-------
      10.Oc:
TJ
 0)
                     I 1  I I
1. Limestone Loading - Open Trucks
2. Limestone Loading - Enclosed Trucks
3. Lime Loading - Enclosed Trucks
        1.0               10.0
          Aerodynamic Particle Diameter
                                                             100.0
1(10)3
     Figure 8.15-3.  Size  specific emission factors for  product loading.
8.15-10
              EMISSION FACTORS
                                                                           10/86

-------
References for Section 8.15

1.    C. J. Lewis and B. B. Crocker, "The Lime Industry's Problem Of  Airborne
      Dust", Journal Of The Air Pollution Control Association,  19(1):31-39,
      January 1969.

2.    Kirk-Othmer Encyclopedia Of Chemical Technology,  2d Edition,  John Wiley
      And Sons, New York, 1967.

3.    Screening Study For Emissions Characterization From Lime  Manufacture,
      EPA Contract No. 68-02-0299, Vulcan-Cincinnati,  Inc.,  Cincinnati,  OH,
      August 1974.

4.    Standards Support And Environmental Impact Statement,  Volume I;  Proposed
      Standards Of Performance For Lime Manufacturing  Plants, EPA-450/2-77-
      007a, U. S. Environmental Protection Agency, Research  Triangle  Park,
      NC, April 1977.

5.    Source test data on lime plants, Office Of Air Quality Planning  And
      Standards, U. S. Environmental Protection Agency,  Research Triangle Park,
      NC, 1976.

6.    Air Pollutant Emission Factors, APTD-0923, U. S.  Environmental  Protection
      Agency, Research Triangle Park, NC, April 1970.

7.    J. S. Kinsey, Lime And Cement Industry - Source  Category  Report,  Volume
      I: Lime Industry, EPA-600/7-86-031, U. S. Environmental Protection
      Agency, Cincinnati, OH, September 1986.
10/86                      Mineral  Products  Industry                     8.15-11

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Mineral Products Industry
8.19.2-5

-------
specific source conditions, these equations should be used instead of  those in
Table 8.19.2-2, whenever emission estimates applicable to specific stone  quarry-
ing and processing facility sources are needed.   Chapter 11.2  provides measured
properties of crushed limestone,  as required for use in the predictive emission
factor equations.

References for Section 8.19.2

1.   Air Pollution Control Techniques for Nonmetallic Minerals Industry,
     EPA-450/3-82-014, U. S. Environmental Protection Agency,  Research
     Triangle Park, NC, August 1982.

2.   P. K. Chalekode, et al., Emissions from the Crushed Granite  Industry;
     State of the Art, EPA-600/2-78-021,  U. S. Environmental Protection
     Agency,  Washington, DC, February 1978.

3.   T. R. Blackwood, et al., Source  Assessment;  Crushed Stone, EPA-600/2-78-
     004L, U. S. Environmental Protection Agency,  Washington,  DC,  May  1978.

4.   F. Record and W. T. Harnett, Particulate Emission Factors for the
     Construction Aggregate Industry, Draft Report,  GCA-TR-CH-83-02, EPA
     Contract No. 68-02-3510, GCA Corporation, Chapel Hill,  NC, February  1983.

5.   Review Emission Data Base and Develop Emission Factors for the Con-
     struction Aggregate Industry, Engineering-Science,  Inc.,  Arcadia,  CA,
     September 1984.

6.   C. Cowherd, Jr., et al., Development of Emission Factors  for  Fugitive  Dust
     Sources, EPA-450/3-74-037, U. S. Environmental Protection Agency,  Research
     Triangle Park, NC, June 1974.

7.   R. Bohn, et al., Fugitive Emissions  from Integrated Iron  and  Steel Plants,
     EPA-600/2-78-050, U. S. Environmental Protection Agency,  Washington, DC,
     March 1978.
8.19.2-6                       EMISSION FACTORS                            9/85

-------
8.22  TACONITE ORE PROCESSING

8.22.1  General  l~2

     More than two thirds of the iron ore produced in  the United  States  con-
sists of taconite, a low grade iron ore largely from deposits in  Minnesota
and Michigan, but from other areas as well.  Processing of taconite  consists
of crushing and  grinding the ore to liberate ironbearing particles,  concen-
trating the ore  by separating the particles from the waste material  (gangue),
and pelletizing  the iron ore concentrate.  A simplified flow diagram of  these
processing steps is shown in Figure 8.22-1.

Liberation - The first step in processing crude taconite ore is crushing and
grinding.  The ore must be ground to a particle size sufficiently close  to
the grain size of the ironbearing mineral to allow for a high degree of
mineral liberation.  Most of the taconite used today requires very fine
grinding.  The grinding is normally performed in three or four stages of dry
crushing, followed by wet grinding in rod mills and ball mills.   Gyratory
crushers are generally used for primary crushing, and  cone crushers  are  used
for secondary and tertiary fine crushing.  Intermediate vibrating screens
remove undersize material from the feed to the next crusher and allow for
closed circuit operation of the fine crushers.  The rod and ball  mills are
also in closed circuit with classification systems such as cyclones.  An
alternative is to feed some coarse ores directly to wet or dry semiautogenous
or autogenous (using larger pieces of the ore to grind/mill the smaller  pieces)
grinding mills,  then to pebble or ball mills.  Ideally, the liberated particles
of iron minerals and barren gangue should be removed from the grinding circuits
as soon as they  are formed, with larger particles returned for further grinding.

Concentration - As the iron ore minerals are liberated by the crushing steps,
the ironbearing  particles must be concentrated.  Since only about 33 percent
of the crude taconite becomes a shippable product for  iron making, a large
amount of gangue is generated.  Magnetic separation and flotation are most
commonly used for concentration of the taconite ore.

     Crude ores in which most of the recoverable iron is magnetite (or,  in
rare cases, maghemite) are normally concentrated by magnetic separation.  The
crude ore may contain 30 to 35 percent total iron by assay, but theoretically
only about 75 percent of this is recoverable magnetite.  The remaining iron
is discarded with the gangue.

     Nonmagnetic taconite ores are concentrated by froth flotation or by a
combination of selective flocculation and flotation.  The method  is  determined
by the differences in surface activity between the iron and gangue particles.
Sharp separation is often difficult.

     Various combinations of magnetic separation and flotation may be used to
concentrate ores containing various iron minerals (magnetite and  hematite, or
maghemite) and wide ranges of mineral grain sizes.  Flotation is  also often
used as a final  polishing operation on magnetic concentrates.
10/86                     Mineral Products Industry                   8.22-1

-------

















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EMISSION FACTORS
10/86

-------
     Pallatization - Iron ore concentrates must be coarser than about No. 10
mesh to be acceptable as blast furnace feed without further treatment.  The
finer concentrates are agglomerated into small "green" pellets.  This is
normally accomplished by tumbling moistened concentrate with a balling drum
or balling disc.  A binder, usually powdered bentonite, may be added to the
concentrate to improve ball formation and the physical qualities of the
"green" balls.  The bentonite is lightly mixed with the carefully moistened
feed at 5 to 10 kilograms per megagram (10 to 20 Ib/ton).

     The pellets are hardened by a procedure called induration, the drying
and heating of the green balls in an oxidizing atmosphere at incipient fu-
sion temperature of 1290 to 1400°C (2350 to 2550°F), depending on the compo-
sition of the balls, for several minutes and then cooling.  Four general
types of indurating apparatus are currently used.  These are the vertical
shaft furnace, the straight grate, the circular grate and grate/kiln.  Most
of the large plants and new plants use the grate/kiln.  Natural gas is most
commonly used for pellet induration now, but probably not in the future.
Heavy oil is being used at a few plants, and coal may be used at future
plants.

     In the vertical shaft furnace, the wet green balls are distributed
evenly over the top of the slowly descending bed of pellets.  A rising
stream of hot gas of controlled temperature and composition flows counter to
the descending bed of pellets.  Auxiliary fuel combustion chambers supply
hot gases midway between the top and bottom of the furnace.  In the straight
grate apparatus, a continuous bed of agglomerated green pellets is carried
through various up and down flows of gases at different temperatures.  The
grate/kiln apparatus consists of a continuous traveling grate followed by
a rotary kiln.  Pellets indurated by the straight grate apparatus are cooled
on an extension of the grate or in a separate cooler.  The grate/kiln product
must be cooled in a separate cooler, usually an annular cooler with counter-
current airflow.

8.22.2  Emissions and Controls^

     Emission sources in taconite ore processing plants are indicated in
Figure 8.22-1.  Particulate emissions also arise from ore mining operations.
Emission factors for the major processing sources without controls are pre-
sented in Table 8.22-1, and control efficiencies in Table 8.22-2.  Table
8.22-3 presents data on particle size distributions and corresponding size-
specific emission factors for the controlled main waste gas stream from
taconite ore pelletizing operations.

     The taconite ore is handled dry through the crushing stages.  All
crushers, size classification screens and conveyor transfer points are major
points of particulate emissions.  Crushed ore is normally wet ground in rod
and ball mills.  A few plants, however, use dry autogenous or semi-autogenous
grinding and have higher emissions than do conventional plants.  The ore
remains wet through the rest of the beneficiation process (through concentrate
storage, Figure 8.22-1) so particulate emissions after crushing are generally
insignificant.

     The first source of emissions in the pelletizing process is the trans-
fer and blending of bentonite.  There are no other significant emissions in

 10/86                     Mineral Products Industry                  8.22-3

-------
                TABLE 8.22-1.  PARTICULATE EMISSION FACTORS FOR
                  TACONITE ORE PROCESSING, WITHOUT CONTROLSa

                           EMISSION FACTOR RATING:  D
                                                          Emissions*'
Source                                              kg/Mg            Ib/ton
Ore transfer
Coarse crushing and screening
Fine crushing
Bentonite transfer
Bentonite blending
Grate feed
Indurating furnace waste gas
Grate discharge
Pellet handling
0.05
0.10
39.9
0.02
0.11
0.32
14.6
0.66
1.7
0.10
0.20
79.8
0.04
0.22
0.64
29.2
1.32
3.4
aReference 1.  Median values.
^Expressed as units per unit weight of pellets produced.


the balling section, since the iron ore concentrate is normally too wet to
cause appreciable dusting.  Additional emission points in the pelletizing
process include the main waste gas stream from the indurating furnace, pellet
handling, furnace transfer points (grate feed and discharge), and for plants
using the grate/kiln furnace, annular coolers.  In addition, tailings basins
and unpaved roadways can be sources of fugitive emissions.

     Fuel used to fire the indurating furnace generates low levels of sulfur
dioxide emissions.  For a natural gas fired furnace, these emissions are about
0.03 kilograms of S02 per megagram of pellets produced (0.06 Ib/ton).  High-
er S02 emissions (about 0.06 to 0.07 kg/Mg, or 0.12 to 0.14 Ib/ton) would
result from an oil or coal fired furnace.

     Particulate emissions from taconite ore processing plants are controlled
by a variety of devices, including cyclones, multiclones, rotoclones, scrub-
bers, baghouses and electrostatic precipitators.  Water sprays are also used
to suppress dusting.  Annular coolers are generally left uncontrolled because
their mass loadings of particulates are small, typically less than 0.11 grams
per normal cubic meter (0.05 gr/scf).

     The largest source of particulate emissions in taconite ore mines is
traffic on unpaved haul roads.4  Table 8.22-4 presents size specific emission
factors for this source determined through source testing at one taconite
mine.  Other significant particulate emission sources at taconite mines are
wind erosion and blasting.^

     As an alternative to the single valued emission factors for open dust
sources given in Tables 8.22-1 and 8.22-4, empirically derived emission
8-22-4                          EMISSION FACTORS                         10/86

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10/86
                          Mineral  Products Industry
8.22-5

-------
                     s „
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                                                              £
                                                              it
                                    5  & • 8 9 10     20

                                    Particle dlaaeter, ua
                                                  JO 40 50 60 70 80 90 100
    Figure 8.22-3.  Particle size distributions and size specific  emission
                    factors for indurating furnace waste gas stream  from
                    taconite ore pelletizing.
 TABLE 8.22-3.
PARTICLE SIZE DISTRIBUTIONS AND SIZE SPECIFIC EMISSION  FACTORS
   FOR CONTROLLED INDURATING FURNACE WASTE GAS  STREAM FROM
                TACONITE ORE PELLETIZING3

   SIZE-SPECIFIC EMISSION FACTOR RATING:  D
                   Particle size distribution*5
                                       Size specific  emission
Aerodynamic
particle
diameter, um
2.5
6.0
10.0
Cyclone
controlled
17.4
25.6
35.2
Cyclone/ESP
controlled
48.0
71.0
81.5
factor,
Cyclone
controlled
0.16
0.23
0.31
kg/MgC
Cyclone/ESP
controlled
0.012
0.018
0.021
  ^Reference 3.  ESP = electrostatic precipitator.  After  cyclone  control,
   mass emission factor is 0.89 kg/Mg, and after cyclone/ESP  control,  0.025
   kg/Mg.  Mass and size specific emission factors are calculated  from data
   in Reference 3, and are expressed as kg particulate/Mg  of  pellets  produced.
  ^Cumulative weight % < particle diameter.
  cSize specific emission factor = mass emission factor x  particle size
   distribution, %/100.
8.22-6
               EMISSION FACTORS
10/86

-------
      TABLE 8.22-4.  UNCONTROLLED EMISSION FACTORS FOR HEAVY DUTY VEHICLE
                    TRAFFIC ON HAUL ROADS AT TACONITE MINES3
Surface Emission factor by aerodynamic diameter Emission
material (urn) Units Factor
<30 £15 <10 <5 <2.5 Rating
Crushed rock
and glacial
till 3.1
11.0
Crushed taconite
and waste 2.6
9.3

2.2 1.7 1.1 0.62 kg/VKT
7.9 6.2 3.9 2.2 Ib/VMT

1.9 1.5 0.9 0.54 kg/VKT
6.6 5.2 3.2 1.9 Ib/VMT

C
C

D
D
 aReference 4.  Predictive emission factor equations, which provide
  generally more accurate estimates, are in Chapter 11.  VKT = vehicle
  kilometers travelled.  VMT = vehicle miles travelled.
factor equations are presented in Chapter 11 of this document.   Each equation
has been developed for a source operation defined by a single dust  generating
mechanism, common to many industries, such as vehicle activity  on unpaved
roads.  The predictive equation explains much of the observed variance in mea-
sured emission factors by relating emissions to parameters which characterize
source conditions.  These parameters may be grouped into three  categories,
1) measures of source activity or energy expended, i. e.,  the speed and weight
of a vehicle on an unpaved road;  2) properties of the material  being disturbed,
i. e. , the content of suspendable fines in the surface material of  an unpaved
road; and 3) climatic parameters, such as the number of precipitation free days
per year, when emissions tend to a maximum.

     Because the predictive equations allow for emission factor adjustment to
specific source conditions, such equations should be used  in place  of the
single valued factors for open dust sources in Tables 8.22-1 and 8.22-4,  when-
ever emission estimates are needed for sources in a specific taconite ore mine
or processing facility.  One should remember that the generally higher quality
ratings assigned to these equations apply only if 1) reliable values of correc-
tion parameters have been determined for the specific sources of interest, and
2) the correction parameter values lie within the ranges tested in  developing
the equations.  In the event that site specific values are not  available,
Chapter 11 lists measured properties of road surface and aggregate  process
materials found in taconite mining and processing facilities, and these can be
used to estimate correction parameter values for the predictive emission factor
equations.  The use of mean correction parameter values from Chapter 11 reduces
the quality ratings of the factor equations by one level.
 10/86
Mineral Products Industry
8.22-7

-------
References for Section 8.22

1.  J. P. Pilney and G. V. Jorgensen, Emissions from Iron Ore Mining,
    Beneficiation and Pelletization, Volume 1, EPA Contract No.  68-02-2113,
    Midwest Research Institute, Minnetonka, MN, June 1983.

2.  A. K. Reed, Standard Support and Environmental Impact Statement for
    the Iron Ore Beneficiation Industry (Draft), EPA Contract No. 68-02-
    1323, Battelle Columbus Laboratories, Columbus, OH,  December 1976.

3.  Air Pollution Emission Test, Empire Mining Company,  Palmer,  MI, EMB-
    76-IOB-2, U. S. Environmental Protection Agency, Research Triangle
    Park, NC, November 1975.

4.  T. A. Cuscino, et al., Taconite Mining Fugitive Emissions Study,
    Minnesota Pollution Control Agency, Roseville, MN,  June 1979.
                                                                                 i
                                                                                 I
8.22-8                          EMISSION FACTORS                      10/86

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Mineral Products Industry
8.24-3

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8.24-4
EMISSION FACTORS
10/86

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The equations were developed through field sampling  of  various western  surface
mine types and are thus applicable to any of  the surface coal mines  located  in
the western United States.

     In Tables 8.24-1 and 8.24-2,  the assigned quality  ratings apply within
the ranges of source conditions that were tested in  developing the equations,
given in Table 8.24-3.  However,  the equations are derated  one letter value
(e. g., A to B) if applied  to eastern surface coal mines.
     TABLE 8.24-3.  TYPICAL VALUES FOR CORRECTION FACTORS  APPLICABLE  TO THE
                     PREDICTIVE EMISSION FACTOR EQUATIONS3
Number
Source Correction of test
factor samples
Coal loading
Bulldozers
Coal

Overburden

Dragline


Scraper


Grader

Light/medium
duty vehicle
Haul truck


Moisture

Moisture
Silt
Moisture
Silt
Drop distance
M II
Moisture
Silt
Weight

Speed


Moisture
Wheels
Silt loading

7

3
3
8
8
19

7
10
15

7


7
29
26

Range Geometric
mean
6.6 -

4.0 -
6.0 -
2.2 -
3.8 -
1.5 -
5 -
0.2 -
7.2 -
33 -
36 -
8.0 -
5.0 -

0.9 -
6.1 -
3.8 -
34 -
38

22.0
11.3
16.8
15.1
30
100
16.3
25.2
64
70
19.0
11.8

1.7
10.0
254
2270
17.8

10.4
8.6
7.9
6.9
8.6
28.1
3.2
16.4
48.8
53.8
11.4
7.1

1.2
8.1
40.8
364
Units
%

%
%
%
7
/a
m
ft
%
%
Mg
ton
kph
mph

7
^
number
g/m2
Ib/ac
aReference
     In using the equations to estimate emissions from sources  found in a
specific western surface mine, it is necessary that  reliable values  for
correction parameters be determined for the specific sources of interest,
if the assigned quality ranges of the equations are  to be applicable.
For example, actual silt content of coal or overburden measured at  a facility
                                                     I
8.24-6
EMISSION FACTORS
10/86
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                          10.0  WOOD PRODUCTS INDUSTRY

     Wood processing involves the conversion of raw wood to pulp,  pulpboard or
types of wallboard such as plywood,  particle board or hardboard.   This chapter
presents emissions data on chemical  wood pulping,  on pulpboard and plywood manu-
facturing, and on woodworking operations.  The burning of wood waste in boilers
and conical burners is discussed in Chapters 1 and 2 of this publication.
10/86                        Wood Products  Industry                         10-1
-------
10.1  CHEMICAL WOOD PULPING
10.1.1  General
     Chemical wood pulping involves
dissolving the lignin that binds the
cesses principally used in chemical
semichemical (NSSC), and soda.  The
for causing air pollution.  The kraft
cent of the chemical pulp produced in
process is determined by the desired
and by economic considerations.

10.1.2  Kraft Pulping
                                    the extraction of cellulose from wood by
                                     cellulose fibers together.  The four pro-
                                    pulping are kraft, sulfite, neutral sulfite
                                    ffirst three display the greatest potential
                                      process alone accounts for over 80 per-
                                      the United States.  The choice of pulping
                                     product, by the wood species available,
     Process Description-'- - The kraft
involves the digesting of wood chips
"white liquor", which is a water solu
The white liquor chemically dissolves
together.
     There are two types of digester
pulping is done in batch digesters,
of continuous digesters.  In a batch
contents of the digester are transfer
to as a blow tank.  The entire conten
washers, where the spent cooking liqu
then proceeds through various stages
which it is pressed and dried into th
digester does not apply to continuous
     The balance of the kraft process
                                      pulping process (See Figure 10.1-1)
                                     •at elevated temperature and pressure in
                                      ion of sodium sulfide and sodium hydroxide.
                                      the lignin that binds the cellulose fibers
                                     systems, batch and continuous.  Most kraft
                                    although the more recent installations are
                                     digester, when cooking is complete, the
                                      ed to an atmospheric tank usually referred
                                     :s of the blow tank are sent to pulp
                                     >r is separated from the pulp.  The pulp
                                      f washing, and possibly bleaching, after
                                       finished product.  The "blow" of the
                                      digester systems.
                                      is designed to recover the cooking
chemicals and heat.  Spent cooking liquor and the pulp wash water are combined
to form a weak black liquor which is concentrated in a multiple effect evaporator
system to about 55 percent solids.  The black liquor is then further concentrated
to 65 percent solids in a direct contact evaporator, by bringing the liquor
into contact with the flue gases from the recovery furnace, or in an indirect
contact concentrator.  The strong black liquor is then fired in a recovery
furnace.  Combustion of the organics dissolved in the black liquor provides
heat for generating process steam and for converting sodium sulfate to sodium
sulfide.  Inorganic chemicals present in the black liquor collect as a molten
smelt at the bottom of the furnace.
     The smelt is dissolved in water to form green liquor, which is transferred
to a causticizing tank where quicklime (calcium oxide) is added to convert the
solution back to white liquor for return to the digester system.  A lime mud
precipitates from the causticizing tank, after which it is calcined in a lime
kiln to regenerate quicklime.
10/86
                             Wood Products Industry
10.1-1
-------
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10.1-2
EMISSION FACTORS
10/86
-------
     For process heating, for driving equipment, for providing electric power,
etc., many mills need more steam than can be provided by the recovery furnace
alone.  Thus, conventional industrial boilers that burn coal,  oil,  natural gas,
or bark and wood are commonly used.

     Emissions And Controls^"? - Particulate emissions from the kraft pro-
cess occur largely from the recovery furnace, the lime kiln and the smelt dis-
solving tank.  These emissions are mainly sodium salts, with some calcium salts
from the lime kiln.  They are caused mostly by carryover of solids  and sublima-
tion and condensation of the inorganic chemicals.

     Particulate control is provided on recovery furnaces in a variety of ways.
In mills with either a cyclonic scrubber or cascade evaporator as the direct
contact evaporator, further control is necessary, as these devices  are generally
only 20 to 50 percent efficient for particulates.  Most often in these cases,
an electrostatic precipitator is employed after the direct contact  evaporator,
for an overall particulate control efficiency of from 85 to more than 99 percent,
Auxiliary scrubbers may be added at existing mills after a precipitator or a
venturi scrubber to supplement older and less efficient primary particulate
control devices.

     Particulate control on lime kilns is generally accomplished by scrubbers.
Electrostatic precipitators have been used in a few mills.  Smelt dissolving
tanks usually are controlled by mesh pads, but scrubbers can provide further
control.

     The characteristic odor of the kraft mill is caused by the emission of
reduced sulfur compounds, the most common of which are hydrogen sulfide, methyl
mercaptan, dimethyl sulfide and dimethyl disulfide, all with extremely low odor
thresholds.  The major source of hydrogen sulfide is the direct contact evapo-
rator, in which the sodium sulfide in the black liquor reacts with  the carbon
dioxide in the furnace exhaust.  Indirect contact evaporators  can significantly
reduce the emission of hydrogen sulfide.  The lime kiln can also be a potential
source of odor, as a similar reaction occurs with residual sodium sulfide in
the lime mud.  Lesser amounts of hydrogen sulfide are emitted with  the noncon-
densible offgasses from the digesters and multiple effect evaporators.

