FACILITIES COMPLIANCE ROADMAP
16 Eskom Power Stations
FACILITIES / COMPLIANCE ROAD MAP- Kriel Power Station
- Particulate matter emission reduction: Fabric Filter Plant (FFP) retrofits
- Electrostatic precipitator (ESPs) and SO₃ injection are the abatement equipment currently used at Kriel power station for the control of PM emissions.
- Lethabo Power Station
- Lethabo already achieves the ‘’existing plant’’ MES of 100mg/Nm3 for Particulate Matter (PM10), 1100mg/Nm3 Nitrogen Oxides (NOx) and 3500mg/Nm3 for Sulphur dioxide (SO₃) emissions.
- Electrostatic precipitator (ESPs) and SO₃ injection are the abatement equipment currently used at Lethabo power station for the control of PM emissions.
- Majuba Power Station
- NOx emission reduction: Low NOx Burner (LNB) retrofits
- Pulse Jet Fabric Filter (FFP) is the abatement equipment currently used at Majuba power station for the control of PM emissions.
- Matimba Power Station
- Matimba already achieves the 100 mg/Nm3 PM10 emission limit (MES for existing plant) as well as the 750 mg/Nm3 NOx limit (MES for new plant) and SO₂ emissions average below the 3500 mg/Nm3 ‘’existing plant’’ limit
- Electrostatic precipitator (ESPs), SO₃ injection and boilers with low NOx design are the abatement equipment currently used at Matimba power station for the control of PM emissions.
- Marapong monitoring station as well as the rehabilitation of and sprinklers on the ash dumps are additional interventions implemented at Matimba
- Matla Power Station
- Particulate matter emission reduction: Fabric Filter Plant (FFP) retrofits
- NOx emission reduction: Low NOx Burner (LNB) retrofits
- Electrostatic precipitator (ESPs) and SO₃ injection are the abatement equipment currently used at Matla power station for the control of PM emissions.
- Medupi Power Station
- SO₂ emission reduction: Flue Gas Desulphurisation (FGD) retrofit
- Fabric Filter Plant (FFP) and Low NOx Burner (LNB) are the emission abatement equipment currently used at Medupi power station
- Port Rex Power Station
- Port Rex already achieves the 50 mg/Nm3 PM10 emission limit (MES for new plant) as well as the 1100 mg/Nm3 NOx limit (MES for existing plant) and 500 mg/Nm3 ‘’new plant’’ MES limit for Sulphur dioxide
- Tutuka Power Station
- Particulate matter emission reduction: Fabric Filter Plant (FFP) retrofits
- NOx emission reduction: Low NOx Burner (LNB) retrofits
- Electrostatic precipitator (ESPs) is the abatement equipment currently used at Tutuka power station for the control of PM emissions.
- Acacia Power Station
- Arnot Power Station
- Camden Power Station
- Duvha Power Station
- Grootvlei Power Station
- Hendrina Power Station
- Kendal Power Station
- Komati Power Station
- The proposed retrofits will reduce emissions of relative PM by 67% between now and 2027; relative NOx by 25% between 2019 and 2025 and relative SO₂ by 30% between 2021 and 2027 (assuming that Medupi and Kusile are fully operational, as they will be once all these retrofits have been realised, and that power station decommissioning starts according to the 50-year life plan).
3 Sasol Operations (Infrachem, Nitro and Secunda)
17. Sasol Infrachem:The lists below presents a summary of the information contained within the Sasolburg Operations motivation reports and associated technical appendices, demonstrating the roadmap to air quality improvement, described by emission source.
A short description is provided for the seven types of air quality improvement actions which Sasol has adopted in past years, and which Sasol will continue to act on. These actions include:
a) Proactive investments informed by a risk-based approach and aligned with voluntary internal targets. For example:
- Investments on upgrading of ESP systems to reduce PM emissions to levels significantly lower that initial design.
b) The implementation of commitments to the Vaal Triangle Airshed Priority Area air quality management plan. Technical investigations have been undertaken to inform Sasol’s plan to reach the VTAPA commitments. These will be presented in November 2014.
c) Implementation of solutions to reach compliance with existing or new plant standards, where feasible solutions for compliance have been identified. For example:
- Renewal of steam plant electrostatic precipitators to reach existing plant PM standards under all normal operating conditions.
d) Implementation of solutions to reach compliance with existing or new plant standards, where feasible solutions for compliance have been identified, and where the initial postponement applications were made, to allow for the successful implementation of projects. For example:
- Renewal of steam plant electrostatic precipitators to reach existing plant PM standards under all normal operating conditions.
e) Implementation of solutions driven by MES compliance, which are aligned with NEMA sustainable development principles and which result in point source emission improvements, but which are unlikely to reach the prescribed emission limits set by the MES. For example:
- Solutions informed by the waste hierarchy either to avoid waste incineration or divert portions of waste streams from incinerators for beneficiation.
f) Technical investigations driven by MES compliance. For example:
- Investigations initiated recently due to November 2013 amendments to the MES, for reduction in flue gas temperature of the B6990 incinerator.
g) Studies implemented to investigate the feasibility and potential for air quality offsets to deliver sustainable ambient air quality improvements. For example:
- Sasol’s current air quality offset pilot study, investigating the feasibility of RDP house insulation to reduce winter domestic coal burning.
