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Protocol for Measurement of Tetrafluoromethane (CF4) and Hexafluoroethane (C2F6) Emissions from Primary Aluminum Production

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Protocol for Measurement of Tetrafluoromethane (CF4) and Hexafluoroethane (C2F6) Emissions from Primary Aluminum Production Protocol for Measurement of Tetrafluoromethane (CF4) and Hexafluoroethane (C2F6) Emissions from Primary Aluminum Production U.S. ENVIRONMENTAL PROTECTION AGENCY Washington, D.C. and the INTERNATIONAL ALUMINIUM INSTITUTE London, U.K. April 2008 Acknowledgements This Protocol has been developed as a joint initiative by the U.S. Environmental Protection Agency’s (EPA) Voluntary Aluminum Industry Partnership (VAIP) and the International Aluminium Institute (IAI). ICF Consulting completed the protocol under EPA Contract No. 68-W7-0069. Dr. Jerry Marks of J. Marks & Associates was the principal author. Sally Rand of the U.S. Environmental Protection Agency, Climate Change Division, served as the EPA Project Manager. Chris Bayliss reviewed the Protocol for the International Aluminium Institute and also coordinated review and validation by IAI member companies. Diana Pape and Ravi Kantamaneni of ICF International provided direction and assistance in preparing the protocol. Many key experts in the field of aluminum production and emissions measurement provided comments on the protocol throughout the protocol’s development. In particular, the authors appreciated the comments provided by Neal Dando, of Alcoa, Inc., Halvor Kvande of Hydro Aluminium, and Jean-Nicolas Maltias of Rio Tinto Alcan. Their comments based on their direct experience with PFC measurements improved the protocol. The EPA’s Voluntary Aluminum Industry Partnership was launched in 1995 to reduce emissions of PFCs emitted as a byproduct of the aluminum smelting process. VAIP members are Rio Tinto Alcan, Sebree Works; Alcoa, Inc.; Century Aluminum Company; Columbia Falls Aluminum Company; Noranda Aluminum Inc.; and the Aluminum Association. 1 Preface The first PFC Measurement Protocol was developed in 2003. This current version builds on the 2003 version, but contains a number of significant updates, incorporating both quantitative and methodological improvements. Some of the key updates include: • The incorporation of anode effect parameters which reflect recent results presented in the International Aluminium Institute’s “Report on the Aluminium Industry’s Global Perfluorocarbon Gas Emissions Reduction Programme: Results of the 2005 Anode Effect Survey” (IAI, 2007). • The utilization of data and estimation methodologies that are consistent with the 2006 IPCC Guidelines for National Greenhouse Gas Inventories. These include: revised slope and overvoltage factors, and the streamlining of Tier 3 coefficients into a single parameter for both slope and overvoltage, thus eliminating the Tier 3a and Tier 3b notation that was utilized in IPCC (2001). • The measurement of fugitive emissions is recommended only if fugitives are estimated to account for more than 10 percent of total PFC emissions, up from 5 percent in the 2003 version of the protocol. The change reflects additional measurement experience that has shown that fugitive emissions can be estimated with sufficient accuracy from data such as historical fluoride collection efficiency. When the collection fraction is greater than 90 percent, rooftop measurements of fugitive PFC emissions are difficult to make and the uncertainties are comparable with a good estimated value. • Based on recent measurement experience, some smelting process data requirements that have been shown to be superfluous have been eliminated, while other smelter data that has been shown to be useful has been added to the data collection requirements. • This version of the protocol also provides more specific guidance on sampling locations. • Spreadsheet templates have been updated to provide additional assistance in planning for measurements and in formatting measurement results to facilitate and maximize quality assurance. 2 TABLE OF CONTENTS TABLE OF CONTENTS.................................................................................................. 3 INTRODUCTION............................................................................................................. 4 BACKGROUND.............................................................................................................. 6 IPCC THREE-TIERED APPROACH............................................................................... 8 PROCESS DATA REQUIREMENTS .............................................................................. 9 SAMPLING DESIGN..................................................................................................... 14 PFC CONCENTRATION MEASUREMENT.................................................................. 22 CALCULATIONS.......................................................................................................... 