.. . . -. - . . . - . . - .. -. . . . .. . . -

ENVIRONMENTAL CONSIDERATIONS

1. Reaction control:

p Q

Should the reaction go out of control there will not be a build up of either temperature or pressure in the reactor and consequently there is no danger of an emission from the reactor. The worst that can happen with an out of control reaction is that the poly- merisation will go to completion in the reactor resulting in the formation of a white solid in the reactor which has then to be manually broken up and removed. Should this happen the solid resin will be temporarily stored on site until a disposal plan has been agreed.

Should the reaction go out of control but be stopped before the final solid resin is pro- duced, the resulting resin can be blended in the storage tank and used in the process.

To prevent the above from happening the following precautions are taken:

( 0

(ii)

(iii)

During the urea manufacturing process some ammonium salts can be produced. During the resin manufacturing process these will break down to ammonia and an acid which will then lower the pH and speed up the reaction. To avoid this urea is purchased only from one source and is purchased on the basis that it con- forms to our specification.

The reactor agitator is connected to a stand-by generator so that in the event of a power failure the reactor contents can still be mixed.

Thermometers, viscometers, and pH meters used are periodically calibrated as per our quality system.

There are remote isolation valves in the steam lines feeding the resin plant so that in the event of a valve failure within the plant, the steam can still be shut off.

There is a standby water pump which is also connected to the generator there- fore during power failures we still have water available to cool the reactor con- tents.

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I ' I I

2. S pi1 lages:

(1) The sodium hydroxide and formic acid storage tanks are both bunded.

(2) Urea spillages are cleaned up and re-used.

(3) The contents of the glue filter which. are emptied during filter,cleaning are returned to the reactor.

(4) Leaks on pumps, etc. are repaired as quickly as possible and resin which spills is either soaked up with sawdust and then burned in the hot gas generator or where possible it is collected and returned to the reactor.

3. Atmosphere emissions:

@ During the addition of urea to the reactor, an extraction fan is switched on which removes formaldehyde fumes emanating from the reactor. This exhausts to atmos- phere. This exhaust has been checked as part of our air emissions monitoring. (air dis- charge point EW)

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GLUE PLANT OPERATION PROCEDURE FOR MANUFACTURE OF FC-4 G

This is a 65% glue used for the manufacture of normal ordinary furniture and flooring grade boards.

1.

2.

3.

5.

6.

7.

8.

9.

i 0.

11.

Ensure that the outlet valve at the base of the reactor is fully closed.

Change the valves on the side of the reactor to the heating position.

(a) (b)

Switch on vacuum pump.

Adjust the plate on the UF80 dipstick to the required level and place i t in the reactor (see Process Specification Sheet).

Check that the valves at the UF80 storage tank are in their correct positions:

(a) (b) all other valves closed.

Open valves 3 and 5 Close valves 1,2,4 and 6.

valves 2,3,4 and 12 open

Switch on UF80 pump and charge UF80 until the level marked on the dipstick is reached. This takes approximately 15 minutes.

During the UF80 filling period, transfer sodium hydroxide and formic acid from the storage tanks to their dosing tanks on top of the reactor (approximately half fill the stor- age tanks).

To transfer sodium hydroxide and formic acid open the valves at the bases of these tanks and switch on the pumps. When pumping is complete close these valves.

Charge the required quantity of water using the meter provided.

Close all covers, switch off the vacuum pump, and start the agitator.

Inform the dryer operator that you are commencing heating.

To start heating:

(a) (b) (c)

Crack open the hot water infeed valve. When the drain off valve gets hot, close this valve. Open the hot water return valve.

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12. Monitor the heating rate. It should take approximately 5060 minutes.

13. Monitor the temperature on the water feed line from the boiler. I f this drops below 175OC switch off the heating until the temperature has recovered.

14. During heating fill the urea storage hopper (approx. 2,000 kg).

15. When the temperature reaches 60°C add the formic acid (12-15 1).

16. When the temperature has reached that specified in the process specification sheet, stop the heating process. To stop the heating process:

(a) (b) (c)

Check the pH. If it is not within the specification in the Process Specification Sheet, make adjustments and check again.

