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20 June 2013 Prague, Czech Republic. Advances in US Lead Producer Emission Controls. Russell Kemp Atlanta, Georgia USA rkemp@environcorp.com. Overview and Update. New rules in US spurring substantial spending on additional emission controls
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20 June 2013Prague, Czech Republic Advances in US Lead Producer Emission Controls Russell Kemp Atlanta, Georgia USA rkemp@environcorp.com
Overview and Update • New rules in US spurring substantial spending on additional emission controls • 2008 revision to National Ambient Air Quality Standard for Lead • Ten-fold reduction to 0.15 ug/m3 three-month rolling avg. • Currently in implementation phase • 2012 revision to National Emission Standard for Hazardous Air Pollutants for both primary and secondary lead smelting • Secondary Lead compliance Deadline January 2014
Fugitive Emission Controls • Key element in achieving low ambient fenceline concentrations is reduction of fugitive emissions – driven by the lowered ambient standard • New Emission Standard includes requirement to place all furnace operations, battery breakers, and feed storage rooms within negative pressure enclosures • To 0.007 inches water (0.013 mmHg, 1.7 Pa) • Continuously monitored
New, large full process enclosures being constructed (Battery Wrecker Enclosure)
Stack Emission Progress • New Secondary Lead Emission Standard • Cuts allowed stack exhaust concentration from 2 mg/dscmPb to 1 mg/dscm for any one stack • Facility-wide, airflow-weighted average limited to 0.2 mg/dscm • Growing deployment of secondary (post-baghouse) HEPA filtration • For both goals, the new ambient standard and the new emission standard • Lowest metals emission rates being achieved by Wet Electrostatic Precipitators downstream of baghouses
Wet Electrostatic Precipitator (WESP) • WESP installation completed at two US facilities, with third unit in final design phase followed by construction. WESP utilized to remove unfilterable sub-micron particles, including arsenic, and condensable gases. • WESP downstream of conventional baghouses for all process emissions from dryer, furnaces & refinery kettles. Total Pb emissions from WESP < 2.3 kg/yr (<5 lb/yr). • Balance of facility ventilation systems provide negative pressure for all total enclosures housing processes and equipped with HEPA secondary filtration. • WESP and HEPAs support potential of < 11.3 kg/yr (25 lb/yr) facility-wide lead emissions from large capacity facilities.
WESP Performance (Installation 1)Note: Installation 2 exhibits comparable results
WESP Performance (Installation 1)Note: Installation 2 exhibits comparable results
US EPA Moving to Retain Ambient Lead Standard • National Ambient Air Quality Standards (NAAQS) must be reviewed every five years • EPA is in midst of review of the 2008 lowered standard • On 05 May 2013, EPA’s full Clean Air Scientific Advisory Committee approved its Lead Review Panel’s conclusion that the available scientific evidence does not support revising the Pb NAAQS.
Dry scrubbing To close with a cross-media development: Facility required to eliminate Salt discharges to surface water Eliminated up-front feed desulfurization, which generated sulfate water discharge Installed dry lime scrubber downstream of primary metal emission control baghouse to control SO2 All while EPA’s new 1-hour SO2 NAAQS being implemented