18. Sasol Nitro: The lists below presents theroadmap to sustainable air quality improvement for Sasol Nitro’s MMA emissions at the MMAN plant.
a) The implementation of process modifications to reduce MMA emissions, following promulgation of MES.
b) Implementation of heat exchanger condenser system to scrubber.
c) Measurement to confirm compliance under all normal operating conditions.
d) Implementation of downstream measures to manage cross-media impacts, if required.
19. Sasol Secunda: The lists below presents a summary of the information contained within the Secunda motivation reports and associated technical appendices, demonstrating the Secunda roadmap to air quality improvement, described by emission source. A short description is provided for the seven types of air quality improvement actions which Sasol has adopted in past years, and which Sasol will continue to act on. These actions include:
a) Proactive investments informed by a risk-based approach and aligned with voluntary internal targets. For example:
- Investments on the VOC roadmap, to reduce emissions of VOCs by 80% by 2020, off a 2009 baseline
b) The implementation of commitments to the Highveld Priority Area air quality management plan. For example:
- The construction of a wet sulphuric acid plant on Sasol Secunda’s eastern factory
c) Implementation of solutions to reach compliance with existing or new plant standards, where feasible solutions for compliance have been identified, and where the initial postponement applications were made, to allow for the successful implementation of projects. For example:
- The construction of 7 regenerative thermal oxidisers to treat VOC emissions from various point and fugitive emission sources
- Renewal of steam plant electrostatic precipitators to reach existing plant PM standards under all normal operating conditions
d) Implementation of solutions driven by MES compliance, which are aligned with NEMA sustainable development principles and which result in point source emission improvements, but which are unlikely to reach the prescribed emission limits set by the MES. For example:
- Solutions informed by the waste hierarchy either to avoid waste incineration or divert portions of waste streams from incinerators for beneficiation
e) Technical investigations driven by MES compliance. For example:
- Investigations initiated recently due to November 2013 amendments to the MES, for Rectisol SO2 emissions and the sewage solids incinerator
f) Implementation of measures which, while not materially reducing mean emission concentrations, serve to manage emission peaks by improving availability. This includes the renewal of the sulphur recovery plant, as part of the renewal roadmap for the Sasol Secunda facility.
g) Compliance with other government policies which either directly or indirectly result in ambient air quality improvements. For example:
- The Department of Energy’s Clean Fuels programme
h) Studies implemented to investigate the feasibility and potential for air quality offsets to deliver sustainable ambient air quality improvements. For example:
- Sasol’s current air quality offset pilot study, investigating the feasibility of RDP house insulation to reduce winter domestic coal burning
20. National Petroleum Refiners of South Africa (Pty) Limited (NATREF)
Summary listing of abatement projects to achieve compliance with the MES, including the project completion schedule and the postponement application implications of the schedules are listed below:
a)Emission source - Fuel gas-fired boilers, project schedule - 6 years, preferred technology option - low NOx burners and postponement - compliance with existing plant standards expected by April 2020.
b) Emission source – amine treating unit flash drums , project schedule –5 to 6 years, preferred technology option – technology options under investigation and postponement - compliance expected by 1 April 2020.
c)Emission source - FCC, project schedule –9 to 10 years, preferred technology option -Replace regenerator cyclones, plus: Third/Fourth stage cyclones, ESP, Wet scrubber, bag houses, gas solid separation and postponement - compliance expected between 2020 and 2025.
d)Emission source - SRU, project schedule –9 to 10 years, preferred technology option – new SRU and postponement - compliance expected between 2020 and 2025.
e)Emission source - tanks, project schedule –5 to 6 years, preferred technology option -compliance will be achieved upon completion of Clean Fuels II implementation and postponement - compliance expected by 1 April 2020 (based on expected completion of Clean Fuels II).
21. Shell Kimberley Fuel Storage
Shell indicated that the facility will install the required abatement equipment at the Kimberley terminal in accordance with the requirements of its AEL and the MES. Shell has commenced the process of designing a VRU for the Kimberley terminal. The VRU is scheduled for installation in 2018.
22. Shell Ladysmith Fuel Storage
Shell has commenced the process of designing a VRU for the Ladysmith terminal. The VRU is scheduled for installation in 2018.
23. Shell Port Elizabeth Fuel Storage
Since the terminal is scheduled for closure in 2017 and the impact of its operations on the ambient environment is not significant, no air quality interventions are required at the terminal.
24. Shell Polokwane Fuel Storage
Shell has commenced the process of designing a VRU for the Polokwane terminal. The VRU is scheduled for installation in 2018.
