Wine Fermentation Emission Controls

Transcription

1 Wine Fermentation Emission Controls 2018 CAPCOA Engineering Symposium Michael Goldman Engineering Division Manager Santa Barbara County Air Pollution Control District October 30,

2 Presentation Overview Background Emission Controls in Santa Barbara Terravant Wine Company Central Coast Wine Services AIP BACT Determination Wine Institute Appeal Wine Institute Settlement 2

3 Air Emissions from Wineries Fermentation produces carbon dioxide and ethanol Oak Barrel Aging The Angel s Share Ethanol is a volatile organic compound (VOC) VOC is a precursor pollutant to ozone and PM 10 both nonattainment Emissions coincide with peak ozone season 3

4 The Fermentation Process Batch process fermentation cycle Yeast is added to grape juice to initiate fermentation Emission rates vary over cycle Fermentation cycle duration 7 days red wines 15 days white wines 4

5 Barrel Room Aging The Angel s Share Ethanol evaporates through pores of the oak barrels Losses range from 1-5% Dependent upon barrel room: Temperature Relative humidity A 10,000 barrel room has annual emissions of ~8 tpy 5

6 California has 4 major winemaking regions: North Coast Central Valley Central Coast South Coast California Wine Regions 6

7 Scale and Types of Wineries 7

8 Boutique/Small Wineries Melville Winery Rancho Sisquoc Winery 8

9 Industrial Sized Wineries Terravant Wine Company Cambria Winery 9

10 Wine Refineries E&J Gallo - Livingston E&J Gallo - Modesto 10

11 Fermentation Emissions Comparison Winery / Project Tankage VOC Emissions (lb/day) VOC Emissions (ton/year) GHG Emissions (tons/year) Melville Winery Not tracked CCWS / 400-Series Tanks 40 Tanks / 564,000 gallons ,592 E&J Gallo / Fresno 1 12 Tanks / 4,200,000 gallons 14, ,293 1 SJVAPCD ATCs: C thru C (10/23/15) 11

12 Wineries in Santa Barbara County 114 wineries in the County 97 qualify for 1-ton permit exemption (85% no permit) 17 require APCD permit 12

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14 Emission Controls in Santa Barbara Terravant Wine Company Buellton, CA 14

15 Custom crush wine center 211 fermentation tanks Terravant Wine Company 838,000 gallon tank capacity Dozens of wineries and wine brands 5,400 oak barrel storage room 15

16 Terravant Permit History New facility permitted in 2008 Designed and installed an emission control system to allow for maximum production without triggering offsets Control system in operation since

17 Control System Usage at Terravant Counter-current packed bed scrubber Water scrubbing liquid General room ventilation system routes fermentation and storage room emissions to scrubber Ethanol from the scrubber is oxidized to CO 2 and H 2 0 using hydrogen peroxide and UV light Operated at all times during fermentation activities 17

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19 Terravant packed bed scrubber 19

20 Packed bed scrubber UV accelerator lamp 20

21 Packed bed scrubber blower 21

22 Packed bed scrubber control panel 22

23 Fermentation room ventilation ducting 23

24 System Performance/Challenges Initial testing showed scrubber achieved 64% control (2008) System was re-engineered, and testing the following year showed scrubber achieved 91% control (2009) Control efficiency declined in subsequent years ( ) Performance issues attributed to improper maintenance 24

25 Current Status Enhanced maintenance program initiated in 2015 System operational and source tested twice per fermentation season (modified EPA Method 18) Since 2015, system has achieved an average 83% control Expansion project may be in the works 25

26 Emission Controls in Santa Barbara Central Coast Wine Services Santa Maria, CA 26

27 Central Coast Wine Services Custom crush wine center 143 fermentation tanks 1.4 million gallon tank capacity 2,500 oak barrel storage room 27

28 Central Coast Permit History Permitted in 2009 to bring existing facility into compliance Operated several years with emission limits set just below offset thresholds Implemented daily recordkeeping to ensure the emission limits were not exceeded 28

