Holcim Emission and Monitoring (EMR) Manual for United States of America

Holcim Emission and Monitoring (EMR) Manual for United States of America Version 2002-02 / 11 th August 2002

HGRS-CTS/MT J. Waltisberg HGRS-CIE/ETPS Th. Lang Revised by: Emission Monitoring Inc. R. Shigehara/J. Peeler 2/91

Table of Contents 1 Introduction 6 1.1 General 6 1.2 EMR Objectives 6 1.3 EMR implementation deadlines for USA 7 1.4 Supporting Documents 7 2 Emission Measurements 8 2.1 General Design of Emission Regulations 8 2.1.1 Air Emissions 8 2.1.2 Control Measures 8 2.1.3 Measurement Procedures and Reporting 9 2.1.4 Assessment of Emissions 9 2.1.5 Emission Limits in Cement Plants 9 2.2 Holcim Emission Guideline Values (EGVs) 10 2.3 Emission Measurements and Monitoring in Cement Plants 10 2.4 Monitor Performance Specifications 11 2.4.1 CEMS Design and Operation 11 2.4.2 Individual Monitor Performance Specifications 11 2.4.3 Performance Evaluation of Continuous Monitoring Systems (CMSs) 14 2.5 General Measuring Techniques 14 2.5.1 In-Situ Measuring Devices 14 2.5.2 Extractive Measuring Devices 15 3 Standardized Continuous EMR Equipment 17 3.1 Introduction: Systematic Applied 17 3.1.1 PM (Dust) Measuring Devices 17 3.1.2 Base Module 18 3.1.3 Extended Module 20 3.2 Emission Measuring Device for Dust 22 3.2.1 DURAG: D-R280-10 22 3.2.2 DURAG: D-R300 23 3.2.3 SICK: FW100 25 3.2.4 SICK: RM210 26 3.3 Emission Measuring Devices: Base Module 28 3.3.1 ABB 28 3.3.2 Maihak respectively SICK/Maihak 30 3.3.3 Siemens 32 3.3.4 Monitor Labs, "extractive cold" 34 3.3.5 SICK: In-situ 35 3.3.6 SICK: Extractive Hot 38 3.3.7 OPSIS 40 3.3.8 Monitor Labs, "Diluting system" 42 3/91

3.4 Emission Measuring Devices: Extended Modules 44 3.4.1 ABB 44 3.4.2 OPSIS 47 3.4.3 SICK 50 3.5 The Integration of VOC Measurement Devices 52 3.5.1 Principle of Operation of VOC Analyzers 52 3.5.2 Connection of the Analyzer 52 3.5.3 FID with a Separate Extraction Line 53 3.5.4 Integration of the FID Analyzer into an Extractive System with "Cold Analyzers" 53 3.5.5 Integration of the FID Analyzer into an Extractive System with "hot" Analyzers 55 3.5.6 Recommended FID Analyzers 56 3.6 Investment Cost Estimates 57 3.7 Standard Purchase and Supply Contract 58 3.7.1 Supplier coordinates 58 3.7.2 Detailed scope of work 58 3.7.3 Technical specifications 58 3.7.4 Exact description of all analyzers 58 3.7.5 Operational data of the analyzing system 59 3.7.6 Project documentation 59 3.7.7 Definition of guarantees 59 3.8 Standard Maintenance and Service Contract 59 3.8.1 Scope of maintenance 59 3.8.2 Repairs 60 3.8.3 Duties of the supplier 60 3.8.4 Duties of the plant 60 3.8.5 Guarantee 60 3.8.6 Damage compensation 60 3.8.7 Costs 60 3.9 Integrated Vendors 61 4 Quality Control Program 62 4.1 Introduction 62 4.2 Performance Evaluation 62 4.2.1 Relative Accuracy (RA) Test 63 4.2.2 Cylinder Gas Audit (CGA) 63 4.2.3 Relative Accuracy Audit (RAA) 63 4.3 Standard Operating Procedure (SOP) 64 5 Standardized Reporting Formats on Basis of DAHS 65 5.1 Summary 65 5.2 Introduction 65 5.3 Standardized Reporting: Continuous Measurements 66 5.3.1 Data acquisition and handling 66 5.4 HTC - The Naming Convention for Environmental Data 68 5.4.1 HTC Location 68 5.4.2 HTC Identifier 68 4/91

5.4.3 HTC Material 69 5.4.4 Examples 69 5.5 Standardized Reporting: Discontinuous Measurements 70 6 Managing Suppliers of Emission Measurement Services 71 6.1 Terms of Reference for Quotations for Emission Measurements Part 1: United States Based Standards 71 6.1.1 Introduction 71 6.1.2 Determination of Acceptable Accuracy of the Installed Continuous Monitoring Devices 72 6.1.3 Other Test Methods 72 6.2 Model Emission Measurement Report 73 6.2.1 Introduction 73 6.2.2 Part 1: Emission Test Report 73 6.2.3 Part 2: The Report about the Operating Conditions of the Measured Kiln 75 6.3 Guide to a First Plausibility Check of Result Obtained 75 6.3.1 Volume Stream 75 6.3.2 Carbon Dioxide 76 6.3.3 Nitrogen Oxides NOx 76 6.3.4 Sulfur Dioxide SO2 76 6.3.5 Carbon Monoxide CO 76 6.3.6 Volatile Organic Compounds VOC (THC) 77 6.3.7 Further Plausibility Check Possibilities 77 7 Other Items of Interest / Annexes 79 7.1 The European Union Directive on the Incineration of Waste, (Coincineration in Cement Plants) 79 7.2 Reporting Requirements according to EPER 81 7.3 Emission Guideline Values 87 7.4 Position of the EMR Project relative to the PEP/EPI/EAR Cement Scheme and vice-versa 89 7.5 Abbreviations 90 5/91

1. Introduction 1.1 General 1. In adherence to the World Business Council for Sustainable Development (WBCSD), Holcim has agreed to publish a corporate Sustainable Development (SD) report (including a chapter on environment) within two years from the date of adherence. 2. In implementing the Alternative Fuels and Raw Materials (AFR), the lack of a systematic record of emission data has been a matter of concern. 3. Because environmental authorities are continually issuing or revising emission limit values for industries, reliable back-up data are needed. 4. Holcim's goal to continuously improve the environment also needs reliable emission data to prepare adequate decisions. 1.2 EMR Objectives The Holcim Executive Committee (Exco) has adopted the EMR scheme, which requires the Group plants to: (a) (b) (c) (d) (e) Install and operate continuous emission monitoring (CEM) equipment for particulate matter (PM) 1 or dust, NO x, SO 2, THC (VOC), CO (if desired), and O 2. 2 Measure HCl, NH 3, C 6 H 6, D/F and HM (Heavy metals) emissions (at least) once per year. Conduct performance evaluation tests of the CEM equipment (at least) once per year. Report in a standardized form once per year (01.03.xy) to Holcim GRoup Support- Corporate Industrial Ecology (HGRS-CIE). Ensure that organizations entrusted with work according to points (a), (b) and (c) are capable of delivering quality work. Note: The Exco decision did not address points (c) and (e), but these points are mandatory to assure a high quality level of information obtained under points (a), (b), and (c). 1 The PM CEMS performance specifications (PS-11) and the quality assurance procedures (Procedure 2) have been proposed on December 12, 2001. The PM CEMS will be installed after the promulgation of PS-11 and Procedure 2. Until then, PM performance tests will be conducted annually. 2 The installation of some of the CEMS is not required by the regulations. Holcim's decision to monitor these emissions is primarily to develop a database for assessing emission levels. It is to also ensure that emissions are not significantly different from plant to plant and to determine appropriate process and emission control measures. 6/91

