Source Emissions Monitoring – Boral Wyee · SOURCE EMISSIONS MONITORING – BORAL WYEE BORAL...

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SOURCE EMISSIONS MONITORING – BORAL WYEE

BORAL ROOFING NSW

Project ID. 10514

R_2

DATE OF RELEASE: 16/09/2016

Source Emissions Monitoring – Boral Wyee


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Table 1: Document approval

Name Position Title Signature Date

Author David Arbuckle General Manager

16.09.2016

Reviewer Jeremy James Senior Consultant 12.09.2016

Approved Jeremy James Senior Consultant

12.09.2016

Table 2: Revision register

Revision Date Name Comment

R_0 18.08.2016 Aaron Dobson Initial release

R_1 12.09.2016 Aaron Dobson Updated PM10 results

R_2 16.09.2016 David Arbuckle Corrected Table 3 & 4 fluoride emission

rate calculationa

a Incorrectly reported as g/min instead of g/sec.

DISCLAIMER

Assured Monitoring Group acts in all professional matters as a faithful advisor to the Client and exercises all reasonable

skill and care in the provision of its professional services.

Reports are commissioned by and prepared for the exclusive use of the Client. They are subject to and issued in

accordance with the agreement between the Client and Assured Monitoring Group. Assured Monitoring Group is not

responsible for any liability and accepts no responsibility whatsoever arising from the misapplication or misinterpretation

by third parties of the contents of its reports.

Except where expressly stated, Assured Monitoring Group does not attempt to verify the accuracy, validity or

comprehensiveness of any information supplied to Assured Monitoring Group for its reports.

Reports cannot be copied or reproduced in whole or part for any purpose without the prior written agreement of Assured

Monitoring Group.

Where site inspections, testing or fieldwork have taken place, the report is based on the information made available by

the client or their nominees during the visit, visual observations and any subsequent discussions with regulatory

authorities. The validity and comprehensiveness of supplied information has not been independently verified and, for the

purposes of this report, it is assumed that the information provided to Assured Monitoring Group is both complete and

accurate. It is further assumed that normal activities were being undertaken at the site on the day of the site visit(s),

unless explicitly stated otherwise.

ACCREDITED FOR COMPLIANCE TO ISO/IEC 17025

The results of the tests, calibrations and/or measurements included in this document are traceable to

Australian/national standards.

Accreditation ID: 19703



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EXECUTIVE SUMMARY

Assured Monitoring Group (AMG) conducted source emissions monitoring at the Boral Roofing

facility located at Wyee, NSW on the 19th & 20th July 2016.

A summary of results is presented below, for further details please refer to the body of this report. No

licence limit breaches were recorded.

Table 3: Summary of results – Kiln stack (EPA Point 4)

Release Point Parameter Unit of Measure Kiln stack - EPA Point 4 Licence

Limit

Date of testing dd-mm-yy 19/07/2016 -

Average exhaust Velocity m/sec 17 -

Average stack temperature °C 151 -

Moisture % 5.2 -

Dry standard stack flow rate Nm3/sec 7.8 -

Total solid particulates mg/Nm3 24 250

emission rate g/sec 0.19 -

PM10 mg/Nm3 6.8 -


Sulphur dioxide mg/Nm3 29 -


Sulphur trioxide (as H2SO4) mg/Nm3 6.7 -


Carbon monoxide mg/Nm3 33 -


Oxides of nitrogen (NO2) g/Nm3 0.055 2.5


Total Fluorides mg/Nm3 10 50


Table 4: Summary of results – Dryer stack (EPA Point 6)

Release Point Parameter Unit of Measure Dryer Stack - EPA Point 6 (VE2)

Licence Limit

Date of testing dd-mm-yy 20/07/2016 -

Average exhaust Velocity m/sec 6.0 -

Average stack temperature °C 32 -

Moisture % 4.9 -

Dry standard stack flow rate Nm3/sec 0.48 -

Total solid particulates mg/Nm3 0.74 -


PM10 mg/Nm3 < 0.74 -

emission rate g/sec < 0.0029 -

Sulphur dioxide mg/Nm3 0.76 -


Sulphur trioxide (as H2SO4) mg/Nm3 0.14 -


Carbon monoxide mg/Nm3 1.8 -


Oxides of nitrogen (NO2) g/Nm3 < 0.0021 -


Total Fluorides mg/Nm3 < 0.71 -




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TABLE OF CONTENTS

1 INTRODUCTION ....................................................................................................................................................... 5

