AECL LABORATORY ANALYSIS REPORT

STACK/POINT SOURCE EMISSION QUALITY REPORT

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Memo # AECL :
Enterprise : Holcim Cement (Bangladesh) Ltd.
Factory Address : Char Ramjan, Sonaullah, Meghna Ferry Ghat, Dhaka

Description of Sample : Stack/Point Source emission test report

Used Fuel : Natural Gas, Diesel (Generator)
Sample Collector : Adroit Environment Consultants Ltd (Monitoring team).
Sampling date : 2nd July, 2019 to 4th July, 2019
Reporting date : 21st July, 2019

Sampling Details:
The sampling locations within the Holcim Cement Plant were at the Mill- 2, 562, FN1 Bag Filter, Mill- 3, 563,
FN1 Bag Filter, Mill- 3, 563, FN2 Bag Filter (Separator), Mill- 4, 565, FN1 Bag Filter, Mill- 5, 565, FN1 Bag
Filter, Mill- 7, 567, FN2 Bag Filter and Mill- 7, 567, FN1 Bag Filter (Separator). Sampling and data collection
was in line with the Bangladesh Department of Environment guidelines and standards for air pollution. The
limits/standards applicable to the possible air pollutants were determined from review of existing regulations,
standards and codes, especially DoE Ambient Air Quality Standards. Sampling and measurements of the
chemical constituents of atmospheric pollutants at each sampling station were measured in-situ using gas
monitors (sensitive analogue and digital gas monitors).The duration of the monitoring exercise was of 3 days.

Fig 1: Plant- 2, Meghna Ghat

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Methodology:
Flue gases enter the system through the nozzle fitted at the tip of the sampling probe, pass through the filter
thimble, where PM is removed and filtered gas reach to the sampling condenser assembly in the cold box
section of the instrument panel. Here the gas stream is split into two portions. One portion passes at low flow
rate (0.3 ~ 3 LPM) through a train of impingers loaded with suitable reagents to absorb gaseous pollutants,
relevant to the emission source while the remaining gas stream bubbles through a distilled water impringer
followed by silica gel. On passing through the cold box section, the flue gases cool down, where moisture or
condensable present are removed and gaseous pollutants get absorbed in reagent kept in the impringer.
Particulates free cool gases then pass through the rotameter for measurement of flow rate and are
subsequently exhausted into the atmosphere through the vacuum pump.

Provision has been made to accurately measure the pressure drop across the thimble and sampling train
assembly using vacuum gauges. Similarly the temperature is measured by a pyrometer. With this data correct
flue gas sample can be calculated normalized as per gas laws. Change in the weight of thimble gives the
quantity of dust present in the extracted flue gas sample, while a product of the sampling rate and time give
volume of sampled gas for calculation of particulate concentration.

The Barnauli Equation to calculate stack gas velocity is as follows-

V= K√2𝐺∆𝐻𝐷𝑚/𝐷𝑠

Where, V= Velocity
K= Pitot calibration constant
G= Gravitational constant equal to 9.81 m/sec2
∆H= Different pressure in mm of Wc
Dm= Density of water 1000 Kg/m3
Ds= Stack gas density in Kg/m3

The KANE905 analyser operates on all boiler types and can display 8 parameters simultaneously showing
measurements and calculations of boiler efficiency and pollution. The KANE905 measures O2, flue and net
temperature and calculates CO2, boiler efficiency, excess air and losses. CO is measured with a hydrogen
compensated sensor for increased accuracy. It also measures CO and calculates CO/CO2 ratio - ‘The Poison
Index’ - to give complete readings for effective boiler analysis and safety. The KANE905 measures NO and
calculates NOx. Optionally, it can also measure either NO2 or SO2 and can be fitted with CO and NO sensors
with different measuring ranges.

Fig 2: Ecotech Ess 100 Stack Sampler

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Mill Emission Monitoring:
Ecotech Stack Sampler model ESS- 100 is used for the detection of suspended particulate matter. The
range of detection is between is 0.001-2000μg/m3. ESS 100 is portable system with light weight suction pump
and with digital pyrometer and digital differential meter. Both these feature are prominent and help operator
in quick monitoring and shifting of instrument from one stack to another stack. Measurement are done for
differential pressure using S-Type Pitot Tube and digital differential meter. Light weight leak proof tubing have
been provided in system. A portable detachable impringer box help user to use this instrument with greater
visibility of impringer connection and bubbling of flue gases in reagents. The impringer tray is made up of rust
free SS which ensure that look of system remain all time new. High quality electronic liquid crystal stop watch
has been fitted in the instrument where display is visible even at high ambient temperature around hot stacks.
Cabinet of ESS 100 is powder coated black color with high quality leak proof push fitting for Thermocouple and
Pitot tube. Two dial type vacuum gauges are provided for online monitoring of pressure drop in gas stream
and particulate stream separately. In the bottom of main panel a threaded socket has been provided for its
easy mounting on the foldable tripod stand for bringing instrument at chest level for better visibility. Thimble
holder nozzle and probe pipe has been fitted with Viton O ring for leak proof connection. Thimble holder can
accommodate CFT and GFT and Silica thimble with no extra efforts. Probe pipe has direction indicator cum
handle for showing direction of the nozzle while sampling.