Close the hot water return valve Close the hot water infeed valve Open the drain off valve.

6 3 : 17.

18. When the ph is correct, begin the addition of urea:

(a) Switch on extraction fan (b) (c) (d) (e) (0

Switch on the vacuum pump Open the vacuum release valve Open the urea dosing hatch and lower the chute into position Switch on No. 2 feed screw Add remainder of urea through No. 1 feed screw.

19. When urea addition is complete:

(a) (b)

(c) (d) (e)

e Switch off No. 2 screw Raise the.chute and close the dosing hatch ensuring that the hatch seal is free from urea. Close the vacuum release valve. Switch off the vacuum pump Switch off the extraction fan.

20. Change valves on the side of the reactor to the cooling position:

(a) Close valve 1 (b) Open valves 2,3,4,5 and 6

21. If the temperature increases above 95OC cool to between 91-93OC.

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22.

23.

24.

25.

26.

t.- Q .

27.

28.

29.

30.

31.

32.

33.

Five minutes after the end'of the urea addition, take a sample and check its pH and vis- cosity. The pH should be between 5.0 and 5.8, the higher the pH, the slower will be the reaction rate. Record the information on the operating data sheet.

Monitor the progress of the reaction by checking the viscosity every 10115 minutes (depending on the speed of the reaction). Follow the reaction graphically on teh oper- ating data sheet.

When the viscosity has reached its target level, stop the reaction by adding (25-30 1) sodium hydroxide 50% to adjust the pH to the required level (see Process Specification Sheet).

Cool the reactor contents to below 7OOC.

Five minutes after beginning cooling, check the pH. If i t is not as specified in the Process Specification Sheet make the necessary adjustments.

When the temperature has dropped to below 7OOC add urea I1 using the same procedure as that followed for urea I.

Continue cooling to below 45OC.

Take a sample and check the pH. If it is not as specified in the Process Specification Sheet, make the necessary adjustments.

When the pH is correct take a sample for final analysis. Take a 500 ml sample and cool to 25OC. Check the following properties:

a) viscosity

*c) gel time d) specific gravity (1 batch/week)

.b) PH

If the properties are not as specified in the Process Specification Sheet inform the Board Plant Production Manager or the Quality Manager.

If the properties are as specified pump the glue to the glue storage tank: a) b) switch off the agitator c) open the reactor cover d)

switch off the cold water valve

switch on the glue transfer pump.

Glue transfer takes approx. 30 minutes. When transfer is complete switch off the pump. NOTE Record the information relating to the batch numbers of the faw materials

used on the Operating Data Sheet.

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PROCEDURE FOR MANUFACTURE OF C-143 GLUE

This is a 65% melamine urea formaldehyde glue for the manufacture of type C3 and C4 mois- ture resistant b6ards with low levels of free formaldehyde.

1.

2.

3.

4.

5.

6.

7

8.

9.

10.

11.

12.

Ensure that the outlet valve at the base of the reactor is fully closed.

Change the valves on the side of the reactor to the heating position.

a) b)

open valves 3 and 5 close valves 1,2,4 and 6

Switch on vacuum pump.

Adjust the plate on the U.F. 80 dipstick to the required level and place i t in the reactor

(see Process Specification Sheet). Q : Check that the valves at the U.E 80 storage tank are in their correct positions.

a) b) all other valves closed

valves 2,3,4 and 12 open

Switch on U.F. 80 pump and charge U.F. 80 until the level marked on the dipstick is reached (this takes approximately 15 minutes).

During the U.F. 80 filling period transfer sodium hydroxide and formic acid from their storage tanks to their dosing tanks on top of the reactor (approximately half fill the stor- age tanks).

To transfer sodium hydroxide and formic acid, open the valves at the bases of these tanks and switch on the pumps. When pumping is complete close these valves.

Charge the required quantity of water using the meter provided. QD

Close the reactor cover. s

If necessary dilute sodium hydroxide (see procedure for dilution of sodium hydroxide from 50% to 25%).

Switch on agitator.

Adjust pH to required level using 25% sodium hydroxide (see Process Specification Sheet - add approximately 21).

Add sodium hydroxide using the jug through the inlet on top of the reactor. During the

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13.

