Bacong - PDD

Transcription

Bacong - PDD

PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 03.1.
CDM – Executive Board
page 1
CLEAN DEVELOPMENT MECHANISM
PROJECT DESIGN DOCUMENT FORM (CDM-PDD)
Version 03 - in effect as of: 28 July 2006
CONTENTS
A.
General description of project activity
B.
Application of a baseline and monitoring methodology
C.
Duration of the project activity / crediting period
D.
Environmental impacts
E.
Stakeholders’ comments
Annexes
Annex 1: Contact information on participants in the project activity
Annex 2: Information regarding public funding
Annex 3: Baseline information
Annex 4: Monitoring plan
page 2
SECTION A. General description of project activity
A.1
Title of the project activity:
Secondary catalytic reduction of N2O emissions at ONPI nitric acid plant in Bacong, the Philippines
PDD version: 06
Date of completion: 28/03/2008
A.2.
Description of the project activity:
Nitrous Oxide (N2O) is an undesired by-product gas from the manufacture of nitric acid. N2O is formed
during the catalytic oxidation of ammonia. Over a suitable catalyst, typically 90-99% of the fed ammonia
is converted to Nitric Oxide (NO). The remainder participates in undesirable side reactions that lead to
the production of N2O, among other compounds. Waste N2O from nitric acid production is typically
released into the atmosphere, as it does not have any economic value or toxicity at typical emission
levels. N2O is an important greenhouse gas (GHG) which has a high Global Warming Potential (GWP) of
310.
The project activity involves installation of a secondary catalyst to decompose N2O inside the Ammonia
Combustion Element (ACE) or ammonia burner once it is formed. It will take place at the nitric acid
production plant of Orica Nitrates Philippines, Inc. (ONPI), located in Bacong, the Philippines. The
project nitric acid plant (“Bacong nitric acid plant” hereinafter) started its commercial production in
January 1983. Its design capacity has been 100 tHNO3 per day (100% HNO3 basis) since the start of its
commercial production.
The baseline scenario is determined to be release of N2O emissions to the atmosphere at the currently
operating conditions, in the absence of regulations to restrict N2O emissions in the Philippines. If
regulations on N2O emissions are introduced during the crediting periods, the baseline scenario shall be
adjusted accordingly.
Baseline emissions rate will be determined by measuring the N2O emission factor during a complete
production campaign prior to project implementation. To assure that the data obtained during the initial
N2O measurement campaign for baseline emission factor determination are representative of the actual
N2O emissions from the project, a set of plant operation parameters known to affect N2O generation will
be controlled based on the analysis on the historical campaigns. The secondary catalyst is expected to
reduce N2O emissions by 85% to 95% of the current level. No leakage is expected from the project
activity because the installation and operation of the secondary catalyst will not lead to any increase of
GHG emissions outside the project boundary. Consequently, the project is expected to achieve annual
emission reductions of 29,474 tCO2e.
The project will contribute to sustainability development of the Philippines through transfer of the
secondary catalyst technology as well as necessary monitoring equipment and its operation and
maintenance know-how from Annex I countries. The project will also contribute to the global
environment by significantly reducing GHG emissions.
page 3
A.3.
Project participants:
Name of Party involved
((host) indicates a host Party)
Private and/or public entity(ies)
project participants
(as applicable)
Kindly indicate if
the Party involved
wishes to be
considered as
project participant
(Yes/No)
The Philippines (host)*
Private entity: Orica Nitrates
Philippines, Inc. (ONPI)
No
The project participant from non-Annex-I country (the Philippines) is ONPI, which shall be the lead and
nodal entity for all communication with the CDM Executive Board (EB) and Secretariat. The contact
information on the project participant in the project activity is provided in Annex 1 of this PDD.
* The Philippines has ratified the Kyoto Protocol on 20 November 2003.
A.4.
Technical description of the project activity:
A.4.1. Location of the project activity:
A.4.1.1.
The Philippines.
Host Party(ies):
A.4.1.2.
Region 7/ Negros Oriental.
Region/State/Province etc.:
A.4.1.3.
City/Town/Community etc:
Bacong.
A.4.1.4.
Detail of physical location, including information allowing the
unique identification of this project activity (maximum one page):
The Bacong nitric acid plant is located at Barangay Buntis and Barangay San Miguel, Bacong Negros
Oriental at KM10 on the South Dumaguete Road. It occupies a six-hectare lot area. It is bounded on the
North and South by private lots, Lot 2667 – Barangay Buntis, and Lot 2864C – Barangay San Miguel,
respectively. To the east is the Tanon Strait and the National Road bounded the west side.
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Figure 1: Location map of the Bacong nitric acid plant
Figure 2: Vicinity map of the Bacong nitric acid plant
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Figure 3: Site map of the Bacong nitric acid plant
A.4.2. Category(ies) of project activity:
The project belongs to Sectoral Scope 5: Chemical Industry.
A.4.3. Technology to be employed by the project activity:
Nitric acid production:
Nitric acid is produced following the Ostwald process. The process involves three main chemical steps:
(i) catalytic oxidation of ammonia (NH3) to form nitric oxide (NO), (ii) oxidation of NO to nitrogen
dioxide (NO2), and (iii) absorption of NO2 in water to produce nitric acid (HNO3).
(i) Catalytic oxidation of ammonia
The secondary catalytic N2O reduction project mainly involves the ACE or ammonia burner at the
Bacong nitric acid plant. In the ACE, the mixture of vaporized anhydrous ammonia and compressed air
will be burned with the aid of a precious metal catalyst (i.e. primary catalyst). The reactions occurring in
the primary catalyst are given below:
(R1)
(R2)
(R3)
(R4)
4 NH3 + 5 O2 4 NO + 6 H2O
4 NH3 + 4 O2 2 N2O + 6 H2O
4 NH3 + 3 O2 2 N2 + 6 H2O
4 NH3 + 5 NO 4 N2 + 6 H2O
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The reaction R1 is the predominant and desired conversion in the ammonia oxidation process, which is
favoured by lower pressure and high temperature. The formation of N2O (R2) and nitrogen (N2) (R3 and
R4) are undesired side reactions. On average, 100 t of 100% (or 185 t of 54%) nitric acid is produced per
day at the Bacong nitric acid plant. At equilibrium conditions, this is roughly 46.7 t of NO produced in
the ACE.
Oxidation of nitric oxide
The gas formed in the reactions above is cooled down. Due to the condensation of water, a weak acid
solution is formed. The gas that is separated from the liquid is led to an absorption column. In the
presence of water in the absorption column, the NO produced in the ACE will be oxidized to yield NO2:
(R5)
2 NO + O2 2 NO2
Absorption of nitrogen oxides
The gas is then readily absorbed by the water, yielding nitric acid, while reducing a portion of it back to
NO:
(R6)
3 NO2 + H2O 2 HNO3 + NO
Secondary catalyst technology:
The project will install a secondary N2O reduction catalyst in the ACE. The technology employed is an
HR-SC (Heraeus Secondary Catalyst System) N2O reduction catalyst, which will be supplied by W.C.
Heraeus GmbH on a lease basis. The catalyst is essentially Aluminium Oxide (Al2O3) ceramic pellets
coated with precious metals (Platinum-Palladium-Rhodium), which is expected to reduce N2O emissions
by 85-95% of its current level with the following reaction:
(R7)
2 N2O 2 N2 + O2
The catalyst does not consume electricity, steam, fuels or reducing agents. It does not change the current
nitric acid production level either. Therefore, the overall energy and material balance of the plant is not
affected. Further, the exhausted secondary catalysts will be returned to the technology provider for
recycling.
Secondary catalyst installation:
Secondary catalyst installation is relatively simple and does not require any new process unit or major redesign of existing units. In addition, the installation can be done simultaneously with a primary gauze
replacement. Consequently, the loss in production due to incremental downtime will be limited.
The secondary catalyst will be installed in the ACE right below the primary gauze pack. It will be filled
in steel cassettes to be fitted in the ammonia burner below the primary catalyst and above the raschig
rings. A layer of raschig rings will be removed for this purpose. A new separation screen and primary
gauze pack will be installed on top of the secondary catalyst.
page 7
Figure 4: Present ACE set-up with only the primary catalyst installed
Figure 5: ACE set-up with the primary and secondary catalysts installed
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A.4.4
Estimated amount of emission reductions over the chosen crediting period:
Year
2009
2010
2011
2012
2013
2014
2015
Total estimated reductions
(tonnes of CO2 e)
Total number of crediting years
Annual average over the crediting period
of estimated reductions (tonnes of CO2 e)
Annual estimation of emission reductions
in tonnes of CO2e
29,474
29,474
29,474
29,474
29,474
29,474
29,474
206,319
A.4.5. Public funding of the project activity:
No public funding is provided to the project.
7
29,474
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SECTION B. Application of a baseline and monitoring methodology
B.1.
Title and reference of the approved baseline and monitoring methodology applied to the
project activity:
• AM0034 (version 03): Catalytic reduction of N2O inside the ammonia burner of nitric acid
plants; and
• Tool for the demonstration and assessment of additionality (version 04).
B.2
Justification of the choice of the methodology and why it is applicable to the project
activity:
The project activity will reduce N2O emissions from the Bacong nitric acid plant meeting all the
applicability conditions specified in AM0034 as follows.
•
•
•
•
•
•
•
•
The Bacong nitric acid plant started its commercial production in January 1983. The design
capacity of the plant has been 100 t HNO3 per day (100% HNO3 basis) since the start of the
commercial production;
The project activity will not result in the shut down of any existing N2O destruction or abatement
facility or equipment at the plant. The Bacong nitric acid plant currently does not have any N2O
destruction or abatement facility or equipment installed;
The project activity will not affect the level of nitric acid production at the Bacong nitric acid
plant;
There are currently no regulatory requirements or incentives to reduce levels of N2O emissions
from nitric acid plants in the Philippines (like many other countries). The Department of
Environment and Natural Resources (DENR) Administrative Order No. 81 Series 2000 which is
the Implementing Rules and Regulations for RA 8749 otherwise known as the “Philippine Clean
Air Act of 1999” has set the NOX emission for Nitric Acid Manufacture to be 2,000 mg/NCM
(Normal Cubic Meter) under the National Emission Standards for Source Specific Air Pollutants
(NESSAP). The regulated emission level is computed to be equal to 1,600 ppm based on the
plant design (undiluted) tail gas volumetric flow rate of 13,417 Nm3/h (at the STP condition)
with a mass flow rate of 16,802 kg/h. No reference is given to N2O emission levels;
The project activity will not increase NOX emissions. The secondary catalyst technology to be
installed has no effect on NOX emission levels;
There has been no NOX abatement catalyst installed at the Bacong nitric acid plant. The plant
currently emits NOX at an average concentration of 464.4 ppm based on the CY07 Fourth
Quarter results submitted to the DENR on 10 January, 2008. Therefore, it is in compliance with
the aforementioned Philippine Clean Air Act of 1999 even without any NOX abatement catalyst
installed;
The operation of the secondary N2O abatement catalyst installed under the project activity will
not lead to any process emissions of GHGs, directly or indirectly. The only GHG emission of
relevance under the project activity is N2O contained in the waste stream exiting the stack. The
secondary catalyst does not consume electricity, steam, fuels or reducing agents, thus not leading
to any increase in GHG emissions, directly or indirectly; and
Continuous real-time measurement of N2O concentration and total gas volume flow gas will be
carried out in the stack (i) prior to the installation of the secondary catalyst for one campaign,
and (ii) after the installation of the secondary catalyst throughout the chosen crediting period of
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the project activity. The project employs an online Continuous Emission Monitoring System
(CEMS/ gas analyzer) along with a differential pressure flow meter. The gas analyzer (Procal
Model P240 LR) is currently pursuing a certificate to QAL1 of EN 14181. The flow meter (D-FL
100) has a TÜV certification pursuant to the Federal German Pollution Control Act, 13th and 17th
Implementing Ordinances (13.BImSchV and 17.BImSchV) and the German Clean Air
Regulations (TA Luft). It is also certified to comply with MCERTS performance standards for
CEMS, version 2, revision 1 (April 2003).
