EPA-450/2-74-021B BACKGROUND INFORMATION FOR STANDARDS OF PERFORMANCE: COAL PREPARATION PLANTS VOLUME 2: TEST DATA SUMMARY Emission Standards and Engineering Division U.S. ENVIRONMENTAL PROTECTION AGENCY Office of Air and Waste Management Office of Air Quality Planning and Standards Research Triangle Park, North Carolina 27711 October 1974 ------- This report is issued by the Environmental Protection Agency to report technical data of interest to a limited number of readers. Copies are avail- able free of charge to Federal employees, current contractors and grantees, and nonprofit organizations as supplies permit from the Air Pollution Technical Information Center, Environmental Protection Agency, Research Triangle Park, North Carolina 27711; or, for a fee, from the National Technical Information Service, 5285 Port Royal Road, Springfield, Virginia 22161. Publication No. EPA~450/2-74-021b ii ------- TABLE OF CONTENTS Section Page INTRODUCTION 1 Participate Test Results 2 Facilities ' 2 SUMMARY OF RESULTS 10 REFERENCES 33 ill ------- COAL PREPARATION PUNTS SUMMARY OF TEST DATA INTRODUCTION This document presents a summary of source tests and visible emission measurements cited in Background Information for Standards of Performance:.. Coal Preparation Plants,Volume 1, Proposed Standards. This volume is principally a summary of test results for pirticulate matter, but also describ the facilities, their operating conditions, and characteristics of exhaust gas streams. Facilities are identified by the same coding used in Volume 1. For example, Table 1 summarizes results of the January 1972 tests of emissions from an air table, Facility A. These same results are also plotted in Figure 9 of Volume 1. Many of the tests summarized herein were conducted using EPA Reference Method 5 for particulate matter (with minor variations in some cases).- When this method was used, additional measurements were made to evaluate materials that condense and collect in the impingers as the gases are cooled. In the summaries, the "probe and filter catch" is the participate emission measurement that was presented in Volume 1 and is the basis for the standard. The "total catch" includes the probe and filter catch plus material collected in the impingers. Some tests summarized herein were conducted using methods which do not use impingers, Particulate matter was collected on an alundum thimble or a -' Environmental Protection Agency, "Standards of Performance for New Stationary Sources," Federal Register, 36. (247): 24888-24890, December 1971 ------- fiberglass filter. In these test methods, the filter or thimble participate catch is analogous to the "probe and filter catch" of Method 5. Particulate Test Results A test program was undertaken by EPA to evaluate the best particulate emission control systems available for installation on new or substantially modified air tables and thermal dryers in coal preparation plants. A total of five plants were tested, three thermal dryer facilities and two air table operations. All thermal dryers were controlled by venturi-type wet scrubbers, while all air tables were controlled by baghouse collectors. In addition, an EPA survey accumulated test data from which one air table test and four thermal dryer tests were chosen as reliable data. Figures 1 and 2 plot emission rates in grains per DSCF versus the applicable coal preparation facility for air tables and thermal dryers, respectively. Facilities A- Air tables. Each air table within Plant A has a design capacity of 75 tons cleaned coal per hour, is equipped with a cyclone and a closed suction-type, cyclic cleaned baghouse of polypropylene fabric. The coal processed was a mixture of lower Kittanning and Upper Freeport seams with a Hardgrove grindability index of approximately 90. Feed analysis showed 28 mesh x 0 material at li.69 percent of te*a4 -feed. The plant was operating at 70 tons per hour cleaned coal during tests. There were no visible emissions from stack. Tests were conducted using EPA Method 5 except that sampling was conducted in a tangential gas flow. ------- Bj. Air tables. Each air table within Plant B has a design capacity of 50 tons cleaned coal per hour, is