no dependencies on location. A 40 metre Cartesian grid network
was established providing 725 and 1341 receptor points inside and outside the boundary
depending on model run. In addition, all receptors were established at a height of 1.80 metres
within the dispersion model assessment. 10 metre spaced boundary receptors were also
established within the dispersion modelling scenarios providing an additional 49 receptors.
Building structures are examined within the dispersion modelling assessment at varying
heights to account for building wake effects (i.e. Building structures located within the Alps
Electric (Ireland) site, while all stack heights and efflux velocities were provided from scaled
maps and measurements.
2.7
Meteorological data
Three years of hourly sequential meteorological data was chosen for the modelling exercise
(i.e. Cork Airport 1993 to 1997 inclusive). Cork Airport was chosen as the representative
meteorological station. A schematic wind rose and tabular cumulative wind speed and
directions of all five years is presented in Section 7. All five years of met data was used to
provide more statistical significant result output from the dispersion model. This is in keeping
with national and international recommendations on quality assurance in operating dispersion
models.
2.8
Terrain data
Topography effects were accounted for within the dispersion modelling assessment, as terrain
effects in the vicinity of the site were considered complex. Ten metre spaced topographical
data was processed and inputted into the dispersion model through the AERMAP software
tool. This allow for the accurate assessment of terrain effects on the dispersion of pollutants in
the vicinity of the operating site.
2.9
Building wake effects
Building wake effects are accounted for in modelling scenarios (i.e. all building features
located within Alps Electric (Ireland) facility) as this can have a significant effect on the
compound plume dispersion at short distances from the source and can significantly
increase GLC’s in close proximity to the facility. Since there are residential properties
close to the facility boundary it was prudent to take account of such effects.
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15
Document No. 2007A145(4)
3.
Alps Electric (Ireland) Ltd
Results
This section describes the results obtained during the survey.
3.1
Volumetric airflow rate results for all emission points.
Table 3.1 illustrates the average airflow rates and volumetric airflow emission rates from
process vents A2-1, A2-2, A2-3, A2-6, A2-7 as measured onsite on the 27th April 2007. In
addition, the historical data for airflow rate for emission points A1-1, A2-4 and A2-5 is provided.
Estimated airflow rate were obtained from the equipment manufacturer for emission point A12. Based on existing data from emission points on site, a theoretical volumetric airflow rate was
estimated for emission point A4-1, A4-2 and A4-3. Emission point gas temperature and source
characteristics such as vent area and height are also included to allow for review of the data.
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Document No. 2007A145(4)
Alps Electric (Ireland) Ltd
Table 3.1. Historical and measured airflow velocity and volumetric airflow rate process vent point results.
Sample
ID
A1-1
Sample location description
Existing
Existing
Normalised
Average
Normalised
Temperature
X
Y
ground
stack
Stack
Duct area
volume flow rate volume flow rate
Airflow velocity
2
(K)
coordinate coordinate level height
height (m)
(m )
level
3
-1
3
(Nm hr )
(m/s)
(m /s)
(m)
height (m)
Main boiler
126863.3
89628.6
133.71
142.78
9.07
0.05
8.20
420
942
0.35
1
Standby generator
126881.2
89603.7
133.71
141.83
8.12
0.11
11.90
410
3,151
1.09
A2-1
1
89545.4
133.71
144.23
10.52
1.23
3.99
291
16,619
4.62
A2-2
126860.8
89615.4
133.71
140.51
6.8
0.20
16.30
301
10,451
2.90
A2-3
1
126870
89610.4
133.71
141.14
7.43
0.13
7.30
294
3,067
0.85
A2-4
1
PAL room extraction stack
Solderwave/Concoat machine
extraction point
Spot dip machine extraction
point
SMT machine extraction point
126868.4
1
A2-5
1
A1-2
126895.5
89559.7
133.71
141.12
7.41
0.20
6
309
3,748
1.04
Storage shed extraction point
126879.4
89536.4
133.71
135.7
1.99
0.20
5
298
3,339
0.93
A2-6
PAL area extraction stack
126858.4
89547
133.71
142.9
9.19
0.28
9.30
291
8,882
2.47
A2-7
PAL area extraction stack
126853.2
89556.7
133.71
142.9
9.19
0.28
8.70
292
8,280
2.30
Sludge storage area extraction
Paint and laser tray cleaning
area extraction point
Hazardous waste storage area
extract point
126855.8
89552
133.71
142.9
9.19
0.28
3.38
298
3,339
0.93
126905.4
89551
133.71
135.7
1.99
0.20
5.0
298
3,339
0.93
126880.3
89536.7
133.71
135.7
1.99
0.20
5.0
298
3,339
0.93
A4-1
A4-2
1
A4-3
1
Notes:
1
denotes that due to constraints within the ISO10780:1994, measurement did not concur to the standard. The required 5 duct diameters were not
available between the nearest obstructions.
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Document No. 2007A145(4)
Alps Electric (Ireland) Ltd
3.2
Historic and measured Total organic
concentration results (as measured on a FID)
carbon
emission
Table 3.2 illustrates the average TOC concentration and mass emission rates from process
vents A2-1, A2-2, A2-3, A2-6 and A2-7 as measured onsite between the hours of 13.00 PM
and 16.55 PM on the 27th April 2007.
During the measurement sequence on the 27th April 2007, intermittent instrument span check
were performed. VOC hang-up in the sample line was also assessed to ensure no bias in
results in the outlet stack. This was performed by removing the sample probe from the stack
and checking displayed VOC readings and comparing to initial start-up reading.
In addition, historical data was reviewed for emission points A2-4 and A2-5. Estimations were
calculated for emission vents A4-1, A4-2 and A4-3 since these emission points are similar in
characteristics to emission points A2-5.
All data is presented as total carbon results in accordance with European standards EN12619:
1999 and EN13526: 2002.
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Document No. 2007A145(4)
Alps Electric (Ireland) Ltd
Table 3.2. Measured and historical Total organic carbon (as carbon) (TOC) emissions from process vents in Alps Electric (Ireland) Ltd.
Sample
location
Sample location description
TOC
concentration
3 1
(mg/Nm )
Volumetric
airflow rate
3
(Nm /s)
Normalised Mass
loading/emission
1,3
(g/s)
Normalised Mass
loading/emission
1,3
(kg/hr)
Notes
Minimum TOC reading 7.98 mg/Nm3
Maximum TOC reading 58.54 mg/Nm3
Minimum TOC reading 252 mg/Nm3
Maximum TOC reading 386 mg/Nm3
Minimum TOC reading 42.57 mg/Nm3
Maximum TOC reading 87.81 mg/Nm3
--Minimum TOC reading 212.86 mg/Nm3
Maximum TOC reading 367.19mg/Nm3
Minimum TOC reading 478.95 mg/Nm3
3
Maximum TOC reading 651.90 mg/Nm
--
A2-11,2
PAL room extraction stack
42.57
4.62
0.20
0.71
A2-21,2
Solderwave/Concoat machine
extraction point
292.6
2.90
0.85
3.0
A2-31,2
Spot dip machine extraction point
63.86
0.85
0.05
0.20
SMT machine extraction point
Storage shed extraction point
0.50
31.20
1.04
0.93
0.0005
0.03
0.0019
0.10
A2-61,2
PAL area extraction stack
303.33
2.47
0.75
2.70
A2-71,2
PAL area extraction stack
598.68
2.30
1.38
4.96
Sludge storage area extraction
Paint and laser tray cleaning area
extraction point
Hazardous waste storage area
extract point
31.20
0.93
0.03
0.10
31.20
0.93
0.03
0.10
--
31.20
0.93
0.03
0.10
--
-
-
-
12.032
A2-4
A2-5
3
A4-1
3
A4-2
3
A4-33
Total VOC
-
Total average mass emission rate of
VOC from ALPS Electric
Notes:1 denotes that normalised to 273.15 K and 101.3 kPa and converted to TOC as carbon from propane using conversion factor of 1.60 (see EN12619:1999).
2
both zero, span and VOC hang-up checks performed intermittently on the FID analyser in order to verify correct operation. In addition, the FID oven and
sample line temperature were checked and verified intermittently.
3
denotes data extracted from historical monitoring reports.
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Document No. 2007A145(4)
Alps Electric (Ireland) Ltd
3.3. Measured and historical speciated VOC results from emission points
located in Alps Electric (Ireland) Ltd.
Table 3.3 illustrates the results obtained from active sorbent tube sampling and analysis both
performed on site and extracted from historical data. An indirect sampling methodology (i.e.
Static) was used whereby sample air was vacuumed using the lung principle into pre-flushed
Tedlar sampling bags. Samples were taken from five process vent points during routine
operation on the 27th April 2007. Sample bags were sealed and pre-concentration as
performed in a separate location using pre-calibrated sampling pumps. Calibration of pumps
was performed using a Primary flow calibrator (NIST traceable) and checked for calibration
before and after sampling. Sample tubes were then sealed and transported to the analytical
laboratory for analysis via solvent extraction GCMS analysis in a UKAS accredited laboratory
(RPS Labs, Manchester).
In addition, historical reports were reviewed and available data extracted to allow for
characterisation of the emission vent points.
The results of the measurement and historical report survey are presented in Table 3.3.
Currently process emission points A2-2, A2-6 and A2-7 will be regulated under the Solvent
Regulations SI543 of 2002.
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Document No. 2007A145(4)
Alps Electric (Ireland) Ltd
Table 3.3. Average measured and historical speciated VOC sampling and analysis results for each emission point located in Alps Electric (Ireland) Ltd.
Sample
identity
Process identity
Compound identity
Isopropyl alcohol
Butyl acetate
Ethyl benzene
Other VOC's
Total VOC’s
Isopropyl alcohol
Methyl isobutyl ketone
Methyl ethyl ketone
Ethyl benzene
Butyl acetate
Other VOC's
Total VOC
Butyl acetate
Isopropyl alcohol
Methyl ethyl ketone
Other VOC's
Total VOC
Detected conc. as C
(mg/Nm3)
4.90
16.40
3.80
13.40
38.50
49.60
12.60
11.40
9.50
18.40
42.60
144.10
4.4
8.40
2.20
14.60
29.60
Volumetric airflow
rate (m3/s)
4.62
4.62
4.62
4.62
4.62
2.90
2.90
2.90
2.90
2.90
2.90
2.90
0.85
0.85
0.85
0.85
0.85
Mass emission
rate (g/s)
0.0226
0.0758
0.0176
0.0619
0.1779
0.1438
0.0365
0.0331
0.0276
0.0534
0.1235
0.4179
0.0037
0.0071
0.0019
0.0124
0.0252
Mass emission
rate (kg/hr)
0.0815
0.2728
0.0632
0.2229
0.6403
0.5178
0.1315
0.1190
0.0992
0.1921
0.4447
1.5044
0.0135
0.0257
0.0067
0.0447
0.0906
Sample No.