25 QA/QC .......................................................................................................................... 31 SAFETY ........................................................................................................................ 33 MEASUREMENT FREQUENCY AND NEW MEASUREMENTS ................................. 33 APPENDIX A: DATA COLLECTION, CALCULATIONS, AND REPORTING TEMPLATE................................................................................................................... 34 APPENDIX B: SUPPLIERS ...................................................................................... 35 APPENDIX C: EXPECTED RANGE OF RESULTS BY TECHNOLOGY.................. 36 APPENDIX D: CHECKLIST ...................................................................................... 37 APPENDIX E: REFERENCES AND INFORMATION SOURCES ................................ 40 3 1.0 Introduction The purpose of this Protocol is to foster consistency in smelter-specific sampling programs.1 The specific objective of the described measurement process is to make measurements of tetrafluoromethane (CF4) and hexafluoroethane (C2F6) that allow the calculation of facility specific emission factors for the accurate estimation of CF4 and C2F6 emissions from primary aluminum production. These emission factors characterize the relationship between facility anode effect performance and periodically or continuously measured PFC. In addition to their role in the development and implementation of anode effect reduction strategies, one of the most important uses of these emission factors is for developing greenhouse gas inventories. The Intergovernmental Panel on Climate Change (IPCC) publishes default Tier 2 smelting technology-specific emission factors, however, as described in IPCC guidance, PFC emission estimates using Tier 3 facility-specific results is significantly higher accuracy.2 1.1 Objective of Measurement Protocol The specific objective of the measurement process, as described herein, is to make measurements of CF4 and C2F6 and collect pertinent smelter process data that allow the calculation of facility specific emission factors as described in the Intergovernmental Panel on Climate Change (IPCC) Tier 3 method. This document provides the necessary guidance to allow individual facilities to develop detailed plans for sampling and analysis based on plant-specific technology, anode effect data and chosen measurement instrumentation. Use of the protocol will result in more consistency in reports of PFC measurements. Additionally, integration of the new measurement data into future Tier 2 equation coefficients will lead to improved accuracy of IPCC Tier 2 PFC emissions calculations. Measurements of perfluorocarbons made over a period of several days provide only a short-term view of emissions for the specific section of cells for which the measurement is carried out. Furthermore, day-to-day variations in anode effect frequency and duration, as well as variations in production levels may well change the PFC emissions for the site. The calculation of long- term average emissions based on the Tier 3 methodology accounts for these temporal variations. 1.2 Why Measure PFCs? Central to any study of climate change is the development of an emissions inventory that identifies and quantifies anthropogenic sources and sinks of greenhouse gases. The most accurate estimates of PFC emissions from primary aluminum make use of facility-specific emission factors based on measurements at the individual production site. In general, industry and governments use inventories to support three major initiatives: 1 J. Marks, R. Kantamaneni, D. Pape and S. Rand, “Protocol For Measurement of Tetrafluoromethane and Hexafluoroethane From Primary Aluminum Production,” Light Metals (2003), pp 221 – 226. 2 Intergovernmental Panel on Climate Change, 2006 IPCC Guidelines for National Greenhouse Gas Inventories Volume 3, Industrial Processes and Product Use, Chapter 4, Section 4.4, Primary Aluminium Production, http://www.ipcc-nggip.iges.or.jp/public/2006gl/pdf/3_Volume3/V3_4_Ch4_Metal_Industry.pdf, pp 4.43 – 4.58. 4 • Benchmarking and Process Improvement. Benchmarking is an important management tool that helps companies evaluate emissions, set goals and develop strategies for reducing emissions. The understanding that is developed from measurements of PFC emissions at individual facilities can be the basis for a well- formulated process improvement plan. Accurate inventories of PFC emissions are also important in benchmarking performance against other producers operating with similar technologies. • United Nations Framework Convention on Climate Change. Countries that are signatories of the Framework Convention on Climate Change are responsible for reporting an annual inventory of greenhouse gas emissions. Over one hundred and
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