2 METHODOLGY & EQUIPMENT ............................................................................................................................ 6

2.1 SAMPLING METHODOLOGY ........................................................................................................................................................ 6

2.2 SAMPLE LOCATION ....................................................................................................................................................................... 7

2.3 PLANT OPERATIONAL DATA ....................................................................................................................................................... 8

2.4 TEST EQUIPMENT ............................................................................................................................................................................ 9

3 QUALITY ASSURANCE & QUALITY CONTROL (QA/QC) ....................................................................... 10

4 DEFINITIONS ............................................................................................................................................................. 11

5 RESULTS .................................................................................................................................................................... 12

LIST OF TABLES

TABLE 1: DOCUMENT APPROVAL .................................................................................................................................................................... II

TABLE 2: REVISION REGISTER ........................................................................................................................................................................... II

TABLE 3: SUMMARY OF RESULTS – KILN STACK (EPA POINT 4).................................................................................................... III

TABLE 4: SUMMARY OF RESULTS – DRYER STACK (EPA POINT 6) ............................................................................................... III

TABLE 5: SAMPLING SCHEDULE ...................................................................................................................................................................... 5

TABLE 6: TEST METHODS ................................................................................................................................................................................... 6

TABLE 7: SAMPLING NOTES .............................................................................................................................................................................. 6

TABLE 8: ANALYSIS NOTES ............................................................................................................................................................................... 6

TABLE 9: SAMPLE LOCATION SUMMARY .................................................................................................................................................... 8

TABLE 10: PRODUCTION DETAILS .................................................................................................................................................................. 8

TABLE 11: SAMPLING DATA QA/QC CHECKLIST ...................................................................................................................................10

TABLE 12: LABORATORY DATA QA/QC CHECKLIST ............................................................................................................................10

TABLE 13: DEFINITIONS ....................................................................................................................................................................................... 11

TABLE 14: TEST RESULTS – KILN STACK MANUAL SAMPLES ............................................................................................................ 12

TABLE 15: TEST RESULTS – KILN STACK GASES ..................................................................................................................................... 13

TABLE 16: TEST RESULTS – DRYER STACK MANUAL SAMPLES ........................................................................................................ 14

TABLE 17: TEST RESULTS – DRYER STACK GASES ................................................................................................................................. 15

LIST OF FIGURES

FIGURE 1: KILN STACK RELEASE POINT (LEFT) AND DRYER STACK RELEASE POINT (RIGHT) ................................................... 7

FIGURE 2: BORAL WYEE SITE LOCATION ..................................................................................................................................................... 7

FIGURE 3: FULL ISOKINETIC SAMPLING ASSEMBLY ................................................................................................................................. 9

FIGURE 4: KILN STACK GAS TRENDS ............................................................................................................................................................ 16



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1 INTRODUCTION

Assured Monitoring Group (AMG) was appointed by Boral Roofing NSW to sample and analyse

source emissions from the Wyee facility. The sources sampled included a kiln stack emission point

and dryer release point. Sampling was conducted by AMG on the 19th & 20th July 2016 during typical

site operations.

AMG was responsible for the collection and analysis of samples, unless otherwise indicated. The

samples were recovered and stored in the appropriate manner until their return to the laboratory

where the samples were prepared and analysed according to the methodologies listed below in this

report.

This test program was conducted to satisfy the conditions detailed in the Environment Protection

Licence (number 2702 – 11 May 2011) issued to Boral Montoro Pty Limited for their facility located at

Toomey’s Road East, Bushels Ridge. The table below details the sampling program as conducted on

this occasion.

Table 5: Sampling schedule

Parameter Kiln stack - EPA Point 4 Dryer Stack - EPA Point 6

Particulate matter – total 1 1

Sulphur dioxide – SO2 1 1

Oxides of nitrogen (as NO2) 2 2

Sulphuric acid mist – SO3 1 1

Fluoride - total 1 1

Particulate matter – PM10 1 1b

b PM10 is reported assuming 100% of total solid particulates are present as PM10



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2 METHODOLGY & EQUIPMENT

2.1 Sampling methodology

All sampling and analysis was carried in accordance to the listed requirements in Table 6. Any

specific method comments have been documented where required.