1898403160
A2-1-PAL room extraction stack
Sample No.
1898403162
A2-2-Solderwave/ Concoat machine
extraction point
Sample No.
1898403169
A2-3-Spot dip machine extraction
point
Historical
data
A2-4- SMT machine extraction point
Total VOC’s
<0.50
1.04
0.0005
0.0019
A2-5- Storage shed extraction point2
Ethanol
Butyl acetate
Toluene
Ethyl benzene
Xylene isomers
Acetone
Tetrahydrofuran
Methyl ethyl ketone
Methyl isobutyl ketone
Cyclohexanone
1,3,5 Trimethylbenzene
Hexane
Heptane
Total VOC
0.18
30
1.63
3.06
3.18
2.28
0.03
0.29
10.3
1.31
0.03
0.07
0.04
31.20
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.93
0.0002
0.0279
0.0015
0.0028
0.0030
0.0021
0.0000
0.0003
0.0096
0.0012
0.0000
0.0001
0.0000
0.0290
0.0006
0.1004
0.0055
0.0102
0.0106
0.0076
0.0001
0.0010
0.0345
0.0044
0.0001
0.0002
0.0001
0.1045
Historical
data
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21
Document No. 2007A145(4)
Alps Electric (Ireland) Ltd
Table 3.3 continued. Average measured and historical speciated VOC sampling and analysis results for each emission point located in Alps Electric (Ireland)
Ltd.
Sample No.
1898403165
A2-6- PAL area extraction stack
Sample No.
1898403164
A2-7- PAL area extraction stack
Estimated
data
A4-1- Sludge storage area
extraction
Estimated
data
A4-2- Paint and laser tray cleaning
area extraction point
Estimated
data
A4-3- Hazardous waste storage
area extract point
Notes:
Ethyl acetate
Methyl cyclopentane
Heptane
Cyclohexane
Other VOC's
Total VOC
Butyl acetate
Methyl cyclopentane
Ethyl benzene
P+M Xylene
Other VOC's
Total VOC
Total VOC-Assume
similar gas phase profile
to Emission point A2-5
Total VOC-Assume
similar gas phase profile
to Emission point A2-5
Total VOC-Assume
similar gas phase profile
to Emission point A2-5
1
71.77
20.71
25.38
16.92
107.36
242.15
58.16
31.51
78.59
33.24
184.50
386.00
2.47
2.47
2.47
2.47
2.47
2.47
2.30
2.30
2.30
2.30
2.30
2.30
0.1773
0.0512
0.0627
0.0418
0.2652
0.5981
0.1338
0.0725
0.1808
0.0765
0.4244
0.8878
0.6382
0.1842
0.2257
0.1505
0.9546
2.1532
0.4816
0.2609
0.6507
0.2752
1.5277
3.1961
31.20
0.93
0.0290
0.1045
31.20
0.93
0.0290
0.1045
31.20
0.93
0.0290
0.1045
denotes an ambient temperature of 293K during pre-concentration.
denotes that two separate sampling events were performed upon the headspace of the building. In order to assess the EAL and fractional
3
exposure the profiles for both surveys are combined. The maximum total concentration measured was 31.20 mg/Nm with the butyl acetate the
predominant compound. All other VOC’s were detected during sample event 2 with a total VOC concentration of 23 mg/Nm3 detected.
2
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22
Document No. 2007A145(4)
Alps Electric (Ireland) Ltd
3.4. Measured and historical classical air pollutants from emission points
located in Alps Electric (Ireland) Ltd.
Table 3.4, 3.5, 3.6, 3.7 and 3.8 illustrates the results obtained from review of historical
emission monitoring data from emission point A1-1, A1-2, A2-2, A2-3 and A2-4 for classical air
pollutants. This data was used to construct the mass emission profile of the vents identified. In
order to allow for the predictive analysis of downwind concentrations of such pollutants.
Carbon monoxide, Oxides of nitrogen, sulphur dioxide, Total particulates as PM10, Lead,
Temperature and volumetric airflow rate were measured onsite.
The results of the review of the historical report surveys are presented in Table 3.4 to 3.8.
In terms of emission point A1-2 operation, the generator has the following characteristics:
•
•
•
•
•
•
•
Proposed hours of operation 16.45PM to 19.15PM Monday to Friday, October to
March each year.
Type of ignition is standard starter motor as per all diesel engines,
Output power is rated at 1500 kVA
Thermal efficiency is unknown
Burn strategy is unknown
Maximum fuel rate is unknown
Maintenance on generator is every 250 to 300 hours operation or annually which ever
occurs first.
The operation of the generator will occur under the winter demand scheme for a time period
16.45PM to 19.15PM Monday to Friday October to March. In terms of BAT consideration for
such operation this limited operation is considered BAT. Coupled with an increase in stack
height up to 16.50 m, ground level impact of pollutants will remain within the SI 271 of 2002
limit values. Emergency operation will only occur when power outages occur during production
hours.
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23
Document No. 2007A145(4)
Alps Electric (Ireland) Ltd
Table 3.4. Historically measured concentration of classical air pollutants for emission vents A11 and A1-2 in Alps Electric (Ireland) Ltd.
Emission point A1-1
Emission point 1-2
Compound identity
3
3
(mg/Nm )
(mg/Nm )
Oxygen (%)
3.8
17
3
Carbon monoxide (CO) (mg/Nm )
1.25
251.25
Oxides of nitrogen (NOx as NO2)
160.18
1047.32
(mg/Nm3)
3
Sulphur dioxide (SO2) (mg/Nm )
131.43
23
Total particulates (TP as PM10)
9.9
8
(mg/Nm3)
Temperature (K)
420
410
Volumetric airflow rate (Nm3/hr)
942
3151
Diameter (m)
0.25
0.375
Area (m2)
0.049
0.110
Airflow rate (m/s)
8.2
11.9
Table 3.5. Historically measured concentration of classical air pollutants referenced to 3%
Oxygen for emission point A1-1 and 5% Oxygen for emission point A1-2 in Alps Electric
(Ireland) Ltd.
Emission point A1-1 (mg/Nm3 Emission point 1-2 (mg/Nm3
Compound identity
ref to 3% O2)
ref to 5% O2)
Oxygen (%)
3.8
17
Carbon monoxide (CO)
1.31
1024
(mg/Nm3)
Oxides of nitrogen (NOx as
168
4,270
NO2) (mg/Nm3)
Sulphur dioxide (SO2)
138
94
(mg/Nm3)
Total particulates (TP as PM10)
10
33
(mg/Nm3)
Temperature (K)
420
410
Volumetric airflow rate
942
3151
(Nm3/hr)
Diameter (m)
0.25
0.375
2
Area (m )
0.049
0.110
Airflow rate (m/s)
8.2
11.9
Table 3.6. Mass emission rate of classical air pollutants for emission points A1-1 located within
Alps Electric (Ireland) Ltd.
Total emission rate for
Volumetric airflow Compound conc.
Compound identity
emission point A1-1
3
3
(mg/Nm )
rate (Nm /s)
(g/s)
Carbon monoxide (CO)
0.261
1.25
0.0003
(mg/Nm3)
Oxides of nitrogen (NOx as
0.261
160.18
0.0418
NO2) (mg/Nm3)
Sulphur dioxide (SO2)
0.261
131.43
0.0343
(mg/Nm3)
Total particulates (TP as
0.261
9.90
0.0026
3
PM10) (mg/Nm )
Notes:
1
denotes boiler operates on demand and therefore would not emit pollutants
continuously.
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24
Document No. 2007A145(4)
Alps Electric (Ireland) Ltd
Table 3.7. Mass emission rate of classical air pollutants for emission points A1-2 located within
Alps Electric (Ireland) Ltd.
Total emission rate for
Volumetric airflow Compound conc.
Compound identity
emission point A1-2
3
3
rate (Nm /s)
(mg/Nm )
1
(g/s)
Carbon monoxide (CO)
0.88
251.25
0.2211
(mg/Nm3)
Oxides of nitrogen (NOx as
0.88
1047.23
0.9216
NO2) (mg/Nm3)
Sulphur dioxide (SO2)
0.88
23
0.0202
(mg/Nm3)
Total particulates (TP as
0.88
8.0
0.0070
PM10) (mg/Nm3)
Notes: 1 denotes standby generator will only operated from Monday to Friday October to March
16.45PM to 19.15PM during this period. Mechanical servicing and tuning of
generator should occur once per year.
Table 3.8. Mass emission rate of Total particulates for emission points A2-2, A2-3 and A2-4
located within Alps Electric (Ireland) Ltd.
Sample
location
Process description
Solderwave/Concoat
machine extraction point
Spot dip machine
extraction point
SMT machine extraction
point
A2-21
A2-3
A2-4
Total mass
emission
--
Volumetric
air flow rate
(Nm3/s)
Total Particulates as
PM10
3
g/s
mg/Nm
Lead (Pb)2
mg/Nm
3
g/s
2.90
<10
2.90E-02
<0.001
2.90E-06
0.85
<10
8.52E-03
<0.001
8.52E-07
1.04
<10
1.04E-02
<0.001
1.04E-06
--
--
<6.23E-02
--
<4.80E-06
1
denotes historical particulate measurements have only detected particulate in
emission point 2-2.
2
denotes historical Lead emission data (particulate based lead only) has been below 1
μg/Nm3.
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25
Document No. 2007A145(4)
3.5
Alps Electric (Ireland) Ltd
Dispersion modelling assessment
AERMOD Prime was used to determine the overall air quality impact of Alps Electric (Ireland)
Ltd emission point operations located in Millstreet, Co. cork. These computations give the
relevant GLC’s at each 40-meter X Y Z Cartesian grid receptor location that is predicted to be
exceeded for the specific air quality impact criteria.
