Document DM3yYRb5Bw0vDjOv47KvzQXOd

DATE: SUBJECT: FROM: THRU: TO: UNITED STATES ENVIRONMENTAL PROTECTION AGENCY REGION 5 77 WEST JACKSON BOULEVARD CHICAGO, ILLINOIS 60604 OCT 3 1 2018 CLEAN AIR ACT INSPECTION REPORT H.B. Fuller, Morris, Illinois Gregory Gehrig, Environmental Engineer AECAB (MI/WI) Sarah Marshall, Section Chief AECAB (MI/WI) File BASIC lNFORMATION Facility Name: H.B. Fuller Facility Location: 7440 W DuPont Road, Morris, IL Date of Inspection: September 17, 2018 EPA Inspectors: 1. Gregory Gehrig, Environmental Engineer 2. Kenneth Ruffatto, Environmental Engineer 3. Cary Secrest, Environmental Protection Specialist Other Attendees: 1. Yousheng Zeng, Providence Photonics 2. Sri Motyala, Providence Photonics 3. Jon Morris, Providence Photonics 4. Dan Deacon, Plant Manager, H.B. Fuller Contact Email Address: dan.deacon@hbfuller.com Purpose of Inspection: CAA Compliance Facility Type: Adhesives manufacturing Regulations Central to Inspection: SIP, NSPS and MACT Facility Name: H.B. Fuller Facility Location: 7440 W DuPont Road, M01Tis, IL Date of Inspection: September 17, 2018 Arrival Time: 08 IO hrs Departure Time: J 110 hrs Inspection Type: lZl Unannounced Inspection D Announced Inspection OPENING CONFERENCE 121 Credentials Presented 121 CBI warning to facility provided The following information was obtained verbally from facility personnel. Process Description: H.B. Fuller manufactures adhesives in batch processes utilizing 3 reactors. Each reactor makes between 4 to 7 batches per day, depending on the exact product specifications required. The facility operates '24/7' with 45 employees. The adhesives are not sold retail, but used in a variety of other products. including dry wall. laminate flooring, and packaging materials. Raw mate1ials include ethylene, vinyl acetate and water. These processes vent to flares associated with each reactor (l, 2 and 3). The reactor l flare is northern most flare, the reactor 2 flare is in the middle and the reactor 3 flare is to the south. Each flare was manufactnred by John Zink Co. and is air-assisted. John Zink Co. came to the facility and made recommendations for improvements on flare operations approx. two years ago that were implemented by H.B. Fuller. Preventative maintenance was conducted on the flares about two weeks ago during a plmmed maintenance shutdown. Neither vent gas nor assist air are directly measured. H.B. Fuller plans to install variable frequency drives on all three air assist fans staring next month with the fan on the reactor I flare. TOUR .l.NFORMAT!ON EPA toured the facility: Yes Data Collected and Ohservations: EPA contracted Providence Photonics (Providence) of Baton Rouge, LA to conduct flare observations at H.B. Fuller using a Video Imaging SpectraRadiography (VISR) imaging device, or VISR. VISR uses infrared sensing and imaging technology to detennine the combustion efficiency (CE) of hydrocarbons combusted by a flare with a visible flame. Providence used the VISR to observe the flming along with a dedicated standard video camera. EPA also utilized a FLIR camera to observe the flare and collect images. At the time of inspection, reactor I was venting ethylene to the reactor J flare. Also, during the inspection reactor 2 vented a de-foaming 'blow over', which routed ethylene, vinyl acetate and water to the reactor 2 flare for approximately 5 minutes. Page 2 of 4 Facility Name: H.B. Fuller Facility Location: 7440 W DuPont Road, Morris, IL Date oflnspection: September l 7, 2018 The VISR indicated an