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APPENDIX D ATMOSPHERIC EMISSION LICENCE APPLICATION

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Page 1: APPENDIX D ATMOSPHERIC EMISSION LICENCE APPLICATION · manufacturer), panel beating, and mechanical workshops. Saxon Industrial Park is bordered by Glucose Way to the east and railway

APPENDIX D

ATMOSPHERIC EMISSION LICENCE APPLICATION

Page 2: APPENDIX D ATMOSPHERIC EMISSION LICENCE APPLICATION · manufacturer), panel beating, and mechanical workshops. Saxon Industrial Park is bordered by Glucose Way to the east and railway
Page 3: APPENDIX D ATMOSPHERIC EMISSION LICENCE APPLICATION · manufacturer), panel beating, and mechanical workshops. Saxon Industrial Park is bordered by Glucose Way to the east and railway

Page 2 of 24

Table of Contents

1 TYPE OF APPLICATION .................................................................................................. 4

2 ENTERPRISE INFORMATION ........................................................................................... 4

3 SITUATION AND EXTENT OF THE PLANT ........................................................................ 5

3.1 Location and extent of plant .................................................................................. 5

3.2 Description of surrounding land use ....................................................................... 5

4 NATURE OF THE PROCESS ............................................................................................. 7

4.1 Process description ................................................................................................... 7

4.2 Listed activities ........................................................................................................ 10

4.3 Unit process or processes ....................................................................................... 11

4.4 Hours of operation .................................................................................................. 11

4.5 Graphical process information ............................................................................. 12

5 RAW MATERIALS AND PRODUCTS .............................................................................. 12

5.1 Raw materials used ................................................................................................ 12

5.2 Production rates ...................................................................................................... 13

5.3 Materials used in energy sources ......................................................................... 13

5.4 Sources of atmospheric emission (including all tiers of greenhouse gas) ...... 14

6 APPLIANCES AND MEASURES TO PREVENT AIR POLLUTION ...................................... 21

6.1 Appliances and control measures ....................................................................... 21

6.2 Start-up, maintenance, and shut down conditions ........................................... 22

6.3 Complaint register .................................................................................................. 22

7 DISPOSAL OF WASTE AND EFFLUENT ARISING FROM ABATEMENT EQUIPMENT ....... 22

8 ANNEX A | SIMPLIFIED BLOCK DIAGRAM ................................................................. 23

9 ANNEX B | BASIC SITE LAYOUT MAP ......................................................................... 24

Page 4: APPENDIX D ATMOSPHERIC EMISSION LICENCE APPLICATION · manufacturer), panel beating, and mechanical workshops. Saxon Industrial Park is bordered by Glucose Way to the east and railway

Page 3 of 24

List of Tables

Table 1: Enterprise information .............................................................................................. 4

Table 2: Contact details of the responsible person ............................................................ 4

Table 3: Location and extent of plant .................................................................................. 5

Table 4: Listed activities under NEMAQA ........................................................................... 10

Table 5: Scheduled processes under APPA ....................................................................... 10

Table 6: Unit processes .......................................................................................................... 11

Table 7: Hours of operation .................................................................................................. 11

Table 8: Raw materials used ................................................................................................ 12

Table 9: Production rates ...................................................................................................... 13

Table 10: Materials used in energy sources ....................................................................... 13

Table 11: Point source parameters ..................................................................................... 14

Table 12: Point source emissions .......................................................................................... 16

Table 13: Greenhouse gas emissions .................................................................................. 17

Table 14: Point source emissions monitoring requirements .............................................. 18

Table 15: Point source emission information ...................................................................... 19

List of Figures

Figure 1: The location of Lead and Solder Sales cc within Belville ................................... 6

Figure 2: Photographs of the 2% and 9% melting pots ....................................................... 7

Figure 3: Photographs of melting pots 1, 2 and 3 and the wire extruder ........................ 8

Figure 4: Photographs of the automated wheel balancing weight machines .............. 9

Figure 5: Photographs of the scrap metal separation process ......................................... 9

Page 5: APPENDIX D ATMOSPHERIC EMISSION LICENCE APPLICATION · manufacturer), panel beating, and mechanical workshops. Saxon Industrial Park is bordered by Glucose Way to the east and railway

