FLUE GAS ANALYSIS at 50% excess air - (Percentage)

FUEL - Teak 43% moisture, Ash= 0.51, S= 0.025

BOILER - SD 8000/1200
Furnace Arrangement - Cyclone
____________________________________________________________
Gas By volume By mass
Constituent Wet Dry Wet Dry
____________________________________________________________
Ar 0.732 0.931 1.048 1.216
CO 0.001 0.001 0.001 0.001
CO2 10.744 13.669 16.947 19.665
HCl 0.002 0.002 0.002 0.002
H2O 21.401 0.000 13.818 0.000
N2 61.610 78.385 61.859 71.777
O2 5.508 7.007 6.317 7.330
SO2 0.003 0.004 0.008 0.009
____________________________________________________________
Notes...
Fyrite measures the volume dry properties
Orsat gives measure of the volume dry properties
ie. Orsat CO2 = 13.67 % volume dry
There are no known limits on the use of this fuel

Continuous Emissions Monitoring

Net heat in 6.5 MWth
National Environmental Management:Air Quality Act, 2004
(South Africa ACT NO. 39 of 2004)
Heat input < 50 MWth using Lower CV NOT Required

Various flue gas properties...

Gas constant 297.996 J/kg K
Gas molecular weight 27.901

Specific heat capacity - initial 914.6°C 1.360 kJ/kg K

Specific heat capacity - flue exit 866.5°C 1.352 kJ/kg K
Specific heat capacity - wrapper exit 765.0°C 1.331 kJ/kg K
Specific heat capacity - Inlet 1st pass 765.0°C 1.331 kJ/kg K
Specific heat capacity - Exit 1st pass 332.3°C 1.198 kJ/kg K
Specific heat capacity - Inlet 2nd pass 332.3°C 1.198 kJ/kg K
Specific heat capacity - Exit 2nd pass 223.3°C 1.163 kJ/kg K
Specific heat capacity - ID fan 223.3°C 1.163 kJ/kg K

Density - initial 914.6°C 0.269 kg/m³

Density - flue exit 866.5°C 0.280 kg/m³
Density - wrapper exit 765.0°C 0.308 kg/m³
Density - Inlet 1st pass 765.0°C 0.308 kg/m³
Density - Exit 1st pass 332.3°C 0.528 kg/m³
Density - Inlet 2nd pass 332.3°C 0.528 kg/m³
Density - Exit 2nd pass 223.3°C 0.644 kg/m³
Density - ID fan 223.3°C 0.644 kg/m³

Viscosity - initial 914.6°C 48.457 µPas

Viscosity - flue exit 866.5°C 46.865 µPas
Viscosity - wrapper exit 765.0°C 43.147 µPas
Viscosity - Inlet 1st pass 765.0°C 43.147 µPas
Viscosity - Exit 1st pass 332.3°C 28.132 µPas
Viscosity - Inlet 2nd pass 332.3°C 28.132 µPas
Viscosity - Exit 2nd pass 223.3°C 24.028 µPas
Viscosity - ID fan 223.3°C 24.028 µPas

Process Flows
Fuel mass flow 2411.7 kg/hour
Fuel (8760 hours) 21126.4 ton/year
Steam rated mass flow 8400.0 kg/hour
Steam operating mass flow 7083.2 kg/hour
Steam (8760 hours) 62049.2 ton/year
Products (dry) 12898.8 kg/hour
Products (wet) 14967.0 kg/hour
Products of combustion (dry) 9450.7 Nm³/hour
Products of combustion (wet) 12023.9 Nm³/hour
Actual Products - 223.3°C 6.1 Am³/s

Ash (bottom) 8.3 kg/hour

Ash (8760 hours) 72.5 ton/year

Carbon dioxide in flue gases 211.0 g/Nm³

Carbon dioxide in flue gases 109.1 g/am³
Carbon dioxide in flue gases 704.6 g/s
Carbon dioxide in flue gases - 7083 kg/hr 358.1 kg/ton steam
Carbon dioxide in flue gases - 5.5 MW 128.8 g/MJ
Carbon dioxide in flue gases - 35.8 g/kWh
Carbon dioxide in flue gases - 1051.8 g/kg of fuel
Carbon dioxide in flue gases (8760 hours) 22219.7 ton/year

Carbon footprint 5592 ton/year

Dissociation at 914.5 °C 0.006 %

Dissociation at 765 °C 0.006 %
Dissociation at 223.3 °C 0.006 %

Carbon monoxide in flue gases 8.2 mg/Nm³

Carbon monoxide in flue gases 4.2 mg/am³
Carbon monoxide in flue gases 27.4 mg/s
Carbon monoxide in flue gases - EPA 566.4 mg/s
Carbon monoxide in flue gases - 7083 kg/hr 13.9 g/ton steam
Carbon monoxide in flue gases - 5.5 MW 5.0 mg/MJ
Carbon monoxide in flue gases 1.4 mg/kWh
Carbon monoxide in flue gases 40.9 mg/kg of fuel
Carbon Monoxide in flue gases 8.3 ppmvd
Carbon Monoxide Anticipated in the Flue Gas 6.6 ppmmw
Carbon Monoxide (wet) 6.6 ppm
Carbon monoxide in flue gases (8760 hours) 863.2 kg/year
CO is below 0.1% limit set in BS 845.
CO measurements are NOT required during performance testing.