     Methyl mercaptan and dimethyl sulfide are formed in reactions  with the
wood component, lignin.  Dimethyl disulfide is formed through the oxidation of
mercaptan groups derived from the lignin.  These compounds are emitted from
many points within a mill, but the main sources are the digester/blow tank
systems and the direct contact evaporator.

     Although odor control devices, per se, are not generally found in kraft
mills, emitted sulfur compounds can be reduced by process modifications and
improved operating conditions.  For example, black liquor oxidation systems,
which oxidize sulfides into less reactive thiosulfates, can considerably reduce
odorous sulfur emissions from the direct contact evaporator, although the vent
gases from such systems become minor odor sources themselves.   Also,  noncon-
densible odorous gases vented from the digester/blow tank system and  multiple
effect evaporators can be destroyed by thermal oxidation, usually by  passing
them through the lime kiln.  Efficient operation of the recovery furnace, by
avoiding overloading and by maintaining sufficient oxygen, residence  time and
turbulence, significantly reduces emissions of reduced sulfur compounds from

10/86                        Wood Products Industry                      10.1-3
-------
this source as well.  The use of fresh water instead of contaminated condensates
in the scrubbers and pulp washers further reduces odorous emissions.

     Several new mills have incorporated recovery systems that eliminate the
conventional direct contact evaporators.  In one system, heated combustion air,
rather than fuel gas, provides direct contact evaporation.  In another,  the
multiple effect evaporator system is extended to replace the direct contact
evaporator altogether.  In both systems, sulfur emissions from the recovery
furnace/direct contact evaporator can be reduced by more than 99 percent.

     Sulfur dioxide is emitted mainly from oxidation of reduced sulfur compounds
in the recovery furnace.  It is reported that the direct contact evaporator
absorbs about 75 percent of these emissions, and further scrubbing can provide
additional control.

     Potential sources of carbon monoxide emissions from the kraft process
include the recovery furnace and lime kilns.  The major cause of carbon monoxide
emissions is furnace operation well above rated capacity, making it impossible
to maintain oxidizing conditions.

     Some nitrogen oxides also are emitted from the recovery furnace and lime
kilns, although amounts are relatively small.  Indications are that nitrogen
oxide emissions are on the order of 0.5 and 1.0 kilograms per air dried mega-
grams (1 and 2 Ib/air dried ton) of pulp produced from the lime kiln and
recovery furnace, respectively.^~6

     A major source of emissions in a kraft mill is the boiler for generating
auxiliary steam and power.  The fuels used are coal, oil, natural gas or bark/
wood waste.  See Chapter 1 for emission factors for boilers.

     Table 10.1-1 presents emission factors for a conventional kraft mill.
The most widely used particulate control devices are shown, along with the odor
reductions through black liquor oxidation and incineration of noncondensible
offgases.  Tables 10.1-2 through 10.1-7 present cumulative size distribution
data and size specific emission factors for particulate emissions from sources
within a conventional kraft mill.  Uncontrolled and controlled size specific
emission factors^ are presented in Figures 10.1-2 through 10.1-7.  The particle
sizes presented are expressed in terms of the aerodynamic diameter.

10.1.3  Acid Sulfite Pulping

     Process Description - The production of acid sulfite pulp proceeds
similarly to kraft pulping, except that different chemicals are used in the
cooking liquor.  In place of the caustic solution used to dissolve the lignin
in the wood, sulfurous acid is employed.  To buffer the cooking solution,  a
bisulfite of sodium, magnesium, calcium or ammonium is used.  A diagram of a
typical magnesium base process is shown in Figure 10.1-8.

     Digestion is carried out under high pressure and high temperature, in
either batch mode or continuous digesters, and in the presence of a sulfurous
acid/bisulfite cooking liquid.  When cooking is completed, either the digester
is discharged at high pressure into a blow pit, or its contents are pumped into
a dump tank at a lower pressure.  The spent sulfite liquor (also called red
liquor) then drains through the bottom of the tank and is treated and discarded,
10.1-4
EMISSION FACTORS                        10/86
-------
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-------
     TABLE  10.1-2.   CUMULATIVE PARTICLE SIZE DISTRIBUTION AND SIZE SPECIFIC
              EMISSION FACTORS FOR A  RECOVERY BOILER WITH A DIRECT
                          CONTACT EVAPORATOR AND AN ESPa

                            EMISSION FACTOR RATING:  C


Particle size
(urn)
15
10
6
2.5
1.25
1.00
0.625
Total
Cumulative mass % <
stated size
Uncontrolled
95.0
93.5
92.2
83.5
56.5
45.3
26.5
100
Controlled

-
68.2
53.8
40.5
34.2
22.2
100
Cumulative emission factor
(kg/Mg of air dried pulp)
Uncontrolled
86
84
83
75
51
41
24
90
Controlled

—
0.7
0.5
0.4
0.3
0.2
1.0
   aReference 7.   Dash = no data
               100
               90 -


               80


               70

               60

               50


               40


               30


               20


               10

                 0
                 0.1
Uncontrolled
                     Controlled
1.0


0.9


0.8


0.7

0.6


0.5


0.4


0.3


0.2


0.1
                                             8-=
         1.0              10
         Particle diameter (pm)
                                                                 100
         Figure  10.1-2.  Cumulative  particle size distribution and
                  specific emission factors for recovery  boiler
                     with direct contact  evaporator and ESP.
                                             size
10.1-6
        EMISSION FACTORS
                                                                             10/86
-------
    TABLE  10.1-3.   CUMULATIVE PARTICLE SIZE DISTRIBUTION AND SIZE SPECIFIC
            EMISSION FACTORS FOR A  RECOVERY BOILER WITHOUT A DIRECT
                      CONTACT EVAPORATOR BUT WITH AN  ESPa

                           EMISSION FACTOR RATING:  C


Particle size
(urn)
15
10
6
2.5
1.25
1.00
0.625
Total
Cumulative mass % <
stated size
Uncontroll ed
_
-
-
78.0
40.0
30.0
17.0
100
Controlled
78.8
74.8
71.9
67.3
51.3
42.4
29.6
100
Cumulative emission factor
(kg/Mg of air dried pulp)
Uncontrolled
_
-
-
90
46
35
20
115
Controlled
0.8
0.7
0.7
0.6
0.5
0.4
0.3
1.0
  aReference  7.   Dash = no data.
              150
           J-q 100
           i.!:
               50
                0.1
                          Controlled
                                           Uncontrolled
                     I   I  I  1 I I 111
                                      I   I  1 I I  I I 11
                                                      I 	I  1 I  I I 1 I
                           1.0              10
                             Particle diameter (\un)
                                                                100
                                                             1.0


                                                             0.9

                                                             0.8


                                                             0.7


                                                             0.6

                                                             0.5




                                                             0.3

                                                             0.2

                                                             0.1


                                                             0
                                                                     is
   Figure  10.1-3.   Cumulative particle size distribution  and
specific emission  factors for recovery boiler without direct
                       evaporator but  with ESP.
                                                                     size
                                                                     contact
10/86
                        Wood Products  Industry
                                                                           10.1-7
-------
     TABLE 10.1-4.  CUMULATIVE PARTICLE SIZE DISTRIBUTION AND SIZE SPECIFIC
           EMISSION FACTORS  FOR A LIME KILN WITH A VENTURI SCRUBBER3


                           EMISSION FACTOR RATING:  C


Particle size
(urn)
15
10
6
2.5
1.25
1.00
0.625
Total
Cumulative mass % <
stated size
Uncontrolled
27.7
16.8
13.4
10.5
8.2
7.1
3.9
100
Controlled
98.9
98.3
98.2
96.0
85.0
78.9
54.3
100
Cumulative emission factor
(kg/Mg of air dried pulp)
Uncontrolled
7.8
4.7
3.8
2.9
2.3
2.0
1.1
28.0
Controlled
0.24
0.24
0.24
0.24
0.21
0.20
0.14
0.25
   aReference 7.
               30
            I!
                20
                        Controlled
                                     Uncontrolled
                 0.1
1.0              10
   Particle diameter
                                                                  0.3
                      i   i  i  i m11	1—i  i  i 11111.	1—i  i  i 11'''°
                                 0.2
         Figure  10.1-4.   Cumulative particle size distribution and size
         specific emission factors for lime kiln with venturi  scrubber.
10.1-8
EMISSION FACTORS
10/86
-------
    TABLE  10.1-5.  CUMULATIVE PARTICLE SIZE DISTRIBUTION AND SIZE SPECIFIC
                 EMISSION FACTORS  FOR A LIME KILN WITH AN ESP3

                           EMISSION FACTOR RATING:  C


Particle size
(urn)
15
10
6
2.5
1.25
1.00
0.625
Total
Cumulative mass % <
stated size
Uncontrolled
27.7
16.8
13.4
10.5
8.2
7.1
3.9
100
Controlled
91.2
88.5
86.5
83.0
70.2
62.9
46.9
100
Cumulative emission factor
(kg/Mg of air dried pulp)
Uncontrolled
7.8
4.7
3.8
2.9
2.3
2.0
1.1
28.0
Controlled
0.23
0.22
0.22
0.21
0.18
0.16
0.12
0.25
aRef erence 7 .
              30
              20
            -* 10
                0.1
                         Controlled
                                     Uncontrolled
   1.0               10
     Particle diameter (urn)
                                                                  0.3
                                                                     I
                                                         i  l  i i il il 0
                                                                 100
        Figure  10.1-5.   Cumulative particle size distribution and  size
              specific  emission factors  for lime kiln with ESP.
10/86
Wood Products  Industry
                                                                           10.1-9
-------
     TABLE 10.1-6.   CUMULATIVE PARTICLE SIZE  DISTRIBUTION AND SIZE  SPECIFIC
              EMISSION FACTORS FOR A SMELT DISSOLVING TANK WITH A
                                  PACKED TOWERa

                            EMISSION FACTOR RATING:   C


Particle size
(urn)
15
10
6
2.5
1.25
1.00
0.625
Total
Cumulative mass % <
stated size
Uncontrolled
90.0
88.5
87.0
73.0
47.5
40.0
25.5
100
Controlled
95.3
95.3
94.3
85.2
63.8
54.2
34.2
100
Cumulative emission factor
(kg/Mg of air dried pulp)
Uncontrolled
3.2
3.1
3.0
2.6
1.7
1.4
0.9
3.5
Controlled
0.48
0.48
0.47
0.43
0.32
0.27
0.17
0.50
   aReference 7.
ii 3
            is;
                                                                  0.6
                0.1
                         Controlled
                                                   Uncontrolled
                                                                  0.5
                                                                  0.4
                                                                  0.3 =£
                                                                  0.1
                   1.0               10
                      Particle diameter (vm)
                                                                100
         Figure  10.1-6.   Cumulative particle size distribution and  size
            specific  emission factors for  smelt  dissolving tank with
                                  packed  tower.
10.1-10
                    EMISSION FACTORS
                                                                            10/86
-------
    TABLE  10.1-7.   CUMULATIVE PARTICLE  SIZE  DISTRIBUTION AND SIZE  SPECIFIC
              EMISSION FACTORS FOR A SMELT DISSOLVING TANK WITH A
                               VENTURI SCRUBBER3

                           EMISSION FACTOR RATING:   C


Particle size
(urn)
15
10
6
2.5
1.25
1.00
0.625
Total
Cumulative mass % <
stated size
Uncontrolled
90.0
88.5
87.0
73.0
47.5
54.0
25.5
100
Controlled
89.9
89.5
88.4
81.3
63.5
54.7
38.7
100
Cumulative emission factor
(kg/Mg of air dried pulp)
Uncontrolled
3.2
3.1
3.0
2.6
1.7
1.4
0.9
3.5
Controlled
0.09
0.09
0.09
0.08
0.06
0.06
0.04
0.09
  aReference 7.
               0.1
                        Controlled
                                               Uncontrolled
   1.0              10
      Particle diameter (vim)
                                     1.0

                                     0.9

                                     0.8

                                     0.7 £„
                                        S^
                                        ZE.
                                     0.6 ^-o

                                     -IS
                                        "S-<-
                                     0.4 2 °
                                        s€
                                        c^
                                     0.3 oi.
                                        t_>

                                     0.2

                                     0.1

                                     0
                                                               100
        Figure  10.1-7.   Cumulative particle  size distribution and size
           specific  emission factors for smelt  dissolving tank with
                               venturi scrubber.
10/86
Wood Products  Industry
10.1-11
-------
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10.1-12
EMISSION FACTORS
10/86
-------
incinerated, or sent to a plant for recovery of heat and chemicals.  The pulp
is then washed and processed through screens and centrifuges to remove knots,
bundles of fibers and other material.  It subsequently may be bleached, pressed
and dried in papermaking operations.

     Because of the variety of cooking liquor bases used, numerous schemes have
evolved for heat and/or chemical recovery.  In calcium base systems, found most-
ly in older mills, chemical recovery is not practical, and the spent liquor is
usually discharged or incinerated.  In ammonium base operations, heat can be
recovered by combusting the spent liquor, but the ammonium base is thereby con-
sumed.  In sodium or magnesium base operations, the heat, sulfur and base all
may be feasibly recovered.

     If recovery is practiced, the spent (weak) red liquor (which contains more
than half of the raw materials as dissolved organic solids) is concentrated in
a multiple effect evaporator and a direct contact evaporator to 55 to 60 per-
cent solids.  This strong liquor is sprayed into a furnace and burned, pro-
ducing steam to operate the digesters, evaporators, etc. and to meet other
power requirements.

     When magnesium base liquor is burned, a flue gas is produced from which
magnesium oxide is recovered in a multiple cyclone as fine white power.  The
magnesium oxide is then water slaked and is used as circulating liquor in a
series of venturi scrubbers, which are designed to absorb sulfur dioxide from
the flue gas and to form a bisulfite solution for use in the cook cycle.  When
sodium base liquor is burned, the inorganic compounds are recovered as a molten
smelt containing sodium sulfide and sodium carbonate.  This smelt may be pro-
cessed further and used to absorb sulfur dioxide from the flue gas and sulfur
burner.  In some sodium base mills, however, the smelt may be sold to a nearby
kraft mill as raw material for producing green liquor.

     If liquor recovery is not practiced, an acid plant is necessary of suf-
ficient capacity to fulfill the mill's total sulfite requirement.  Normally,
sulfur is burned in a rotary or spray burner.  The gas produced is then cooled
by heat exhangers and a water spray and is then absorbed in a variety of dif-
ferent scrubbers containing either limestone or a solution of the base chemical.
Where recovery is practiced, fortification is accomplished similarly, although
a much smaller amount of sulfur dioxide must be produced to make up for that
lost in the process.

     Emissions And Controls^- - Sulfur dioxide is generally considered the major
pollutant of concern from sulfite pulp mills.  The characteristic "kraft" odor
is not emitted because volatile reduced sulfur compounds are not products of
the lignin/bisulfite reaction.

     A major S02 source is the digester and blow pit (dump tank) system.  Sul-
fur dioxide is present in the intermittent digester relief gases, as well as in
the gases given off at the end of the cook when the digester contents are dis-
charged into the blow pit.  The quantity of sulfur dioxide evolved and emitted
to the atmosphere in these gas streams depends on the pH of the cooking liquor,
the pressure at which the digester contents are discharged, and the effective-
ness of the absorption systems employed for SC>2 recovery.  Scrubbers can be
installed that reduce S02 from this source by as much as 99 percent.


10/86                        Wood Products Industry                     10.1-13
-------
     Another source of sulfur dioxide emissions is the recovery system.  Since
magnesium, sodium, and ammonium base recovery systems all use absorption systems
to recover SC>2 generated in recovery furnaces, acid fortification towers, mul-
tiple effect evaporators, etc., the magnitude of SC>2 emissions depends on the
desired efficiency of these systems.  Generally, such absorption systems recover
better than 95 percent of the sulfur so it can be reused.

     The various pulp washing, screening, and cleaning operations are also
potential sources of SC>2•  These operations are numerous and may account for a
significant fraction of a mill's SC>2 emissions if not controlled.

     The only significant particulate source in the pulping and recovery pro-
cess is the absorption system handling the recovery furnace exhaust.  Ammonium
base systems generate less particulate than do magnesium or sodium base systems.
The combustion productions are mostly nitrogen, water vapor and sulfur dioxide.

     Auxiliary power boilers also produce emissions in the sulfite pulp mill,
and emission factors for these boilers are presented in Chapter 1.

     Table 10.1-8 contains emission factors for the various sulfite pulping
operations.

10.1.4  Neutral Sulfite Semichemical (NSSC) Pulping

     Process Description"' 12-14 _ jn this method, wood chips are cooked in a
neutral solution of sodium sulfite and sodium carbonate.  Sulfite ions react
with the lignin in wood, and the sodium bicarbonate acts as a buffer to maintain
a neutral solution.  The major difference between all semichemical techniques
and those of kraft and acid sulfite processes is that only a portion of the
lignin is removed during the cook, after which the pulp is further reduced by
mechanical disintegration.  This method achieves yields as high as 60 to 80
percent, as opposed to 50 to 55 percent for other chemical processes.

     The NSSC process varies from mill to mill.  Some mills dispose of their
spent liquor, some mills recover the cooking chemicals, and some, when operated
in conjunction with kraft mills, mix their spent liquor with the kraft liquor
as a source of makeup chemcials.  When recovery is practiced, the involved
steps parallel those of the sulfite process.

     Emissions And Controls^,12-14 _ Particulate emissions are a potential prob-
lem only when recovery systems are involved.  Mills that do practice recovery
but are not operated in conjunction with kraft operations often utilize fluid-
ized bed reactors to burn their spent liquor.  Because the flue gas contains
sodium sulfate and sodium carbonate dust, efficient particulate collection may
be included for chemical recovery.

     A potential gaseous pollutant is sulfur dioxide.  Absorbing towers, diges-
ter/blower tank system, and recovery furnace are the main sources of S02, with
amounts emitted dependent upon the capability of the scrubbing devices installed
for control and recovery.

     Hydrogen sulfide can also be emitted from NSSC mills which use kraft type
recovery furnaces.  The main potential source is the absorbing tower, where a


10.1-14                         EMISSION FACTORS                        10/86
-------
                     TABLE 10.1-8.   EMISSION  FACTORS  FOR SULFITE PULPING3


Source


Digester/blow pit or
dump tankc












Recovery system6




Acid plantf


Otherh


Base



All
MgO
MgO
MgO

MgO

NH3
NHj

Na

Ca
MgO

NH3

Na
NH3
Na
Ca
All


Control



None
Process change1*
Scrubber
Process change and
scrubber
All exhaust vented through
recovery system
Process change
Process change and
scrubber
Process change and
scrubber
Unknown
Multlcyclone and venturl
scrubbers
Ammonia absorption and
mist eliminator
Sodium carbonate scrubber
Scrubber
UnknownS
Jenssen scrubber
None
Emission factorb
Partlculate


kg/ADUMg

Neg
Neg
Neg

Neg

Neg
Neg

Neg

Neg
Neg

1

0.35
2
Neg
Neg
Neg
Neg

Ib/ADUT

Neg
Neg
Neg

Neg

Neg
Neg

Neg

Neg
Neg

2

0.7
4
Neg
Neg
Neg
Neg
Sulfur dioxide


kg/ADUMg

5 to 35
1 to 3
0.5

0.1

0
12.5

0.2

1
33.5

4.5

3.5
1
0.2
0.1
4
6

Ib/ADUT

10 to 70
2 to 6
1

0.2

0
25

0.4

2
67

9

7
2
0.3
0.2
8
12


Emission
Factor
Rating

C
C
B

B

A
D

B

C
C

A

B
C
C
D
C
D
aReference 11.  All factors represent long  term average emissions.   ADUMg " Air dried unbleached megagram.
 ADUT » Air dried unbleached ton.  Neg » negligible.
''Expressed as kg (Ib) of pollutant/air dried unbleached ton (mg)  of  pulp.
cFactors represent emissions after cook is  completed and when digester  contents are discharged  into blow pit or
 dump tank. Some relief gases are vented from digester during cook  cycle, but these are  usually transferred to
 pressure accumulators and S02 therein reabsorbed for use in cooking liquor.  In some mills, actual emissions
 will be intermittent and for short periods.
 May include such measures as raising cooking liquor pH (thereby  lowering free 802), relieving  digester
 pressure before contents discharge, and pumping out digester contents  instead of blowing out.
eRecovery system at most mills is closed and includes recovery furnace, direct contact evaporator, multiple
 effect evaporator, acid fortification tower, and S02 absorption  scrubbers.  Generally only one emission point
 for entire system.  Factors include high S02 emissions during periodic purging of recovery systems.
^Necessary in mills with insufficient or nonexistent recovery systems.
SControl is practiced, but -type of system is unknown.
^Includes miscellaneous pulping operations  such as knotters, washers, screens, etc.
  10/86
Wood  Products Industry
10.1-15
-------
significant quantity of hydrogen sulfite is  liberated  as  the  cooking  liquor  is
made.  Other possible sources,  depending on  the  operating conditions,  include
the recovery furnace, and in mills  where some  green  liquor is used  in the  cook-
ing process, the digester/blow tank system.  Where green  liquor  is  used, it
is also possible that significant quantities of  mercaptans will  be  produced.
Hydrogen sulfide emissions can be eliminated if  burned to sulfur dioxide before
the absorbing system.

     Because the NSSC process differs  greatly  from mill to mill,  and  because
of the scarcity of adequate data, no emission  factors  are presented for this
process.


References for Section 10.1

1 .   Review of New Source Performance  Standards  for  Kraft Pulp Mills,  EPA-450/
     3-83-017, U. S.  Environmental Protection Agency,  Research  Triangle Park,
     NC, September 1983.

2 .   Standards Support and Environmental Impact  Statement,  Volume I:   Proposed
     Standards of Performance for Kraft  Pulp Mills,  EPA-450/2-76-014a, U.  S.
     Environmental Protection Agency,  Research Triangle Park,  NC, September
     1976.

3.   Kraft Pulping - Control of TRS Emissions  from Existing Mills,  EPA-450/78-
     003b, U. S. Environmental Protection Agency, Research Triangle Park,  NC,
     March 1979.

4 .   Environmental Pollution Control,  Pulp and Paper Industry, Part I:  Air,
     EPA-625/7-76-001, U. S. Environmental Protection  Agency,  Washington,  DC,
     October 1976.

5.   A Study of Nitrogen Oxides Emissions from Lime  Kilns,  Technical  Bulletin
     Number 107, National Council of the Paper Industry for Air  and Stream
     Improvement, New York, NY, April  1980.

6.   A Study of Nitrogen Oxides Emissions from Large Kraft Recovery Furnaces,
     Technical Bulletin Number 111, National Council of the Paper Industry for
     Air and Stream Improvement, New York, NY, January 1981.

7.   Source Category Report for the Kraft Pulp Industry,  EPA  Contract Number
     68-02-3156, Acurex Corporation, Mountain  View,  CA, January  1983.

8.   Source test data, Office Of Air Quality Planning  And Standards,  U. S.
     Environmental Protection Agency,  Research Triangle Park,  NC, 1972.

9.   Atmospheric Emissions from the Pulp and Paper Manufacturing Industry,
     EPA-450/1-73-002, U. S. Environmental Protection  Agency,  Research Triangle
     Park, NC, September 1973.