Table 6: Test methods

Parameter Reference

Test Method NSW EPA TM Notes Analysis

Sample plane criteria AS4323.1 TM-1 A 1

Flow rate, temperature and

velocity USEPA Method 2 TM-2 nil 1

Stack gas molecular weight USEPA Method 3 TM-23 B 1

Oxygen (O2) USEPA Method 3A TM-25 B 1

Carbon dioxide (CO2) USEPA Method 3A TM-24 B 1

Moisture content USEPA Method 4 TM-22 nil 1

Total solid particulates AS4323.2 TM-15 nil 1

Sulphur dioxide – SO2 USEPA Method 6 TM-4 nil 1

Oxides of nitrogen (as NO2) USEPA Method 7E TM-11 B 1

Sulfuric acid mist – SO3 USEPA Method 8 TM-3 nil 1

Fluoride – total USEPA Method 13B TM-9 nil 2

Particulate matter – PM10 USEPA Method 201A OM-5 nil 3

Table 7: Sampling notes

Note Comment

A

Sample location on the dryer release point is compliant but non-ideal as per AS4323.1. The sample location is greater than two, but less than six diameters downstream from a disturbance. The temperature and velocity survey showed that the sample position was in compliance to items (a) to (f) as per AS4323.1.

B Analyser calibration pre and post field work in our laboratory.

Table 8: Analysis notes

Note Company Work performed NATA ID Report Number

1 Assured Monitoring Group Sampling & analysis 19703 10514

2 EnviroLab Services Fluoride analysis 2901 150669

3 Particulate & surface sciences Analysisc - 10514-2-3

c A particulate sample was collected isokinetically from the stack, with the particulate catch them being

analysed by particle counting instruments for determination of particle size distribution. The percentage of particles less than 10μm in size was then applied to the total particle matter result to determine the PM10

fraction of the total catch.



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2.2 Sample Location

The figures below show the site and sample location.

Figure 1: Kiln stack release point (left) and dryer stack release point (right)

Figure 2: Boral Wyee site location



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Table 9: Sample location summary

Sample location Kiln Stack Dryer Stack

Stack Shape CIRCULAR CIRCULAR

Stack Diameter (m) 0.97 0.89

Stack Cross Section Area (m2) 0.74 0.62

Distance to upstream disturbance (m) 9.6 2.8

Diameters (D) 9.9 3.1

Distance to downstream disturbance (m) 2.4 4.0

Diameters (D) 2.5 4.5

Total traverse point factors 1 , 1 , 1 , 12 1.1 , 1 , 1.1 , 16

Port size (mm) 100 100

Port Thread Type BSP BSP

Number of traverses 2 2

Number of points per traverse 6 8

Total number of traverse points 12 16

Flow & temperature compliance check YES YES

2.3 Plant operational data

The table below summarises the plant operation data at the time of sampling.

Table 10: Production details

Item

Cars per shift 35

Tiles per shift 33, 600



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2.4 Test equipment

The sampling equipment was transported to site and specifically setup at the test location. Sampling

was performed using one complete isokinetic sampling train with an out-of-stack heated filter.

All equipment used during the course of the testing is sourced from Apex Instruments, an industry

leader in the supply of source testing equipment.

Figure 3: Full isokinetic sampling assembly



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3 QUALITY ASSURANCE & QUALITY CONTROL (QA/QC)

AMG operates within a quality system based upon the requirements of ISO17025. Our quality system

defines specific procedures and methodologies to ensure any project undertaken by AMG is

conducted with the highest level of quality given the specific confines of each project. The overall

objective of our QA/QC procedures is to representatively sample and accurately analyse

components in the gas streams and therefore report valid measurements of emission concentrations.

To ensure representativeness of field work, our quality procedures target:

1. Correct sampling locations

2. Sample time

3. Frequency of samples and

4. Method selection & adherence

To ensure representativeness of lab work, our quality procedures target:

1. Sample preservation

2. Chain of custody (COC)

3. Sample preparation and

4. Analytical techniques

AMG maintains strict quality assurance throughout all its sampling programs, covering on-site ‘field

work’ and the analytical phase of our projects. Our QA program covers the calibration of all sampling

and analytical apparatus where applicable and the use of spikes, replicate sample and reference

standards. The test methodologies used for this project are outlined in section 2 of this document.

