General terms

Term used

Definition

Base coat

Paint which, when applied to a substrate, determines the colour and the effect (e.g. metallic, pearlescent).

Batch discharge

Discharge of a discrete, contained volume of water.

Clear coat

Coating material which, when applied to a substrate, forms a solid transparent film with protective, decorative or specific technical properties.

Combiline

Combination of hot-dip galvanising and coil coating in the same process line.

Continuous measurement

Measurement using an automated measuring system permanently installed on site for continuous monitoring of emissions, according to EN 14181.

Direct discharge

Discharge to a receiving water body without further downstream waste water treatment.

Emission factors

Coefficients that can be multiplied by known data such as plant/process data or throughput data to estimate emissions.

Existing plant

A plant that is not a new plant.

Fugitive emissions

Fugitive emissions as defined in Article 57(3) of Directive 2010/75/EU.

Grade B or C creosote

Types of creosote for which specifications are given in EN 13991.

Indirect discharge

Discharge which is not a direct discharge.

Major plant upgrade

A major change in the design or technology of a plant with major adjustments or replacements of the process and/or abatement technique(s) and associated equipment.

New plant

A plant first permitted on the site of the installation following the publication of these BAT conclusions or a complete replacement of a plant following the publication of these BAT conclusions.

Off-gas

The gas extracted from a process, piece of equipment or area which is either directed to treatment or discharged directly to air through a stack.

Organic compound

Organic compound as defined in Article 3(44) of Directive 2010/75/EU.

Organic solvent

Organic solvent as defined in Article 3(46) of Directive 2010/75/EU.

Plant

All parts of an installation that carry out an activity listed in point 6.7 or 6.10 of Annex I to Directive 2010/75/EU and any other directly associated activities which have an effect on consumption and/or emissions.

Plants may be new plants or existing plants.

Primer coat

Paint formulated for use as a layer on a prepared surface, to provide good adhesion, protection of any layers below and filling of surface irregularities.

Sector

Any of the surface treatment activities that are part of activities listed in point 6.7 of Annex I to Directive 2010/75/EU and are referred to in Section 1 of these BAT conclusions.

Sensitive receptor

Area which needs special protection, such as:

Solid mass input

The total mass of solids used as defined in Part 5, 3(a)(i) of Annex VII to Directive 2010/75/EU.

Solvent

‘Solvent’ refers to ‘organic solvent’.

Solvent input

The total quantity of organic solvents used as defined in Part 7, 3(b) of Annex VII to Directive 2010/75/EU.

Solvent-based (SB)

Type of paint, ink or other coating material using solvent(s) as the carrier. For the preservation of wood and wood products, it refers to the type of treatment chemicals.

Solvent-based-mix (SB-mix)

Solvent-based coating where one of the coating layers is water-based (WB).

Solvent mass balance (SMB)

A mass balance exercise conducted at least once every year according to Part 7 of Annex VII to Directive 2010/75/EU.

Surface run-off water

Water from precipitation that flows over land or impervious surfaces, such as paved streets and storage areas, rooftops, etc. and does not soak into the ground.

Total emissions

The sum of fugitive emissions and emissions in waste gases as defined in Article 57(4) of Directive 2010/75/EU.

Treatment chemicals

Chemicals used in wood and wood products preservation such as biocides, chemicals used for waterproofing (e.g. oils, emulsions) and flame retardants. This also includes the carrier of active substances (e.g. water, solvent).

Valid hourly/half-hourly average

An hourly/half-hourly average is considered valid when there is no maintenance or malfunction of the automated measuring system.

Waste gases

Waste gases as defined in Article 57(2) of Directive 2010/75/EU.

Water-based (WB)

Type of paint, ink or other coating material in which water replaces all or part of the solvent content. For the preservation of wood and wood products, it refers to the type of treatment chemicals.

Wood preservation

Activities whose purpose is to protect wood and wood products from the damaging effects of fungi, bacteria, insects, water, weather or fire; to provide long-term conservation of structural integrity; and to improve the resistance of wood and wood products.

Pollutants and parameters

Term used

Definition

AOX

Adsorbable organically bound halogens, expressed as Cl, include adsorbable organically bound chlorine, bromine and iodine.

CO

Carbon monoxide.

COD

Chemical oxygen demand. Amount of oxygen needed for the total chemical oxidation of the organic matter to carbon dioxide using dichromate. COD is an indicator for the mass concentration of organic compounds.

Chromium

Chromium, expressed as Cr, includes all inorganic and organic chromium compounds, dissolved or bound to particles.

DMF

N,N-Dimethylformamide.

Dust

Total particulate matter (in air).

F-

Fluoride.

Hexavalent chromium

Hexavalent chromium, expressed as Cr(VI), includes all chromium compounds where the chromium is in the oxidation state +6 (dissolved or bound to particles).

HOI

Hydrocarbon oil index. The sum of compounds extractable with a hydrocarbon solvent (including long-chain or branched aliphatic, alicyclic, aromatic or alkyl-substituted aromatic hydrocarbons).

IPA

Isopropyl alcohol: propan-2-ol (also called isopropanol).

Nickel

Nickel, expressed as Ni, includes all inorganic and organic nickel compounds, dissolved or bound to particles.

NOX

The sum of nitrogen monoxide (NO) and nitrogen dioxide (NO2), expressed as NO2.

PAHs

Polycyclic aromatic hydrocarbons.

TOC

Total organic carbon, expressed as C (in water).

TVOC

Total volatile organic carbon, expressed as C (in air).

TSS

Total suspended solids. Mass concentration of all suspended solids (in water), measured via filtration through glass fibre filters and gravimetry.

VOC

Volatile organic compound as defined in Article 3(45) of Directive 2010/75/EU.

Zinc

Zinc, expressed as Zn, includes all inorganic and organic zinc compounds, dissolved or bound to particles.

Acronym

Definition

BPR

Biocidal Products Regulation (Regulation (EU) No 528/2012 of the European Parliament and of the Council of 22 May 2012 concerning the making available on the market and use of biocidal products, OJ L 167, 27.6.2012, p. 1).

DWI

Drawn and wall ironed (a type of can in the metal packaging industry).

EMS

Environmental management system.

IED

Industrial Emissions Directive (2010/75/EU).

IR

Infrared.

LEL

Lower explosive limit – the lowest concentration (percentage) of a gas or vapour in air capable of producing a flash of fire in the presence of an ignition source. Concentrations lower than LEL are ‘too lean’ to burn. Also called lower flammable limit (LFL).

OTNOC

Other than normal operating conditions.

STS

Surface treatment using organic solvents.

UV

Ultraviolet.

WPC

Preservation of wood and wood products with chemicals.

Type of measurement

Averaging period

Definition

Continuous

Daily average

Average over a period of one day based on valid hourly or half-hourly averages.

Periodic

Average over the sampling period

Average value of three consecutive measurements of at least 30 minutes each (3).

Technique

Description

Applicability

(a)

Use of raw materials with a low environmental impact

As part of the EMS (see BAT 1), systematic evaluation of the adverse environmental impacts of the materials used (in particular substances that are carcinogenic, mutagenic and toxic to reproduction as well as substances of very high concern) and substitution by others with no or lower environmental and health impacts where possible, taking into consideration the product quality requirements or specifications.

Generally applicable.

The scope (e.g. level of detail) and nature of the evaluation will generally be related to the nature, scale and complexity of the plant and the range of environmental impacts it may have, as well as to the type and quantity of materials used.

(b)

Optimisation of the use of solvents in the process

Optimisation of the use of solvents in the process by a management plan (as part of the EMS (see BAT 1)) that aims to identify and implement necessary actions (e.g. colour batching, optimising spray pulverisation).

Generally applicable.

Technique

Description

Applicability

(a)

Use of high-solids solvent-based paints/coatings/varnishes/inks/adhesives

Use of paints, coatings, liquid inks, varnishes and adhesives containing a low amount of solvents and an increased solids content.

The selection of the surface treatment techniques may be restricted by the activity type, the substrate type and shape, product quality requirements as well as the need to ensure that the materials used, coating application techniques, drying/curing techniques and off-gas treatment systems are mutually compatible.

(b)

Use of water-based paints/coatings/inks/varnishes/adhesives

Use of paints, coatings, liquid inks, varnishes and adhesives where organic solvent is partially replaced by water.