equipped with a cyclone and a closed suction-type, cyclic cleaned baghouse of nylon fabric. The coal processed was from the Pocahontas seam with a Hardgrove grindability index of 100. Feed analysis showed 28 mesh x 0 material at 36.0 percent of total feed. The plant was operating at 38 tons cleaned coal per hour. No visible emissions were observed from the stack. Tests were conducted using EPA Method 5 except sampling was conducted in a tangential gas flow. B2. Same facility as B^t but tests were conducted privately under contract to the company. The coal being processed, feed analysis, and production rate during these tests are not known. Tests were conducted using an alundum thimble inside the stack. Sampling was done in a tangential gas flow. C-|. Fluid-bed thermal dryer. The dryer design capacity is 408.5 tons per hour coal feed and 40 tons per hour evaporation. Filter cake (-28 mesh) at 35 percent of plant output is fed to the dryer with all 1/4 x 28 M product. The plant normally operates the dryer at 293 tons/hour coal feed. The dryer is controlled by multiclone bank precleaners and a venturi-type scrubber with a cyclonic mist eliminator. The stack had straightening vanes permanently installed. During the test, dryer feed was 300 tons/hour. Scrubber-mist eliminator pressure drop was 28 inches w.g. The coal processed was a mixture of Pochaontas No. 3 and No. 5 seams of 100+ Hardgrove grindability. Previous sieve analysis showed an average -325 mesh ------- feed content of 8 percent. Inlet grain loadings averaged 9.8 gr/DSCF, Plume aftertall showed 5-10 percent opacity. The test method was EPA Method 5. C2« Same facility as Cp but the scrubber-mist eliminator pressure drop was 26.5 Inches w.g. during this test. No visible emissions were noted during these tests. DT Fluid-bed thermal dryer. The dryer design capacity 1s 385 tons per hour feed and 35-45 tons per hour evaporation. Filter cake (-28 mesh) at either 50 or 100 percent of plant output can be fed,to the dryer with all 1/4 x 28M product. The plant normally operates the dryer at 325 tons/hour feed with 50 percent filter cake in the feed. The dryer is controlled by two cyclones in parallel followed by a venturi-type scrubber with a cyclonic mist eliminator. During tests dryer feed was 300 to 360 tons/ hour with 100 percent of filter cake being dried. Scrubber AP was 35 inches w.g. The coal processed was Pocahontas No. 3 seam of 100+ grindabllity. Sieve analysis showed that 4.22 percent of the feed was less than 325 mesh. Inlet grain loadings averaged 1.58 graln/DSCF. Tests were con- ducted using EPA Method 5 except that sampling was conducted in a tangential gas flow. Plume opacity was less than 10 percent. Dg. Same facility, plant operation, and test method as for Dj. Plume opacity was less than 10 percent. ------- D3. Same facility and plant operation as for D^ and Dg. Egg-crate type vanes were inserted into the stack to straighten the gas flow for comparison to the D2 tests, EPA Method 5 was used. Plume opacity was less than 10 percent. Dj. Same facility as D,, D2, and D3- Only visible emission data (using EPA Method 9) was obtained, ET Fluid-bed thermal dryer. The dryer design capacity is 274 tons per hour coal feed and 36 tons per hour evaporation. All filter cake passes through the dryer. Plant operation averaged 125 tons/hour feed to the dryer prior to the test. The dryer is controlled by a multiclone bank followed by a venturi-fype scrubber with a cyclonic mist eliminator. During tests the dryer feed was 200 tons per hour and scrubber A? was 21 inches total. The coal processed was Taggart seam of 55 Hardgrove grind- ability and was dried to 2.5 percent surface moisture. Coal fed to the dryer was 5.0 percent less than 325 mesh. Plume aftertail was 5 to 10 percent opacity. Tests were conducted using EPA Method 5 except that sampling was conducted in a tangential gas flow. Eg. Same facility, plant operation and test method as for E. except that Osaka seam coal, 55 Hardgrove grindability, was dried to 1.3 percent surface moisture. The coal fed to the dryer was still 5.0 percent less than 325 mesh. Plume aftertail ranged from 10 to 15 percent opacity. F. Fluid-bed thermal dryer. The dryer design capacity is 400 tons per hour coal feed and 40 tons per hour evaporation. Thirty-five percent of thi filter i ------- cake is fed to the dryer. The plant operation averages 360 tons per hour dryer feed. The dryer is controlled by a multiclone bank followed by * a venturi-type scrubber with a cyclonic mist eliminator UP of 26 inches w.g.