10.  Carbon Monoxide Emissions from Selected Combustion Sources  Based on Short-
     Term Monitoring Records, Technical  Bulleting Number  416, National Council
     of the Paper Industry for Air  and Stream  Improvement, New York,  NY,
     January 1984.
10.1-16
                                EMISSION FACTORS                       10/86
-------
 11.  Backgound Document;  Acid Sulfite Pulping, EPA-450/3-77-005, U. S. Environ-
     mental Protection Agency, Research Triangle Park, NC, January 1977.

 12.  E. R. Hendrickson, et al., Control of Atmospheric Emissions in the Wood
     Pulping Industry, Volume I, HEW Contract Number CPA-22-69-18, U. S.
     Environmental Protection Agency, Washington, DC, March 15, 1970.

 13.  M. Benjamin, et al., "A General Description of Commercial Wood Pulping and
     Bleaching Processes", Journal of the Air Pollution Control Association, ^9_
     (3):155-161, March 1969.

 14.  S. F. Galeano and B. M. Dillard, "Process Modifications for Air Pollution
     Control in Neutral Sulfite Semi-chemical Mills", Journal of the Air Pollu-
     tion Control Association. 22(3):195-199, March 1972.
10/86                        Wood Products Industry                     10.1-17
-------
 11.2.6  INDUSTRIAL PAVED ROADS

 11.2.6.1  General

     Various field studies have indicated that dust emissions from industrial
 paved roads are a major component of atmospheric particulate matter in the
vicinity of industrial operations.  Industrial traffic dust has been found to
 consist primarily of mineral matter, mostly tracked or deposited onto the
 roadway by vehicle traffic itself when vehicles enter from an unpaved area or
 travel on the shoulder of the road, or when material is spilled onto the paved
 surface from haul truck traffic.

 11.2.6.2  Emissions And Correction Parameters

     The quantity of dust emissions from a given segment of paved road varies
 linearly with the volume of traffic.  In addition,  field investigations have
 shown that emissions depend on correction parameters (road surface silt content,
 surface dust loading and average vehicle weight) of a particular road and
 associated vehicle traffic.1'2

     Dust emissions from industrial paved roads have been found to vary in
direct proportion to the fraction of silt (particles <75 microns in diameter)  in
 the road surface material.^"^  xhe silt fraction is determined by measuring the
proportion of loose dry surface dust that passes a 200 mesh screen, using the
ASTM-C-136 method.  In addition, it has also been found that emissions vary in
direct proportion to the surface dust loading.1~2  -jhe road surface dust loading
 is that loose material which can be collected by broom sweeping and vacuuming  of
 the traveled portion of the paved road.  Table 11.2.6-1 summarizes measured silt
 and loading values for industrial paved roads.

 11.2.6.3  Predictive Emission Factor Equations

     The quantity of total suspended particulate emissions generated by vehicle
 traffic on dry industrial paved roads, per vehicle kilometer traveled (VKT) or
vehicle mile traveled (VMT) may be estimated, with a rating of B or D (see
below), using the following empirical expression^:


              E ' °-022 '                       °''         (kg/VKT)        ("


                                                °'7

     where:   E = emission factor
             I = industrial augmentation factor (dimensionless) (see below)
             n = number of traffic lanes
             s = surface material silt content (%)
             L = surface dust loading, kg/km (Ib/mile) (see below)
             W = average vehicle weight, Mg (ton)

9/85                         Miscellaneous Sources                      11.2.6-1
-------
     TABLE  11.2.6-1.   TYPICAL SILT CONTENT AND LOADING VALUES FOR PAVED ROADS
                             AT INDUSTRIAL FACILITIES3
Industry
Copper smelting
Iron and steel
production
No. of
No. of No. of Silt (Zi w/w) Travel Total loading x 10~3
Sites Samples Range Mean lanes Range
1 3 [15.4-21.7] [19.0] 2 [12.9-19.5]
[45.8-69.2]
6 20 1.1-35.7 12.5 2 0.006-4.77
Mean
[15.9]
[55.4]
0.495
Units6
kg/km
Ib/mi
kg/km
Silt loading
Range Mean
[188-400] [292]
0.09-79 12
Iron and steel
production 6
Asphalt batching 1
Concrete batching 1
Sand and gravel
processing 1
20
3
3
3
1
[2
[5
[6
.1-35.7
.6-4.6]
.2-6.0]
.4-7.9]
12
[3
[5
[7
.5
.3]
.5)
•U
2 0.006-4.77
0.020-16.9
1 [12.1-18.0]
[43.0-64.0]
2 [1.4-1.8]
[5.0-6.4]
1 [2.8-5.5]
[9.9-19.4]
0.495
1.75
[14.
[52.
[1.
(5.
[3.
[13.
9]
8]
7]
9]
8]
3]
kg/km
Ib/mi
kg/km
Ib/mi
kg/km
Ib/ml
kg/km
Ib/mi
0.09-79
[76-193]
[11-12]
[53-95]
12
[120]
[12]
[70]
"References 1-5. Brackets indicate values based on only one plant test.
bMultlply entries by 1,000 to obtain stated units.
      The industrial  road  augmentation factor (I) in the Equation 1 takes  into
 account higher emissions  from industrial roads than from urban roads.   I  =  7.0
 for an industrial  roadway which traffic enters from unpaved areas.  I = 3.5 for
 an industrial  roadway with unpaved shoulders where 20 percent of the vehicles
 are forced  to  travel  temporarily with one set of wheels on the shoulder.  I =
 1.0 for cases  in which traffic does not travel on unpaved areas.  A value
 between 1.0 and 7.0  which best represents conditions for paved roads at a
 certain industrial facility should be used for I in the equation.

      The equation  retains the quality rating of B if applied to vehicles
 traveling  entirely on paved surfaces (I = 1.0) and if applied within the  range
 of source  conditions  that were tested in developing the equation as follows:
Silt
content
(%)
5.1 - 92
Surface loading
kg /km
42.0 - 2000
Ib/mile
149 - 7100
No. of
lanes
2-4
Vehicle weight
Mg tons
2.7 - 12 3-13
  If  I is >1.0,  the rating of the equation drops to D because of the subjectivity
  in  the guidelines for estimating I.

      The  quantity of fine particle emissions generated by traffic consisting
  predominately  of  medium and heavy duty vehicles on dry industrial paved  roads,
  per vehicle unit  of travel, may be estimated, with a rating of A, using  the
                                                    I
  11.2.6-2
EMISSION FACTORS
9/85
-------
        APPENDIX B
(Reserved for future use.)
        Appendix B                               B-l
-------
                       APPENDIX C.I










PARTICLE SIZE DISTRIBUTION DATA AND SIZED EMISSION FACTORS




                           FOR




                     SELECTED SOURCES
                                                               C.l-1
-------
C.l-2                           EMISSION FACTORS
-------
                                    CONTENTS
AP-42
  Section                                                                Page

      Introduction	  C. 1-5
1.8   Bagasse Boiler 	  C.l-6
2.1   Refuse Incineration
        Municipal Waste Mass Burn Incinerator 	  C.l-8
        Municipal Waste Modular Incinerator 	  C.l-10
4.2   Automobile Spray Booth 	  C.l-12
5.3   Carbon Black:  Off Gas Boiler 	  C.l-14
5.15  Detergent Spray Dryer 	  TBA
5.17  Sulfuric Acid
        Absorber	  C.l-18
        Absorber, 20% Oleum 	  C.l-20
        Absorber, 32% Oleum 	  C.l-22
        Absorber, Secondary 	  C.l-24
5.xx  Boric Acid Dryer 	  C.l-26
5.xx  Potash Dryer
        Potassium Chloride	  C.l-28
        Potassium Sulfate 	  C.l-30
6.1   Alfalfa Dehydrating - Primary Cyclone 	  C.l-32
6.3   Cotton Ginning
        Battery Condenser 	  C.l-34
        Lint Cleaner Air Exhaust 	  C.l-36
        Roller Gin Gin Stand 	  TBA
        Saw Gin Gin Stand 	  TBA
        Roller Gin Bale Press 	  TBA
        Saw Gin Bal e Press 	  TBA
6.4   Feed And Grain Mills And Elevators
        Carob Kibble Roaster 	  C.l-44
        Cereal Dryer 	  C.l-46
        Grain Unloading In Country Elevators 	  C.l-48
        Grain Conveying	  C.l-50
        Rice Dryer 	  C.l-52
6.18  Ammonium Sulfate Fertilizer Dryer 	  C.l-54
7.1   Primary Aluminum Production
        Bauxite Processing - Fine Ore Storage 	  C.l-56
        Bauxite Processing - Unloading From Ore Ship 	  C.l-58
7.13  Steel Foundries
        Castings Shakeout 	  C.l-60
        Open Hearth Exhaust 	  C.l-62
7.15  Storage Battery Production
        Grid Casting 	  C.l-64
        Grid Casting And Paste Mixing 	  C.l-66
        Lead Oxide Mill 	  C.l-68
        Paste Mixing; Lead Oxide Charging 	  C.l-70
        Three Process Operation 	  C.1-72
7.xx  Batch Tinner 	•.	  C.l-74
10/86                             Appendix C.I                            C.l-3
-------
                                CONTENTS (cont.)
AP-42
  Section                                                                Page

 8.9   Coal Cleaning
         Dry Process 	  C.l-76
         Thermal Dryer 	  C. 1-78
         Thermal Incinerator 	  C.l-80
 8.18  Phosphate Rock Processing
         Calciner 	  C.1-82
         Dryer - Oil Fired Rotary And Fluidized Bed  	  C.l-84
         Dryer - Oil Fired Rotary 	  C.l-86
         Ball Mill	  C.l-88
         Grinder - Roller And Bowl Mill  	  C.l-90
 8.xx  Feldspar Ball Mill 	  C.l-92
 8.xx  Fluorspar Ore Rotary Drum  Dryer 	  C.l-94
 8.xx  Lightweight Aggregate
         Clay - Coal Fired Rotary Kiln	  C.l-96
         Clay - Dryer 	  C.l-98
         Clay - Reciprocating Grate Clinker Cooler 	  C.1-100
         Shale - Reciprocating Grate Clinker Cooler  	  C.1-102
         Slate - Coal Fired Rotary Kiln	  C. 1-104
         Slate - Reciprocating Grate Clinker Cooler  	  C.1-106
 8.xx  Nonmetallic Minerals - Talc Pebble Mill 	  C.1-108
10.4   Woodworking Waste Collection Operations
         Belt Sander Hood Exhaust 	  C.1-110
C.l-4                           EMISSION FACTORS                          10/86
-------
                                  APPENDIX C.I
                        PARTICLE SIZE DISTRIBUTION DATA
                                      AND
                  SIZED EMISSION FACTORS FOR SELECTED SOURCES
                                  Introduction
     This Appendix presents particle size distributions  and  emission  factors
for miscellaneous sources or processes for which documented  emission  data were
available.  Generally, the sources of data used to develop particle size
distributions and emission factors for this Appendix were:

     1)  Source test reports in the files of the Emission Measurement Branch
(EMB) of EPA's Emission Standards And Engineering Division,  Office Of Air
Quality Planning And Standards.
     2)  Source test reports in the Fine Particle Emission Information System
(FPEIS), a computerized data base maintained by EPA's Air And Energy  Engineer-
ing Research Laboratory, Office Of Research And Development.
     3)  A series of source tests titled Fine Particle Emissions From Station-
ary And Miscellaneous Sources In The South Coast Air Basin,  by  H. J.  Taback.^
     4)  Particle size distribution data reported in the literature by various
individuals and companies.

     Particle size data from FPEIS were mathematically normalized into more
uniform and consistent data.  Where EMB tests and Taback report data  were
filed in FPEIS, the normalized data were used in developing  this Appendix.

     Information on each source category in Appendix C.I is  presented in a two
page format.  For a source category, a graph provided on the first page presents
a particle size distribution expressed as the cumulative weight percent of
particles less than a specified aerodynamic diameter (cut point), in  micro-
meters.  A sized emission factor can be derived from the mathematical  product
of a mass emission factor and the cumulative weight percent  of  particles smaller
than a specific cut point in the graph.  At the bottom of the page is  a table
of numerical values for particle size distributions and  sized emission factors,
in micrometers, at selected values of aerodynamic particle diameter.   The
second page gives some information on the data used to derive the particle size
distributions.

     Portions of the Appendix denoted TEA in the table of contents refer to
information which will be added at a later date.
                                  Appendix C.I                            C.l-5
-------
                EXTERNAL COMBUSTION -
                                   1.8  BAGASSE FIRED  BOILER
        99.99
         99.9
          99


          98
          95
          "


          90
       0)
       4-1
       flj  80
       03

       V
        bfl
70


60


50


40


30


20
       ,3 10
        i
        a <
          2


          1


         0.5




         0.1







         0.01
                                             CONTROLLED
                                       —•—  Weight   percent
                                       	  Emission factor
                                                                    1.5
M
9
H-
05
cn
H.
o
3
                                                                             i.o to
                                                                                o
                                                                                rr
                                                                                O
                                                                             0.5
                                                                   0.0
                           3   4   5 4 7 8 9 10       20

                                 Particle diameter,  urn
                                                          30   40  50 60 70 80 90 100
Aerodynamic
particle
diameter, urn
2.5
6.0
10.0
Cumulative wt . % < stated size
Wet scrubber controlled
46.3
70.5
97.1
Emission factor, kg/Mg
Wet scrubber controlled
0.37
0.56
0.78
C.l-6
                          EMISSION FACTORS
 10/86
-------
               EXTERNAL COMBUSTION -    1.8  BAGASSE FIRED BOILER
NUMBER OF TESTS:  2, conducted after wet scrubber control
STATISTICS:  Aerodynamic particle diameter (urn):         2.5     6.0   10.0

                 Mean (Cum. %):                         46.3    70.5   97.1
                 Standard deviation (Cum. %):            0.9     0.9    1.9
                 Min (Cum. %):                         45.4    69.6   95.2
                 Max (Cum. %):                         47.2    71.4   99.0
TOTAL PARTICULATE EMISSION FACTOR:   Approximately 0.8 kg particulate/Mg  bagasse
charged to boiler.  This factor is  derived from AP-42, Section 1.8,  4/77,  which
states that the particulate emission factor from an uncontrolled  bagasse fired
boiler is 8 kg/Mg and that wet scrubbers typically provide 90% particulate
control.

SOURCE OPERATION:  Source is a Riley Stoker Corp. vibrating grate spreader
stoker boiler rated at 120,000 Ib/hr but operated during this  testing at 121%
of rating.  Average steam temperature and pressure were 579°F  and 199 psig
respectively.  Bagasse feed rate could not be measured, but was estimated  to be
about 41 (wet) tons/hr.
SAMPLING TECHNIQUE:   Anderson Cascade impactor.
EMISSION FACTOR RATING:  D
REFERENCE:

       Emission Test Report,  U. S.  Sugar Company,  Bryant,  Fl,  EMB-80-WFB-6,
       U.  S.  Environmental  Protection Agency,  Research Triangle Park,  NC,
       May 1980.
 10/86                            Appendix C.I                             C.l-7
-------
          2.1   REFUSE  INCINERATION:   MUNICIPAL WASTE MASS  BURN INCINERATOR
        99.99
         99.9
    99

    98


    95


    90


    80

    70

    60

»•«   50
•U   40
f.
y  30
      CO

      V
      0)
      a
      o
    20


    10


     5


     2

     1

    0.5


    0.1




   0.01
                                               UNCONTROLLED
                                             — Weight percent
                                             • — Emission factor
                                  lllil
                                                                       •  »  2.0
                                                                           10.0
                                                                               M
                                                                            ,.o  B.
                                                                               CO
                                                                               n
                                                                               o
                                                                               3
                                                                               »
                                                                               O
                                                                           4.0
                              4   5  6  7  8 9 10       20    30

                                Particle  diameter,  um
                                                       40 50 60 70 80 90 100
Aerodynamic
particle
diameter, um
2.5
6.0
10.0
Cumulative wt. % < stated size
Uncontrolled
26.0
30.6
38.0
Emission factor, kg/Mg
Uncontrolled
3.9
4.6
5.7
C.l-8
                             EMISSION FACTORS
                                                                             10/86
-------
        2.1  REFUSE INCINERATION:  MUNICIPAL WASTE MASS BURN INCINERATOR
NUMBER OF TESTS:  7, conducted before control
STATISTICS:  Aerodynamic Particle Diameter (urn):

                 Mean (Cum. %):
                 Standard deviation (Cum. %):
                 Min (Cum. %):
                 Max (Cum. %):
 2.5
6.0
10.0
26.0     30.6      38.0
 9.5     13.0      14.0
18       22        24
40       49        54
TOTAL PARTICULATE EMISSION FACTOR:  15 kg of particulate/Mg of refuse charged,
Emission factor from AP-42 Section 2.1.
SOURCE OPERATION:  Municipal incinerators reflected in the data base include
various mass burning facilities of typical design and operation.
SAMPLING TECHNIQUE:  Unknown.
EMISSION FACTOR RATING:  D
REFERENCE:

      Determination Of Uncontrolled Emissions, Product 2B, Montgomery County,
      Maryland, Roy F. Weston, Inc.,  West Chester, PA, August 1984.
 10/86
                                  Appendix C.I
                     C.l-9
-------
          2.1  REFUSE INCINERATION:  MUNICIPAL WASTE MODULAR  INCINERATOR
         99.9
         99


         98


        ZO
       cd
      rH


       3
  2


  I


 0.5





 0.1







0.01
                                                     UNCONTROLLED

                                                -•—  Weight  percent
                                                	  Emission factor
                                                                            10.0
                                                                        w
                                                                        B
                                                                        H-
                                                                    8.0  GO
                                                                        cn

                                                                        o
                                                                        3

                                                                        Hi
                                                                        0)
                                                                        O
                                                                        rr
                                                                        O
                                                                        i-l
                                                                               0?
                                                                            4.0
                                                                            2.0
                              4S67S910       20    30


                                Particle  diameter,  urn
                                                     40  SO  60 70 80 90 IOC
Aerodynamic
particle
diameter, urn
2.5
6.0
10.0
Cumulative wt. % < stated size
Uncontrolled
54.0
60.1
67.1
Emission factor, kg/Mg
Uncontrolled
8.1
9.0
10.1
C.l-10
                           EMISSION FACTORS
10/86
-------
          2.1   REFUSE  INCINERATION:  MUNICIPAL WASTE MODULAR INCINERATOR


 NUMBER  OF TESTS:   3,  conducted before control


 STATISTICS:   Aerodynamic Particle Diameter  (urn):    2.5     6.0   10.0

                 Mean (Cum. %):                    54.0    60.1   67.1
                 Standard deviation (Cum. %):      19.0    20.8   23.2
                 Min  (Cum. %):                     34.5    35.9   37.5
                 Max  (Cum. %):                     79.9    86.6   94.2
TOTAL PARTICULATE EMISSION FACTOR:   15 kg of particulate/Mg of refuse charged.
Emission factor from AP-42.
SOURCE OPERATION:  Modular incinerator (2 chambered) operation was at 75.9% of
the design  process rate  (10,000 Ib/hr) and 101.2% of normal steam production
rate.  Natural gas is required to start the incinerator each week.  Average
waste charge  tate was 1.983T/hr.  Net heating value of garbage 4200-4800 BTU/lb
garbage charged.


SAMPLING TECHNIQUE:  Andersen Impactor
EMISSION FACTOR RATING: C
REFERENCE:

       Emission Test Report, City of Salem, Salem, Va, EMB-80-WFB-1, U. S. Envi-
       ronmental Protection Agency, Research Triangle Park, NC, February 1980.
10/86                             Appendix C.I                           C.l-11
-------
       4.2.2.8  AUTOMOBILE  & LIGHT  DUTY TRUCK SURFACE COATING OPERATIONS:
                  AUTOMOBILE SPRAY  BOOTHS (WATER BASE ENAMEL)




0)
N
09
•o
0)
4J
CO
JJ
w

V
&•"?

*
•H
§
(U
>
•H
4J
(0
iH
a
5








99.9
99

98

95

90

80


70
60

50
40
30

20



10
5

2
1
0.5
0.1



-


-

_

m


/

/
'
/ -
x/ ^^
B^**^ /
/
X
/

M*

«•

••

CONTROLLED
-*- Weight percent
	 Emission factor
• • i ,,.,,, , , ,,,,,,


3.0





M
^.
CO
0)
s-
3
2-° «.
ractor,

TO
~^.

TO


1.0






0.0
3  4  56789 10       20

    Particle  diameter,  urn
                                                       30   40 50  60 70 80 90 IOC
Aerodynamic
particle
diameter, um
2.5
6.0
10.0
Cumulative wt. % < stated size
Water curtain controlled
28.6
38.2
46.7
Emission factor, kg/Mg
Water curtain controlled
1.39
1.85
2.26
C.l-12
      EMISSION FACTORS
                                                                           10/86
-------
      4.2.2.8  AUTOMOBILE AND LIGHT DUTY TRUCK SURFACE COATING OPERATIONS:
                  AUTOMOBILE SPRAY BOOTHS (WATER BASE ENAMEL)
NUMBER OF TESTS:  2, conducted after water curtain control.


STATISTICS:   Aerodynamic particle diameter (urn):     2.5     6.0   10.0

                 Mean (Cum. %):                     28.6    38.2   46.7
                 Standard deviation (Cum. %):       14.0    16.8   20.6
                 Min (Cum. %):                     15.0    21.4   26.1
                 Max (Cum. %):                     42.2    54.9   67.2


TOTAL PARTICULATE EMISSION FACTOR:  4.84 kg particulate/Mg of water base
enamel sprayed.  From References a and b.


SOURCE OPERATION:  Source is a water base enamel  spray booth in an automotive
assembly plant.  Enamel spray rate is 568 Ibs/hour, but spray gun type is not
identified.   The spray booth exhaust rate is 95,000 scfm.   Water flow rate to
the water curtain control device is 7181 gal/min.  Source is operating at 84%
of design rate.


SAMPLING TECHNIQUE:  SASS and Joy trains with cyclones.