(c)

Use of radiation-cured inks/coatings/paints/varnishes/adhesives

Use of paints, coatings, liquid inks, varnishes and adhesives suitable to be cured by the activation of specific chemical groups by UV or IR radiation, or fast electrons, without heat and without emission of VOCs.

(d)

Use of solvent-free two-component adhesives

Use of solvent-free two-component adhesive materials consisting of a resin and a hardener.

(e)

Use of hot-melt adhesives

Use of coating with adhesives made from the hot extrusion of synthetic rubbers, hydrocarbon resins and various additives. No solvents are used.

(f)

Use of powder coatings

Use of solvent-free coating which is applied as a finely divided powder and cured in thermal ovens.

(g)

Use of laminate film for web or coil coatings

Use of polymer films applied onto a coil or web in order to give aesthetic or functional properties, which reduces the number of coating layers needed.

(h)

Use of substances which are not VOCs or are VOCs of a lower volatility

Substitution of high-volatility VOC substances with others containing organic compounds that are non-VOCs or VOCs of a lower volatility (e.g. esters).

Technique

Description

Applicability

Management techniques

(a)

Preparation and implementation of a plan for the prevention and control of leaks and spillages

A plan for the prevention and control of leaks and spillages is part of the EMS (see BAT 1) and includes, but is not limited to:

Generally applicable. The scope (e.g. level of detail) of the plan will generally be related to the nature, scale and complexity of the installation, as well as to the type and quantity of materials used.

Storage techniques

(b)

Sealing or covering of containers and bunded storage area

Storage of solvents, hazardous materials, waste solvents and waste cleaning materials in sealed or covered containers, suitable for the associated risk and designed to minimise emissions. The containers’ storage area is bunded and of adequate capacity.

Generally applicable.

(c)

Minimisation of storage of hazardous materials in production areas

Hazardous materials are present in production areas only in amounts that are necessary for production; larger quantities are stored separately.

Techniques for pumping and handling liquids

(d)

Techniques to prevent leaks and spillages during pumping

Leaks and spillages are prevented by using pumps and seals suitable for the material handled and which ensure proper tightness. This includes equipment such as canned motor pumps, magnetically coupled pumps, pumps with multiple mechanical seals and a quench or buffer system, pumps with multiple mechanical seals and seals dry to atmosphere, diaphragm pumps or bellow pumps.

Generally applicable.

(e)

Techniques to prevent overflows during pumping

This includes ensuring for example that:

(f)

Capture of VOC vapour during solvent-containing material delivery

When delivering solvent-containing materials in bulk (e.g. loading or unloading of tanks), the vapour displaced from receiving tanks is captured, usually by back-venting.

May not be applicable for solvents with low vapour pressure or due to cost considerations.

(g)

Containment for spills and/or rapid take-up when handling solvent-containing materials

When handling solvent-containing materials in containers, possible spills are avoided by providing containment, e.g. by using trolleys, pallets and/or stillages with built-in containment (e.g. ‘catch pans’) and/or rapid take-up by using absorbent materials.

Generally applicable.

Technique

Description

Applicability

(a)

Centralised supply of VOC-containing materials (e.g. inks, coatings, adhesives, cleaning agents)

Supply of VOC-containing materials (e.g. inks, coatings, adhesives, cleaning agents) to the application area by direct piping with ring lines, including system cleaning such as pig cleaning or air flushing.

May not be applicable in the case of frequent changes of inks/paints/coatings/adhesives or solvents.

(b)

Advanced mixing systems

Computer-controlled mixing equipment to achieve the desired paint/coating/ink/adhesive.

Generally applicable.

(c)

Supply of VOC-containing materials (e.g. inks, coatings, adhesives, cleaning agents) at the point of application using a closed system

In the case of frequent changes of inks/paints/coatings/adhesives and solvents or for small-scale usage, supply of inks/paints/coatings/adhesives and solvents from small transport containers placed near the application area using a closed system.

(d)

Automation of colour change

Automated colour changing and ink/paint/coating line purging with solvent capture.

(e)

Colour grouping

Modification of the sequence of products to achieve large sequences with the same colour.

(f)

Soft purge in spraying

Refilling the spray gun with new paint without intermediate rinsing.

Technique

Description

Applicability

Techniques for non-spraying application

(a)

Roller coating

Application where rollers are used to transfer or meter the liquid coating onto a moving strip.

Only applicable to flat substrates (4).

(b)

Doctor blade over roller

The coating is applied to the substrate through a gap between a blade and a roller. As the coating and substrate pass, the excess is scraped off.

Generally applicable (4).

(c)

No-rinse (dry-in-place) application in the coating of coil

Application of conversion coatings which do not require a further water rinse using a roller coater (chemcoater) or squeegee rollers.

Generally applicable (4).

(d)

Curtain coating (casting)

Work-pieces are passed through a laminar film of coating discharged from a header tank.

Only applicable to flat substrates (4).

(e)

Electrocoating (e-coat)

Paint particles dispersed in a water-based solution are deposited on immersed substrates under the influence of an electric field (electrophoretic deposition).

Only applicable to metal substrates (4).

(f)

Flooding

The work-pieces are transported via conveyor systems into a closed channel, which is then flooded with the coating material via injection tubes. The excess material is collected and reused.

Generally applicable (4).

(g)

Co-extrusion

The printed substrate is coupled with a warm, liquefied plastic film and subsequently cooled down. This film replaces the necessary additional coating layer. It may be used between two different layers of different carriers acting as an adhesive.

Not applicable where high bond strength or resistance to sterilisation temperature is needed (4) .

Spraying atomisation techniques

(h)

Air-assisted airless spraying

An airflow (shaping air) is used to modify the spray cone of an airless spray gun.

Generally applicable (4).

(i)

Pneumatic atomisation with inert gases

Pneumatic paint application with pressurised inert gases (e.g. nitrogen, carbon dioxide).

May not be applicable to coating of wooden surfaces (4).

(j)

High-volume low-pressure (HVLP) atomisation

Atomisation of paint in a spray nozzle by mixing paint with high volumes of air with a low pressure (max. 1,7 bar). HVLP guns have a paint transfer efficiency of > 50 %.

Generally applicable (4).

(k)

Electrostatic atomisation (fully automated)

Atomisation by high-speed rotational discs and bells and shaping the spray jet with electrostatic fields and shaping air.

(l)

Electrostatically assisted air or airless spraying

Shaping the spray jet of pneumatic or airless atomisation with an electrostatic field. Electrostatic paint guns have a transfer efficiency of > 60 %. Fixed electrostatic methods have a transfer efficiency of up to 75 %.

(m)

Hot spraying

Pneumatic atomisation with hot air or heated paint.

May not be applicable for frequent colour changes (4).

(n)

‘Spray, squeegee and rinse’ application in the coating of coil

Sprays are used for application of cleaners, pretreatments and for rinsing. After spraying, squeegees are used to minimise solution dragout, which is followed by rinsing.

Generally applicable (4).

Automation of spray application

(o)

Robot application

Robot application of coatings and sealants to internal and external surfaces.

Generally applicable (4).

(p)

Machine application

Use of paint machines for the handling of the sprayhead/spray gun/nozzle.

Technique

Description

Applicability

(a)

Inert gas convection drying/curing

The inert gas (nitrogen) is heated in the oven, enabling solvent loading above the LEL. Solvent loads of > 1 200 g/m3 nitrogen are possible.

Not applicable where dryers need to be opened regularly (5).

(b)

Induction drying/curing

Online thermal curing or drying by electromagnetic inductors that generate heat inside the metallic work-piece by an oscillating magnetic field.

Only applicable to metal substrates (5).

(c)

Microwave and high-frequency drying

Drying using microwave or high-frequency radiation.

Only applicable to water-based coatings and inks and non-metallic substrates (5).

(d)

Radiation curing

Radiation curing is applied based on resins and reactive diluents (monomers) which react on exposure to radiation (infrared (IR), ultraviolet (UV)), or high-energy electron beams (EB).

Only applicable to specific coatings and inks (5).

(e)

Combined convection/IR radiation drying

Drying of a wet surface with a combination of circulating hot air (convection) and an infrared radiator.

Generally applicable (5).