1.3 EMR implementation deadlines for USA Implementation in 2002 First EMR reporting on 01.03.03 1.4 Supporting Documents In order to standardize and streamline EMR in the Group, to facilitate EMR implementation, and generally to assure a high EMR quality level, two documents were prepared by HGRS CIE and CTS, namely: The EMR-Manual (document on hand) The EMR-Guidelines Both documents can be found in ENVIROnet on HolSpace. The EMR Manual and Guidelines are intended to be living documents; thus, they are subject to continuous improvement. Any comments are, therefore, welcome and will be integrated in new versions of the manual. 7/91

2. Emission Measurements 2.1 General Design of Emission Regulations 2.1.1 Air Emissions Authorities can specify the following measures: Ambient air quality standards Emission limits Operation and maintenance practices Raw material or fuel requirements or specifications Process equipment specifications Associated with the above measures are requirements for monitoring, emission testing, reporting, and recordkeeping. 2.1.2 Control Measures Anyone who operates an installation that is regulated for air emissions must submit to the authorities on a regular basis a certificate of compliance report, including the type, level of emissions, and time period of discharge. The reports may also include operational status of process equipment, control equipment, CEMS equipment, and corrective actions for malfunctions or poor process, control, or CEMS performance. The authorities supervise the compliance of emissions with the applicable limits. There are basically two types of control measures: Performance testing and continuous monitoring. Performance testing emission measurements are made at regular intervals, e.g., once every one to three years using reference methods. The measurements may be pollutant concentrations or mass rates, or control device parameters, e.g., inlet temperature. Continuous monitoring emission measurements made on a continual basis using automated instrumentation. 8/91

2.1.3 Measurement Procedures and Reporting Emission measurements must be carried out using standard methodology. Measurements must be related to the operating modes that are important for assessing emissions. Measured and calculated values, the measuring methods used, the respective CEM operating conditions, process operating conditions during the measuring period must be recorded. Emissions must be expressed in the units of the emission limit, such as: Concentration mass per unit volume of flue gas, e.g. [mg/m 3 ]. The flue gas volume might be corrected to a standard flue gas composition, e.g., 7 [%] or 10 [%] O 2 (Holcim standard). Mass flows mass per unit of time, e.g. [g/h. Emission factors ratios of mass per product produced, e.g. [g/ton of clinker]. 2.1.4 Assessment of Emissions Measured values must be converted to the averaging time specified by the rules. For performance measurements, the number of measurements (test runs) is usually three. The average of the three runs is then reported. For continuous measurements, except for system breakdowns, repairs, calibration checks, and zero and span adjustments, the measurements are made continuously. The frequency of measurements is specified in the applicable regulations. For Holcim plants, at least one reading every minute is recorded and daily averages are compared against the Holcim's applicable emission guideline values (EGVs) that are listed in Section 2.2. Unless specifically specified by State or local control agencies, there are no emission limits for some of the gases, such as SO 2. 2.1.5 Emission Limits in Cement Plants Emissions from cement plants may be regulated by the following rules: 40 CFR 60, Subpart F Standards of Performance for Portland Cement Plants 40 CFR 63, Subpart EEE National Emission Standards for Hazardous Air Pollutants from Hazardous Waste Combustors 40 CFR 63, Subpart LLL National Emission Standards for Hazardous Air Pollutants from the Portland Cement Manufacturing Industry 40 CFR 52 Approval and Promulgation of Implementation Plans 40 CFR 70/71 State and Federal Implementation Plans State or Local Agency Rules In addition to the Holcim requirements, each individual plant should determine whether any of the above rules apply. 9/91

2.2 Holcim Emission Guideline Values (EGVs) The EGVs are used internally by Holcim for determining relative emission levels among Holcim plants worldwide. The data gathered will be used by management to make sound technical judgments to guide business and engineering decisions, to allocate resources, and to minimize emissions. The data gathered will assist in the implementation of AFR. The following EGVs are used as benchmarking values for Holcim plants in the USA: Emission Emission Guideline Value (benchmark value) Dust 50 NOx (as NO 2 ) 800 SO 2 500 VOC 100*) HCl 30 *) as [mgc/m 3 N,dry] 2.3 Emission Measurements and Monitoring in Cement Plants The measurement of emissions from cement plants falls into two categories: Performance tests Continuous monitoring Each performance test consists of three separate runs using the applicable test method. The arithmetic mean of the three runs is used to determine the level of emissions. The performance tests are further detailed in "Guidelines for Annual Emissions Measurement at Holcim Cement Plants." The continuous monitoring of emissions is used as a means of assessing levels of emissions on a continuous basis. Holcim has adopted a company-wide policy that requires all plants to install and operate CEMSs on the main stack, whether or not required by any federal or state rules, for the following emissions: PM (dust) (Note: The installation of a PM CEMS is not required until PS-11 and Procedure 2 are promulgated.) NO x SO 2 VOC (THC) CO (if desired) O 2 Flow (if necessary) 10/91

2.4 Monitor Performance Specifications 2.4.1 CEMS Design and Operation Each CEMS must automatically check the zero (or low level value between zero and 20% of span value) and span (50 to 100% of span value) calibration drifts of at least once daily in accordance with a written procedure (manufacturer's manual). The CEMS must quantify and record the amount of zero and span drifts and determine the excess amounts. Whenever the daily zero or span drift exceeds two times the limit of the applicable performance specification, the zero and span must be adjusted. (Note: This specification is based on 40 CFR 63. However, if Appendix F, Procedure 1, is specified, the above specifications may be changed to "two times the limit of the applicable performance specification on five consecutive daily checks or four times the limit on any daily check.) In addition, the date/time and duration in excess of the limits must be recorded. The CEMS must complete and record a measurement once every minute. In some cases, the US EPA rules may require more frequent measurements, e.g., THC measurements must be done every 15 seconds. In this case, the US EPA rule shall apply. In other cases, the US EPA rules may allow one measurement every 15 minutes. The 15-minute specification may be used, if necessary. The CEMS must be able to determine an hourly average by using at least 40 minutes of 1-minute values in any hour, except during calibrations. The CEMS must reduce the data to daily averages from at least 16 hours per day. Data recorded during periods of continuous system breakdown, repair, calibration checks, and zero and span adjustments are not to be included in the data averages. 2.4.2 Individual Monitor Performance Specifications The individual monitor performance specifications below are based on 40 CFR 60, except for the flow monitor specifications, which are derived from 40 CFR 75. 40 CFR 60 does not have performance specifications for flow monitors. Where EPA has no specifications or where EPA specifications are more restrictive, the specifications are noted at "Holcim." In some cases, the specifications include references to emission limits or span values, which may not apply. These specifications have been revised to refer to meaningful references. 11/91