average CE over 99% on both flares for the periods observed. A description of FUR and camera images is provided in the digital image log below. A report from Providence on the VISR data and images is provided in Appendix A. EPA toured the facility and observed the flare control panel, the adhesive making process, including the reactors, the ethylene offloading area, and a carbon absorber used to control EPA G. Gehrig and K. Ruffatto conducted the opening conference, closing conference and toured the facility, while C. Secrest worked with the Providence crew and took FLIR observations and images. Field Measurements: were taken during this inspection. RECORDS REVIEW Basic information on flares (taken) Facility diagram (taken) CLOSLNG CONFERENCE Requested documents: Specifications of flares, including O&M manuals/procedures, design inforn1ation, a summary of recent preventative maintenance activities and 20] 6 recommendations by John Zink Co. (to be sent via email). JO-~/-/</ 10/3t/t8 Page 3 of4 Facility Name: H.B. Fuller Facility Location: 7440 W DuPont Road, Morris, IL Date of Inspection: September 17, 2018 DIGITAL IMAGE LOG* l. Inspector Name: Gregory Gehrig 3. Company/Facility Name: H.B. Fuller 5. Number of Images: 12 2. Date(s) oflnspection: September 17,2018 4. Street Address, City, State: 7440 W DuPont Road, Morris, IL 6. Archival Record Location: CD-R labeled H.B. Ful1er Images 9.17.2018 Time Image name (CDT) Description MVI 126 1029 Video of three flare system with Reactor #2 flare flarirni. IMG 0124 0900 Providence crew preparing to col1ect VISR data and images. IMG 0125 0901 Cary Secrest collecting OGI images. IMG 0127 1030 Flare control panel IMG 0128 1031 View of ethylene process IMG 0129 1035 Glue (product) at solids separation phase IMG 0130 1037 Carbon absorber, slated for replacement by TO next year MOV 0285 0850 FUR video of reactor l flare. MOV 0286 0853 FUR video of reactor 1 flare with slightly larger VOC signature. MOV 0288 0929 FUR video of reactor 1 flare with CE of 99 to 100%. MOV 0291 1043 FUR video of reactor 1 flare sudden increase, then shut down. DC 0289 1011 VISR set-up. *Note additional images of flares were collected by Providence as detailed in Appendix A. Page4 of 4 Facility Name: H.B. Fuller Facility Location: 7440 W DuPont Road, Morris, lL Date oflnspection: September 17, 2018 APPENDIX A: FIELD NOTES AND FIELD MEASUREMENT DATA Video Imaging Spectro-Radiography Report provided by Providence Photonics Appendices Page 1 of 1 Flare VISR Test Report Facility: H.B. Fuller Adhesives, LLC September 2018 Prepared for US Environmental Protection Agency Region 5 77 West Jackson Boulevard Chicago, IL 60604 PROVIDENCE PHOTONICS PROJECT NO. 1198-001 PREPARED BY Providence Photonics, LLC I 1201 Main Street, Baton Rouge, LA 70802 ~ PROVIDENCE , . PHOTON ICS Project No. 1198-001 US EPA Reg ion 5 Table of Contents INTRODUCTION ...................................................................................................................................... 2 SUMMARY OF VISR TEST RESULTS AND OBSERVATIONS ... .................................. ..... ........ .. .................... 2 Test Results and Observat ions - North Fla re... ... .. ... .. .... ..... .... .... .... ..................... ....... .. .............. ... ......... ... ..... .. .. 3 Test Results and Observations- Middle Flare ..... .. ......... .. ...... ... ................ .... .. .... ....... ............. ....... .. ......... .... .. .. .6 ELECTRONIC DATA GENERATED FROM THE TEST .... ....... ....... .... ...... .......................... ..... .. ........ ..... .. .... .... 8 REFERENCES .......... .......... .... ... ...... .............................................................................. ..... ......... .. ... ...... ... 8 Revised: 10/11/2018 5:41:00 PM Page 1 I8 Project No. 1198-001 US EPA Regio n 5 VISR Flare Testing Introduction EPA Region 5 retained Providence Photonics, LLC (Providence) to assist the inspection of H.B. Fuller Adhesives, LLC (HB Fuller) located at 7440 West DuPont Road, Morris, Illinois. Providence measured the combustion efficiency (CE) and other performance metrics of HB Fuller's North Flare and Middle Flare using the Video Imaging Spectral Radiometry (VISR) method. The South Flare was idling during the time of the inspection and therefore was not measured. The VISR method utilizes a multi-spectral mid-wave infrared imager to remotely and continuously measure relative concentrations of combustion gases. Based on these relative concentrations, flare CE is calculated. The VISR method provides continuous measurement of the following five flare performance metrics at 1-second data rate. Combustion Efficiency (CE): This is the primary metric that VISR measures. CE is the concentration of unburned hydrocarbons relative to the concentration of carbon dioxide (CO2, the end product of combustion) in the post-combustion gases. CE is expressed in percentage. If combustion is complete and there are no unburned hydrocarbons in the post-combustion gases, CE will be 100%. Smoke Index (SI): SI is used to indicate the level of smoke in the flare flame. It has a range of 0 to 10. When flare has no smoke, the SI is very low (generally below 1 to 2). As smoke level increases, the SI monotonically (but not linearly) increases. Flame Stability (FS): FS is used to measure the degree of flare radiance fluctuation with in 1 second, which indicates stability of the flare. It has a range of 0-100. When the FS value is in about 80 or higher, it generally indicates a very stable flare. Flame Footprint (FF): FF represents the flame cross section area (in square feet) of the flare and associated hot post-combustion gases perpendicular to the VISR instrument. The footprint is based on the Infrared radiance, and it is generally larger than the size of the flame observed in the visible spectrum by the naked eye. Heat Release (HR). HR measures the amount of heat released by the flare in regions of the midwave Infrared (MWIR) spectrum monitored by the VISR instrument. HR is reported as Btu/min. Because the HR only represents the energy released by the flare in the MWIR, the total heat released by the flare is larger than the HR metric reported by VISR. More information about the VISR method and its validation is provided at https ://www.providencephotonics.com/flare-monitoring . Summary of VISR Test Results and Observations Date: September 17, 2018 Personnel: Gregory Gehrig (EPA Region 5) Kenneth Ruffatto (EPA Region 5) Cary Secrest (EPA OECA) Yousheng Zeng (Providence) Jon Morris (Providence) Sri Mutyala (Providence) Revised: 10/11/2018 5:41:00 PM Facility: H.B. Fuller Adhesives, LLC 7440 West DuPont Road, Morris, Illinois 60450 Location of Flares and VISR Instrument: see Figures 1. Project No. 1198-001 US EPA Region 5 VISR Flare Testing Figure 1. Three air assisted flares at HB Ful ler. Left: Google map with a red "X" indicating the location of the VISR instrument and red circles indicating the locations of three flares. Distance: North Flare: 324 ft. Middle