EMISSION FACTOR RATING:   D
REFERENCES:

a.     H. J. Taback,  Fine Particle Emissions from Stationary and Miscellaneous
       Sources in the South Coast Air Basin, PB 293 923/AS,  National Technical
       Information Service, Springfield, VA, February 1979.

b.     Emission test data from Environmental Assessment Data Systems, Fine Par-
       ticle Emission Information System, Series Report No.  234,  U.  S. Environ-
       mental Protection Agency, Research Triangle Park, NC, June 1983.
10/86                             Appendix C.I                           C.l-13
-------
               5.3   CARBON  BLACK:  OIL  FURNACE PROCESS OFF  GAS BOILER
          99.9
 99

 98
         N "
        •H
         CO

        •o90
         (U
        4J
         « 80
        V
 70


 60


 50
         §30


         £20
          10
         g
        U
  2


  1


 0.5




 0.1






0.01
                              X
                            X
                                                     UNCONTROLLED
                                                 —•—  Weight percent
                                                 	  Emission  factor
                                                                             1.75
                                                                             1.50
w
B
H-
CO
01

o
3
                                                                       a>
                                                                       o
                                                                       rt
                                                                       o
                                                                       •i
                                                                       7?
                                                                       OQ


                                                                       I
                                                                             1.25
                               *   5  6 7  8 9 10        20    30

                                  Particle diameter, urn
                                                                     I  i  i I  I 1.00

                                                              40 SO 60 70 80 90 100
Aerodynamic
particle
diameter, um
2.5
6.0
10.0
Cumulative wt. % < stated size
Uncontrolled
87.3
95.0
97.0
Emission factor, kg/Mg
Uncontrolled
1.40
1.52
1.55
C.l-14
                            EMISSION FACTORS
                                                                                   10/86
-------
             5.3  CARBON BLACK:   OIL FURNACE PROCESS OFF GAS BOILER
NUMBER OF TESTS:   3,  conducted at off gas boiler outlet


STATISTICS:   Aerodynamic particle diameter (urn):     2.5     6.0    10.0

                 Mean (Cum. %):                     87.3    95.0    97.0
                 Standard Deviation (Cum. %):        2.3     3.7     8.0
                 Min (Cum. %):                     76.0    90.0    94.5
                 Max (Cum. %):                     94.0    99     100


TOTAL PARTICULATE EMISSION FACTOR:   1.6 kg particulate/Mg carbon black  produced,
from reference.
SOURCE OPERATION:   Process operation:   "normal" (production rate = 1900 kg/hr).
Product is collected in fabric filter,  but the off gas boiler outlet  is
uncontrolled.
SAMPLING TECHNIQUE:   Brinks Cascade Impactor
EMISSION FACTOR RATING:  D
REFERENCE:

       Air Pollution Emission Test,  Phillips Petroleum Company,  Toledo,  OH,  EMB-
       73-CBK-l, U. S. Environmental Protection Agency, Research Triangle Park,
       NC,  September 1974.
10/86                             Appendix C.I                             C.l-15
-------
                       5.17  SULFURIC ACID:   ABSORBER (ACID ONLY)
       0)

       N
•a
cu
4J
CO
4-1
CO


V
      4-1

      A
         99.99
          99.9
           99



           98
90





80




70



60



50
       01   30
       s
           10
            1


           0.5
           0.1
          0.01
                                                       UNCONTROLLED

                                                   >-  Weight percent

                                                   ..  Emission factor (0.2)

                                                   —  Emission factor (2.0)
                                                                                    2.0
                                                                                    1.5
                                                                                    1.0
                                                                                    0.5
                                                                                    0.0
                                                                                         H
                                                                                         CO
                                                                                         CO
                                                                                         o
                                                                                         0
                                                                                   B>
                                                                                   n
                                                                                   rf
                                                                                   o
                                                                                  €
                                                                                  OQ
                                      5  6 7  8 9 10
                                                          20
                                                                30   40 50 60 70 80 90 100
                                   Particle  diameter,  um
Aerodynamic
particle
diameter, um
2.5
6.0
10.0
Cumulative wt . % < stated size
Uncontrolled
51.2
100
100
Emission factor, kg/Mg
Uncontrolled
(0.2) (2.0)
0.10
0.20
0.20
1.0
2.0
2.0
C.l-18
                                 EMISSION FACTORS
                                                                               10/86
-------
                   5.17  SULFURIC ACID:  ABSORBER (ACID ONLY)


NUMBER OF TESTS:   Not available


STATISTICS:  Aerodynamic particle diameter (urn):        2.5     6.0   10.0

                 Mean (Cum. %):                        51.2   100    100
                 Standard deviation (Cum. %):
                 Min (Cum. %):
                 Max (Cum. %):
TOTAL PARTICULATE EMISSION FACTOR:  0.2 to 2.0 kg acid mist/Mg sulfur charged,
for uncontrolled 98% acid plants burning elemental sulfur.  Emission factors
are from AP-42.
SOURCE OPERATION:  Not available


SAMPLING TECHNIQUE:   Brink Cascade Impactor


EMISSION FACTOR RATING:   E


REFERENCES:

a.     Final Guideline Document:  Control of Sulfuric Acid Mist Emissions from
       Existing Sulfuric Acid Production Units, EPA-450/2-77-019,  U. S. Environ-
       mental Protection Agency, Research Triangle Park, NC, September 1977.

b.     R. W. Kurek,  Special Report On EPA Guidelines For State Emission Stand-
       ards For Sulfuric Acid Plant Mist, E. I. du Pont de Nemours and Company,
       Wilmington, DE, June 1974.

c.     J. A. Brink,  Jr., "Cascade Impactor For Adiabatic Measurements", Indus-
       trial and Engineering Chemistry, 50:647, April 1958.
10/86                             Appendix C.I                           C.l-19
-------
                     5.17  SULFURIC ACID:   ABSORBER,  20%  OLEUM
           99.99
           99.9
            99

            98



            95
        N
        •H   90
        CO
        a)
        jj
        CO

        v
        .C
        bO
         CO
         3
80


70


60


50


40


30


20




10
            0.5
            0.1
           0.01
                                                       UNCONTROLLED
                                                        Weight percent
                              3   4   5  6  7  8 9 10        20    30   40 50  60 70 80 90 100


                                    Particle  diameter,  urn
Aerodynamic
particle
diameter, um
2.5
6.0
10.0
Cumulative wt. % < stated size
Uncontrolled
97.5
100
100
Emission factor, kg/Mg
Uncontrolled
See Table 5.17-2


C.l-20
                        EMISSION  FACTORS
                                                                                 10/86
-------
                   5.17  SULFURIC ACID:  ABSORBER, 20% OLEUM


NUMBER OF TESTS:  Not available


STATISTICS:  Aerodynamic particle diameter (urn)*:       1.0     1.5    2.0

                 Mean (Cum. %):                        26      50     73
                 Standard deviation (Cum. %):
                 Min (Cum. %):
                 Max (Cum. %):


TOTAL PARTICULATE EMISSION FACTOR:  Acid mist emissions from sulfuric acid
plants are a function of type of feed as well as oleum content of product.
See AP-42 Section 5.17, Table 5.17-2.


SOURCE OPERATION:  Not available


SAMPLING TECHNIQUE:   Brink Cascade Impactor


EMISSION FACTOR RATING:  E


REFERENCES:

a.     Final Guideline Document;  Control of Sulfuric Acid Mist Emissions from
       Existing Sulfuric Acid Production Units, EPA-450/2-77-019, U. S. Environ-
       mental Protection Agency, Research Triangle Park, NC, September 1977.

b.     R. W. Kurek,  Special Report On EPA Guidelines For State Emission Stand-
       ards For Sulfuric Acid Plant Mist, E. I. du Pont de Nemours and Company,
       Wilmington, DE, June 1974.

c.     J. A. Brink,  Jr., "Cascade Impactor For Adiabatic Measurements", Indus-
       trial and Engineering Chemistry, 50:647, April 1958.
 '100% of the particulate is less than 2.5 urn in diameter.
10/86                             Appendix C.I                           C.l-21
-------
                     5.17   SULFURIC  ACID:  ABSORBER, 32% OLEUM
           99.99
            99.9
            99


            98




            95
         0)
         N

        "«>   90
         0)
         4J
         CO
         u
         (0

        V
        •u

        bo
80



70


60


50


40


30


20




10
             2


             1


            0.5





            0.1







           0.01
                                            UNCONTROLLED

                                             Weight  percent
                              3  4   56789 10        20


                                   Particle  diameter,  um
                                                             30   40  50 60 70 80 90 100
Aerodynamic
particle
diameter, um
2.5
6.0
10.0
Cumulative wt . % < stated size
Uncontrolled
100
100
100
Emission factor, kg/Mg
Uncontrolled
See Table 5.17-2


C.l-22
                       EMISSION FACTORS
10/86
-------
                   5.17  SULFURIC ACID:  ABSORBER, 32% OLEUM
NUMBER OF TESTS:  Not available


STATISTICS:   Aerodynamic particle diameter (urn)*:       1.0    1.5    2.0

                 Mean (Cum. %):                        41     63     84
                 Standard deviation (Cum. %):
                 Min (Cum. %):
                 Max (Cum. %):


TOTAL PARTICULATE EMISSION FACTOR:  Acid mist emissions from sulfuric acid
plants are a function of type of feed as well as oleum content of product.  See
AP-42 Section 5.17, Table 5.17-2.


SOURCE OPERATION:  Not available


SAMPLING TECHNIQUE:  Brink Cascade Impactor
EMISSION FACTOR RATING:  E


REFERENCES:

a.     Final Guideline Document;  Control of Sulfuric Acid Mist Emissions from
       Existing Sulfuric Acid Production Units, EPA-450/2-77-019,  U. S. Environ-
       mental Protection Agency, Research Triangle Park, NC, September 1977.

b.     R. W. Kurek, Special Report On EPA Guidelines For State Emission Stand-
       ards For Sulfuric Acid Plant Mist, E. I. du Pont de Nemours and Company,
       Wilmington, DE, June 1974.

c.     J. A. Brink, Jr., "Cascade Impactor For Adiabatic Measurements", Indus-
       trial and Engineering Chemistry, 50:647, April 1958.
 100% of the particulate is less than 2.5 urn in diameter.
10/86                             Appendix C.I                           C.l-23
-------
                      5.17   SULFURIC ACID:   SECONDARY ABSORBER
           99.99
            99.9
             99

             98


          V
          N  95
          •H
          00

          TJ  9°
          V
          u

          2  8°
          00

          v  70

          »<  60
             50
            40
Ml
T-l

a
3  30
0)
>  20
 i  10
 i
 >  5

   2

   1

   0.5


   0.1




  0.01
                                                        UNCONTROLLED
                                                         Weight percent
                                                                                            i
                              3   4   5 6 7 8 9 10        20

                                   Particle diameter, um
                                                             30
                                                                 40  50  60 70 80 90 100
Aerodynamic
particle
diameter , um
2.5
6.0
10.0
Cumulative wt. 7, <. stated size
Uncontrolled
48
78
87
Emission factor , kg/Mg
Uncontrolled
Not Available
Not Available
Not Available
C.l-24
                         EMISSION FACTORS-
10/86
-------
                    5.17  SULFURIC ACID: SECONDARY ABSORBER
NUMBER OF TESTS:  Not available
STATISTICS:      Particle Size (urn):                    2.5    6.0    10.0
                 Mean (Cum. %):                        48     78      87
                 Standard Deviation (Cum. %):
                 Min (Cum. %):
                 Max (Cum. %):
TOTAL PARTICULATE EMISSION FACTOR:  Acid mist emission factors vary widely
according to type of sulfur feedstock.  See AP-42 Section 5.17 for guidance.


SOURCE OPERATION:  Source is the second absorbing tower in a double absorption
sulfuric acid plant.  Acid mist loading is 175 - 350 mg/m^.


SAMPLING TECHNIQUE:   Andersen Impactor
EMISSION FACTOR RATING:   E
REFERENCE:

      G. E. Harris and L. A. Rohlack, "Particulate Emissions from Non-fired
      Sources in Petroleum Refineries:   A Review of Existing Data", Publica-
      tion No. 4363,  American Petroleum Institute, Washington, DC, December
      1982.
10/86                             Appendix C.I                           C.l-25
-------
                5.xx  CHEMICAL PROCESS INDUSTRY:   BORIC ACID DRYER
99. »9
99.9


99
98
d) QS
N 95
•H
co
90

4J
«C 80
4->
CO
70
V
SsS 60

4J 50
j:
W> 40
*^
0)
!* 30
SJ 20
•H
l |
(0
H 10
3
a
3 .
u 5
2
1

0.5

0.1
0 01

UNCONTROLLED
—•— Weight percent
	 Emission factor
CONTROLLED
— •- Weight percent
-

^





^


*

~ —
;
'
/
"
/
1
' —
_
" / -sS^"^
^f^1^^
^-~^ff ^^
m^^^^^ J^^
/T
/ /
~ x^ / —
/ /
* /
^ '
1 1 Illllll 1 1 Illlll

0.5




0.4

W
1 ',
f— •
0)
CO
H-
O
3

HI
0.3 *
rt
O
i-t
"
7?
0?
0.2







0.1



0.0
1 2 3 4 5 6 7 8 9 10 20 30 40 50 60 70 80 90 IOC
                                 Particle  diameter, urn
Aerodynamic
particle
diameter, urn
2.5
6.0
10.0
Cumulative wt. % < stated size
Uncontrolled
0.3
3.3
6.9
Fabric filter
3.3
6.7
10.6
Emission factor, kg/Mg
Uncontrolled
0.01
0.14
0.29
Fabric filter
controlled
0.004
0.007
0.011
C.l-26
EMISSION FACTORS
10/86
-------
                             5.xx  BORIC ACID  DRYER


NUMBER OF TESTS:   a)   1,  conducted  before controls
                  b)   1,  conducted  after fabric  filter  control


STATISTICS:   (a)  Aerodynamic particle diameter (urn):  2.5     6.0     10.0

                     Mean (Cum.  %):                   0.3     3.3      6.9
                     Standard Deviation (Cum.  %):
                     Min (Cum. %):
                     Max (Cum. %):

             (b)  Aerodynamic particle diameter (urn):  2.5     6.0     10.0

                     Mean (Cum.  %):                   3.3     6.7     10.6
                     Standard Deviation (Cum.  %):
                     Min (Cum. %):
                     Max (Cum. %):
TOTAL PARTICULATE EMISSION FACTOR:   Before control,  4.15  kg  particulate/Mg
boric acid dried.  After fabric filter control,  0.11  kg particulate/Mg  boric
acid dried.  Emission factors from Reference a.
SOURCE OPERATION:  100% of design process rate.
SAMPLING TECHNIQUE:   a)  Joy train with cyclones
                     b)  SASS train with cyclones
EMISSION FACTOR RATING:  E
REFERENCES:

a.     H. J. Taback,  Fine Particle Emissions from Stationary and  Miscellaneous
       Sources in the South Coast Air Basin,  PB 293 923/AS,  National  Technical
       Information Service, Springfield, VA,  February 1979.

b.     Emission test data from Environmental  Assessment Data Systems,  Fine  Par-
       ticle Emission Information System, Series Report No.  236, U.  S.  Environ-
       mental Protection Agency, Research Triangle Park, NC, June  1983.
 10/86                            Appendix C.I                            C.l-27
-------
                      5.xx   POTASH (POTASSIUM CHLORIDE) DRYER
        99.99
        99.9
         99


         98




         95
      •O
      0)  80
      V
bO
•H
—Weight percent

                                          — Emission factor

                                           CONTROLLED


                                          k- Wt.  % high pressure
                                                                           5.0
                                                                           4.0
                                                                           3.0
                                                                         I
                                                                         09
                                                                         CO
                                                                         H-
                                                                         O
                                                                         3
                                                                               O
                                                                               i-l
                                                                              0?
                                                                           2.0
                                 56789 10
                                                   20
                                                                     0.0

                                                   30   40 50  60 70 80 90 100
                                 Particle  diameter,  urn
Aerodynamic
particle
diameter (um)
2.5
6.0
10.0
Cumulative wt. % < stated size
Uncontrolled
0.95
2.46
4.07
High pressure
drop venturi
scrubber
5.0
7.5
9.0
Emission factor
(kg/Mg)
Uncontrolled
0.31
0.81
1.34
C.l-28
                              EMISSION FACTORS
                                                                                 10/86
-------
                    5.xx   POTASH (POTASSIUM CHLORIDE) DRYER
NUMBER OF TESTS:   a)  7,  before control
                  b)  1,  after cyclone and high pressure drop venturi scrubber
                      control
STATISTICS:   a) Aerodynamic particle diameter (urn):   2.5     6.0    10.0

                     Mean (Cum. %):                    0.95    2.46   4.07
                     Standard deviation (Cum. %):      0.68    2.37   4.34
                     Min (Cum. %):                     0.22    0.65   1.20
                     Max (Cum. %):                     2.20    7.50  13.50
              b) Aerodynamic particle diameter (urn):   2.5     6.0    10.0

                     Mean (Cum. %):                    5.0     7.5     9.0
                     Standard deviation (Cum. %):
                     Min (Cum. %):
                     Max (Cum. %):
TOTAL PARTICULATE EMISSION FACTOR:  Uncontrolled emissions of 33 kg particu-
late/Mg of potassium chloride product from dryer, from AP-42 Section 5.16.  It
is assumed that particulate emissions from rotary gas fired dryers for potassium
chloride are similar to particulate emissions from rotary steam tube dryers for
sodium carbonate.
SOURCE OPERATION:  Potassium chloride is dried in a rotary gas fired dryer.
SAMPLING TECHNIQUE:   a)  Andersen Impactor
                     b)  Andersen Impactor
EMISSION FACTOR RATING:   C
REFERENCES:

a)  Emission Test Report, Kerr-Magee, Trona, CA, EMB-79-POT-4, U.  S.
    Environmental Protection Agency, Research Triangle Park, NC,  April 1979.

b)  Emission Test Report, Kerr-Magee, Trona, CA, EMB-79-POT-5, U.  S.
    Environmental Protection Agency, Research Triangle Park, NC  April 1979.
10/86                             Appendix C.I                           C.l-29
-------
                     5.xx  POTASH  (POTASSIUM SULFATE) DRYER

99.9

99
98
95
OU
N
•H 90
co
0) 80
TO
•U 70
CO
v 60

8s? 30

j- *0
•H* 30
»>
9 20
-------
                     5.xx  POTASH (POTASSIUM SULFATE) DRYER
NUMBER OF TESTS:   2, conducted after fabric filter


STATISTICS:  Aerodynamic particle diameter (urn):       2.5      6.0      10.0

                 Mean (Cum. %):                       18.0     32.0      43.0
                 Standard deviation (Cum. %):          7.5     11.5      14.0
                 Min (Cum. %):                       10.5     21.0      29.0
                 Max (Cum. %):                       24.5     44.0      14.0


TOTAL PARTICULATE EMISSION FACTOR:   After fabric  filter control, 0.033 kg
of particulate per Mg of potassium sulfate product from the dryer.  Calculated
from an uncontrolled emission factor of 33 kg/Mg  and control efficiency of
99.9 %.  From Reference a and AP-42 Section 5.16.  It is assumed that
particulate emissions from rotary gas fired dryers are similar to those from
rotary steam tube dryers.


SOURCE OPERATION:  Potassium sulfate is dried in a rotary gas fired dryer.


SAMPLING TECHNIQUE:  Andersen Impactor


EMISSION FACTOR RATING:  E


REFERENCES:

a)     Emission Test Report, Kerr-McGee, Trona, CA, EMB-79-POT-4, Office Of Air
       Quality Planning And Standards, U. S. Environmental Protection Agency,
       Research Triangle Park, NC, April 1979.

b)     Emission Test Report, Kerr-McGee, Trona, CA, EMB-79-POT-5, Office Of Air
       Quality Planning And Standards, U. S. Environmental Protection Agency,
       Research Triangle Park, NC, April 1979.
10/86                             Appendix C.I                           C.l-31
-------
               6.1 ALFALFA DEHYDRATING: DRUM  DRYER PRIMARY CYCLONE
         99.9
         99

         98
       0) 95
       N
         90
         80
       4J
       CO
   60

ij  50
J=
       e
      o
                                                    UNCONTROLLED
                                                —•-  Weight percent
                                                	  Emission factor
                                                                          0.3
                                                                      cn
                                                                      en
                                                                             01
                                                                             o
                                                                             o
                                                                             1-1
                                                                             7?
                                                                             V)
                                                            -0  ;0
                                                                   "0 30
                                                                          0.0
                                                                          .DC
                               Particle diameter,  urn
Aerodynamic
Particle
diameter, urn
2.5
6.0
10.0
Cum. wt. % < stated size
Uncontrolled
70.6
82.7
90.0
Emission factor, kg/Mg
Uncontrolled
3.5
4.1
4.5
C.l-32
                              EMISSION FACTORS
                                                                             10/86
-------
              6.1  ALFALFA DEHYDRATING: DRUM DRYER PRIMARY CYCLONE
 NUMBER  OF TESTS:   1, conducted before control
 STATISTICS:  Aerodynamic particle diameter (urn):       2.5     6.0   10.0

                 Mean (Cum. %):                       70.6    82.7   90.0
                 Standard deviation (Cum. %)
                 Min (Cum. %):
                 Max (Cum. %):
TOTAL PARTICULATE EMISSION FACTOR:  5.0 kg particulate/Mg alfalfa pellets
before control.  Factor from AP-42.
SOURCE OPERATION:  During this test, source dried 10 tons of alfalfa/hour in a
direct fired rotary dryer.
SAMPLING TECHNIQUE:  Nelson Cascade Impactor
EMISSION FACTOR RATING: E
REFERENCE:
       Emission test data from Environmental Assessment Data Systems, Fine Par-
       ticle Emission Information System, Series Report No. 152, U. S. Environ-
       mental Protection Agency, Research Triangle Park, NC, June 1983.
10/86                             Appendix C.I                           C.l-33
-------
                    6.3  COTTON GINNING:   BATTERY CONDENSER









0)
N
•H
0)
•o

O
0.050 o
P-)
<•
_
TO
-•v.
o*
95
(D


f
0.006


0.003
0
100
                             Particle diameter,  urn
Aerodynamic
particle
diameter (urn)
2.5
6.0
10.0
Cumulative wt. % < stated size
With
cyclone
8
33
62
With cyclone &
wet scrubber
11
26
52
Emission factor (kg/bale)
With
cyclone
0.007
0.028
0.053
With cyclone
& wet scrubber
0.001
0.003
0.006
C.l-34
EMISSION FACTORS
10/86
-------
                    6.3  COTTON GINNING:   BATTERY CONDENSER
NUMBER OF TESTS:  a)  2, after cyclone
                  b)  3, after wet scrubber
STATISTICS:  Aerodynamic particle diameter (urn):        2.5      6.0      10.0

             a)  Mean (Cum. %):                        8       33        62
                 Standard deviation (Cum. %):
                 Min (Cum. %):
                 Max (Cum. %):

             b)  Mean (Cum. %):                       11       26        52
                 Standard deviation (Cum. %):
                 Min (Cum. %):
                 Max (Cum. %):
TOTAL PARTICIPATE EMISSION FACTOR:  Particulate emission factor for battery
condensers with typical controls is 0.09 kg (0.19 lb)/bale of cotton.  From
AP-42.  Factor with wet scrubber after cyclone is 0.012 kg (0.026 lb)/bale.
Scrubber efficiency is 86%.  From Reference b.
SOURCE OPERATION:  During tests, source was operating at 100% of design capa-
city.  No other information on source is available.
SAMPLING TECHNIQUE:  UW Mark 3 Impactor
EMISSION FACTOR RATING:   E
REFERENCES:

a)  Emission test data from Environmental Assessment Data Systems,  Fine Par-
    ticle Emission Information System (FPEIS), Series Report No. 27,  U. S.
    Environmental Protection Agency, Research Triangle Park, NC, June 1983.

b)  Robert E. Lee, Jr.,  et al.,  "Concentration And Size Of Trace Metal Emis-
    sions From A Power Plant, A Steel Plant, And A Cotton Gin",  Environmental
    Science And Technology, 9(7):643-7,  July 1975.
10/86                             Appendix C.I                           C.l-35
-------
                     6.3   COTTON GINNING:   LINT CLEANER AIR  EXHAUST
      01
      N
CO


01
      09


      V
      01



      01
      (0
      rH
      3
         99.99
         99.9
99


98



95



90




80



70


60


50


40


30


20




10
           2


           1


          0.5




          0.1







         0.01
                                     5 6  7  8 9 10
                                                 CYCLONE

                                                • Weight percent

                                              	 Emission factor

                                                CYCLONE AND WET SCRUBBER
                                              —•—Weight percent
                                                                                   0.3
                                                                                   0.2
                                                                                       I
                                                                                       CO
                                                                                       CO
                                                                                       H-
                                                                                       o
                                                                                       3
                                                                                       o
                                                                                       rt
                                                                                       O
                                                                                 0"
                                                                                 PJ
                                                                                   0.1
                                                         20
                                                               30
                                                                   40  50  60 70 80 90 IOC
                                   Particle  diameter,  urn
Aerodynamic
particle
diameter (um)
2.5
6.0
10.0
Cumulative wt. % < stated size
After
cyclone
1
20
54
After cyclone
& wet scrubber
11
74
92
Emission factor
(kg /bale)
After cyclone
0.004
0.07
0.20
C.l-36
                             EMISSION  FACTORS
                                                                                    10/86
-------
                 6.3  COTTON GINNING:  LINT CLEANER AIR EXHAUST
NUMBER OF TESTS:  a)  4, after cyclone
                  b)  4, after cyclone and wet scrubber


STATISTICS:  a)  Aerodynamic particle diameter (urn):    2.5      6.0      10.0

                     Mean (Cum. %):                    1       20        54
                     Standard deviation (Cum. %):
                     Min (Cum. %):
                     Max (Cum. %):

             b)  Aerodynamic particle diameter (um):    2.5      6.0      10.0

                     Mean (Cum. %):                   11       74        92
                     Standard deviation (Cum. %):
                     Min (Cum. %):
                     Max (Cum. %):
TOTAL PARTICULATE EMISSION FACTOR:  0.37 kg particulate/bale of cotton
processed, with typical controls.  Factor is from AP-42.