(f)

Convection drying/curing combined with heat recovery

Heat from off-gases is recovered (see BAT 19 (e)) and used to preheat the input air of the convection dryer/curing oven.

Generally applicable (5).

Technique

Description

Applicability

(a)

Protection of spraying areas and equipment

Application areas and equipment (e.g. spray booth walls and robots) susceptible to overspray and drips, etc. are covered with fabric covers or disposable foils where foils are not subject to tearing or wear.

The selection of cleaning techniques may be restricted by the type of process, the substrate or equipment to be cleaned and the type of contamination.

(b)

Solids removal prior to complete cleaning

Solids are removed in a (dry) concentrated form, usually by hand, with or without the aid of small amounts of cleaning solvent. This reduces the amount of material to be removed by solvent and/or water in subsequent cleaning stages, and therefore the amount of solvent and/or water used.

(c)

Manual cleaning with pre-impregnated wipes

Wipes pre-impregnated with cleaning agents are used for manual cleaning. Cleaning agents may be solvent-based, low-volatility solvents or solvent-free.

(d)

Use of low-volatility cleaning agents

Application of low-volatility solvents as cleaning agents, for manual or automated cleaning, with high cleaning power.

(e)

Water-based cleaning

Water-based detergents or water-miscible solvents such as alcohols or glycols are used for cleaning.

(f)

Enclosed washing machines

Automatic batch cleaning/degreasing of press/machine parts in enclosed washing machines. This can be done using either:

(g)

Purging with solvent recovery

Collection, storage and, if possible, reuse of the solvents used to purge the guns/applicators and lines between colour changes.

(h)

Cleaning with high-pressure water spray

High-pressure water spray and sodium bicarbonate systems or similar are used for automatic batch cleaning of press/machine parts.

(i)

Ultrasonic cleaning

Cleaning in a liquid using high-frequency vibrations to loosen the adhered contamination.

(j)

Dry ice (CO2) cleaning

Cleaning of machinery parts and metallic or plastic substrates by blasting with CO2 chips or snow.

(k)

Plastic shot-blast cleaning

Excess paint build-up is removed from panel jigs and body carriers by shot-blasting with plastic particles.

Technique

Description

(a)

Full identification and quantification of the relevant solvent inputs and outputs, including the associated uncertainty

This includes:

(b)

Implementation of a solvent tracking system

A solvent tracking system aims to keep control of both the used and unused quantities of solvents (e.g. by weighing unused quantities returned to storage from the application area).

(c)

Monitoring of changes that may influence the uncertainty of the solvent mass balance data

Any change that could influence the uncertainty of the solvent mass balance data is recorded, such as:

Substance/Parameter

Sectors/Sources

Standard(s)

Minimum monitoring frequency

Monitoring associated with

Dust

Coating of vehicles – Spray coating

EN 13284-1

Once every year (6)

BAT 18

Coating of other metal and plastic surfaces – Spray coating

Coating of aircraft – Preparation (e.g. sanding, blasting) and coating

Coating and printing of metal packaging – Spray application

Coating of wooden surfaces – Preparation and coating

TVOC

All sectors

Any stack with a TVOC load < 10 kg C/h

EN 12619

Once every year (6)  (7)  (8)

BAT 14, BAT 15

Any stack with a TVOC load ≥ 10 kg C/h

Generic EN standards (9)

Continuous

DMF

Coating of textiles, foils and paper (10)

No EN standard available (11)

Once every three months (6)

BAT 15

NOX

Thermal treatment of off-gases

EN 14792

Once every year (12)

BAT 17

CO

Thermal treatment of off-gases

EN 15058

Once every year (12)

BAT 17

Substance/Parameter

Sector

Standard(s)

Minimum monitoring frequency

Monitoring associated with

TSS (13)

Coating of vehicles

EN 872

Once every month (14)  (15)

BAT 21

Coil coating

Coating and printing of metal packaging (only for DWI cans)

COD (13)  (16)

Coating of vehicles

No EN standard available

Coil coating

Coating and printing of metal packaging (only for DWI cans)

TOC (13)  (16)

Coating of vehicles

EN 1484

Coil coating

Coating and printing of metal packaging (only for DWI cans)

Cr(VI) (17)  (18)

Coating of aircraft

EN ISO 10304-3 or EN ISO 23913

Coil coating

Cr (18)  (19)

Coating of aircraft

Various EN standards available (e.g. EN ISO 11885, EN ISO 17294-2, EN ISO 15586)

Coil coating

Ni (18)

Coating of vehicles

Coil coating

Zn (18)

Coating of vehicles

Coil coating

AOX (18)

Coating of vehicles

EN ISO 9562

Coil coating

Coating and printing of metal packaging (only for DWI cans)

F-  (18)  (20)

Coating of vehicles

EN ISO 10304-1

Coil coating

Coating and printing of metal packaging (only for DWI cans)

Technique

Description

(a)

Identification of critical equipment

Equipment critical to the protection of the environment (‘critical equipment’) is identified on the basis of a risk assessment. In principle, this concerns all equipment and systems handling VOCs (e.g. off-gas treatment system, leak detection system).

(b)

Inspection, maintenance and monitoring

A structured programme to maximise critical equipment availability and performance which includes standard operating procedures, preventive maintenance, regular and unplanned maintenance. OTNOC periods, duration, causes and, if possible, emissions during their occurrence are monitored.

Technique

Description

Applicability

(a)

System selection, design and optimisation

An off-gas system is selected, designed and optimised taking into account parameters such as:

The following order of priority for the system selection may be considered:

Generally applicable.

(b)

Air extraction as close as possible to the point of application of VOC-containing materials

Air extraction as close as possible to the point of application with full or partial enclosure of solvent application areas (e.g. coaters, application machines, spray booths). Extracted air may be treated by an off-gas treatment system.

May not be applicable where enclosure leads to difficult machinery access during operation.

Applicability may be restricted by the shape and size of the area to be enclosed.

(c)

Air extraction as close as possible to the point of preparing paints/coatings/adhesives/inks

Air extraction as close as possible to the point of preparing paints/coatings/adhesives/inks (e.g. mixing area). Extracted air may be treated by an off-gas treatment system.

Only applicable where paints/coatings/adhesives/inks are prepared.

(d)

Extraction of air from the drying/curing processes

The curing ovens/dryers are equipped with an air extraction system. Extracted air may be treated by an off-gas treatment system.

Only applicable to drying/curing processes.

(e)

Minimisation of fugitive emissions and heat losses from the ovens/dryers either by sealing the entrance and the exit of the curing ovens/dryers or by applying sub-atmospheric pressure in drying

The entrance to and the exit from curing ovens/dryers are sealed to minimise fugitive VOC emissions and heat losses. The sealing may be ensured by air jets or air knives, doors, plastic or metallic curtains, doctor blades, etc. Alternatively, ovens/dryers are kept under sub-atmospheric pressure.

Only applicable when curing ovens/dryers are used.

(f)

Extraction of air from the cooling zone

When substrate cooling takes place after drying/curing, the air from the cooling zone is extracted and may be treated by an off-gas treatment system.

Only applicable when substrate cooling takes place after drying/curing.

(g)

Extraction of air from storage of raw materials, solvents and solvent-containing wastes

Air from raw material stores and/or individual containers for raw materials, solvents and solvent-containing wastes is extracted and may be treated by an off-gas treatment system.

May not be applicable for closed containers or for storage of raw materials, solvents and solvent-containing wastes with a low vapour pressure and low toxicity.

(h)

Extraction of air from cleaning areas

Air from the areas where machine parts and equipment are cleaned with organic solvents, either by hand or automatically, is extracted and may be treated by an off-gas treatment system.

Only applicable to areas where machine parts and equipment are cleaned with organic solvents.

Technique

Description

Applicability

I. Capture and recovery of solvents in off-gases

(a)

Condensation

A technique for removing organic compounds by reducing the temperature below their dew points so that the vapours liquefy. Depending on the operating temperature range required, different refrigerants are used, e.g. cooling water, chilled water (temperature typically around 5 °C), ammonia or propane.

Applicability may be restricted where the energy demand for recovery is excessive due to the low VOC content.