14.

15.

16.

17.

18.

19.

handling of sodium hydroxide, wear the following protective clothing.:

a) face mask b) chemical suit c) long chemical resistant gloves d) wellington boots

When the pH has been checked and conforms with the Process Specification Sheet add melamine (see Process Specification Sheet).

a) b) c) d)

switch on exhaustion fan and open the vacuum release valve open the urea dosing hatch and lower the chute irito position switch on No. 2 feed screen switch on No. 1 feed screen

When melamine addition is complete

a) b)

c) d) Switch off extraction fan. .

switch off feeding screws 1 and 2 raise the chute and close the dosing hatch ensuring that the hatch seal is free from melamine. switch off vacuum pump and close the vacuum release valve.

Inform the dryer operator that you are commencing heating.

To start heating:

a) b) c)

crack open the hot water infeed valve when the drain off valve gets hot, close this valve open the hot water return valve.

Monitor the heating rate. I t should take approximately 50 to 60 minutes.

Monitor the temperature on the water feed line from the boiler. If i t drops below 175OC, switch off the heating until the temperature has recovered.

When the temperature has reached that specified in the process specification sheet, stop the heating process. To stop the heating:

a) b) c)

close the hot water return valve close the hot water infeed valve open the drain off valve.

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20.

21.

22. *

23.

8 t..

24.

25.

26.

27.

28.

29.

30.

Change the valves on the side of the reactor to cooling position:

a) close valve 1 b) open valve 2,3,4,5 and 6

Five minutes after the melamine addition, take a sample and check its pH and viscosi- ty. The pH should be between 7.0 and 7.5, the higher the ph the slower will be the reac- tion rate. Record the information on the operating data sheet.

Monitor the progress of the reaction by checking the viscosity every 10/15 minutes (depending on the speed of the reaction). Follow the reaction graphically on the oper- ating data sheet.

When the viscosity has reached its target level, stop the reaction by adding 8-12 1. sodi- um hydroxide 50% to adjust the pH to the required level (see Process Specification

Sheet). e : Cool reactor contents to below 7WC.

Five minutes after the beginning cooling - check the pH. If i t is not as specified in the Process Specification Sheet, make the necessary adjustments.

When the temperature has dropped to below 7OoC add the urea, using the same proce- dure as that followed for the melamine addition.

Continue cooling to below 45OC.

Take a sample and check the pH. If it is not as specified in the Process Specification Sheet make the necessary adjustments.

When the pH is correct, take a sample for final analysis.

Take a %Om1 sample and cool to 25OC. Check the following properties: e

a) viscosity

c) gel time d) specific gravity

b) PH a

If the properties are as specified, inform board plant personnel that the glue is ready for use.

a) b) switch off the agitator c) open the reactor cover

switch off the cold water valve

. ,

J

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d) e)

open valve at base of reactor open by-pass valve before pump

NOTE Record the information relating to the batch numbers of the raw materi- als used on the Operating Data Sheet.

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i

FORESA

.

7

2.- CHEMISTRY O F UREA FORMALDEHYDE RESINS

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I FORESA

2.1. CHEMICAL. REACTIONS -

2.1.1. Primarv Products

a

The primary reaction products of formaldehyde and

. urea are the methylolureas which are the raw material

f o r making res'ins.

NH -CO-NH +CII 0 ----7)NH -CO-NH-CH20H 2 2 2 2

, Monome thy lo1 ur e a

NH CO-NH2+2 CH 0 +CH20H-NH-CO-NH-CH20H 2- 2

Dimethylolurea

These reactions are reversible at pH about 7, and

consequently, urea, formaldehyde, monomethylolurea

and dimethylolurea coexist in the UF concentrate.

2.1.2.Intermediate Products

6 ,: '.

The increase in the molecular size and, consequently,

in the molecular weight are probably caused by a

serie of chemical reactions with water separation and sometimes with CH 0 separation. 2

a) Formation of unsaturated azometine groups

NH -CO-NH-CH OH-(NH2-CO-N=CH )+H 0 2 -2 2 2

These products are easily polimerisable.

- ' ' . 1. . / -

.