CO Limits
Canada Threshold limit, O. Reg 127/01 20000 kg/year
CFR Vol. 76, No. 247, Dec 23, 2011 - CO 58.0 ppmvd
CFR Vol. 76 - CO, CEMS Alternative 1400.0 ppmvd

Grits - EPA released from the boiler 1.2 g/s

Grits - EPA released to atmosphere 1.2 g/s
Grits in the boiler flue gas 348.5 mg/Nm³
Grits in the boiler flue gas 180.2 mg/am³
Grits in the boiler flue gas 1.2 g/s
Grits in the boiler flue gas - 7083 kg/hr 591.7 mg/ton steam
Grits in the boiler flue gas - 5.5 MW 766.4 g/MW
Grits from the boiler (8760 hours) 36.7 ton/year
Grits - after grit collector 250.0 mg/Nm³
Grits - after grit collector 129.3 mg/am³
Grits - after grit collector 835.0 mg/s
Grits - after grit collector 7083 kg/hr 424.4 g/ton steam
Grits - after grit collector - 5.5 MW 152.7 mg/MJ
Grits - after grit collector 42.4 mg/kWh
Grits - after typical grit collector 1246.4 mg/kg of fuel
Grits after the collector (8760 hours) 26.3 ton/year
Grits - collected 329.1 mg/s
Grits - collected (8760 hours) 10.4 ton/year
Grit collector input performance 90.0 %
Grit collector calculated performance 28.3 %

NPI - PM 10 uncontrolled 2170.5 mg/s

ESP - from 2.2 mg/s
to 217.1 mg/s
Fabric Filter - from 2.2 mg/s
to 217.1 mg/s
Single high throughput cyclone - from 1302.3 mg/s
to 1953.5 mg/s
Single conventional cyclone - from 217.1 mg/s
to 1302.3 mg/s
Single high efficiency cyclone - from 108.5 mg/s
to 651.2 mg/s
Multi cyclones - from 162.8 mg/s
to 434.1 mg/s
Venturi scrubber - from 21.7 mg/s
to 651.2 mg/s
Condensation scrubber - from 2.2 mg/s
to 21.7 mg/s
Impingement scrubber - from 21.7 mg/s
to 1085.3 mg/s
Orifice scrubber - from 21.7 mg/s
to 434.1 mg/s

PM Limits
Canada Threshold limit, O. Reg 127/01 20000 kg/year
CFR Vol. 76, Dec 23, 2011 - Filterable PM 169.9 mg/s

NOx estimates - Standard (refer J.D Barnes) for oil/gas...

NOx volume flow wet (O2 = 7.0%)- measured 376.4 mg/Nm³
NOx volume flow dry (O2 = 7.0%) 478.9 mg/Nm³
NOx volume flow dry (O2 = 6%) - report as NO2 513.6 mg/Nm³
NOx volume flow wet 194.6 mg/am³
NOx volume flow dry (O2 = 11%) - Europe 341.3 mg/Nm³
NOx mass flow 4525.9 g/hour
NOx mass flow 1.3 g/s
EPA NOx (as NO2) 0.1 g/s
EPA NOx (as NO) 0.0 g/s
NOx mass (specific) - 7083 kg/hr 639.0 g/ton steam
NOx mass (specific) 229.9 mg/MJ
NOx mass (specific) 63.9 mg/kWh
NOx mass flow 1876.7 mg/kg of fuel
NOx mass (O2 = 7.0%) 233.4 ppmvd
NOx mass (O2 = 6%) - report as NO2 250.3 ppmvd
NOx - Anticipated in the flue gas (O2 = 7.0%) 183.4 ppmvw
NOx (wet) 302.4 ppm
NOx mass (O2 = 11%) - Europe 166.3 ppmvd
NOx mass flow (8760 hours) 39.6 ton/annum
NOx as fraction of exhaust gas 0.233 % vol x 1E3
NOx as NO2 0.5345 lb/MMBTU