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1 TYPE OF APPLICATION

X New Application Transfer

Renewal Variation/Amendment/Review

Current APPA Permit / Atmospheric Emission

Licence Number:

APPA Registration Certificate Number 1930

2 ENTERPRISE INFORMATION

Table 1: Enterprise information

Table 2: Contact details of the responsible person

Enterprise name Lead and Solder Sales cc

Trading as Lead and Solder Sales cc

Type of enterprise Closed corporation

Close corporation registration number 2010/104356/23

VAT registration number 4680133248

Business partner number Not applicable

Registered address Unit 6A, Saxon Park, Glucose Rd, Belville

Postal Address P.O. Box 457, Kasselsvlei, 7533

Telephone number (general) +27 21 951 4133

Fax number (general) +27 21 951 4318

Industry type/Nature of trade Manufacturing of solder and lead products

Land use zoning as per town planning scheme General Industrial 1

Land use rights if outside town planning scheme Not applicable

Responsible person name or emission control

officer (where appointed)

Lenon Guzha

Telephone number +21 951 4133

Cell phone number +27 73 141 4780

Fax number +27 21 951 4318

E-mail address [email protected]

After hours contact details +27 73 141 4780

Page 6: APPENDIX D ATMOSPHERIC EMISSION LICENCE APPLICATION · manufacturer), panel beating, and mechanical workshops. Saxon Industrial Park is bordered by Glucose Way to the east and railway

Page 5 of 24

3 SITUATION AND EXTENT OF THE PLANT

3.1 Location and extent of plant

Table 3: Location and extent of plant

3.2 Description of surrounding land use

Lead and Solder Sales cc (LASS) is situated within Saxon Industrial Park in Mimosa, a

general industrial area in Belville, in the City of Cape Town (Figure 1). Businesses within

the Saxon Industrial Park include Telesnacks, Kerlizons (a plastic product

manufacturer), panel beating, and mechanical workshops. Saxon Industrial Park is

bordered by Glucose Way to the east and railway line to the north. The Tongaat Hulett

Starch, Bellville Mill lies directly across Glucose Way from Saxon Industrial Park. SCP

Southern Canned Products and Transpaco Flexables are also situated along Glucose

Way, approximately 500 m from Lead and Solder cc.

The closest residential suburbs, within 1 km of Lead and Solder cc, are:

• Belville Lot 6, approximately 200 m to the west.

• Belville Lot 3, approximately 560 m to the south-west.

• Belrail, approximately 550 m to the north-west.

• Belville South Ext. 13, approximately 600 m to the south-east.

There are numerous schools, tertiary education and medical facilities within 5 km of

Lead and Solder cc. The closest school and hospital are; the Belville-suid Secondary

School (1 km to the south-west) and Belville Medical Centre (1.5 km to the north-west).

Physical address of the plant Unit 6A, Saxon Park, Glucose Rd, Belville

Description of site (Where no street address) Not applicable

Coordinates of approximate centre of operations 33°54'39" S

18°38'36" E

Extent (km²) 0.0032 km2 (3 200 m2)

Elevation above mean sea level (m) 73 m

Province Western Cape Province

Metropolitan/District municipality City of Cape Town

Local municipality Not applicable

Designated priority area Not applicable

Page 7: APPENDIX D ATMOSPHERIC EMISSION LICENCE APPLICATION · manufacturer), panel beating, and mechanical workshops. Saxon Industrial Park is bordered by Glucose Way to the east and railway

Page 6 of 24

Figure 1: The location of Lead and Solder Sales cc within Belville

Page 8: APPENDIX D ATMOSPHERIC EMISSION LICENCE APPLICATION · manufacturer), panel beating, and mechanical workshops. Saxon Industrial Park is bordered by Glucose Way to the east and railway

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4 NATURE OF THE PROCESS

4.1 Process description

LASS produces solder, pewter for the jewellery industry, sash weights for windows, and

wheel balancing weights as well as lead shot and billets. Raw materials in the form of

lead, tin, antimony, and copper ingots, are delivered by truck. Ingots are moved from

trucks to the factory store by forklift. The lead, solder, pewter, sash weight, and wheel

balancing weight manufacturing processes, are described hereafter.