(b)

Adsorption using activated carbon or zeolites

VOCs are adsorbed on the surface of activated carbon, zeolites or carbon fibre paper. Adsorbate is subsequently desorbed, e.g. with steam (often on site), for reuse or disposal and the adsorbent is reused. For continuous operation, typically more than two adsorbers are operated in parallel, one of them in desorption mode. Adsorption is also commonly applied as a concentration step to increase the subsequent oxidation efficiency.

Applicability may be restricted where the energy demand for recovery is excessive due to the low VOC content.

(c)

Absorption using a suitable liquid

Use of a suitable liquid to remove pollutants from the off-gas by absorption, in particular soluble compounds and solids (dust). Solvent recovery is possible, for example, using distillation or thermal desorption.

(For dust removal, see BAT 18.)

Generally applicable.

II. Thermal treatment of solvents in off-gases with energy recovery

(d)

Sending off-gases to a combustion plant

Part or all of the off-gases are sent as combustion air and supplementary fuel to a combustion plant (including CHP (combined heat and power) plants) used for steam and/or electricity production.

Not applicable for off-gases containing substances referred to in IED Article 59(5). Applicability may be restricted due to safety considerations.

(e)

Recuperative thermal oxidation

Thermal oxidation using the heat of the waste gases, e.g. to preheat the incoming off-gases.

Generally applicable.

(f)

Regenerative thermal oxidation with multiple beds or with a valveless rotating air distributor

An oxidiser with multiple beds (three or five) filled with ceramic packing. The beds are heat exchangers, alternately heated by flue-waste gases from oxidation, then the flow is reversed to heat the inlet air to the oxidiser. The flow is reversed on a regular basis. In the valveless rotating air distributor, the ceramic medium is held in a single rotating vessel divided into multiple wedges.

Generally applicable.

(g)

Catalytic oxidation

Oxidation of VOCs assisted by a catalyst to reduce the oxidation temperature and reduce the fuel consumption. Exhaust heat can be recovered with recuperative or regenerative types of heat exchangers. Higher oxidation temperatures (500–750 °C) are used for the treatment of off-gas from the manufacturing of winding wire.

Applicability may be restricted by the presence of catalyst poisons.

III. Treatment of solvents in off-gases without solvent or energy recovery

(h)

Biological off-gas treatment

Off-gas is dedusted and sent to a reactor with biofilter substrate. The biofilter consists of a bed of organic material (such as peat, heather, compost, root, tree bark, softwood and different combinations) or some inert material (such as clay, activated carbon, and polyurethane), where the off-gas stream is biologically oxidised by naturally occurring microorganisms into carbon dioxide, water, inorganic salts and biomass. The biofilter is sensitive to dust, high temperatures or high variations in the off-gas, e.g. of the inlet temperature or the VOC concentration. Supplementary nutrient feeding may be needed.

Only applicable to the treatment of biodegradable solvents.

(i)

Thermal oxidation

Oxidation of VOCs by heating off-gases with air or oxygen to above their auto-ignition point in a combustion chamber and maintaining a high temperature long enough to complete the combustion of VOCs to carbon dioxide and water.

Generally applicable.

Technique

Description

Applicability

(a)

Maintaining the VOC concentration sent to the off-gas treatment system by using variable-frequency drive fans

Use of a variable-frequency drive fan with centralised off-gas treatment systems to modulate the airflow to match the exhaust from the equipment that may be in operation.

Only applicable to central thermal off-gas treatment systems in batch processes such as printing.

(b)

Internal concentration of solvents in the off-gases

Off-gases are recirculated within the process (internally) in the curing ovens/dryers and/or in spray booths, so the VOC concentration in the off-gases increases and the abatement efficiency of the off-gas treatment system increases.

Applicability may be limited by health and safety factors such as the LEL, and product quality requirements or specifications.

(c)

External concentration of solvents in the off-gases through adsorption

The concentration of solvent in off-gases is increased by a continuous circular flow of the spray booth process air, possibly combined with curing oven/dryer off-gases, through adsorption equipment. This equipment can include:

Applicability may be restricted where the energy demand is excessive due to the low VOC content.

(d)

Plenum technique to reduce waste gas volume

Off-gases from curing ovens/dryers are sent to a large chamber (plenum), and partly recirculated as inlet air in the curing ovens/dryers. The surplus air from the plenum is sent to the off-gas treatment system. This cycle increases the VOC content of the curing ovens/dryers’ air and decreases the waste gas volume.

Generally applicable.

Technique

Description

Applicability

(a)

Optimisation of thermal treatment conditions (design and operation)

Good design of the combustion chambers, burners and associated equipment/devices is combined with optimisation of combustion conditions (e.g. by controlling combustion parameters such as temperature and residence time) with or without the use of automatic systems and the regular planned maintenance of the combustion system according to suppliers’ recommendations.

Design applicability may be restricted for existing plants.

(b)

Use of low-NOX burners

The peak flame temperature in the combustion chamber is reduced, delaying but completing the combustion and increasing the heat transfer (increased emissivity of the flame). It is combined with increased residence time in order to achieve the desired VOC destruction.

Applicability may be restricted at existing plants by design and/or operational constraints.

Parameter

Unit

BAT-AEL (21)

(Daily average or average over the sampling period)

Indicative emission level (21)

(Daily average or average over the sampling period)

NOX

mg/Nm3

20–130 (22)

No indicative level

CO

No BAT-AEL

20–150

Technique

Description

(a)

Wet separation spray booth (flushed impact panel)

A water curtain cascading vertically down the spray cabin rear panel captures paint particles from overspray. The water-paint mixture is captured in a reservoir and the water is recirculated.

(b)

Wet scrubbing

Paint particles and other dust in the off-gas are separated in scrubber systems by intensive mixing of the off-gas with water. (For VOC removal, see BAT 15 (c).)

(c)

Dry overspray separation with pre-coated material

A dry paint overspray separation process using membrane filters combined with limestone as pre-coating material to prevent fouling of the membranes.

(d)

Dry overspray separation using filters

Mechanical separation system, e.g. using cardboard, fabric or sinter.

(e)

Electrostatic precipitator

In electrostatic precipitators, particles are charged and separated under the influence of an electrical field. In a dry electrostatic precipitator (ESP), the collected material is mechanically removed (e.g. by shaking, vibration, compressed air). In a wet ESP, it is flushed with a suitable liquid, usually a water-based separation agent.

Parameter

Sector

Process

Unit

BAT-AEL

(Daily average or average over the sampling period)

Dust

Coating of vehicles

Spray coating

mg/Nm3

< 1–3

Coating of other metal and plastic surfaces

Spray coating

Coating of aircraft

Preparation (e.g. sanding, blasting), coating

Coating and printing of metal packaging

Spray application

Coating of wooden surfaces

Preparation, coating

Technique

Description

Applicability

Management techniques

(a)

Energy efficiency plan

An energy efficiency plan is part of the EMS (see BAT 1) and entails defining and calculating the specific energy consumption of the activity, setting key performance indicators on an annual basis (e.g. MWh/tonne of product) and planning the periodic improvement targets and related actions. The plan is adapted to the specificities of the plant in terms of process(es) carried out, materials, products, etc.

The level of detail and nature of the energy efficiency plan and of the energy balance record will generally be related to the nature, scale and complexity of the installation and the types of energy sources used. It may not be applicable if the STS activity is carried out within a larger installation, provided that the energy efficiency plan and the energy balance record of the larger installation sufficiently cover the STS activity.

(b)

Energy balance record

The drawing up once every year of an energy balance record which provides a breakdown of the energy consumption and generation (including energy export) by the type of source (e.g. electricity, fossil fuels, renewable energy, imported heat and/or cooling). This includes:

The energy balance record is adapted to the specificities of the plant in terms of process(es) carried out, materials, etc.

Process-related techniques

(c)

Thermal insulation of tanks and vats containing cooled or heated liquids, and of combustion and steam systems

This may be achieved for example by:

Generally applicable.

(d)

Heat recovery by cogeneration – CHP (combined heat and power) or CCHP (combined cooling, heat and power)

Recovery of heat (mainly from the steam system) for producing hot water/steam to be used in industrial processes/activities. CCHP (also called tri-generation) is a cogeneration system with an absorption chiller that uses low-grade heat to produce chilled water.

Applicability may be restricted by the plant layout, the characteristics of the hot gas streams (e.g. flow rate, temperature) or the lack of a suitable heat demand.