}. The coal processed is No. 3 Pocahontas, 100+ Hardgrove grindability. No sieve analysis of feed is available. Process data during the test is limited. Tests were conducted privately using American Air Filter Method No. 139.^ Sampling was conducted with a fiberglass filter followed with a back-up filter. The probe tip was tilted to sample from the direction of maximum velocity. A measuring orifice was used instead of a dry test meter, G. Fluid-bed thermal dryer. The dryer design capacity is 365 tons per hour coal feed and 37 tons per hour evaporation. Thirty-five percent of the filter cake is fed to the dryer. The plant operation is normally at rated capacity. The dryer is controlled by a multiclone bank followed by a venturi-type scrubber with a tray scrubber as a mist eliminator. Total &P is estimated at 25 inches w.g. The coal processed is No. 3 Pocahontas, Hardgrove grindability index 100. No sieve analysis of feed is available. Process data during the test is limited. The test method is the same as for B2- H* Fluid-bed thermal dryer. The dryer design capacity is 197 tons coal per hour feed and 22 tons per hour evaporation. The dryer operates at 210 tons coal per hour. All the filter cake goes through the dryer. The dryer is controlled by twin cyclones in parallel, followed by a venturi-type scrubber. Total -* American Air Filter Company, Incorporated, "Operating Instructions-- Five Inch Dust Sampler and Thirteen Inch Dust Sampler," Report 139, May 16, 1956. ------- aP Is 21.75 Inches w. g. The coal processed is Beckley seam, Hardgrove grindability of 102. Sieve analysis of the dryer feed shows 0.59 percent is less than 325 mesh. Process data during the test is limited. Company personnel conducted the test using EPA Method 5 except that sampling was conducted in a tangential gas flow. I- Fluid-bed thermal dryer. The dryer design capacity is 184 tons per hour feed and 14 tons per hour evaporation. The dryer operates at 100 tons per hour. All the filter cake i:, fed to the dryer. Emission controls consist of cyclone banks followed by a venturi-type scrubber. Coal processed is Pocahontas, 100+ Hardgrove grindability. Sieve analysis of the dryer feed shows 3.75 percent less than 100 mesh. Limited process data is available during the emission tests. The test method is the same as for F. X. This facility is identical to that of facility D-j. Only visible emission data (using EPA Method 9) was obtained. ------- 0.02 O uii 0.01 3 o AVERAGE EPA TEST METHOD O OTHER TEST METHOD I t PLANT' Figure 1. Particulate emissions from air table exhausts controlled by fabric filters ------- 0.06 0.05 0.04 1 0.03 u O £ 0.02 0.01 0 ! i Hr1 ! i AVERAGE & EPA TEST METHOD O OTHER TEST 1ETHOD fi n b PLANT C2 pi D2 Da El £2 F G H ;I Figure 2. Particulate emissions from thermal dryer exhausts controlled by wet scrubbers ------- Table 1 FACILITY A - Suumary of Results Run Number Date Test Time-minutes Production rate - TPH « Stack Effluent Flow rate - ACFM Flow fate - DSCFM Flow rate - DSCF/ton Temperature - °F Water vapor - Vol.% COa - Vol.1 dry 02 -.Vol.* dry CO - Vol. % dry Visible Emissions % opacity Particulate Emissions Probe and filter catch ir/DSCF gr/ACF Ib/hr Ib/ton of product Total catch gr/DSCF gr/ACF Ib/hr Ib/ton of product 1 1/20/72 120 70,3 33,700 33 ,COO 23,713 56 1.42 0 .0109 .0109 3.14 0.045 .0142 .0142 4.09 0.053 2 1/21/72 120 70.3 33,000 . ' 35, COO 30,343' * 30 0.?7 o- .0052 .0056 1.5C 0.022 .0129' .0139 ' ' 3.92 0.056 Averac 70,3 33,350 34,C50 29 ,501 46 T.09 0 .3001 . .0003 - 2.3G 0.034 .013C .0141 4.00 0.057 Reference 1. 10 ------- .Table 2 FACILITY BI - Sunmary of Results Run Number Date Test Time-minutes Production rate --TPH Stack Effluent Flow rate - ACFM Flow rate - DSCFM Flow rate - DSCF/ton Temperature - °F Water vapor - Vol.1 C0£ - Vol.% dry Og - Vol.