4.1.1 Lead billets for wire and shot

Lead wire and shot are produced through the melting of lead and antimony ingots in

two six (6) tonne capacity melting pots referred to as the 9% and 2% pots (Figure 2a

and Figure 2b). The 9% and 2% refers to the amount of antimony in the alloy. Antimony

increases the hardness of the lead wire and shot. The melting pots are heated with

paraffin burners located at the bottom of each pot. The molten alloy is manually cast

into moulds and cooled using a soluble oil and water mixture. Cooled bars from the

moulds are then sent to the extruder or tumbler for the manufacturing of lead wire

and shot. Final products from this process include spooled lead wire, lead shot packed

in boxes, and if requested by a client, sold as lead billets.

Each melting pot is covered by an extraction hood (Figure 2c) to evacuate fumes

generated by the melting process from the factory. Fumes are released to

atmosphere through vents on the factory roof.

(a) 2% melting pot (b) 9% melting pot (c) 2% melting pot

extraction hood

Figure 2: Photographs of the 2% and 9% melting pots

Page 9: APPENDIX D ATMOSPHERIC EMISSION LICENCE APPLICATION · manufacturer), panel beating, and mechanical workshops. Saxon Industrial Park is bordered by Glucose Way to the east and railway

Page 8 of 24

4.1.2 Solder, sash weights, and pewter bars

To produce solder bars and sticks, lead, antimony and tin are melted in paraffin

heated pots (Figure 3b) referred to as melting pot 1, melting pot 2, and melting pot 3

(Figure 3a). Whereas melting pot 1 has a capacity of three (3) tonnes, melting pots 2

and 3 each have capacity of 600 kilograms. Molten alloy from these pots are

manually cast into trays and the solder bars cooled with a soluble oil and water

mixture. Solder bars are either sold as is, or extruded to form solder sticks and wire

(Figure 3).

To produce pewter, tin and copper is melted in pot 3 and similarly cast and cooled to

form pewter bars for the jewellery industry. Lead sash weights are manufactured from

lead melted in pot 2, which is cast into moulds and cooled using the soluble oil and

water mixture.

Each pot is covered by an extraction hood through which melting fumes are

extracted into a common duct. Fumes are leased to atmosphere through a vent in

the factory roof.

(a) Melting pots 1, 2 and 3

(from right to left)

(b) Melting pot 1

paraffin burner

(c) Extruder

Figure 3: Photographs of melting pots 1, 2 and 3 and the wire extruder

4.1.3 Wheel balancing weights

Lead billets are melted in seven (7) electric melting pots and automated casting

machines (Figure 4a). Several different sizes wheel balancing weights are

manufactured. A fume extraction hood is positioned above each machine (Figure

4b). Fumes from machine numbers 1 to 4 are extracted to a common duct and

vented through the wall of the factory near roof level. Machines 5, 6, and 7 each have

a dedicated duct and vent (Figure 4c).

Page 10: APPENDIX D ATMOSPHERIC EMISSION LICENCE APPLICATION · manufacturer), panel beating, and mechanical workshops. Saxon Industrial Park is bordered by Glucose Way to the east and railway

Page 9 of 24

(a) Wheel balancing

weight machine

melting pot and

automated casting

(b) Extraction hood

positioned over wheel

balancing weight

machine

(c) Extraction hood

ducting and capped

vent to atmosphere

Figure 4: Photographs of the automated wheel balancing weight machines

4.1.4 Metal recovery

LASS also operates a scrap metal separation and reclamation process on their

premises. Wastes such as old municipal street lamps are disassembled to extract

copper and other metals that are bagged and sent to a factory in Gauteng for

recycling. Only mechanical separation methods are used. Emissions from this process

are limited to dust and exhaust emissions from the three forklifts used to move

materials. These emissions are considered negligible.

(a) Forklift operational is scrap metal seperation area (b) Recovered lead

Figure 5: Photographs of the scrap metal separation process

Page 11: APPENDIX D ATMOSPHERIC EMISSION LICENCE APPLICATION · manufacturer), panel beating, and mechanical workshops. Saxon Industrial Park is bordered by Glucose Way to the east and railway

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4.2 Listed activities

Listed Activities, as published in terms of Section 21 of the National Environmental

Management Air Quality Act (NEMAQA) (no. 39 of 2004), conducted at the premises

are listed in Table 4. Scheduled Processes as per the Second Schedule of the repealed

Atmospheric Pollution Prevention Act (APPA) (no. 45 of 1965) are listed in Table 5.