Field test data has been recorded and calculated using direct entry into Microsoft Excel spreadsheets

following the procedures of the appropriate test methods. Determination of emission concentrations

has been performed using the same Microsoft Excel spreadsheets which are partially supplied as an

attachment to this report. More detailed information can be supplied upon request.

QA/QC checks for this project will use validation techniques and criteria appropriate to the type of

data and the purpose of the measurement to approve the test report. Records of all data will be

maintained. Complete chain of custody (COC) procedures has been followed to document the entire

custodial history of each sample. The COC forms also served as a laboratory sheet detailing sample

ID and analysis requirements.

Table 11: Sampling data QA/QC checklist

Sampling Data QA/QC Checklist Comment

Use of appropriate test methods Yes

‘Normal’ operation of the process being tested Yes – as instructed by client

Use of properly operating and calibrated test equipment Yes

Use of high purity reagents Yes

Performance of leak checks post sample (at least) Yes

Table 12: Laboratory data QA/QC checklist

Laboratory Data QA/QC Checklist Comment

Use of appropriate analytical methods Yes

Use of properly operating and calibrated analytical equipment Yes

Precision and accuracy comparable to that achieved in similar

projects Yes

Accurate reporting Yes



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4 DEFINITIONS

The following terms and abbreviations may be used in this report:

Table 13: Definitions

Symbol Definition

< The analytes tested for was not detected; the value stated is the reportable limit of detection

Am3 Gas volume in cubic metres at measured conditions

AS Australian Standard

BH Back half of sample train (filter holder and impingers) (referred to during sample recovery)

oC Degrees Celsius

CARB California Air Resources Board methods

dscm dry standard cubic meters

FH Front half of sample train (probe and filter holder) (referred to during sample recovery)

f/ml Fibres per millilitre

g Grams

kg Kilograms

m Metres

m3 actual gas volume in cubic metres as measured

mbar Millibars

mg Milligrams (10-3 grams)

min Minute

ml Millilitres

mmH2O Millimetres of water

Mole SI unit that measures the amount of substance

N/A Not applicable

ng Nanograms (10-9 grams)

NATO North Atlantic Treaty Organisation

NIOSH National institute for occupational safety and health (USA)

Nm3 Gas volume in dry cubic metres at standard temperature and pressure (0°C and 101.3 kPa)

NMI National Measurement Institute

NM VOC Non methane volatile organic compound

NR Not required on this occasion

OSHA Occupational Safety and Health Act

ou Odour unit

PCDD Polychlorinated dibenzo-p-dioxin

PCDF Polychlorinated dibenzofuran

PM Particulate matter

ppb Parts per billion

ppm Parts per million

sec Second

Sm3 Gas volume in dry cubic metres at standard temperature and pressure (0°C and 101.3 kPa) and

corrected to a standardised value (e.g. 15% O2)

STP Standard temperature and pressure (0°C and 101.3 kPa)

TO USEPA air toxics method

TWA Time weighted average

USEPA United States Environmental Protection Authority


Project ID 10514 | R_2 12

5 RESULTS

Table 14 - 17 present a summary of the isokinetic and gases analyser sample runs.

Table 14: Test results – Kiln stack manual samples

Unit sampled Kiln Stack

Sampling date 19/07/2016 19/07/2016 19/07/2016 19/07/2016 19/07/2016

Begin sampling time 10:25 12:40 10:25 10:25 10:25 Units

End sampling time 11:25 13:40 11:25 11:25 11:25

Equipment rated capacity Not specified

Equipment load during sampling 35 cars per shift

Sampling plane diameter 970 mm

Sampling plane area 0.74 m2

Sampling port size, number and depth 100, 2, 130 mm , - , mm

Duct orientation and shape Vertical, Circular -

No. of traverse points sampled 12 -

Parameters Units PM-total - RUN Ftotal - RUN SO2 - RUN SO3 (as H2SO4) PM10 Average results