The results of the dispersion modelling assessment are divided into two distinct sections in
order to provide clarity on the existing and proposed site operations for each pollutant dataset.
Section 3.5.1 will present the results for the classical air pollutant impact assessment, while
Section 3.5.2 and 4.2 will present the results for the volatile organic compound air pollutant
impact assessment.
3.5.1 Results of dispersion modelling assessment for Classical air
pollutants.
Various averaging intervals were chosen to allow direct comparison of predicted GLC’s with
the relevant air quality assessment criteria as outline in Table 2.1. In particular, 1-hour, 8hour, 24 hour, and annual average GLC’s of the various pollutants were calculated at various
distances from the site. Relevant percentiles of these GLC’s were also computed for
comparison with the relevant Air Quality Standards presented in Table 2.1 (see Table 3.4 to
3.8 for input data) (ref: Scenario 1 and 2 below).
Ref: Scenario 1:
Dispersion modelling assessment of existing operations located
within Alps Electric (Ireland) Ltd for classical air pollutants (Emission
points A1-1, A2-2, A2-3 and A2-4 for Carbon monoxide, Oxides of
nitrogen, Sulphur dioxide, Total particulates and Lead).
Ref: Scenario 2:
Dispersion modelling assessment of proposed operations located
within Alps Electric (Ireland) Ltd for classical air pollutants (i.e. the
addition of emission point A1-2 to Scenario 1, increase in emission
point A1-2 stack height to 16.50 metres and operation hours of
16.45PM to 19.15PM Monday to Friday between October to March).
Table 3.9 and 3.10 illustrates the tabular results obtained from the dispersion modelling
assessment for Scenarios 1 and 2. Maximum predicted GLC’s for the percentile scenario are
presented within this table to allow for comparison with SI 271 of 2002 and other specified
regulations and assessment criterion. In addition, graphical contour plots are provided for
information within Appendix I (ref: Section 6) for the proposed scenarios only.
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Document No. 2007A145(4)
Alps Electric (Ireland) Ltd
Table 3.9. Tabular illustration of Predicted maximum percentile GLC’s in the vicinity of Alps
Electric (Ireland) Ltd emission points (see Table 3.6 and 3.8) for Scenario 1-existing site
operations.
Identity-Scenario 1 existing
operation using existing stack Compound
characteristics
Maximum percentile predicted
GLC conc. Percentile value (%)
-3
(μg m )
Maximum 8 hour concentration
CO
0.42
100th
Maximum 1 hour concentration
NO2 as NOX
84.14
100th
Maximum 1 hour concentration
NO2 as NOX
61.40
99.79th
Maximum annual mean
concentration
NO2 as NOX
7.05
-
Maximum 24 hour concentration PM as PM10
32
100th
Maximum 24 hour concentration PM as PM10
20.50
98.08th
Maximum annual mean
concentration
PM as PM10
8.95
-
Maximum 1 hour concentration
SO2
69
100th
Maximum 1 hour concentration
SO2
47
99.73th
Maximum 24 hour concentration
SO2
28.40
100th
Maximum 24 hour concentration
SO2
20.12
99.18
Maximum annual mean
concentration
SO2
5.79
-
Maximum 1 hour
Pb (as
particulate)
0.035
100
Maximum 1 hour
Pb (as
particulate)
0.0124
99th
Maximum 1 hour
Pb (as
particulate)
0.0093
98th
Maximum annual mean
concentration
Pb (as
particulate)
0.00257
-
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Document No. 2007A145(4)
Alps Electric (Ireland) Ltd
For Scenario 2 operations, the generator emission point A1-2 will be operated between the
periods of October to March between the hours of 16.45 PM to 19.15 PM Monday to Friday.
This will result in emissions of Carbon monoxide, Oxides of nitrogen, Sulphur dioxide, and
Particulate matter. At present the existing stack height of the generator is 8.12m. This will be
increased to a height of 16.50 metres in order to achieve ground level limit values. No other
source characteristics will change. This will result in a reduction in the short-term impact of
such classical air pollutants to within their respective GLC’s limit values.
Table 3.10. Tabular illustration of Predicted maximum percentile GLC’s in the vicinity of Alps
Electric (Ireland) Ltd emission points (see Table 3.6, 3.7 and 3.8) for Scenario 2-proposed site
operations.
Identity-Scenario 2 proposed
operation using proposed
stack characteristics
Maximum percentile predicted
GLC conc. Percentile value (%)
Compound
-3
(μg m )
Maximum 8 hour concentration
CO
49.50
100th
Maximum 1 hour concentration
NO2 as NOX
181
100th
Maximum 1 hour concentration
NO2 as NOX
61.40
99.79th
Maximum annual mean
concentration
NO2 as NOX
7.05
-
Maximum 24 hour concentration PM as PM10
32
100th
Maximum 24 hour concentration PM as PM10
20.50
98.08th
Maximum annual mean
concentration
PM as PM10
8.95
-
Maximum 1 hour concentration
SO2
69
100th
Maximum 1 hour concentration
SO2
46.50
99.73
Maximum 24 hour concentration
SO2
28.40
100th
Maximum 24 hour concentration
SO2
20.10
99.18
Maximum annual mean
concentration
SO2
5.79
-
Maximum 1 hour
Pb (as
particulate)
0.035
100th
Maximum 1 hour
Pb (as
particulate)
0.0124
99th
Maximum 1 hour
Pb (as
particulate)
0.0093
98th
Maximum annual mean
concentration
Pb (as
particulate)
0.00257
-
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Document No. 2007A145(4)
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3.5.2 Results of dispersion modelling assessment for Volatile organic
compound pollutants.
Various averaging intervals were chosen to allow direct comparison of predicted GLC’s with
the relevant air quality assessment criteria as outline in Table 2.1. In particular, 1-hour and
percentile average GLC’s of Total volatile organic compounds were calculated at various
distances from the site. Relevant percentiles of these GLC’s were also computed for
comparison with the relevant proposed assessment criteria presented in Table 2.2 (see Table
3.2 and 3.3 for input data for existing site operations) (ref: Scenario 3).
Ref: Scenario 3:
Dispersion modelling assessment of existing operations located
within Alps Electric (Ireland) Ltd for Total volatile organic compounds
(see Table 3.2 for input data).
In terms of overall VOC’s currently, emission points A2-2, A2-6 and A2-7 emit the greatest
mass of VOC from the facility operations. The overall mass emission rate for Total VOC’s
from all emission points within the site is an average 12.032 kg/hr. Emission points A2-2, A2-6
and A2-7 account for up to 67% of there total VOC emission with a total mass emission rate
of 8.012 kg/hr (see Table 3.2). In term of ground level concentrations in the vicinity of the site
operations it is necessary to provide VOC mitigation. In terms of mitigation it is fair to assume
that greatest reduction in GLC’s will be achieved by abating the greatest emission rate
source. Multiple dispersion modelling scenarios were utilised to select those sources, which
provide greatest reduction in GLC. In order to present the results of this assessment,
Scenario 4 was used to demonstrate the overall results of this study. Table 3.11 illustrates the
input data utilised within the dispersion model following the implementation of VOC mitigation.
Section 3.5.2.1 provides specific details on the potential VOC mitigation techniques to be
utilised within the site to achieve the emission limits and ground level concentrations. Section
4.2 provides additional results in relation to the maximum predicted GLC’s for Total VOC’s
before and after abatement.
Ref: Scenario 4:
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Dispersion modelling assessment of proposed operations located
within Alps Electric (Ireland) Ltd for Total volatile organic compounds
following the implementation of VOC abatement strategy on
Emission points A2-2, A2-6, and A2-7. A detailed description of the
emission reduction strategy is contained in 3.5.2.1 (see Table 3.11
for input data).
29
Document No. 2007A145(4)
Alps Electric (Ireland) Ltd
Table 3.11. Total VOC emissions from process vents in Alps Electric (Ireland) Ltd following the implementation of VOC abatement on emission points A2-2, A2-6
and A2-7.
Sample
location
A2-1
Sample location description
PAL room extraction stack
Solderwave/Concoat machine extraction
point
Spot dip machine extraction point
SMT machine extraction point
Storage shed extraction point
PAL area extraction stack
PAL area extraction stack
Sludge storage area extraction
Paint and laser tray cleaning area
extraction point
Hazardous waste storage area extract
point
A2-2
A2-3
A2-4
A2-5
A2-6
A2-7
A4-1
A4-2
A4-3
Proposed A131, 2
3, 4
Total VOC
VOC abatement system
-
4.62
Normalised Mass
loading/emission
(g/s)1,3
0.20
Normalised Mass
loading/emission
(kg/hr)1,3
0.71
See VOC abatement
-
-
-
63.86
0.50
31.20
See VOC abatement
See VOC abatement
31.20
0.85
1.04
0.93
0.93
0.05
0.0005
0.03
0.03
0.20
0.0019
0.10
0.10
31.20
0.93
0.03
0.10
31.20
0.93
0.03
0.10
50
12.16
0.608
2.188
-
-
-
3.512
TOC concentration
3 1
(mg/Nm )
Volumetric airflow
3
rate (Nm /s)
42.57
Notes: 1denotes that it is assumed that the VOC abatement technology will achieve a stack VOC concentration of 50 mg/Nm3 as detailed in BREF.
2
denotes that it is assumed that the total treatment volume of 12.16 Nm3/s will be treated from emission point sources A2-2, A2-6 and
A2-7. The total exhaust emission stack height attached to the abatement equipment will be a total 16.5 m from existing ground level of
136 m. The exhaust emission point efflux will be 19 m/s and the exhaust temperature will be 433 K assuming regenerative thermal
oxidation is the chosen technology.
3
denotes that the overall mass rate emission rate reduction of approximately 67% will be achieved from the site.
4
denotes it is assumed that emissions from all sources occur 24 hours per day and simultaneously. This assessment can be
considered worst case and conservative.
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Document No. 2007A145(4)
Alps Electric (Ireland) Ltd
In addition to the assessment of Total volatile organic compound GLC’s, the individual EAL’s
for the speciated VOC’s were screened in order to ascertain the GLC’s for such compounds
in the vicinity of the operating facility. Since there exists at least 22 compounds emitted to
atmosphere from the various processes, a screening mechanism was used to ascertain the
highest risk impact compound criterion. If such selected compounds pass the screening
mechanism, then it would be unlikely that any other speciated VOC’s would impact in the
vicinity of the site location since the presented data is maximum detected air phase
concentration and mass emission rate over the time period (i.e. such chosen compounds are
maximum emissions of speciated VOC’s). This facilitates the assessment of worst-case
impact assessment of the individual compounds, which provides added safety factor for
maximum emission occurring at similar times (which would not be the case in real time
operation).