Table 4: Listed activities under NEMAQA

Listed

Activity

Number

Category of

Listed Activity

Sub-

category of

the Listed

Activity

Name of the Listed

Activity Description of the Listed Activity

4 Metallurgical

industry 4.2

Combustion

installations

Combustion installations not

used primarily for steam raisin

and electricity generation.

4 Metallurgical

industry 4.13 Lead smelting

The extraction, processing and

use of lead in production by the

application of heat.

The production of lead-

containing electric batteries.

4 Metallurgical

industry 4.15

Processing of

arsenic, antimony,

beryllium,

chromium and

silicon

The metallurgical production

and processing of arsenic,

antimony, beryllium, chromium,

and silicon and their compounds

by the application of heat.

Table 5: Scheduled processes under APPA

APPA Registration

Certificate Number

Date of Registration

Certificate

Scheduled Process

Number

Scheduled Process

Description

1830 27 November 1992 23 Lead processes

Page 12: APPENDIX D ATMOSPHERIC EMISSION LICENCE APPLICATION · manufacturer), panel beating, and mechanical workshops. Saxon Industrial Park is bordered by Glucose Way to the east and railway

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4.3 Unit process or processes

Unit process associated with listed activities in operation at the premises are listed in

Table 6.

Table 6: Unit processes

Unit Process Unit Process Function Batch or Continuous Process

2% melting pot (6 t)

Melting of lead and antimony

to produce lead bars for billets,

wire or shot.

Batch

9% melting pot (6 t)

Melting of lead and antimony

to produce lead bars for billets,

wire or shot.

Batch

Melting pot 1 (3 t)

Melting of lead, antimony and

tin to produce solder bars, sticks

or wire.

Batch

Melting pot 2 (600 kg)

Melting of lead, antimony and

tin to produce solder bars, sticks

or wire; or

Melting lead to produce sash

weights.

Batch

Melting pot 3 (600 kg)

Melting of lead, antimony and

tin to produce solder bars, sticks

or wire; or

Melting of tin and copper to

produce pewter bars.

Batch

7 x wheel balancing weight

melting pot (700 kg) and

casting machines

Melting of lead to produce

wheel balancing weights. Continuous

4.4 Hours of operation

LASS’s operational hours are listed in Table 7. The factory is closed on Saturdays,

Sundays, and public holidays.

Table 7: Hours of operation

Unit Process Operating hours Number of Days Operated per

Year(a)

2% melting pot (6 t) Mon to Thu 07:30 to 16:00

Fri 07:15 to 13:00 250

9% melting pot (6 t) Mon to Thu 07:30 to 16:00

Fri 07:15 to 13:00 250

Melting pot 1 (3 t) Mon to Thu 07:30 to 16:00

Fri 07:15 to 13:00 250

Melting pot 2 (600 kg) Mon to Thu 07:30 to 16:00

Fri 07:15 to 13:00 250

Page 13: APPENDIX D ATMOSPHERIC EMISSION LICENCE APPLICATION · manufacturer), panel beating, and mechanical workshops. Saxon Industrial Park is bordered by Glucose Way to the east and railway

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Unit Process Operating hours Number of Days Operated per

Year(a)

Melting pot 3 (600 kg) Mon to Thu 07:30 to 16:00

Fri 07:15 to 13:00 250

7 x wheel balancing weight

melting pot (700 kg) and

casting machines

Mon to Thu 07:30 to 16:00

Fri 07:15 to 13:00 250

Notes:

(a) LASS operates 250 days per year. Except for the WBWM, melting pots produce products in

batches and might not be continually operational for 250 days of the year.

4.5 Graphical process information

The following is submitted with the application form:

• Annex A, a simplified block diagram

• Annex B, a basic site layout map (a floor plan was not available)

5 RAW MATERIALS AND PRODUCTS

Raw material information, production and by-production rates and emissions

information are supplied in this section of the application.