% dry CO - Vol. % dry Visible Emissions % opacity Parti culate Emissions Probe and filter catch gr/DSCF gr/ACF Ib/hr Ib/ton of product Total catch gr/DS£F gr/ACf Ib/hr Ib/ton of product 1 2/23/72 120 38 27,318 25,918 40,923 63 0.886 0 o.on 0.010 2,41 0.063 0.015 Ov014 3.35 0.088 2 2/24/72 120 38 25,468 23,902 40,213 65 .0.908 0 0.002 0.002 0.36 0.010 0.012 0.012 2.54 0.067 3 2/24/72 120 3S. 26,607 24,002 41 ,786 65 1.072 0 - 0.003 0.003 0.57 0.015 0.007 0.007 1.56 0,041 Averac 120 33 26,464 24,907 40,974 64 0.982 0 0.005 0.005 1.11 0.029 o.on 0.011 2.40 0.065 Reference 2, ------- Table 3 FACILITY B2 Summary of Results Run Number _ _ _ Date Test Time-minutes Production rate --TPH Stack Effluent Flow rate - ACFM Flow rate - OSCFM * Flow rate - DSGF/ton Temperature - °F Water vapor - Vol.% C02 - Vol.% dry 02 - Vol.% dry CO - Vol. % dry Visible Emissions % opacity P .'\ r t leu la t e^ E mi s s i on s^ ari d f i Her catch 1 5/12/70 60 2 5/12/70 60 3 5/13/70 60 4 5/ 13/70 60 gr/OSCF gr/ACF Ib/hr lb/1:on of product 0.006 0.008 0.008 0.006 r/ACf Ib/hr Ib/tcn oi: product' ------- Table 3 (continuad) FACILITY B2 Summary of Results Run Number Date Test Time-minutes 5 5/13/70 60 6 5/14/70 60 7 5/14/70 60 8 5/14/70 60 Production rate --TPH Stack Effluent Flow rate - ACFM Flow rate - OSCFM Flow rate - DSCF/ton Temperature - °F Water vapor - Vol.f C02 - Vol.% dry CO - Vol. % dry Visible Emissions % opacity P. '.rticujajte Emissions^ Prgb o_jind f i 1 ter CQt.cj\ gr/DSCF gr/ACF Ib/hr Ib/ton of product O.-/DSCF Or/,\CF lb/hr ]b/t"on oi: product 0.005 0.004 o.on 0.009 ------- Table 3 (continued) FACILITY B2 Suntnary of Results Run_Huniber Date Test Time-minutes Production rate --TPH Stack Effluent Flow rate - ACFM Flow rate - DSCFH Flov/ rate - DSCF/ton Temperature - °F Water vapor - Vol.1 C02 - Vol.% dry 02 - .Vol.% dry CO - Vol. % dry Visible .Emissions % opacity f ^ j" t i o 1 1 a t e Errri 5 si o n s_ 9 5/15/70 s 60 10 5/15/70 60 Average 60 gr/DSCF gr/ACF Ib/hr Ib/tcn of product 0.005 0,007 0.007 gr/DSCF gr/ACF Ib/hr lb/tcn o!: Reference 3. 14 ------- Table 4 FACILITY C1 - Summary of Results Run Number Date Test Time-minutes .._ Production rate - TPH Stack Effluent Flow rate - ACFM Flow rate - DSCFM Flow rate - DSCF/ton dryer capacity Temperature - F Water vapor - Vol.1 CQ£ - Vol.1 dry 0? - Vol.% dry 2/29/72 120 300 145,072 Kj.330 21 ,266 125 14.37 1.0 19.2 _2__ 3/1/72 120 300 145,207 107,530 21,506 125 12.98 0.7 19,7 3 3/2/72 120 300 151,456 111,560 22,312 . , 125 12.74 0.1 20.6 . ^Average . 120 300 147,272 100,473 21 ,695 125 13.30 0.6 19.0 CO - Vol. % dry Visible Emissions % opacity Particulate Emissions 10 10 10 Probe and filter catch gr/DSCF gr/ACF Ib/hr Ib/ton of product Total catch gr/DSCF gr/ACF Ib/hr Ib/ton of product 0.017 - 0.012 15.16 0.051 0.021 0.015 18.77 0.063 0.013 0.010 12.39 0-.041 0.016 0.012 14.55 0.049 0.013 0.010 13.83 0.046 * 0,015 0.011 14.81 ' 0.049 0.014 . . 0.011 13.43 0.0 0.017 0.013 16.04 0.053 Reference 4. 15 ------- laoie 5 FACILITY C, - Summary of Results Run Number Date Test Time-minutes Production rate - TPH m Stack Effluent Flow rate - ACFM Flow rate - DSCFM Flow rate - DSC F/ ton capaci ty Temperature - °F Water vapor - Vol.2 COg - Vol.% dry Og -.Vol.% dry CO - Vol. % dry Visible Emissions % opacity Parti cul ate Emissions Probe and filter catch gr/DSCF gr/ACF Ib/hr Ib/ton of product Total catch gr/DSCF gr/ACF Ib/hr Ib/ton of product 1 10/24/72 120 300 157,812 114,589 22,918 126 14.14 - . - * <10 3.016 0.011 15.25 0,051 0.01? 0.012 1C. 42 0.055 2 , 10/25/72 120 300 154,183 113,253 22,771 123 12,41 * ** «. H <10 0.021 0.015 20.17 0.067 0.022 0.016 21.20 0.071 3 10/26/72 120 280 149,481 109,405 21 ,001. T26 13.5P, " * " <50 0.021 0.016 20.10 0.072 0,025' 0.010 - 23,17 0.083 Average - 120 293 153,325 112,516 21*,523 125 13,71 w <10 0.019 0.014 18.51 . 0,063 0.021 0.015 20,28 0.069 Reference 5, ------- jTable 6 7 FACILITY 01- Summary of Results Run Number Date Test Time-minutes Production rate --TPH Stack Effluent * Flow rate - ACFM * Flow rate - DSCFM Flow rate - DSCF/ton* dryer capacity Temperature - °F Water vapor - Vol.% C02 - Vol.* dry 02 - Vol.56 dry CO - Vol. % dry Visible Emissions % opacity Parti culatejrnijsjons Probe and filter catch gr/DSCF gr/ACF Ib/hr* * Ib/ton of product Total .patch. gr/DSCF gr/ACF Ib/hr* Ib/ton of product 1 1/25/72 120 360 215,722 . 