Flare: 315 ft. South Flare: 243 ft. This flare was in an idle condition and was not measured. Right: A photo of the three flares taken during the test. Test Results and Observations - North Flare Three flaring events were observed, in whole or in part. Test results for the North Flare are summarized in Table 1. Variability (or trending) of the flare during the test can be seen in Figures 2-4. Figure 5 provides a snapshot of the spectral image and a visible image of the flare. Table 1. VISR test resu lts for the North Flare Average for the Duration (8:40 am -10:45 am) 1-sec (Avg.-SD, Avg.+SD) Combustion Efficiency(%) 99.8 (99.3, 100.0)* Smoke Index (unitless) 1.08 (0.90, 1.26) Flame Stability (unitless) 85.1 (79.4, 90.9) Flame Footprint (ft2) 23.36 (13.24, 33.49) Heat Release (Btu/min) 212 (29, 394) *: (Avg.+SD) > 100, the value of 100 is assigned to the upper bound. 1-min (Avg.-SD, Avg.+SD) (99.6, 100.0) (0.94, 1.25) (80.4, 90.0) (13.41, 32.26) (42,363) Revised: 10/11/2018 5:41:00 PM Page3 I8 80:;:g:;i ' V> OOQJ ~f- rl ~ ~ G: tQJ -~ e > a.. 0~ QrnJ ac: ~ a.. I.W l/l :::::> IS 00000 ~ ~ ~ ~ ~ ~ ~ ~ ~ <"'! q N .-I .-t .-t .-I .-I O O O O O -~~~==-- -' 1-~--'----''-~-'------'-~~~~ ~I I -- = ! ~ : : ; - - :~ ' 1 10: 55 AM 10:50AM 10:45 AM 10:40 AM 10:35 AM ~-li;lliic='- vi' r +-' I 10:30 AM ' 10:25AM j 10:20 AM V> "O 'v, c :~:I - r -1. 10:15 AM I ('O rl l/) (I) I - LI.. ,_ . 10: 10 AM (./) , I I I LJ..J UQJ - - ~ .- 10:05 AM U '-fl " -~ - ~ Q~ J "'11111111!!~ = 'ro .L.cL +-' ,_ O Z 1 i... QJ ~ CO =--- :::r: ,_ II 10:00 AM . 9:55AM w 'v, .l:l 1 ] J 950AM I -~ .-1 ::I v, I . 1--- Q) 9:45 AM (./) '- I (Ou.. -o I ' 9:40AM ~ I -' u ' 9 :3 5 A M a, I IJ) 9 :30AM ~ I v, .,._ 9 :2 5 A M <rl o I - ...., -- I 9 '20AM wu -o 9:15 AM ~ _1 9:10 AM -~ ' l ' 9:05AM ~ ' ' 9:00AM ~ 8:55 AM .=: t 8 :50 AM ~ 8 :45AM ~ 8:40AM 8 :35AM ~ 0 0 0 0 0 0 0 0 qqq ciciciciciciciciooo . o,:;-,oor--.l.DLl)'</"rY")N.-1 N .-1 Q) S:I pue (%) 3J 5 0-.0 LI.. co {U!W/n:i.s) llH -.ta., ~ 0 0 0 0 ro ~8 ~8 8 o.. 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(I) r 9:15 AM ~ r ~:::i -I-- -- : g :::r: -~ - -~- 1-------i-- - - - -; t- - ' 9:10 AM 9:05AM 1 9:00AM 8:55 AM - 8 :50 AM 8:45AM 8 :40AM -~ ~ .S 2: ~ ~ :j. ~ /j; " ~ '--------------" oo Oo OO OO OO qO qO Oq 0 0 0 ci ci o o o '<I" NO 00 ID '<I" N .-1 .-1 .-1 ( bs) :1:1 8 :35AM z ~ orl rti -u QJ a., ,_ .~ ~ 32 _ _ __ _ _ _ _ _ ____, L-I.. Project No. n98-001 US EPA Region 5 VISR Flare Testing 100.0 98.0 96.0 -- 94.0 92.0 ~ 90.0 LU u 88.0 86.0 84.0 82.0 80.0 Flare CE in Different Averaging Periods HB Fuller - North Flare i I I ~ l JJI j I - I ~_J oooooooooo~~~~~~~~~~~~PPPPPPPPPPPPPP w~~~~oo~~NNWW~~~~999999999999~~ ~O~O~O~O~O~O~O~O~OO P PNN~ ~ ~~~~oo o~o~o~o~o~o~o~ sssssssssssssssss~~~~~~;~~~~~~~ local Time - CE (1-s) - CE (1-m) - cE (15-m) - CE (duration) Figure 4. North Flare. Time series plot of CE with different averaging periods. Figure 5. North Flare. Left: A representative composite spectral image generated by VISR instrument. Red colo r represents CO2; green color represents hydrocarbon; and blue or bluish white color represents aerosol (e.g., soot) or hot solid object (e.g., the shield fo r pilots) . Right: A representative image in visible spectru m. Rev ise d: 10/11/ 2018 5:41:00 PM Pages 18 Project No . 