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FORESA 9

b) Formation of methylene bridges between methylol and amino

groups

R-NH-CH20H+R ' -NH2 -9 R-NH-CH 2 -NH-R ' +!I 2 0

c) Formation.of ether bridges between methylol groups

R-NH-CH20H+HOCH2-NH-R' .->R-NH-CH 2 - 0 - C H 2 - N H - R ' + H 2 0

d) Formation of methylene bridges between two methylol groups

Q : with separation of H 2 0 and C H 2 0 .

R-NH-CH 2- O H + H O - C H 2 - N H - R ' j R - N H - C H 2- N H - R ' + H 2 0 + C H 2 0

In aqueous solution catalized by acid, methylol and amina groups react forming methylene groups (reaction b).

The reactions between urea (U) and monomethylolurea (UF) and

dimethylolurea (UF ) are the following : 2

' I .

.

U+IJFJNH2-CO-NH-CH2-NH-CO-NH 2 2 +H 0

U+UF 4 N H 2 - C O - N H - C H 2 -NH-CO-NH-CH20H+H20 2

U F t U F 3 NH -CO-NH-Ch2-NH-CO-NH-CH20H+H20H+H20 2

U F + U F 3 C H QH-NH-CO-NH-CH NH-CO-NH-CH O H + H 2 0 2 2 2- 2

UF +UF--+CH OH-NH-CO-NH-CH2-N-CO-NH-CH OH+H 0 2 2 2 2

Experimental results show that the last reaction takes place

very seldom. This is an indication of a low reactivity

between methylol groups and substituted amides. The group NH2

,

. i .

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. ... .. .... .. ..-. ...... ........,. . .. . .... ....-. ..... .. ..---

.

10

i n t h e monomethylo lurea is a lso less r e a c t i v e t h a n t h e

u r e a ; and t h e m e t h y l o l g r o u p i n t h e same compound is

more r e a c t i v e t h a n t h e m e t h y l o l group i n t h e d i m e t h y l o l -

u r e a .

I n a l k a l i n e medium t h e c o n d e n s a t i o n s a re , i n t h e most

p a r t , c a u s e d by t h e r e a c t i o n be tween m e t h y l o l g r o u p s .

R-CH OH+HOCHi-R -+R-CH -0-CCI -R+H 0 2 2 2 2

2.1.3. F inal p r o d u c t s

Remaining a t h i g h t e m p e r a t u r e s , t h e r e i s a r e a c t i o n

between free f o r m a l d e h y d e and -NH-groups, f o r m i n g pro-

d u c t s l i k e :

CHZOH

The i n c r e a s e in v i s c o s i t y , is c a u s e d b y t h e c h a i n

g r a v i n g by means o f t h e reaction b e t w e e n m e t h y l o l

g r o u p s and -NH g r o u p s o r a n o t h e r m e t h y l o l . 2

R-CH20H+R'-NH2 -R-CH - N H - R ' + H 0 2 2

Z R - C ~ ~ O H ___l_j R-CH -0-CH -R-H o 2 2 2

At t h e same time, la teral methylol groups reac t w i t h

-NH- groups s t a r t i n g , by means o f t h i s , a n i n t e r c r o s -

sing s t r u c t u r e a n d , c o n s e q u e n t l y , t h e g e l i f i c a t i o n .

,

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FORESA

-CO-N- CH 2.

-CO-N-CH -

t. H 2 0 I I

2

CIi* ! CH20H -)

2- + -CO-N-CH

2- -CO-NH-CH

-CO-N-CH,- 1 L

-CO-N-CH2- I

CH20H IH2

0 + CH20 - 1

+

CH20H

I I

11

-CO-N-CH2- -CO-N-CH2-

A complete intercrossing estructure (network) would be :

-CO-N-CH2-N-CO-N-CH N-CO-N-CH -N-CO-N

' I 2- I CH2

I CH2 CH2 I I

This is, of course, an ideal structure because many

methylol and -NH-groups remain unreacted.

The final product has an irregular tridimensional cons-

titution and some investigators suppose that the primary

product obtained by reaction between the formaldehyde --

and the urea is methylenurea (NH2-CO-N=CH 2 1, easily poll

.