European NOx limits

Level 1 - less than 260 mg/kWh
Level 2 200 mg/kWh
Level 3 150 mg/kWh
Level 4 100 mg/kWh
Level 5 70 mg/kWh

NOx abatement - typical results

NPI - NOx uncontrolled 998.2 mg/s
SCR - from 99.8 mg/s
to 299.5 mg/s
SNCR - from 99.8 mg/s
to 299.5 mg/s
SNCR with LNB - from 249.5 mg/s
to 349.4 mg/s
LEA - from 559.0 mg/s
to 898.4 mg/s
LNB (Air staged) - from 648.8 mg/s
to 748.6 mg/s
LNB (Flue gas recirculation) - from 798.5 mg/s
to 998.2 mg/s
LNB (fuel staged) - from 399.3 mg/s
to 499.1 mg/s

Total installed capital cost estimate

Standard Burner 179513 1990 CDN
Total NOx control installed 2717627 April 2013 USD
Annual Operating Costs...
Maintenance - Standard 4937 April 2013 USD
Maintenance - None 5963120 April 2013 USD
Maintenance - None 10167 April 2013 USD
ref. EPA-453/R-93-034 for fired heaters

Oxygen standard reference 6.0 %

Oxygen volume 7.0 % volume dry
Oxygen volume 5.5 % volume wet
Excess air 50.0 %

Sulphur dioxide in flue gases 98.9 mg/Nm³

Sulphur dioxide in flue gases 51.2 mg/am³
Sulphur dioxide in flue gases 0.3 g/s
Sulphur dioxide in flue gases - EPA 0.1 g/s
Sulphur dioxide in flue gases - 7083 kg/hr 168.0 g/ton steam
Sulphur dioxide in flue gases - 5.5 MW 60.4 mg/MJ
Sulphur dioxide in flue gases 16.8 mg/kWh
Sulphur dioxide in flue gases 0.5 g/kg of fuel
Sulphur dioxide in flue gases 44.0 ppmvd
Sulphur dioxide anticipated in the Flue Gas 34.6 ppmvw
Sulphur dioxide (wet) 79.5 ppm
Sulphur dioxide in flue gases (8760 hours) 10.4 ton/year
Typical conversion to SO2 95% sulphur
Typical conversion to SO3 1- 5% sulphur
Typical conversion to sulphate particulate 1- 3% sulphur

NPI - Sulphur dioxide uncontrolled 2.8 mg/s

Wet scrubber - Lowest achieved 0.1 mg/s
to upper value expected 0.3 mg/s
Semi-dry scrubber - Lowest achieved 0.3 mg/s
to upper value expected 0.6 mg/s
Dry scrubber - Lowest achieved 0.6 mg/s
to upper value expected 1.4 mg/s

Dry Sorbent Injection - SO2 abatement

Dry alkaline Sorbent chemical use 3.41 kg TRONA/kg SO2
Sodium sesqui-Carbonate required 35.5 ton/year
Cost delivered PPC, Dec. 2010 181.91 USD/MT
Sorbent cost 6466.0 USD/year
SO2 reduction 85.0 %
Sulphur Dioxide (85% reduction) in flue gas 5.2 ppmvw
Fly ash 30.0 ton/annum
Minimum flue gas temperature 200 °C
Trona gas exhaust analysis
Flue gas mass flow 14967 kg/hour
Argon (1.0) 1.048 % mass
Carbon monoxide (0.0) 0.001 % mass
Carbon dioxide (16.9) 16.954 % mass
Hydrogen Chloride (0.0) 0.000 % mass
Moisture (13.8) 13.823 % mass
Nitrogen (61.9) 61.858 % mass
Oxygen (6.3) 6.315 % mass
Sulphur Dioxide (0.0) 0.001 % mass
OR
Dry alkaline Sorbent chemical use 3.80 kg NaHCO3/kg SO2
Sodium sesqui-Carbonate required 35.5 ton/year
Cost delivered Solvay, 2002 181.91 USD/MT
Sorbent cost 6466.0 USD/year
Sulphur Dioxide (90% reduction) in flue gas 3.5 ppmvw

Moisture dew point in the hot gas 103.7 °C

Sulfurous acid (SO2) dew point estimate 56.9 °C

Sulphuric Acid Dew Point

_____________________________________________
Percentage SO3 Sulphuric acid dew point
% °C
_____________________________________________
1.0 114.2
1.5 117.5
2.0 119.9
2.5 121.8
 3.0 123.4
3.5 124.7
4.0 125.9
4.5 126.9
5.0 127.8
_____________________________________________
Sulphur dioxide 0.0 % vol
Steam plant calculations manual by Ganapathy p94 table 2.9...
Hydrochloric acid dew point estimate 57.7 °C
Reference: Steam plant calculations manual by Ganapathy p94 table 2.9...
Dew point temperatures HBr, HNO3, HCl and sulfurous acids are within 6 °C
Dew point temperature of H2SO4 is within 9 °C

