ALPS ELECTRIC (IRELAND) LTD. Clara Road, Millstreet Town, Co. Cork, Ireland ALPS Phone: +353-29-70677 Fax: +353-29-70603 I , Environmental Protection Agency PO Box 3000, Johnstown Castle Estate, County Wexford. Quality Systems Engineer (Direct Line: (029) 30229. Email: [email protected]e - <@& - / Headquarters, \ 2008 Ref: Reg No. PO835-01 Council) (Air Pollution Act 1987 Licence No. A.P. 2/05 Cork County To Whom It May Concern: Attached please find results report of quarterly monitoring for Alps Electric (Ireland) Ltd. of the following process vents: A2-1 Paint and Laser Process A2-2 Concoat Process and Wave Solder 1 & 2 A2-3 Spot Dip (x3) and manual soldcring, This monitoring was carried out on the 15’ February 2008. Report indicates that results on all emission points are within their respective licence limits. If you require any further information, please do not hesitate to contact me. ~1 Regards, # . \ +&Le I Mailk Walsh l e @ Printed on Recycled Paper EAGLE R+hdh Inc. ISOfLS 16949:ZOOZ For inspection purposes only. Consent of copyright owner required for any other use. EPA Export 26-07-2013:00:13:06
Transcript
ALPS ELECTRIC (IRELAND) LTD. Clara Road, Millstreet Town, Co. Cork, Ireland ALPS Phone: +353-29-70677 Fax: +353-29-70603
I
,
Environmental Protection Agency PO Box 3000, Johnstown Castle Estate, County Wexford.
Quality Systems Engineer (Direct Line: (029) 30229. Email: [email protected]
e -
<@& - / Headquarters, \
2008
Ref: Reg No. PO835-01 Council)
(Air Pollution Act 1987 Licence No. A.P. 2/05 Cork County
To Whom It May Concern:
Attached please find results report of quarterly monitoring for Alps Electric (Ireland) Ltd. of the following process vents:
A2-1 Paint and Laser Process A2-2 Concoat Process and Wave Solder 1 & 2 A2-3 Spot Dip (x3) and manual soldcring, This monitoring was carried out on the 15’ February 2008.
Report indicates that results on all emission points are within their respective licence limits.
If you require any further information, please do not hesitate to contact me.
(as measured on FID) 7 Speciated VOC monitoring of process vents 2-1,2-2 and 2-3
2.1 2.2 2.3.
2.3.1
3.2
3.3.
Total organic carbon emission as carbon concentration results
9
4. Discussion of results 11
5. Conclusions 11
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Confidential Report 2008A87(1)
Document Amendment Record
Project Number: 2008A87(1)
2008A87(1) Document for review B.A.S.
Revision PurposelDescription Originated
Alps Electric (Ireland) Ltd
Document Reference: Quarter 1- Environmental monitoring of named stack process located in Alps Electric (Ireland), Millstreet, Co. Cork. JMC B.A.S 21/03/2008
Checked Authorised Date
Client: Alps Electric (Ireland) Ltd)
- Title: Quarter 1 - Environmental monitoring of named stack process located in Alps Electric (Ireland), Millstreet, Co. Cork.
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Confidential Report 2008A87(1)
EXECUTIVE SUMMARY
- Alps Electric (Ireland) Ltd
Odour Monitoring Ireland were commissioned by Alps Electric (Ireland) Ltd to perform emission testing of the process vent stacks A2-1, A2-2 and A2-3 for volatile organic compounds (VOC's). Testing was performed in accordance with approved and accredited test methodologies on the 15Ih February 2008.
Primarily, four testing methodologies were used to characterise the airstreams. These included:
0 IS01 0780:1994- 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 gases- Continuous 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.
As part of the IPPC licence proposed decision - Licence Number PO835-01, Alps Electric (Ireland) Ltd was requested to monitor the process emissions in order to ensure that emission limit value (ELV) in accordance with the IPPC licence are been achieved.
The following conclusions were drawn from the study:
1.
2.
3.
4.
5.