Table 3.12 illustrates the maximum detected air phase concentration of most common VOC’s
detected in the emission points located in Alps Electric (Ireland) Ltd. Primarily, 6 individual
compounds were close to or above their respective EAL 1 hour short term limit value at the
emission point source; therefore based on this fact, there is the potential that such compounds
could result in an EAL impact downwind of the facility (i.e. next the residential dwellings).
These compounds included:
•
•
•
•
•
•
Isopropyl alcohol,
Xylene isomers,
Butyl acetate,
Toluene,
Methyl isobutyl ketone and
Ethyl benzene.
All other compounds were below their respective 1-hour short term EAL values at the emission
source (highest concentration that can be perceived) and therefore were not considered
significant in terms of environmental impact. It would be fair to conclude that those compounds
below their respective 1-hour short term EAL value at source would not breach the GLC value
downwind of the facility.
In addition, the long term EAL value (annual mean) was used to assess long term impact as
recommended in the H1 guidance notes.
In order to rank the mass emission of a compound in terms of dispersion modelling, the source
concentration of each compound is divided by its known EAL value and the significance of the
compound in terms of dispersion modelling impact assessment becomes clearer (see Table
3.12). The compounds presented in Table 3.13 are those maximum detected concentration of
compounds reviewed from the historical dataset thereby facilitating worst-case estimate. Total
worst case mass emission rates over a 2 year period from identified emission points, and
respective EAL’s are presented to allow the reader to ascertain the significance of speciated
VOC’s in terms of impact.
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Document No. 2007A145(4)
Alps Electric (Ireland) Ltd
Table 3.12. Review of speciated VOC data and presentation of maximum emission concentration for selected emission points.
Compounds with highest detected air phase concentration from historical reports over 2 year period
Ethyl
Trimethyl
1
Xylene Acetic acid
Butyl
Cyclohexane
Cyclohexanone Hexane
MIBK
Toluene
Emission point
Isopropyl alcohol (mg/Nm3)
benzene
benzene Pentene
isomers ethyl ester acetate
(mg/Nm3)
(mg/Nm3)
(mg/Nm3) (mg/Nm3)
(mg/Nm3)
(mg/Nm3)
(mg/Nm3) (mg/Nm3)
(mg/Nm3) (mg/Nm3) (mg/Nm3)
A2-1
22.6
21.3
14
25.6
3.8
0.31
3.8
A2-2
200.8
1.34
7.3
18.4
0.5
-
4
-
-
12.6
9.5
-
A2-3
18.2
-
0.5
4.4
-
-
1.5
-
-
-
-
-
A2-4
-
-
-
-
-
-
-
-
-
-
-
-
A2-5
-
3.18
-
30
1.63
0.03
-
1.31
0.07
10.3
-
-
A2-6
-
-
-
-
-
-
-
-
-
-
-
16.9
A2-7
Total conc. at
source
(mg/Nm3)
Short term EAL1 hour impact
(mg/Nm3)
Long term EALAnnual mean
(mg/Nm3)
Ratio of short
term EAL to air
phase conc.
-
33.24
-
58.16
-
-
-
-
-
-
78.59
-
241.6
59.06
21.8
136.56
5.93
0.34
5.5
1.31
0.07
22.9
91.89
16.9
81.30
66.20
420
96.60
8.00
37.50
-
40.80
21.60
20.80
55.20
105.00
2.71
4.41
14.60
7.24
1.91
1.25
-
1.02
0.72
0.83
4.41
3.50
2.97
0.89
-
1.44
0.74
-
-
-
-
1.10
1.66
-
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Document No. 2007A145(4)
Alps Electric (Ireland) Ltd
The main interim conclusions before detailed dispersion modelling from this screening exercise
included:
Only 4 compounds including Isopropyl alcohol, Butyl acetate, Methyl isobutyl ketone and Ethyl
benzene were above their respective 1-hour short term EAL. All other compounds were below
their respective EAL in term of source-based ratio to EAL concentration levels. In order to be
conservative throughout the assessment Xylene isomers, and Toluene are also assessed for
the existing situation (ref Scenario 3). In addition, the long term EAL annual mean value is also
compared to the proposed short term EAL’s in Table 2.2.
The overall mass emission rates of the maximum measured speciated VOC concentrations
can be observed in Table 3.13. This data was used in conjunction with the source
characteristics presented in Table 3.1 to predict the worst case 1 hour and Annual mean
concentration of these individual compounds in the vicinity of the existing facility only.
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Document No. 2007A145(4)
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Table 3.13. Maximum worst-case mass emission rates of identified speciated VOC’s for Alps Electric (Ireland) Ltd existing facility operation.
Acetic acid
Butyl
Toluene
ethyl ester
acetate (g/s)
(g/s)
(g/s)
0.06463
0.11818
0.01754
Trimethyl
benzene
(g/s)
0.00143
1
Cyclohexanone Hexane
MIBK (g/s)
Pentene
(g/s)
(g/s)
(g/s)
-
A2-1
Isopropyl
alcohol
(g/s)
0.10433
Xylene
isomers
(g/s)
0.09833
0.01754
-
A2-2
0.58295
0.00389
0.02119
.05342
0.00145
-
0.01161
-
-
0.03658
0.02758
-
A2-3
0.01551
-
0.00043
0.00375
-
-
0.00128
-
-
-
-
-
A2-4
-
-
-
-
-
-
-
-
-
-
-
-
A2-5
-
0.00295
-
0.02783
0.00151
0.00003
-
0.00122
0.00006
0.00955
-
-
Emission
point
Ethyl benzene
(g/s)
Cyclohexane
(g/s)
A2-6
-
-
-
-
-
-
-
-
-
-
-
0.04170
A2-7
Total mass
emission rate
(g/s)
-
0.07646
-
0.13377
-
-
-
-
-
-
0.18077
-
0.70279
0.18162
0.08625
0.33694
0.02051
0.00146
0.01289
0.00122
0.00006
0.04613
0.22589
0.04170
Notes: Compounds with highest mass emission rate from historical reports over 2 year period using average volumetric air flow rate data in Table 3.1.
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In addition to this screening, the TA Luft GLC assessment criterion is also assessed to provide
a picture of the total VOC GLC levels at the sensitive receptor locations and would be termed
worst case catch all technique in terms of composite VOC impact assessment.
Table 4.3, 4.4 and 4.5 illustrates the tabular results obtained from the dispersion modelling
assessment for Scenarios 3 and 4 for Total and Speciated VOC’s. Maximum predicted GLC’s
for the percentile scenario are presented within this table to allow for comparison with
proposed regulatory guidelines and other specified regulations and assessment criterion
contained in Table 2.2. In addition, graphical contour plots are provided for information within
Appendix I (ref: Section 6) for the existing and proposed Scenarios 3 and 4.
For Scenario 4, it is assumed that VOC mitigation will be applied to emission points A2-2, A2-6
and A2-7 due to their respective high total VOC concentration and mass emission level in the
exhaust vent (i.e. account for up to 67% of Total VOC emissions) and the fact that these
emission points come under the regulation of SI543 of 2002. The overall type of installed
mitigation may change in future months depending on process optimisation and air handling
reduction strategies occurring at the individual emission points in the coming months. For the
sake of this assessment, worst-case volumetric airflow rate is utilised in order to allow the
regulatory body to establish emission limit values.
3.5.2.1
BAT Volatile organic compound abatement strategy
In order to reduce the overall mass emission of VOC from the facility, a combination of
techniques will be investigated to achieve this reduction. Primarily, process optimisation and
recycling of air will form a large part of the overall mitigation plan. In addition to this and where
deemed necessary following the implementation of the process optimisation mitigation
technique, a number of end of pipe techniques will be considered. For this assessment, it is
assumed that all waste air generated within the processes will be ducted to a VOC abatement
technology. The final design and type of VOC abatement system has not been finalised but for
this assessment it is assumed that a two canister with buffer tank regenerative thermal oxidiser
operating on LPG will be utilised. A buffer tank will be implemented into the design to prevent
cyclic emissions from the system when valve switching is occurring.
Specific details of the various applicable technologies are provided in Section 3.5.2.2 to 3.5.2.4
of this document. The specific treatment volumes, VOC emission rates as non-methane VOC’s
and overall VOC emission rate from the abatement system is provided in Section 3.5.2.
It is assumed for the dispersion modelling assessment for the proposed facility operation, that
this VOC abatement strategy will achieve greater than 95% removal efficiency on emission
points A2-2, A2-6 and A2-7. A stack limit concentration of Total VOC will be approximately less
than or equal to 50 mg/Nm3 which is in keeping with literature and BAT.
3.5.2.2 Review of BREF document for surface treatment using organic solvents-treatment
techniques in general.
BAT is to provide for design, operation and maintenance of the proposed waste treatment
plant installation. The following elements should be considered:
1. Minimise emissions at source, recover solvent from emissions or destroy solvents in
waste gases. Using low solvent materials can lead to excessive energy demands to
operate thermal oxidisers. Oxidisers may be decommissioned where the negative
cross-media effects outweigh the benefits of destroying the VOC)
2. Seek opportunities to recover and use excess heat generated in VOC destruction and
minimise the energy used in extraction and destruction of VOCs
3. Reduce solvent emissions and energy consumption by using the techniques
described, including reducing the volume extracted and optimising and/or
concentrating the solvent content. In the case of Alps electric Ireland catalyst based
oxidizers are considered high risk due to possibilities of poisoning the catalyst.
For the machines not connected to waste gas treatment, BAT is one of:
1. Use low solvent or solvent free products on these machines
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Alps Electric (Ireland) Ltd
2. Connect to the waste gas abatement equipment when there is capacity
3. Preferentially run high solvent content work on machines connected to waste gas
abatement.
This is addressed in detail within Point 13 reply for request for addition information.