1198-001 US EP A Region 5 VISR Flare Testing Test Results and Observations - Middle Flare Flaring wa s observed for only several minutes and the test results for the M iddle Flare are summarized in Table 2. Variability (or trending) of the flare during the test can be seen in Figures 6-8. Figure 9 provides a snapshot of the spectral image and a visible image of the flare. Table 2. VISR test results for the Midd le Flare Average for the Duration (10:08 am -10:14 am) Combustion Efficiency (%) 99.4 Smoke Index (unitless) 0.89 Flame Stabi lity (unitless) 95.0 Flame Footprint (ft2) 178.24 Heat Release (Btu/min) 3,181 1-sec Avg. SD (99.2, 99.6) (0.75, 1.03) {93.3, 96.6) (159.06, 197.42) (2,689, 3,673) 1-min Avg. SD (99.3, 99.5) (0.76, 1.02) (94.7, 95 .2) (163.16, 195.06) (2,725, 3,704) 100.0 90.0 80.0 V'l 70.0 LL "O 60.0 C: lIQ 50.0 40.0 UJ u 30.0 20.0 10.0 0 .0 l--' 9 0 -...J )> s HB Fuller - Middle Flares (1-sec results) -'-- .... l--' 1--' 1--' 1--' l--' 1--' 0 0 9 9 9 9 6 6 1--' 1--' 1--' O'J I.D 0 1--' N IJJ )> )> )> s s s s ~ s local Time CE (1-s) - FS (1 -s) - SI (1-s) Figure 6. Midd le Flare. Time series plot of 1-second resu lts for CE, FS, and SI. 1 .40 1 .20 1.00 0 .80 iii 0.60 0.40 0.20 0.00 1--' 9 ~ s Rev ised : 10/1.1/2018 5:41:00 PM Page 6 I8 Project No . 1198 -001 US EPA Region 5 VISR Flare Testing 250.00 HB Fuller - Middle Flare (1 -second results) 200.00 ; 150.00 C" ~ tt 100.00 50.00 0.00 I-' I-' I-' I-' I-' I-' q 9 9 9 q 9 0 0 I-' I-' I-' I-' 00 \D 0 I-' N VJ )> s s s s s s Local Time - FF (1-s) - HR (1-s) Figure 7. Middle Flare. Time series plot of 1-second results for FF and HR. 5,000 4,500 4,000 - - 3,500 "2 3,000 E 2,500 .:..l. i:a 2,000 0:: 1,500 ::c 1,000 500 0 I-' 9 ~ s 100.0 9 8 .0 96.0 -- 94.0 92.0 ~ 90.0 w u 88.0 86.0 84.0 82.0 80.0 I-' q 0 '1 s Flare CE. in Different Averaging Periods HB Fuller - Mi ddle Flare V -- 7 I l I I I-' I-' I-' I-' I-' I-' I-' 9 9 q 9 q q 9 0 0 I-' I-' I-' I-' 00 \D 0 I-' N VJ ~ )> )> )> s s s s s s s Local Time - CE (1-s) - CE (1-m) ~ CE (15-m) - CE (duration) Figu re 8. Middle Flare. Time series plot of CE with different averaging periods. Revised: 10/11/2018 5:41:00 PM Project No. 1.198-001 US EPA Regio n 5 VISR Fl are Testing Figure 9. Middle Flare. Left: A representative composite spectral image generated by VISR instrument. Red color represents CO2; green color represents hydrocarbon; and blue or bluish white color represents aerosol (e.g., soot) or hot solid object (e.g., the shield for pilots). Right: A representative image in visible spectrum. Electronic Data Generated from the Test The following electronic data are submitted to the US EPA Region 5 as part of this report: A Microsoft Excel file containing second-by-second results from the VISR instrument, derived 1minute average resu lts, and 15-minute average results when applicable. Video recording of the flare during the test, taken by a regular video camera in visible spectrum . Spectral video generated by the VISR instrument. References 1. Validation of a New Method for Measuring and Continuously Monitoring the Efficiency of Industrial Flares, Y. Zeng, J. Morris, M. Dombrowski, J. Air & Waste Manage. Assoc. 66:76-86 (2016). 2. Performance Review of Remote and Direct Flare Combustion Efficiency Monitor, Y. Zeng and J. Morris, presented at American Fuel & Petrochemical Manufacturers (AFPM) 2017 Environmental Conference, Denver, Colorado, October 15-17, 2017 3. Video Imaging Spectral Radiometer (VISR) Based Flare Monitor, Y. Zeng, presented at Air Quality Measurement Methods and Technologies, Long Beach, California, November 7-9, 2017 More information about the VISR method and its validation can be found at https ://www.providencephotonics.com/flare -m o n i t o r i n g. Revised : 10/11/2018 5:41:00 PM Page 8 \ 8