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 Report—Mon1toring  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)

-------