162,000. 27,000.. 53 , 13.3 1.1 17.4 0.0236 0.0177 32.8 0.091 0.0305 0.0229 42.3 0.118 '2- . 1/26/72 120 360 210,151 157, HOO 26,167 69 13.4 1.6 17.7 0.0118 0.0088 15.9 0.044 ' 0.0157 0.0117 21.1 0.059 3 1/27/72 120 3CO 208,062 157,000 26,167 65 12.7 1.5 17.7 0.0159 0.0120 21.4 0.060 0.0203 0.0157 28.0 0.078 Averagi - 120 360 211,312 150,667 26,445 62 13.1 1.4 17.6 0.0171 0.0120 23.4 0.065 0.0223 0.0168 30.5 O.OC5 * IHnh results due to inaccuracy of pi tot readings in swirling gas flow. Actual values are approximately 0.7 times the values shown in the table. ------- FACILITY n2~ Suranary of Results Run Hunter Date Test Time-minutes t. Production rate - TPH Stick Effluent Flow rate - ACFM* Flow rate - DSCFM* Flow rate - DSCF/ton * dryer capacity Temperature - °F Hater vaoor - Vol.2 1 '9/12/72 .126 344 215,130 165,033 28,786 119 13.41 2 0/13/72 120 3% 216,563 164,013 31,767 125 13.16 3 D/20/72 120 306 225,451 169,055 33,143 . . 125 14.59 Averag ,-....1 ,.,, "_., ,, , .. ** 120 31 QA 219,051 166,034 31,227 123 13.72 C02 - Vol.% dry 02 - Vol.* dry CO - Vol. % dry Visible Emissions % opacity Particulate Emissions Probe and filter catch gr/DSCF gr/ACF Ib/hr * Ib/ton of product* Total catch gr/DSCF §r/ACF Ib/hr* * Ib/ton of product 0.0196 0.0150 27.75 0.031 0.0377 0.0289 53.32 0.155 0.0211 0.01CO 20.66 0-.097 0.0253 0.0102 35.56 0. .11 6 0.0300 0.0232.,. . 44.53 0,145 * 0.0369 0.0277 53.46 ' 0.175 0.0230 ...IL0191 34.00 0.107- 0.0333 0.0253 47.40 0.140 * High results due to inaccuracy of pi tot readings in values are approximately 0.7 times the values shown swirling flas flon. Actual in the table. ------- Table 8 FACILITY D3 - Sunt:ir> of Results Run Number Date Test Time-minutes Production rate - TPH Stack Effluent Flow rate - ACFM Flow rate - DSCFM Flow rate - DSCF/ton capacity Temperature - °F Water vapor - Vol.% C02 -Vol.* dry Oa -.Vol.% dry CO - Vol. % dry Visible Emissions % opacity Parti culate Emissions Probe and filter catch gr/DSCF gr/ACF Ib/hr Ib/ton of product Total catch gr/DSCF gr/ACF Ib/hr Ib/ton of product Reference 7, 1 9/20/72 120 _ * 306 177,649 127/33 24,987 126 14.59 . " - <10 0.0461 0.0344 50.35 0.165 0.0531 0.0396 5C.OO 0.184 2 3 9/20/72 9/21/72 120 120 335 306 175,139 176,764 127,723 129,760 22,808 25,443 * 124 123 13.98 13.36 * - - <10 <13 0.0498 0.0350 0.0372 0.0266 54.51 30.92 0.162 0.127 0.0590 0.0417' 0.0445 0.0317' 64.58 46.37 0.192 0.152 Average 120 316 176,517 120,050 24,413 124 13.90 - . - <10 .0402 . 0.0327 47.93 0.151 0.0513 0.0389 56.32 0.176 19 ------- Table 9 FACILITY D4 SUMMARY OF VISIBLE EMISSIONS Date: 2/5/74 Type of Plant: Coal Preparation Type of Discharge: Vertical Stack Location of DischargeiClean Coal Transfer Point Height of Point of Discharge: 60 ft. Description of Background: Brown Hillside Distance from Observer to Discharge Point: ISO ft. Height of Observation Point: Ground Level Direction of Observer from Discharge Point: North Description of Sky: Scattered Clouds (4W cover) Wind Direction: Calm Color of Plume: Lt. grey when visible Interference of Steam Plume: Occasional Duration of Observation; 2 hours Wind Velocity: Calm Detached Plume: No mi/hr Summary of Data: Opacity, Percent 7 10 15 20 25 30 35 40 45 50 Total Time Equal to or Greater Than Given Opacity HTn. 8 4 Sec. 0 15 Opacity, Percent S5 60 65 70 75 80 85 90 95 100 Total Tfae Equal to or Greater Than Given Opacity MTn, Sec7 Opacity Variation with Time: ID 3 4 TIME, hours Reference 8. 20 ------- Table 10 FACILITY D4 SUMMARY OF VISIBLE EMISSIONS Date: 2/5/74 Type of Plant: Coal Preparation Type of Discharge: Vertical Stack Location of Discharge: Load-out (Rotoclone) Height of Point of Discharge: 80 ft. Description of Background: Brown Hillside Distance from Observer to Discharge Point: 300 ft. Height of Observation Point: Ground Level Direction of Observer from Discharge Point: North Description of Sky: Partly Cloudy (50% cover) Wind Direction: Calm Color of Plume: Lt. grey when visible Interference of Steam Plume: Occasional Duration of Observation: 2 hours Wind Velocity: Calm Detached Plume: No mi/hr Summary of Data: Opacity, Percent 3 10 15 20 25 30 35 40 45 50 Total Time Equal to or Greater Than Given Opacity Min. Sec. Opacity, Percent 55 60 65 70 75 80 85 90 95 100 Total Time Equal to or Greater Than' Given Opacity Mm. Sec^ Opacity Variation with Time: 40 10 3 4 TIME, hours Reference 8, 21 ------- TaMe 11 FACILITY D4 SWWARY OF VISIBLE EMISSIONS Date: 2/7/74 Type of Plant: Coal Preparation Tyoe jf Discharge: Horizontal Stack Location of Discharge: Breaker-Baghouse Exhaust Height of Point of Discharge: 35 ft. Distance from Observer to Discharge Point: 100 ft Height of Observation Point: Ground Level Direction of Observer from Discharge Point: East Description of Background: Side of plant; gray metal background. Description of Sky: Cloudy Wind Direction: Northwest Color of Plume: None Interference of Steam Plume: None Duration of Observation: 2 hours Wind Velocity. --IS Detached Plume: No m1/hr Summary of Data: Opacity, Percent 5 10 15 20 25 30 35 40 45 50 Total Time Equal to or Greater Than Given Opacity Mln. Sec. Opacity, Percent 55 60 65 70 75 80 85 90 95 100 Total Time-Equal to or Greater Than Given Opacity Min. SecT Opacity Variation with Time: 4D 30 20 10 3 4 TIME, hours Reference 8. 22 ------- Table 12 FACILITY D4 SUMMARY OF VISIBLE EMISSIONS Date; 2/5/74 Type of Plant: Coal Preparation Type of Discharge: Vertical Stack Distance from Observer to Discharge Point: 300 ft. Location of Discharge:Therinal Dryer-Scrubber uutletHeight of Observation Point: Ground Level Height of Point of Discharge: ^120 ft. Direction of Observer from Discharge Point: Northeast Description of Background: Sky Description of Sky: Clear, Wind Direction: Calm Wind Velocity: Calm Color of Plume: Lt. Srey when visible Detached Plume: No Interference of Steam Plume: Total at stack; partial up to 500 ft, elevation Duration of Observation: 4 hours mi/hr Summary of Data: Opacity, Percent 5 10 IS 20 25 30 35 40 45 50 Total Time Equal to or Greater Than Given Opacity Hln. 12 12 jeer; 0 0 Opacity, Percent 55 60 65 70 75 80 85 90 95 100 Total Time Equal to or Greater Than Given Opacity Min. Sec. Opacity Variation with Time: 40 30 20 I " o TIME, hours Reference 8. 23 ------- Table 13 FACILITY ET Suimtary of Results Run Number Date Test Time-minutes Production rate --TPH Stack Effluent Flow rate - ACFM* Flow rate - DSCFM Flow rate - DSCF/ton* capacity Temperature - °F Water vapor - Vol.% C0£ - Vol.% dry 02 - Vol.% dry CO - Vol. % dry Visible .Emissions % opacity Parti cul ate Emissions Probe and filter catch gr/DSCF gr/ACF Ib/hr* Ib/ton of product* Total catch gr/DSCF gr/ACF Ib/hr * Ib/ton of product * 1 3/23/72 120 200 133,193 135,450 4Q5:35. '120 11.93 0.3 10.0 - <10 0.027' 0.-Q20 31.57 0.153 0.035 0.025 - 41.09 0.205 2 3/23/72 120 210 173 ,124 136,170 40,821 120 . 1.37 0.4 ID. 3 - <10 . 0.023 0.021 "JO f>*"* a£ «oo 0.164 " 0.037 0.023 42.80 0.214 Average 101,061 135,760 40,720 ' 120 I 10. GJ 0.3t I 19. R 0.0275 O.D205 32.23 0.1G1 .027 41,9 * High results due to inaccuracy of pitot readings in swirling gas flow. values are approximately 0.7 times the values shown in the table. Reference 9. 24 . Actual ------- Table 14 FACILITY E?~ Stannary of Results Run Number Date Test Time-minutes Production rate --TPH Stack Effluent Flow rate - ACFM * Flow rate - DSCFM* Flow rate - DSCF/ton * capaci ty Temperature - °F Water vapor - Vol.1 COa - Vol.% dry Og - Vol.X dry ,-|U; 3/20/72 120 200- 134,093 : 137,313 41,103 "200- 12.61 3.2 IS. 2 - Z . 3/22/72 120 200 I77,nn 123,320 3/*» f- f* f- o,j;}u 200 . 13. Gl 0.3 10. C . 3 3/22/72 120 *^"SA t--'\- 1 -I T r*- f\ -f i / 1 9 >*J/ "f IT-* -I *%n t.W ,1.1', *<-. i -jn *'\-' , 1 ->> ^»«^n (, ::> 12. 5C . 0.2 10.4 Average - 120 200 174,574 127,310 30,343 200 -i n.'vj. ''.25 I I CO - Vol. % dry Visible Emissions % opacity Particulate Emissions 10 1-1 Probe and filter catch gr/DSCF gr/ACF Ib/hr* Ib/ton of product * Total catch gr/DSCF gr/AC? Ib/hr* Ib/ton of product * 3.04G" 0.034 53.54 0.2C7 0.050 0.344 CC.OC 0 3*iO 0,037 *~t nn 7 i ,.Ut / l>*\ 11 H j . -J 1 n C"^o 0.050 ,-^ H n/ . JOM 54.74 0,274 (^ f\ 4 *\ ,--.''K> ^ n-«"7 1 . V J*'i._ 47.15 n.23«3 0.036 O.OAi C1.22 0.30C 0.040 3.030 43.7? 