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

FUEL - Teak 43% moisture, Ash= 0.537, S= 0.026

BOILER - SD 8000/1200
Furnace Arrangement - Cyclone
____________________________________________________________
Gas By volume By mass
Constituent Wet Dry Wet Dry
____________________________________________________________
Ar 0.754 0.931 1.068 1.216
CO 0.001 0.001 0.001 0.001
CO2 11.059 13.670 17.265 19.665
HCl 0.002 0.002 0.002 0.002
H2O 19.099 0.000 12.206 0.000
N2 63.414 78.385 63.016 71.777
O2 5.669 7.007 6.435 7.329
SO2 0.004 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 294.935 J/kg K
Gas molecular weight 28.190

Specific heat capacity - initial 928.4°C 1.342 kJ/kg K

Specific heat capacity - flue exit 865.4°C 1.333 kJ/kg K
Specific heat capacity - wrapper exit 796.3°C 1.320 kJ/kg K
Specific heat capacity - Inlet 1st pass 796.3°C 1.320 kJ/kg K
Specific heat capacity - Exit 1st pass 335.4°C 1.183 kJ/kg K
Specific heat capacity - Inlet 2nd pass 335.4°C 1.183 kJ/kg K
Specific heat capacity - Exit 2nd pass 223.7°C 1.148 kJ/kg K
Specific heat capacity - ID fan 223.7°C 1.148 kJ/kg K

Density - initial 928.4°C 0.269 kg/m³

Density - flue exit 865.4°C 0.284 kg/m³
Density - wrapper exit 796.3°C 0.302 kg/m³
Density - Inlet 1st pass 796.3°C 0.302 kg/m³
Density - Exit 1st pass 335.4°C 0.531 kg/m³
Density - Inlet 2nd pass 335.4°C 0.531 kg/m³
Density - Exit 2nd pass 223.7°C 0.650 kg/m³
Density - ID fan 223.7°C 0.650 kg/m³

Viscosity - initial 928.4°C 48.991 µPas

Viscosity - flue exit 865.4°C 46.959 µPas
Viscosity - wrapper exit 796.3°C 44.412 µPas
Viscosity - Inlet 1st pass 796.3°C 44.412 µPas
Viscosity - Exit 1st pass 335.4°C 28.415 µPas
Viscosity - Inlet 2nd pass 335.4°C 28.415 µPas
Viscosity - Exit 2nd pass 223.7°C 24.210 µPas
Viscosity - ID fan 223.7°C 24.210 µPas

Process Flows
Fuel mass flow 2251.8 kg/hour
Fuel (8760 hours) 19725.9 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) 12672.2 kg/hour
Products (wet) 14433.9 kg/hour
Products of combustion (dry) 9284.6 Nm³/hour
Products of combustion (wet) 11476.5 Nm³/hour
Actual Products - 223.7°C 5.8 Am³/s

Ash (bottom) 8.1 kg/hour

Ash (8760 hours) 71.3 ton/year

Carbon dioxide in flue gases 217.1 g/Nm³

Carbon dioxide in flue gases 112.2 g/am³
Carbon dioxide in flue gases 692.2 g/s
Carbon dioxide in flue gases - 7083 kg/hr 351.8 kg/ton steam
Carbon dioxide in flue gases - 5.5 MW 125.2 g/MJ
Carbon dioxide in flue gases - 34.8 g/kWh
Carbon dioxide in flue gases - 1106.7 g/kg of fuel
Carbon dioxide in flue gases (8760 hours) 21829.7 ton/year

Carbon footprint 5497 ton/year

Dissociation at 928.4 °C 0.006 %

Dissociation at 796.3 °C 0.006 %
Dissociation at 223.6 °C 0.006 %

Carbon monoxide in flue gases 8.4 mg/Nm³

Carbon monoxide in flue gases 4.4 mg/am³
Carbon monoxide in flue gases 26.9 mg/s
Carbon monoxide in flue gases - EPA 556.8 mg/s
Carbon monoxide in flue gases - 7083 kg/hr 13.7 g/ton steam
Carbon monoxide in flue gases - 5.5 MW 4.9 mg/MJ
Carbon monoxide in flue gases 1.4 mg/kWh
Carbon monoxide in flue gases 43.0 mg/kg of
fuel
Carbon Monoxide in flue gases 8.3 ppmvd
Carbon Monoxide Anticipated in the Flue Gas 6.8 ppmmw
Carbon Monoxide (wet) 6.7 ppm
Carbon monoxide in flue gases (8760 hours) 848.1 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 1.1 g/s
Grits - EPA released to atmosphere 1.1 g/s
Grits in the boiler flue gas 358.9 mg/Nm³
Grits in the boiler flue gas 185.4 mg/am³
Grits in the boiler flue gas 1.1 g/s
Grits in the boiler flue gas - 7083 kg/hr 581.5 mg/ton steam
Grits in the boiler flue gas - 5.5 MW 744.8 g/MW
Grits from the boiler (8760 hours) 36.1 ton/year
Grits - after grit collector 250.0 mg/Nm³
Grits - after grit collector 129.2 mg/am³
Grits - after grit collector 797.0 mg/s
Grits - after grit collector 7083 kg/hr 405.1 g/ton steam
Grits - after grit collector - 5.5 MW 144.1 mg/MJ
Grits - after grit collector 40.0 mg/kWh
Grits - after typical grit collector 1274.1 mg/kg of
fuel
Grits after the collector (8760 hours) 25.1 ton/year
Grits - collected 347.2 mg/s
Grits - collected (8760 hours) 10.9 ton/year
Grit collector input performance 90.0 %
Grit collector calculated performance 30.3 %