2.4.2.1 NO x /SO 2 and O 2 Parameter NO/SO 2 (PS-2) O 2 (PS-3/4B) Calibration error Holcim 2 : = 2.5 [%] of span = 0.5 [%] O 2 or = 5 [ppm] for spans less than 200 [ppm] Response time Holcim: 2 [min] 2 [min] Zero/calibration drift = 2.5 [%] of span (range) 0.5 [%] O 2 (24-hr) Relative accuracy 1 = 20 [%] of RM value, or = 10 [%] of emission = 1.0 [%] O 2 standard, or 5 [%] of range (if no emission standards), or 5 [ppm], whichever is less restrictive 3 Measurement Holcim: once every minute Same as PS-2 (USA: at least once every 15 minutes) 4 Recording 1-hour averages Same as PS-2 Range As specified by Holcim 25 [%] O 2 1 Expressed as the sum of the absolute values of the mean difference and confidence coefficient 2 Holcim-recommended specifications 3 If SO 2 concentrations are low, the alternative procedure specified in Section 16.0 (cylinder gas calibration procedure) may be used 4 During calibration, measurements could be made at least once every 15 minutes to allow 1-hour averages to be calculated 2.4.2.2 CO and THC (VOC) Parameter CO (PS-4B) THC (VOC) (PS-8A) Design Dual range (if necessary) Hot/wet system to prevent condensation (300 to 350 [ F]) Calibration error = 5 [%] of span value, both ranges = 5 [ppm] or 5 [%] of span value at three levels Response time = 2 [min] = 2 [min] Zero/calibration drift = 3 [%] of span (range) on either = 3 [%] of span value (24-hr) high or low range Relative accuracy 1 = 10 [%] of RM value, or 10 [%] of emission standard, or (if no emission standard) 5 [%] of range, or = 5 [ppm], whichever is less restrictive Conditioning period Measurement Holcim: once every minute; (USA: at least once every 15 minutes); resolution: 0.5 [%] of range Calibration drift, response time, calibration error tests specs = 168 hours (recommended) Once every 15 [sec]; resolution: 0.5 [ppm] (0.5 [%] of span value) 12/91

Recording 1-hour averages 1-minute averages; 3-hour block averages; separate for roller mill on/off conditions, or 30-day block average, as applicable Range Low: 200 [ppm]; high: 3000 [ppm] 2 Span value: 100 [ppm] as propane 1 Expressed as the sum of the absolute values of the mean difference and confidence coefficient 2 As specified in PS 4B; may be changed as applicable 2.4.2.3 Flow Flow meters are not mandatory prescribed by Holcim. If the local authorities prescribed the installation of such an instrument, the device must fulfill the following performance specifications. Parameter Flow Calibration error = 3 [%] of span (range) Zero/calibration drift (24-hr)* = 3 [%] of span (range) on either high or low range Relative accuracy 1 = 10 [%] Measurement Holcim: once every minute (USA: at least once every 15 minutes) Recording 1-hour averages Range Readings must be within 20-80 [%] of span value at typical unit operation 1 Expressed as the sum of the absolute values of the mean difference and confidence coefficient 13/91

2.4.3 Performance Evaluation of Continuous Monitoring Systems (CMSs) Regulations require an initial performance evaluation of CMSs when specified in the rules. For example, if hazardous waste is being burned, monitoring is required for CO or THC, and O 2. THC monitoring is also required in greenfield applications. Even if no EPA or State rules apply and performance evaluations are not mandatory, performance specifications are still necessary to evaluate the CMS to ensure acceptable instruments from suppliers. The suggested performance specifications are as follows: CEMS/COMS Performance Specification 1 NO x PS-2 SO 2 PS-2 CO PS-4B O 2 PS-3 THC PS-8A Flow See Section 2.4.2 1 In those cases where the specifications do not apply (e.g., when there is no emission limit), see Section 2.4.2 for modifications to specifications Subsequent performance evaluations are conducted according to a schedule developed in a Quality Assurance/Quality Control Program (see Section 4). 2.5 General Measuring Techniques The concentration of a substance in the exhaust gas can be measured directly in the stack (insitu) or a part of the exhaust gas can be extracted from the stack and then measured (extractive). 2.5.1 In-Situ Measuring Devices The measurement is made directly in the stack and no gas is extracted. Example: Dust can be measured using the physical principle of light absorption. The light is sent directly through the stack and the light absorption is an indication of the dust content. 14/91

FIGURE 2.1: Principle of an In-Situ Measuring Device Sender Light Beam Emitter Receiver Problems with this measuring device are very often related to calibration. A calibration gas cannot be introduced easily. Therefore special calibration facilities need to be installed. 2.5.2 Extractive Measuring Devices Part of the gas stream is extracted from the stack and fed to the analyzing system. The extracted gas must be cleaned and eventually dried before entering the analyzers The Cold Extractive Measuring Device After the extraction the sample gas stream is cooled down to approximately 4 [ C}. The water vapor condenses and is extracted through a special output system. Then the gas is fed to the analyzers. FIGURE 2.2: Example of a Cold Extractive Measuring Device Filter (heated) Sample Gas Cooler Gas Probe Pump "Cold" Analyzer(s) Heated Tube Outlet Condensate 15/91

The problems of this device are related to reactions of some components with the condensate in the gas cooler. So, compounds like ammonia, sulfur, hydrogen chlorides, etc. are completely or partly washed out with the condensate and a measurement is not possible. The "Hot" Extractive Measuring Device The gas is extracted and kept at a temperature, which does not allow condensation or chemical reactions to occur. Depending on the substances measured this temperature must kept between 140 and 200 [ C]. FIGURE 2.3: Example of a Hot Extractive Measuring Device Filter (heated) Heated Pump Gas Probe Hot Analyzer(s) Heated Tube 16/91

3. Standardized Continuous EMR Equipment 3.1 Introduction: Systematic Applied 3.1.1 PM (Dust) Measuring Devices Suitable PM (dust) measuring devices are In-Situ monitors. The supplier of an emission measuring system buys one out of the four dust analyzers below and integrates the signal into the electronic part of the system. Durag D-R-280-10 10 12,000 US-$ Suitable for high dust applications (> 200 [mg/m 3 ]) A dust concentration below approximately 10 [mg/m 3 ] cannot be measured. Durag D-R300 10 12,000 US-$ Measuring volume limited Suitable for very small dust concentrations (below 1 [mg/m 3 ]) SICK FW100 6,000 US-$ Point measurement Suitable for very small dust concentrations (below 1 [mg/m 3 ]) SICK RM210 10 12,000 US-$ Penetration depth is adjustable Suitable for very small dust concentrations (below 1 [mg/m 3 ]) 17/91