Odour Monitoring performed emission monitoring of three-emission point A2-1, A2-2 and A2-3 in accordance with accredited methodologies at the Alps Electric (Ireland) Ltd facility on 1 5'h Feb 2008. The volumetric airflow rate from emission points A2-1, A2-2 and A2-3 was 3.58, 1.51 and 0.85 Nm3/s, respectively. All emission points were within their respective emission limit values contained within the IPPC licence PO835-01. The air stream concentration of total organic carbon as measured upon a FID for emission points A2-1, A2-2 and A2-3 were 19.13, 162.12 and 48.21 mgC/Nm3, respectively. All emission points were within their respective emission limit values contained within the IPPC licence PO835-01. The total mass emission rate of total organic carbon as measured upon a FID for emission points A2-1, A2-2 and A2-3 were 0.25, 0.88 and 0.15 kglhr, respectively. The total mass emission of compounds as measured upon a FID in accordance with EN13526:2002 and EN12619:1999 do not exceed the proposed decision licence number PO835-01 emission limit value.
iii
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Confidential Report 2008A87(1) Alps Electric (Ireland) Ltd
1. Introduction and scope
1.1 Introduction
Odour Monitoring Ireland were commissioned by Alps Electric (Ireland) Ltd to perform Volatile Organic Compound (VOC’s) monitoring of three exhaust stacks ventilating three processes in order to assess compliance with their proposed decision IPPC licence Number PO835-01 emission limit values.
The air emission points tested included:
A2-1 - Paint and laser process: A2-2 - Concoat process and Wave solder 1 & 2; A2-3 - Spot dip (X3) and manual soldering.
Primarily, four testing methodologies were used to characterise the airstreams. These included:
IS01 0780:1994- 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 EN1261 9:1999-Stationary source emissions-Determination of the mass concentration of total gaseous organic carbon at low concentrations in flue gases- Continuous 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.
As part of the IPPC licence number PO835-01, Alps Electric (Ireland) Ltd was requested to monitor the process emissions in order to ensure that emission limit value (ELV) in accordance with the IPPC licence regulations were achieved. An overview of the testing methodologies, results and conclusions are provided within this document.
1.2 Scope of the work
The main aims of the study included: Assessment of airflow rate and volumetric airflow rate of extraction system installed upon Process vents A2-1, A2-2 and A2-3 in accordance with 1S010780:1994, Assessment of Total hydrocarbon concentration as carbon (THC) mass emission concentrations from emission vents A2-1, A2-2 and A-2-3, in accordance with EN1261 9:1999 and EN1 3526:2002. Assessment of speciated VOC profile concentrations from emission vents A2-1, A2-2 and A-2-3 in accordance with EN13649:2002.
This section describes the materials and methods used throughout the survey.
The following standards were used for reference and adhered to where possible:
a
a
a
2.1
IS010780:1994- Stationary source emissions-Measurement of velocity and volume flowrate of gas streams in ducts. IS EN1 3526:2002-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 EN1261 9:1999-Stationary source emissions-Determination of the mass concentration of total gaseous organic carbon at low concentrations in flue gases- Continuous flame ionisation detector method. I.S. EN 13649:2002-Stationary source emissions-Determination of the mass concentration of individual gaseous organic compounds-Activated carbon and solvent desorption method.
Airflow rate measurement
Airflow rate measurement was performed in accordance with IS010780:1994-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:
L type pitot probe, PTIOO temperature probe,
Testo 400 and 3501454 MXL handheld and differential pressure sensors,
The following control procedure was used through the measurement sequence: 1.
2. 3.
4.
5.
'6.
7.
8. 9.
10
Measurement 'was performed at two diameters at right angles to each other where possible, The internal diameter of the ductwork was measured and verified using a SS rod, 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. 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, Approx. eight (depending on duct diameter) 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. The difference in the average airflow velocity across each diameter did not exceed 5% of the mean for all the diameters (2 in total). The number of sample points across the 2 diameters were determined in accordance with Table 7.1.4 of IS010780:1994. The sample locations were marked upon the L type pitot using a water resistant marker. The L type pitot was checked for any burrs and obstructions in the pitot orifices, The absence of swirling flow was determined in accordance with Section 7.2 and Annex
The measurement sequence was performed in accordance with the procedure . described in Section 7.2-IS010780:1994.
C-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.
2.2
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.
Flame ionisation detector (FID) measurement
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Confidential Report 2008A87( 1) Alps Electric (Ireland) Ltd
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 0.5- 1 .O 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.
2.
3.
4.
5.
6. 7.
8. 9.
Thef lD was switched on and the oven temperature and sample line temperature were allowed to stabilise. The set-point temperatures were 180 OC sample line temperature and 2OO0C oven temperature. This took approximately 45 minutes. The HydrogenlHe fuel, and Propane calibration gases (50 and 500 ppm) were individually attached to the instrument. Once temperatures had stabilised, the instrument was started and the ignition procedure was commenced. Once ignited, the sample procedure was commenced and any VOC upon the sample line was baked off. 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. The analyser calibration procedure was rechecked and recorded, 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 spanlzero reading. The probe was inserted into the stack. The datalogger was commenced ( I O second intervals) and manual readings were takinn and recorded (every 10 minutes). .~
IO. The 'hstrument 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 EN1261931999 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 carbon (multiply ppm value by 1.60). This was used to assess the VOC emission from each emission point and allowed the determination of cyclic emissions.