Fig 3: KANE905 Analyzer

Generator Emission Monitoring:

KANE905 Hand-held Combustion Analyzer is a flue gas analyzer which is ideal for installing,
commissioning and servicing oil, gas and biomass appliances found in commercial applications. It calculates
oxygen (O2) from 0 to 21%, carbon monoxide (CO) from 0 to 4000ppm (hydrogen-compensated), CO2,
CO/CO2 ratio, NOx, NO2, SO2. It measures inlet, flue gas and differential temperature levels and differential
pressure. It has optional wireless module that allows the analyzer to wirelessly send data to a PC.

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 Fig 4 & 5: SPM sampling & monitoring at Holcim Cement Plant, Meghna Ghat.

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 Result of Mill Emission Analysis

Sl Location Date of Duration SPM Velocity Flow rate

Experiment (min) (Concentration
No. in mg/Normal
(Meter/sec) (Normal
cubic meter) cubic meter/
sec)
1 Mill- 2, 562, FN1 Bag 03/07/2019 22 173 16.69 20.0
Filter (**B)
2 Mill- 3, 563, FN1 Bag 03/07/2019 29 228 12.13 21.5
Filter (**B)
3 Mill- 3, 563, FN2 Bag 03/07/2019 25 186 14.27 19.3
Filter (Separator)
(**B)
4 Mill- 4, 565, FN1 Bag 04/07/2019 22 133 21.21 19.0
Filter (**B)
5 Mill- 5, 565, FN1 Bag 04/07/2019 25 202 20.66 19.0
Filter (**B)
6 Mill- 7, 567, FN2 Bag 02/07/2019 30 194 23.90 16.0
Filter (*A)
7 Mill- 7, 567, FN1 Bag 02/07/2019 28 182 27.40 18.9
Filter (Separator) (*A)
DoE limit for SPM in cement industry Category A : Above 1000 ton= 200 mg/Nm3
according to daily production capacity Category B : 200 ~ 1000 ton= 300 mg/Nm3
Category C : Up to 200 ton= 400 mg/Nm3

Note:
SPM = Suspended Particular Matter, DoE = Department of Environment
*** Serial number 1, 2, 3, 4, 5 complies with Category B; Number 6 & 7 complies with Category A.

N.B. Mill- 1, 561, FN1 Bag Filter Mill was out of order at the time of monitoring.

Comment: From the above study, it is concluded that all the concentrations of suspended particulate matter
recorded at the Holcim Cement Plant, Meghna Ghat were within stipulated standard and therefore safe
according to DoE, Bangladesh standards.

Description of the Diesel Generators:

Generator 1

Key information
Manufacturer Caterpillar
Model Number 700
Location Plant 2
Serial Number CAT00000HC6C00681
Year of Manufacture 2009

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 Generator 2

Key information
Manufacturer Stamford
Frame/Core Hc1634j1
Location Plant 1
Serial Number A16J421123
Year of Manufacture -

Generator 3

Key information
Manufacturer Caterpillar
Model Number 700
Location Plant 1
Serial Number CAT00000TC6C00684
Year of Manufacture 2009

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 Fig 6 & 7: Stack Emission Monitoring of generators at Holcim Cement Plant, Meghna Ghat.

Result of Generator Air Emission Monitoring

SN Description NOX SO2 CO CO2 O2

Portable Portable Portable Portable Portable
01 Method of Analysis Stack Stack Stack Stack Stack
Analyzer Analyzer Analyzer Analyzer Analyzer
02 Unit mg/Nm3 mg/Nm3 mg/Nm3 V/v V/v
03 Bangladesh (DoE) Standard **NF NYS NYS NYS NYS
International Standard (World
04 ***1460 ***1170 NF NF NF
Bank Standard)
05 Generator#1 (Plant 2) 98 0 545 8.27% 10.2%

06 Generator#2 (Plant 1) 54 26 482 5.17% 16.8%

07 Generator#3 (Plant 1) 19 22 479 2.19% 18.2%

Note:
1. NOX - Oxides of Nitrogen.
2. SO2 - Sulphur Di-Oxide.
3. CO – Carbon Mono-Oxide.
4. NYS – Not Yet Set, NF – not found, N/A- No Emission Guideline
5. V/v – Volume / volume
6. DoE – Department of Environment
7. mg/Nm3 – milligram per cubic meter at 1 atmospheric pressure and 00C temperature

**Not found for liquid fuel based power plants

*** For 3 MWth-50 MWth (heat input capacity) liquid fuel based small combustion engine limit for NOx
emission limit is 712 ppm (if bore size diameter is < 400 mm) [Source: IFC General EHS Guideline, 2007]

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 Graphical Presentation of NOx, SO2 and CO
600.00 concentrations
545
500.00 482 479
Concentration in mg/Nm3

400.00

300.00

200.00
98
100.00 54
26 19 22
0
0.00
GENERATOR 1 GENERATOR 2 GENERATOR 3

NOX SO2 CO

Comment: Stack emission from the generators that are run by natural gas has been analyzed to evaluate
NOx, SO2, CO & CO2 emission level. It was observed that the emission of NOx and SO 2 to environment were
within the standard limits as per Bangladesh and International Standard. However it is recommended that gas
mask should be provided to related workers to avoid occupational health hazard.

_________________________ _______________________ __________________________

Md. Faisal Bin Mahmud Md. Saiful Islam Muhammad Zulfiker Noman
Sr. Chemist Sr. Manager (Engineering) Chief Operating Officer.

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