25. Engen Petroleum (Engen Refinery Durban)
Abatement equipment and control technology currently in use at Engen Refinery are:
a)CO Boiler - combusts CO emissions from FCCU process thereby reducing CO emissions to atmosphere.
b)Fuel Gas Scrubber - removes H₂S for Refinery Fuel Gas which in turn lowers SO₂emissions to atmosphere when fuel gas is combusted.
c)Cyclone Separators - reduces particulat₂e emissions to atmosphere by capturing escaped catalyst dust from FCCU process.
d)DeSox Additive - reduces SOx emission to atmosphere by capturing SO₃ emissions pre-injected into FCCU catalyst.
e)Sulphur Recovery Unit 2 Claus Reaction - uses Claus Reactors to convert H₂S from the fuel gas scrubbers into elemental sulphur which is sold as a product. This reduces SO₂ emissions to atmosphere by reducing the volume of H₂S that is combusted.
f)Sulphur Recovery Unit 3 Claus and Superclaus Reaction - uses Claus and Superclaus Reactors to convert H₂S from the fuel gas scrubbers into elemental sulphur which is sold as a product. This reduces SO₂ emissions to atmosphere by reducing the volume of H₂S that is combusted.
g)North Flare - combusts hydrocarbon emissions from a series of safety vents which reduces VOC emissions to atmosphere.
h)South Flare - combusts hydrocarbon emissions from a series of safety vents which reduces VOC emissions to atmosphere.
In order to further reduce emissions and to comply with the MES requirements for PM and VOCs, a detailed technology review is being conducted by Engen and a design and engineering package is being developed. The refinery has also initiated a capital project to achieve the MES for new facilities. This project is currently underway with activities such as review of available technology; identification of alternatives for further evaluation, project risk analysis, initial cost estimates, and schedule planning and project charter is taking place. It is expected that modifications to existing process units, for the purpose of complying with the MES requirements, may include technology such as wet gas scrubbers or cyclones for PM reduction.
Engen refinery over the years has conducted various initiatives to reduce emissions and environmental impacts. These include: SO₂ reduction initiatives, PM reduction initiatives VOC reduction initiatives and NOx reduction initiatives.
26. PPC Limited (Dwaalboom Plant Limpopo)
PPC Dwaalboom currently has the following air quality management interventions in place:
a)Point source abatement - electrostatic precipitator and Bag filter (pulse-jet fabric filter).
b)Fugitive sources - application of water sprays to reduce fugitive dust emissions from various sources including selected material transfer points and major unpaved haul roads.
c)Several other management and mitigation measures - De-dusting systems on drill, water sprayers on roads, road maintenance, and all conveyor belts covered and dust extraction systems in place.
PPC Dwaalboom have committed to the following upgrades:
a)Replacing the Kiln 1 cooler in by the end of 2015.
b)Additional modifications/repairs to existing equipment during 2014 and 2015 to ensure that the 80 mg/Nm3 particulate emission limit is met.
c)Installation of a bag filter on Kiln 1 by the end of the 2018 calendar year to reach the required 30 mg/Nm3 Particulate Matter (PM)emission limit.
27. PPC Limited (De Hoek Plant Western Cape)
PPC De Hoek plant currently has the following air quality management interventions in place:
a)Point source abatement - electrostatic precipitator and Bag filter (pulse-jet fabric filter).
b)Fugitive sources - application of water sprays to reduce fugitive dust emissions from various sources including selected material transfer points and major unpaved haul roads.
PPC De Hoek plant planned air quality management intervention - finishing mill 6 will be fitted with a bag filter to replace the existing ESP, in order to bring emissions down to an acceptable level.
28. PPC Limited (Port Elizabeth Plant)
PPC Port Elizabeth plant currently has the following air quality management interventions in place:
a)Point source abatement - Bag filter (reverse pulse jet),electrostatic precipitator and dust collector.
b)Fugitive sources - application of water sprays to reduce fugitive dust emissions from various sources including selected material transfer points and major unpaved haul roads.
PPC Port Elizabeth plant planned air quality management intervention - finishing mill 4 will be fitted with a bag filter to replace the existing dust collector, in order to bring emissions down to an acceptable level. Kiln ESP will be replaced with a Bag Filter in 2018.
29. PPC Limited (Mahikeng Slurry Plant)
PPC Mahikeng plant currently has the following air quality management interventions in place:
a)Point source abatement - electrostatic precipitator and Bag filter (pulse-jet fabric filter).
b)Fugitive sources - application of water sprays to reduce fugitive dust emissions from various sources including selected material transfer points and major unpaved haul roads.
PPC Mahikeng plant planned air quality management intervention - Kiln 7 will remain operational during the upgrade of Kiln 8 and then put on care and maintenance after the upgrade is complete. The ESP for finishing mils 1 and 2 will be replaced by bag filters. The ESP for Kiln 8 will be replaced by a bag filter as well.
30. Anglo American Platinum (Mortimer Smelter)
Mortimer smelter has installed and commissioned in mid-November 2013 three additionalambient air monitoring stations to enhance further understanding of the impact that the smelter emissions have on the surrounding areas. Studies related to future SO2 abatement control technologies to ensure compliance with the Section 21 new plant standard by 2020, are underway. Appliances and abatement equipment control technology used in Mortimer smelter is the drying process cyclones and baghouse used for particulate emission control. Also used for particulate emission control is smelting process electrostatic precipitator (ESP).
31. Anglo American Platinum (Polokwane Smelter)