Where installations have no waste gas abatement equipment and are using substitution, it is
BAT to follow the developments of low solvent and organic solvent free paints, varnishes and
adhesives, and continuously decreases the amount of solvents consumed. This is been
considered by Alps Electric Ireland Ltd and will be implemented where possible.
BAT is also to:
1. Minimise energy consumption when optimising waste gas treatment in all sites
2. Seek opportunities to recover and use any surplus energy in all sites.
In terms of system maintenance, all waste gas systems need maintenance, both
preventative and for breakdowns.
Untreated emissions can be minimised by:
• Planned maintenance (see Section 20.2.6-BREF). Where it is necessary to shut down
key emission abatement equipment (and this may include some days for cooling
before the equipment can be touched), the emissions can be minimised by carrying
out maintenance:
• During low or no-production times (e.g. vacation shutdown periods),
• During periods when emissions will have least impact, i.e. for VOC emissions, during
periods of low sunlight levels, low probability of inversion layers, etc. This is dependent
on weather, time of year and local conditions.
• Monitoring key equipment for problems such as vibration, emission leaks and planning
repairs (as above), using decentralised/dedicated treatment systems so
breakdown/repair only affects the systems in question (see Section 20.11.1.6), dealing
with breakdowns efficiently and detected faults as rapidly as possible.
3.5.2.3 Suggested treatment techniques applicable to Alps Electric (Ireland) Ltd and
taken from BREF.
Thermal oxidation
Thermal oxidation involves the destruction of solvent vapours in the presence of heat and
Oxygen. The destruction process is complex whereby solvent air is fed into the combustion
zone of the thermal oxidiser and heated to a temperature of approximately 680 to 750 Deg C.
the air stream is passed through a heated ceramic zone whereby sufficient retention time is
maintained to allow for full oxidation of the VOC to be completed. Retention times vary from 1
sec to 2 sec and are directly dependent on the inlet VOC and its oxidation potential. Higher
temperatures are required for low retention times and are indeed interlinked to the type of
media utilised (surface area). In recent years up to three ceramic beds are provided in order to
allow for the efficient capture of waste heat within the ceramic bed and to prevent the cyclic
emissions of VOC’s during valve switching. In some cases two canister system can be utilised
in conjunction with an outlet buffer tank whereby the cooled air is directed to the buffer tank to
prevent such cyclic emissions. The thermal oxidiser can be operated on different fuel types
including Gas oil, LPG and natural gas. In the case of Alps Electric Ireland LPG would be the
preferred fuel while either a two canister coupled to a buffer tank or a three-canister system
would be utilised. Up to 96% thermal recovery can be achieved on properly designed and
insulated system (4% energy loss to stack). In addition, the overall thermal efficiency of the
thermal oxidiser is improved if it can be operated in auto thermal mode (if sufficient VOC’s are
present). In the case of Alps Electric Ireland if an oxidiser is chosen as end of pipe, direct gas
lance injection will be performed into the ceramic. This will reduce the fuel consumption costs
by up to approximately 25% since the preheating of combustion air is not required.
Achieved environmental benefits: Reduction in overall emission loads. Generally, defects in
Thermal oxidation equipment can give rise to VOC emissions equivalent to 0.4 % of the annual
input per day, see Section 2.4.2.5.4-BREF. In terms of operating temperature, BREF suggests
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Alps Electric (Ireland) Ltd
temperature ranges of 680 to 750 Deg C for thermal oxidizers. For a waste gas with a VOC
concentration of 10 g/Nm3, the removal efficiency is about 95 to 98%. VOC concentrations in
the treated waste gas of 25 - 50 mg/Nm3 are achievable. The higher the inlet solvent
concentration the lower the running costs.
Cross-media effects: Energy consumption from the exhaust ventilator and fuel can vary
depending on system design. Gas consumptions of up to 0.8 m3 /1000 m3 waste gas treated
are anticipated. Particulate filtration of the waste gas stream will be required in the case of Alps
to prevent paint residues affecting the thermal efficiency. A burn out cycle will be implemented
into the system to reduce shut down time. Noise levels might increase.
Operational data: The temperature of the waste gas should if possible be high and the
humidity should be low to reduce energy consumption in the combustion process.
Economics: Thermal oxidation is operation costs can be considered high if proper
engineering design is not incorporated into the system design. In terms of any installation, high
efficiency thermal insulation, direct gas lance injection into the ceramic bed should be
achieved, inlet air stream should be low in aerosols and moisture and pressure loss across the
ceramic should be lowered. High efficiency fans should be utilised and VSD controlled. Twin
burners should be installed and LPG would be preferred fuel type. At least two canisters
should be utilised while the delta T should be no greater than 40 Deg C. Manufacturer data
3
3
suggests a LPG consumption rate of 0.80 m / 1000 m of waste gas treated. Lowering the
treatment volume results in a near directly proportional reduction in the operation costs for this
technology.
UV oxidation
Solvent-laden air is routed through a series of UV lamps. VOC molecules are fragmented by
the short wavelength energy and ozone is formed from the oxygen. The ozone reacts with the
fragmented VOC molecules, which lead it to partly oxidised. The subsequent unit contains a
catalytic agent (mainly TiO2), the oxidation of the ozone and VOC molecules continues and
the excess ozone is destroyed.
Achieved environmental benefits: For a waste gas with a VOC concentration of 0.5 g/Nm3,
the removal efficiency is about 95 %. VOC concentrations in the treated waste gas of 25 - 50
mg/Nm3 are achievable.
Cross-media effects: Energy consumption from the lamps and exhaust ventilator together are
50 kWh per 1000 m3 waste gas treated. The lamps emit O3 (which is destroyed), and contain
mercury, which has to be disposed of with suitable precautions. Noise levels might increase. In
the case of Alps Electric
Operational data: The temperature of the waste gas should not exceed 60 ºC and the
humidity should be less than 85 %. The technique was originally developed to achieve odour
reduction and for the destruction of toxic substances. However, increasingly the technique is
used for the complete destruction of VOCs, especially in waste gases containing low
concentrations (on average <0.5 g/Nm3 and occasionally peaks of <1.0 g/Nm3).
Economics: In an installation that can treat several 10,000 m3/h, investment costs are about
EUR 5000 – 7000 per 1000 m3/h waste gas. After 8000 hours the UV lamps need to be
replaced; costs are about EUR 0.06 – 0.2 per 1000 m3/h waste gas. Energy costs are about
EUR 4 per 1000 m3/h waste gas. The operational costs (including lamps, energy and
catalyser) are in the range EUR 3 – 25 per kilo VOC removed. In the specific situations where
this technique is used, UV oxidation has been reported to be cheaper compared to adsorption
to activated carbon or any type of thermal oxidation.
Non-thermal plasma treatment
In the waste gas, a plasma is created at low temperatures (30 – 120 ºC) by routing the waste
gas through two electrodes with an alternating current of 20 – 30 kV. In the plasma, the VOC
vapours react very quickly with oxygen to form CO2 and water vapour. In a plasma, the
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Document No. 2007A145(4)
Alps Electric (Ireland) Ltd
molecules of the gasflow are in a partly ionised condition. This condition is normally achieved
by extremely high temperatures, such as that caused by lightning. However, it can also be
created at ambient temperatures if enough energy is added.
Achieved environmental benefits: Efficiencies of 97 - 99.9 % are achieved without heating
the waste gas. The installation for this technique is very compact compared to thermal
oxidation and also consumes far less energy.
Cross-media effects: Energy consumption of 0.5 – 3.0 kWh electric energy per 1000 m3
waste gas treated.
Operational data: Different layouts are available. Sometimes the space between the
electrodes is filled with small glass balls to amplify the electric field.
Applicability: This technique has only been commercially applied for a few years to reduce
odour emissions and sometimes to treat waste gases containing VOC. In theory, there is no
restriction in applications concerning the VOC concentrations in the waste gas; however, it is
currently applied for treating low concentrations. Also small or large flows can be treated
In terms of all treatment technologies, the author has experience in operating and trailing all
technology types included above, therefore their individual limitation are realised.
In terms of moving forward in Alps Electric (Ireland) any technology chosen other then thermal
oxidation will be trailed on site to ascertain their respective removal efficiency before
placement of order. The EPA will be included in the process of isolation of the equipment.
Specified engineering works will be submitted to the EPA for review before placement of order.
This process has been used successfully on other Waste and IPCC licensed sites throughout
Ireland (Dublin office).
3.5.2.4 Technical issue to be addressed in any technologies.
The elements form a significant part of the technology selection process. These include:
• Applicability to air stream,
• Published performance data for review and if not available perform trial works on site
to ensure technology achieved performance guarantees.
• Air stream preparation forms a significant part of the system operation. The air stream
will be conditioned for aerosols to prevent issues with operation.
• Where possible volumes of air treatment will be reduced through optimisation. This is
currently under review in Alps Electric Ireland Ltd and will be finalised before isolation
of technology.
• Design the system with energy efficiency in mind. Eff 1 motors to be used on all fans,
VSD to be fitted to all motors, and thermal insulation provided where necessary.
• 100% duty 50% standby on major components will be provided (i.e. fans, pumps,
burners,) and the system will be designed to allow for partial operation (50%) if
necessary.
• Necessary spares on consumables will be maintenance on site to ensure continued
operation.
• A full maintenance schedule in accordance with manufacturers instructions will be
incorporated into the operation cycle and controlled through the Environmental
Management system for the site.
• Energy recovery where possible will be considered with each specific technology.
• Emission and environmental benefits will be considered through Life system cost
analysis and CO2 eq will be calculated.
• The VOC abatement plant will be designed to deal with maximum emission events.
• Abnormal operation will only occur if maintenance needs are not addressed
adequately within the Environmental Management System.
• Emergency operation conditions will only occur if plant failure occurs. Production
operations will be limited till plant system is operational or emergency VOC abatement
system will be installed on site.
This is considered BAT.
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Alps Electric (Ireland) Ltd
Table 3.14 illustrates the approach and time line will be utilised to realise the installation of end
of pipe abatement where necessary for Alps electric (Ireland) Ltd.
Table 3.14. Schedule for isolation, installation and operation of VOC abatement plant in Alps
Electric (Ireland) Ltd.