29 Control System Usage at Central Coast Emission control systems voluntarily installed and operated to reduce emissions below offset thresholds One NoMoVo installed in 2013 One EcoPAS and second NoMoVo installed in

30 NoMoVo Control System Counter-current wet scrubber Water scrubbing liquid Piping manifold 1 connected to closed-top fermentation tanks routes fermentation emissions to the control system Release of gas from wine fermentation used to drive emissions toward the control system (passive) Slurry shipped offsite to an approved facility for disposal

31 NoMoVo control system NoMoVo temperature control panel 31

32 NoMoVo slurry level gauge NoMoVo tank piping and P/V valve 32

33 NoMoVo isolation valve 33

34 EcoPAS Control System Glycol chilled tube-in-shell condenser Piping manifold connected to closed-top fermentation tanks routes fermentation emissions to the control system Release of gas from wine fermentation used to drive emissions toward the control system (passive) Aromatic condensate is a usable by-product or is shipped offsite to an approved facility for disposal 34

35 EcoPAS control system 35

36 EcoPAS tank piping and P/V valve 36

37 EcoPAS manifold piping 37

38 AIP BACT Determination Central Coast Wines Services (CCWS) Authority to Construct August

39 40 stainless steel tanks 400-Series Tank Project 7,527 20,736 gallons each 563,690 gallon total capacity Project subject to New Source Review - BACT 39

40 Achieved-in-Practice Determination BACT definition has three parts: The most effective emission control that has been achieved-in-practice (AIP) for the type of equipment comprising such stationary source, or Any other emission control that is technologically feasible and costeffective, or The most stringent limitation contained in any State Implementation Plan. District policy defines AIP as a proven track record of reliability Both controls were operated successfully for a reasonable amount of time: 2-3 full fermentation seasons. 40

41 Achieved-in-Practice Determination (contd.) Data analyses by the District, EPA and CARB confirmed effectiveness of the NoMoVo and EcoPAS controls. AIP does not require the control technology to meet a prior BACT requirement, just that the controls have operated successfully for a reasonable period of time. Basis documented in the District s AIP BACT Memo

42 Authority to Construct Permit Authorized: Fermentation in all 400-series tanks 50% increase in wine fermentation capacity Installation of new oak barrel storage room (2,500 bbls) Required use of control systems as AIP BACT Control systems required to meet 67% control efficiency over entire fermentation season via mass balance approach No source testing CCWS voluntarily added the controls to the entire facility 42

43 CARB BACT / Technology Clearinghouse 43

44 Wine Institute Appeal 44

45 Wine Institute Appeal Wine Institute appealed the permit and raised a myriad of incorrect and misleading technical claims: Insufficient Track Record Performance Standard Basis Wine Quality & Contamination Use on All Tank Sizes Not Consistent with Policy Source Testing Necessary Use on All Wine Types Use Over a Full Fermentation Cycle Performance Based on Theory Economic Analysis San Joaquin Valley Memo EPA Views are Inconclusive 45

46 CARB Input In summary, CARB staff agrees with the District s findings: the performance standards and the control technologies used to meet the performance standard are properly designated as achieved-in-practice BACT for control of VOC from wine fermentation tanks. - Richard W. Corey, Executive Officer California Air Resources Board 46

47 Wine Institute Settlement 47

48 Wine Institute Settlement 1. AIP determination limited to class and category: Closed-top tanks 30,000 gallons or less 2. AIP Memo updated 1 : Notation that all fermentation occurs indoors at CCWS Notation that control systems have not been used on tanks less than 1,100 gallons in size at CCWS 3. Wine Institute withdrew appeal and agreed to not appeal future permit actions (including individual members) 1 Not part of the BACT Determination. 48

49 Wine Institute Settlement (cont.) APCD offered class and category settlement in November 2017 WI initially rejected offer First AIP BACT Determination for winery controls Size limit was implied due to technology transfer requirements Closed-top tank limit was implied due to control system operating principles 49

50 Conclusions Emission controls for wineries work The emission controls are cost effective District s should think outside the box when confronted with unique operating conditions Seek input from CARB and EPA on complex issues 50

51 Questions? 51