Project activity
Baseline
activity
B.3.
Description of the sources and gases included in the project boundary
The spatial extent of the project boundary covers the Bacong nitric acid plant and equipment for the complete
nitric acid production process from the inlet to the ammonia burner plant to the stack. The only GHG emission
relevant to the project activity is N2O contained in the waste stream exiting the stack. The secondary
catalyst does not consume electricity, steam, fuels or reducing agents, thus not leading to any increase in
GHG emissions, directly or indirectly.
Source
Nitric acid plant
(Burner inlet to stack)
Gas
CO2
CH4
Included?
Excluded
Excluded
Nitric acid plant
(Burner inlet to stack)
N2O
CO2
CH4
Included
Excluded
Excluded
N2O
CO2
CH4
N2O
Excluded
Excluded
Excluded
Excluded
Leakage emissions
from production,
transport, operation
and decommissioning
of the catalyst
Justification/Explanation
The project does not lead to any change
in CO2 or CH4 emissions. Therefore,
these emission sources are excluded.
Major emission source.
The project does not lead to any change
in CO2 or CH4 emissions. Therefore,
these emission sources are excluded.
Major emission source.
No leakage emissions are expected.
page 11
Figure 6: Process flow diagram of the Bacong nitric acid plant
B.4.
Description of how the baseline scenario is identified and description of the identified
baseline scenario:
As per the guidance given in AM0034, the most likely baseline scenario is to be identified following the
procedure for “identification of the baseline scenario” stipulated in AM0028 (version 04.1) “Catalytic
N2O destruction in the tail gas of Nitric Acid or Caprolactam Production Plants”. The identification
procedure involves the following five steps:
Step 1: Identify technically feasible baseline scenario alternatives to the project activity:
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This step is divided into the following two steps: (i) identification of all possible options that are
technically feasible to handle N2O emissions, and (ii) identification of all possible options that are
technically feasible to handle NOX emissions
Step 1a: The baseline scenario alternatives should include all possible options that are technically
feasible to handle N2O emissions. These options are, inter alia:
• Status quo: The continuation of the current situation, where there will be no installation of
technology for the destruction or abatement of N2O.
• Switch to alternative production method not involving ammonia oxidation process
• Alternative use of N2O such as:
o Recycling of N2O as a feedstock for the plant;
o The use of N2O for external purposes.
• Installation of a Non-Selective Catalytic Reduction (NSCR) DeNOX unit;
• The installation of an N2O destruction or abatement technology:
o Primary approach;
o Secondary approach;
o Tertiary approach.
These options should include the CDM project activity not implemented as a CDM project.
Step 1b: In addition to the baseline scenario alternatives of step 1a, all possible options that are
technically feasible to handle NOX emissions should be considered. The installation of a NSCR DeNOX
unit could also cause N2O emission reduction. Therefore, NOX emission regulations have to be taken into
account in determining the baseline scenario. The respective options are, inter alia:
• The continuation of the current situation, where either a DeNOX-unit is installed or not;
• Installation of a new Selective Catalytic Reduction (SCR) DeNOX unit;
• Installation of a new NSCR DeNOX unit;
• Installation of a new tertiary measure that combines NOX and N2O emission reduction.
Step 2: Eliminate baseline alternatives that do not comply with legal or regulatory requirements:
Currently, there is no national regulation or legal obligation in the Philippines concerning N2O emissions.
On the other hand, the Philippine Clean Air Act of 1999 has set the NOX emission for Nitric Acid
Manufacture to be 2,000 mg/NCM, which is equivalent to 1,600 ppm. The Bacong nitric acid plant
currently emits NOX at the average concentration level of 464.4 ppm, hence in compliance with the
Philippine Clean Air Act of 1999. Therefore, the continuation of status quo is a valid baseline scenario
alternative. None of the baseline scenario alternatives can be eliminated in this step because all of them
are in compliance with the relevant enforced legal or regulatory requirements in the Philippines.
Step 3: Eliminate baseline alternatives that face prohibitive barriers (barrier analysis):
Sub-Step 3a: List of barriers
page 13
To assess barriers the project or its alternatives are facing, it is important to understand the three different
groups of N2O destruction or abatement technologies at nitric acid plants: (i) primary, (ii) secondary, and
(iii) tertiary.1
The primary approach, suppression of N2O formation, requires modifications to ammonia oxidation
gauzes in order to reduce N2O formation. Generally, 30-40% reduction of N2O formation can be achieved
in conventional nitric acid plants.2 Therefore, this approach will not be able to achieve as much N2O
emission reductions as the project aims to. In addition, the technology is yet to be proven in practice.3
For the secondary approach, removal of N2O in the ammonia burner after the ammonia oxidation
gauzes, two abatement techniques exist: (i) homogeneous decomposition, and (ii) high temperature
catalytic reduction. The former implies expanding the volume of the process burner after the ammonia
oxidation gauzes to obtain a longer reaction time, thus resulting in homogeneous decomposition of N2O.
This technology is in principle only suitable when building new nitric acid plants. Existing nitric acid
plants would require extensive and costly rebuilding.4 Therefore, it is not a credible alternative to the
project activity. The project activity employs the latter approach, high temperature catalytic reduction.
This approach consists of constructing a catalyst basket under the ammonia oxidation gauzes, and filling
the basket with selective de-N2O catalyst to promote N2O decomposition. There is a wide range of
technology suppliers for this option (e.g. Heraeus, BASF, Yara, Johnson Matthey). The secondary
abatement method involves replacing an existing bed of Raschig rings with the abatement catalyst. There
is no need for additional equipment, hence it is easy to install.
The tertiary approach, removal of N2O from the tail gas, has two different techniques: (i) NSCR, and
(ii) SCR. NSCR has been used widely in North America and Russia for NOX reductions, but also has the
positive effect of reducing N2O emissions at the same time. However, the technique requires high energy
consumption and results in emissions of other GHGs (CO2 and CH4). Due to the high energy
consumption, it is of significantly higher cost than other N2O abatement techniques. Therefore, it is not
recognized as a sustainable technique for abatement of N2O emissions.5 The SCR technique can achieve
as much N2O emission reductions as the secondary approach offers. Both NSCR and SCR have
significant requirements regarding space and downtime for installation, and consume reducing agents
(fuel and/or ammonia). Consequently, these techniques are normally considered more costly N2O
abatement technique than the secondary one.6
1
The technical description for the primary, secondary, and tertiary measures are based on Jenssen, T-K (2006) N2O
emissions in industrial processes – An industry perspective.
2
Jenssen, T-K (2006) N2O emissions in industrial processes – An industry perspective, pp.6.
3
Ibid., pp.6.
4
Ibid., pp.6.
5
Ibid., pp.6.
6
Ibid., pp.7.
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For tertiary abatement, the system needs a supply of ammonia and a reductant (usually natural gas) to
operate in the temperature ranges seen in the Bacong plant.7 The site does not have access to natural gas,8
so it must use an alternative (likely LPG, which is more costly than natural gas). A new storage facility
would be needed to supply the alternative. A system is available which does not use the reductant,9 but
this requires operating temperatures > 425 °C, higher than the maximum allowable for the materials used
in the plant. The design temperature of the expander (tail gas turbine) in the plant is 380 °C.
Consequently, the existing expander would be damaged if it were to operate with heated tail gas above
425 °C from a tertiary abatement system.
Barriers to the tertiary approach in comparison to the secondary approach are therefore the higher cost,
requirement of greater modifications, and need for an alternative reductant.
Switch to alternative production method not involving ammonia oxidation process faces prohibitive
barriers as there is no other commercially viable alternative for nitric acid production.
Recycling of N2O as a feedstock for the nitric acid plant is impossible because N2O is not a feedstock
for nitric acid production.
The use of N2O for external purposes is not technically feasible in the Bacong nitric acid plant because
the quantity of gas to be treated is enormous compared to the amount of N2O that could be recovered.
The current N2O concentration level in the tail gas of the Bacong nitric acid is too low (i.e. in a ppm
range) to economically recover N2O from the tail gas. The use of N2O from a nitric acid plant for external
purposes has not been practiced anywhere in the world.
Sub-Step 3b: Show that the identified barriers would not prevent the implementation of at least one of
the alternatives (except the proposed CDM project activity):
As described in step 3a, the following baseline scenario alternatives can be eliminated in this step due to
prohibitive barriers:
• Switch to alternative production method not involving ammonia oxidation process;
• Alternative use of N2O such as:
o Recycling of N2O as a feedstock for the plant;
o The use of N2O for external purposes.
• Installation of a Non-Selective Catalytic Reduction (NSCR) DeNOX unit;
• The installation of an N2O destruction or abatement technology:
o Primary approach;
o Tertiary approach.
Consequently, the following alternatives are remaining for further analysis:
• Status quo: The continuation of the current situation, where there will be no installation of
technology for the destruction or abatement of N2O;
7
Uhde, ‘EnviNOx® – Climate protection solutions for nitric acid plants’, http://www.uhde.biz/cgibin/byteserver.pl/archive/upload/uhde_brochures_pdf_en_5000028.00.pdf, pp. 7
8
Department of Energy, the Philippines – Energy resources, Natural gas, http://www.doe.gov.ph/ER/Natgas.htm.
9
Uhde, ‘EnviNOx® – Climate protection solutions for nitric acid plants’, pp. 8.
page 15
•
The installation of an N2O destruction or abatement technology:
o Secondary approach.
Step 4: Identify the most economically attractive baseline scenario alternative:
Sub-step 4a: Determine appropriate analysis method:
Since none of the remaining alternatives generates financial or economic benefits other than CDM
related income, the simple cost analysis should be applied.
Sub-step 4b: Apply simple cost analysis:
The remaining alternatives are (i) status quo, and (ii) the installation of a secondary N2O abatement
technology. The applied methodology stipulates, “If all alternatives do not generate any financial or
economic benefits, then the least costly alternative among these alternative is pre-selected as the most
plausible baseline scenario candidate.” The secondary N2O abatement requires substantial investment
and O&M costs without generating any marketable products or by-products in the absence of the CDM.
As the continuation of the current situation (i.e. no N2O or NOX abatement) does not require any
additional costs, it clearly represents the most plausible baseline scenario.
Step 5: Re-assessment of baseline scenario in course of proposed project activity’s lifetime:
At the start of a crediting period, a re-assessment of the baseline scenario due to new or modified NOX or
N2O emission regulations should be executed as follows:
Sub Step 5a: New or modified NOX-emission regulations
If new or modified NOX emission regulations are introduced after the project start, determination of the
baseline scenario will be re-assessed at the start of a crediting period. Baseline scenario alternatives to be
analysed should include, inter alia:
• SCR De-NOX installation;
• NSCR De-NOX installation;
• Tertiary measures incorporating a selective catalyst for destroying N2O and NOX emissions;
• Continuation of the original baseline scenario.
For the determination of the adjusted baseline scenario the project participant should re-assess the
baseline scenario and shall apply baseline determination process as stipulated above (Steps 1-5).
Table 1: Potential consequence of re-assessment of the baseline scenario
Potential outcomes of the re-assessment
Consequence
of the baseline scenario
(adjusted baseline scenario)
(to be in line with NOX regulation)
SCR De-NOX installation
Continuation of the original (N2O) baseline
scenario
NSCR De-NOX installation
The N2O emissions outlet of NSCR become
adjusted baseline N2O emissions, as NSCR may
reduce N2O emissions as well as NOX
Tertiary measure that combines NOX and N2O Adjusted baseline scenario results in zero N2O
page 16
emission reduction
Continuation of the original baseline scenario
emission reduction
Continuation of the original baseline scenario
Sub Step 5b: New or modified N2O regulation
If legal regulations on N2O emissions are introduced or changed during the crediting period, the baseline
emissions shall be adjusted at the time the legislation is legally enforced.
The methodology is applicable if the procedure to identify the baseline scenario results in that the most
likely baseline scenario is the continuation of emitting N2O to the atmosphere, without the installation of
N2O destruction or abatement technologies, including technologies that indirectly reduce N2O emissions
(e.g. NSCR DeNOX units).
B.5.