NPI - PM 10 uncontrolled 2026.2 mg/s

ESP - from 2.0 mg/s
to 202.6 mg/s
Fabric Filter - from 2.0 mg/s
to 202.6 mg/s
Single high throughput cyclone - from 1215.7 mg/s
to 1823.5 mg/s
Single conventional cyclone - from 202.6 mg/s
to 1215.7 mg/s
Single high efficiency cyclone - from 101.3 mg/s
to 607.8 mg/s
Multi cyclones - from 152.0 mg/s
to 405.2 mg/s
Venturi scrubber - from 20.3 mg/s
to 607.8 mg/s
Condensation scrubber - from 2.0 mg/s
to 20.3 mg/s
Impingement scrubber - from 20.3 mg/s
to 1013.1 mg/s
Orifice scrubber - from 20.3 mg/s
to 405.2 mg/s

PM Limits
Canada Threshold limit, O. Reg 127/01 20000 kg/year
CFR Vol. 76, Dec 23, 2011 - Filterable PM 167.0 mg/s

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

NOx volume flow wet (O2 = 7.0%)- measured 386.6 mg/Nm³
NOx volume flow dry (O2 = 7.0%) 477.8 mg/Nm³
NOx volume flow dry (O2 = 6%) - report as NO2 512.5 mg/Nm³
NOx volume flow wet 199.8 mg/am³
NOx volume flow dry (O2 = 11%) - Europe 340.5 mg/Nm³
NOx mass flow 4436.6 g/hour
NOx mass flow 1.2 g/s
EPA NOx (as NO2) 0.1 g/s
EPA NOx (as NO) 0.0 g/s
NOx mass (specific) - 7083 kg/hr 626.4 g/ton steam
NOx mass (specific) 222.8 mg/MJ
NOx mass (specific) 61.9 mg/kWh
NOx mass flow 1970.2 mg/kg of
fuel
NOx mass (O2 = 7.0%) 232.8 ppmvd
NOx mass (O2 = 6%) - report as NO2 249.7 ppmvd
NOx - Anticipated in the flue gas (O2 = 7.0%) 188.4 ppmvw
NOx (wet) 307.4 ppm
NOx mass (O2 = 11%) - Europe 165.9 ppmvd
NOx mass flow (8760 hours) 38.9 ton/annum
NOx as fraction of exhaust gas 0.233 % vol x 1E3
NOx as NO2 0.5181 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 931.8 mg/s
SCR - from 93.2 mg/s
to 279.5 mg/s
SNCR - from 93.2 mg/s
to 279.5 mg/s
SNCR with LNB - from 232.9 mg/s
to 326.1 mg/s
LEA - from 521.8 mg/s
to 838.6 mg/s
LNB (Air staged) - from 605.7 mg/s
to 698.8 mg/s
LNB (Flue gas recirculation) - from 745.4 mg/s
to 931.8 mg/s
LNB (fuel staged) - from 372.7 mg/s
to 465.9 mg/s

Total installed capital cost estimate

Standard Burner 178159 1990 CDN
Total NOx control installed 2712424 April 2013
USD
Annual Operating Costs...
Maintenance - Standard 4899 April 2013
USD
Maintenance - None 5962924 April 2013
USD
Maintenance - None 10063 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 5.7 % volume wet
Excess air 50.0 %
Sulphur dioxide in flue gases 100.6 mg/Nm³
Sulphur dioxide in flue gases 52.0 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 163.1 g/ton steam
Sulphur dioxide in flue gases - 5.5 MW 58.0 mg/MJ
Sulphur dioxide in flue gases 16.1 mg/kWh
Sulphur dioxide in flue gases 0.5 g/kg of fuel
Sulphur dioxide in flue gases 43.5 ppmvd
Sulphur dioxide anticipated in the Flue Gas 35.2 ppmvw
Sulphur dioxide (wet) 80.0 ppm
Sulphur dioxide in flue gases (8760 hours) 10.1 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 34.5 ton/year
Cost delivered PPC, Dec. 2010 181.91 USD/MT
Sorbent cost 6277.4 USD/year
SO2 reduction 85.0 %
Sulphur Dioxide (85% reduction) in flue gas 5.3 ppmvw
Fly ash 29.1 ton/annum
Minimum flue gas temperature 200 °C
Trona gas exhaust analysis
Flue gas mass flow 14434 kg/hour
Argon (1.1) 1.068 % mass
Carbon monoxide (0.0) 0.001 % mass
Carbon dioxide (17.3) 17.272 % mass
Hydrogen Chloride (0.0) 0.000 % mass
Moisture (12.2) 12.211 % mass
Nitrogen (63.0) 63.015 % mass
Oxygen (6.4) 6.433 % mass
Sulphur Dioxide (0.0) 0.001 % mass
OR
Dry alkaline Sorbent chemical use 3.80 kg NaHCO3/kg
SO2
Sodium sesqui-Carbonate required 34.5 ton/year
Cost delivered Solvay, 2002 181.91 USD/MT
Sorbent cost 6277.4 USD/year
Sulphur Dioxide (90% reduction) in flue gas 3.5 ppmvw