(e)

Heat recovery from hot gas streams

Energy recovery from hot gas streams (e.g. from dryers or cooling zones), e.g. by their recirculation as process air, through the use of heat exchangers, in processes, or externally.

(f)

Flow adjustment of process air and off-gases

Adjustment of the flow of process air and off-gases according to the need. This includes reduction of air ventilation during idle operation or maintenance.

Generally applicable.

(g)

Spray booth off-gas recirculation

Capture and recirculation of the off-gas from the spray booth in combination with efficient paint overspray separation. Energy consumption is less than in the case of fresh air use.

Applicability may be restricted by health and safety considerations.

(h)

Optimised circulation of warm air in a large-volume curing booth using an air turbulator

Air is blown into a single part of the curing booth and distributed using an air turbulator which turns the laminar airflow into the desired turbulent flow.

Only applicable to spray coating sectors.

Sector

Product type

Unit

BAT-AEPL

(Yearly average)

Coating of vehicles

Passenger cars

MWh/vehicle coated

0,5–1,3

Vans

0,8–2

Truck cabins

1–2

Trucks

0,3–0,5

Coil coating

Steel and/or aluminium coil

kWh/m2 of coated coil

0,2–2,5 (23)

Coating of textiles, foils and paper

Coating of textiles with polyurethane and/or polyvinyl chloride

kWh/m2 of coated surface

1–5

Manufacturing of winding wires

Wires with an average diameter > 0,1 mm

kWh/kg of coated wire

< 5

Coating and printing of metal packaging

All product types

kWh/m2 of coated surface

0,3–1,5

Heatset web offset printing

All product types

Wh/m2 of printed area

4–14

Flexography and non-publication rotogravure printing

All product types

Wh/m2 of printed area

50–350

Publication rotogravure printing

All product types

Wh/m2 of printed area

10–30

Technique

Description

Applicability

(a)

Water management plan and water audits

A water management plan and water audits are part of the EMS (see BAT 1) and include:

Water audits are carried out at least once every year.

The level of detail and nature of the water management plan and water audits will generally be related to the nature, scale and complexity of the plant. It may not be applicable if the STS activity is carried out within a larger installation, provided that the water management plan and the water audits of the larger installation sufficiently cover the STS activity.

(b)

Reverse cascade rinsing

Multiple stage rinsing in which the water flows in the opposite direction to the work-pieces/substrate. It allows a high degree of rinsing with a low water consumption.

Applicable where rinsing processes are used.

(c)

Reuse and/or recycling of water

Water streams (e.g. spent rinse water, wet scrubber effluent) are reused and/or recycled, if necessary after treatment, using techniques such as ion exchange or filtration (see BAT 21). The degree of water reuse and/or recycling is limited by the water balance of the plant, the content of impurities and/or the characteristics of the water streams.

Generally applicable.

Sector

Product type

Unit

BAT-AEPL

(Yearly average)

Coating of vehicles

Passenger cars

m3/vehicle coated

0,5–1,3

Vans

1–2,5

Truck cabins

0,7–3

Trucks

1–5

Coil coating

Steel and/or aluminium coils

l/m2 of coated coil

0,2–1,3  (24)

Coating and printing of metal packaging

Two-piece DWI beverage cans

l/1 000 cans

90–110

Techniques

Description

Typical pollutants targeted

Preliminary, primary and general treatment

(a)

Equalisation

Balancing of flows and pollutant loads by using tanks or other management techniques.

All pollutants.

(b)

Neutralisation

The adjustment of the pH of waste water to a neutral value (approximately 7).

Acids, alkalis.

(c)

Physical separation, for example, by using screens, sieves, grit separators, primary settlement tanks and magnetic separation

Gross solids, suspended solids, metal particles.

Physico-chemical treatment

(d)

Adsorption

The removal of soluble substances (solutes) from the waste water by transferring them to the surface of solid, highly porous particles (typically activated carbon).

Adsorbable dissolved non-biodegradable or inhibitory pollutants, e.g. AOX.

(e)

Vacuum distillation

The removal of pollutants by thermal waste water treatment under reduced pressure.

Dissolved non-biodegradable or inhibitory pollutants that can be distilled, e.g. some solvents.

(f)

Precipitation

The conversion of dissolved pollutants into insoluble compounds by adding precipitants. The solid precipitates formed are subsequently separated by sedimentation, flotation or filtration.

Precipitable dissolved non-biodegradable or inhibitory pollutants, e.g. metals.

(g)

Chemical reduction

Chemical reduction is the conversion of pollutants by chemical reducing agents into similar but less harmful or hazardous compounds.

Reducible dissolved non-biodegradable or inhibitory pollutants, e.g. hexavalent chromium (Cr(VI)).

(h)

Ion exchange

The retention of ionic pollutants from waste water and their replacement by more acceptable ions using an ion exchange resin. The pollutants are temporarily retained and afterwards released into a regeneration or backwashing liquid.

Ionic dissolved non-biodegradable or inhibitory pollutants, e.g. metals.

(i)

Stripping

The removal of purgeable pollutants from the aqueous phase by a gaseous phase (e.g. steam, nitrogen or air) that is passed through the liquid. The removal efficiency may be enhanced by increasing the temperature or reducing the pressure.

Purgeable pollutants, e.g. some adsorbable organically bound halogens (AOX).

Biological treatment

(j)

Biological treatment

Use of microorganisms for waste water treatment (e.g. anaerobic treatment, aerobic treatment).

Biodegradable organic compounds.

Final solids removal

(k)

Coagulation and flocculation

Coagulation and flocculation are used to separate suspended solids from waste water and are often carried out in successive steps. Coagulation is carried out by adding coagulants with charges opposite to those of the suspended solids. Flocculation is a gentle mixing stage so that collisions of microfloc particles cause them to bond to produce larger flocs. It may be assisted by adding polymers.

Suspended solids and particulate-bound metals.

(l)

Sedimentation

The separation of suspended particles by gravitational settling.

(m)

Filtration

The separation of solids from waste water by passing them through a porous medium, e.g. sand filtration, nano-, micro- and ultrafiltration

(n)

Flotation

The separation of solid or liquid particles from waste water by attaching them to fine gas bubbles, usually air. The buoyant particles accumulate at the water surface and are collected with skimmers.

Substance/Parameter

Sector

BAT-AEL (25)

Total suspended solids (TSS)

Coating of vehicles

Coil coating

Coating and printing of metal packaging (only for DWI cans)

5–30 mg/l

Chemical oxygen demand (COD) (26)

30–150 mg/l

Adsorbable organically bound halogens (AOX)

0,1–0,4 mg/l

Fluoride (F-) (27)

2–25 mg/l

Nickel (expressed as Ni)

Coating of vehicles

Coil coating

0,05–0,4 mg/l

Zinc (expressed as Zn)

0,05–0,6 mg/l (28)

Total chromium (expressed as Cr) (29)

Coating of aircraft

Coil coating

0,01–0,15 mg/l

Hexavalent chromium (expressed as Cr(VI)) (30)

0,01–0,05 mg/l

Substance/Parameter

Sector

BAT-AEL (31)  (32)

Adsorbable organically bound halogens (AOX)

Coating of vehicles

Coil coating

Coating and printing of metal packaging (only for DWI cans)

0,1–0,4 mg/l

Fluoride (F-) (33)

2–25 mg/l

Nickel (expressed as Ni)

Coating of vehicles

Coil coating

0,05–0,4 mg/l

Zinc (expressed as Zn)

0,05–0,6 mg/l (34)

Total chromium (expressed as Cr) (35)

Coating of aircraft

Coil coating

0,01–0,15 mg/l

Hexavalent chromium (expressed as Cr(VI)) (36)

0,01–0,05 mg/l

Technique

Description

(a)

Waste management plan

A waste management plan is part of the EMS (see BAT 1) and is a set of measures aiming to: 1) minimise the generation of waste, 2) optimise the reuse, regeneration and/or recycling of waste and/or the recovery of energy from waste, and 3) ensure the proper disposal of waste.

(b)

Monitoring of waste quantities

Annual recording of waste quantities generated for each type of waste. The solvent content in the waste is determined periodically (at least once every year) by analysis or calculation.

(c)

Recovery/recycling of solvents

Techniques may include:

(d)

Waste-stream-specific techniques

Techniques may include:

Coating system

Description

Applicability

(a)

Mixed (SB-mix) coating

A coating system where one coating layer (primer or base coat) is water-based.