Description of how the anthropogenic emissions of GHG by sources are reduced below
those that would have occurred in the absence of the registered CDM project activity (assessment
and demonstration of additionality):
As stipulated in AM0034, the latest version (i.e. version 04) of the “Tool for demonstration and
assessment of additionality” (additionality tool) is applied to demonstrate additionality of the project.
Step 1: Identification of alternatives to the project activity consistent with current laws and
regulations:
This step is omitted as suggested by AM0034. The identification of the baseline scenario was already
covered in the analysis carried out in section B.4.
Step 2: Investment analysis:
Sub-step 2a: Determine appropriate analysis method:
Since the project does not generate financial or economic benefits other than CDM related income, the
simple cost analysis is applied.
Sub-step 2b: Apply simple cost analysis:
The purpose of the simple cost analysis is to determine whether the project is financially less attractive
than any other baseline alternatives without CER revenues. The baseline alternative is identified as the
continuation of the current practice (i.e. no N2O or NOX abatement), which does not require any
additional costs. On the other hand, the project requires substantial investment and O&M costs but does
not generate any marketable products or by-products in the absence of the CDM. The capital costs for the
monitoring equipment are about 8 million Philippine Pesos (Php), while the annual costs for O&M of the
monitoring equipment and secondary catalyst are estimated to be 5 million Php. Therefore, in the absence
of CER revenues, the project is clearly financially less attractive than the baseline scenario.
Step 3: Barrier analysis is omitted. The additionality tool (version 04) says, “If it is concluded that the
proposed CDM project activity is not financially attractive then proceed to Step 4 (Common practice
analysis)”.
Step 4: Common practice analysis:
page 17
N2O is typically released into the atmosphere from nitric acid plants because it does not have any
economic value or toxicity at typical emission levels. Therefore, most counties do not have regulations or
incentives to reduce N2O emissions from nitric acid plants. Like many other countries, the Philippines
does not have any enforced regulations on N2O emission levels. As a consequence, there is no
precedence in N2O emission reduction at nitric acid plants in the country. Further, there is no other nitric
acid plant in the Philippines. Therefore, the project is clearly not the common practice in the country.
Conclusion:
Currently, there is no national regulation or legal obligation in the Philippines to reduce N2O emissions
from nitric acid plants. Therefore, ONPI is in no need to invest in any N2O emission reduction
technology at the Bacong nitric acid plant. Hence, the project is clearly a voluntary action to combat the
climate change in a proactive manner. No such N2O emission reduction projects at nitric acid plants are
observed in the Philippines.
Without the sales of CERs, the project would only result in substantial investment and O&M costs.
Therefore, the net present value (NPV) of the project would be negative. However, the revenue from the
sales of the CERs will offset the substantial costs for the secondary catalyst and monitoring equipment,
thus enabling the project to be undertaken. Based on the ex-ante estimation of the CER generation from
the project, it is expected that the CER sales revenue will make the NPV of the project investment
positive and financially attractive over the chosen crediting periods. Therefore, the CDM registration of
the project is essential for ONPI to commit investing in the project; hence the project is additional to the
identified baseline scenario.
B.6.
Emission reductions:
B.6.1. Explanation of methodological choices:
Baseline emissions:
1. Determination of the permitted operating conditions of the nitric acid plant to avoid
overestimation of baseline emissions:
In order to avoid the possibility that the operating conditions of the nitric acid production plant are
modified in such a way that increases N2O generation during the baseline campaign, the normal ranges
for operating conditions shall be determined based on at least the last five complete campaigns,
excluding abnormal ones (or fewer, if the plant has not been operating for five campaigns).
Table 2 summarizes the last seven historic campaigns of the Bacong nitric acid plant. The campaigns
No.1 and 3 are considered abnormal because the average daily acid production was considerably lower
towards the middle of the catalyst campaign and onwards. The catalyst analysis results show rhodium
oxide formation and oil contamination in the form of chlorides and sulphur. Therefore, the campaigns are
excluded from the determination of the permitted operating conditions.
page 18
Table 2: Summary of the historic campaigns of the Bacong nitric acid plant
25/6/2007
(12:56 AM)
30/10/2006
(5:30 PM)
05/05/2006
(1:00 PM)
Last ACE
tripping (prior
to gauze
change)
21/12/2007
(12:25 AM)
16/06/2007
(11:30 PM)
25/10/2006
(1:30 AM)
19/09/2005
20/09/2005
(9:30 PM)
04/05/2006
(1:00 AM)
225.0
5,400.0
18,773.1
Johnson
Matthey*2
1.5
5
03/02/2005
03/02/2005
(9:30 PM)
18/09/2005
(1:00 AM)
225.2
5,403.6
21,008.9
Johnson
Matthey*2
2.9
6
07/06/2004
09/06/2004
(5:00 PM)
29/01/2005
(2:00 AM)
233.4
5,601.1
21,791.3
Johnson
Matthey*2
5.8
7
04/11/2003
05/11/2003
(7:00 AM)
06/06/2004
(6:00 PM)
213.4
5,121.6
16,357.5
Johnson
Matthey*2
3.0
Gauze
installation
date
1
21/06/2007
2
30/10/2006
3
04/05/2006
4
First successful
firing (after
gauze change)
Average*3
Days
Hours
100% Nitric
acid produced
(t)
Catalyst
provider
Days
off-line
178.0
4,271.5
16,447.3
Heraeus*1
1.4
228.2
5,476.1
20,837.5
Heraeus*1
8.1
171.5
4,116.0
15,465.7
Johnson
Matthey*2
5.7
225.0
5,400.5
19,753.7
*1 – 62% Pt/ 4% Rh/ 34% Pd.
*2 – 74% Pt/ 5% Rh/ 21% Pd.
*3 – The average figures exclude the campaign No.1 and 3 as abnormal campaigns.
4.2
The analysis of the permitted operating conditions is based on the historical campaigns up to the start of
the baseline campaign, which is expected to start in July 2008. At the time of validation of the project,
however, the necessary plant operation data for the currently running campaign is not available.
Therefore, the permitted operating conditions given in this PDD are tentative estimates. The permitted
operating conditions will finally be determined based on the historical campaign data up to the start of the
baseline campaign and assessed by the verification DOE at the initial verification.
Based on the currently available historical campaign data, excluding the abnormal campaigns No.1 and 3,
the permitted operating conditions are tentatively estimated as follows:
page 19
Table 3: Permitted operating conditions of the Bacong nitric acid plant (tentative estimates)
Description
Parameter
Value
Source
* Analysis of the operation condition
campaigns in accordance with AM0034
procedures
Normal range for oxidation temperature
(°C)
OTnormal
675.8 - 996.2
Normal range for oxidation pressure
(bar-g)10
OPnormal
3.7 - 4.9
*.As above
Maximum ammonia gas flow rate to the
ACE (Nm3/h)
AFRmax
1,652.1
* As above
Maximum ammonia to air ratio (% v/v)
AIFRmax
11.1
* As above
2. Determination of baseline emission factor: measurement procedure for N2O concentration and
gas volume flow:
N2O concentration and gas volume flow are monitored throughout the baseline campaign, using a
monitoring system consistent with the European Norm (EN) 14181 (2004). In the absence of any national
or regional regulations for N2O emissions, the resulting baseline N2O emissions factor will be used as the
baseline emission factor unless the plant operates outside the permitted range for more than 50% of the
duration of the baseline campaign. If the plant operates outside the permitted range for more than 50% of
the duration of the baseline campaign, the baseline campaign will be repeated.
Impact of regulations:
In case N2O emissions regulations that apply to nitric acid plants are introduced in the Philippines, such
regulations will be compared to the calculated baseline emissions factor EFBL of the project. A
corresponding plant-specific emissions factor cap is to be derived from the regulatory level in accordance
with AM0034.
The composition of the ammonia oxidation catalyst:
As shown in Table 2 above, the ammonia oxidation catalyst supplier was changed in October 2006 from
Johnson Matthey to Heraeus. This was because Heraeus catalysts have proven in other plants to provide
better ammonia oxidation efficiencies at lower cost than the Johnson Matthey catalysts. Both Johnson
Matthey and Heraeus are commonly used manufacturers of catalysts for nitric acid production
worldwide. The two catalyst manufacturers use similar materials to manufacture their catalysts and they
operate in the same location, using the same equipment. Consequently, there was no change in plant
operation as a result of the catalyst change.
Historic Campaign Length
10
The oxidation pressure data for the entire historical campaigns are not available at the Bacong nitric acid plant. On
the other hand, the plant has continuously measured pressure of the primary air to the ammonia air mixer. Since the
location of this pressure probe has remained and will remain the same during the historical, baseline, and project
campaigns, the primary air pressure is used to establish the permitted pressure range.
page 20
Based on the historic campaign data summarized in Table 2, the average historic campaign length is
determined as 19,753.7 tHNO3 (100% HNO3). The value is a tentative estimate based on the currently
available data. The final value will be determined based on the historical campaign data up to the start of
the baseline campaign and assessed by the verification DOE at the initial verification.
Baseline Campaign Length
The project plans to initiate the baseline campaign in July 2008. The baseline emissions factor EFBL will
be calculated subject to the conditions on the baseline campaign length stipulated in AM0034. The
results will be made available at the initial verification.
Project emissions:
Project Campaign Length
The project plans to initiate the first project campaign in January 2009. The project campaign emissions
factor EFn will be calculated subject to the conditions on the project campaign length stipulated in
AM0034. The results will be made available at the initial verification.
Leakage:
No leakage calculation is required. Therefore, no methodological choice is involved.
Emission reductions will be calculated as per AM0034; there are no specific methodological choices that
need to be explained in detail.
B.6.2. Data and parameters that are available at validation:
This section describes the data and parameters that are available at validation. All the data will be archived in
electronic and paper forms at least for two years after the end of the crediting period.
Data / Parameter:
Data unit:
Description:
Source of data used:
Value applied:
Justification of the
choice of data or
description of
measurement methods
AFRmax
Nm3/h
Maximum ammonia flow rate (at the STP condition)
Plant records
1,652.1 Nm3/h
In accordance with AM0034, AFRmax is used to determine those periods where
the plant may be operating outside the permitted operating conditions. The
upper limit to the ammonia gas flow rate shall be determined using one of the
following three options, in a preferential order:
page 21
and procedures
actually applied :
Any comment:
Data / Parameter:
Data unit:
Description:
Value applied:
choice of data or
description of
measurement methods
and procedures
actually applied :
a) Historical maximum operating data for hourly ammonia gas flow rate
for the previous five campaigns (or fewer, if the plant has not been
operating for five campaigns; excluding abnormal campaigns); or
b) If no data is available, calculation of the maximum permitted ammonia
gas flow rate as specified by the ammonia oxidation catalyst
manufacturer or for typical catalyst loadings; or
c) If information for b) is not available, based on a relevant literature
source.
The maximum ammonia to air ratio is tentatively assessed according to the
option a) based on the currently available data. As explained in section B.6.1,
the final value will be determined based on the historical campaign data up to
the start of the baseline campaign and assessed by the verification DOE at the
initial verification.
None.
Any comment:
AIFRmax
% v/v
Maximum ammonia to air ratio
Molar ratio of NH3 flow per (Air flow + NH3 flow)
11.1% v/v
In accordance with AM0034, AIFRmax is used to determine those periods where
upper limit to the ammonia to air ratio shall be determined using one of the
following three options, in a preferential order:
a) Historical maximum operating data for hourly ammonia to air ratio for
the previous five campaigns (or fewer, if the plant has not been
operating for five campaigns; excluding abnormal campaigns); or
b) If no data is available, calculation of the maximum permitted ammonia
to air ratio as specified by the ammonia oxidation catalyst manufacturer
or for typical catalyst loadings; or
c) If information for b) is not available, based on a relevant literature
source.
The maximum ammonia to air ratio is tentatively assessed according to the
None.