3.1.2 Base Module Includes the following components: PM (Dust) and NO, SO 2, CO, O 2, VOC Extractive Cold with NDIR-/NDUV- or IR-Technology System with sample gas cooler to dry and cool the gas Known technology Problem: SO 2 -measurement: requires acidification of sample gas! VOC only with hot extraction (bypass) and flame ionization detector ABB Advanced Cemas-NDIR 50 60,000 US-$ Former Hartmann&Braun Calibration possibility with cells Instruments well known in cement industry Maihak Extractive cold module Maihak 64,000 US-$ Maihak has been bought by SICK Not very much experience in cement industry Problems with some instruments in the past Siemens Monitor Labs Extractive cold module Siemens Extractive cold module 55,000 US-$ Instruments are known in the cement industry 75,000 US-$ Note: Prices do not include dust measuring devices. 18/91

Other Systems In-situ or extractive hot with IR-technology VOC only with hot extraction (bypass) and flame ionization detector SICK SICK Opsis SICK base mo dule insitu Sick base module extractive hot Opsis base mo dule insitu 54,000 US-$ (without FID) 58,000 US-$ (without FID) CO, NO, NO 2, SO 2, O 2: 90,000 US-$ VOC: 24,000 US-$ Option: H 2 O: 5,500 US-$ In-situ is requires in special cases With the lance method, calibration with gases is possible FID requires separate extraction system MCS100 of former Bodenseewerk / Perkin Elmer Hot extraction for base module is not recommended Rather small service organization Excessive price for a not extendable base module Monitor Labs Measuring system with gas diluting system CO, NO, NO 2, SO 2, O 2 120'000 US-$ (???) Diluting system works for SO 2, CO NO problematic (own experience in Switzerland) Note: Prices do not include dust measuring devices. 19/91

3.1.3 Extended Module Includes the following components: PM (Dust) and NO, SO 2, CO, O 2, VOC ( Base Module ) plus HCl, NH 3 and others ( Extension ) 3.1.3.1 FTIR-Analyzer Extractive hot with FTIR analyzer with integrated flame ionization detector ABB Advanced Cemas-FTIR CO, NO, SO 2, HCl, NH 3, H 2 O, O 2, VOC: 72 81,00 US-$ Former Hartmann&Braun Good experience in Alsen, Höver Note: Prices do not include dust measuring devices. 3.1.3.2 Differential Optical Absorption Spectrometroscopy In-situ Technology similar to FTIR but absorption in exhaust gas duct Opsis Opsis extended module in-situ CO, NO, NO 2, SO 2 and O 2 150,000 US-$ VOC: 24,000 US-$ Rather small service organization Wide extension possibilities Selectable Compounds: CO 2 : 5,500 US-$ H 2 O: 5,500 US-$ HCl: 5,500 US-$ HF: 5,500 US-$ NH 3 : 5,500 US-$ C 6 H 6 : 8,500 US-$ 20/91

3.1.3.3 "Extractive Hot with IR-Technology SICK SICK extended module extractive hot CO, NO, SO 2, H 2 O, CO 2, HCl, O 2 76,000 US-$ (without FID) Former Bodenseewerk/ Perkin Elmer A hot IR-Technology is always a compromise with regard to the cell lengths required for the different components 21/91

3.2 Emission Measuring Device for Dust 3.2.1 DURAG: D-R280-10 Supplier DURAG, Industrie Elektronik GmbH&Co KG, Kollaustr. 105 D-22453 Hamburg/Germany Phone: ++49 40 55 42 18 0; Fax: ++49 40 58 41 54 Internet: www.durag.de Type Dust Concentration Meter D-R280-10 Measuring principle In-Situ, two-beams alternate light method Measuring range 10 to 250 [mg/m 3 ] (higher ranges possible) Calibration Comparison measurement, e.g. according to VDI 2066. Gas conditions Above dew point Ambient conditions -20 to + 50 [ C] Configuration Regulations TA Luft, 13. BimSchV Budget price Approximately 10,000 to 12,000 US-$ Remarks For high dust applications (> 200 [mg/m 3 ]) suitable Concentration below approximately 10 [mg/m 3 ] cannot be measured. 22/91

3.2.2 DURAG: D-R300 Supplier DURAG Industrie Elektronik GmbH&Co KG, Kollaustr. 105 D-22453 Hamburg/Germany Phone: ++49 40 55 42 18 0, Fax: ++49 40 58 41 54 Internet: www.durag.de Type Dust Concentration Meter D-R300 Measuring principle In-situ Scattered light measurement principle Measuring ranges 0 to 1 [mg/m 3 ] (minimum range) 0 to 200 [mg/m 3 ] (maximum range) Calibration Comparison measurement, e.g. according to VDI 2066. Gas conditions Temperature above dew point up to 320 C Ambient conditions -20 to + 50 C 23/91

Configuration Regulations Budget price: Remarks TA Luft, 13. BImSchV, 17. BimSchV (Co-incineration of waste) Approximately 10,000 to 12,000 US-$ Measured volume ranging from 80 to 280 [mm] off wall only. Eventually not representative determination of dust load in ducts where the concentration profile varies significantly over the diameter. 24/91

3.2.3 SICK: FW100 Supplier SICK AG Environmental Monitoring, Nimburger Strasse 11 D-79276 Reute/Germany Phone: ++49 7641 469 0, Fax: ++49 7641 469 11 49 Internet: www.sick.de Type Dust Concentration Monitor FW100 FW 101: for gas ducts with a diameter larger than 500 [mm] FW 102: for gas ducts with a diameter larger than 200 [mm] Measuring principle In-situ Scattered light measurement principle (forward scattering). Suitable for measuring of very small particle concentrations. Measuring ranges 0 to 5 [mg/m 3 ] (minimum range) 0 to 200 [mg/m 3 ] (maximum range) Calibration Comparison measurement, e.g. according to VDI 2066. Gas conditions Standard version: 0 to 220 [ C] High temperature version: 0 to 400 [ C] Version with external purge air: -50 [mbar] to +70 [mbar] Version with instrument air: -50 [mbar] to 1 [bar] Ambient conditions -20 to + 50 [ C] for transmitter/receiver unit -20 to + 50 [ C] intake-air temperature for fan 25/91

Configuration Budget price: Remarks Approximately 6,000 US-$ The dust concentration is measured in a small area of the duct only. If the concentration profile varies significantly over the duct diameter, the instrument should not be used. 3.2.4 SICK: RM210 Supplier SICK AG Environmental Monitoring, Nimburger Strasse 11 D-79276 Reute/Germany Phone: ++49 7641 469 0, Fax: ++49 7641 469 11 49 Internet: www.sick.de Type Dust Concentration Monitor RM210 Measuring principle In-situ Scattered light measurement principle (forward scattering). Suitable for measuring of very small particle concentrations. Measuring ranges 0 to 0.5 [mg/m 3 ] (minimum range) 0 to 200 [mg/m 3 ] (maximum range) Measurement ranges switching effected automatically 26/91