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. . . . . . . . . . _ _ . . . . . . . . . . . . . . . . . . . . . . .. . . . . .. - -. - . . . . . . . . . . . . - - -. . -. . . . . . . .

. .

FORESA

12

. : :!. I I . .

merisable to the trimeric from (.,r,.nethylentriamine

and at last, by means of the formation of methylen-

bisamides, to the final polimeric form (cured resin

3 IH2 -

'J" 2 CO I

/ N \

'Zi i"' 0 - N I CHZ -

I - NH - CO - N N-CO

NH NH

H2c .\ ,+ N I CO -NH - C H2 -

N-CO-NH-CHZ - I ,cH2\

C O -N

. I

The amorphous final product and its X ray diffraction,

seem to confirm this theory.

E;H 5O

/N\

"i i"'

N

CO-NH-CH2- I

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2.2. CURING

2.2.1. Hardener or curing agent

e -

$$- .. 0 . Y.. ,

It's a chemical substance which, when added to the

glue, decreases its pH, so polimerisation can take

place.

2.2.2. Types of hardeners

A ) Free acids : HCOOH 20% w/w

B) Ammonium salts of strong acids : NHqC1, NH4N03,

(NH412S04, etc. (2-3% on dry glue).

C ) Easily hydrolisable metalic salts : FeC13, A1

Clg, etc. (1-2% on dry glue).

D) A mixture of urea, NH40H (ammonia) or (CH216N4

(hexamethylenetetramine) plus B or C.

B) 2.2.3. Chemical actions

A ) kree acids are only recommendable for carpenters

or small factories with cold press. The curing is

rapid because of the low pH and the short pot life.

B) These types of hardeners are slower curing agents

than the above mentioned but still fast. The

effect of these hardeners may be explained by

means of the following chemical reactions.

N H ~ C I 7 N H ~ + C I - a1

'NH,+OH ' CIH

' ? . f

. .

. . . . ' ~ .

I. .

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14

FORESA

The ammonium salt liberates free acid when the equilibrium

is broken by the evaporation of ammonia.

The ammonium salt also reacts with free formaldehyde in

the glue causing liberation of free acid. The equilibrium

is here broken because of the reaction between hexa end

the methylol groups in the glue.

C) The effect of these hardeners may be explained by means of

the following chemical reaction

Fe (OH) + HC1 3

H2° FeC13 - D) These are the mostcommon used hardeners.

The gluing mixture with these hardeners has a pot life - longer than it does with groups A , B and C. This is because acid liberation is slower :

- Effect of ammonia

NHqCl NH; t CI-

NHbOH C I H

t

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FORESA

Because of Le Chatelier Principle this reaction is slower

(addition of NIl40H) than reaction I la' I .

15

- Effect of hexamethylenetetramine

H

Because of Le Chatelier Principle the reaction is going

slower (addition of hexa) than reaction. "b"

- Effect of urea

Because of the combination of a part of free formaldehyde

and urea (formation of mono and dimethylolurea) reaction

"b" is slower.

Generally speaking, addition of NH OH and urea increases pH and thereby delays polimerisation.

4

, . . .

. . , . .. I

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CONSULTANCY LIMITED A I 11-

REPORT

Title or Report: Air E~nission Survey

Client: Finsa Forest Products

Attention: Mr. Pat I-Iorg,m

Date: 26th September, 1995.

TMS Ref. No.: 950 19

Written By :

EAMONN CORBElT

4iB

TMS . . . Consultancy Limited 12 Bnrrington Street Limerick Tel(O61) 400525 Fax (061) 401093

. I . . I

. . . I ... 6

. . .

. a ! '

* . . , . . .

. . . . . . . . .

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1.0. INTRODUCTION

TMS Consultancy Ltd., were requested by Finsa Forest Products to carry out an

evaluation of airborne emissions from their plant at Scarriff, Co. Clare. As a result or

this a number of samples were taken from various emission points throughout the plant.

The sampling was carried out on the 26th and 27th June, 1995. A n analysis of' polenlial

dioxins was also requested. This parameter was outside the scope of activities oflered by

TMS Consultancy Ltd., so an outside laboratory was contracted to carry o u t both the

sampling and laboratory determination. This contractors namely Fugro Environmenlal

Ltd., used validated US/EPA methodologies.