Data / Parameter:
Data unit:
Description:
Value applied:
choice of data or
OTnormal
°C
Normal operating temperature
Thermocouple
675.8 – 996.2 °C
In accordance with AM0034, OTnormal is used to determine those periods where
page 22
description of
measurement methods
and procedures
actually applied :
Any comment:
Data / Parameter:
Data unit:
Description:
Value applied:
choice of data or
description of
measurement methods
and procedures
actually applied :
upper and lower limits to the oxidation temperature shall be determined using
one of the following three options, in a preferential order:
a) Historical data for the operating range of temperature from the previous
five campaigns (or fewer, if the plant has not been operating for five
campaigns); or, then
b) If no data on historical temperature is available, the range of
temperature stipulated in the operating manual for the existing
equipment; or,
c) If no operating manual is available or the operating manual gives
insufficient information, from an appropriate technical literature
source.
The normal operating temperature is tentatively assessed according to the
None.
OPnormal
bar-g
Normal oxidation pressure
Pressure probe
3.7 – 4.9 bar-g
The manual reading of oxidation pressure has been taken since July 2007.
Therefore, the oxidation pressure data for the entire historical campaigns are
not available at the Bacong nitric acid plant. On the other hand, the plant has
continuously measured pressure of the primary air to the ammonia air mixer.
Since the location of this pressure probe remained and will remain the same
during the historical, baseline, and project campaigns, the primary air pressure
is used to establish the permitted pressure range.
In accordance with AM0034, OPnormal is used to determine those periods where
upper and lower limits to the oxidation pressure shall be determined using one
of the following three options, in a preferential order:
a) Historical data for the operating range of pressure from the previous
five campaigns (or fewer, if the plant has not been operating for five
campaigns); or, then
b) If no data on historical pressure is available, the range of temperature
stipulated in the operating manual for the existing equipment; or,
c) If no operating manual is available or the operating manual gives
insufficient information, from an appropriate technical literature
source.
The normal oxidation pressure is tentatively assessed according to the option a)
based on the currently available data. As explained in section B.6.1, the final
value will be determined based on the historical campaign data up to the start of
the baseline campaign and assessed by the verification DOE at the initial
page 23
verification.
None.
Any comment:
B.6.3
Ex-ante calculation of emission reductions:
Baseline emissions:
The baseline campaign has not been completed at the time of validation. The results will be available at
the initial verification. The following ex-ante calculation of the baseline emissions is based on the
following assumptions:
Table 4: Assumptions for the ex-ante baseline emission calculation
Description
Parameter
Value
Mean gas volume flow rate at the stack
during the baseline campaign (Nm3/h)
VSGBC
37,167.3
Mean concentration of N2O in the stack
gas during the baseline campaign
(mgN2O/Nm3)
Source
* Diluted stack gas volume flow11 estimated
from Process Flow Diagram (Original Vendor
Drawing Number 114910-11T020101) and
laboratory samples. The value is at the STP
condition.
* Samples of diluted stack gas12 taken by a
temporary Procal instrument. The value is at
the STP condition.
NCSGBC
330.6
Operating hours of the baseline
campaign (hours)
OHBC
5,400.5
* Average of the last five campaigns
(excluding abnormal ones)
Nitric acid production during the
baseline campaign (tHNO3)
NAPBC
19,753.7
Overall uncertainty of the monitoring
system (%)
UNC
2.8%
* Individual uncertainty - CEMS: +2%; Flow
meter: +2%. Overall uncertainty calculated in
accordance with the Gauss law of error
propagation.
Based on the equation (1), the total N2O emissions during the baseline campaign (BEBC) is calculated as:
BEBC = VSGBC * NCSGBC * OHBC * 10-9
= 37,167.3 * 330.6 * 5,400.5 * 10-9
= 66.4 (tN2O)
Consequently, the baseline N2O emission factor (EFBL) is calculated based on the equation (2):
11
The stack at the Bacong nitric acid plant has a large hole in its base. This hole draws in air by convection (the
chimney effect), diluting the tail gas. The current NOx instrument is in the stack above this hole. This instrument is
modified to allow the measure of N2O. There is no path for the N2O to bypass the NOx instrument, i.e. there is no
leakage of N2O emissions. Namely, the dilution air reduces the concentration measured, but not the absolute rate of
N2O emissions.
12
Ibid.
page 24
EFBL = (1 – UNC/100) * (BEBC / NAPBC)
= (1-2.8/100) * (66.4/19,753.7)
= 0.00336 (tN2O/tHNO3)13
Project emissions:
The following ex-ante calculation of the project emissions is based on the following assumptions:
Table 5: Assumptions for the ex-ante project emission calculation
Description
Parameter
Value
Mean gas volume flow rate at the stack
during the project campaign (Nm3/h)
VSG
37,167.3
Mean concentration of N2O in the stack
gas during the project campaign
(mgN2O/Nm3)
NCSG
33.1
OH
5,400.5
NAPn
19,753.7
Operating hours of the nth project
campaign (hours)
Nitric acid production during the
project campaign (tHNO3)
Source
* Diluted stack gas volume flow14 estimated
from Process Flow Diagram (Original Vendor
Drawing Number 114910-11T020101) and
laboratory samples. The value is at the STP
condition.
* Samples of diluted stack gas15 taken by a
temporary Procal instrument, with an assumed
N2O reduction rate of 90%. The value is at the
STP condition.
The total N2O emissions during the project campaign (PEn) are calculated in accordance with the equation
(3):
PEn = VSG * NCSG * OH * 10-9
= 37,167.3 * 33.1 * 5,400.5 * 10-9
= 6.64 (tN2O)
Consequently, the N2O emission factor for a specific project campaign “n” (EFn) is calculated based on
the equation (4):
EFn = PEn / NAPn (tN2O/tHNO3)
= (6.64/19,753.7)
= 0.000336 (tN2O/tHNO3)16
13
Minor rounding error is involved.
14
See footnote 11.
15
Ibid.
16
Minor rounding error is involved.
page 25
As the ex-ante project emission calculation is based on the assumed constant figures in Table 5, the
moving average emission factor (EFma,n) equals to EFn. Consequently, the emission factor that will be
applied to calculate the emission reductions from the specific campaign (EFP) is EFn.
Leakage:
No leakage calculation is required.
The emission reductions of the project over the specific campaign are calculated following the equation
(7) as:
ER = (EFBL – EFP) * NAP *GWPN2O
= (0.00336 - 0.000336) * 19,753.7 * 310
= 18,508 (tCO2e)17
The emission reductions per campaign are multiplied by the number of campaigns per annum to calculate
the annual emissions reductions. In the following calculation, the number of campaigns per annum is
based on the average value during the operation condition campaigns:
ERy = ER * 365/ (campaign length + days offline per campaign)
= 18,508 * 365/ (225.0 + 4.2)
= 29,474 (tCO2e)18
B.6.4
Summary of the ex-ante estimation of emission reductions:
Year
2009
2010
2011
2012
2013
2014
2015
Total
(tonnes of CO2 e)
17
Ibid.
18
Ibid.
Estimation of
project activity
emissions
(tonnes of CO2 e)
Estimation of
baseline emissions
(tonnes of CO2 e)
Estimation of
leakage
(tonnes of CO2 e)
Estimation of
overall emission
reductions
(tonnes of CO2 e)
3,276
3,276
3,276
3,276
3,276
3,276
3,276
22,932
32,759
32,759
32,759
32,759
32,759
32,759
32,759
229,315
0
0
0
0
0
0
0
0
29,474
29,474
29,474
29,474
29,474
29,474
29,474
206,319
page 26
B.7
Application of the monitoring methodology and description of the monitoring plan:
B.7.1
Data and parameters monitored:
This section describes the data and parameters to be monitored. All the data will be archived in electronic and
paper forms at least for two years after the end of the crediting period.
Data / Parameter:
Data unit:
Description:
Source of data to be
used:
Value of data applied
for the purpose of
calculating expected
emission reductions in
section B.5
Description of
measurement methods
and procedures to be
applied:
QA/QC procedures to
be applied:
Any comment:
Data / Parameter:
Data unit:
Description:
used:
for the purpose of
section B.5
Description of
measurement methods
applied:
19
See footnote 11.
20
Ibid.
NCSG
mgN2O/Nm3
N2O concentration in the stack gas (at the STP condition; diluted stack gas)
N2O analyzer
33.1 (mgN2O/Nm3; at the STP condition).19 As the project campaigns have not
been completed at the time of validation, the sampling results taken from October
to December 2007 are applied for the ex-ante calculation of emission reductions.
N2O reduction rate is assumed to be 90%.
Procal Model P240 LR is employed (supplier: Procal Analytics). It is an
automated in-situ gas analyzer based on the dual infrared wavelength principle. It
operates with the wavelength range from 2 to 12 µm. According to the
manufacturer’s specification, its margin of error is typically + 2% of full scale
concentration. The N2O analyzer is currently in the certification process of
QAL1 of EN 14181.
No additional QA/QC procedures are required.
None.
VSG
Nm3/h
Volume flow rate of the stack gas (at the STP condition; diluted stack gas)
Gas volume flow meter
37,167.3 (Nm3/h; at the STP condition).20 As the baseline campaign has not been
completed at the time of validation, the estimated value from Process Flow
Diagram (Original Vendor Drawing Number 114910-11T020101) and laboratory
samples is applied for the ex-ante calculation of emission reductions.
D-FL 100 is employed (supplier: Durag). It continuously monitors flow velocity
and flow rate of the stack gas using the differential pressure principle. It also
monitors temperature and pressure in the stack gas in order to calculate the flow
velocity and flow rate at calculate at the normal conditions. According to the
page 27
QA/QC procedures to
be applied:
Any comment:
Data / Parameter:
Data unit:
Description:
used:
for the purpose of
section B.5
Description of
measurement methods
applied:
QA/QC procedures to
be applied:
Any comment:
Data / Parameter:
Data unit:
Description:
used:
for the purpose of
section B.5
Description of
measurement methods
applied:
QA/QC procedures to
be applied:
Any comment:
manufacturer’s specification, its margin of error is typically + 2%. It has a TÜV
certification pursuant to the Federal German Pollution Control Act, 13th and 17th
Implementing Ordinances (13.BImSchV and 17.BImSchV) and the German
Clean Air Regulations (TA Luft). It is also certified to comply with MCERTS
performance standards for CEMS, version 2, revision 1 (April 2003).
None.
OH
Hours
Operating hours
Production log
5,400.5 (hours): Average of the last five campaigns (excluding the abnormal
ones).
During each catalyst change, the date is recorded. The operating hours is
computed from the time the catalyst is installed to the time it is removed for
replacement.
None.
NAP
tHNO3 (100% concentrated)
Nitric acid production (100% concentrated)
Production log
19,753.7 (tHNO3): Average of the last five campaigns (excluding the abnormal
ones).
An ultrasonic level meter is installed at the product acid tank. The level is
determined at the start of each day. The acid production from the previous
operating day is the change in the acid level plus the acid volume used in the
production of ammonium nitrate. The volume consumed is computed from
stoichiometric ratio of the tonnage of ammonium nitrate produced. The total acid
production is the sum of the daily productions over the entire campaign period.
None.
page 28
Data / Parameter:
Data unit:
Description:
used:
for the purpose of
section B.5
Description of
measurement methods
applied:
QA/QC procedures to
be applied:
Any comment:
Data / Parameter:
Data unit:
Description:
used:
for the purpose of
section B.5
Description of
measurement methods
applied:
TSG
°C
Temperature of the stack gas (diluted stack gas)
Temperature probe
N/A.
AM0034 requires the determination of gas volume flow at the normal conditions
in the stack. In order to calculate VSG at the normal conditions from monitored
VSG, the temperature in the stack is monitored by temperature probe installed in
the flow meter. The flow meter has a TÜV certification pursuant to the Federal
German Pollution Control Act, 13th and 17th Implementing Ordinances
(13.BImSchV and 17.BImSchV) and the German Clean Air Regulations (TA
Luft). It is also certified to comply with MCERTS performance standards for
None.
PSG
bar-g
Pressure of the stack gas (diluted stack gas)
Pressure probe
N/A.
AM0034 requires the determination of gas volume flow at the normal conditions
in the stack. In order to calculate VSG at the normal conditions from monitored
VSG, the pressure in the stack is monitored by pressure probe installed in the
flow meter. The flow meter has a TÜV certification pursuant to the Federal
German Pollution Control Act, 13th and 17th Implementing Ordinances
(13.BImSchV and 17.BImSchV) and the German Clean Air Regulations (TA
Luft). It is also certified to comply with MCERTS performance standards for
QA/QC procedures to
be applied:
Any comment:
None.