Only applicable to new plants or major plant upgrades.

(b)

Water-based (WB) coating

A coating system where the primer and base coat layers are water-based.

(c)

Integrated coating process

A coating system which combines the functions of primer and base coat and is applied by spray coating in two steps.

(d)

Three-wet process

Coating system where the primer, base coat and clear coat layers are applied without intermediate drying. The primer and base coat may be solvent-based or water-based.

Parameter

Vehicle type

Unit

BAT-AEL (37)

(Yearly average)

New plant

Existing plant

Total VOC emissions as calculated by the solvent mass balance

Passenger cars

g VOCs per m2 of surface area (38)

8–15

8–30

Vans

10–20

10–40

Truck cabins

8–20

8–40

Trucks

10–40

10–50

Buses

< 100

90–150

Parameter

Vehicle type

Relevant waste streams

Unit

Indicative level

(Yearly average)

Waste quantity sent off site

Passenger cars

kg/vehicle coated

3–9 (39)

Vans

4–17 (39)

Truck cabins

2–11 (39)

Parameter

Process

Unit

BAT-AEL

(Yearly average)

Total VOC emissions as calculated by the solvent mass balance

Coating of metal surfaces

kg VOCs per kg of solid mass input

< 0,05–0,2

Coating of plastic surfaces

< 0,05–0,3

Parameter

Unit

BAT-AEL

(Yearly average)

Fugitive VOC emissions as calculated by the solvent mass balance

Percentage (%) of the solvent input

< 1–10

Parameter

Unit

BAT-AEL

(Daily average or average over the sampling period)

TVOC

mg C/Nm3

1–20 (40)  (41)

Technique

Description

Applicability

Waste and waste water management

(a)

Segregation of waste and waste water streams

Docks and slipways are constructed with:

Only applicable to new plants or major plant upgrades.

Techniques relating to preparation and coating processes

(b)

Restrictions for adverse weather conditions

Where the treatment areas are not fully enclosed, blasting and/or airless spray coating are not carried out if adverse weather conditions are observed or forecast.

Generally applicable.

(c)

Partial enclosure of treatment areas

Fine nets and/or water spray curtains are used around areas where blasting and/or airless spray coating are carried out to prevent dust emissions. They may be permanent or temporary.

Applicability may be restricted by the shape and size of the area to be enclosed. Water spray curtains may not be applicable in cold climatic conditions.

(d)

Full enclosure of treatment areas

Blasting and/or airless spray coating are carried out in halls, closed workshops, areas tented with textiles or areas fully enclosed with nets to prevent dust emissions. Air from the treatment areas is extracted and may be sent to off-gas treatment; see also BAT 14 (b).

Applicability may be restricted by the shape and size of the area to be enclosed.

(e)

Dry blasting in a closed system

Dry blasting using steel grit or shot is carried out in closed blasting systems equipped with a suction head and centrifugal blasting wheels.

Generally applicable.

(f)

Wet blasting

Blasting is carried out with water containing a fine abrasive material, such as a fine cinder (e.g. copper slag cinder) or silica.

May not be applicable in cold climatic conditions and/or in enclosed areas (cargo tanks, double bottom tanks) due to the heavy mist formation.

(g)

(Ultra-)High-Pressure ((U)HP) water jetting or blasting

(U)HP blasting is a dustless surface treatment method using extremely high-pressure water. There are options with or without an abrasive.

May not be applicable in cold climatic conditions, or due to surface specifications (e.g. new surfaces, spot blasting).

(h)

Stripping of coatings by induction heating

An inductor head is moved over the surface, causing localised fast heating of the steel to lift old coatings.

May not be applicable for surfaces with a thickness of less than 5 mm and/or for surfaces with components sensitive to induction heating (e.g. insulation, flammable).

(i)

Underwater hull and propeller cleaning system

Underwater cleaning system using water pressure and rotating polypropylene brushes.

Not applicable for ships in full dry dock.

Parameter

Unit

BAT-AEL

(Yearly average)

Total VOC emissions as calculated by the solvent mass balance

kg VOCs per kg of solid mass input

< 0,375

Technique

Description

Applicability

(a)

Enclosure

Component parts are coated in enclosed spray booths (see BAT 14 (b)).

Generally applicable.

(b)

Direct printing

Use of a printing device to directly print complex layouts on the aircraft parts.

Applicability may be restricted by technical considerations (e.g. accessibility of the applicator gantry, customised colours).

Parameter

Unit

BAT-AEL

(Yearly average)

Total VOC emissions as calculated by the solvent mass balance

kg VOCs per kg of solid mass input

0,2–0,58

Parameter

Unit

BAT-AEL

(Yearly average)

Fugitive VOC emissions as calculated by the solvent mass balance

Percentage (%) of the solvent input

< 1–3

Parameter

Unit

BAT-AEL

(Daily average or average over the sampling period)

TVOC

mg C/Nm3

1–20 (42)  (43)

Parameter

Unit

BAT-AEL

(Yearly average)

Total VOC emissions as calculated by the solvent mass balance

Percentage (%) of the solvent input

< 1–3 (44)

Parameter

Unit

BAT-AEL

(Daily average or average over the sampling period)

TVOC

mg C/Nm3

2–20 (45)  (46)

Parameter

Unit

BAT-AEL

(Yearly average)

Fugitive VOC emissions as calculated by the solvent mass balance

Percentage (%) of the solvent input

< 1–5

Parameter

Unit

BAT-AEL

(Daily average or average over the sampling period)

TVOC

mg C/Nm3

5–20 (47)  (48)

Technique

Description

Applicability

(a)

Process-integrated VOC oxidation

The air/solvent mix resulting from solvent evaporation during the repeated enamel curing process is treated in a catalytic oxidiser (see BAT 15 (g)) integrated in the curing oven/dryer. The waste heat from the catalytic oxidiser is used in the drying process to heat up the circulating airflow and/or as process heat for other purposes within the plant.

Generally applicable.

(b)

Solvent-free lubricants

Solvent-free lubricants are applied as follows:

Applicability may be limited due to product quality requirements or specifications, e.g. diameter.

(c)

Self-lubricating coatings

A solvent-containing lubrication step is avoided by using a coating system that also contains lubricant (a special wax).

Applicability may be limited due to product quality requirements or specifications.

(d)

High-solids enamel coating

Use of enamel coating with a solids content of up to 45 %. In the case of fine wires (with a diameter less than or equal to 0.1 mm), the solids content is up to 30 %.

Parameter

Product type

Unit

BAT-AEL

(Yearly average)

Total VOC emissions as calculated by the solvent mass balance

Coating of winding wire with an average diameter greater than 0,1 mm

g VOCs per kg of coated wire

1–3,3

Parameter

Unit

BAT-AEL

(Daily average or average over the sampling period)

TVOC

mg C/Nm3

5–40

Parameter

Unit

BAT-AEL

(Yearly average)

Total VOC emissions as calculated by the solvent mass balance

g VOCs per m2 of coated/printed surface

< 1–3,5

Parameter

Unit

BAT-AEL

(Yearly average)

Fugitive VOC emissions as calculated by the solvent mass balance

Percentage (%) of the solvent input

< 1–12

Parameter

Unit

BAT-AEL

(Daily average or average over the sampling period)

TVOC

mg C/Nm3

1–20 (49)

Technique

Description

Applicability

Material-based and printing techniques

(a)

Use of low-IPA or IPA-free additives in dampening solutions

Reduction or avoidance of isopropanol (IPA) as a wetting agent in dampening solutions, through substitution by mixtures of other organic compounds which are not volatile or have a low volatility.

Applicability may be limited by technical and product quality requirements or specifications.

(b)

Waterless offset

Modification of the press and the pre-press processes to enable the use of specially coated offset plates, eliminating the need for dampening.

May not be applicable for long print runs due to the need for more frequent changes of plates.

Cleaning techniques

(c)

Use of VOC-free solvents or solvents with low volatility for automatic blanket cleaning

Use of organic compounds which are not volatile or have a low volatility as cleaning agents for automatic blanket cleaning.

Generally applicable.

Off-gas treatment techniques

(d)

Web offset dryer integrated with off-gas treatment

A web offset dryer with an integrated off-gas treatment unit, enabling incoming dryer air to be mixed with a part of the waste gases returned from the off-gas thermal treatment system.