Calibration Comparison measurement, e.g. according to VDI 2066. Gas conditions Temperature above dew point up to 500 [ C] Ambient conditions -20 to + 50 [ C] -20 to + 65 [ C] and 50 [% rf] (storage) Configuration Regulations TA Luft, 13. BImSchV, 17. BimSchV (Co-incineration of waste) Budget price Approximately 10,000 to 12,000 US-$ Remarks High penetration and detection depths up to 1700 [mm] due to adjustable transmitter and receiver segments Representative determination of dust load in ducts where the concentration profile varies significantly over the diameter. 27/91

3.3 Emission Measuring Devices: Base Module 3.3.1 ABB Supplier ABB Automation Products GmbH (former Hartmann&Braun) Analysentechnik, Stierstädter Strasse 5 D-60488 Frankfurt am Main/Germany Phone: ++49 (0)69 79 30-0, Fax: ++49 (0)69 79 30-45 66 Internet: www.abb.de/automation Type Advanced Cemas-NDIR Base Module: Cold extraction and NDIR technology and with VOC-measurement Emission measuring device for NO, SO 2, CO, O 2 and VOC Gas extraction Gas probe type 40 Max. temperature: 500 [ C] Pressure: 0.8 to 1.05 [bar] Filter PFE2, high-grade steel (1.4571/1.0718), heated Heated tube, max. length: 40 [m] tube 6/8x1 [mm] PTFE Gas preparation Cooler advanced SCC Gas flow module SCM with diaphragm pump, flow controller Acidification station for SO 2 measurement Measuring range Compound Analyzer Minimum Maximum 17. BimSchV CO Uras 14 0 to 75 [mg/m 3 ] 0 to 2500 [mg/m 3 ] 0 to 75 [mg/m 3 ] NO Uras 14 or Limas 11 0 to 75 [mg/m 3 ] 0 to 75 [mg/m 3 ] 0 to 3000 [mg/m 3 ] 0 to 3000 [mg/m 3 ] 0 to 75 [mg/m 3 ] 0 to 75 [mg/m 3 ] 28/91

SO 2 URAS 14 or Limas 11 0 to 75 [mg/m 3 ] 0 to 75 [mg/m 3 ] 0 to 3000 [mg/m 3 ] 0 to 3000 [mg/m 3 ] 0 to 75 [mg/m 3 ] 0 to 75 [mg/m 3 ] O 2 Electrochem. Sensor or Magnos 16 0 to 10 [vol%] 0 to 10 [vol%] 0 to 25 [vol%] 0 to 25 [vol%] 0 to 10 [vol%] 0 to 25 [vol%] 0 to 10 [vol%] 0 to 25 [vol%] VOC Multi-FID 14 0 to 10 [mgc/m 3 ] 0 to 200 [mgc/m 3 ] 0 to 15 [mgc/m 3 ] Calibration Zero adjustment and span of O 2 analyzer with clean air CO, NO, SO 2 with integrated calibration cells (check with calibration gases once a year) VOC with calibration gases, more frequently Ambient condition 0 to +35 [ C] in steal sheet cabinet 0 to +45 [ C] in steal sheet cabinet with air conditioning -20 to +35 [ C] in KFR model -20 to +50 [ C] in KFR model with cooling aggregate Configuration Signal from dust analyzer Electronics Air calibration Multi-FID14 (VOC) Analyzers CO, NO, SO 2, O 2 Gas extraction Sample gas cooler Gas flow module Acidification Condensate 29/91

Budget price Included steel sheet analysis cabinet Included is the VOC-measurement (Multi-FID 14) Between 50,000 and 60,000 US-$ Remarks Extension to CO 2 and NO x (with catalyst) is possible The dust signal can be integrated. Usually ABB works together with DURAG 3.3.2 Maihak respectively SICK/Maihak Supplier Maihak Aktiengesellschaft, Poppenbuetteler Bogen 9b D-22399 Hamburg/Germany Phone: ++49 40 2 78 94-0, Fax: ++49 40 2 78 94-366 Internet: www.maihak.de Type Extractive cold module Maihak Base module: Extractive cold with VOC-measurement Emission measuring device for NO, SO 2, CO, O 2 and VOC Gas extraction Gas probe: GAS222.20 Max. temperature: 600 [ C] Tube length: 1000 [mm] Sinter metal filter Heated tube, max. length: 40 [m] Inner tube diameter 4 [mm], interchangeable Gas preparation Cooler EGK 1 / 2 Gas pump, P2.3P, etc. Acidification station for SO 2 measurement Compound Analyzer Measuring range 17. BimSchV NO UNOR 0 to 2000 [mg/m 3 ] 0 to 100 [mg/m 3 ] 0 to 500 [mg/m 3 ] 30/91

SO 2 UNOR 0 to 1500 [mg/m 3 ] 0 to 100 [mg/m 3 ] 0 to 500 [mg/m 3 ] CO UNOR 0 to 2000 [mg/m 3 ] 0 to 100 [mg/m 3 ] 0 to 500 [mg/m 3 ] O 2 OXOR-P 0 to 25 [vol%] VOC Bernath Atomic BA3002 0 to 100 [mgc/m 3 ] Yes Calibration With calibration gases Gas conditions 600 [ C] maximum gas temperature Ambient conditions 0 to + 45 [ C] Configuration Signal from dust analyzer Electronics Air calibration BA3002 (VOC) Analyzers CO, NO, SO 2, O 2 Gas extraction Sample gas cooler Gas flow module Acidification Condensate 31/91

Budget price: Included steel sheet analysis cabinet Price: 64,000 US-$ Remarks Remark: Maihak and Bernath Atomic (FID) has been bought by SICK 3.3.3 Siemens Supplier Siemens AG Automatisierungs- und Antriebstechnik Prozessautomatisierung und instrumente Analytik Letter address: Siemens AG, A&D PA 241 D-76181 Karlsruhe / Germany House address: Siemensallee 84 D-76187 Karlsruhe / Germany Type Extractive cold module Siemens Base Module: Extractive cold with VOC-Measurement Emission Measuring Device for NO, SO 2, CO, O 2 and VOC Gas extraction Gas probe with ceramic filter, extraction tube: 1 m Heated tube, inner tube diameter 4/6 mm PTFE, interchangeable Gas preparation Cooler Gas pump Acidification station for SO 2 measurement 32/91

Compound Analyzer Measuring range 17. BimSchV NO ULTRAMAT 6E Not defined yes SO 2 ULTRAMAT 6E Not defined yes CO ULTRAMAT 6E Not defined yes O 2 OXIMAT Not defined VOC FIDAMAT 5E-E Not defined yes Calibration With calibration gases Gas conditions Ambient conditions Configuration Signal from dust analyzer Electronics Air calibration Fidamat (VOC) Ultramat CO, NO, SO 2, O 2 Gas extraction Sample gas cooler Gas flow module Acidification Condensate Budget price: Included steel sheet analysis cabinet with cooler Price: 55,000 US-$ 33/91