Data / Parameter:
NCSGBC
page 29
Data unit:
Description:
used:
for the purpose of
section B.5
Description of
measurement methods
applied:
QA/QC procedures to
be applied:
Any comment:
Data / Parameter:
Data unit:
Description:
used:
for the purpose of
section B.5
Description of
measurement methods
applied:
QA/QC procedures to
be applied:
Any comment:
Data / Parameter:
21
See footnote 11.
22
Ibid.
mgN2O/Nm3
N2O concentration in the stack gas (at the STP condition; diluted stack gas)
N2O analyzer
330.6 (mgN2O/Nm3; at the STP condition).21 As the baseline campaign has not
been completed at the time of validation, the sampling results taken from October
to December 2007 are applied for the ex-ante calculation of emission reductions.
Procal Model P240 LR is employed (supplier: Procal Analytics). It is an
automated in-situ gas analyzer based on the dual infrared wavelength principle. It
operates with the wavelength range from 2 to 12 µm. According to the
manufacturer’s specification, its margin of error is typically + 2% of full scale
concentration. The N2O analyzer is currently in the certification process of
QAL1 of EN 14181.
The N2O analyzer will be operated according to EN 14181. No additional
QA/QC procedures are required.
None.
VSGBC
Nm3/h
Volume flow rate of the stack gas (at the STP condition; diluted stack gas)
Gas volume flow meter
37,167.3 (Nm3/h; at the STP condition).22 As the baseline campaign has not been
completed at the time of validation, the estimated value from Process Flow
Diagram (Original Vendor Drawing Number 114910-11T020101) and laboratory
samples is applied for the ex-ante calculation of emission reductions.
D-FL 100 is employed (supplier: Durag). It continuously monitors flow velocity
and flow rate of the stack gas using the differential pressure principle. It also
monitors temperature and pressure in the stack gas in order to calculate the flow
velocity and flow rate at calculate at the normal conditions. According to the
manufacturer’s specification, its margin of error is typically + 2%. It has a TÜV
certification pursuant to the Federal German Pollution Control Act, 13th and 17th
Implementing Ordinances (13.BImSchV and 17.BImSchV) and the German
Clean Air Regulations (TA Luft). It is also certified to comply with MCERTS
performance standards for CEMS, version 2, revision 1 (April 2003).
None.
OHBC
page 30
Data unit:
Description:
used:
for the purpose of
section B.5
Description of
measurement methods
applied:
QA/QC procedures to
be applied:
Any comment:
Data / Parameter:
Data unit:
Description:
used:
for the purpose of
section B.5
Description of
measurement methods
applied:
Hours
Operating hours
Production log
5,400.5 (hours): Average of the last five campaigns (excluding the abnormal
ones).
During each catalyst change, the date is recorded. The operating hours are
computed from the time the catalyst is installed to the time it is removed for
replacement.
None.
NAPBC
Nitric acid production (100% concentrated) over the baseline campaign
Production log
19,753.7 (tHNO3): Average of the last five campaigns (excluding the abnormal
ones).
An ultrasonic level meter is installed at the product acid tank. The level is
determined at the start of each day. The nitric acid production from the previous
operating day is the change in the acid level plus the acid volume used in the
production of ammonium nitrate. The volume consumed is computed from
stoichiometric ratio of the tonnage of ammonium nitrate produced. The total
nitric acid production is the sum of the daily productions over the entire
campaign period.
QA/QC procedures to
be applied:
Any comment:
None.
Data / Parameter:
Data unit:
Description:
used:
for the purpose of
UNC
%
Overall measurement uncertainty of the monitoring system
Calculated as the combined uncertainty of the applied monitoring equipment at
the QAL2 test
2.8%: Tentatively calculated in accordance with the Gauss law of error
propagation as follows:
UNC = ((uncertainty of the gas analyzer: +2%)2 + (uncertainty of the flow meter:
page 31
section B.5
Description of
measurement methods
applied:
QA/QC procedures to
be applied:
Any comment:
Data / Parameter:
Data unit:
Description:
used:
for the purpose of
section B.5
Description of
measurement methods
applied:
QA/QC procedures to
be applied:
Any comment:
Data / Parameter:
Data unit:
Description:
used:
for the purpose of
section B.5
Description of
measurement methods
applied:
QA/QC procedures to
+2%)2)1/2.
The final value of the overall measurement uncertainty of the monitoring system
is to be calculated once at the QAL2 test, which is to be conducted after the
monitoring system is commissioned.
None.
AFR
Nm3/h
Ammonia gas flow rate to the ACE (at the STP condition)
Flow meter
N/A.
An orifice plate and pressure transmitters are provided at a position in the piping.
The volumetric flow rate is determined by the differential pressure across this
orifice plate. This data is reflected in the Distributed Control System (DCS) in
terms of real time trending. A report is also generated at the end of the shift
showing hourly readings.
None.
AIFR
% v/v
Ammonia to air ratio
Molar ratio of NH3 flow per (Air flow + NH3 flow)
N/A.
Volumetric flow meter and temperature transmitter are installed in the primary
air line and the ammonia line. Using the principle of differential pressure across
a fixed cross-section, volumetric flow rates are determined. This is compensated
for the temperature difference to get the molar ratio: NH3/ (Air + NH3). This data
is reflected in the DCS. A report is generated at the end of the shift showing
hourly readings.
page 32
be applied:
Any comment:
Data / Parameter:
Data unit:
Description:
used:
for the purpose of
section B.5
Description of
measurement methods
applied:
QA/QC procedures to
be applied:
Any comment:
Data / Parameter:
Data unit:
Description:
used:
for the purpose of
section B.5
Description of
measurement methods
applied:
QA/QC procedures to
be applied:
None.
CLnormal
Normal campaign length
Calculated from nitric acid production data
19,753.7 (tHNO3). Calculated from nitric acid production data (average
historical campaign length during the operation condition campaigns).
During each catalyst change, the date is recorded. The recorded acid production
on the days between each catalyst changed is added together. The daily acid
production is determined from the difference in the product acid tank level taken
using an ultrasonic level gauge plus the stoichiometric quantity of acid consumed
in the previous day’s ammonium nitrates production.
In accordance with AM0034, the normal campaign length is defined as the
average campaign length of the historic campaigns that were used to define the
permitted operating conditions. The value is a tentative estimate based on the
currently available data. As explained in section B.6.1, the final value will be
determined based on the historical campaign data up to the start of the baseline
campaign and assessed by the verification DOE at the initial verification
None.
CLBL
Length of the baseline campaign
page 33
Any comment:
None.
Data / Parameter:
Data unit:
Description:
used:
for the purpose of
section B.5
Description of
measurement methods
applied:
CLn23
Length of the project campaigns
QA/QC procedures to
be applied:
Any comment:
None.
Data / Parameter:
Data unit:
Description:
used:
for the purpose of
section B.5
Description of
measurement methods
applied:
QA/QC procedures to
be applied:
Any comment:
None.
Data / Parameter:
Data unit:
Description:
OPh
bar-g
Oxidation pressure for each hour
23
OTh
°C
Oxidation temperature for each hour
Thermocouple
N/A.
The temperature is determined via thermocouple probes inserted to the
thermowells in the ACE. The thermowells are a few centimetres below the
gauze. The temperature reading is reflected in the DCS. A report is generated at
the end of the shift showing hourly readings
This parameter is not listed in AM0034 (version 03). However, it is added in this PDD as it is considered necessary
for comparison of the project campaign length (CLn) and the average historical campaign length (CLnormal) (see
AM0034 (version 03), pp. 11).
page 34
used:
for the purpose of
section B.5
Description of
measurement methods
applied:
QA/QC procedures to
be applied:
Any comment:
Pressure probe
N/A.
A capacitive pressure transmitter is provided. This has a diaphragm sensor. The
change in the capacitive output is correlated to the pressure reading. This data is
reflected in the DCS. A report is generated at the end of the shift showing hourly
readings.
The manual reading of oxidation pressure has been taken since July 2007.
Therefore, the oxidation pressure data for the entire historical campaigns are not
available at the Bacong nitric acid plant. On the other hand, the plant has
continuously measured pressure of the primary air to the ammonia air mixer.
Since the location of this pressure probe remained and will remain the same
during the historical, baseline, and project campaigns, the primary air pressure is
used to establish the permitted pressure range.
None.
Data / Parameter:
Data unit:
Description:
used:
for the purpose of
section B.5
Description of
measurement methods
applied:
QA/QC procedures to
be applied:
Any comment:
None.
Data / Parameter:
GSBL24
24
GSnormal
Normal gauze supplier for the operation condition campaigns
Gauze supplier invoices
Johnson Matthey from 4 November 2003 to 25 October 2006;
Heraeus from 30 October 2006 onwards.
The name of the oxidation catalyst gauze supplier will be monitored by invoices
from the gauze supplier invoices.
This parameter is listed in Section “Data and parameters not monitored” section of AM0034 (version 03).
However, it is listed in Section “B.7.1 Data and parameters monitored” in this PDD as the project has not completed
the baseline campaign at the time of validation.
page 35
Data unit:
Description:
used:
for the purpose of
section B.5
Description of
measurement methods
applied:
QA/QC procedures to
be applied:
Any comment:
Data / Parameter:
Data unit:
Description:
used:
for the purpose of
section B.5
Description of
measurement methods
applied:
QA/QC procedures to
be applied:
Any comment:
Data / Parameter:
Data unit:
Description:
used:
for the purpose of
section B.5
Description of
Gauze supplier for the baseline campaign
N/A.
None.
GSProject
Gauze supplier for the project campaigns
N/A.
None.
GCnormal
Gauze composition for the operation condition campaigns
74% Pt/ 5% Rh/ 21% Pd from 4 November 2003 to 25 October 2006 (Johnson
Matthey);
62% Pt/ 4% Rh/ 34% Pd from 30 October 2006 onwards (Heraeus).
The composition of the oxidation catalyst gauze will be monitored by invoices
page 36
measurement methods
applied:
QA/QC procedures to
be applied:
Any comment:
Data / Parameter:
Data unit:
Description:
used:
for the purpose of
section B.5
Description of
measurement methods
applied:
QA/QC procedures to
be applied:
Any comment:
Data / Parameter:
Data unit:
Description:
used:
for the purpose of
section B.5
Description of
measurement methods
applied:
QA/QC procedures to
be applied:
Any comment:
25
None.
GCBL25
Gauze composition for the baseline campaign
N/A.
None.
GCProject
Gauze composition for the project campaigns
N/A.
None.
This parameter is listed in Section “Data and parameters not monitored” section of AM0034 (version 03).
However, it is listed in Section “B.7.1 Data and parameters monitored” in this PDD as the project has not started the
baseline campaign at the time of validation.
page 37
Data / Parameter:
Data unit:
Description:
used:
for the purpose of
section B.5
Description of
measurement methods
applied:
QA/QC procedures to
be applied:
Any comment:
B.7.2
EFreg
Emission level set by incoming policies or regulations
Official source of the policies or regulations
Not existent in the Philippines.
At the date of enforcement of the policies or regulations.
None.
Description of the monitoring plan:
1. Introduction
The purpose of this Monitoring Plan (MP) is to provide a standard in the conduct of monitoring and
consistent data recording by ONPI as required for the project verification. The monitoring plan for the
project is compliant with the monitoring methodology AM0034. Specifically, this MP facilitates the
following:
• Introduction of an appropriate monitoring system;
• Guide for the implementation of necessary measurement and management operation; and
• Guide for meeting the CDM requirements for verification and certification.
2. Operational and Management Structure
To ensure the successful operation of the project and the verifiability and creditability of the CERs
achieved, the project shall have the following management and operating system.
2.1 Process Description
a. Data collection: In the data collection process, the data will be grouped into three major
classifications:
i.