The laboratory is NAMAS accredited and the scope of this accreditation extends to the

sampling and determination of dioxins. The actual report 'obtained is included in

k e3 Appendix A.

In conclusion the object of the emission survey was to establish compliance with the

Environmental Protection Agencies Draft of 25/8/94 (ie BATNEEC Guidance Note lor

Board Manufacture).

The survey is also intended for use in preliminary development of an Environmental

Management System. The results oblained will also facili tale air dispersion studies.

2.0. PROCEDURE . Particulates were determined in accordance with the requirements of USEPA method 5.

Formaldehyde was determined by Gas Chromatography arter absorption on XADZ resin

traps using an modified US EPA method 5 sampling train.

General organic screening was determined by Gas Chromalography and Mass

Spectroscopic detection after absorption on TENAX tubes using a modified US EPA

method 5 sampling train.

Ammonia was determined colorimetrically arter absorption in dilute sodium hydroxide.

Combustion gas analysis was carried out on-site using a TEST0 33 combustion gas

' analyser with electrochemical detection.

Other formaldehyde meadtirementb associated with the veneer press were detcrmincd

using colorimetric tubes and pistoti ptrmp as manoiactured by Casteb.

Volatile organic. carbon'at lbcati (3 hain Press wddelemined by Gas Chromatography

and flame ionization dettctlon after cbllection in' SKC gas sampling bags.

Volatile organic carbon at the dr

lied silica and ultra pure water. 'The determination ttas cotllpleted ji trimetrically.

thhaust was collected in an absbrption train of puri-

I + * > '

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3.0. RESULTS

3.1 Parliculates

Note : EPA Emission Limit Value for particulates

(wood driers and MDF plants) : 20mg/m3; others 50mglm3

Note : hrticulate determinations have previously been carried out on the dryer exhaust and on

the bag fillers for the veneer line at the new value added building. While the determina-

tions were carried out by Forbairt the values obtained have been supplied by Pat Horgan

and are included in Appendix C. i .,,

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3.2 Formaldehyde

Emux Volume (m3/11r)

135734

36854

12545

1 NIA

~ ' 9979

Location Concentration Mass Flow (mgflum3> (kg/l1r)

2.6 0.236

30.5 0.993

0.20 0.0025

0.20 $ NIA

20 0.20

[ 1) Dryer exhaust

* (2) Main Press

[ 10):veneer Press Wall Vent

(10) Veneer Press Ambient

(7) Glue Plant

18.75

16.0 I 36.0

8.0 35.0

I

NIA 28.7

I

* (2)Notes: Re Main Press Aldehyde Determination

The emission of aldehydes at this source is primarily cyclical in nature. Peak emissions

occur for 15 seconds during a cycle which varies between 170 and 360 seconds depend-

ing on the product being manufactured. The nature and concentration of the emission are

such that an accurate representation of the event is diflicult to obtain using standard

XAD-2 absorbent tubes. Preliminary studies using Gastech colorimetric tubes indicatcd

an emission concentration ranging from an average concentration (based on hourly eniis-

sions) of 63.2mgINm3 rising to a peak ol 692mglNm3 at times of maximum emission, ie

during the 15 second cycle.

I t should also be noted that only one of six extractor vents in this location was sampled.

-,

@ * (7)Nofe.r: Re Glue Plant Determination

The extractor fan in the glue plant is only switched on while urea addition is in progress.

This takes approximately 20 minutes.

The above analysis was carried out during this period. I " . $ : ! ' I *

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3.3 Other Aldehydes

("C) (n13hr) (1ng/Nm3) (kg/)W

Main Press 16.0 36 36,854 4 . 0 <0.05

,ocation

CO2 CO

NO, as NO so, ;Is so,

1) Dryer Exhaust

2) Main Press

5.5% by volume

50PPm

3lPPm 1 PPm

Concentration as acetaldehyde (mg/m3)

<o. 1

0.4"

(0.014

0.0 15

i

* Note: The aldehyde compound detected was acetaldehyde.