5.1 Raw materials used

Table 8: Raw materials used

Raw Material

Type

Maximum

Permitted

Consumption

Rate (Quantity)

Design

Consumption

Rate (Quantity)

Actual

Consumption

Rate (Quantity)

Units (Quantity

per Period)

Lead ingots n/a1 n/a 1 600 kg per month

Tin ingots n/a n/a 300 kg per month

Antimony ingots n/a n/a 100 kg per month

Copper ingots n/a n/a 30 kg per month

Water soluble oil

for cooling n/a n/a 40 litres per month

1 n/a, not available

Page 14: APPENDIX D ATMOSPHERIC EMISSION LICENCE APPLICATION · manufacturer), panel beating, and mechanical workshops. Saxon Industrial Park is bordered by Glucose Way to the east and railway

Page 13 of 24

5.2 Production rates

Table 9: Production rates

Raw Material

Type

Maximum

Permitted

Consumption

Rate (Quantity)

Design

Consumption

Rate (Quantity)

Actual

Consumption

Rate (Quantity)

Units (Quantity

per Period)

Lead billets, wire

and shot n/a n/a

Only if specifically

ordered,

maximum 500

kg per month

Solders n/a n/a 200 kg per month

Pewter n/a 300 kg per month

Sash weights n/a n/a 500 kg per month

Wheel balancing

weights n/a n/a 1 000 kg/month

5.3 Materials used in energy sources

Table 10: Materials used in energy sources

Materials for

Energy

Sulphur

Content of

the Material

(%)

Ash Content

of Material

(%)

Maximum

Permitted

Consump-

tion Rate

(Quantity)

Design

Consump-

tion Rate

(Quantity)

Actual

Consump-

tion Rate

(Quantity)

Units

(Quantity

per

Period)

Paraffin 0.05 Not

applicable n/a n/a 700

litres per

month

Page 15: APPENDIX D ATMOSPHERIC EMISSION LICENCE APPLICATION · manufacturer), panel beating, and mechanical workshops. Saxon Industrial Park is bordered by Glucose Way to the east and railway

Page 14 of 24

5.4 Sources of atmospheric emission (including all tiers of greenhouse gas)

5.4.1 Point source parameters

Table 11: Point source parameters

Unique

Stack ID Source Name

Latitude

(decimal

degrees)2

Longitude

(decimal

degrees)

Height of

Release

Above

Ground (m)

Height

Above

Nearby

Building (m)

Diameter at

Stack Tip /

Vent Exit (m)

Actual Gas

Exit Temp.

(°C)3

Actual Gas

Volumetric

Flow (m³/hr)4

Actual Gas

Exit Velocity

(m/s)

S01 2% melting pot

roof vent -33.910827° 18.643461° 7

2 m above

roof 0.25

Ambient,

20 ºC 41.3 14.0

S02 9% melting pot

roof vent -33.910827° 18.643461° 7

2 m above

roof 0.25

Ambient,

20 ºC 41.3 14.0

S03

Combined roof

vent of melting

pots 1, 2, and 3

-33.910827° 18.643461° 5.5 0.5 m above

roof 0.3

Ambient,

20 ºC 49.3 11.6

S04

Combined vent

for wheel

balancing

weight machines

1 to 4

-33.910735° 18.642893° 4.5

Below roof

level on the

side of the

building

0.18 Ambient,

20 ºC 28.2 18.5

S05

Wheel balancing

weight machines

5 vent

-33.910735° 18.642893° 3

Below roof

level on the

side of the

building

0.18 Ambient,

20 ºC 7.05 4.62

2 Point sources are in very close proximity to each other and more accurate GPS readings not available. Point sources are grouped by approximate

location. 3 Assumption 4 Actual values not available. Refer to Section 5.4.4 (page 19) for a description of the method adopted to calculate volumetric flow rate and exit

velocity

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Unique

Stack ID Source Name

Latitude

(decimal

degrees)2

Longitude

(decimal

degrees)

Height of

Release

Above

Ground (m)

Height

Above

Nearby

Building (m)

Diameter at

Stack Tip /

Vent Exit (m)

Actual Gas

Exit Temp.