Primary data: Operation parameters and stack gas parameters which are measured
directly using in-situ instruments (transmitters). The readings are reflected on the DCS
along with the trend graphs. At the end of the shift, reports are generated showing the
average reading per hour.
page 38
Operation parameters = Oxidation temperature, oxidation pressure, ammonia gas
flow rate, ammonia-air ratio
• Stack gas parameters = N2O concentration, stack gas volumetric flow rate, stack gas
pressure, stack gas temperature
Secondary or derived data: Computed figures from primary data
• Nitric acid production = Previous day’s acid production is computed from the change
in the level of the product acid tank plus the tonnage of the acid consumed in the
manufacture of ammonium nitrate. This is computed in an excel worksheet. The total
acid production over the entire campaign is the sum of the daily acid production over
that period.
• Operating hours = The campaign operating hours shall be computed from the first
firing of the ammonia oxidation equipment until the last tripping of the equipment in
preparation for the next gauze change. This is computed in the excel worksheet.
• Tons of N2O = Previous day’s N2O is computed from the average N2O concentration
on the stack gas multiplied by the volume of the stack gas.
Miscellaneous data
• Catalyst supplier and composition = The catalyst supplier shall provide a catalyst
description for each shipment. Changes in catalyst composition will be reflected in
the document, including the reason for the change.
•
ii.
iii.
b. Data archiving: All data shall be archived as follows:
i.
Primary Data = A Historian unit will be installed. All DCS data shall be stored in this
system. In addition, the system will be connected through a Modem to another unit in
Australia which also stores the data.
ii.
Secondary Data = The excel worksheet containing all the secondary data shall be kept in
the local network. This excel file will be password protected. A back-up of the file will
be generated every Friday.
iii.
Miscellaneous Data = Miscellaneous data shall be kept in the purchasing file.
c. Calculation of emission reductions: At the end of each campaign period, the N2O emission
reduction shall be calculated using the method prescribed by AM0034.
d. Communication with the DOE and CDM EB: At the end of each monitoring period, a
monitoring report will be submitted to a DOE for verification of the emission reductions
achieved during the corresponding period. The DOE will then send a verification report to the
CDM EB for CER issuance.
page 39
2.2. Process Flow
In-situ Instruments
Primary
Data
Distributed Control
System (DCS)
DCS
Trends
Calculation
Secondary
Back-up Historian
(in Australia)
Local Historian
Data
Local Network
ER Calculation
Verification by a DOE
CER issuance by the CDM EB
2.3. Organizational Structure
Resident General Manager
Operations
Manager
Reliability
Manager
Operations
Supervisors
Instrumentation/
Electrical
Supervisor
DCS
Technicians
Instrumentation
Technicians
Purchasing
Orica Australia
Technical
Manager
Information
Technology
Consultant
2.4. Responsibilities and Accountabilities
a. Resident General Manager shall assume over-all responsibility of the project.
page 40
b. Operations Manager shall ensure that the data collected are accurate as to the level of confidence
required. He shall take charge of the computation of the daily figures as reflected in the
production summary, take note of the accuracy of catalyst change records, determine catalyst
campaign length and campaign figures. He shall address any issues referred to him by the
operations supervisors through coordination with the Reliability Manager.
c. Reliability Manager shall coordinate with the Operations Manager for the proper operation of the
monitoring system and address any abnormalities.
d. Technical Manager shall conduct routine review of the monitoring plan. He will routinely review
the figures reflected in the daily summary reports. He shall coordinate with Orica Australia for
any issues that will arise during the crediting period.
e. Instrumentation/Electrical (I/E) Supervisor shall ensure the functionality of the monitoring
system. He shall coordinate with operations to address the concerns and problems with the
monitoring equipment. He will also assign manpower to conduct QAL3.
f. Information Technology (IT) Consultant shall check the historian on routine basis if the data has
been properly stored. He shall also conduct routine back-up of the production summary report in
the network file.
g. Instrumentation Technician shall conduct QAL 3 on the monitoring equipment. He shall address
maintenance and operation issues of the monitoring equipment that will arise during the project
life.
h. Operations Supervisor shall check data abnormalities at the start of each shift. He will coordinate
with I/E Supervisor on any problems he noted and the issues elevated to him by the DCS
technicians. He will also record pertinent data during catalyst change.
i. DCS Technician shall ensure that required data are reflected in the DCS. Any observed
abnormalities shall be reported immediately to Operations Supervisor.
j. Purchasing shall keep gauze supplier files. Any changes in catalyst composition or supplier shall
be recorded and properly communicated to all concern.
k. Orica Australia shall provide technical support, conduct routine audit of the project compliance
to CDM requirements and assist in data monitoring though a backup historian. They shall
monitor backup files to identify irregularities for site action.
3. Quality Assurance and Quality Control Procedures
a. Monitoring Equipment
To ensure accuracy of the N2O emissions monitoring results, a QAL 1 certified N2O analyser is
employed. This unit shall undergo the QAL2, QAL3 and AST requirements of EN 14181. The gas
flow meter to be installed has a TÜV certification pursuant to the Federal German Pollution Control
Act, 13th and 17th Implementing Ordinances (13.BImSchV and 17.BImSchV) and the German Clean
Air Regulations (TA Luft). It is also certified to comply with MCERTS performance standards for
To protect the equipment from the harsh operating conditions, both monitoring units, the gas analyser
and the gas flow meter, are equipped with air purging system. The mechanism is automatic and does
not require human intervention. .
The data measured by the installed monitoring system is sent directly to the DCS. This system has a
historian that will archive the data without the need of human intervention. This will ensure data
page 41
integrity. In the event wherein abnormalities are observed, including manual adjustments done on the
monitoring equipment (e.g. manual purging), the incident shall be recorded on the Control Room
Logbook.
The recorded data, the N2O concentration and volumetric flow rate, shall be reviewed at the start of
each production day prior to encoding them to the daily productions summary. The summary will be
available on the local network. In addition, a back-up system is installed in Orica Australia. The
technical manager will be designated to review the data on routine basis. Should discrepancies be
observed, the root cause of the problem will be determined and corrective actions will be
implemented.
At the end of each campaign period, after the emission reduction calculations will be computed, a
report will be furnished to Orica Australia. The summary and the computed values shall be compared
against the back-up system record for verification. Again, should discrepancies be observed, the root
cause of the problem will be determined and corrective actions will be implemented.
On routine basis, a representative from Orica Australia shall visit the plant to conduct an internal
audit. This will be done to check GHG project compliance with operational requirements.
b. Training of Monitoring Personnel
Key plant personnel were trained when the gas analyser was installed. These individuals will also
undergo training once the gas flow meter will be installed. In addition, a representative from Orica
Australia has undergone training on EN 14181 in the UK. As part of the training process, he has
visited a plant with EN 14181-certified CEMS in practice. The learning he gained will be transferred
to the local staff through training. The representative will provide ongoing support to ONPI as
necessary.
c. Emergency Procedures
In the event that the monitoring system is down, the lower of the conservative IPCC value (4.5
kgN2O/tHNO3) and the last measured value will be applied for the downtime period for the baseline
emissions factor. Also, the highest measured value in the campaign will be applied for the downtime
period for the project campaign emissions factor.
In addition, any abnormal readings, which could be due to process shutdown and start-up, will be
eliminated from the computation. Erratic data trends occurring during a normal run will be
investigated for their causes and corrected. If these reading are outside the normal range (within 95%
of the distribution), they will also be eliminated from the computation.
The DCS data is stored in a historian system. In the event that the local historian will be
malfunctioning, figures from the back-up historian in Orica Australia will be utilized in the
computation.
page 42
B.8
Date of completion of the application of the baseline study and monitoring methodology
and the name of the responsible person(s)/entity(ies)
The baseline study and monitoring methodology has been determined on 28/03/2008 by:
Contact person:
Company name:
Telephone number:
Fax number:
E-mail:
Mr. Daisuke Hayashi
Perspectives Climate Change GmbH, Gockhausen, Switzerland
+41 44 820 42 13
+41 44 820 42 06
[email protected]
The person listed above is not a project participant.
page 43
SECTION C. Duration of the project activity / crediting period
C.1
Duration of the project activity:
C.1.1. Starting date of the project activity:
22 March 2008 (i.e. date of the gas analyzer installation).
C.1.2. Expected operational lifetime of the project activity:
21 years.
C.2
Choice of the crediting period and related information:
C.2.1. Renewable crediting period
The project participant has chosen renewable crediting periods of 3 x 7 years.
C.2.1.1.
Starting date of the first crediting period:
1 January 2009 or the date of registration of the project activity, whichever occurs later.
C.2.1.2.
Length of the first crediting period:
7 years.
C.2.2. Fixed crediting period:
N/A.
C.2.2.1.
Starting date:
C.2.2.2.
Length:
N/A
N/A.
page 44
SECTION D. Environmental impacts
D.1.
Documentation on the analysis of the environmental impacts, including transboundary
impacts:
The project will reduce N2O emissions, hence positively contributing to the global environment. The
secondary catalyst does not consume electricity, steam, fuels or reducing agents. It does not change the
current nitric acid production level either. Therefore, the overall energy and material balance of the plant
is not affected. Further, the exhausted secondary catalysts will be returned to the technology provider for
recycling. No waste liquids, solids or gases are generated by the project. Therefore, no negative impacts
on the environment or on the stakeholders are expected.26 An Environmental Impact Assessment (EIA)
for the proposed project type is not required by any relevant regulations or legislations in the Philippines.
D.2.
If environmental impacts are considered significant by the project participants or the host
Party, please provide conclusions and all references to support documentation of an environmental
impact assessment undertaken in accordance with the procedures as required by the host Party:
As there is no negative environmental impacts are expected by the project, an EIA is not required for
implementation of the project.
26
As of 28 March 2008, the application for an Environmental Compliance Certificate (ECC) is in process by the
Environmental Management Bureau (EMB) of DENR, the Philippines.
page 45
SECTION E. Stakeholders’ comments
E.1.
Brief description how comments by local stakeholders have been invited and compiled:
The local stakeholder consultation was conducted following the guidelines set under Annex II of DAO
2005-17.27 All documentation relevant to this stakeholder consultation was submitted to the Philippine
DNA as part of the project’s application for host country approval.
In order to invite the stakeholders of the project, written announcements in English and Cebuano
languages were published in the following six issues of a local newspaper prior to the event:
November 3, 2007, The Visayan Daily Star, pp. 11;
November 4, 2007, Daily Star- Star Life Sunday, pp. 9;
November 7, 2007, The Visayan Daily Star, pp. 9; and
November 8, 2007, The Visayan Daily Star, pp. 3.
Furthermore, stakeholders were identified and selected based on the definition of what constitutes a
“stakeholder” under DAO 2005-17.28 Then, written invitations to each of these stakeholders were given
by ONPI representatives indicating the purpose and details regarding the stakeholder consultation.
Additional announcements in English and Cebuano languages were also posted in the Barangay Halls of
Brgy. Buntis and Brgy. San Miguel to supplement the announcements in the newspapers and the written
invitations.
The local stakeholder consultation was conducted on November 9, 2007. It started at 9:30 in the morning
and ended at 11:30 in the morning. It was held in the Bacong Auditorium, a place chosen as the most
convenient, accessible and neutral venue for the consultation. A total of 104 participants composed of the
following attended the stakeholder consultation:
Representatives from the local government units of Barangays San Miguel, Buntis and South
Poblacion (Brgy. Captain, present and newly elected councilors/kagawad members);
Local government officials of the municipality of Bacong (the Mayor and the municipal
officials);
ONPI representatives (plant managers, supervisors and staff);
a representative from a Non –Government Organization;
a representative from a People’s Organization;
Department of Environment and Natural Resources representatives (PENRO and Dumaguete
Offices);
the CDM project team (ONPI and CaFiS Inc. on behalf of Perspectives GmbH); and
27
Implementing Rules and Regulations for Executive Order 320 Designating the Department of Environment and
Natural Resources as the National Authority for the Clean Development Mechanism
28
Paragraph 5.39 of the DAO 2005-17 defines stakeholders as “the public, including individuals, groups or
communities, affected, or likely to be affected, by the proposed CDM project activity”. This definition by the
Philippine DNA was taken from Paragraph 1(e) of Annex to decision 17/CP7 of the modalities and procedures for the
CDM.
page 46
Interested stakeholders within the local communities.