3.3.4 Monitor Labs, "extractive cold" Supplier Monitor Labs, Inc. Company Headquarters 76 Inverness Drive East Englewood, CO 80112 1-800-422-1499 Toll Free 1-303-792-3300 Phone 1-303-799-4853 Fax Type ML 660 Conventional Extractive System Base model includes NO x, CO, O 2 (CO 2 & SO 2 also available) Gas extraction Gas probe (Universal Analyzers 270BB) Max. temperature: 1000 [ F] Tube length: various available [mm] Ceramic 2 [mm] filter Heated tube, max. length: 350 [ft] Inner tube diameter 1/4 [in], interchangeable Compound Analyzer Measuring range NO ML 9841AS (Chemiluminescent) 0 1000 [ppm] SO 2 ML 9850 (UV Fluorescence) 0 20 [ppm] CO ML 9830 (NDIR gas filter correlation) 0 200 [ppm] O 2 ML 422 (Paramagnetic) 0 to 25 [vol%] 34/91

Calibration With calibration gases Gas conditions Inlet to analyzers: 40 [ F] (maximum); moisture: dew point Ambient conditions +5 to +40 [ C] Budget price: Price for the basic configuration: $ 75,000 US $ (NOx, CO, O 2 only) Price for environmentally controlled shelter $ 30,000 US $ Remarks ML also provides a THC monitoring system. 3.3.5 SICK: In-situ Supplier SICK AG Environmental Monitoring, Nimburger Strasse 11 D-79276 Reute/Germany Phone: ++49 7641 469 0, Fax: ++49 7641 469 11 49 Internet: www.sick.de Type SICK base module In-situ In-situ measuring devices for CO, NO, SO 2 and O 2 Measuring principle In-situ NO, SO 2 : opto-electronic direct measurement in one instrument CO: Opto-electronic direct measurement O 2: Zirconium dioxide probe VOC: Extractive hot with flame ionization detector 35/91

Compound Analyzer Measuring range 17. BimSchV NO GM 31-2 (lance version) 0 to 2000 [mg/m 3 ] Yes SO 2 GM 31-2 (lance version) 0 to 1500 [mg/m 3 ] Yes CO GM 901 (cross stack version) 0 to 2000 [mg/m 3 ]??? O 2 GM 301 (ZrO 2 -Probe) 0 to 25 [vol%]??? VOC Calibration GM 31-2: NO with calibration cell SO 2 with calibration gas GM 901: CO???? GM 301: O 2 with zero gas and air Gas Conditions GM 31-2: 550 [ C] maximum temperature GM 901: 300 [ C] GM 301: Ambient conditions GM 31-2 and GM 901: -20 to + 55 [ C] 36/91

Configuration Figure without CO- and VOC-analyzer Budget price: At the moment no VOC-measurement offered Price: 54,000 US-$ Remarks These in-situ analyzers do not work in exhaust gases with droplets (e.g. behind a wet scrubber) Preferable solution if extractive solutions are not possible due to the long distance between extraction and analyzing system Bottleneck: Situation of VOC-measurement (FID) 37/91

3.3.6 SICK: Extractive Hot Supplier SICK AG Environmental Monitoring, Nimburger Strasse 11 D-79276 Reute/Germany Phone: ++49 7641 469 0, Fax: ++49 7641 469 11 49 Internet: www.sick.de Type SICK base module extractive hot Extractive hot with NIR-/IR-photometer MCS100 of former Bodenseewerk/ Perkin Elmer Gas extraction and preparation Gas probe tube, not heated, steal 1.4539 Coarse (20 [µm], max. 400 [ C]) and fine filter (2 [µm], max. 220 [ C]), high-grade steel 1.4404 Heated tube, tube 6/8 [mm] PTFE, interchangeable Compound Analyzer Measuring range 17. BimSchV NO MCS 100 HW KWK 0 to 2000 [mg/m 3 ] 0 to 200 [mg/m 3 ] SO 2 MCS 100 HW KWK 0 to 1500 [mg/m 3 ] 0 to 500 [mg/m 3 ] (only TA Luft) CO MCS 100 HW KWK 0 to 2000 [mg/m 3 ] 0 to 100 [mg/m 3 ] O 2 GM 301 (ZrO 2 -Probe) 0 to 25 [vol%]??? VOC 38/91

Calibration With calibration gases Gas conditions MCS 100: 400 [ C] maximum gas temperature GM 301: Ambient conditions MCS 100: +5 to +45 [ C] Configuration Figure without dust- and VOC-analyzer Budget price: Price without container At the moment no VOC-measurement offered Price: 58,000 US-$ Remarks For the compounds NO, SO 2, CO and O 2 alone such an extractive hot system is not recommended 39/91

3.3.7 OPSIS Supplier OPSIS AB Box 244 SE-244 02 Furulund / Sweden Phone: ++46 (0)46 72 25 00, Fax: ++46 (0)46 72 25 01 Internet: www.opsis.se Type OPSIS base module in-situ In-situ measuring devices for NO, NO 2, SO 2, CO and O 2 Measuring principle In-situ NO, NO 2, SO 2, CO: Differential optical absorption spectroscopy O 2 : ZrO 2 method VOC: extractive hot with flame ionization detector Compound Analyzer Measuring range (recommended for a 2 [m] stack) DL --> detection limit 17. BimSchV 1 [m] measuring length NO AR 600S 0 to 1000 [mg/m 3 ] 0 to 150 [mg/m 3 ] NO 2 AR 600S 0 to 20 [mg/m 3 ] (DL: 0.5 [mg/m 3 ]) 0 to 20 [mg/m 3 ] SO 2 AR 600S 0 to 800 [mg/m 3 ] 0 to 80 [mg/m 3 ] CO AR 650 0 to 1000 [mg/m 3 ] 0 to 150 [mg/m 3 ] H 2 O (selectable) AR 650 S 12 to 18 [vol%] 0 to 30 [vol%] O 2 O2000 (ZrO 2 -Probe) 0 to 25 [vol%] VOC M&A Thermo FID 0 to 1000 [mgc/m 3 ]??? 40/91

Calibration Opsis: calibration with gases every 6 month (according to German TUV, 17. BimSchV) Gas conditions Ambient conditions Spectrometer: +15 to +25 [ C] Receiver and emitter: -40 to +50 [ C] Configuration Figure without VOC-analyzer Budget price: Prices without cabinet Basic set (NO, NO 2, SO 2, CO, O 2 ): 90,000 US-$ Selectable compound: H 2 O: 5,500 US-$ VOC: 24,000 US-$ Remarks Base system without extension possibilities Rather small service organization VOC measurement directly with OPSIS analyzer is not recommended FID (VOC) from Mess- und Analysentechnik, Leverkusen The direct coupled version is not acceptable Temperature class T2 must be chosen 41/91