(°C)3

Actual Gas

Volumetric

Flow (m³/hr)4

Actual Gas

Exit Velocity

(m/s)

S06

Wheel balancing

weight machine

6 vent

-33.910735° 18.642893° 3

Below roof

level on the

side of the

building

0.18 Ambient,

20 ºC 7.05 4.62

S07

Wheel balancing

weight machine

7 vent

-33.910735° 18.642893° 3

Below roof

level on the

side of the

building

0.18 Ambient,

20 ºC 7.05 4.62

Page 17: APPENDIX D ATMOSPHERIC EMISSION LICENCE APPLICATION · manufacturer), panel beating, and mechanical workshops. Saxon Industrial Park is bordered by Glucose Way to the east and railway

Page 16 of 24

5.4.2 Point source emissions

Since emission values have not been measured at the LASS, emissions reported below (Table 12) are estimates based on Minimum

Emission Standards reported under normal conditions of 273 K, 101. 3 kPa. Greenhouse gas emissions are included in Table 13.

Table 12: Point source emissions

ID Pollutant (mg/Nm³)5,6 (mg/Am³)7 g/s Averaging period Tons per annum Emission hours Type of emission

S01

Pb 2 1.84 6.56E-04 8-hour average 0.00469 8 h/d, 250 d/y Routine, continuous

PM(b) 100 92 3.28E-02 8-hour average 0.235 8 h/d, 250 d/y Routine, continuous

SO2 500 460 1.64E-01 8-hour average 1.17 8 h/d, 250 d/y Routine, continuous

NOx as NO2 2 000 1840 6.56E-01 8-hour average 4.69 8 h/d, 250 d/y Routine, continuous

S02

Pb 2 1.84 6.56E-04 8-hour average 0.00469 8 h/d, 250 d/y Routine, continuous

PM(b) 100 92 3.28E-02 8-hour average 0.235 8 h/d, 250 d/y Routine, continuous

SO2 500 460 1.64E-01 8-hour average 1.17 8 h/d, 250 d/y Routine, continuous

NOx as NO2 2 000 1840 6.56E-01 8-hour average 4.69 8 h/d, 250 d/y Routine, continuous

S03

Pb 2 1.84 7.83E-04 8-hour average 0.0056 8 h/d, 250 d/y Routine, continuous

PM(b) 100 92 3.92E-02 8-hour average 0.28 8 h/d, 250 d/y Routine, continuous

SO2 500 460 1.96E-01 8-hour average 1.4 8 h/d, 250 d/y Routine, continuous

NOx as NO2 2 000 1840 7.83E-01 8-hour average 5.6 8 h/d, 250 d/y Routine, continuous

S04 Pb 2 1.84 4.47E-04 8-hour average 0.0032 8 h/d, 250 d/y Routine, continuous

5 Section 21 Minimum Emission Standards for Section 21 listed activity subcategory 4.2, 4.13 or 4.15, plant status existing 6 Were PM emissions from more than one listed activity are released from a combined point source (ID 1, 2, and 3), the maximum PM Minimum

Emission Standard is applied 7 Reference conditions for actual pollutant concentrations, 293 K, 100 kPa

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ID Pollutant (mg/Nm³)5,6 (mg/Am³)7 g/s Averaging period Tons per annum Emission hours Type of emission

PM 30 27.6 6.71E-03 8-hour average 0.048 8 h/d, 250 d/y Routine, continuous

S05 Pb 2 1.84 1.12E-04 8-hour average 0.0008 8 h/d, 250 d/y Routine, continuous

PM 30 27.6 1.68E-03 8-hour average 0.012 8 h/d, 250 d/y Routine, continuous

S06 Pb 2 1.84 1.12E-04 8-hour average 0.0008 8 h/d, 250 d/y Routine, continuous

PM 30 27.6 1.68E-03 8-hour average 0.012 8 h/d, 250 d/y Routine, continuous

S07 Pb 2 1.84 1.12E-04 8-hour average 0.0008 8 h/d, 250 d/y Routine, continuous

PM 30 27.6 1.68E-03 8-hour average 0.012 8 h/d, 250 d/y Routine, continuous

Table 13: Greenhouse gas emissions

Source Pollutant Emission rate

Paraffin combustion at: 2% melting pot, 9% melting

pot, and melting pots 1 to 3

Total CO2eq 98.8 tonnes per annum

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5.4.3 Point source emissions monitoring

Emissions monitoring have, to date, not been conducted at LASS. Monitoring requirements are listed in Table 14.