3.4 Ammonia

3.5 Slack Gas

(8) Boiler

New Value

Added

Building

I Concentrat ion Parameter 1

I r ,

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3.6 General Organic Screening

Location (1) Drver Exhaust

Parameter

Pentane

Dichloro'melhane

Hexane

Toulene

Terpene (RT 9.60)

Terpene (RT 10.59)

Terpene (RT 10.66)

Terpene (RT 11.38)

Terpene (RT 11.82)

Terpene (RT 12.94)

Notes : Temp ("C)

mls

m3lhr

mglNm3

Nm3

kglhr

PPm % by vol

Concentration (mg/N1113)

20

4 '

6

6

8

4

6

4

15

4

Temperature degrees Celsius

meters per second

cubic metres per hour

milligrams per normal cubic meter

cubic meters @ 273°K and 101.3kPa

kilograms per hour

part per million

percentage by volume

3.7 Volatile Organic Carbon

1 ' 1 I ,

. . . % *

. . , I < . , , ; '

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i

4.0. CONCLUSION

An evaluation of the results obtained is based on Table 5.1 Emission Limit Values for

Discharges to Air as defined in the EPA draft 25/8/94.

(1) Particulates

E.L.V. from wood driers : 20mgim3

E.L.V. from others 50mg/m3

The location identified as No. G Main Prewexceeds this limit.

(2) Formalde hvde

E.L.V. from wood driers 2Omg/m3

E.L.V. from others 5mglm3.

The location identified as No. 6 Main Press exceeds this limit.

. .

. . . .

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APPENDIX A

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EMISSIONS MONITORING SURVEY DIOXINS AND FURANS

FINSA FOREST PRODUCTS SCARRIFF, CO. CLARE

01 01/08/95 Final Report G G lcks issue Date Description Prepared Checked

REPORT NO

GCG Approved

: 58190R1 I

Client : TMS Consultancy Limited 12 Barrington Street Limerick Eire

DOCUMENT ISSUE STATUS

9 Michigan Avenue, Salford Quays, Manchester, M5 2GY. England Tel.: 0161-876 4220 Fax: 0161-876 4231 Registration London No. 261 1785 VAT No. 579 3459 84

A Member of the Fugro Group of Companies with offices throughoutthe world

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TMS CONSULTANCY LIMITED. EMISSIONS MONITORING SURVEY - FINSA FOREST PRODUCTS

TABLE OF CONTENTS

1.

2.

3.

INTRODUCTION

1.1 OBJECTIVES OF THE SURVEY 1.2 PLANT DESCRIPTION 1.3 PORT GEOMETRY

SAMPL ING AND ANALYSIS

2.1 ANALYSIS

RESULTS

3.1 DIOXIN AND FURAN RESULTS

LIST OF TABLES

Table 2.1: Sampling Log Table 3.1: Dioxin And Furan Results - Stack Emissions Table 3.2: Sampling Conditions

APPENDICES

Appendix1 - Sampling Procedures Appendix2 - Sample Analysis Method Appendix3 - Dioxin and Furan Analysis - Detailed Results

Page

1

1 1 1

- Report No. 58190R1 (01) Table of Contents Page 1 of 1

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TMS CONSULTANCY LIMITED =- a EMISSIONS MONITORING SURVEY - FINSA FOREST PRODUCTS

I

-__-____--- Report No 58190R1 (01) QA Statement Paae I of I

QA STATEMENT

Sample management protocol for the main reception and sample preparation laboratory requires that the samples be logged in and allocated FEL project and identification numbers on receipt. The samples are then transferred to the appropriate laboratory for extraction and analyses. Protocol is in place to minimise cross contamination.

For the dioxin and furan analysis, recovery tests are used and are necessary to evaluate the analytical methodology. In the absence of field blanks, efforts are made to obtain blank samples that best simulate a sample that does not contain the analyte. Isotopically labelled (13C and j7CI ) analytes are spiked into the sample. These provide the greatest accuracy since they are subject to the same matrix effects as the analytes. The '3C-labelled compounds are used to validate analytical pre-treatment (clean-up surrogate) and quantification (as internal standards).