Time required
Objective
Item
(weeks)
To define the works required and
Development of scope of works
4 weeks
agree the full procurement process
with Alps electric (Ireland) Ltd
Alps Electric Ltd to finalise process
Optimisation of process emission
optimisation and air recirculation
points A2-2, A2-6 and A2-7 for
scheme to allow for reduction in
development
of
contract
overall treatment volume. In addition
5 weeks
specifications. Full characterisation
trials
will
be
performed
on
study performed in terms of
technologies that have limited
interrelationship between process
process data.
and end of pipe abatement
Development
of
contract
To
develop
performance
specifications,
performance
specifications and minimum electrical
4 weeks
specifications, Terms of reference
and mechanical specifications for the
and selection of 5 proven companies
contract
with capabilities to supply technology
To allow for sufficient time line to
Receipt of tender submissions and
4 weeks
allow contractors to provide details
review process and initial design
tender submission
Clarification requests forwarded to
To allow for clarifications of
2 weeks
preferred bidders
presented bids.
Detailed clarification process and if
Interview and Selection of preferred
possible visit installed plants in
bidder
and
signing
of
operation. Contracts will be signed
4 weeks
contracts/placement of order on
and
detailed
design
process
agreed time frame
commences.
Submission of Specified Engineering
Specified
engineering
works
5 weeks
works on initial design to EPA for
submitted to EPA for review.
review and receipt of agreement
Detailed
design
stage
and
Detailed design, development of
agreement of general layout and
6 weeks
drawings and installed plan for the
design
contract.
Some technologies may require up to
Delivery of all major items to site for
Up to 20
20 weeks for delivery. This time line
installation
weeks
could be reduced to 14 week if
available slot on production line.
Installation of abatement plant and
Installation of abatement plant
Up to 3 weeks
initial optimisation
Final
snag
items
before
Snagging of installed plant before
1 week
commissioning
operation
Commissioning and performance
Commissioning and performance
testing to be complete before full
1 week
time operation. All P&ID values
testing of system installed
included on O&M
Training
on
operation
and
Full training provided to Alps Electric
1 week
maintenance of installed system.
staff before signoff on plant build.
Submission of final testing and
Performance testing reports, all
performance reports to the EPA for
1 week
certificated submitted to the EPA for
review.
information.
Plant operation commences in full
Operation of abatement plant
N/A
flow
To
ensure
all
service
and
Incorporation
of
service
and
N/A
maintenance needs identified and
maintenance
schedule
into
flagged to plant personnel.
Environmental Management system.
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39
Document No. 2007A145(4)
4.
Alps Electric (Ireland) Ltd
Discussion of results
This section will describe the results obtained throughout the study.
4.1
Assessment of air quality impacts due to classical air pollutants
Table 4.1 and 4.2 presents the comparison between model predictions for classical air quality
impacts, baseline air quality concentrations for the compounds and the percentage impact of
the air quality criterion for Scenarios 1 and 2 (i.e. existing and proposed operations). As can be
observed, all predicted GLC’s (ref: Scenarios 1 and 2) are within the relevant air quality impact
criteria for all assessed compounds and therefore it is predicted that the facility will contribute
negligibly to air quality impact in the vicinity of the site.
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Table 4.1. Comparison between predicted GLC’s + baseline national air quality data and regulatory guideline and limit GLC’s for Scenario 1.
Identity
Compound
Maximum predicted
GLC -Scenario 2
(μg m-3)
Maximum 8 hour concentration (100th ile)
Maximum 1 hour concentration (100th ile)
Maximum 1 hour concentration (99.79th ile)
Maximum annual mean concentration
th
Maximum 24 hour concentration (100 ile)
Maximum 24 hour concentration (98.09th
ile)
Maximum annual mean concentration
Maximum 1 hour concentration (100th ile)
Maximum 1 hour concentration (99.73th ile)
Maximum 24 hour concentration (100th ile)
Maximum 24 hour concentration (99.18th
ile)
Maximum annual mean concentration
Maximum 1 hour (100th ile)
Maximum 1 hour (99th ile)
Maximum 1 hour (98th ile)
Maximum annual mean concentration
CO
NO2 as NOX
NO2 as NOX
NO2 as NOX
PM as PM10
0.42
84.14
61.40
7.05
32
1900
9.60
9.60
9.0
16.90
Baseline +
Maximum
predicted
GLC (μg m-3)
1900.42
93.74
71
16.05
48.9
PM as PM10
20.50
16.90
PM as PM10
SO2
SO2
SO2
8.95
69
47
28.40
SO2
Notes:
SO2
Pb (as particulate)
Pb (as particulate)
Pb (as particulate)
Pb (as particulate)
Impact
criterion
(μg m-3)2
% of Criterion
10000
200
200
40
50
19.00
46.87
35.50
40.13
97.80
37.4
50
74.80
13.0
63.60
63.60
17.70
21.95
132.6
110.6
46.10
40
350
350
125
54.88
37.89
31.60
36.80
20.12
17.70
37.82
125
30.26
5.79
0.035
0.0124
0.0093
0.00257
5.0
0.010
10.79
0.035
0.0124
0.0093
0.01257
20
0.5
0.5
0.5
0.5
53.95
7.00
2.48
1.86
2.51
1
denotes based on data presented in Table 3.4, 3.6, 3.7 and 3.8.
denotes for impact criterion see Table 2.1
3
denotes for baseline data see Table 2.3
2
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Baseline conc.
value
(μg m-3)1
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Document No. 2007A145(4)
Alps Electric (Ireland) Ltd
Table 4.2. Comparison between predicted GLC’s + baseline national air quality data and regulatory guideline and limit GLC’s for Scenario 2.
Identity
Compound
Maximum predicted
GLC -Scenario 2
(μg m-3)
Maximum 8 hour concentration (100th ile)
Maximum 1 hour concentration (100th ile)
Maximum 1 hour concentration (99.79th ile)
Maximum annual mean concentration
th
Maximum 24 hour concentration (100 ile)
Maximum 24 hour concentration (98.09th
ile)
Maximum annual mean concentration
Maximum 1 hour concentration (100th ile)
Maximum 1 hour concentration (99.73th ile)
Maximum 24 hour concentration (100th ile)
Maximum 24 hour concentration (99.18th
ile)
Maximum annual mean concentration
Maximum 1 hour (100th ile)
Maximum 1 hour (99th ile)
Maximum 1 hour (98th ile)
Maximum annual mean concentration
CO
NO2 as NOX
NO2 as NOX
NO2 as NOX
PM as PM10
49.50
181
61.40
7.05
32
1900
9.60
9.60
9.0
16.90
Baseline +
Maximum
predicted
GLC (μg m-3)
1949.5
190.6
71
16.05
48.9
PM as PM10
20.50
16.90
PM as PM10
SO2
SO2
SO2
8.95
69
47
28.40
SO2
Notes:
SO2
Pb (as particulate)
Pb (as particulate)
Pb (as particulate)
Pb (as particulate)
Impact
criterion
(μg m-3)2
% of Criterion
10000
200
200
40
50
19.50
95.30
35.50
40.13
97.80
37.4
50
74.80
13.0
63.60
63.60
17.70
21.95
132.6
110.1
46.10
40
350
350
125
54.88
37.89
31.46
36.80
20.10
17.70
37.8
125
30.24
5.79
0.035
0.0124
0.0093
0.00257
5.0
0.010
10.79
0.035
0.0124
0.0093
0.01257
20
0.5
0.5
0.5
0.5
53.95
7.00
2.48
1.86
2.51
1
denotes based on data presented in Table 3.4, 3.6, 3.7 and 3.8.
denotes for impact criterion see Table 2.1
3
denotes for baseline data see Table 2.3
2
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Baseline conc.
value
(μg m-3)1
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Document No. 2007A145(4)
4.1.1
Alps Electric (Ireland) Ltd
Carbon monoxide (CO)
The results for the potential air quality impact for dispersion modelling of CO for both Scenario
1 and 2 (i.e. existing and proposed facility operation) based on the emission rates in Tables 3.4
to 3.8 are presented in Table 3.9 and 3.10, respectively.
Results are presented for the identified maximum emission regime. As can be observed in
Tables 4.1 and 4.2, the maximum GLC+Baseline for CO for both Scenarios 1 and 2 from the
operation of emission points A1-1 and A1-2 is 0.42 and 49.50 μg m-3 for the 100th percentile for
a 8-hour mean worst-case concentration. When combined predicted and baseline conditions
are compared to the Irish guideline/limit values and EU Limit values laid out in the EU
Daughter directive on Air Quality 99/30/EC, this is up to 80.50% times lower than the set target
limits. Figure 6.1 provides graphical illustration of the contour plume spread in the vicinity of
the facility.
4.1.2
Oxides of nitrogen (NO2 as NOX)
The results for the potential air quality impact for dispersion modelling of NOX as NO2 for both
Scenario 1 and 2 (i.e. existing and proposed facility operation) based on the emission rates in
Tables 3.4 to 3.8 are presented in Table 3.9 and 3.10, respectively.
Results are presented for the identified maximum emission regime. As can be observed in
Tables 4.1 and 4.2, the maximum GLC+Baseline for NO2 as NOX for both Scenarios 1 and 2 is
93.74 and 190.60 μg m-3 for the 100th percentile and 84.14 μg m-3 for the 99.79th percentile for
a 1-hour mean worst-case concentration. When combined predicted and baseline conditions
are compared to the Irish guideline/limit values and EU Limit values laid out in the EU
Daughter directive on Air Quality 99/30/EC, this is from 4.70 to 54% lower than the set target
guidelines for the 100th percentile.
An annual average was also generated for Scenarios 1 and 2 to allow comparison with the SI
271 of 2002. When compared to the impact criteria, the annual average NO2 air quality impact
for Scenarios 1 and 2 are up to 60 % lower than the set target guideline (see Table 4.1 and
4.2) assuming a baseline concentration of 9 μg m-3.
The implementation of a stack height up to 16.50 metres on emission point A1-2 ensures no
ground level impact of NO2 in the vicinity of the site for the proposed operation cycle. Figure
6.2 provides graphical illustration of the contour plume spread in the vicinity of the facility.
4.1.3
Sulphur dioxide (SO2)
The results for the potential air quality impact for dispersion modelling of SO2 for both Scenario
1 and 2 (i.e. existing and proposed facility operation) based on the emission rates in Tables 3.4
to 3.8 are presented in Table 3.9 and 3.10, respectively.