Applicable to new plants or major plant upgrades.

(e)

Extraction and treatment of air from the press room or the press encapsulation

Routing of extracted air from the press room or the press encapsulation to the dryer. As a result, a part of the solvents evaporated in the press room or press encapsulation is abated by the thermal treatment (see BAT 15) downstream of the dryer.

Generally applicable.

Parameter

Unit

BAT-AEL

(Yearly average)

Total VOC emissions as calculated by the solvent mass balance

kg VOCs per kg of ink input

< 0,01–0,04 (50)

Parameter

Unit

BAT-AEL

(Yearly average)

Fugitive VOC emissions as calculated by the solvent mass balance

Percentage (%) of the solvent input

< 1–10 (51)

Parameter

Unit

BAT-AEL

(Daily average or average over the sampling period)

TVOC

mg C/Nm3

1–15

Parameter

Unit

BAT-AEL

(Yearly average)

Total VOC emissions as calculated by the solvent mass balance

kg VOCs per kg of solid mass input

< 0,1–0,3

Parameter

Unit

BAT-AEL

(Yearly average)

Fugitive VOC emissions as calculated by the solvent mass balance

Percentage (%) of the solvent input

< 1–12

Parameter

Unit

BAT-AEL

(Daily average or average over the sampling period)

TVOC

mg C/Nm3

1–20 (52)  (53)

Technique

Description

(a)

Use of retention inks

Retention inks slow the formation of the dried film surface, which allows toluene to evaporate over a longer time and therefore more toluene to be released in the dryer and recovered by the toluene recovery system.

(b)

Automatic cleaning systems connected to the toluene recovery system

Automated cylinder cleaning with air extraction to the toluene recovery system.

Parameter

Unit

BAT-AEL

(Yearly average)

Fugitive VOC emissions as calculated by the solvent mass balance

Percentage (%) of the solvent input

< 2,5

Parameter

Unit

BAT-AEL

(Daily average or average over the sampling period)

TVOC

mg C/Nm3

10–20

Parameter

Coated substrates

Unit

BAT-AEL

(Yearly average)

Total VOC emissions as calculated by the solvent mass balance

Flat substrates

kg VOCs per kg of solid mass input

< 0.1

Other than flat substrates

< 0.25

Parameter

Unit

BAT-AEL

(Yearly average)

Fugitive VOC emissions as calculated by the solvent mass balance

Percentage (%) of the solvent input

< 10

Parameter

Unit

BAT-AEL

(Daily average or average over the sampling period)

TVOC

mg C/Nm3

5-20 (54)

Technique

Description

Applicability

(a)

Use of an efficient preservative application system

Application systems where the wood is immersed in the preservative solution are more efficient than, for example, spraying. The application efficiency of vacuum processes (closed system) is close to 100 %. The selection of the application system takes into account the use class and the penetration level needed.

Only applicable to new plants or major plant upgrades.

(b)

Control and optimisation of the consumption of the treatment chemicals for the specific end use

Control and optimisation of the consumption of the treatment chemicals by:

The consumption of the treatment chemicals follows suppliers’ recommendations and does not lead to exceedances of the retention requirements (e.g. set in product quality standards).

Generally applicable.

(c)

Solvent mass balance

The compilation, at least once every year, of organic solvent inputs and outputs of a plant as defined in Part 7(2) of Annex VII to Directive 2010/75/EU.

Only applicable to plants using solvent-based treatment chemicals or creosote.

(d)

Measurement and adjustment of wood moisture before treatment

Wood moisture is measured prior to treatment (e.g. by measuring the electric resistance or by weighing) and adjusted if needed (e.g. by further seasoning of the wood) in order to optimise the impregnation process and ensure the required product quality.

Only applicable if wood with a specific moisture content is needed.

Technique

Description

(a)

Back-venting

Also referred to as vapour balancing. Vapours of solvents or creosote which are displaced from the receiving tank during filling are collected and returned to the tank or truck from which the liquid is delivered.

(b)

Capture of displaced air

Vapours of solvents or creosote which are displaced from the receiving tank during filling are collected and led to a treatment unit, e.g. an activated carbon filter or a thermal oxidation unit.

(c)

Techniques to reduce evaporation losses due to heating up of stored chemicals

When exposure to sunlight may lead to evaporation of solvents and creosote stored in above-ground storage tanks, tanks are covered by a roof or coated with light-coloured paint to reduce the heating up of stored solvents and creosote.

(d)

Securing delivery connections

Delivery connections to storage tanks located within the bunded/contained area are secured and shut off when not in use.

(e)

Techniques to prevent overflows during pumping

This includes ensuring that:

(f)

Closed storage containers

Use of closed storage containers for treatment chemicals.

Technique

Description

Applicability

(a)

Separation of wood in packs by spacers

Spacers are placed at regular intervals in the packs to facilitate the flow of treatment chemicals through the pack and the draining after treatment.

Generally applicable.

(b)

Sloping of wood packs in traditional horizontal treatment vessels

Wood packs are inclined in the treatment vessel to facilitate the flow of treatment chemicals and the draining after treatment.

Generally applicable.

(c)

Use of tilting pressure treatment vessels

The whole treatment vessel is inclined after treatment so that excess treatment chemicals drain easily and can be recovered from the bottom of the vessel.

Only applicable to new plants or major plant upgrades.

(d)

Optimised positioning of shaped wood pieces

Shaped wood pieces are positioned so as to prevent trapping of treatment chemicals.

Generally applicable.

(e)

Securing wood packs

The wood packs are secured inside the treatment vessel in order to limit the movement of wood pieces which could change the structure of the pack and reduce the impregnation efficiency.

Generally applicable.

(f)

Maximisation of the wood load

The wood load in the treatment vessel is maximised to ensure the best ratio between the wood to be treated and the treatment chemicals.

Generally applicable.

Technique

(a)

Double-walled treatment vessels with automatic leak detection devices

(b)

Single-walled treatment vessels with sufficiently large and wood-preservative-resistant containment, fender and automatic leak detection device

Technique

Description

(a)

Process controls to prevent operation unless the treatment vessel door is locked and sealed

The treatment vessel door is locked and sealed once the treatment vessel is loaded and before treatment takes place. Process controls are in place that prevent the operation of the treatment vessel unless the door is locked and sealed.

(b)

Process controls to prevent the treatment vessel from opening while it is pressurised and/or filled with preservative solution

Process controls display the pressure and whether liquid is present in the treatment vessel. They prevent the opening of the treatment vessel while it is still pressurised and/or filled.

(c)

Catch-lock for the treatment vessel door

The door of the treatment vessel is equipped with a catch-lock to prevent the release of liquids in the event that the treatment vessel door needs to be opened in an emergency situation (e.g. door seal is broken). The catch-lock permits the door to be partially opened to release the pressure while retaining liquids.

(d)

Use and maintenance of safety relief valves

Treatment vessels are fitted with safety relief valves to protect the vessels from excessive pressure.

Discharges from valves are directed to a tank of sufficient capacity.

Safety relief valves are regularly inspected (e.g. once every 6 months) for signs of corrosion, contamination or incorrect fitting and are cleaned and/or repaired as required.

(e)

Control of emissions to air from the vacuum pump exhaust

Air extracted from pressure treatment vessels (i.e. the vacuum pump outlet) is treated (e.g. in a vapour-liquid separator).

(f)

Reduction of emissions to air when opening the treatment vessel

Sufficient time for dripping and condensation is allowed between the depressurisation period and the opening of the treatment vessel.

(g)

Application of a final vacuum to remove excess treatment chemicals from the surface of treated wood

To avoid dripping, a final vacuum is applied in the treatment vessel before opening it to remove excess treatment chemicals from the surface of treated wood.

Application of a final vacuum may not be necessary if the removal of excess treatment chemicals from the surface of treated wood is ensured by the application of an appropriate initial vacuum (e.g. less than 50 mbar).

Technique

Description

(a)

Removal of debris prior to treatment

Debris (e.g. sawdust, woodchips) is removed from the surface of the wood/wood products before treatment.

(b)

Recovery and reuse of waxes and oils

When waxes or oils are used for impregnation, surplus waxes or oils from the impregnation process are recovered and reused.