SOURCE OPERATION:  Testing was conducted while processing both machine picked
and ground harvested upland cotton, at a production rate of about 6.8
bales/hr.
SAMPLING TECHNIQUE:  Coulter counter.
EMISSION FACTOR RATING:   E
REFERENCE:

    S. E. Hughs, et al.,  "Collecting Particles From Gin Lint Cleaner Air
    Exhausts", presented  at the 1981 Winter Meeting of the American Society of
    Agricultural Engineers, Chicago, IL, December 1981.
10/86                             Appendix C.I                            C.l-37
-------
                    6.4  FEED AND GRAIN MILLS AND ELEVATORS:
                              CAROB KIBBLE ROASTER
'99.9
99
98
N
.j_f
w 90
•o
0)
J-" 80
U
w 70
^ 60
6-S
4J 5°
"§> 40
^_f
S 3°
0) 20
<0 10
3
U
2
1
0.5
0.1
0.01
-

"™
-
.


•
.
.
7
/
//-*
	 ^xy
/
/
	
"""" UNCONTROLLED
— •— Weight percent
	 Emission factor
A 1 Illlill 1 A Illlll


0.75




0.50





0.25
0.0
                                                                             M
                                                                             s
                                                                             H-
                                                                             01
                                                                             01
                                                                             M.
                                                                             O
                                                                             3
                                                                              O
                                                                              rt
                                                                              O
                               4   5  6  7  8 9 10       20

                                Particle  diameter, urn
                                                        30  40 50  60 70 80 90 IOC
Aerodynamic
particle
diameter, urn
2.5
6.0
10.0
Cumulative wt . % < stated size
Uncontrolled
3.0
3.2
9.6
Emission factor, kg/Mg
Uncontrolled
0.11
0.12
0.36
                                                                                       I
C.l-44
EMISSION FACTORS
10/86
-------
         6.4  FEED AND GRAIN MILLS AND ELEVATORS:  CAROB KIBBLE ROASTER
NUMBER OF TESTS:   1, conducted before controls
STATISTICS:  Aerodynamic particle diameter (urn):         2.5      6.0    10.0

                 Mean (Cum. %):                          3.0      3.2     9.6
                 Standard deviation (Cum.  %):
                 Min (Cum. %):
                 Max (Cum. %):
TOTAL PARTICULATE EMISSION FACTOR:   3.8 kg/Mg carob kibble roasted.   Factor
from Reference a, pg. 4-175.
SOURCE OPERATION:  Source roasts 300 kg carob pods per hour,  100% of  the design
rate.  Roaster heat input is 795 kj/hr of natural gas.
SAMPLING TECHNIQUE:   Joy train with 3 cyclones.
EMISSION FACTOR RATING:  E
REFERENCES:

a.     H. J. Taback,  Fine Particle Emissions from Stationary and  Miscellaneous
       Sources in the South Coast Air Basin, PB 293 923/AS,  National  Technical
       Information Service, Springfield,  VA, February 1979.

b.     Emission test data from Environmental Assessment Data Systems, Fine Par-
       ticle Emission Information System Series, Report No.  229, U. S.  Environ-
       mental Protection Agency, Research Triangle Park, NC, June  1983.
 10/86                             Appendix C.I                             C.l-45
-------
          99.99
           99.9
            99


            98
         S  95
         •H
         CO
         -0
            90
         4-1
         
                                                                                 O
                                                                                 rr
                                                                                 O
                                                                                 n
                                                                              0.25
                                                                              0.0
                             3   4   56789 10        20

                                  Particle diameter, urn
                                                   30   40  50 60 70 80 90 100
Aerodynamic
particle
diameter, urn
2.5
6.0
10.0
Cumulative wt. % < stated size
Uncontrolled
27
37
44
Emission factor, kg/Mg
Uncontrolled
0.20
0.28
0.33
C.l-46
                          EMISSION  FACTORS
10/86
-------
             6.4  FEED AND GRAIN MILLS AND ELEVATORS: CEREAL DRYER
NUMBER OF TESTS:  6, conducted before controls
STATISTICS:  Aerodynamic particle diameter (urn):      2.5     6.0   10.0

                 Mean (Cum. %):                         27      37     44
                 Standard deviation (Cum. %):          17      18     20
                 Min (Cum. %):                          13      20     22
                 Max (Cum. %):                          47      56     58
TOTAL PARTICULATE EMISSION FACTOR:  0.75 kg particulate/Mg cereal dried.
Factor taken from AP-42.
SOURCE OPERATION:  Confidential.
SAMPLING TECHNIQUE:  Andersen Mark III Impactor
EMISSION FACTOR RATING:  C
REFERENCE:
       Confidential test data from a major grain processor, PEI Associates,
       Inc., Golden, CO, January 1985.
10/86                             Appendix C.I                           C.l-47
-------
        99.99
         99.9
99


98
       01  9!
       N
       •O
       01
       V
90



80



70


60


50





30
       rH 10

       6

       5  5
          2


          1


         0.5
        0.01
                     6.4   FEED AND GRAIN MILLS AND  ELEVATORS:

                       GRAIN UNLOADING  IN COUNTRY ELEVATORS
                          y
                                                    UNCONTROLLED
                                               —•—  Weight  percent
                                               	  Emission factor
                                                                           1.5
                                                                           i.o
$
H-
CO
CO
H-
O
3
                                                                               CO
                                                                               O
                                                                               It
                                                                               O
                                                                          0.5
                                                                           0.0
                              4   5 6 7 8 9 10        20

                                Particle diameter, urn
                                               30   40  50  60 70 80 90 IOC
Aerodynamic
particle
diameter, urn
2.5
6.0
10.0
Cumulative wgt. % 
-------
                    6.4  FEED AND GRAIN MILLS AND ELEVATORS:
                      GRAIN UNLOADING IN COUNTRY ELEVATORS
NUMBER OF TESTS:  2, conducted before control
STATISTICS:  Aerodynamic particle diameter (urn):    2.5     6.0     10.0

                 Mean (Cum. %):                   13.8    30.5     49.0
                 Standard deviation (Cum. %):       3.3     2.5
                 Min (Cum. %):                     10.5    28.0     49.0
                 Max (Cum. %):                     17.0    33.0     49.0
TOTAL PARTICULATE EMISSION FACTOR:   0.3 kg particulate/Mg of grain unloaded,
without control.  Emission factor from AP-42.
SOURCE OPERATION:  During testing,  the facility was continuously receiving
wheat of low dockage.  The elevator is equipped with a dust collection system
which serves the dump pit boot and  leg.
SAMPLING TECHNIQUE:   Nelson Cascade Impactor
EMISSION FACTOR RATING:   D
REFERENCES:

a.  Emission test data from Environmental Assessment Data Systems,  Fine
    Particle Emission Information System (FPEIS),  Series Report  No.  154,  U.  S.
    Environmental Protection Agency,  Research Triangle Park,  NC, June 1983.

b.  Emission Test Report, Uniontown Co-op, Elevator No. 2,  Uniontown, WA,
    Report No. 75-34, Washington State Department  Of Ecology, Olympia, WA,
    October 1975.
 10/86                             Appendix C.I                           C.l-49
-------
                6.4   FEED AND GRAIN MILLS AND ELEVATORS:  CONVEYING
         0)
         CO

         CO

         V
         81
         CJ
             99.9
99


98



95



90



80



70


60


50


40


30


20
         £   10
             2


             1


             0.5




             0.1







            0.01
                                            UNCONTROLLED

                                            >— Weight percent

                                            -— Emission factor
                                                                               0.3
                                                                                  rt
CO
CO
H-
O
o

i-h
CO
n
rt
o
H
                                                                  0.1
                                                                  o
                                  4   5 6 7 8 9 10        20


                                    Particle diameter, urn
                                                             30   40 50 60 70 80 90 100
Aerodynamic
particle
diameter, urn
2.5
6.0
10.0
Cumulative wt . % < stated size
Uncontrolled
16.8
41.3
69.4
Emission factor, kg/Mg
Uncontrolled
0.08
0.21
0.35
C.l-50
                      EMISSION FACTORS
                                                                                10/86
-------
                6.4   FEED AND GRAIN MILLS AND ELEVATORS: CONVEYING


 NUMBER OF  TESTS:  2, conducted before control


 STATISTICS:   Aerodynamic particle diameter (urn):        2.5     6.0   10.0

                 Mean  (Cum. %):                        16.8    41.3   69.4
                 Standard deviation (Cum. %):           6.9    16.3   27.3
                 Min (Cum. %):                          9.9    25.0   42.1
                 Max (Cum. %):                         23.7    57.7   96.6
 TOTAL  PARTICIPATE EMISSION FACTOR:  0.5 kg particulate/Mg of grain processed,
 without control. Emission factor from AP-42.
 SOURCE  OPERATION:  Grain is unloaded from barges by "marine leg" buckets lifting
 the grain from  the barges and discharging it onto an enclosed belt conveyer,
 which transfers the grain to the elevator.  These tests measured the combined
 emissions from  the "marine leg" bucket unloader and the conveyer transfer
 points.  Emission rates averaged 1956 Ibs particulate/hour (0.67 kg/Mg grain
 unloaded).  Grains are corn and soy beans.
 SAMPLING TECHNIQUE:  Brinks Model B Cascade Impactor
EMISSION FACTOR RATING: D
REFERENCE:

       Air Pollution Emission Test, Bunge Corporation, Destrehan, LA, EMB-74-
       GRN-7, U. S. Environmental Protection Agency, Research Triangle Park,
       NC, January 1974.
10/86                             Appendix C.I                           C.l-51
-------
              6.4 FEED AND GRAIN MILLS AND ELEVATORS:  RICE DRYER
99.9



99

98
0) „.
N 95
,.,-J
fn
09
01
4J
« 80
u
CO
v 70
8^ 60

Jd 5°
W)
•H 40
> 30

> 20
•H
CO
•-j 10
3
2
CJ 5

2
1


0.5

0.1


0.01
/
1
1
1
t
" 1
1 ^
/'
/
t
1
1
- f

/
t
/ "**
/
t
1
9
1
1 -
1 /
t /
1 /
1 /
1 ^^
1 ^^^ ^
^^f
t
1
t
J
UNCONTROLLED
-•— Weight percent
	 Emission factor

2 3 4 5 6 7 8 9 10 20 30 40 50 60 70 80 90






0.015


W
H»
0)
CO
l_l.
o
l-tl
0.010 pi
n
rt
O
"•
?T
TO
"^
TO




0.005








0.00
100
                              Particle diameter, urn
Aerodynamic
Particle
diameter, urn
2.5
6.0
10.0
Cumulative wt. % < Stated Size
Uncontrolled
2.0
8.0
19.5
Emission Factor (kg/Mg)
Uncontrolled
0.003
0.01
0.029
C.l-52
EMISSION FACTORS
                                                                         10/86
-------
              6.4 FEED AND GRAIN MILLS AND ELEVATORS:   RICE DRYER
NUMBER OF TESTS:   2, conducted on uncontrolled source.
STATISTICS:   Aerodynamic Particle Diameter' (urn):     2.5        6.0         10.0

                Mean (Cum. %):                        2.0        8.0         19.5
                Standard Deviation (Cum.  %):           -         3.3          9.4
                Min (Cum. %):                         2.0        3.1         10.1
                Max (Cum. %):                         2.0        9.7         28.9


TOTAL PARTICULATE EMISSION FACTOR:   0.15  kg particulate/Mg of  rice dried.
Factor from AP-42, Table 6.4-1,  footnote  b for column dryer.
SOURCE OPERATION:   Source operated at 100% of rated capacity,  drying  90.8  Mg
rice/hr.  The dryer is heated by four 9.5 kg/hr burners.
SAMPLING TECHNIQUE:    Sass train with cyclones.
EMISSION FACTOR RATING:  D
REFERENCES:

a.     H. J. Taback,  Fine Particle Emissions from Stationary and  Miscellaneous
       Sources in the South Coast Air Basin,  PB 293 9237AS,  National  Technical
       Information Service, Springfield,  VA,  February 1979.

b.     Emission test data from Environmental  Assessment Data Systems, Fine  Par-
       ticle Emission Information System, Series Report No.  228, U. S.  Environ-
       mental Protection Agency, Research Triangle Park,  NC, June  1983.
 10/86                            Appendix C.I                            C.l-53
-------
                  6.18  AMMONIUM SULFATE FERTILIZER:   ROTARY DRYER
        99.99
         99.9
          99

          98
-------
                6.18  AMMONIUM SULFATE FERTILIZER:  ROTARY DRYER
NUMBER OF TESTS:  3, conducted before control.
STATISTICS:  Aerodynamic particle diameter (urn)      2.5        6.0       10.0

                Mean (Cum. %):                       10.8       49.1       98.6
                Standard Deviation (Cum. %):          5.1       21.5        1.8
                Min (Cum. %):                         4.5       20.3       96.0
                Max (Cum. %):                        17.0       72.0      100.0
TOTAL PARTICULATE EMISSION FACTOR:   23 kg particulate/Mg of ammonium sulfate
produced.  Factor from AP-42.
SOURCE OPERATION:  Testing was conducted at three ammonium sulfate plants
operating rotary dryers within the following production parameters:

            Plant	A	C	D

             % of design process rate       100.6      40.1    100
             production rate, Mg/hr          16.4       6.09     8.4
SAMPLING TECHNIQUE:   Andersen Cascade Impactors
EMISSION FACTOR RATING: C
REFERENCE:

       Ammonium Sulfate Manufacture - Background Information For Proposed
       Emission Standards, EPA-450/3-79-034a> U. S. Environmental Protection
       Agency, Research Triangle Park, NC,  December 1979.
10/86                             Appendix C.I                           C.l-55
-------
             7.1   PRIMARY  ALUMINUM  PRODUCTION:   BAUXITE PROCESSING

                                   FINE ORE STORAGE
        99.99
         99.9
 99


 98
      
-------
             7.1  PRIMARY ALUMINUM PRODUCTION:  BAUXITE PROCESSING
                                FINE ORE STORAGE
NUMBER OF TESTS:   2,  after fabric filter control
STATISTICS:   Aerodynamic particle diameter (urn):         2.5      6.0    10.0

                 Mean (Cum. %):                         50.0     62.0    68.0
                 Standard deviation (Cum.  %):           15.0     19.0    20.0
                 Min (Cum. %):                         35.0     43.0    48.0
                 Max (Cum. %):                         65.0     81.0    88.0
TOTAL PARTICULATE EMISSION FACTOR:   0.0005 kg particulate/Mg of  ore filled,
with fabric filter control.  Factor calculated from emission and process  data
in reference.
SOURCE OPERATION:  The facility purifies bauxite to alumina.   Bauxite ore,
unloaded from ships, is conveyed to storage bins from which it is  fed to  the
alumina refining process.  These tests measured the emissions  from the bauxite
ore storage bin filling operation (the ore drop from the conveyer  into the  bin),
after fabric filter control.  Normal bin filling rate is between 425  and  475
tons per hour.
SAMPLING TECHNIQUE:   Andersen Impactor
EMISSION FACTOR RATING:  E
REFERENCE:

       Emission Test Report, Reynolds Metals Company,  Corpus  Christi,  TX,  EMB-
       80-MET-9, U. S. Environmental Protection Agency,  Research Triangle  Park,
       NC, May 1980.
  10/86                            Appendix C.I                           C.l-57
-------
              7.1   PRIMARY  ALUMINUM  PRODUCTION:    BAUXITE PROCESSING
                               UNLOADING ORE FROM SHIP
         99.99
         99.9
          99

          98


       01
       N  95
       •H
       CO

       -O  9°
       0
       •H
          60
          50
          30

       01
       >  20
          2

          1


          0.5




          0.1






         0.01
                   CONTROLLED
              —•—  Weight percent
              	  Emission  factor
                                          0.0075
                                               H-
                                               CO
                                               CO
                                               H-
                                               O
                                               3
                                                                             0.0050  »
                                               £
                                                                             0.0025
                                          0.00
                                  5 6  7  8 9 10        20    30   40 50  60 70 80 90 IOC.

                                 Particle  diameter, urn
Aerodynamic
particle
diameter, um
2.5
6.0
10.0
Cumulative wt . % < stated size
Wet
scrubber controlled
60.5
67.0
70.0
Emission factor, kg/Mg
Wet scrubber
controlled
0.0024
0.0027
0.0028
C.l-58
EMISSION FACTORS
10/86
-------
              7.1  PRIMARY ALUMINUM PRODUCTION:  BAUXITE PROCESSING
                            UNLOADING ORE FROM SHIP
NUMBER OF TESTS:   1, after venturi scrubber control
STATISTICS:   Aerodynamic particle diameter (urn):         2.5      6.0    10.0

                 Mean (Cum. %):                         60.5     67.0    70.0
                 Standard deviation (Cum.  %):
                 Min (Cum. %):
                 Max (Cum. %):
TOTAL PARTICULATE EMISSION FACTOR:   0.004 kg particulate/Mg bauxite ore unloaded
after scrubber control.  Factor calculated from emission and process data
contained in reference.
SOURCE OPERATION:   The facility purifies bauxite to alumina.   Ship  unloading
facility normally operates at 1500-1700 tons/hr, using a self  contained
extendable boom conveyor that interfaces with a dockside conveyor belt  through
an accordion chute.  The emissions originate at the point of  transfer of  the
bauxite ore from the ship's boom conveyer as the ore drops through  the  the
chute onto the dockside conveyer.  Emissions are ducted to a  dry  cyclone  and
then to a Venturi scrubber.  Design pressure drop across scrubber is  15 inches,
and efficiency during test was 98.4 percent.
SAMPLING TECHNIQUE:   Andersen Impactor
EMISSION FACTOR RATING:  E
REFERENCE:

       Emission Test Report,  Reynolds  Metals  Company,  Corpus  Christi,  TX,  EMB-
       80-MET-9,  U. S. Environmental Protection Agency,  Research  Triangle  Park,
       NC,  May 1980.
 10/86                               Appendix C.I                         C.l-59
-------
                    7.13   STEEL FOUNDRIES:  CASTINGS SHAKEOUT
        ^9.99
        99.9
         99

         98
       g
         90
      T)
      V
      4_l
      to 8°
      JJ
      CO
      V

       §
70

60

50




30

20



10
         0.1
        0.01
                                           UNCONTROLLED
                                       —•—  Weight percent
                                       	  Emission factor
                                                                 15
                                                                    M
                                                                    S
                                                                    H-
                                                                    CD
                                                                    CO
                                                                    H-
                                                                    O
                                                                          10
                                                                             O
                                                                             rr
                                                                             O
                           3   4   56789 10        20

                                Particle diameter, urn
                                                        30  40 50  60 70 80 90 100
Aerodynamic
particle
diameter, urn
2.5
6.0
10.0
Cumulative wt . % < stated size
Uncontroll ed
72.2
76.3
82.0
Emission factor, kg/Mg
Uncontroll ed
11.6
12.2
13.1
C.l-60
                            EMISSION  FACTORS
10/86
-------
                   7.13  STEEL FOUNDRIES:   CASTINGS SHAKEOUT
NUMBER OF TESTS:   2, conducted at castings shakeout  exhaust  hood  before  controls
STATISTICS:  Aerodynamic particle diameter (urn):         2.5     6.0    10.0

                 Mean (Cum. %):                         72.2    76.3    82.0
                 Standard deviation (Cum.  %):            5.4     6.9     4.3
                 Min (Cum. %):                          66.7    69.5    77.7
                 Max (Cum. %):                          77.6    83.1    86.3
TOTAL PARTICULATE EMISSION FACTOR:   16 kg particulate/Mg metal  melted,  without
controls.  Although no nonfurnace emission factors  are available  for  steel
foundries, emissions are presumed to be similar to  those in iron  foundries.
Nonfurnace emission factors for iron foundries are  presented in AP-42.
SOURCE OPERATION:  Source is a steel foundry casting steel  pipe.   Pipe  molds
are broken up at the castings shakeout operation.   No additional  information  is
available.
SAMPLING TECHNIQUE:   Brinks Model BMS-11 Impactor
EMISSION FACTOR RATING:  D
REFERENCE:

       Emission test data from Environmental  Assessment  Data Systems,  Fine
       Particle Emission Information System,  Series  Report  No.  117,  U.  S. Envi-
       ronmental Protection Agency,  Research  Triangle Park,  NC, June 1983.
10/86                             Appendix C.I                           C.l-61
-------
                     7.13 STEEL FOUNDRIES:   OPEN HEARTH  EXHAUST
       0)
       N
       0>
       JJ
       cd
       4J
       CO

       V
          99. S
          99.9
    99


    98



    95



    90



    80


    70


    60


    50
M   30


    20


01
       g
       (0
       §
       u
    10






    2

    1


    0.5



    0.1





   0.01
                          UNCONTROLLED
                         - Weight  percent
                         -  Emission  factor
                          CONTROLLED
                         - Weight  Percent
                         •  Emission  factor
                                                                            - 8.0
                                                                              7.0
                                                                             6.0
                                                5.0
                                                    g

                                                                                 i-h

                                                                                 O
                                                                             4.0  rt
                                                                                 O
                                                                                 0X3
                                                                             3.0
                                                0.5



                                                0.4



                                                0.3



                                                0.2



                                                0.1


 	 0.0

3  4   5  6  7  8 9 10        20    30  40 50 60 70 80 90 100


      Particle  diameter,  urn
Aerodynamic
particle
diameter, um
2.5
6.0
10.0
Cumulative wt . % < stated size
Uncontrolled
79.6
82.8
85.4
ESP
49.3
58.6
66.8
Emission Factor (kg/Mg)
Uncontrolled
4.4
4.5
4.7
ESP
0.14
0.16
0.18
C.l-62
                            EMISSION FACTORS
                                                                                 10/86
-------
                   7.13 STEEL FOUNDRIES:  OPEN HEARTH EXHAUST
NUMBER OF TESTS:  a)  1, conducted before control
                  b)  1, conducted after ESP control
STATISTICS: a) Aerodynamic particle diameter (urn):    2.5     6.0    10.0

                   Mean (Cum. %):                   79.6    82.8    85.4
                   Standard Deviation (Cum. %):
                   Min (Cum. %):
                   Max (Cum. %):

            b) Aerodynamic particle diameter (urn):    2.5     6.0    10.0

                   Mean (Cum. %):                   49.3    58.6    66.8
                   Standard Deviation (Cum. %):
                   Min (Cum. %):
                   Max (Cum. %):
TOTAL PARTICULATE EMISSION FACTOR:  5.5 kg particulate/Mg metal processed,
before control.  Emission factor from AP-42.  AP-42 gives an ESP control
efficiency of 95 to 98.5%.  At 95% efficiency, factor after ESP control is
0.275 kg particulate/Mg metal processed.
SOURCE OPERATION:   Source produces steel castings by melting,  alloying,  and
casting pig iron and steel scrap.  During these tests, source was operating at
100% of rated capacity of 8260 kg metal scrap feed/hour, fuel  oil fired,  and 8
hour heats.
SAMPLING TECHNIQUE:  a)  Joy train with 3 cyclones
                     b)  Sass train with cyclones
EMISSION FACTOR RATING:  E
REFERENCE:

       Emission test data from Environmental Assessment Data Systems,  Fine Par-
       ticle Emission Information System,  Series Report No.  233,  U.  S.  Environ-
       mental Protection Agency, Research Triangle Park, NC, June 1983.
10/86                                Appendix C.I                       C.l-63
-------
                  7.15   STORAGE BATTERY PRODUCTION:   GRID CASTING
11. It
99.9
99
98
95
0)
N
•* 90
00
"S 8°
JJ
(0
£J 70
CO
60
V
M 50
•£ 40
•H1 30
0)
3 20
0)
IJ 10
Q)
2 5
O
2
1
0.5

0.1


0. 01
/
/
/
/
/
/
» /
^
_

^ .^» <^B .^ —
^ ^
^s
_^x
- S
'
.

