STACK

EMISSION
ANALYSIS
REPORT

LafargeHolcim Bangladesh Ltd. (LHBL)

Meghnaghat Plant

Technical Support From

Adroit Environment Consultants Ltd.
House # 01, Road # 16 Sector # 07, Uttara
Dhaka-1230, Bangladesh.
Tel: +8802-48950261-62, Phone: +880 1711-565728
E-mail: aecldhaka@gmail.com
Website: www.aecl-bd.org
 Point Source Emission Analysis Report of LafargeHolcim Bangladesh Ltd. (LHBL)

STACK/POINT SOURCE EMISSION QUALITY ANALYSIS REPORT

Enterprise : LafargeHolcim Bangladesh Ltd. (LHBL)

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 : AECL Monitoring team
Sampling date : 6th to 8th June, 2022
Reporting date : 29th June, 2022

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Table of Contents

STACK/POINT SOURCE EMISSION QUALITY ANALYSIS REPORT..........................................................................2

1.0 Introduction.....................................................................................................................................................4
2.0 Scope of Work..................................................................................................................................................4
3.0 Sampling Details..............................................................................................................................................4
4.0 Methodology...................................................................................................................................................5
4.1 Mill Emission Monitoring.............................................................................................................................6
4.2 Generator Emission Monitoring...................................................................................................................7
5.0 Description of the Diesel Generators.............................................................................................................11

Table of Tables
Table 1: Result of Mill Emission Analysis..............................................................................................................10
Table 2: Result of Generator Air Emission Monitoring.........................................................................................12

Table of Figures
Figure 1: Plant- 2, Meghna Ghat............................................................................................................................5
Figure 2: Ecotech Ess 100 Stack Sampler...............................................................................................................6
Figure 3: KANE905 Analyzer...................................................................................................................................7
Figure 4: Monitoring Photographs at LafargeHolcim Cement Plant, Meghna Ghat...............................................9

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1.0 Introduction
LafargeHolcim Bangladesh Ltd. (LHBL)is a frontline cement producer in Bangladesh. Operating for almost two
decades, it has made about US$ 500 million investment in building one fully integrated cement plant and three
grinding plants the largest foreign direct investment in the sector. It is a joint venture of Holcim and Cementos
Molins. With state-of-the art technology and well-groomed staff, the company produces world class cement to
meet the growing demand generated by massive infrastructure development programs and improved socio-
economic conditions.

HBL has three grinding plants. Among them two plants namely Meghnaghat 1 & Meghnaghat 2 are located on
the bank of Meghna River at Sonargaon, Narayanganj District which is about 30km from Dhaka. All the mills
are closed circuit ball mills. Being a grinding plant (cement) heavy emission from the mills is a major concern.
To measure the emission level and to check out the compliance status with DoE Bangladesh, HBL has
appointed AECL, a leading environmental consultancy firm in Bangladesh to conduct the said analysis.

2.0 Scope of Work

As per the purchase order no. 3960010819, dated 10/02/2021 stack emission analysis of 7 mills and 3
generators shall have to be done accordingly in the Meghnaghat plant.

3.0 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.

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Figure 1: Plant- 2, Meghna Ghat

4.0 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

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K= Pitot calibration constant

G= Gravitational constant equal to 9.81 m/sec 2
∆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.

Figure 2: Ecotech Ess 100 Stack Sampler

4.1 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 features are prominent and help operator in quick
monitoring and shifting of instrument from one stack to another stack. Measurement is done for differential
pressure using S-Type Pitot Tube and digital differential meter. Light weight leak proof tubing has 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

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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.

Figure 3: KANE905 Analyzer

4.2 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), CO 2, 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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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

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Mill- 7, 567, FN1 Bag Filter (Separator) Generator 1

Generator 2 Generator 3

Figure 4: Monitoring Photographs at LafargeHolcim Cement Plant, Meghna Ghat

Table 1: Result of Mill Emission Analysis

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Sl Location Duration SPM Velocity Flow rate

No. (min) (Concentrati (Meter/sec) (Normal cubic
on in meter/ sec)
mg/Normal
cubic meter)
1 Mill- 2, 562, FN1 Bag Filter (**B) 25 159 23.2 16.3
2 Mill- 3, 563, FN1 Bag Filter (**B) 25 286 18.4 19.4
3 Mill- 3, 563, FN2 Bag Filter (Separator) 25 194 14.8 22.8
(**B)
4 Mill- 4, 565, FN1 Bag Filter (**B) 25 142 18.4 19.3
5 Mill- 5, 565, FN1 Bag Filter (**B) 25 283 31.8 21.8
6 Mill- 7, 567, FN2 Bag Filter (*A) 25 191 21.6 12.3
7 Mill- 7, 567, FN1 Bag Filter (Separator) 25 149 24.6 17.2
(*A)
DoE limit for SPM in cement industry according Category A: Above 1000 ton= 200 mg/Nm 3
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.

Remarks: From the above study, it is discernible that all the sampling points comply to the corresponding
maximum allowable limits set by the DoE, Bangladesh.

5.0 Description of the Diesel Generators

Generator 1

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

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 2
Serial Number CAT00000HC6C00681
Year of Manufacture 2009

Table 2: Result of Generator Air Emission Monitoring

SN Description NOX SO2 CO CO2 O2

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Method of Analysis Portable Portable Portable Portable Portable

Stack Stack Stack Stack Stack
Analyzer Analyzer Analyzer Analyzer Analyzer
Unit mg/Nm3 mg/Nm3 mg/Nm3 V/v V/v
01 Bangladesh (DoE) Standard **NF NYS NYS NYS NYS
02 International Standard (World ***1460 ***1170 NF NF NF
Bank Standard)
03 Generator#1 (Plant 2) 9 0 396 2.56% 16.3%
04 Generator#2 (Plant 1) 12 66 1181 2.01% 17.3%
05 Generator#3 (Plant 1) 8 43 291 2.33% 13.7%

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 0 0C 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]

Comment: Stack emission from the generators that are run by diesel has been analyzed to evaluate NOx, SO 2,
CO & CO2 emission level. It was observed that the emission of NOx and SO 2 to environment were within the
standard limits as per IFC Standard.

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