Temperature °C 151 150 151 151 151 151

Carbon dioxide vol-% 0.5 1.3 0.5 0.5 1 0.90

Oxygen vol-% 19.5 18.1 19.5 19.5 20 18.8

Stack gas water vapour vol-% 4.3 6.1 4.3 4.3 4 5.2

Gas molecular weight - dry g/g mole 28.9 28.9 28.9 28.9 29 29

Gas density - dry kg/m3 1.29 1.29 1.29 1.29 1 1.3

Average velocity m/s 17 17 17 17 17 17

Volumetric flow rate - actual, wet m3/min 756 760 756 756 756 758

Volumetric flow rate - dry & STP dsm3/min 470 466 470 470 470 468

Total sampling time min 60 60 60 60 60 60

Isokinetic rate (90%-110%) % 99 101 99 99 99 100

Isokinetic rate (80%-120%) % - - - - - -

Cut point µm - - - - - -

Results mg/Nm3 24.4 10.2 29.3 6.74 6.77 -

Release limit mg/Nm3 250 50 - - - -

Emission rate g/s 0.191 0.079 0.23 0.05 0.05



Table 15: Test results – Kiln stack gases

Unit sampled Kiln Stack

Sampling date 19/07/2016

Begin sampling time 12:27:37

End sampling time 13:40:37


Equipment load during sampling 35 cars per shift

Parameters Units

Temperature °C 151

Carbon dioxide vol-% 0.904

Oxygen vol-% 18.8

Stack gas water vapour vol-% 5.2

Gas molecular weight - dry g/g mole 28.9

Gas density - dry kg/m3 1.29

Average velocity m/s 17

Volumetric flow rate - wet m3/min 758

Volumetric flow rate - dry dsm3/min 468

Sampling time min 1:13:00

Sample result Release Limit

Carbon monoxide (CO) mg/Nm3 33 -

Emission rate g/s 0.25 -

Sample result Release Limit

Nitrogen Oxides (NOx as NO2) mg/Nm3 55 2,500




Table 16: Test results – Dryer stack manual samples

Unit sampled Dryer (EF-VE-2)

Sampling date 20/07/2016 19/07/2016 20/07/2016 20/07/2016 20/07/2016

Begin sampling time 8:00 14:30 8:00 8:00 8:00 Units

End sampling time 9:20 15:50 9:20 9:20 9:20


Equipment load during sampling Normal operation

Sampling plane diameter 890 mm

Sampling plane area 0.62 m2

Sampling port size, number and depth 100, 2, 90 mm , - , mm

Duct orientation and shape Vertical, Circular -

No. of traverse points sampled 16 -

Parameters Units PM-total - RUN Ftotal - RUN SO2 - RUN SO3 (as H2SO4) PM10 Average results

Temperature °C 31 32 31 31 31 32

Carbon dioxide vol-% 0.010 0.010 0.010 0.010 0 0.010

Oxygen vol-% 21.0 21.0 21.0 21.0 21 21.0

Stack gas water vapour vol-% 3.1 6.8 3.1 3.1 3 4.9

Gas molecular weight - dry g/g mole 28.8 28.8 28.8 28.8 29 28.8

Gas density - dry kg/m3 1.29 1.29 1.29 1.29 1 1.29

Average velocity m/s 7.2 4.8 7.2 7.2 7 6.0

Volumetric flow rate - wet m3/min 269 179 269 269 269 224

Volumetric flow rate - dry dsm3/min 234 150 234 234 234 192

Sampling time min 80 80 80 80 80 80

Isokinetic rate (90%-110%) % 100 103 100 100 100 102

Isokinetic rate (80%-120%) % - - - - - -

Cut point µm - - - - - -

Results mg/Nm3 0.735 < 0.706 0.755 0.140 < 0.735 -

Release limit mg/Nm3 - - - - -

Emission rate g/s 0.0029 < 0.0018 0.0029 0.00055 < 0.0029



Table 17: Test results – Dryer stack gases

Unit sampled Dryer (EF-VE-2)

Sampling date 19/07/2016

Begin sampling time 14:30:37

End sampling time 15:50:37


Equipment load during sampling Normal operation

Parameters Units

Temperature °C 32

Carbon dioxide vol-% 0.01

Oxygen vol-% 21.0

Stack gas water vapour vol-% 4.93

Gas molecular weight - dry g/g mole 28.8

Gas density - dry kg/m3 1.29

Average velocity m/s 6.0

Volumetric flow rate - wet m3/min 224

Volumetric flow rate - dry dsm3/min 192

Sampling time min 1:20:00

Concentration Release Limit

Carbon monoxide (CO) mg/Nm3 1.8 -


Concentration Release Limit

Nitrogen Oxides (NOx as NO2) mg/Nm3 < 2.1 -

Emission rate g/s < 0.0080 -



Figure 4: Kiln stack gas trends

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