-



.

_
-
-
UNCONTROLLED
— •— Weight percent
	 Emission factor

2 3 4 5 6 7 8 9 10 20 30 40 50 60 70 80 90

2.0






1.5









1.0






0.5




0
100
                                                                             01
                                                                             CO
                                                                             H)
                                                                             Pi
                                                                             It
                                                                             O
                                                                             cr
                                                                             0>
                                                                             
                                                                             09
                                Particle diameter,  um
Aerodynamic
particle
diameter (um)
2.5
6.0
10.0
Cumulative wt. % < stated size
Uncontrolled
87.8
100
100
Emission factor
(kg/103 batteries)
Uncontrolled
1.25
1.42
1.42
C.l-64
                                 EMISSION FACTORS
10/86
-------
                7.15  STORAGE BATTERY PRODUCTION:  GRID CASTING
NUMBER OF TESTS:  3, conducted before control
STATISTICS:  Aerodynamic particle diameter (urn):        2.5     6.0   10.0

                 Mean (Cum. %):                        87.8   100    100
                 Standard deviation (Cum. %):          10.3
                 Min (Cum. %):                         75.4   100    100
                 Max (Cum. %):                        100     100    100
      Impactor cut points were so small that most data points had to be
extrapolated.
TOTAL PARTICULATE EMISSION FACTOR:  1.42 kg particulate/103 batteries
produced, without controls.  Factor from AP-42.


SOURCE OPERATION:  During tests, plant was operated at 39% of design process
rate.  Six of nine of the grid casting machines were operating during the test,
Typically, 26,500 to 30,000 pounds of lead per 24 hour day are charged to the
grid casting operation.
SAMPLING TECHNIQUE:    Brinks Impactor
EMISSION FACTOR RATING:  E
REFERENCE:

    Air Pollution Emission Test, Globe Union, Inc., Canby, OR, EMB-76-BAT-4,
    U. S. Environmental Protection Agency, Research Triangle Park, NC,
    October 1976.
10/86                             Appendix C.I                           C.l-65
-------
           7.15  STORAGE BATTERY  PRODUCTION:   GRID CASTING AND PASTE MIXING
            99.99
         N
         •H
         00

         •O
         4J
         03
         V
         .C
         W)
         •H
         
-------
        7.15  STORAGE BATTERY PRODUCTION:  GRID CASTING AND PASTE MIXING
NUMBER OF TESTS:  3, conducted before control


STATISTICS:  Aerodynamic particle diameter (urn):      2.5     6.0    10.0

                 Mean (Cum. %):                      65.1    90.4   100
                 Standard deviation (Cum. %):        24.8     7.4
                 Min (Cum. %):                       44.1    81.9   100
                 Max (Cum. %):                      100     100     100


TOTAL PARTICULATE EMISSION FACTOR:  3.38 kg particulate/103 batteries,
without controls.  Factor is from AP-42, and is the sum of the individual
factors for grid casting and paste mixing.


SOURCE OPERATION:  During tests, plant was operated at 39% of the design
process rate.  Grid casting operation consists of 4 machines.  Each 2,000 Ib/hr
paste mixer is controlled for product recovery by a separate low energy impinge-
ment type wet collector designed for an 8 - 10 inch w. g. pressure drop at
2,000 acfm.


SAMPLING TECHNIQUE:  Brinks Impactor
EMISSION FACTOR RATING:
REFERENCE:

    Air Pollution Emission Test, Globe Union, Inc., Canby, OR, EKB-76-BAT-4,
    U. S. Environmental Protection Agency, Research Triangle Park, NC,
    October 1976.
10/86                             Appendix C.I                           C.l-67
-------
               7.15   STORAGE  BATTERY  PRODUCTION:   LEAD OXIDE MILL
99.9

99
98
95
OJ
N
•H 90
CO

V 80
(0
W 70
CO
V 60

^ 50
4j 40
M
•H 30
* 20

>
•H
J-) 10
M
B 5
g
O
2
1

0.5

0.1

0.01
1

Aerodynamic
particle
diameter (ui
2.5
6.0
10.0



-
f
1
^ i
/
1
i P
I /
/ /
//
^*
" S*
;/ 1
/s .
,/ /
/
f

/
/
/
/









• i i i i i i i i
2 3 4 56789 10
Particle diamet«
Cumulative wt. % < stated size

n) After fabric filter
32.8
64.7
83.8

-



-








—







—






—

CONTROLLED
-•— Weight percent
— Emission factor

20 30 40 50 60 70 80 90
>r, urn
Emission factor
(kg/103 batteries)
After fabric filtei
0.016
0.032
0.042

0.05


9
0.0* »
H*
o
o
f-tl
0>
rt
O
1
0.03 "
;«r
«
o
Co
cr
o>
rf
0.02 n
i*
n>
CO




0.01




o
100







C.l-68
EMISSION FACTORS
10/86
-------
               7.15  STORAGE BATTERY PRODUCTION:  LEAD OXIDE MILL
NUMBER OF TESTS:  3, conducted after fabric filter


STATISTICS:  Aerodynamic particle diameter (urn):        2.5     6.0   10.0

                 Mean (Cum. %):                        32.8    64.7   83.8
                 Standard deviation (Cum. %):          14.1    29.8   19.5
                 Min (Cum. %):                         17.8    38.2   61.6
                 Max (Cum. %):                         45.9    97.0  100


TOTAL PARTICULATE EMISSION FACTOR:  0.05 kg particulate/103 batteries, after
typical fabric filter control (oil to cloth ratio of 4:1).  Emissions from a
well controlled facility (fabric filters with an average air to cloth ratio of
3:1) were 0.025 kg/103 batteries (Table 7.15-1 of AP-42).


SOURCE OPERATION: Plant receives metallic lead and manufactures lead oxide by
the ball mill process.  There are 2 lead oxide production lines, each with a
typical feed rate of 15 one hundred pound lead pigs per hour.  Product is
collected with a cyclone and baghouses with 4:1 air to cloth ratios.
SAMPLING TECHNIQUE:  Andersen Impactor
EMISSION FACTOR RATING:  E
REFERENCE:

     Air Pollution Emission Test, ESB Canada Limited, Mississouga, Ontario,
     EMB-76-BAT-3, U. S. Environmental Protection Agency, Research Triangle
     Park, NC, August 1976.
10/86                             Appendix C.I                           C.l-69
-------
     7.15   STORAGE BATTERY PRODUCTION:   PASTE MIXING & LEAD OXIDE CHARGING
          99.99
          99.9
       N
       i-l
       00
       73
       0)
       V
       JJ
       bC
       •H
       SI
       §1
       JJ   10
                                                    UNCONTROLLED
                                                  • • Weight  percent
                                                	 Emission factor
                                                    CONTROLLED
                                                 —•—Weight  percent
          0.01
                           3   4   56789 10        20

                                Particle  diameter,  urn
                           40 50  60 70 80 90 100
Aerodynamic
particle
diameter (um)
2.5
6.0
10.0
Cumulative wt. % < stated size
Uncontrolled
80
100
100
Fabric filter
47
87
99
Emission factor
(kg/103 batteries)
Uncontrolled
1.58
1.96
1.96
C.l-70
EMISSION FACTORS
10/86
-------
     7.15  STORAGE BATTERY PRODUCTION:  PASTE MIXING & LEAD OXIDE CHARGING
NUMBER OF TESTS:  a)  1, conducted before control
                  b)  4, conducted after fabric filter control
STATISTICS:  a)  Aerodynamic particle diameter (urn):    2.5     6.0   10.0

                     Mean (Cum. %):                    80     100    100
                     Standard deviation (Cum. %):
                     Min (Cum. %):
                     Max (Cum. %):

             b)  Aerodynamic particle diameter (urn):    2.5     6.0   10.0

                     Mean (Cum. %):                    47      87     99
                     Standard deviation (Cum. %):      33.4    14.5    0.9
                     Min (Cum. %):                     36      65     98
                     Max (Cum. %):                    100     100    100
     Impactor cut points were so small that many data points had to be extra-
polated.  Reliability of particle size distributions based on a single test
is questionable.


TOTAL PARTICULATE EMISSION FACTOR:  1.96 kg particulate/103 batteries,
without controls.  Factor from AP-42.
SOURCE OPERATION:  During test, plant was operated at 39% of the design
process rate.  Plant has normal production rate of 2,400 batteries per day and
maximum capacity of 4,000 batteries per day.  Typical amount of lead oxide
charged to the mixer is 29,850 lb/8 hour shift.  Plant produces wet batteries,
except formation is carried out at another plant.


SAMPLING TECHNIQUE:  a)  Brinks Impactor
                     b)  Andersen
EMISSION FACTOR RATING:
REFERENCE:

    Air Pollution Emission Test, Globe Union, Inc., Canby, OR, EMB-76-BAT-4,
    U. S. Environmental Protection Agency, Research Triangle Park, NC,
    October 1976.
10/86                                Appendix C.I                        C.l-71
-------
               7.15   STORAGE  BATTERY PRODUCTION:   THREE PROCESS OPERATION
            99.99
             99.9
    99


    98



    95
         01
         N
         T)
         01   80
•M   70


\y   60


X   50


£   40

bO
•H   30


*   20
          ifl

          3
    10







     2


     1


    0.5




    0.1






    0.01
                                                        UNCONTROLLED

                                                     —•—Weight  percent
                                                      	Emission factor
                                                                          lkl
                                                                                AS
                                                                                40
                                                                                35
                                                                                    w
  w
  CO
  H-
  O
  9

  l-h
  Pi
  O
  ft
  O
  f(
                                                                                   Jf
                                                                                    CT-
                                                                                    0)
                                                                                    ft
                                                                                    (T
                                                                                    (D
  (D
  CO
                               3   4   56789 10        20

                                    Particle diameter, urn
                                                                                30

                                                              30   40  50 60 70 80 90 100
Aerodynamic
particle
diameter (um)
2.5
6.0
10.0
Cumulative wt. % < stated size
Uncontrolled
93.4
100
100
Emission factor
(kg/103 batteries)
Uncontrolled
39.3
42
42
C.l-72
                          EMISSION FACTORS
10/86
-------
           7.15  STORAGE BATTERY PRODUCTION:   THREE PROCESS OPERATION
NUMBER OF TESTS:       3, conducted before control
STATISTICS:    Aerodynamic particle diameter (urn):     2.5     6.0   10.0

                   Mean (Cum. %):                     93.4   100    100
                   Standard deviation (Cum. %):        6.43
                   Min (Cum. %):                      84.7
                   Max (Cum. %):                     100
      Impactor cut points were so small that data points had to be
extrapolated.
TOTAL PARTICULATE EMISSION FACTOR:  42 kg particulate/103 batteries, before
controls.  Factor from AP-42.
SOURCE OPERATION:  Plant representative stated that the plant usually operated
at 35% of design capacity.  Typical production rate is 3,500 batteries per day
(dry and wet), but up to 4,500 batteries per day can be produced.   This is
equivalent to normal and maximum daily element production of 21,000 and 27,000
battery elements, respectively.
SAMPLING TECHNIQUE:  Brinks Impactor
EMISSION FACTOR RATING:  E
REFERENCE:

    Air Pollution Emission Test, ESB Canada Limited, Mississouga, Ontario,
    EMB-76-BAT-3, U. S. Environmental Protection Agency, Research Triangle
    Park, NC, August 1976.
10/86                             Appendix C.I                           C.l-73
-------
                                   7.xx  BATCH TINNER
           99.99
            99.9
             99


             98
0>
N
•H
CO


•o
CD
             90
          CD  80
          j_i


             70
             50
          CU
          I*  30


          gl  20
          •H
          U

          CO
          .H  10




          j.
             2


             1


            0.5





            0.1








            0.01
                                                UNCONTROLLED

                                           —•—  Weight percent

                                           	  Emission factor
                                                                                 2.0
w
a
H.
CO
CO
H-
o
o

H>
V
o
rr
O
                                                                           TO
                                                                       1.0
                                                                        0.0
                               3   4   56789 10        20


                                    Particle diameter, um
                                                              30   40  50  60 70 80 90 IOC
Aerodynamic
particle
diameter, um
2.5
6.0
10.0
Cumulative wt. % < stated size
Uncontrolled
37.2
45.9
55.9
Emission factor, kg/Mg
Uncontrolled
0.93
1.15
1.40
C.l-74
                             EMISSION FACTORS
                                                                                   10/86
                                                                                               I
-------
                               7.xx  BATCH TINNER
NUMBER OF TESTS:  2, conducted before controls
STATISTICS:  Aerodynamic particle diameter (urn):         2.5     6.0   10.0

                 Mean (Cum. %):                         37.2    45.9   55.9
                 Standard deviation (Cum. %):
                 Min (Cum. %):
                 Max (Cum. %):
TOTAL PARTICULATE EMISSION FACTOR:   2.5 kg particulate/Mg tin consumed,  without
controls.  Factor from AP-42, Section 7.14.
SOURCE OPERATION:  Source is a batch operation applying a lead/tin coating to
tubing.  No further source operating information is available.
SAMPLING TECHNIQUE:   Andersen Mark III Impactor



EMISSION FACTOR RATING: D



REFERENCE:

       Confidential  test data, PEI Associates,  Inc., Golden,  CO,  January 1985.
 10/86                            Appendix C.I                              C.l-75
-------
                           8.9   COAL CLEANING:   DRY PROCESS
          99.99
           99.9
    99


    98




N   95
•H
CO

•a   90
0)

CO   80

CO
        V
        t>0
        •H
        01
        i
    70


    60


    50





    30







    10




    5



    2


    1


    0.5





    0.1







   0.01
                                                          CONTROLLED
                                                    —•—  Weight  percent
                                                    	  Emission factor
                                                                                0.004
                                                                                0.003
                                                                                     w
                                                                                     GO
                                                                                     CO
O
3
                                                                                     H)


                                                                                     O
O
i-l
                                                                                0.002
                                                                                     TO
                                                                                0.001
                                                                                0.00
                                     5  6 7 8 9 10        20


                                    Particle diameter,  urn
                                                             30
                                                                 40 50  60 70 80 90 100
Aerodynamic
particle
diameter, urn
2.5
6.0
10.0
Cumulative wt. % < stated size
After fabric filter control
16
26
31
Emission factor, kg/Mg
After fabric filter control
0.002
0.0025
0.003
C.l-76
                             EMISSION FACTORS
                                                                                   10/86
-------
                        8.9 COAL CLEANING:   DRY PROCESS
NUMBER OF TESTS:   1, conducted after fabric filter control
STATISTICS:     Aerodynamic particle diameter (urn):   2.5        6.0        10.0

                    Mean (Cum. %):                   16         26          31
                    Standard deviation (Cum.  %):
                    Min (Cum. %):
                    Max (Cum. %):


TOTAL PARTICULATE EMISSION FACTOR:   0.01 kg particulate/Mg of coal processed.
Emission factor is calculated from data in AP-42,  assuming 99% particulate
control by fabric filter.
SOURCE OPERATION:  Source cleans coal with the dry (air table)  process.
Average coal feed rate during testing was 70 tons/hr/table.
SAMPLING TECHNIQUE:   Coulter counter
EMISSION FACTOR RATING:  E
REFERENCE:

       R. W. Kling,  Emissions from the Florence Mining Company Coal Process-
       ing Plant at  Seward, PA, Report No. 72-CI-4,  York Research Corporation,
       Stamford, CT, February 1972.
10/86                             Appendix C.I                           C.l-77
-------
                    SECTION 8.9  COAL  CLEANING:  THERMAL DRYER
       N

       CO

      T3
       01

       cd
       u
       W

      V
      J3


       0)
       §
       u
         99.9
          99


          98
90




80



70


60


50


40


30


20




10
          0.5
          0.1
         0.01
                                           UNCONTROLLED

                                          - Weight  percent

                                          - Emission factor

                                           CONTROLLED

                                          - Weight  percent
                                                                           5.0
   w
   3
   H-
   CO
   CO

   o
   3

   Hi
3.0 0)
   o
                                                                              £
                                                                           1.0
                                                                            0.0
                                  5  6  7  8 9 10       20    30


                                 Particle  diameter,  urn
                                                             40  50 60 70 80 90 100
Aerodynamic
particle
diameter, um
2.5
6.0
10.0
Cumulative wt . % < stated size
Uncontrolled
42
86
96
After
wet scrubber
53
85
91
Emission factor, kg/Mg
Uncontrolled
1.47
3.01
3.36
After
wet scrubber
0.016
0.026
0.027
C.l-78
                         EMISSION FACTORS
                                                                               10/86
-------
                   SECTION 8.9 COAL CLEANING:  'THERMAL DRYER
NUMBER OF TESTS:   a)  1,  conducted before control
                  b)  1,  conducted after wet scrubber control
STATISTICS:   a) Aerodynamic particle diameter (urn):   2.5         6.0         10.0

                    Mean (Cum. %):                   42         86           96
                    Standard deviation (Cum.  %):
                    Min (Cum. %):
                    Max (Cum. %):

             b) Aerodynamic particle diameter (urn):   2.5         6.0         10.0

                    Mean (Cum. %):                   53         85           91
                    Standard deviation (Cum.  %):
                    Min (Cum. %):
                    Max (Cum. %):
TOTAL PARTICULATE EMISSION FACTOR:   3.5 kg particulate/Mg of  coal  processed,
(after cyclone) before wet scrubber control.  After wet scrubber control,  0.03
kg/Mg.  These are site specific emission factors and are calculated  from process
data measured during source testing.
SOURCE OPERATION:   Source operates a thermal dryer to dry coal  cleaned  by  wet
cleaning process.   Combustion zone in the thermal  dryer is about  1000°F, and
the air temperature at the dryer exit is about 125°F.  Coal processing  rate is
about 450 tons per hour.  Product is collected in cyclones.
SAMPLING TECHNIQUE:   a)  Coulter counter
                     b)  Each sample was dispersed with aerosol  OT,  and  further
                         dispersed using an ultrasonic bath.   Isoton was the
                         electrolyte used.
EMISSION FACTOR RATING: E


REFERENCE:

       R. W. Kling, Emission Test Report, Island Creek Coal  Company  Coal  Pro-
       cessing Plant, Vansant, Virgina, Report No.  Y-7730-H,  York Research
       Corporation, Stamford, CT, February 1972.


 10/86                            Appendix C.I                           C.l-79
-------
                    8.9   COAL PROCESSING:  THERMAL INCINERATOR
        rt.99
         99.9
   99

   98



N  95
•H
CO

^  90
0)
4J

5  80
CO
       V
          70
          60
       bC
          40
       •*  30


       SI  20
       •H  10



       0  5



          2


          1


          0.5




          0.1






         0.01
                   UNCONTROLLED
                —•— Weight percent
                	 Emission  factor
                   CONTROLLED
                 •  Weight percent
                                                                           0.4
                                            CO
                                            CO
                                            H-
                                            O
                                            CJ

                                            l-h
                                            CB
                                            O
                                            rt
                                            O
                                            H
                                                                               0
                                                                           0.2
                               4   5 6 7 8 9 10        20    30


                                 Particle diameter,  urn
                                         o.o
                                                             40 50  60 70 80 90 100
Aerodynamic
particle
diameter, urn
2.5
6.0
10.0
Cumulative wt . % < stated size
Uncontrolled
9.6
17.5
26.5
Cyclone
controlled
21.3
31.8
43.7
Emission factor, kg/Mg
Uncontrolled
0.07
0.12
0.19
C.l-80
EMISSION FACTORS
                                                                                10/86
-------
                   8.9  COAL PROCESSING:  THERMAL INCINERATOR
NUMBER OF TESTS:  a)  2, conducted before controls
                  b)  2, conducted after multicyclone control
STATISTICS:   a) Aerodynamic particle diameter (urn):    2.5     6.0   10.0

                     Mean (Cum. %):                     9.6    17.5   26.5
                     Standard deviation (Cum. %):
                     Min (Cum. %):
                     Max (Cum. % ):

              b) Aerodynamic particle diameter (urn):    2.5     6.0   10.0

                     Mean (Cum. %):                    26.4    35.8   46.6
                     Standard deviation (Cum. %):
                     Min (Cum. %):
                     Max (Cum. %):
TOTAL PARTICULATE EMISSION FACTOR:  0.7 kg particulate/Mg coal dried, before
multiclone control.  Factor from AP-42.
SOURCE OPERATION:  Source is a thermal incinerator controlling gaseous emissions
from a rotary kiln drying coal.  No additional operating data are available.


SAMPLING TECHNIQUE:  Andersen Mark III Impactor
EMISSION FACTOR RATING:  D
REFERENCE:

       Confidential test data from a major coal processor, PEI Associates,  Inc.,
       Golden, CO, January 1985.
10/86                             Appendix C.I                           C.l-81
-------
                    8.18  PHOSPHATE ROCK PROCESSING:   CALCINER
       cu
       N
       •O
       
0.050 0>
    O
    ft
    O
    n
    ff
                                                                          0.025
                           3   4   5 6 7  8 9 10       20     30  40 50  60 70 80 90 100


                                Particle diameter, urn
Aerodynamic
particle
diameter, urn
2.5
6.0
10.0
Cumulative wt. % < stated size
After cyclone3 and
wet scrubber
94.0
97.0
98.0
Emission factor, kg/Mg
After cyclone3 and
wet scrubber
0.064
0.066
0.067
3Cyclones  are typically used  in phosphate rock  processing as product collectors.