Table 14: Point source emissions monitoring requirements

ID Emission Sampling / Monitoring Method Sampling

Frequency Sampling Duration

Measured

Parameters

S01 Standard sampling and analysis methods listed in

Annex A of Section 218 Annually

Standard sampling and analysis methods listed in

Annex A of Section 21

Pb, PM, SO2, and

NOx

S02 Standard sampling and analysis methods listed in

Annex A of Section 21 Annually

Standard sampling and analysis methods listed in

Annex A of Section 21

Pb, PM, SO2, and

NOx

S03 Standard sampling and analysis methods listed in

Annex A of Section 21 Annually

Standard sampling and analysis methods listed in

Annex A of Section 21

Pb, PM, SO2, and

NOx

S04 Standard sampling and analysis methods listed in

Annex A of Section 21 Annually

Standard sampling and analysis methods listed in

Annex A of Section 21 Pb, PM

S05 Standard sampling and analysis methods listed in

Annex A of Section 21 Annually

Standard sampling and analysis methods listed in

Annex A of Section 21 Pb, PM

S06 Standard sampling and analysis methods listed in

Annex A of Section 21 Annually

Standard sampling and analysis methods listed in

Annex A of Section 21 Pb, PM

S07 Standard sampling and analysis methods listed in

Annex A of Section 21 Annually

Standard sampling and analysis methods listed in

Annex A of Section 21 Pb, PM

8 Section 21 of the National Environmental Management Air Quality Act (Act 39 of 2004)

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5.4.4 Point source emission estimation information

Table 15: Point source emission information

ID Basis for Emission Rates

S01 Existing plant minimum emission standard (MES) for; subcategory 4.2 listed activity ‘Combustion processes’, subcategory 4.13 listed activity

‘Lead processes’, and subcategory 4.15 listed activity ‘Processing of arsenic, antimony, beryllium, chromium, and silicon’.

S02 Existing plant MES for; subcategory 4.2 listed activity ‘Combustion processes’, subcategory 4.13 listed activity ‘Lead processes’, and

subcategory 4.15 listed activity ‘Processing of arsenic, antimony, beryllium, chromium, and silicon’.

S03 Existing plant MES for; subcategory 4.2 listed activity ‘Combustion processes’, subcategory 4.13 listed activity ‘Lead processes’, and

subcategory 4.15 listed activity ‘Processing of arsenic, antimony, beryllium, chromium, and silicon’.

S04 Existing plant MES for; subcategory 4.13 listed activity ‘Lead processes’, and subcategory 4.15 listed activity ‘Processing of arsenic, antimony,

beryllium, chromium, and silicon’.

S05 Existing plant MES for; subcategory 4.13 listed activity ‘Lead processes’, and subcategory 4.15 listed activity ‘Processing of arsenic, antimony,

beryllium, chromium, and silicon’.

S06 Existing plant MES for; subcategory 4.13 listed activity ‘Lead processes’, and subcategory 4.15 listed activity ‘Processing of arsenic, antimony,

beryllium, chromium, and silicon’.

S07 Existing plant MES for; subcategory 4.13 listed activity ‘Lead processes’, and subcategory 4.15 listed activity ‘Processing of arsenic, antimony,

beryllium, chromium, and silicon’.

Volumetric

flow rates

(S01 to S07)

Calculation of point source volumetric flow rate:

Information on the volumetric flow rate of the fume extraction systems at LASS is not currently available. Theoretical estimates of volumetric

flow rates were made based on (a) available lead emission factors for solder manufacturing and (b) the MES of 2 mg/Nm3 lead for the lead

smelting process. The methodology is explained stepwise:

1. The scrubber controlled emission factor for melting pots used in solder manufacturing facilities is 0.023 kg Pb/tonne material processed.

2. A theoretical uncontrolled emission factor of 0.46 kg Pb/tonne material processed was calculated by conservatively assuming a

theoretical scrubber control efficiency of 95%.