0.219 0.053 0.040 57.03 0.2?n * i'in'i results dm? to inaccuracy of pi tot readings in swirlirn g^s flov;. Actual values are approximately 0.7 times the values shown in the table. 0 "rocuss unstable Reference 9 '} /-.i.-raij'-5 for runr, 2 -an-i 3 ------- :tuiL,H umber "i ;s t Time-mi mi tos Production rate -'TPH Stack Effluent Flow rata - ACFM How rate - DSCFM Flov/ rate - DSCF/ton Temperature - °F U.rter vapor ~ Vol.% COg - Vol.% dry Q'l - Vol." dry CO - Vol. 5J dry I opaci ty ;[:.: (3ri '. ' i': i IJ;s r ca t c h_ gr/OSCF gr/ACF Table 15 FACILITY F Summary of Results Aver-aye* 1/5/71 141,000 118°F 0.01 a/i'.on iji: product 0.029 * Individual runs not reported. Reference 10. 26 ------- Table 16 FACILITY G Summary of Results Run Number ' Date Test Timo-minutes 1 2/11/71 66 2 2/11/71 63 3 2/11/71 63 Average 64 Production rate --TPH Stack Effluent Flow rate - ACFM Flow rate - DSCFM Flow rate - DSCF/ton Temperature - °F Water vapor - Vol.% C0£ - Vol.% dry G2 - Vol.% dry CO - Vol. % dry Visible Emissions % opacity a te_ Emi ss 1 ons Pro ho and fil ter catch gr/DSCF gr/ACF Ib/hr lb/tcn of product Total c 0.011 0,014 0.008 0.011 gr/DSCF gr/ACF Ib/hr Ib/tcn of product Reference 10. ------- J\un__ I i urnbe r _______ _ ___ Da ta Tes L Ti ma-minutes Production rate --TPH Stack EFfluGnt Flow rate - ACFM Flow rate - OSCFM Flow rate - DSCF/ton temperature - °F Hater vapor - Vol.% CO? - Vol.fJ dry ,A i * ^ 1 ^/ 4 , , , , v/ " v O i - .-> Ui j CO - Vol. i^-dry Visible E'iiissions % opacity Table 17 FACILITY H Summary of Results 1 9/14/71 70,170 9/15/71 68,604 Avoraye 69,380 nr/DSCF gr/ACF ib/hr lb/tori or prcduct 0.031 .0275 0,087 0.079 0.029 0.083 Reference 10, 28 ------- Table 18 FACILITY I Summary of Results J\unjj umber Date Test Time-n Production rate --TPH Stack Effluent Flow rate - ACFM Flow rate - DSCFM Flow rate - DSCF/ton Temperature - °F Uater vapor - Vol.SJ C02 - Vol.% dry 1 7/26/72 inutes 48 2 7/26/72 48 3 7/26/72 48 Average 48 CO -- Vol. % dry Visible Emissions % opacity P.yrLi ci.i 1 ate ilrrn' ssions Proh;5 and filter catch gr/DSCF gr/ACF Ib/hr Ib/tori of product gr/DSCr Gr/A.Cf Ib/hr Ib/tcn of-" [rro 114 117 108 113 0.013 0.019 0.012 0.015 Reference 10." ------- Table 19 FACILITY X SUMWRY OF VISIBLE EMISSIONS Date: 2/6/74 Type of Plant: Coal Preparation Type of Discharge: Vertical Stack Location of Discharge: .Clean Coal Transfer Point Height of Point of Discharge: 60 ft. Description of Background: Brown Hillside Distance from Observer to Discharge Point: 250 ft. Height of Observation Point: Ground Level Direction of Observer from Discharge Point: North Description of Sky: Overcast Wind Direction: Calm Wind Velocity; Calm mi/hr Color of Plume: Grey when visible Detached Plume: No Interference of Steam Plume: Intermittent Duration of Observation: l hour, 14 minutes. Halted due to rain. Start-ups and shutddwns not included; upsets are included. Summary of Data: Opacity, Percent 5 10 15 20 25 30 35 40 45 50 Total Time Equal to or Greater Than GivenOpacity Hin. 18 17 15 13 7 Z 0 0 Sec. 0 30 0 14 0 45 30 0 Opacity, Percent 55 60 65 70 75 80 85 90 §5 100 Total Time Equal to or Greater Than Given Opacity MTru Sec. Opacity Variations with Time: 40 30 20 I Reference 8, TIME, hours 30 ------- Table 20 FACILITY X SUMMARY OF VISIBLE EMISSIONS Date: 2/6/74 Type of Plant: Coal Preparation Type of Discharge: Vertical Stack Location of Discharge; Load-out (Rotoclone) Height of Point of Discharge: 80 ft. Description of Background: Sky Distance from Observer to Discharge Point: 400 ft. Height of Observation Point: Ground Level Direction of Observer from Discharge Point: North Description of Sky: Overcast Wind Direction: Calm Wind Velocity: Calm Color of Plume: Grey when visible. Detached PI are: No Interference of Steam Plume: Intermittent Duration of Observation: 1 hour, 13 minutes. Halted dut to rain. included; upsets are included. Summary of Data: Opacity, Percent 5 10 15 20 25 30 35 43 45 50 Total Time Equal to or Greater Than Given Opacity HTrL 19 18 IS n 8 4 0 0 sec, 30 45 0 30 0 0 IS 0 Opacity, Percent 55 60 65 70 75 80 85 90 95 100 mi/hr Start-ups and shutdowns not Total Time Equal to or Greater Than Given Opacity Hln.. Sec. Opacity Variations with Tine: 40 30 20 Reference 8, 3 4 TIME, hours 31 ------- Table 