Moisture dew point in the hot gas 103.2 °C

Sulfurous acid (SO2) dew point estimate 54.7 °C
Sulphuric Acid Dew Point
_____________________________________________
Percentage SO3 Sulphuric acid dew point
% °C
_____________________________________________
1.0 112.9
1.5 116.3
2.0 118.7
2.5 120.6
3.0 122.2
3.5 123.6
4.0 124.7
4.5 125.8
5.0 126.7
_____________________________________________
Sulphur dioxide 0.0 % vol
Steam plant calculations manual by Ganapathy p94 table 2.9...
Hydrochloric acid dew point estimate 55.6 °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 25.997 MM BTU/hour
Annual emission period 8760.0 hours/year

Carbon monoxide CO 556.8 mg/s 17.6

ton/year
Carbon dioxide CO2 638.6 g/s 20140.0
ton/year
Hydrogen chloride HCl 62.2 mg/s 1962.4
kg/year
Nitrogen oxides NOx 137.6 mg/s 4337.9
kg/year
Particulate matter PM - filterable 1.1 g/s 34.1
ton/year
Particulate matter CPM - condensable 55.7 mg/s 1755.8
kg/year
Particulate matter 10 µ filterable 972.7 mg/s 30.7
ton/year
Particulate matter 2.5 µ filterable 821.4 mg/s 25.9
ton/year
Sulphur dioxide SO2 81.9 mg/s 2582.1
kg/year
Sulphur trioxide -1 ND -1 NA
Sulphate particulate -1 ND -1 NA
Sulphur oxides SOx 81.9 mg/s 2582.1
kg/year
Sulphur in the ash -1 ND -1 NA
Total organic compounds TOC 127.7 mg/s 4028.0
kg/year
VOC non methane -1 ND -1 NA
Methane 68.8 mg/s 2168.9
kg/year
2,3,7,8 Tetrachlorodibenzo-p-dioxins 28.2 pg/s 0.9
mg/year
Tetrachlorodibenzo-p-dioxins 1.5 ng/s 48.5
mg/year
2,3,7,8 Tetrachlorodibenzo-p-furans 294.8 pg/s 9.3
mg/year
Tetrachlorodibenzo-p-furans 2.5 ng/s 77.5
mg/year
Metals...
Antimony 25.9 µg/s 815.9
g/year
Arsenic 72.1 µg/s 2.3
kg/year
Barium 13.4 µg/s 423.5
g/year
Cadmium 13.4 µg/s 423.5
g/year
Chromium total 68.8 µg/s 2.2
kg/year
Chromium hexavalent 11.5 µg/s 361.5
g/year
Cobalt 21.3 µg/s 671.3
g/year
Copper 160.5 µg/s 5.1
kg/year
Iron 3.2 mg/s 102.2
kg/year
Lead 157.2 µg/s 5.0
kg/year
Manganese 5.2 mg/s 165.3
kg/year
Mercury 11.5 µg/s 361.5
g/year
Molybdenum 6.9 µg/s 216.9
g/year
Nickel 108.1 µg/s 3.4
kg/year
Phosphorous 88.4 µg/s 2.8
kg/year
Potasium 127.7 mg/s 4028.0
kg/year
Selenium 9.2 µg/s 289.2
g/year
Silver 5.6 mg/s 175.6
kg/year
Sodium 1.2 mg/s 37.2
kg/year
Strontium 32.8 µg/s 1.0
kg/year
Tin 75.3 µg/s 2.4
kg/year
Titanium 65.5 µg/s 2.1
kg/year
Vanadium 3.2 µg/s 101.2
g/year
Yttrium 982.5 ng/s 31.0
g/year
Zinc 1.4 mg/s 43.4
kg/year

Environmental Protection Agency - EPA A-42 controlled emissions

NOx (NO2) - Standard 137.6 mg/s 4337.9
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 72.1 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 2.8 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.