Results are presented for the identified maximum emission regime. As can be observed in
Tables 4.1 and 4.2, the maximum GLC+Baseline for SO2 for Scenarios 1 and 2 is 69 μg m-3 for
the 100th percentile and 47 μg m-3 for the 99.73th percentile for a 1-hour mean worst-case
concentration. When combined predicted and baseline conditions are compared to the Irish
guideline/limit values and EU Limit values laid out in the EU Daughter directive on Air Quality
99/30/EC, this is up to 63% lower than the set target limits.
In addition, Tables 4.1 and 4.2 illustrates the maximum 100th and 99.18th percentile 24-hour
GLC+Baseline concentration for SO2 for Scenarios 1 and 2. As can be observed in Tables 4.1
and 4.2, the maximum GLC+Baseline for SO2 for Scenarios 1 and 2 is 28.4 μg m-3 for the 100th
percentile and 20.10μg m-3 for the 99.18th percentile for a 24-hour mean worst-case
concentration. When combined predicted and baseline conditions are compared to the Irish
guideline/limit values and EU Limit values laid out in the EU Daughter directive on Air Quality
99/30/EC, this is up to 60% lower than the set target guidelines.
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An annual average was also generated for Scenarios 1 and 2 to allow comparison with the SI
271 of 2002. When compared to the impact criteria, the annual average SO2 air quality impact
for Scenario 2 is up to 47% lower than the set target guideline (see Table 4.1 and 4.2)
assuming a baseline concentration of 5 μg m-3.
The implementation of a stack height up to 16.50 metres on emission point A1-2 ensures no
ground level impact of SO2 in the vicinity of the site for the proposed operation cycle. Figures
6.4 and 6.5 provide graphical illustration of the contour plume spread in the vicinity of the
facility.
4.1.4
Total particulates as PM10
The results for the potential air quality impact for dispersion modelling of Total particulates as
PM10 for both Scenarios 1 and 2 (i.e. existing and proposed facility operation) based on the
emission rates in Tables 3.4 to 3.8 are presented in Table 3.9 and 3.10, respectively.
Results are presented for the identified maximum emission regime. As can be observed in
Tables 4.1 and 4.2, the maximum GLC+Baseline for PM10 for Scenarios 1 and 2 is 32μg m-3 for
the 100th percentile and 20.50 μg m-3 for the 98.08th percentile for a 24-hour mean worst-case
concentration. When combined predicted and baseline conditions are compared to the Irish
guideline/limit values and EU Limit values laid out in the EU Daughter directive on Air Quality
99/30/EC, this is up to 2.20% lower than the set target guidelines.
An annual average was also generated for Scenarios 1 and 2 to allow comparison with the SI
271 of 2002. When compared to the impact criteria, the annual average PM10 air quality impact
for Scenarios 2 are up to 46 % than the set target guideline (see Table 4.1 and 4.2) assuming
-3
a baseline concentration of 13μg m .
The implementation of a stack height up to 16.50 metres on emission point A1-2 ensures no
ground level impact of PM10 in the vicinity of the site for the proposed operation cycle. Figure
6.3 provides graphical illustration of the contour plume spread in the vicinity of the facility.
4.1.5
Particulate based Lead
The results for the potential air quality impact for dispersion modelling of Total particulates as
PM10 for both Scenarios 1 and 2 (i.e. existing and proposed facility operation) based on the
emission rates in Tables 3.4 to 3.8 are presented in Table 3.9 and 3.10, respectively. Both,
Scenarios 1 and 2 are identical in exhaust emission rates for particulate-based lead. All lead
values were obtained from historic reports generated on site through grab based monitoring
over a 2-year period. In terms of impact, the predicted ground level concentrations of lead
were compared to both annual and 1-hour percentile impact criterion. As can be observed in
Tables 4.1 and 4.2, the over predicted lead impact for the operating site is negligible and less
than 3% of the proposed impact criteria contained in Table 2.1. Figure 6.6 provides graphical
illustration of the contour plume spread in the vicinity of the facility.
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4.2
Assessment of air quality impacts due to volatile organic
compound air pollutants.
Predictive air dispersion modelling was used to ascertain the ground level concentrations of
selected worst case speciated volatile organic compound concentrations and total volatile
organic compound concentrations as carbon to allow for comparison with published
Environmental assessment levels (EAL’s as specified in H1 guidance document) and
regulatory guideline values. Table 4.3 illustrates the results of the dispersion modelling
assessment of selected speciated VOC’s. These VOC’s were selected as they represented the
worst-case emission concentration of individual VOC’s emitted from the site operations over
the past 2 years. Data was collated from historical measured values (see Section 3.5.2). As
can be observed, the overall impact of speciated VOC’s from existing operations (ref Scenario
3) is negligible in terms of the individual EAL’s for each compound with all predicted
concentration less than 58% of their respective assessment levels. The maximum predicted
GLC for each screened compounds is illustrates in Table 4.3. The VOC impact assessment
and review of historical data suggests the existing facility operation will have negligible impact
on surrounding receptors in terms of speciated VOC’s.
Total VOC’s mass emission rates as presented in Table 3.2 and Table 3.11 were used to
assess the overall predicted impact of existing and proposed operations (ref: Scenarios 3 and
4). As can be observed in Figures 6.7 to 6.8, when total VOC’s is modelled it is predicted that
some impact may occur outside the boundary of the facility for existing operations (ref:
Scenario 3) with maximum ground level concentrations of 1,459 and 2003 μg/m3 at the 98th
th
and 99 percentile of hourly averages been predicted. Further investigation of individual
source characteristics predicted that emission points A2-2, A2-6, A2-7 and to a lesser extent
A2-1 contributing greatest to VOC plume spread in the vicinity of the facility operations.
Following the application of VOC mitigation, the overall predicted ground level concentration
(GLC’s) of total VOC’s is significantly reduced with GLC’s of 233 and 351 μg/m3 at the 98th and
99th percentile of hourly averages been predicted. This is a result of an overall reduction of
approximately 67% in the mass of VOC’s emitted by the facility through the application of
mitigation of mitigation to emission points A2-2, A2-6 and A2-7 (see Table 3.11).
Taking into account that the predictive analysis assumes that all emission points emit VOC
simultaneously 24/7 365 days per year, this assessment is considered conservative in terms of
actual conditions.
This will allow compliance with the proposed regulatory guideline vale of less than 1000 μg/m3
at the 98th for grouped compounds classified as Class 3 (see Figures 6.9 and 6.10).
Tables 4.4 and 4.5 illustrate the predicted maximum GLC’s for the existing and proposed plant
operations (ref: Scenario 3 and 4) for the 98th and 99th percentile of hourly averages for 5 years
of meteorological data. As can be observed there is a predicted overall reduction of 84% and
83% for the 98th and 99th percentile of 1-hour averages, respectively.
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Table 4.3. Predicted worst-case ground level concentrations of individual VOC’s emitted from processes located in Alps Electric (Ireland) Ltd and comparison
with individual Environmental assessment levels.
Worst case compound conc.
Assessed for EAL's
Predicted Annual
average maximum GLC
(ug/m3)
Long term
Annual EAL
(ug/m3)
Isopropyl alcohol
1132
81,300
105
2,710
Xylene isomers
219
44,200
11.10
2,210
7,100
Butyl acetate
409
95,000
18.90
22.47
8,000
1.03
500
Methyl isobutyl ketone
76
20,800
6.66
830
Ethyl benzene
371
55,200
16.11
1,000
Toluene
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Predicted 100th
Short term 1 hour
percentile 1 hour
EAL (ug/m3)
maximum GLC (ug/m3)
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Table 4.4. Predicted maximum total VOC GLC’s for existing facility (ref: Scenario 3).
Location of maximum detected
value
X coordinate
X coordinate
126918.1719
126918.1719
89648.1172
89648.1172
Percentile
Value (%ile) 1
hour
Maximum GLC
(μg/m3)
98
99
1,459
2,003
Table 4.5. Predicted maximum total VOC GLC’s for proposed facility (ref: Scenario 4).
Location of maximum detected
value
X coordinate
X coordinate
126886.7031
126886.7031
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89534.7969
89534.7969
47
Percentile
Value (%ile) 1
hour
Maximum GLC
3
(μg/m )
98th
99th
233
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5.
Alps Electric (Ireland) Ltd
Conclusions
Twelve emission points are located within the Alps Electric (Ireland) Ltd boundary. In terms of
emission characteristics, emission points A1-1 and A1-2 are combustion based for the
production of steam and electricity while Emission points A2-1, A2-2, A2-3, A2-4, A2-6 and A27 are scheduled emission points from process operations located within the production
building. Emission points A2-5, A4-1, A4-2 and A4-3 are considered fugitive emission points
ventilated storage rooms located within the facility operations. In terms of significant emissions
of VOC’s, vents A2-2, A2-6 and A2-7 would be considered highest with all other VOC emission
points negligible in terms of mass emission. It proposed during future operations to operate
emission point A1-2 during the time period 16.45PM to 19.15PM Monday to Friday October to
March on the winter demand scheme.
The following conclusions are drawn from the air quality impact assessment of process vents
located in Alps Electric (Ireland) Ltd:
1. The existing and proposed boiler and generator (i.e. emission points A1-1 and A1-2)
operations will not cause any significant classical air pollutant impact with all predicted
ground level concentrations of Carbon monoxide, Oxides of nitrogen, Sulphur dioxide
and Particulate matter within the regulatory guideline and limit values. In order to
ensure compliance with statutory limit values, emission point A1-2 (generator) stack
will require increasing up to a final height of 16.50 metres above ground level.
2. Following a review of historical particulate based lead emissions and dispersion
modelling it was concluded that lead emissions are insignificant from process vents
A2-2, A2-3 and A2-4. Particulate-based emission from these process vents are also
insignificant.
3. Following a review of measured and historical emission profile data on speciated
VOC’s (over two years), all maximum emission concentration of VOC’s are within their
respective environmental assessment concentration level for the protection of human
health. A screening mechanism was used to ascertain the maximum potential
speciated VOC concentrations impact. Advanced dispersion modelling was used to
predict maximum ground level and downwind concentration in order to allow for
comparison with the assessment criteria. Isopropyl alcohol, Xylene isomers, Toluene,
Butyl acetate, Ethyl benzene and Methyl isobutyl ketone were used for the screening
exercise.