21 ' / ; FACILITY X SUMMARY OF VISIBLE EMISSIONS Date: 2/6/74 Type of Plant: Coal Preparation Type of Discharge: Vertical Stack Distance from Observer to Discharge Point: 300 ft. Location of Dlscharge:Thennal Dryer-Scrubber OutletHelght of Observation Point: Ground Level Height of Point of Discharge: 120 ft. Direction of Observer from Discharge Point: Northeast Description of Background: Sky Description of Sky: Qvercase; rain began during observation, became heavy. Readings terminated when rainfall mi/hr Wind Direction: Calm Wind Velocity: Calm Color of Plume: Lt. grey when visible Detached Plume: No Interference of Steam Plume: Total at stack; partial up to 100-300 ft. above stack. Duration of Observation: 1 hour, 18 minutes. Dryer upset, then rainfall became heavy before dryer started up again. Readings for start-up and shutdown not Included in this summary; upsets are included. Summary of Data: Opacity, Percent 5 10 IS 20 25 30 35 40 45 50 Total Time Equal to or Greater Than Given Opacity Hln. 13 11 5 3 1 0 0 Sec. 15 45 15 15 15 30 0 Opacity, Percent 55 60 65 70 75 80 85 90 95 100 Total Time Equal to or Greater Than Given Opacity win. Sec, Opacity Variations with Time: 40 30 20 10 3 4 TIME, hours Reference 8, 32 ------- REFERENCES 1, "Report by York Research Corporation on Emissions From [Facility A]»" prepared for EPA by York Research Corporation, Report No. Y-773Q-G, February 18, 1972, EPA Test No. 72-CI-4. 2. "Coal Preparation Plant Emission Tests" For Facility BI , prepared for EPA by Scott Research Laboratories, Incorporated, Contract No. 68-02-0233, EPA Test No. 72-CI-13. 3. Emission Test Report for Facility Bg, July 21, 1970, submitted by the owner to EPA. 4. "Coal Preparation Plant Emission Tests" for Facility C-,, prepared for EPA by Scott Research Laboratories, Incorporated, Contract No. 68-02-0233, EPA Test No. 72-CI-19. 5. "Coal Preparation Plant Emission Tests" for Facility C«, prepared for EPA by Scott Research Laboratories, Incorporated, Contract No. 68-02-0233, November 1972, EPA Test No. 72-CI-19(CCL). 6. "Report by York Research Corporation on Emissions From [Facility D-]§" prepared for EPA by York Research Corporation, Report No. Y-7730-H, February 14, 1972, EPA Test No. 72-CI-6. 7. "Coal Preparation Plant Emission Tests" for Facilities D« and D-, prepared for EPA by Scott Research Laboratories, Incorporated, Contract No. 68-02-0233, October 1972, EPA Test No. 73-CCL-2. 33 ------- 8, Sedman, Charles B.» "Trip ReportMon1toring of Visible Emissions From Coal Preparation Plants," February 13, 1974. 9, "Coal Preparation Plant Emission Tests" for Facilities E, and Eg, prepared for EPA by Scott Research Laboratories, Incorporated, Contract No. 68-02-0233, EPA Test No. 72-CI-22. 10. EPA questionnaire data. ------- TECHNICAL REPORT DATA (Please read Instructions on t*">. reverse before completing) 1. REPORT NO. EPA-450/2-74-021b 2. 3. RECIPIENT'S ACCESSION NO. 4. TITLE AND SUBTITLE Background Information for Standards of Performance: Coal Preparation Plants, Volume 2, Summary of Test Dgtp6RFORMINGORGANIZAT'ONCODE |5. REPORT DATE October 7. AUTHOR(S) 8. PERFORMING ORGANIZATION REPORT NO. 9. PERFORMING ORGANIZATION NAME AND ADDRESS U.S. Environmental Protection Agency Office of Air Quality Planning and Standards Research Triangle Park, N.C. 27711 10. PROGRAM ELEMENT NO. 11. CONTRACT/GRANT NO. 12, SPONSORING AGENCY NAME AND ADDRESS 13. TYPE OF REPORT AND PERIOD COVERED 14. SPONSORING AGENCY CODE 15. SUPPLEMENTARY NOTES 16. ABSTRACT This volume is the first of a series on standards of performance for coal preparation plants. This volume presents the proposed standards and the rationale for the degree of control selected. The volume also discusses the analytical methods for sampling emissions and the environmental and economic impact of the standards. KEY WORDS AND DOCUMENT ANALYSIS DESCRIPTORS Air pollution r Pollution control Performance standards Coal Preparation Plants b.lDENTIFIERS/OPEN ENDED TERMS Air pollution control c. cos AT I Field/Group 3. DISTRIBUTION STATEMENT Unlimited 19. SECURITY CLASS (ThisReport) Unclassified 21. NO. OF PAGES 3u 20. SECURITY CLASS (TMspage) Unclassified 22. PRICE EPA Form 2220-1 (9-73) ------- |