These participants were identified and selected based on the definition of what constitutes a “stakeholder”
under DAO 2005-17.29
Also, in accordance with the guidelines set by the Philippine DNA, a facilitator, Ms. Jocelyn R. Maxino
of the Purchasing, Quality Assurance and Loss Control Manager, of ONPI who is a local resident and
who speaks the local language, served as emcee and host during the stakeholder consultation.
Opening Session and Introductions
Each of the participants was called on to stand as a way of introducing them to all the stakeholders
present in the consultation. The Honourable Mayor of the Municipality of Bacong, Hon. Lenin P. Alviola,
was among the stakeholders invited and his presence was properly acknowledged. After all introductions
were made, all four ONPI managers as well as the CDM consultant were invited to sit in front so that they
can listen and address the queries that the stakeholders may have. The facilitator then explained the
purpose as well as the objectives of the stakeholder consultation. She also presented the agenda and
desired flow of the consultation.
Presentation of ONPI Company Profile
Engineer Arturo Ylagan, Resident General Manager, ONPI
To provide the stakeholders a background of the ONPI and the context as to why ONPI is undertaking the
proposed CDM project, Mr. Ylagan presented a brief history of the company, its vision and mission, the
location its plant, the people, the company’s products and its market. Since the proposed CDM project
will involve a reduction in one of the by-products in nitric acid production, Mr. Ylagan also explained
the chemical reactions that occur during production. The process flow in the production of nitric acid
was also explained to the stakeholders.
Mr. Ylagan delivered his presentation in cebuano, the local language.
Presentation of the Planned CDM N2O Project
Engineer Jackson Sia, Technical Manager, ONPI
As the designated ONPI personnel in-charge of the CDM project, Mr. Sia was tasked to explain the
proposed project to the stakeholders. To provide the stakeholders a thorough understanding of the context
of the project, Mr. Sia first explained the Kyoto Protocol, the landmark agreement that aimed to address
climate change, as well as the responsibilities of the parties that signed the Protocol (including the
Philippines). He then proceeded to explain the concept of the CDM as well as the relationships between
N2O & climate change, and ONPI’s production of nitric acid & the CDM.
29
Paragraph 5.39 of the DAO 2005-17 defines stakeholders as “the public, including individuals, groups or
communities, affected, or likely to be affected, by the proposed CDM project activity”. This definition by the
Philippine DNA was taken from Paragraph 1(e) of Annex to decision 17/CP7 of the modalities and procedures for the
CDM.
page 47
A comprehensive presentation of the planned N2O project followed next. This included a short discussion
of the technology, the local sustainable development benefits that the project can provide, and why CDM
is needed to make this project happen.
Mr. Sia delivered his presentation in cebuano, the local language.
Question and Answer Session
Facilitated by: Ms. Jocelyn Maxino, ONPI
Main language used: Cebuano
(translated and summarized for purposes of this documentation in English)
Mr. Apolinario Carino of the Mount Talinis People’s Organization’s Federation Incorporated, an NGO
which also represents a people’s organization was the first stakeholder to raise his questions and offer two
comments. He questioned that since the project only aims to reduce 85 to 95% of N2O emissions, there
will still be some emissions left. His concern was on the mitigating measures regarding the 5% N2O
emissions that cannot be reduced by the project activity. Mr. Carino’s comments, on the other hand, were
on the following: 1) The responsibilities of the different parties to the Kyoto Protocol, the need to
implement projects which support the Kyoto Protocol & his hope that the ONPI implement these type of
projects soon; and 2) that ONPI let more people be aware of the positive benefits of their project by
organizing or inviting field trips (e.g. for students).
Mr. Sia answered the question of Mr. Carino by explaining that the present available technology that
offers the highest N2O reduction is one with only 85 to 95% efficiency, and that there is no economically
feasible technology to further reduce the residual 5%.
Mr. Carino then offered another suggestion that, perhaps ONPI, as part of its mitigating measures to
reduce N2O and other gases, may consider enhancing its existing tree planting activities.
This suggestion was seconded by Mr. Mario Aragon of DENR – Dumaguete, saying that indeed nature
has a way of mitigating greenhouse gases, and ONPI should engage more in its tree-planting activities.
Mr. Mario also reminded ONPI that their office (DENR in Dumaguete) has seedlings that they can share
if ONPI wants to enhance its present tree planting activities.
Mr. Mario also addressed the question regarding the mitigation of the remaining 5% N2O emissions from
the point of view of the DENR and the government. He said that there is no law that requires N2O
reduction in the Philippines. Present Philippine standards have been substantially complied by ONPI and
the use of the said German technology with such efficiency rating is just an additional measure for ONPI
to enhance environmental quality of the plant.
Mr. Mario also encouraged ONPI to look into the possibility of capturing N2O and converting these to
nitrogen and oxygen which can be put into cylinders that the hospitals can use.
Mr. Edilberto Tubilag, a concerned resident of Brgy. San Miguel in Bacong also raised his concern
regarding the foul smell that emanates from the ONPI nitric acid plant on certain times.
Mr. Godofredo Pachorro, OIC - Operations Manager of ONPI, answered on behalf of the ONPI. He said
that the foul smell that can be experienced happens when there are occasional power failures which force
page 48
the plant to shutdown. He said that the ONPI strives to address this high emission during shutdowns by
improving on the equipments being used in the plant.
The next set of questions came from Mr. Arthur Noble, a representative of the local government of Brgy.
Buntis. He asked about how ONPI can ensure the 85-95% emission reduction so that it cannot affect the
local health of communities nearby.
Mr. Sia of ONPI answered that N2O does not affect local health directly, but it only contributes to global
warming. He reiterated that the monitoring of N2O emissions (because of this project) will consist of
effective procedures that meet the strict European standards. In addition, he informed the stakeholders
that Orica head office in Australia has designated a dedicated staff to train for EN 14181 in the UK. This
staff will then share his skills by training the local staff at the ONPI in Bacong. Mr. Sia then proceeded to
explain how the monitoring of N2O emission reductions will be done (i.e. data will be hooked to
computers in Australia through internet so that monitoring failures will be easily detected, and data is
backed up).
Mr. Sia also assured the stakeholders that the lease contract specifies for an 85-95% reduction. If the
monitoring will show that the results are not within the range, the supplier will replace the catalyst. He
said that t he lease price is based on the reduction rate.
Meanwhile, Mr. Rodolfo Laure, a local government official from North Poblacion suggested that since
ONPI has decided to invest in this N2O project, it would also be worth considering investing in studies
that can utilize N2O for commercial purposes. Mr. Laure thinks that investing in such studies can pave the
way for making possible the additional 5% reduction.
Mr. Sia, on behalf of the ONPI, responded to the suggestion of Mr. Laure by explaining that this is a pilot
project of ONPI and as such, if it becomes successful will be replicated in other Orica plants across the
globe. In the future, also, there is some possibility that maybe studies such as the one suggested by Mr.
Laure, might become possible.
Closing
Ms. Jocelyn Maxino, ONPI
The facilitator thanked all the stakeholders who joined the consultation. She also mentioned that this will
not be the last time that the stakeholders will be hearing about the project as every now and then ONPI is
conducting an “open house” in their plant. An “open house” is an opportunity for the stakeholders to visit
the plant, see the production process at ONPI and learn from it.
page 49
E.2.
Summary of the comments received:
In general, responses to the project during the stakeholder consultation were very favourable. Few
questions were asked, and all the questions were substantially addressed by the ONPI representatives
present during the consultation.
The following summarizes the issues and concerns raised during the consultation:
Issues
Mitigating
measures
regarding the 5%
N2 O
emissions
that cannot be
reduced by the
project activity
Specific Question/s
The project aims to reduce
only 85-95% of N2O
emissions. What about the
remaining 5% of emissions
that cannot be addressed
by the project?
Responses
Present available technology that offers the highest
N2O reduction is the one with 85 to 95% efficiency.
There is no available technology higher than this.
There is no economically feasible technology to further
reduce the residual 5%.
Also, there is no law that requires N2O reduction in the
Philippines. Present Philippine standards have been
substantially complied by ONPI and the use of the said
German technology with such efficiency rating is just
an additional measure for ONPI to enhance
environmental quality of the plant.
Monitoring
How do you ensure N2O does not affect local health directly, it only
measures for N2O monitoring
of
N2O contributes to global warming.
emissions
emissions to ensure that it
does not affect local health The monitoring of N2O emissions (because of this
of communities nearby?
project) will consist of effective procedures that meet
the strict European standards.
The Orica head office in Australia has designated a
dedicated staff in the person of Mr. Luke Rawnsley to
train for EN 14181 in the UK. He will then share his
skills by training the local staff at the ONPI in Bacong.
Furthermore, the catalyst lease contract specifies for an
85 to 95% reduction. If the monitoring results show
that the reductions are not within range, the supplier
will replace the catalyst. The lease price is based on the
reduction rate.
In addition, there is also a concern raised that is not directly related to the proposed CDM project
activity. Thus, even if the measures of ONPI substantially addresses this concern, the issue will not be
deemed included as part of the significant issues for the proposed CDM project activity that needs to be
mitigated. The issue which is summarized below is included here for purposes of documentation.
page 50
Issues
Experiences
of
some
stakeholders
regarding
foul
smell
that
emanates
from
the ONPI nitric
acid plant on
certain times
Specific Question/s
On certain times, foul smell
from
the
plant
is
experienced by people in
the nearby areas. Why do
these happen and how can
these be addressed?
Responses
The foul smell that can be experienced happens when
there are occasional power failures which force the
plant to shutdown.
The ONPI strives to address this high emission during
shutdowns by improving on the equipments being used
in the plant.
Various suggestions and affirmative comments were also mentioned during the Question-and-Answer
Session. These do not form part of the issues that the project has to address so there is no need to
provide/consider measures to directly address them. However, for purposes of documentation, these
comments and suggestions were noted. The following is a summary of these comments and suggestions:
•
•
•
•
To promote this first-of-a-kind project and to let more people be aware of the positive benefits of
these kinds of project, field trips (e.g. for students) will have to be organized.
The Philippines is a signatory to the Kyoto Protocol, so as part of adhering to its goals, we have
to implement projects such as this N2O reduction project. It is hoped that implementation of such
a project by ONPI has to be made soon.
As part of mitigating measures to reduce N2O and other gases, ONPI might consider enhancing
their existing tree planting activities.
Since ONPI has decided to invest in this N2O process anyway [by engaging in the proposed
CDM project activity], it is strongly suggested that ONPI further consider conducting studies that
can utilize N2O for commercial purposes.
E.3.
Report on how due account was taken of any comments received:
All the questions were substantially addressed by the ONPI representatives present during the
consultation. The project is not expected to incur any negative impacts on the environment or
stakeholders. This was confirmed during the stakeholder’s consultation wherein there was no
unfavourable response to the CDM project from the invitees. Consequently, no response measures are
considered necessary.
page 51
Annex 1
CONTACT INFORMATION ON PARTICIPANTS IN THE PROJECT ACTIVITY
Organization:
Street/P.O.Box:
Building:
City: (Municipality)
State(Province)/Region:
Postfix/ZIP:
Country:
Telephone:
FAX:
E-Mail:
URL:
Represented by:
Title:
Salutation:
Last Name:
Middle Name:
First Name:
Department:
Mobile:
Direct FAX:
Direct tel:
Personal E-Mail:
Orica Nitrates Philippines, Incorporated
KM 10 South Dumaguete Road/ PO Box 101 Dumaguete City (6200)
--Bacong
Negros Oriental/Region 7
6216
Philippines
+63 35 424 0310
+63 35 424 0247 and +63 35 424 0650
----Jackson Talbo Sia
Technical Manager
Engineer
Sia
Talbo
Jackson
Office of the Resident General Manager
+63 928 502 1753
+63 35 424 0247 and +63 35 424 0650
+63 35 424 0310 local 116
[email protected]
page 52
Annex 2
INFORMATION REGARDING PUBLIC FUNDING
No public funding is provided to the project.
page 53
Annex 3
BASELINE INFORMATION
The background information used in the application of the baseline methodology is summarized below.