In addition, measurements are made to ascertain whether, and to what extent, any reagents, solvents or glassware used may contribute to or interfere with the analytical results (laboratory [system] and solvent blanks).

'- @

The Q A system employed by FEL is detailed in the Quality Assurance Manual For Analytical Testing Operations. This is a controlled document but is available for inspection by clients.

Opinions and interpretations expressed herein are outside the scope of NAMAS accreditation.

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TMS CONSULTANCY LIMITED EMJSSJONS MONITORING SURVEY - FINSA FOREST PRODUCTS

. 1'

I. INTRODUCTION

Fugro Environmental Limited (FEL) was contracted by TMS Consultancy Limited to perform a dioxin/furan emissions monitoring survey at Finsa Forest Products, Scarriff.

The test was carried out on 27th June 1995, with actual timings detailed in the sampling log (Table 2.1). Due to the rapid fluctuations in the flow in the emissions stack, it was not possible to undertake isokinetic sampling of the flue gases. Also, due to restricted access and limited platform area, sampling was not performed to 883405.

1.1 OBJECTIVES OF THE SURVEY

(a) To measure the emissions of polychlorinated dibenzo-p-dioxins (PCDDs) and polychlorinated dibenzofurans (PCDFs) from the emissions stack.

@

(b) To measure the moisture content of the emissions from the stack.

1.2 PLANT DESCRIPTION

The hot gas from the boiler is used to dry wood chips, prior to discharge from the emissions stack. The sampling position was located on the emissions stack which emanates from the apex of the horizontal (inclined) ductwork of the hot-gas system.

1.3 PORT GEOMETRY

a The sampling port provided was a single 4 inch unthreaded port, located 0.6m above the ductwork junction of the hot gas system and the emissions stack, and 1.66m below the stack exit. The duct diameter at this position was 1.7m.

All measured distances are reported as nominal distances only.

-_ _____ - __ Report No. 58190R1 (01) Main Text Page 1 of 3

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T 1

1

1 J 1

]

1 I 1 1 I

DATE

27/06/95

27/06/95

TMS CONSULTANCY LIMITED EMISSIONS MONITORING SURVEY - FINSA FOREST PRODUCTS

TIME PAWM ETER FEL Ref No

15120 - 17:30 Dioxins and Furans 7157 - 7160

16:Ol - 17130 Water Vapour nla

2. SAMPLING AND ANALYSIS

Site attendance by Mr G. Graham, FEL, was on the 27th June 1995. Procedures for sampling are detailed in Appendix 1 and a summary sampling log is provided below (Table 2.1).

Table 2.1: Sampling Log

Note: n/a not applicable

2.1 ANALYSIS

Samples collected during the emissions survey were subjected to laboratory analysis using the methods documented in Appendix 2.

__ -

Report No: 58190Rl (01) Main Text Page 2 of 3

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TMS CONSULTANCY LIMITED EMISSIONS MONITORING SURVEY - FINSA FOREST PRODUCTS

3. RESULTS

The results for the emissions testing are presented in Table 3.1. dioxinlfuran analysis results are given in Appendix 3.

The detailed

All results are corrected to reference conditions: 273K and 101.3 kPa, no correction for water vapour or oxygen.

3.1 DIOXIN AND FURAN RESULTS

DATE STACK VELOCITY mls FEL REF 0 PE RAT1 0 N I-TEQ

VALUES @ (ng I Nm3)

at stack temp 58190

27/06/95 Emission nd 7157 - 7160 Normal c0.02

Table 3.1: Dioxin and Furan Results - Stack Emissions

NB: Velocity was not determined due to the variation in flow at the sampling point. This variation was due to the close proximity of the ductwork and the stack exit, which created turbulence in the emissions stack.

The dioxin/furan result is corrected to 273K and 101.3 kPa with no correction for water vapour or oxygen. The sampling conditions recorded over the sampling period are as follows:

Parameter Value

Stack Temperature 403 K Meter Temperature 310 K Duct Pressure 250 Pa Amb Pressure 102.0 kPa Oxygen 16.5 % Water Vapour 16.8 %(v/v)

Table 3.2: Sampling Conditions

__

Report No. 58190R1 (01) Main Text Page 3 of 3

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