3.3.8 Monitor Labs, "Diluting system" Supplier Monitor Labs, Inc. Company Headquarters 76 Inverness Drive East Englewood, CO 80112 1-800-422-1499 Toll Free 1-303-792-3300 Phone 1-303-799-4853 Fax Type ML 675 Dilution-Extractive System Base system includes SO 2, NO x, and CO 2 Separate O 2 analyzer is needed Gas extraction Gas probe (EPM various models) Max. temperature: 800 [ F] Tube length: various available Sinter metal filter Heated tube, max. length: 350 [ft] Inner tube diameter 4 [mm], interchangeable Typical sample flow rate: 5 [l/min] Typical dilution flow rate: variable Configuration 1 5 2 3 4 Measuring-gas diluter in the exhaust gas stack 12 7 9 10 6 8 11 Control unit 1 Measuring gas 2 Stainless steel filter 3 Glass wool filter 4 Critical nozzle 5 Injector pump 6 Exit of diluted gas 10 Back flushing valve analyzers 11 Calibration gas port 7 Negative pressure (nozzle) 12 Negative pressure 8 Blank gas connection (air) (exhaust gas stack) 9 Precision pressure regulator 42/91

Compound Analyzer Measuring range NO ML 9841AS (Chemiluminescent) 0 1000 [ppm] SO 2 Model (UV Fluorescence) 0 20 [ppm] CO ML 9830 (NDIR gas filter correlation) 0 200 [ppm] O 2 ML 422 (Paramagnetic) 0 to 25 [vol% Calibration With calibration gases Gas conditions Most conditions can be supported Ambient conditions +5 to +40 [ C] Budget price: Price for the basic configuration using a GE PLC controller: 120,000 US $ Price with environmentally controlled room $35,000 US $ Dilution probe only: 12,000 US $ GE PLC dilution system controller with programming: 10,000 US $ Remarks A separate oxygen analyzer will be needed Moisture analysis will not be needed to determine mass emission rates A DAS system would be about 35,000 US $ Cost of sample line ($35/ft) is not included 43/91

3.4 Emission Measuring Devices: Extended Modules 3.4.1 ABB Supplier ABB Automation Products GmbH (former Hartmann&Braun) Analysentechnik, Stierstädter Strasse 5 D-60488 Frankfurt am Main/Germany Phone: ++49 (0)69 79 30-0, Fax: ++49 (0)69 79 30-45 66 Internet: www.abb.de/automation Type Advanced Cemas-FTIR Extended module: Hot extraction with FTIR-technology (Fast Fourier Transformation Infrared Analyzer) Emission measuring device for NO, SO 2, CO, O 2 and VOC ( base module ) and H 2 O, HCl, NO 2, NH 3, HF, CO 2 ( extension ) Gas Extraction Gas probe type 40 Max. temperature: 500 [ C] Pressure: 0.8 to 1.05 [bar] Filter,heated, 180 [ C] Heated tube, 180 [ C], length: 10 [m] Gas preparation Fine filter Gas flow module with pump, flow controller Measuring range Compound Analyzer Minimum Maximum 17. BimSchV CO FTIR 0 to 75 [mg/m 3 ] 0 to 2500 [mg/m 3 ] 0 to 75 [mg/m 3 ] 0 to 300 [mg/m 3 ] NO FTIR 0 to 200 [mg/m 3 ] 0 to 2000 [mg/m 3 ] 0 to 200 [mg/m 3 ] 0 to 390 [mg/m 3 ] 44/91

SO 2 FTIR 0 to 75 [mg/m 3 ] 0 to 1500 [mg/m 3 ] 0 to 75 [mg/m 3 ] 0 to 300 [mg/m 3 ] HCl FTIR 0 to 15 [mg/m 3 ] 0 to 325 [mg/m 3 ] 0 to 15 [mg/m 3 ] 0 to 90 [mg/m 3 ] NH 3 FTIR 0 to 15 [mg/m 3 ] 0 to 230 [mg/m 3 ] 0 to 15 [mg/m 3 ] H 2 O FTIR 0 to 10 [vol%] 0 to 40 [vol%] 0 to 40 [vol%] O 2 Electrochem. Sensor 0 to 10 [vol%] 0 to 25 [vol%] 0 to 10 [vol%] 0 to 25 [vol%] VOC (organic C) Multi-FID 14 0 to 10 [mgc/m 3 ] 0 to 200 [mgc/m 3 ] 0 to 15 [mgc/m 3 ] CO 2 (Option) HF (Option) Calibration FTIR 0 to 5 [vol%] 0 to 30 [vol%] 0 to 20 [vol%] FTIR 0 to 10 [mg/m 3 ] 0 to 1800 [mg/m 3 ] Daily self-control with zero gas Calibration with gases every 6 months VOC with calibration gases, more frequently Ambient condition 5 to +40 C, short-time: +50 [ C] The measuring device should be protected against heat radiation, dust 45/91

Configuration 3 4 2 1: FTIR-Spectrometer 2: Computer 3: Control and analog outputs 4: Temperature controller 5: O 2 Analyzer (not in the figure) 6: Gas flow module (heated) 1 5 6 Budget Price Included steel sheet analysis cabinet with air conditioning Included is the VOC-measurement (Multi-FID 14) Between 72,000 and 81,000 US-$ Remarks The dust signal can be integrated. Usually ABB works together with DURAG 46/91

3.4.2 OPSIS Supplier OPSIS AB Box 244 SE-244 02 Furulund / Sweden Phone: ++46 (0)46 72 25 00, Fax: ++46 (0)46 72 25 01 Internet: www.opsis.se Type OPSIS extended module in-situ In-situ measuring devices for NO, NO 2, SO 2, CO, CO 2, H 2 O, HCl, HF and O 2 Measuring principle In-situ NO, NO 2, SO 2, CO, etc. Differential optical absorption spectroscopy O 2: ZrO 2 method VOC: extractive hot with flame ionization detector Compound Analyzer Measuring range (recommended for a 2 [m] stack) DL --> detection limit 17. BimSchV 1 [m] measuring length NO AR 600 0 to 1000 [mg/m 3 ] 0 to 150 [mg/m 3 ] NO 2 AR 600 0 to 20 [mg/m 3 ] (DL: 0.5 [mg/m 3 ]) 0 to 20 [mg/m 3 ] SO 2 AR 600 0 to 800 [mg/m 3 ] 0 to 80 [mg/m 3 ] CO AR 650 0 to 1000 [mg/m 3 ] 0 to 150 [mg/m 3 ] CO 2 (selectable) AR 650 0 to 25 [vol%] H 2 O (selectable) AR 650 12 to 18 [vol%] 0 to 30 [vol%] 47/91

HCl (selectable) AR 650 0 10 [mg/m 3 ] (DL: 0.5 [mg/m 3 ]) 0 to 15 [mg/m 3 ] HF (selectable) AR 650 0 to 5 mg/m 3 (DL: 0.2 mg/m 3 ) NH 3 (selectable) AR 600 0 to 40 mg/m 3 (DL: 1 mg/m 3 ) 0 to 10 mg/m 3 C 6 H 6 AR 600 0 to 5 mg/m 3 (DL: 0.5 mg/m 3 ) O 2 O2000 (ZrO 2 -Probe) 0 to 25 Vol% VOC M&A Thermo FID 0 to 100 mgc/m 3??? Calibration Opsis: calibration with gases every 6 month Gas conditions Ambient conditions Spectrometer: +15 to +25 C Receiver and emitter: -40 to +50 C 48/91