4. The overall individual impact of screened compounds Isopropyl alcohol, Xylene
isomers, Toluene, Butyl acetate, Ethyl benzene and Methyl isobutyl ketone is within
proposed Environmental Assessment Levels (EALs), and therefore in accordance with
the requirements of H1 Guidance will not cause any significant impact.
5. Total volatile organic compounds as carbon as measured over a two-year period were
used in conjunction with dispersion modelling to ascertain the maximum GLC’s of total
VOC in the vicinity of the facility. This was compared to the regulatory assessment
criteria contained within the Ta Luft guidance document. During existing operations,
the overall plume spread and maximum GLC values are above the regulatory
guideline values. Predictive modelling was used to ascertain the emission sources that
contributed greatest to overall plume spread. Emission points A2-2, A2-6, A2-7 and to
a lesser extent emission point A2-1 were found to contribute most while all other
emission points contributing negligibly to ground level impact.
6. This was used to construct the basis of a predictive mitigation strategy where
investigation of VOC emission minimisation (process optimisation and end of pipe
abatement). Due to the air stream characteristics, three technologies may be suitable
including regenerative thermal oxidation and non-thermal plasma technology. It was
assumed for the dispersion modelling assessment that an exhaust gas concentration
of less than or equal to 50 mg/Nm3 would be achieved (i.e. this is achievable on such
technologies). Following implementation upon emission points A2-2, A2-6 and A2-7,
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the overall Total VOC impact will be less than 233 and 351 μg/m3 for the 98th and 99th
percentile isopleths for 5 years of meteorological data utilising Aermod Prime
dispersion model.
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Document No. 2007A145(4)
6.
Alps Electric (Ireland) Ltd
Appendix VI-Air dispersion modelling contour plots.
Only NO2 as NOX, SO2, and PM as PM10 percentile contour plots for the classical air pollutants
are illustrated in this section due to the large number of contour graphic files. Annual average
plots are not included for NO2 as NOX, SO2, and PM10 due to the large file size. Contour plots
are only supplied in this section for illustrative purposes only and refer to Scenarios 2, 3 and 4.
6.1
Classical air pollutants for Scenario 2-proposed plant operation
-3
Figure 6.1. Predicted CO ground level concentration of 36
μg m (
percentile of 8-hour maximum GLC values for emission points A1-1 and A1-2.
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50
th
)at the 100
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-3
Figure 6.2. Predicted NO2 ground level concentration of 150 μg m (
percentile of 1-hour maximum GLC values for emission points A1-1 and A1-2.
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51
) at the 100th
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Figure 6.3. Predicted PM ground level concentration of 20 μg m-3 (
) at the 100th
percentile of 24-hour maximum GLC values for emission points A1-1, A1-2, A2-2, A2-3 and
A2-4
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-3
Figure 6.4. Predicted SO2 ground level concentration of 30 μg m (
of 1-hour maximum GLC values for emission points A1-1 and A1-2.
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53
th
) at the 100 percentile
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-3
th
Figure 6.5. Predicted SO2 ground level concentration of 20 μg m (
) at the 100
percentile of 24-hour maximum GLC values for emission points A1-1 and A1-2.
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-3
) at the 100th
Figure 6.6. Predicted Lead ground level concentration of 0.020 μg m (
percentile of 1-hour maximum GLC values for emission points A2-2, A2-3 and A2-4.
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6.2
Total volatile organic compounds for Scenario 3-existing plant
operation
Figure 6.7. Predicted VOC impact contribution of existing facility operation to VOC plume
dispersal for Scenario 3 at the 98th percentile for combined VOC concentrations ≤ 650 μg m-3
(
).
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Figure 6.8. Predicted VOC impact contribution of existing facility operation to VOC plume
th
-3
dispersal for Scenario 3 at the 99 percentile for combined VOC concentrations ≤ 1000 μg m
(
).
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6.3
Total volatile organic compounds for Scenario 4-proposed plant
operation
Figure 6.9. Predicted VOC emission contribution of proposed facility operation with the
th
implementation of VOC abatement protocols to VOC plume dispersal for Scenario 4 at the 98
-3
percentile for VOC (as C) concentrations ≤ 100 μg m (
).
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Figure 6.10. Predicted VOC emission contribution of proposed facility operation with the
th
implementation of VOC abatement protocols to VOC plume dispersal for Scenario 4 at the 99
-3
percentile for VOC (as C) concentrations ≤ 150 μg m (
).
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7.
Appendix II-Meteorological data used within the Dispersion
modelling study.
7.1
Meteorological file Cork 1993 to 1997 inclusive
Figure 7.1. Schematic illustrating windrose for meteorological data used for atmospheric
dispersion modelling, Dublin 1993 to 1997 inclusive.
Table 7.1. Cumulative wind speed and direction for meteorological data used for atmospheric
dispersion modelling, Cork 1993 to 1997 inclusive.
Cumulative Wind Speed Categories
Relative Direction
> 1.54
>3.09
>5.14
>8.23
> 10.80
< 10.80
Total
0
0.56
0.67
1.45
0.80
0.12
0.02
3.61
22.5
0.55
0.68
1.41
0.78
0.07
0.00
3.49
45
0.43
0.59
1.10
0.44
0.11
0.00
2.67
67.5
0.63
0.77
1.62
0.61
0.23
0.03
3.90
90
0.62
0.77
1.76
0.77
0.29
0.07
4.30
112.5
0.83
1.09
1.98
0.86
0.29
0.16
5.20
135
0.57
0.71
1.62
1.01
0.34
0.22
4.47
157.5
0.87
1.04
2.15
1.68
0.73
0.33
6.81
180
0.91
1.10
2.22
1.39
0.52
0.23
6.38
202.5
1.21
1.53
3.53
1.78
0.51
0.27
8.84
225
1.11
1.54
4.31
2.00
0.63
0.23
9.80
247.5
1.16
1.40
3.74
2.41
0.77
0.36
9.84
270
1.10
1.10
2.02
1.23
0.45
0.13
6.03
292.5
1.41
1.62
2.60
1.45
0.50
0.25
7.83
315
1.29
1.74
3.04
1.18
0.31
0.11
7.67
337.5
1.25
1.70
3.42
1.31
0.14
0.02
7.84
Total
14.49
18.06
37.97
19.70
6.01
2.42
98.67
Calms
-1.05
Missing
0.28
Total
100
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8.
Appendix III: Checklist for EPA requirements for air dispersion
modelling reporting
Table 8.1. EPA checklist as taken from their air dispersion modelling requirements report.
Item
Location map
Site plan
List of pollutants modelled and
relevant air quality guidelines
Details of modelled scenarios
Details of relevant
concentrations used
ambient
Model description and justification
Special model treatments used
Table of emission parameters
used
Details of modelled domain and
receptors
Details of meteorological data
used (including origin) and
justification
Details of terrain treatment
Details of building treatment
Details of
deposition
modelled
wet/dry
Yes/No
Section 2
Section 2
Reason for omission/Notes
-
Yes
-
Yes
Baseline
dataSection 2
Yes
Yes
-
-
Yes
-
Yes
-
Yes
-
Yes
Yes
No mass fraction data, particle densities and
no particle distribution data for specific
operation.
Particulates
emission
not
significant from site processes.
Three years of hourly sequential data used
from nearest valid met station. Terrain
effects are accounted for in the modelling
assessment.
Flue gas, VOC, and particulate emissions
assessment from processes identified.
E-mailed upon request
No
Sensitivity analysis
No
Assessment of impacts
Yes
Model input files
No
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9.
Appendix IV-Proposed emission guideline/limit values for
emission points in Alps Electric (Ireland) Ltd.
Table 9.1. Proposed emission guideline/limit values for emission points located in Alps
Electric (Ireland) Ltd.
Process
Compound
Oil fired boilers emission limit
identity
values ref. to 3% Oxygen
Boiler/generator
Carbon monoxide
800 mg/Nm3
Boiler/generator
Oxides of nitrogen
450 mg/Nm3
Boiler/generator
Sulphur di/trioxide
500 mg/Nm3
Boiler/generator
Particulate matter
Less than 50 mg/Nm3
Other emission pointsTVOC
Other emission pointsTVOC
Other emission pointsTVOC
VOC emission Points
(SI543 of 2002)
Other emission points
Particulate based Lead
Other emission pointsParticulates (for
inorganic particulates
see Lead above)
Health risk
3
Class I
Class II
Class III
Category 8
Class II
20 mg/Nm at mass flow of less
than 0.10 kg/hr
100 mg/Nm3 at mass flow of less
than 2 kg/hr
150 mg/Nm3 at mass flow of less
than 3 kg/hr1
3
Less than 75 mgC/Nm with
less than 20% fugitive
emissions.
3
Less than 0.50 mg/Nm with a
mass flow less than 0.0025 kg/hr
--
Less than 10 mg/Nm3
--
See EAL’s in Table 2.2
Notes: When Class I, II and III present the Class III guideline limits will apply.
When Class I and II present the Class II guideline limits will apply.
For more specific information on emission guideline limit values see TA Luft 1996,
2002 and BATNEEC Notes EPA Manufacture of Integrated circuits and printed circuit
boards.
SI543 of 2002-Emissions of Volatile Organic compounds from organic solvent
regulations 2002.
Specific output data from dispersion model to be adapted where necessary.
Ref: Ta Luft 2002, EPA BAT Note for the waste sector (2003).
According to the Danish legislation the guideline limits and threshold values in Table 9.2
apply. Threshold values and limits for solvents in accordance with Directive 1999/13/EG,
Appendix II A. The regulation means that each company shall fulfil the limits for exhaust
gases and diffuse emissions or the total emission limit (then the limit for exhaust gases can
be exceeded.).
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Table 9.2. Threshold limit values for VOC emitting processes.
Process
Solvent
emitting
processes
Activity
Threshold
value t/a
Emissions limit
for exhaust
gases (mg
C/Nm³)
Limits for
diffuse
emissions (%)
Total
emission
limit (%)
Manufacture of
coating
materials, clear
lacquers,
printing inks and
adhesives
100-1,000
>1,000
150
150
5
3
5
3
It may be assumed that more stringent limit or threshold values arising from the specific
situation at the site or from any other officially imposed conditions will continue to apply.
Ref: Environmental Guidelines No.1 of 2002,-Guidelines for air emission regulation, Danish
EPA.
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