3. LASS processes a total 2 030 kg of material per month. It was assumed that all material first passes through the 2% and 9% melting pots

before entering the rest of the process. Per melting pot, the following material processing rates were assumed based on pot capacity:

a. 2% melting pot, 850 kg/month

b. 9% melting pot, 850 kg/month

c. Melting pot 1, 203 kg/month

d. Melting pot 2, 508 kg/month

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ID Basis for Emission Rates

e. Melting pot 3, 305 kg/month

f. WBW machines 1 to 7, 145 kg/month-pot, 1 015 kg/month-total

4. Total Pb emissions per pot were calculated using the emission factor from step (2) and the pot throughputs from step (3) using the

following equation:

𝑒𝑚𝑖𝑠𝑠𝑖𝑜𝑛 𝑟𝑎𝑡𝑒 (𝑚𝑔

𝑠⁄ ) = 𝐸𝑚𝑖𝑠𝑠𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 (𝑘𝑔

𝑡𝑜𝑛𝑛𝑒⁄ ) ∙ 𝑡ℎ𝑟𝑜𝑢𝑔ℎ𝑝𝑢𝑡(𝑡𝑜𝑛𝑛𝑒𝑚𝑜𝑛𝑡ℎ⁄ ) ∙

1 000 000 (𝑚𝑔

𝑘𝑔⁄ )

166 (𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛𝑎𝑙 ℎ𝑜𝑢𝑟𝑠

𝑚𝑜𝑛𝑡ℎ⁄ ) ∙ 3 600 (𝑠

ℎ𝑜𝑢𝑟⁄ )

5. The total emission rate (in mg/s) calculated per point source since some emission sources share a common stack.

6. The normalised volumetric flow rate requirement for each point source (in Nm3/s) was calculated by assuming the minimum emission

standard of 2 mg/Nm3 will be met:

𝑣𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 (𝑁𝑚3

𝑠) =

𝑒𝑚𝑖𝑠𝑠𝑖𝑜𝑛 𝑟𝑎𝑡𝑒 (𝑚𝑔

𝑠)

𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑒𝑚𝑖𝑠𝑠𝑖𝑜𝑛 𝑠𝑡𝑎𝑛𝑑𝑎𝑟𝑑 (𝑚𝑔

𝑁𝑚3)

7. Actual volumetric flow rates (in Am3/s) were calculated at 100 kPa and ambient air temperature (293 K).

8. Stack gas exit velocities were calculated as follows:

𝑒𝑥𝑖𝑡 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 (𝑚

𝑠) =

𝑣𝑜𝑙𝑢𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 (𝐴𝑚3

𝑠)

𝑠𝑡𝑎𝑐𝑘 𝑒𝑥𝑖𝑡 𝑎𝑟𝑒𝑎 (𝑚2)

Greenhouse

gas

emissions

(S01 to S04)

Greenhouse gas emissions calculations are based on the carbon dioxide (CO2), methane (CH4) and nitrous oxide (N2O) emission factors for

distillate fuel oil of 2.7, 0.11 and 0.021 kg/L respectively. 4.2 L of paraffin is used per hour to heat the melting pots. The global warming potential

of CO2, CH4, and N2O is 1, 25 and 298 respectively. Emissions are reported as the total CO2eq.

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5.4.5 Area and/or line source parameters

Not applicable to LASS.

5.4.6 Area and/or line source emissions

Not applicable to LASS.

5.4.7 Area and/or line source management and mitigation measures

Not applicable to LASS.

5.4.8 Area and/or line source emissions estimation information

Not applicable to LASS.

6 APPLIANCES AND MEASURES TO PREVENT AIR POLLUTION

6.1 Appliances and control measures

At the time of writing this application, no pollution control or appliances were installed at LASS.

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6.2 Start-up, maintenance, and shut down conditions

Due to the nature of the process, the variation in atmospheric emissions during start-up, operation, and shut down is considered

immaterial.

6.3 Complaint register

Is a complaint register maintained at the site of works?

X Yes No complaints received

No

To be initiated, by date:

7 DISPOSAL OF WASTE AND EFFLUENT ARISING FROM ABATEMENT EQUIPMENT

Not currently applicable to LASS.

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8 ANNEX A | SIMPLIFIED BLOCK DIAGRAM

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9 ANNEX B | BASIC SITE LAYOUT MAP