(c)

Bulk delivery of treatment chemicals

Delivery of treatment chemicals in tanks to reduce the amount of packaging.

(d)

Use of reusable containers

Reusable containers used for treatment chemicals (e.g. intermediate bulk containers) are returned to the supplier for reuse.

Substance/Parameter

Standard(s)

Biocides (55)

EN standards might be available depending on the composition of the biocidal products

Cu (56)

Various EN standards available

(e.g. EN ISO 11885, EN ISO 17294-2, EN ISO 15586)

Solvents (57)

EN standards available for some solvents

(e.g. EN ISO 15680)

PAHs (58)

EN ISO 17993

Benzo[a]pyrene (58)

EN ISO 17993

HOI

EN ISO 9377-2

Substance/Parameter (59)

Standard(s)

Biocides (60)

EN standards might be available depending on the composition of the biocidal products

As

Various EN standards available

(e.g. EN ISO 11885, EN ISO 17294-2, EN ISO 15586)

Cu

Cr

Solvents (61)

EN standards available for some solvents

(e.g. EN ISO 15680)

PAHs

EN ISO 17993

Benzo[a]pyrene

EN ISO 17993

HOI

EN ISO 9377-2

Parameter

Process

Standard(s)

Monitoring associated with

TVOC (62)

Wood and wood products preservation using creosote and solvent-based treatment chemicals

EN 12619

BAT 49, BAT 51

PAHs (62)  (63)

Wood and wood products preservation using creosote

No EN standard available

BAT 51

NOX  (64)

Wood and wood products preservation using creosote and solvent-based treatment chemicals

EN 14792

BAT 52

CO (64)

EN 15058

Technique

Description

(a)

Plant and equipment containment or bund

The parts of the plant in which treatment chemicals are stored or handled, i.e. treatment chemicals storage area, treatment, post-treatment conditioning and interim storage areas (comprising treatment vessel, working vessel, unloading/pull-out facilities, dripping/drying area, cooling zone), pipes and ductwork for treatment chemicals, and creosote (re)conditioning facilities, are contained or bunded. Containments and bunds have impermeable surfaces, are resistant to treatment chemicals and have sufficient capacity to capture and hold the volumes handled or stored in the plant/equipment.

Drip trays (made of treatment-chemical-resistant material) may also be used as local containments for the collection and recovery of drips and spills of treatment chemicals from critical equipment or processes (i.e. valves, inlets/outlets of storage tanks, treatment vessels, working tanks, unloading/pull-out zones, handling of freshly treated wood, cooling/drying zone).

The liquids in the containments/bunds and drip trays are collected to recover the treatment chemicals for their reuse in the treatment chemicals system. Sludge generated in the collection system is disposed of as hazardous waste.

(b)

Impermeable floors

Floors of areas which are not contained or bunded, and where drips, spills, accidental releases or leaching of treatment chemicals may occur are impermeable to the substances concerned (e.g. storage of treated wood on impermeable floors in the event that it is required in the BPR authorisation for the wood preservative used for the treatment). The liquids on the floors are collected to recover the treatment chemicals for their reuse in the treatment chemicals system. Sludge generated in the collection system is disposed of as hazardous waste.

(c)

Warning systems for equipment identified as ‘critical’

‘Critical’ equipment (see BAT 30) is equipped with warning systems to indicate malfunctions.

(d)

Prevention and detection of leaks from underground storage and ductwork for harmful/hazardous substances and record-keeping

The use of underground components is minimised. When underground components are used for the storage of harmful/hazardous substances, secondary containment (e.g. double-walled containment) is put in place. Underground components are equipped with leak detection devices.

Risk-based and regular monitoring of underground storage and ductwork is carried out to identify potential leakages; when necessary, leaking equipment is repaired. A record is kept of incidents that may cause soil and/or groundwater pollution.

(e)

Regular inspection and maintenance of plant and equipment

The plant and the equipment are regularly inspected and serviced to ensure proper functioning; this includes in particular checking the integrity and/or leak-free status of valves, pumps, pipes, tanks, pressure vessels, drip trays, and containments/bunds and the proper functioning of warning systems.

(f)

Techniques to prevent cross-contamination

Cross-contamination (i.e. the contamination of plant areas that usually do not come into contact with treatment chemicals) is prevented by using appropriate techniques such as:

Technique

Description

Applicability

(a)

Techniques to prevent contamination of rain and surface run-off water

Rain and surface run-off water are kept separated from areas where treatment chemicals are stored or handled, from areas where freshly treated wood is stored and from contaminated water. This is achieved by using at least the following techniques:

For existing plants, the applicability of drainage channels and an outer kerb bund may be restricted by the size of the plant area.

(b)

Collection of potentially contaminated surface run-off water

Surface run-off water from areas that are potentially contaminated with treatment chemicals is collected separately. Collected waste water is discharged only after appropriate measures are taken e.g. monitor (see BAT 43), treat (see BAT 47 (e)), re-use (see BAT 47 (c).

Generally applicable.

(c)

Use of potentially contaminated surface run-off water

After its collection, potentially contaminated surface run-off water is used for the preparation of water-based wood preservative solutions.

Only applicable to plants using water-based treatment chemicals. Applicability may be restricted by the quality requirements for its intended use.

(d)

Reuse of cleaning water

Water used to wash equipment and containers is recovered and reused in the preparation of water-based wood preservative solutions.

Only applicable to plants using water-based treatment chemicals.

(e)

Treatment of waste water

Where contamination in the collected surface run-off water and/or cleaning water is detected or can be expected, and where the use of the water is not feasible, the waste water is treated in an adequate waste water treatment plant (on or off site).

Generally applicable.

(f)

Disposal as hazardous waste

Where contamination in the collected surface run-off water and/or cleaning water is detected or can be expected, and where the treatment or use of the water is not feasible, the collected surface run-off water and/or cleaning water is disposed of as hazardous waste.

Generally applicable.

Technique

Description

Applicability

(a)

Thermal oxidation

See BAT 15 (i). Exhaust heat can be recovered by means of heat exchangers.

Generally applicable.

(b)

Sending off-gases to a combustion plant

Part or all of the off-gases are sent as combustion air and supplementary fuel to a combustion plant (including CHP (combined heat and power) plants) used for steam and/or electricity production.

Not applicable for off-gases containing substances referred to in IED Article 59(5). Applicability may be restricted due to safety considerations.

(c)

Adsorption using activated carbon

Organic compounds are adsorbed on the surface of activated carbon. Adsorbed compounds may be subsequently desorbed, e.g. with steam (often on site) for reuse or disposal and the adsorbent is reused.

Generally applicable.

(d)

Absorption using a suitable liquid

Use of a suitable liquid to remove pollutants from the off-gases by absorption, in particular soluble compounds.

Generally applicable.

(e)

Condensation

A technique for removing organic compounds by reducing the temperature below their dew points so that the vapours liquefy. Depending on the operating temperature range required, different refrigerants are used, e.g. cooling water, chilled water (temperature typically around 5 °C), ammonia or propane.

Condensation is used in combination with another abatement technique.

Applicability may be restricted where the energy demand for recovery is excessive due to the low VOC content.

Parameter

Unit

Process

BAT-AEL

(Average over the sampling period)

TVOC

mg C/Nm3

Creosote and solvent-based treatment

< 4–20

PAHs

mg/Nm3

Creosote treatment

< 1 (65)

Technique

Description

Applicability

(a)

Optimisation of thermal treatment conditions

(design and operation)

See BAT 17 (a).

Design applicability may be restricted for existing plants.

(b)

Use of low-NOX burners

See BAT 17 (b).

Applicability may be restricted at existing plants by design and/or operational constraints.

Parameter

Unit

BAT-AEL (66)

(Average over the sampling period)

Indicative emission level (66)

(Average over the sampling period)

NOX

mg/Nm3

20–130

No indicative level

CO

No BAT-AEL

20–150

Technique

Storage and handling of raw materials

(a)

Installation of noise walls and utilisation/optimisation of the noise-absorbing effect of buildings

(b)

Enclosure or partial enclosure of noisy operations

(c)

Use of low-noise vehicles/transport systems

(d)

Noise management measures (e.g. improved inspection and maintenance of equipment, closing of doors and windows)

Kiln drying

(e)

Noise reduction measures for fans