Configuration Figure without VOC-analyzer Budget price: Prices without cabinet Basic set (NO, NO 2, SO 2, CO, O 2 ): 150,000 US-$ Selectable compounds: CO 2 : 5,500 US-$ H 2 O: 5,500 US-$ HCl: 5,500 US-$ HF: 5,500 US-$ C 6 H 6 : 8,500 US-$ VOC: 24,000 US-$ Remarks Rather small service system VOC measurement directly with OPSIS analyzer is not recommended! FID from Mess- und Analysentechnik, Leverkusen The direct coupled version is not recommended Temperature class T2 must be chosen 49/91

3.4.3 SICK Supplier SICK AG Environmental Monitoring Nimburger Strasse 11 D-79276 Reute/Germany Phone: ++49 7641 469 0 Fax: ++49 7641 469 11 49 Internet: www.sick.de Type SICK Extended Module Extractive Hot Extractive hot with NIR-/IR-photometer ZrO 2 -Probe integrated in analysing system Gas extraction and preparation Gas probe tube, not heated, steal 1.4539 Coarse (20 µm, max. 400 C) and fine filter (2 µm, max. 220 C), high-grade steel 1.4404 Heated tube, tube 6/8 mm PTFE, interchangeable Compound Analyzer Measuring Range 17. BimSchV NO MCS 100 HW KHK-75 0 to 2000 mg/m 3 0 to 200 mg/m 3 SO 2 MCS 100 HW KHK-75 0 to 1500 mg/m 3 0 to 500 mg/m 3 (only TA Luft) CO MCS 100 HW KHK-75 0 to 2000 mg/m 3 0 to 100 mg/m 3 H 2 O MCS 100 HW KHK-75 0 to 25 vol% 0 to 40 vol% CO 2 MCS 100 HW KHK-75 0 to 30 vol% 0 to 25 vol% HCl MCS 100 HW KHK-75 0 to 50 mg/m 3 0 to 15 mg/m 3 50/91

O 2 PEOX100 (ZrO 2 -Probe) 0 to 25 Vol%??? VOC Calibration With calibration gases Gas conditions MCS 100: 400 C maximum gas temperature GM 301: Ambient conditions MCS 100: +5 to +45 C GM 301: Configuration Figure without dust- and VOC-Analyzer Budget price: Price without container At the moment no VOC-measurement offered Price: 76,000 US-$ 51/91

3.5 The Integration of VOC Measurement Devices In this chapter the correct integration of VOC analyzers into existing and new measuring stations is described. 3.5.1 Principle of Operation of VOC Analyzers The Flame Ionization Detection (FID) method is used to determine the presence of volatile organic compounds (or total hydrocarbon) concentrations in a gaseous sample: Sample gas Fuel gas Oven Air Gas outlet FIGURE 3.1: Measuring Principle Burning hydrocarbon-free hydrogen in hydrocarbon-free air produces negligible number of ions. Once a sample containing hydrocarbons is introduced into the flame a very complex ionization process is started. This process creates a large number of ions. A high polarizing voltage, producing an electrostatic field, is applied between the two electrodes around the burner nozzle. Now negative ions migrate to the collector electrode and positive ions migrate to the high voltage electrode. The so generated ionization current between the two electrodes is directly proportional to the concentration of volatile organic compounds in the sample that is burned by the flame. 3.5.2 Connection of the Analyzer The gas sample must be extracted from the stack or duct and kept hot until the sample enters the FID analyzer. From experience it is known that organic compounds with high evaporation temperatures can be present in the exhaust gas of a cement plant. If these compounds enter the flame ionization analyzer with too low temperatures the compounds condense in the internal fine filter, in the internal capillary system, etc. and block the analyzer. 52/91

Therefore it is recommended: to keep the gas temperature inside the flame ionization detector at a temperature of at least 180 [ C], if possible at 200 [ C]. to kept the gas temperature in the extraction system above the maximum gas temperature in the chimney, but at least at 150 [ C]. 3.5.3 FID with a Separate Extraction Line If the FID can not be integrated into an extraction line, e.g. in connection with in-situ measuring devices, the gas must be extracted through a separate extraction line and fed to the FID analyzer. The volume stream should be sucked through the analyzer by an integrated pump inside the analyzer. The gas temperature inside the whole line and the analyzer should be kept at least at 180 [ C]. Sample Gas Extraction FID with internal pump Heated tubes 3.5.4 Integration of the FID Analyzer into an Extractive System with Cold Analyzers Very often, the plant has an extractive measuring system with cold analyzers, and the flame ionization detector should be integrated into the emission cabinet. In this case the gas can be extracted directly from the hot line. It is important, that the gas remains hot, i.e. the sample gas temperature should not drop below 150 [ C] around the connection point. The problem of such an arrangement is in any case the gas flow. It must be checked that the volume stream for the cold analyzers, respectively for the flame ionization detector, is large enough and additionally it must be checked that the flame ionization detector is not subject to any pressure fluctuation in the measuring system. 53/91

FID Air Calibration Cold Analyzers Filter Gas pump Sample Gas Extraction Sample Gas Cooler Condensate Output Cabinet Heated tubes An alternative solution is the distribution of the gases in a separate box with a hot pump. This solution has the advantage that a constant gas stream can be fed two the two gas analyzing systems. FID Sample Gas Extraction Heated distribution box Cold Analyzer(s) 54/91

3.5.5 Integration of the FID Analyzer into an Extractive System with hot Analyzers In systems with hot analyzers, the distribution of the gas is usually made in a heated box. Therefore the connection of a flame ionization detector should not be a problem. In any case, it must be only checked that the delivered volume of the pump is enough. FID Hot part of analyzer(s) Cold analyzing system Heated distribution box Sample Gas Extraction Cabinet Air Calibration Heated tubes 55/91

3.5.6 Recommended FID Analyzers In the following table some acceptable flame ionization detectors are mentioned. All these analyzers are proven by a German institute (e.g. TÜV) and are recommended from the German authorities to measure the organic emissions as total carbon. Supplier Type Bernath Atomic BA 3002 J.U.M. VE 7 3-300A 3-400 ( wall model ) TESTA FID123, FID 1230 Modul Siemens FIDAMAT 5E ABB Hartmann+Braun FID-14 56/91

3.6 Investment Cost Estimates A. Continuous Measurements 1000 USD Dust measurement only 10 12 Base module (NO, SO 2, CO, O 2, VOC) 50 70 Module including - Base module - Extension module (HCl, NH 3, others) Measuring cabin (climatized, power and pressurized air supply 80 180 10 20 Annual cost for service contract 3 5 Annual cost for maintenance by plant personnel 3 5 DAS (TIS) software for emission data handling and reports generation 20 30 B. Discontinuous Measurements 1000 USD Gas sampling (6 to7 mandays) Analysis of sample 20 25 Reporting 57/91