cems challenges of cement neshap cdawg november 2017
TRANSCRIPT
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MITSUBISHI CEMENT CORPORATION
CEMS Challenges of Cement NESHAP
CDAWG November 2017
David Rib, Environmental Manager Keith Shannon, Environmental Specialist
Mitsubishi Cement Corporation
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MITSUBISHI CEMENT CORPORATION
OR…. NESHAP turned my CEMS into a MONSTER
The dreaded “Ka-boo-key”
monster!
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MITSUBISHI CEMENT CORPORATION
CEMS “In the Beginning”
A couple analyzers and a strip chart.
But the Times they are A-Changin’
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MITSUBISHI CEMENT CORPORATION
MCC CEMS in 2005
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MITSUBISHI CEMENT CORPORATION
Mitsubishi Cement Corporation Cushenbury Plant
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MITSUBISHI CEMENT CORPORATION
Exhausting Challenges
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MITSUBISHI CEMENT CORPORATION
California AB32 – GHG monitoring adds CO2,
flow and coal mill vents
– GHG verification requires auditable DAS, strict QC and high availability
– Alternate fuels help GHG
liability, but all fuels must have tight accounting.
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MITSUBISHI CEMENT CORPORATION
US EPA NESHAP – Initial limits on D/F and
required opacity monitoring (D/F means WHAT???)
– New limits for HCl, Hg, THC, PM with monitoring flow and clinker production
– MCC uses lime injection and activated carbon injection for emissions control
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MITSUBISHI CEMENT CORPORATION
MCC CEMS in 2015
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MITSUBISHI CEMENT CORPORATION
A New Stack Arises!
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MITSUBISHI CEMENT CORPORATION
Stack of 105’ is high enough.
Someone called it a “Baby Stack”
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MITSUBISHI CEMENT CORPORATION
And a New CEM Building
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MITSUBISHI CEMENT CORPORATION
MCC CEMS in 2016
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MITSUBISHI CEMENT CORPORATION
“CEMS” Rack: Moisture
THC
CO2
CO
SOx
NOx
O2
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MITSUBISHI CEMENT CORPORATION
Even the reliable Oxygen monitor is vulnerable to
corrosive gases!
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MITSUBISHI CEMENT CORPORATION
FTIR HCl CEMS Backup for:
CO2
CO
SOx
NOx
Moisture
Mr. PS-18
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MITSUBISHI CEMENT CORPORATION
Mercury CEMS Elemental & Ionic
Calibrator(s)
Permeater
Permeater permeater
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MITSUBISHI CEMENT CORPORATION
So many calibrations! It becomes a…….
Mercury Analyzer QC: Hg Analyzer QA (PS12A-Procedure 5): •Weekly Oxidation Test-System Integrity Test •Monthly Permeation Test •System Response Times (Elemental and Oxidized)-upscale and downscale •Quarterly Calibration Gas Audits (Elemental and Oxidized)-Quarterly, Except RATA Quarter. •Analyzer Linearity Test (Elemental and Oxidized)-Internal Calibrations •Measurement Error Test (3 Point Test in Triplicate)-Elemental and Oxidized (System Calibration) •Relative Accuracy Test Audit (RATA)-Annual •7-Day Calibration Drift Test: Initial Compliance Test Only
FTIR HCl QC: •7-Day Calibration Drift Test •Quarterly Calibration Gas Audits: Quarterly, Except RATA Quarter. •Analyzer Linearity Test (Elemental and Oxidized)-Internal Calibrations •Measurement Error Test (3 Point Test in Triplicate)-System Calibrations •Relative Accuracy Test Audit (RATA)-Annual •Interference Tests: N2, CO, CO2, SO2, O2, THC, NOx, NH3, and Formaldehyde •System Response Times (upscale and downscale) •Dynamic Spiking (DS) •Level of Detection (LOD)
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MITSUBISHI CEMENT CORPORATION
Clinker Cooler Dust Collector Retrofitted for particulate monitoring Two new ducts with particulate CPMS
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MITSUBISHI CEMENT CORPORATION
Particulate spiking feeder
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MITSUBISHI CEMENT CORPORATION
Data Acquisition System Data Inputs:
Analyzer measurements Analyzer status
Flow values and checks Particulate CPMS output
Clinker Production Emission Control Injection Rates Process Status
Reporting Outputs: Daily Calibrations Weekly Hg checks Quarterly audits
Annual RATA Adjustments to 7% O2
Data Substitutions Periodic Compliance Reports
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MITSUBISHI CEMENT CORPORATION
Can cement manufacturing and environment sustain each other?