 Uncontrolled emissions are emissions in the air  exhausted from  such cyclones.
C.l-82
                        EMISSION FACTORS
   10/86
-------
                   8.18  PHOSPHATE ROCK PROCESSING:  CALCINER
      NUMBER OF TESTS:  6, conducted after wet scrubber control
      STATISTICS:  Aerodynamic particle diameter (urn):        2.5    6.0   10.0

                       Mean (Cum. %):                        94.0   97.0   98.0
                       Standard deviation (Cum. %):            2.5    1.6    1.5
                       Min (Cum. %):                         89.0   95.0   96.0
                       Max (Cum. %):                         98.0   99.2   99.7
      TOTAL PARTICULATE EMISSION FACTOR:  0.0685 kg particulate/Mg of phosphate
      rock calcined, after collection of airborne product in a cyclone, and wet
      scrubber controls.  Factor from reference cited below.
      SOURCE OPERATION:   Source is a phosphate rock calciner fired with #2 oil,
      with a rated capacity of 70 tons/hour.  Feed to the calciner Is beneficiated
      rock.
      SAMPLING TECHNIQUE:  Andersen Impactor.
      EMISSION FACTOR RATING:  C
      REFERENCE:   Air Pollution Emission Test, Beker Industries, Inc., Conda, ID,
      EMB-75-PRP-4, U. S. Environmental Protection Agency, Research Triangle Park,
      NC, November 1975.
10/86                                Appendix C.I                        C.l-83
-------
            8.18 PHOSPHATE ROCK PROCESSING:   OIL FIRED ROTARY AND
                         FLUIDIZED BED TANDEM DRYERS
99.9
99
98
95
<0
N
i-t 90
00

01 80
JJ
CD
i-> 70
CO
v 6°

*« 50
4J 40
bC
•H 30

•H
JJ 10
(0
3 ,
B 5
O
2
I
0.5

0.1

0. 01
1
-

-
"

^^^*
^^^"^
m m^^
^S^
^^^^^ ^ '
^^^^^ s
W*^ s
^
^
^ -*
""^ —m










-



WET SCRUBBER AND ESP
— •— Weight percent
	 Emission factor

2 3 4 5 6 7 8 9 10 20 30 40 50 60 70 80 90


0.015




M
0
H*
co
CO

o
0
l-t(
0.010 0)
O
o
,r

^
0?




.005






o
100
                             Particle diameter, um
Aerodynamic
particle
diameter, um
2.5
6.0
10.0
Cumulative wt. % < stated size
After wet scrubber and
ESP control
78.0
88.8
93.8
Emission factor, kg/Mg
After wet scrubber and
ESP control
0.010
0.011
0.012
                                                                                 I
C.l-84
EMISSION FACTORS
10/86
-------
                        8.18 PHOSPHATE ROCK PROCESSING:
                OIL FIRED ROTARY AND FLUIDIZED BED TANDEM DRYERS
 NUMBER OF TESTS:  2, conducted after wet scrubber and electrostatic pre-
                      clpitator control
 STATISTICS:  Aerodynamic particle diameter (urn):    2.5       6.0        10.0

                  Mean (Cum. %):                    78.0      88.8        93.8
                  Standard deviation (Cum. %):      22.6       9.6         2.5
                  Min (Cum. %):                     62        82          92
                  Max (Cum. %):                     94        95          95
 TOTAL PARTICULATE EMISSION FACTOR:  0.0125 kg particulate/Mg phosphate rock
 processed, after collection of airborne product in a cyclone and wet scrubber/
 ESP controls.  Factor from reference cited below.
 SOURCE OPERATION:  Source operates a rotary and a fluidized bed dryer to dry
 various types of phosphate rock.  Both dryers are fired with No. 5 fuel oilv
 and exhaust into a common duct.  The rated capacity of the rotary dryer is
 300 tons/hr, and that of the fluidized bed dryer is 150-200 tons/hr.  During
 testing, source was operating at 67.7% of rated capacity.
 SAMPLING TECHNIQUE:  Andersen Impactor
 EMISSION FACTOR RATING:  C
 REFERENCE:  Air Pollution Emission Test, W. R. Grace Chemical Company, Bartow,
 FL, EMB-75-PRP-1, U. S. Environmental Protection Agency, Research Triangle
 Park, NC, January 1976.
10/86                             Appendix C.I                           C.l-85
-------
             8.18  PHOSPHATE ROCK  PROCESSING:   OIL FIRED ROTARY DRYER
       N
       •H
       CO

       T3
       0)
       u
       n)
       4J
       CO

       V
       be
       •H
       
-------
              8.18 PHOSPHATE ROCK PROCESSING:   OIL  FIRED  ROTARY DRYER


  NUMBER OF TESTS:   a)   3,  conducted  after  cyclone
                    b)   2,  conducted  after  wet  scrubber control


  STATISTICS:  a)  Aerodynamic particle diameter  (urn):   2.5        6.0         10.0

                     Mean (Cum.  %):                   15.7       41.3         58.3
                     Standard deviation  (Cum. %):      5.5        9.6         13.9
                     Min (Cum.  %):                    12          30           43
                     Max (Cum.  %):                    22          48           70

              b)  Aerodynamic particle diametet  (urn):   2.5        6.0         10.0

                     Mean (Cum.  %):                   89.0       92.3         96.6
                     Standard Deviation  (Cum. %):      7.1        6.0          3.7
                     Min (Cum.  %):                    84          88           94
                     Max (Cum.  %):                    94          96           99
  Impactor  cut  points  for  the  tests  conducted  before  control  are  small,  and
  many  of  the  data points  are  extrapolated.  These  particle size  distributions
  are related  to  specific  equipment  and  source operation,  and are most appli-
  cable to  particulate emissions  from  similar  sources operating similar  equip-
  ment.  Table  8.18-2, Section 8.18, AP-42  presents particle  size distributions
  for generic phosphate rock dryers.


  TOTAL PARTICULATE EMISSION FACTORS:  After cyclone, 2.419 kg particulate/Mg
  rock  processed.   After wet scrubber  control, 0.019  kg/Mg.   Factors  from
  reference cited below.
  SOURCE  OPERATION:   Source  dries  phosphate  rock  in  #6  oil  fired  rotary  dryer.
  During  these  tests, source  operated  at  69%  of  rated dryer  capacity  of 350  ton/
  day,  and processed coarse  pebble rock.


  SAMPLING TECHNIQUE:   a)  Brinks  Cascade  Impactor
                       b)  Andersen Impactor
  EMISSION FACTOR RATING:   D
  REFERENCE:   Air  Pollution  Emission  Test,  Mobil  Chemical,  Nichols,  FL, EMB-75-
  PRP-3,  U.  S.  Environmental Protection  Agency, Research  Triangle  Park, NC,
  January 1976.
10/86                              Appendix  C.I                          C.l-87
-------
                   8.18  PHOSPHATE  ROCK PROCESSING:   BALL MILL
 CU
 N
 •H
 CO





 CO

 CO

V

fr*




§
 CU


 CU

•H
J_l
 CO

3
          99.9
           99.9
99


98



95



90



80



70


60


50


40


30


20
           0.1
          0.01
                                                 CYCLONE
                                            • • Weight percent
                                           	Emission factor
                                                                           0.4
                                                                               w
                                                                               co
                                                                               CO
                                                                               l-h
                                                                               P)
                                                                               O
                                                                               ft
                                                                               O
                                                                               i-l
                                                                               ff
                                                                           0.2
                        4   5 6 7 8 9 10        20

                         Particle  diameter, um
                                                         30   40  50  60 70 80 90 100
Aerodynamic
particle
diameter, um
2.5
6.0
10.0
Cumulative wt. % < stated size
After cyclone3
6.5
19.0
30.8
Emission factor, kg/Mg
After cyclone3
0.05
0.14
0.22
3Cyclones  are  typically used  in phosphate rock  processing as product collectors.
 Uncontrolled  emissions are emissions in the  air exhausted from such cyclones.
   i — £
  • -L  C
                          EMISSION FACTORS
                                                                   10/86
-------
                     8.18  PHOSPHATE ROCK PROCESSING:  BALL MILL
      NUMBER OF TESTS:  4, conducted after cyclone
      STATISTICS:  Aerodynamic particle diameter (urn):        2.5    6.0   10.0

                       Mean (Cum. %):                         6.5   19.0   30.8
                       Standard deviation (Cum. %):           3.5    0.9    2.6
                       Min (Cum. %):                           3     18     28
                       Max (Cum. %):                          11     20     33
      Impactor outpoints were small, and most data points were extrapolated.


      TOTAL PARTICULATE EMISSION FACTOR:  0.73 kg particulate/Mg of phosphate rock
      milled, after collection of airborne product in cyclone.  Factor from
      reference cited below.
      SOURCE OPERATION:  Source mills western phosphate rock.  During testing^
      source was operating at 101% of rated capacity, producing 80 tons/hour.
      SAMPLING TECHNIQUE:   Brinks Impactor
      EMISSION FACTOR RATING:  C
      REFERENCE:  Air Pollution Emission Test, Beker Industries, Inc., Conda, ID,
      EMB-75-PRP-4, U. S. Environmental Protection Agency, Research Triangle
      Park, NC, November 1975.
10/86                                Appendix C.I                        C.l-89
-------
        8.18  PHOSPHATE ROCK PROCESSING:   ROLLER MILL AND BOWL MILL GRINDING
            99.99
          V
          N
          •H
          «0
          CO

          V
            99.9
99

98


95


90


80

70

60

50

40
          $  30
          V
          01

          •H
          4J
          «t
          — I

          I
          o
 20


 10


 5


 2

 1

 0.5



 0.1




0.01
                                 CYCLONE
                                >— Weight percent
                                --Emission factor
                                 CYCLONE AND FABRIC FILTER
                                I—Weight percent
                                                                            1.5
                                                                            1.0
                                                                    I
                                                                    CD
                                                                    01
                                                                    H-
                                                                    o
                                                                    o
                                                                                n
                                                                                rt
                                                                                o
                                                               0.5
                              3   *   5 6 7 8 9 10       20    30  40 50  60 70 80 90 100

                                  Particle diameter, um
Aerodynamic
particle
diameter, um
2.5
6.0
10.0
Cumulative wt. % < stated size
After
cyclone3
21
45
62
After fabric filter
25
70
90
Emission factor, kg/Mg
After
cyclone3
0.27
0.58
0.79
After fabric filter
Negligible
Negligible
Negligible
a Cyclones are  typically used in phosphate rock processing  as  product collectors.
  Uncontrolled  emissions are emissions  in the air exhausted from such cyclones.
   C.l-90
                                   EMISSION FACTORS
                                                                               10/86
-------
     8.18  PHOSPHATE ROCK PROCESSING:  ROLLER MILL AND BOWL MILL GRINDING
     NUMBER OF TESTS:  a)  2, conducted after cyclone
                       b)  1, conducted after fabric filter control
     STATISTICS: a) Aerodynamic particle diameter (urn):     2.5     6.0    10.0

                        Mean (Cum. %):                     21.0    45.0    62.0
                        Standard deviation (Cum. %):        1.0     1.0     0
                        Min (Cum. %):                      20.0    44.0    62.0
                        Max (Cum. %):                      22.0    46.0    62.0

                 b)  Aerodynamic particle diameter (urn):    2.5     6.0    10.0

                        Mean (Cum. %):                     25      70      90
                        Standard deviation (Cum. %):
                        Min (Cum. %):
                        Max (Cum. %):
     TOTAL PARTICULATE EMISSION FACTOR:  0.73 kg particulate/Mg of rock pro-
     cessed, after collection of airborne product in a cyclone.  After fabric
     filter control, 0.001 kg particulate/Mg rock processed.  Factors calculated
     from data in reference cited below.  AP-42 (2/80) specifies a range of
     emissions from phosphate rock grinders (uncontrolled).  See Table 8.18-1
     for guidance.
     SOURCE OPERATION:  During testing, source was operating at 100% of design
     process rate.  Source operates 1 roller mill with a rated capacity of 25
     tons/hr of feed, and 1 bowl mill with a rated capacity of 50 tons/hr of
     feed.  After product has been collected in cyclones, emissions from each
     mill are vented to a common baghouse.  Source operates 6 days/week, and
     processes Florida rock.
     SAMPLING TECHNIQUE:  a)  Brinks Cascade Impactor
                          b)  Andersen Impactor
     EMISSION FACTOR RATING:  D
     REFERENCE:  Air Pollution Emission Test, The Royster Company, Mulberry,
     FL, EMB-75-PRP-2, U. S. Environmental Protection Agency, Research Triangle
     Park, NC, January 1976.

10/86                               Appendix C.I                         C.l-91
-------
                  8.xx   NONMETALLIC MINERALS:   FELDSPAR  BALL MILL
         99.99
          99.9
           99


           98
         0) 95
         N
        •H
•O
0)
4-1
n>
4-1
CO

V
  90



  80


  70


  60

jj 50
fi
00 40
•H

•J 30

-------
                8.xx  NONMETALLIC MINERALS:   FELDSPAR BALL MILL
NUMBER OF TESTS:  2, conducted before controls
STATISTICS:  Aerodynamic particle diameter (urn):         2.5     6.0   10.0

                 Mean (Cum. %):                         11.5    22.8   32.3
                 Standard deviation (Cum. %):            6.4     7.4    6.7
                 Min (Cum. %):                           7.0    17.5   27.5
                 Max (Cum. %):                          16.0    28.0   37.0
TOTAL PARTICULATE EMISSION FACTOR:   12.9 kg particulate/Mg feldspar produced.
Calculated from data in reference and related documents.
SOURCE OPERATION:   After crushing and grinding of feldspar ore,  source produces
feldspar powder in a ball mill.
SAMPLING TECHNIQUE:   Alundum thimble followed by 12 inch section of stainless
steel probe followed by 47 mm type SGA filter contained in a stainless  steel
Gelman filter holder.  Laboratory analysis methods:  microsieve and electronic
particle counter.
EMISSION FACTOR RATING:  D
REFERENCE:

       Air Pollution Emission Test,  International  Minerals  and Chemical  Company,
       Spruce Pine, NC, EMB-76-NMM-1,  U. S.  Environmental Protection Agency,
       Research Triangle Park, NC, September 1976.
 10/86                            Appendix C.I                            C.l-93
-------
           8.xx  NONMETALLIC  MINERALS:   FLUORSPAR ORE  ROTARY DRUM DRYER

           99.99
           99.9
            99


            98
         OJ  95
         N
         00

         -O
          40


•J  30


5>  20
          cd
         o
            10
             i

            0.5
            0.1
           0.01
                       CONTROLLED
                       Weight  percent
                       Emission factor
                                                                               0.4
                                              w
                                              B
                                              H-
                                              cn
                                              09
                                              M.
                                              O
                                              B

                                              l-h
                                              to
                                              r>
                                              rt
                                              O
                                              "I
                                                                               0.2
                                  4   5 6  7 8 9 10       20    30

                                    Particle  diameter,  um
                                            0.0

                             40 50 60 70 80 90 100
Aerodynamic
particle
diameter, um
2.5
6.0
10.0
Cumulative wt. % < stated size
After fabric filter control
10
30
48
Emission factor, kg/Mg
After fabric filter control
0.04
0.11
0.18
C.l-94
EMISSION FACTORS
                                                                                  10/86
-------
         8.xx   NONMETALLIC MINERALS:   FLUORSPAR ORE ROTARY DRUM DRYER
NUMBER OF TESTS:  1, conducted after fabric filter control
STATISTICS:  Aerodynamic particle diameter (urn):         2.5     6.0   10.0

                 Mean (Cum. %):                         10      30     48
                 Standard deviation (Cum. %):
                 Min (Cum. %):
                 Max (Cum. %):
TOTAL PARTICULATE EMISSION FACTOR:   0.375 kg particulate/Mg ore dried,  after
fabric filter control.  Factors from reference.
SOURCE OPERATION:  Source dries fluorspar ore in a rotary drum dryer at a feed
rate of 2 tons/hour.
SAMPLING TECHNIQUE:  Andersen  Mark III Impactor
EMISSION FACTOR RATING:  E
REFERENCE:

       Confidential test data from a major fluorspar ore processor,  PEI
       Associates, Inc., Golden, CO, January 1985.
 10/86                            Appendix C.I                            C.l-95
-------
            8.xx  LIGHTWEIGHT AGGREGATE (CLAY):   COAL FIRED ROTARY KILN

           99.99
            99.9
   99

   98



   95



   90



   80


   70


B^S  6°

jj  50


H1? 40
•rH

U  30

y  20
         CO

         T3
         01
         JJ
         (fl
         XJ
         CO

         V
          cfl
            1.0
         I  '
             1


            0.5
            0.1
           0.01
                     WET  SCRUBBER and
                    SETTLING CHAMBER
                    •— Weight percent
                       Emission factor
                      WET  SCRUBBER
                    •— Weight percent
                                                                              2.0
                                              m
                                              en
                                              m
                                                                                Mi
                                                                                0>
                                                                                r>
                                                                                ff
                                                                             1.0
                              3   4   56789 10       20

                                   Particle diameter, urn
                                                            30
                                                                              0.0
                                                                40 50 60 70 80 90 100
Aerodynamic
particle
diameter (um)
2.5
6.0
10.0
Cumulative wt. % < stated size
Wet scrubber
and settling chamber
55
65
81
Wet
scrubber
55
75
84
Emission factor (kg/Mg)
Wet scrubber
and settling chamber
0.97
1.15
1.43
C.l-96
EMISSION FACTORS
                                                                        10/86
-------
          8.xx  LIGHTWEIGHT AGGREGATE (CLAY):   COAL FIRED ROTARY KILN
NUMBER OF TESTS:   a)  4, conducted after wet scrubber control
                  b)  8, conducted after settling chamber and wet scrubber
                      control

STATISTICS:   a) Aerodynamic particle diameter, (urn):  2.5       6.0      10.0

               Mean (Cum. %):                        55        75       84
               Standard Deviation (Cum. %):
               Min (Cum. %):
               Max (Cum. %):

             b) Aerodynamic particle diameter, (urn):  2.5       6.0      10.0

               Mean (Cum. %):                        55        65       81
               Standard Deviation (Cum. %):
               Min (Cum. %):
               Max (Cum. %):

TOTAL PARTICULATE EMISSION FACTOR:  1.77 kg particulate/Mg of clay processed,
after control by settling chamber and wet scrubber.  Calculated from data in
Reference c.
SOURCE OPERATION:  Sources produce lightweight clay aggregate in pulverized
coal fired rotary kilns.  Kiln capacity for Source b is 750 tons/day,  and
operation is continuous.
SAMPLING TECHNIQUE:  Andersen Impactor
EMISSION FACTOR RATING: C
REFERENCES:

a.     Emission Test Report, Lightweight Aggregate Industry, Texas Industries,
       Inc., EMB-80-LWA-3, U. S. Environmental Protection Agency, Research
       Triangle Park, NC, May 1981.

b.     Emission test data from Environmental Assessment Data Systems, Fine Par-
       ticle Emission Information System, Series Report No. 341, U. S. Environ-
       mental Protection Agency, Research Triangle Park, NC, June 1983.

c.     Emission Test Report, Lightweight Aggregate Industry, Arkansas Light-
       weight Aggregate Corporation, EMB-80-LWA-2, U. S. Environmental
       Protection Agency, Research Triangle Park, NC, May 1981.
10/86                             Appendix C.I                           C.l-97
-------
                     8.xx   LIGHTWEIGHT AGGREGATE  (CLAY):   DRYER
          99.f
           99.9
            99


            98
0)  95
N
•H

w  90
            80
            70
         V
   60


AJ  5°

"S) *0
•H

S  30


0)  20

i-t
4J
CO  10
        CJ
            2


            1


           0.5




           0.1






           0.01
                                               UNCONTROLLED
                                          —•—  Weight percent
                                          	  Emission factor
                                                                              40
w
0

CO
CO
H-
O
s

i-h
09
O

O
i-i
                                                                                 OQ
                                                                              20
                             3   4   56789 10        20     30

                                  Particle diameter, urn
                                                                AO  50  60 70 80 90 IOC
Aerodynamic
particle
diameter, um
2.5
6.0
10.0
Cumulative wt . % < stated size
Uncontrolled
37.2
74.8
89.5
Emission factor, kg/Mg
Uncontrolled
13.0
26.2
31.3
C.l-98
                           EMISSION  FACTORS
                                                                                 10/86
-------
                   8.xx  LIGHTWEIGHT AGGREGATE (CLAY):  DRYER
NUMBER OF TESTS:  5, conducted before controls
STATISTICS:  Aerodynamic particle diameter (urn):         2.5     6.0   10.0

                 Mean (Cum. %):                         37.2    74.8   89.5
                 Standard deviation (Cum.  %):            3.4     5.6    3.6
                 Min (Cum. %):                          32.3    68.9   85.5
                 Max (Cum. %):                          41.0    80.8   92.7
TOTAL PARTICULATE EMISSION FACTOR:   35 kg/Mg clay feed to dryer.   From
AP-42, Section 8.7.
SOURCE OPERATION:  No information on source operation is available
SAMPLING TECHNIQUE:   Brinks impactor
EMISSION FACTOR RATING:  C
REFERENCE:

       Emission test data from Environmental Assessment Data Systems,  Fine  Par-
       ticle Emission Information System,  Series Report No.  88,  U.  S.  Environ-
       mental Protection Agency, Research  Triangle Park, NC, June 1983.
 10/86                            Appendix C-l                            C.l-99
-------
    8.xx   LIGHTWEIGHT AGGREGATE  (CLAY):   RECIPROCATING GRATE CLINKER COOLER
        99.9
         99

         98


       N  95
       CO

       0)
       j_i
       (0  80
       4J
       05
      V
   70

g^  60

•U  50

S *0
0)
IS  30

y  20
      m
         10
a

U  5

   7

   1

   0.5



   0. 1




  0.01
                                       MULTICLONE CONTROLLED
                                        —•— Weight  percent
                                        	 Emission  factor
                                            FABRIC FILTER
                                        —•— Weight  percent
                                                                    0.15
    a
    CO
    en
    O
    3
    l-h
0.10 (U
    rr
    O
    i-l
                                                                             (JQ
                                                                          0.05
                                                                          0.0
                          3   4   56789 10        20
                                Particle diameter, urn
                                                        30   40  50 60 70 80 90 100
Aerodynamic
particle
diameter, um
2.5
6.0
10.0
Cumulative wt . % < stated size
Multi clone
19.3
38.1
56.7
Fabric filter
39
48
54
Emission factor, kg/Mg
Multi clone
0.03
0.06
0.09
C.1-100
                            EMISSION FACTORS
      10/86
-------
    8.xx  LIGHTWEIGHT AGGREGATE (CLAY):   RECIPROCATING GRATE CLINKER COOLER
NUMBER OF TESTS:   a)  12, conducted after Multiclone control
                  b)   4, conducted after Multiclone and fabric  filter control


STATISTICS:  a) Aerodynamic particle diameter (urn):     2.5     6.0     10.0

                   Mean (Cum. %):                     19.3     38.1     56.7
                   Standard deviation (Cum.  %):        7.9     14.9     17.9
                   Min (Cum. %):                       9.3     18.6     29.2
                   Max (Cum. %):                      34.6     61.4     76.6

            b)  Aerodynamic particle diameter (urn):    2.5     6.0     10.0

                   Mean (Cum. %):                     39      48      54
                   Standard deviation (Cum.  %):
                   Min (Cum. %):
                   Max (Cum. %) :


TOTAL PARTICULATE EMISSION FACTOR:  0.157 kg particulate/Mg  clay processed,
after multiclone control.  Factor calculated from data in  Reference b.   After
fabric filter control, particulate emissions are negligible.


SOURCE OPERATION:  Sources produce lightweight  clay aggregate in a coal  fired
rotary kiln and reciprocating grate clinker  cooler.