Environmental Protection Agency - EPA A-42 uncontrolled emissions

EPA A42 chapter Section 1.6
EPA boiler class Industrial
EPA heat rating 26.446 MM BTU/hour
Annual emission period 8760.0 hours/year

Carbon monoxide CO 566.4 mg/s 17.9 ton/year

Carbon dioxide CO2 649.7 g/s 20487.7 ton/year
Hydrogen chloride HCl 63.3 mg/s 1996.2 kg/year
Nitrogen oxides NOx 139.9 mg/s 4412.7 kg/year
Particulate matter PM - filterable 1.1 g/s 34.7 ton/year
Particulate matter CPM - condensable 56.6 mg/s 1786.1 kg/year
Particulate matter 10 µ filterable 989.5 mg/s 31.2 ton/year
Particulate matter 2.5 µ filterable 835.6 mg/s 26.4 ton/year
Sulphur dioxide SO2 83.3 mg/s 2626.6 kg/year
Sulphur trioxide -1 ND -1 NA
Sulphate particulate -1 ND -1 NA
Sulphur oxides SOx 83.3 mg/s 2626.6 kg/year
Sulphur in the ash -1 ND -1 NA
Total organic compounds TOC 129.9 mg/s 4097.5 kg/year
VOC non methane -1 ND -1 NA
Methane 70.0 mg/s 2206.4 kg/year
2,3,7,8 Tetrachlorodibenzo-p-dioxins 28.7 pg/s 0.9 mg/year
Tetrachlorodibenzo-p-dioxins 1.6 ng/s 49.4 mg/year
2,3,7,8 Tetrachlorodibenzo-p-furans 299.8 pg/s 9.5 mg/year
Tetrachlorodibenzo-p-furans 2.5 ng/s 78.8 mg/year
Metals...
Antimony 26.3 µg/s 830.0 g/year
Arsenic 73.3 µg/s 2.3 kg/year
Barium 13.7 µg/s 430.8 g/year
Cadmium 13.7 µg/s 430.8 g/year
Chromium total 70.0 µg/s 2.2 kg/year
Chromium hexavalent 11.7 µg/s 367.7 g/year
Cobalt 21.7 µg/s 682.9 g/year
Copper 163.2 µg/s 5.1 kg/year
Iron 3.3 mg/s 104.0 kg/year
Lead 159.9 µg/s 5.0 kg/year
Manganese 5.3 mg/s 168.1 kg/year
Mercury 11.7 µg/s 367.7 g/year
Molybdenum 7.0 µg/s 220.6 g/year
Nickel 109.9 µg/s 3.5 kg/year
Phosphorous 90.0 µg/s 2.8 kg/year
Potasium 129.9 mg/s 4097.5 kg/year
Selenium 9.3 µg/s 294.2 g/year
Silver 5.7 mg/s 178.6 kg/year
Sodium 1.2 mg/s 37.8 kg/year
Strontium 33.3 µg/s 1.1 kg/year
Tin 76.6 µg/s 2.4 kg/year
Titanium 66.6 µg/s 2.1 kg/year
Vanadium 3.3 µg/s 103.0 g/year
Yttrium 999.5 ng/s 31.5 g/year
Zinc 1.4 mg/s 44.1 kg/year

Environmental Protection Agency - EPA A-42 controlled emissions

NOx (NO2) - Standard 139.9 mg/s 4412.7 kg/year
NOx (NO) - Standard 0.0 pg/s 0.0 mg/year

Hydrogen Chloride Limits

Canada Threshold limit, O. Reg 127/01 - HCl 10000.0 kg/year
CFR Vol. 76, No. 247, Dec 23, 2011 - HCl 73.3 mg/s

Mercury Limits
Canada Threshold limit, O. Reg 127/01 - Hg 5.0 kg/year
CFR Vol. 76, No. 247, Dec 23, 2011 - Hg 2.9 µg/s

______________________________________________________________________
NOTE: The above are estimates, and calculated values.
The values measured in practice may vary significantly.
The above is not a performance guarantee.
The above is not contractually binding.

Normal pressure is 101.325 kPa.

Normal temperature is 0 °C.
Standard pressure is 101.325 kPa.
Standard temperature is 15 °C.

NOx = NO and NO2

SOx = SO2 and SO3, excluding sulphate particualtes
Most common flue gas analysers do not test for N2O

ND = no data
NA = not applicable

ng = nanograms - 1/1000,000,000 grams

pg = picogram - 1/1,000,000,000,000 grams

Check with Tanzania for specific statutory limits.