Table 6: Example of the raw and processed data on the operating conditions of the Bacong nitric acid
plant
c
Date
31-Oct-2006
OH
h
1:00 AM
2:00 AM
3:00 AM
4:00 AM
5:00 AM
6:00 AM
7:00 AM
8:00 AM
9:00 AM
10:00 AM
11:00 AM
12:00 PM
1:00 PM
2:00 PM
3:00 PM
4:00 PM
5:00 PM
6:00 PM
7:00 PM
8:00 PM
9:00 PM
10:00 PM
11:00 PM
12:00 AM
AFR
Nm3/h
1339.20
1334.20
1334.60
1333.20
1332.20
1333.60
1337.30
1353.50
1327.20
1310.10
1293.60
1288.20
1343.60
1372.00
1360.70
1357.80
1361.40
1383.40
1375.90
1380.80
1383.80
1386.10
1391.30
1397.80
Raw data
AIFR
% v/v
10.56
10.48
10.49
10.44
10.43
10.45
10.44
10.63
10.41
10.35
10.38
10.35
10.22
10.34
10.32
10.28
10.22
10.39
10.33
10.32
10.35
10.34
10.33
10.35
11
OPh
bar-g
3.60
3.63
3.63
3.64
3.64
3.64
3.65
3.59
3.56
3.53
3.54
3.54
3.77
3.85
3.81
3.82
3.86
3.84
3.84
3.86
3.85
3.87
3.90
3.93
OTh
oC
864.10
860.80
861.20
859.80
859.20
860.10
860.30
871.00
860.50
858.60
860.70
858.80
854.70
860.50
861.30
858.50
854.70
863.30
861.20
858.90
861.20
861.20
860.90
861.50
Date
OH
h
31-Oct-2006 1:00 AM
2:00 AM
3:00 AM
4:00 AM
5:00 AM
6:00 AM
7:00 AM
8:00 AM
9:00 AM
10:00 AM
11:00 AM
12:00 PM
1:00 PM
2:00 PM
3:00 PM
4:00 PM
5:00 PM
6:00 PM
7:00 PM
8:00 PM
9:00 PM
10:00 PM
11:00 PM
12:00 AM
AFR
Nm3/h
1339.20
1334.20
1334.60
1333.20
1332.20
1333.60
1337.30
1353.50
1327.20
1310.10
1293.60
1288.20
1343.60
1372.00
1360.70
1357.80
1361.40
1383.40
1375.90
1380.80
1383.80
1386.10
1391.30
1397.80
Processed data
AIFR
OPh
% v/v
bar-g
10.56
10.48
10.49
10.44
10.43
10.45
10.44
10.63
10.41
10.35
10.38
10.35
10.22
3.77
10.34
3.85
10.32
3.81
10.28
3.82
10.22
3.86
10.39
3.84
10.33
3.84
10.32
3.86
10.35
3.85
10.34
3.87
10.33
3.90
10.35
3.93
OTh
oC
864.10
860.80
861.20
859.80
859.20
860.10
860.30
871.00
860.50
858.60
860.70
858.80
854.70
860.50
861.30
858.50
854.70
863.30
861.20
858.90
861.20
861.20
860.90
861.50
Note: The above table shows the plant operating conditions on 31 October 2006. The raw data is
processed as per AM0034 (OPh data are deleted for several hours in the processed data as they lie in the
lower 2.5 percentile of the data set).
First of all, rows with missing or abnormal data (e.g. data with negative values, data during start-up
periods30) are eliminated. For AFR and AIFR, the maximum parameter value found in the processed data
set is set as the permitted operating conditions, AFRmax and AIFRmax.
As for OTh and OPh, the mean (µ) and standard deviation (σ) of their processed data set are calculated.
Based on the mean and standard deviation, the upper and lower ends of the 95% confidence interval
(upper and lower limits) are calculated as “µ + 1.96 * σ” for OTh and OPh. For the data set of OTh and
OPh, all the data lying outside the 95% confidence interval are eliminated as outliers. The permitted
range of OTnormal and OPnormal is defined as the range between the minimum and maximum parameter
values found in the processed data set.
30
It is necessary to eliminate the start-up periods as AFIR is set intentionally high during these periods. The AFIR
data during these periods would incorrectly represents the permitted operating conditions, if it would have not been
excluded from the analysis. As the ACE will trip at AFIR of 11.2 % v/v, data rows with AFIR higher than or equal to
11.2 % v/v are excluded as start-up periods.
page 54
Table 7: Summary of the operating conditions campaigns of the Bacong nitric acid plant
Summary of operating condition campaigns (excl. abnormal ones)
OH
AFR
AIFR
OPh
OTh
h
Nm3/h
% v/v
bar-g
oC
Count
Raw
Processed
Remaining share of data sets
Minimum
Maximum
Mean
Standard deviation
27,035
21,542
21,046
98%
1.7
1,652.1
1,274.4
232.4
21,547
21,049
98%
0.0
11.1
8.9
1.3
21,598
20,353
94%
3.7
4.9
4.3
0.2
21,546
20,524
95%
675.8
996.2
872.5
10.0
* Permitted operating conditions in yellow
Limits for upper and lower 2.5% percentiles (OPh & OTh only)
Lower limit
Upper limit
3.7
4.9
674.8
1,041.6
Note: The above table shows the summary of the analysis of the operation condition campaigns
(excluding abnormal ones). The values highlighted yellow represent the permitted operating conditions
of the corresponding parameters.
page 55
Annex 4
MONITORING INFORMATION
Background of EN 1418131
EN 14181 describes the quality assurance procedures required to assure that a CEMS installed to
measure emissions to air are capable of meeting the uncertainty requirements on measured values given
by relevant legislation, e.g. EU Directives or national legislation, and more generally by competent
authorities.
Three different Quality Assurance Levels (QAL1, QAL2, and QAL3) are defined to achieve the
objective. These Quality Assurance Levels cover the suitability of a CEMS for its measuring task (e.g.
before or during the purchase period of the CEMS), the validation of the CEMS following its installation,
and the control of the CEMS during its ongoing operation on an industrial plant. An Annual Surveillance
Test (AST) is also defined.
The suitability evaluation of the CEMS and its measuring procedure are described in EN ISO 1495632
(QAL1). The total uncertainty of the CEMS is calculated from the evaluation of all uncertainty
components arising from its individual performance characteristics that contribute. EN 14181 is designed
to be used after the CEMS has been accepted according to the procedures specified in EN ISO 14956
(QAL1). In addition, EN 14181 is restricted to quality assurance of the CEMS, and does not include the
quality assurance of the data collection and recording system of the plant.
QAL1 (Instrument certification based on EN ISO 14956):
A CEMS to be used at installations covered by EU Directives shall have been proven suitable for its
measuring task (parameter and composition of the flue gas) by use of the QAL1 procedure, as specified
by EN ISO 14956. It shall be proven that the total uncertainty of the results obtained from the CEMS
meets the specification for uncertainty stated in the applicable regulations. In QAL1 the total uncertainty
required by the applicable regulation is calculated by summing in an appropriate manner all the relevant
uncertainty components arising from the individual performance characteristics.
QAL2 (Calibration and validation of the CEMS):
QAL2 is a procedure for the determination of the calibration function and its variability, and a test of the
variability of the measured values of the CEMS compared with the uncertainty given by legislation. The
QAL2 tests are performed on suitable CEMS that have been correctly installed and commissioned. A
calibration function is established from the results of a number of parallel measurements (at least 15
31
The EN 14181 description is based on Deutsches Institut für Normung (DIN) e.V. (2004) DIN EN 14181:
Stationary source emissions - Quality assurance of automated measuring systems.
32
International Standards Organization (ISO) (2002) ISO 14956: Air quality – Evaluation of the suitability of a
measurement procedure by comparison with a required measurement uncertainty.
page 56
valid measurements) performed with a Standard Reference Method (SRM). The variability of the
measured values obtained with the CEMS is then evaluated against the required uncertainty.
A QAL2 procedure shall be performed for all measurands at least every five years for every CEMS or
more frequently if so required by legislation or by the competent authority. Furthermore, a QAL2 shall be
performed for all the measurands influenced by any major change in plant operation (e.g. change in flue
gas abatement system or change of fuel), or any major changes or repairs to the CEMS, which will
influence the results obtained significantly. The results of the QAL2 shall be reported within six months
after the changes. During the period before a new calibration function has been established the previous
calibration function (where necessary with extrapolation) shall be used.
The implementation of QAL2 is the responsibility of an independent testing laboratory which has an
accredited quality assurance system according to EN ISO/IEC 17025,33 or is approved directly by the
relevant competent authority.
QAL3 (Ongoing quality assurance during operation):
After the acceptance and calibration of the CEMS, further quality assurance and quality control
procedures shall be followed so as to ensure that the measured values obtained with the CEMS meet the
stated or required uncertainty on a continuous basis. This is achieved by conducting periodic zero34 and
span35 checks on the CEMS – based on those used in the procedure for zero and span repeatability tests
carried out in QAL1 – and then evaluating the results obtained using control charts. Zero and span
adjustments or maintenance of the CEMS may be necessary depending on the results of the evaluation.
The implementation of QAL3 is the responsibility of the plant operator. It is also the responsibility of the
plant operator to ensure that the CEMS is operating within the valid calibration range.
AST (Verification of the continuing validity of the calibration function):
AST is a procedure which is used to evaluate whether the measured values obtained from the CEMS still
meet the required uncertainty criteria – as demonstrated in the previous QAL2 test. It also determines
whether the calibration function obtained during the previous QAL2 test is still valid. The validity of the
measured values obtained with the CEMS is checked by means of a series of functional tests as well as
by the performance of a limited number of parallel measurements (at least five valid measurements)
using an appropriate SRM.
The requirements and responsibilities for carrying out the AST tests are the same as for QAL2.
33
ISO/International Electrotechnical Commission (IEC) (1999) EN ISO/IEC 17025: General requirements for the
competence of testing and calibration laboratories.
34
Instrument reading of the CEMS on simulation of the input parameter at zero concentration.
35
Instrument reading of the CEMS for a simulation of the input parameter at a fixed elevated concentration.
page 57
Gas analyzer
The project employs Procal Model P240 LR, which is supplied by Procal Analytics, the UK. It is an
automated in-situ gas analyzer based on the dual infrared wavelength principle, which consists of the
following components:
• Optical head unit (Pulsi 200LR) – operates on dual infrared wavelength principle. It has an Auto
Zero Unit (AZU) which is an automatic zero and span calibration system;
• Analyser Control Unit (ACU) – processes raw data from OHU to produce concentration
readings;
• AZU – is triggered by the ACU which uses instrument air;
• In Situ Heater – contains an electrical heater which keeps the sample cell above the dew point;
and
• On line test gas – standard gas for calibration purposes.
The technical specifications and relevant certificate report of the gas analyzer are summarized in the
following figures.
Figure 7: Optical Head Unit of Procal Model P240 LR
page 58
Figure 8: Technical specifications of Procal Model P240 LR
page 59
Figure 8: Technical specifications of Procal Model P240 LR (cont’d)
page 60
page 61
page 62
Flow meter
The project employs D-FL100, which is supplied by Durag, Germany. It continuously determines the
flow velocity and flow rate of the stack gas using the pressure-differential principle. It also monitors
temperature and pressure of the stack gas in order to calculate the stack gas velocity and flow rate at the
normal conditions. The D-FL 100 system consists of the following components:
• Differential pressure bar – provides a defined separation point for the gas flow around its edges
to create differential pressure (i.e. impact pressure and reference pressure);
• Differential pressure transducer – measures the differential pressure; and
• D-FL 100-10 Display – evaluates the measuring signal from the differential pressure transducer.
Figure 9: D-FL 100 system components
The technical specifications and relevant certificate report of the flow meter are summarized in the
following figures.
page 63
Figure 10: Technical specifications of D-FL 100
page 64
Figure 10: Technical specifications of D-FL 100 (cont’d)
page 65
Figure 11: TÜV certification report for D-FL 100
page 66
Figure 12: MCERTS certification report for D-FL 100
-----

Bacong - PDD

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