2.3. Speciated VOC monitoring of exhaust emission points A2-1, A2-2 and A2-3.
2.3.1
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 I min-'. 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 setup by placing a
Sampling of VOC from exhaust emission points A2-1, A2-2 and A2-3.
Confidential Report 2008A87(1) Alps Electric (Ireland) Ltd
Primary flow calibrator inline after the sorption tube. 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 charcoaVanasorb sorbent was chosen to efficiently bind and pre-concentrate speciated VOC for analysis by GCFlDlGCMS in accordance with established and accredited methodologies. Sealed sorbent tubes (two bed packed) were used throughout the study to maintain repeatability and integrity. Each tube contained a minimum of 200 mg of sorbent. All sampling for speciated VOC’s was performed in accordance with EN1 3649:2002.
2.3.2 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 samplinglpumped 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 79 to 194 ml min.’ 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 desorptionlsolvent extraction GCFID/GCMS in a UKAS accredited laboratory.
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Confidential Report 2008A87(1) Alps Electric (Ireland) Ltd
3. Results
This section describes the results obtained during the survey.
3.1 Airflow rate measurement results
Table 3.7 illustrates the average airflow rates and volumetric airflow emission rates from each process vent as measured onsite on the Feb 2008.
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Confidential Report 2008A87(1) Alps Electric (Ireland) Ltd
3.2 FID calibrated on Propane) !$%i
Table 3.2 illustrates the average TOC concentration and mass emission rates from process vents A2-1, A2-2 and A2-3 as measured onsite on the 15th Feb 2008.
Total hydrocarbon emission concentration as carbon :results (as measured on tWt;;1
During the measurement sequence intermittent instrument span check was 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 inlet stack and checking displayed VOC readings and comparing to initial start-up reading.
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Confidential Report 2008A87(1) Alps Electric (Ireland) Ltd
3.3. Speciated VOC monitoring of process vents 2-1, 2-2 and 2-3
Table 3.3 illustrates the results obtained from active sorbent tube sampling and analysis. 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 the three process vent points during routine operation. 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. The results of the survey are presented in Table 3.3.
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Confidential Report 2008A87(1) Alps Electric (Ireland) Ltd
4. Discussion of results
Table 3.7 illustrates the results of the volumetric airflow rate testing performed on emission points A2-1, A2-2 and A2-3. As can be observed, emission point A2-1 emitted the largest quantity of air in comparison to emission points A2-2 and A2-3. All emission points were in compliance with the emission limit values contained within the IPPC licence PO835-01.
Table 3.2 illustrates the result of the total hydrocarbon concentration (THC) monitoring using approved and accredited techniques performed on emission points A2-1, A2-2 and A2-3. As can be observed, the mass emission of THC was highest from emission point A2-2 with a time weighted average stack concentration of 162.12 mgClNm3 and mass emission of 0.88 kglhr. The emission concentration of THC from emission points A2-1, A2-3 was 0.25 and 0.15 kglhr, respectively. All emission points were within the emission limit value specified within the IPPC licence PO835-01.
Table 3.3 illustrates the results obtained from the speciated VOC monitoring of the three process vents A2-1, A2-2 and A2-3 in accordance with accredited methodologies. As can be observed, the main compounds emitted from emission point A2-1, A2-2 and A2-3 include isopropyl alcohol, p-Xylene Acetic acid butyl ester, Methyl Isobutyl Ketone and Ethyl Acetate.
5. Conclusions
The following conclusions are drawn from the assessment of the three process vents located in Alps Electric (Ireland) Ltd:
1. Odour Monitoring performed emission monitoring of three-emission point A2-1, A2-2 and A2-3 in accordance with accredited methodologies at the Alps Electric (Ireland) Ltd facility on 15'h Feb 2008.
2. The volumetric airflow rate from emission points A2-1, A2-2 and A2-3 was 3.58, 1.51 and 0.85 Nm3/s, respectively. All emission points were within their respective emission limit values contained within the IPPC licence PO835-01.
3. The air stream concentration of total organic carbon as measured upon a FID for emission points A2-1, A2-2 and A2-3 were 19.13, 162.12 and 48.21 mgClNm3, respectively. All emission points were within their respective emission limit values contained within the IPPC licence PO835-01.
4. The total mass emission rate of total organic carbon as measured upon a FID for emission points A2-1, A2-2 and A2-3 were 0.25, 0.88 and 0.15 kglhr, respectively.
5. The total mass emission of compounds as measured upon a FID in accordance with EN13526:2002 and EN12619:1999 do not exceed the proposed decision licence number PO835-01 emission limit value.