SAMPLING TECHNIQUE:  a)  Andersen Impactor
                     b)  Andersen Impactor
EMISSION FACTOR RATING:  C
REFERENCES:

a.     Emission Test Report,  Lightweight Aggregate Industry,  Texas  Industries,
       Inc.,  EMB-80-LWA-3,  U. S. Environmental  Protection Agency, Research
       Triangle Park, NC, May 1981.

b.     Emission Test Report,  Lightweight Aggregate Industry,  Arkansas  Light-
       weight Aggregate Corporation,  EMB-80-LWA-2, U.  S.  Environmental
       Protection Agency, Research Triangle Park, NC,  May 1981.

c.     Emission test data from Environmental Assessment Data  Systems,  Fine
       Particle Emission Information System, Series Report No.  342,  U.  S.
       Environmental Protection Agency, Research Triangle Park,  NC,  June 1983.
 10/86                            Appendix C.I                          C.1-101
-------
    8.xx   LIGHTWEIGHT AGGREGATE (SHALE):  RECIPROCATING GRATE  CLINKER  COOLER

        99.99
        99.9
         99

         98
       CU
       N
       0)
       4J
       CO 80
       4J
       CO
         70
      V
4-1  JO


§40

-------
    8.xx  LIGHTWEIGHT AGGREGATE (SHALE):   RECIPROCATING GRATE CLINKER COOLER
NUMBER OF TESTS:   4, conducted after settling chamber control
STATISTICS:  Aerodynamic particle diameter (urn):         2.5     6.0  10.0

                 Mean (Cum. %):                          8.2    17.6  25.6
                 Standard deviation (Cum. %):            4.3     2.8   1.7
                 Min (Cum. %):                           4.0    15.0  24.0
                 Max (Cum. %):                          14.0    21.0  28.0
TOTAL PARTICULATE EMISSION FACTOR:   0.08 kg particulate/Mg of aggregate
produced.  Factor calculated from data in reference.
SOURCE OPERATION:  Source operates two kilns to produce lightweight shale
aggregate, which is cooled and classified on a reciprocating grate clinker
cooler.  Normal production rate of the tested kiln is 23 tons/hr,  about 66% of
rated capacity.  Kiln rotates at 2.8 rpm.  Feed end temperature is 1100°F.
SAMPLING TECHNIQUE:   Andersen Impactor
EMISSION FACTOR RATING:  B
REFERENCE:

       Emission Test Report, Lightweight Aggregate Industry,  Vulcan Materials
       Company, EMB-80-LWA-4,  U. S. Environmental  Protection  Agency, Research
       Triangle Park, NC, March 1982.
 10/86                            Appendix C.I                           C.1-103
-------
          8.xx  LIGHTWEIGHT AGGREGATE (SLATE):   COAL FIRED ROTARY KILN
99.99
99.9
99
98
0) a.
N "
•H
CO
T3 *°
0)
JJ
CO 80
4J
CO
70
V
6O
*"*
W 50
.c:
bO
•rj ^0
OJ
» 30
S| 20
•H
a_i
CO
iH 10
«3 5

2


1
0.5


0. 1



0.01

-

-

^

,



™


•

—

"
— ^-^
* 	 T'''^
.x^^ /
^^ /
^^ /
^^ / «
/
/
/
/
/
/

' UNCONTROLLED
— •— Weight percent
	 Emission factor

CONTROLLED
— •— Weight percent

2 3 4 5 6 7 8 9 10 20 30 40 50 60 70 80 90





40
M
B
0)
CO
p.
o
3

i-h
Cu
n
r^
O


CK)
J

20













0
IOC
Aerodynamic
particle
diameter, urn
2.5
6.0
10.0
Cumulative wt. % < stated size
Without
controls
13
29
42
After wet
scrubber control
33
36
39
Emission factor, kg/Mg
Without
controls
7.3
16.2
23.5
After wet
scrubber control
0.59
0.65
0.70
C.1-104
EMISSION FACTORS
10/86
-------
          8.xx  LIGHTWEIGHT AGGREGATE (SLATE):   COAL FIRED ROTARY KILN
NUMBER OF TESTS:  a)  3, conducted before control
                  b)  5, conducted after wet scrubber control


STATISTICS:  a) Aerodynamic particle diameter (urn):      2.5     6.0   10.0

                   Mean (Cum. %):                      13.0    29.0   42.0
                   Standard deviation (Cum. %):
                   Min (Cum. %):
                   Max (Cum. %):

            b) Aerodynamic particle diameter (urn):      2.5     6.0   10.0

                   Mean (Cum. %):                      33.0    36.0   39.0
                   Standard deviation (Cum. %):
                   Min (Cum. %):
                   Max (Cum. %):
TOTAL PARTICULATE EMISSION FACTOR:  For uncontrolled source, 56.0 kg parti-
culate/Mg of feed.  After wet scrubber control, 1.8 kg particulate/Mg of feed.
Factors are calculated from data in reference.
SOURCE OPERATION:  Source produces light weight aggregate from slate in coal
fired rotary kiln and reciprocating grate clinker cooler.  During testing
source was operating at a feed rate of 33 tons/hr., 83% rated capacity.  Firing
zone temperatures are about 2125°F and kiln rotates at 3.25 RPM.
SAMPLING TECHNIQUE:  a.  Bacho
                     b.  Andersen Impactor
EMISSION FACTOR RATING:  C
REFERENCE:

       Emission Test Report, Lightweight Aggregate Industry,  Galite Corporation,
       EMB-80-LWA-6, U. S. Environmental Protection Agency,  Research Triangle
       Park, NC, February 1982.
 10/86                            Appendix C.I                          C.1-105
-------
    8.xx   LIGHTWEIGHT AGGREGATE (SLATE):   RECIPROCATING GRATE  CLINKER COOLER


         99.99
          99.9
   99


   98




N  *5
•H
CO


•O  »
0)
AJ
«  80
4-1
CO
       v
          70
       *->  50


       y 40
          30


          20
       «
          10
       s


       o   5


           2

           1

          0.5



          0.1





         0.01
                                                CONTROLLED

                                           —•—  Weight percent

                                           	  Emission factor
                                                             I  I «  I In n
                                                                            0.2
                                                                               w
en
CO
H-
o
o
                                                                               01
                                                                               O
                                                                        1-1


                                                                        7?
                                                                            0.1
                                \   5  6  7  8 9 10        20


                                Particle diameter,  urn
                                                          30   40  50  60 70 80 90 100
Aerodynamic
particle
diameter, um
2.5
6.0
10.0
Cumulative wt . % < stated size
After settling chamber control
9.8
23.6
41.0
Emission factor, kg/Mg
After
settling chamber control
0.02
0.05
0.09
C.1-106
                            EMISSION FACTORS
10/86
-------
    8.xx  LIGHTWEIGHT AGGREGATE (SLATE):  RECIPROCATING GRATE CLINKER COOLER
NUMBER OF TESTS:  5, conducted after settling chamber control
STATISTICS:  Aerodynamic particle diameter (urn):         2.5     6.0  10.0

                 Mean (Cum. %):                         9.8    23.6  41.0
                 Standard deviation (Cum. %):
                 Min (Cum. %):
                 Max (Cum. %):
TOTAL PARTICULATE EMISSION FACTOR:   0.22 kg particulate/Mg of raw material
feed.  Factor calculated from data in reference.
SOURCE OPERATION:   Source produces lightweight slate aggregate in a cool  fired
kiln and a reciprocating grate clinker cooler.  During testing, source was
operating at a feed rate of 33 tons/hr, 83% of rated capacity.  Firing zone
temperatures are about 2125°F, and kiln rotates at 3.25 rpm.
SAMPLING TECHNIQUE:   Andersen Impactors
EMISSION FACTOR RATING:  C
REFERENCE:

       Emission Test Report, Lightweight Aggregate Industry,  Galite Corporation,
       EMB-80-LWA-6, U. S. Environmental Protection Agency,  Research Triangle
       Park, NC, February 1982.
 10/86                               Appendix C.I                        C.1-107
-------
                   8.xx   NONMETALLIC  MINERALS:   TALC PEBBLE MILL
        99.99
         99.9
  99


  98




»95

•H
CO



0)

CO 30
4J
CO
       v
       "§>
70


60


50


40


30
        £20
        (8
       iH  10



       Is
         0.1
         0.01
                                              UNCONTROLLED
                                          —•—  Weight percent
                                          	  Emission factor
                                                                            25
                                                                            20
                                                                            15
                                                                               rt
                                                                               3
                                                                               H-
                                                                               0)
                                                                               CO
                                                                               H-
                                                                               O
                                                                               0
                                                                       O
                                                                       i-l
                                                                              ciT
                                                                            10
                           3   4   5 6 7 8 9 10        20

                                 Particle diameter, urn
                                                          30   40 50 60 70 80 90 100
Aerodynamic
particle
diameter, urn
2.5
6.0
10.0
Cumulative wt. % < stated size
Before controls
30.1
42.4
56.4
Emission factor, kg/Mg
Before controls
5.9
8.3
11.1
C.1-108
                            EMISSION FACTORS
                                                                                 10/86
-------
                 8.xx  NONMETALLIC MINERALS:   TALC PEBBLE MILL
NUMBER OF TESTS:  2, conducted before controls
STATISTICS:  Aerodynamic particle diameter (urn):         2.5     6.0   10.0

                 Mean (Cum. %):                        30.1    42.4   56.4
                 Standard deviation (Cum. %):            0.8     0.2    0.4
                 Min (Cum. %):                          29.5    42.2   56.1
                 Max (Cum. %):                          30.6    42.5   56.6
TOTAL PARTICULATE EMISSION FACTOR:  19.6 kg particulate/Mg ore processed.
Calculated from data in reference.
SOURCE OPERATION:  Source crushes talc ore then grinds crushed ore in a pebble
mill.  During testing, source operation was normal,  according to the operators.
An addendum to reference indicates throughput varied between 2.8 and 4.4
tons/hour during these tests.


SAMPLING TECHNIQUE:  Sample was collected in an alundum thimble and analyzed
with a Spectrex Prototron Particle Counter Model ILI 1000.
EMISSION FACTOR RATING:  E
REFERENCE:

       Air Pollution Emission Test, Pfizer, Inc.,  Victorville,  CA,  EMB-77-NMM-5,
       U. S. Environmental Protection Agency, Research Triangle Park,  NC,  July
       1977.
10/86                             Appendix C.I                          C.1-109
-------
         99.99
          99.9
           99


           98
        CO
        N  95
-0  90
oi
4->
*  80

CO

v  70

6~S  60


£  50
be
•H  40
01

•*  30

CU
>  20
O
           10




           5




           2


           I


           0.5





           0.1







          0.01
                   10.4  WOODWORKING WASTE COLLECTION OPERATIONS:

                          BELT  SANDER HOOD EXHAUST CYCLONE
                                         CYCLONE CONTROLLED

                                         -•- Weight  percent

                                         	 Emission factor

                                           FABRIC FILTER

                                         —•- Weight  percent
                                                                    3.0
                                                                    2.0
                                                                               CD
                                                                               CO
                                                                               H-
                                                                               O
                                                                               0

                                                                               Hi
                                                                               0>
                                                                               n
                                                                               (T
                                                                               o
                                                                               7?
                                                                               TO
                                                                    i.o
                                                                    n
                            3  4   5  6  7  8 9 10       .20    30   40  50 60 70 80 90 100

                                 Particle diameter,  urn
Aerodynamic
particle
diameter, um
2.5
6.0
10.0
Cumulative wt . % < stated size
Cyclone
29.5
42.7
52.9
After cyclone
and fabric filter
14.3
17.3
32.1
Emission factor, kg/hour
of cyclone operation
After
cyclone collector
0.68
0.98
1.22
C.1-110
                           EMISSION FACTORS
                                                                               10/86
-------
                 10.4  WOODWORKING WASTE COLLECTION OPERATIONS:
                        BELT SANDER HOOD EXHAUST CYCLONE
NUMBER OF TESTS:   a)  1, conducted after cyclone control
                  b)  1, after cyclone and fabric filter  control
STATISTICS:   a) Aerodynamic particle diameter (urn):      2.5      6.0    10.0

                    Mean (Cum. %):                      29.5     42.7    52.9
                    Standard deviation (Cum. %):
                    Min (Cum. %):
                    Max (Cum. %):

             b) Aerodynamic particle diameter (urn):      2.5      6.0    10.0

                    Mean (Cum. %):                      14.3     17.3    32.1
                    Standard deviation (Cum. %) :
                    Min (Cum. %):
                    Max (Cum. %):
TOTAL PARTICULATE EMISSION FACTOR:   2.3 kg particulate/hr of  cyclone operation.
For cyclone controlled source, this emission factor applies  to typical  large
diameter cyclones into which wood waste is fed directly,  not  to cyclones  that
handle waste previously collected in cyclones.  If baghouses  are used for waste
collection, particulate emissions will be negligible.   Accordingly,  no  emission
factor is provided for the fabric filter controlled source.   Factors from AP-42.
SOURCE OPERATION:   Source was sanding 2 ply panels of mahogany veneer,  at  100%
of design process  rate of 1110 m^/hr.
SAMPLING TECHNIQUE:   a)  Joy train with 3 cyclones
                     b)  Sass train with cyclones
EMISSION FACTOR RATING:  E
REFERENCE:

       Emission test data from Environmental Assessment Data Systems,  Fine
       Particle Emission Information System, Series Report No.  238,  U.  S.
       Environmental Protection Agency,  Research Triangle Park,  NC,  June 1983.


10/86                             Appendix C.I                           C. 1-111
-------
                                 APPENDIX C.2




                    GENERALIZED PARTICLE SIZE DISTRIBUTIONS
10/86                           Appendix C.2                            C.2-1
-------
                                    CONTENTS
                                                                      Page
C.2.1     Rationale For Developing Generalized Particle
            Distributions  	   C.2-3
C.2.2     How To Use The Generalized Particle Size Distributions
            For Uncontrolled Processes   	   C.2-3
C.2.3     How To Use The Generalized Particle Size Distributions
            For Controlled Processes  	   C.2-17
C.2.4     Example Calculation  	   C.2-17

Tables

C.2-1     Particle Size Cateogry By AP-42 Section 	   C.2-5
C.2-2     Description of Particle Size Categories 	   C.2-8
C.2-3     Typical Collection Efficiencies of Various Particulate
            Control Devices  (percent) 	   C.2-17

Figures

C.2-1     Example Calculation  for Determining Uncontrolled and
            Controlled Particle Size Specific Emissions  	   C.2-4
C.2-2     Calculation Sheet  	   C.2-7

References  	   C.2-18
C.2-2
EMISSION FACTORS
10/86
-------
                                 APPENDIX C.2

                    GENERALIZED PARTICLE SIZE DISTRIBUTIONS


C.2.1  Rationale For Developing Generalized Particle Size Distributions

     The preparation of size specific particulate emission inventories
requires size distribution information for each process.  Particle size
distributions for many processes are contained in appropriate industry
sections of this document.  Because particle size information for many
processes of local impact and concern are unavailable, this Appendix provides
"generic" particle size distributions applicable to these processes.  The
concept of the "generic particle size distribution is based on categorizing
measured particle size data from similar processes generating emissions from
similar materials.  These generic distributions have been developed from
sampled size distributions from about 200 sources.

     Generic particle size distributions are approximations.  They should be
used only in the absence of source-specific particle size distributions for
areawide emission inventories.

C.2.2  How To Use The Generalized Particle Size Distributions For
       Uncontrolled Processes

     Figure C.2-1 provides an example calculation to assist the analyst in
preparing particle size specific emission estimates using generic size
distributions.

     The following instructions for the calculation apply to each particulate
emission source for which a particle size distribution is desired and for
which no source specific particle size information is given elsewhere in this
document:

     1.   Identify and review the AP-42 Section dealing with that process.

     2.   Obtain the uncontrolled particulate emission factor for the process
          from the main text of AP-42, and calculate uncontrolled total
          particulate emissions.

     3.   Obtain the category number of the appropriate generic particle size
          distribution from Table C.2-1.

     4.   Obtain the particle size distribution for the appropriate category
          from Table C.2-2.  Apply the particle size distribution to the
          uncontrolled particulate emissions.

     Instructions for calculating the controlled size specific emissions are
given in C.2.3 and illustrated in Figure C.2-1.


10/86                           Appendix C.2                            C.2-3
-------
         Figure  C.2-1.   EXAMPLE  CALCULATION  FOR DETERMINING UNCONTROLLED
                AND  CONTROLLED PARTICLE  SIZE SPECIFIC  EMISSIONS.

 SOURCE IDENTIFICATION

 Source name  and address:   ABC Brick Manufacturing	_____	
 Process  description:
 AP-42  Section:
 Uncontrolled  AP-42
   emission  factor:

 Activity parameter:
 Uncontrolled  emissions:
                           24  Dusty  Way
                           Anywhere,  USA
                          Dryers/Grinders
                          8.3,  Bricks And Related Clay Products
                          96 Ibs/ton
                          63,700 tons/year
                          3057.6 tons/year
                       (units)

                       (units)
                       (units)
 UNCONTROLLED  SIZE  EMISSIONS

 Category  name:   Mechanically Generated/Aggregate,  Unprocessed  Ores

 Category  number:     3

                                                  Particle  size (ym)
 Generic  distribution,  Cumulative
   percent  equal  to  or  less  than the  size:
Cumulative mass
  (tons/year) :
                   particle  size  emissions
< 2.5


 15

458.6
  < 6


  34

1039.(
 < 10


  51

1559.4
 CONTROLLED  SIZE  EMISSIONS*

 Type  of  control  device:   Fabric  Filter
 Collection  efficiency  (Table  C.2-3):
 Mass  in size  range** before control
   (tons/year):
 Mass  in size  range  after  control
   (tons/year):
 Cumulative  mass  (tons/year):
                                                     Particle  size (urn)

                                            0-2.5        2.5-6         6 - 10
                                             99.0

                                            458.6

                                              4.59
                                              4.59
             99.5

            581.0

              2.91
              7.50
               99.5

              519.8

                2.60
               10.10
 *   These  data do  not  include  results  for  the  greater  than 10 ym particle size range.
 ** Uncontrolled size  data  are cumulative  percent  equal  to or less  than the size.
    Control  efficiency data apply only to  size range and are not cumulative.
C.2-4
                               EMISSION FACTORS
                          10/86
-------
                TABLE  C.2-1.   PARTICLE  SIZE  CATEGORY BY AP-42 SECTION
AP-42
Section


1.1
1.2
1.3






1.4
1.5
1.6

1.7
1.8
1.9
1.10
1.11



2.1
2.3




3.2



5.4
5.8



5.10
5.11

5.12
5.16
5.17



6.1




6.2
6.3
6.4


Source Category
External combustion

Bituminous coal combustion
Anthracite coal combustion
Fuel oil combustion
Utility, residual oil
Industrial , residual oil
Utility, distillate oil
Commercial, residual oil
Commerci al, distill ate
Residential, distillate
Natural gas combustion
Liquefied pettoleum gas
Mood waste combustion in
boilers
Lignite, combustion
Bagasse Combustion
Residential fireplaces
Wood stoves
Waste oil combustion

Solid waste disposal

Refuse Incinerators
Conical burners (wood waste)

Internal combustion engine

Highway vehicles
Off highway

Chemical process

Charcoal production
Hydrofluoric acid
Spar drying
Spar handling
Transfer
Paint
Phosphoric acid (thermal
process)
Phthalic anhydride
Sodium carbonate
Sulfuric acid

Food and agricultural

Alfalfa dehydrating
Primary cyclone
Meal collector cyclone
Pellet cooler cyclone
Pellet regrind cyclone
Coffee roasting
Cotton ginning
Feed and grain mills and
elevators
Unloading
Category
Number


a
a
a
a
a
a
a
a
a
a
a
a
a
b
a
a
2



b
2



a
1



9

3
3
3
4

a
9
a
b




b
7
7
7
6
b


b
AP-42
Section



6.5
6.7
6.8
6.10
6.10.3



6.11
6.14
6.16



6.17



6.18





7.1






7.2
7.3
7.4
7.5








7.6
7.7
7.8




7.9

7.10

Category
Source Category Number
Food and agricultural (cont.)
Grain elevators
Grain processing
Fermentation
Meat smokehouses
Ammonium nitrate fertilizers
Phosphate fertilizers
Ammonium phosphates
Reactor/aitmoniator-
granulator
Dryer/cooler
Starch manufacturing
Urea manufacturing
Defoliation and harvesting
of cotton
Trailer loading
Transport
Harvesting of grain
Harvesting machine
Truck loading
Field transport
Ammonium sulfate manufacturing
Rotary dryer
Fluidized-bed dryer

Heta11ur9ica1 industry

Primary aluminum production
Bauxite grinding
Aluminum hydroxide calcining
Anode baking furnace
Prebake cell
Vertical Soderberg
Horizontal Soderberg
Coke manufacturing
Primary copper smelting
Ferroalloy production
Iron and steel production
Blast furnace
Slips
Cast house
Sintering
Windbox
Sinter discharge
Basic oxygen furnace
Electee arc furnace
Primary lead smelting
Zinc smelting
Secondary aluminum
Sweating furnace
Smelting
Crucible furnace
Reverberatory furnace
Secondary copper smelting
and alloying
Gray iron foundries


6
7
6&7
9
a
3


4
4
7
3

6
6

6
6
6

b
b




4
5
9
a
8
a
a
a
a


a
a

a
a
a
a
a
8

8

8
a

8
a

       a.   Categories with particle size data specific to  process included in the main  body of  the text.
       b.   Categories with particle size data specific to  process included in Appendix  C.I.
       c.   Data for each numbered category are shown in Table C.2-2.
       d.   Highway vehicles data are reported in AP-42 Volume II:  Mobile Sources.
10/86
Appendix  C.2
C.2-5
-------
TABLE  C. 2-1  (continued).
AP-42
Section

7.11
7.12
7.13

7.14
7.15
7.18



Source Category
Metallurgical industry (cont.)
Secondary lead processing
Secondary magnesium smelting
Steel foundaries
melting
Secondary zinc smelting
Storage battery production
Leadbearing ore crushing and
grinding

Mineral products
Category
Number

a
8

b
8
b

4


AP-42
Section Source Category
Mineral products (cont.)
Impact mill
Flash calciner
Continuous kettle calciner
8.15 Lime manufacturing
8.16 Mineral wool manufacturing
Cupola
Reverberatory furnace
Blow chamber
Curing oven
Cooler
Category
Number

4
a
a
a

8
8
8
9
9
8.5
8.6
8.7
8.8
8.9
8.10
8.11
8.13
8.14
                   Asphaltic  concrete plants
                     Process                           a
                   Bricks  and related clay
                   products
                     Raw materials handling
                       Dryers, grinders, etc.          b
                     Tunnel/periodic kilns
                       Gas fired                       a
                       Oil fired                       a
                       Coal fired                      a
                   Castable refractories
                     Raw material dryer                3
                     Raw material crushing and
                       screening                       3
                     Electric arc melting              8
                     Curing oven                       3
                   Portland cement manufacturing
                     Dry process
                       Kilns                           a
                       Dryers, grinders, etc.          4
                     Wet process
                       Kilns                           a
                       Dryers, grinders, etc.          4
                   Ceramic clay manufacturing
                     Drying                            3
                     Grinding                         4
                     Storage                           3
                   Clay and fly ash sintering
                     Fly ash  sintering, crushing,
                       screening and yard storage      5
                     Clay  mixed with coke
                       Crushing, screening, and
                        yard storage                  3
                   Coal cleaning                       3
                   Concrete batching                   3
                   Glass fiber manufacturing
                     Unloading and conveying           3
                     Storage  bins                      3
                     Mixing and weighing               3
                     Class furnace - wool              a
                     Glass furnace - textile           a
                   Glass manufacturing                 a
                   Gypsum  manufacturing
                     Rotary ore dryer                  a
                     Roller mill                       4
 8.18    Phosphate rock processing
          Drying                            a
          Calcining                         a
          Grinding                          b
          Transfer and storage              3
 8.19.1   Sand  and gravel processing
          Continuous drop
            Transfer station                a
            Pile formation - stacker        a
          Batch drop                        a
          Active storage piles              a
          Vehicle traffic unpaved road      a
 8.19.2   Crushed stone processing
          Dry crushing
            Primary crushing                a
            Secondary crushing
              and screening                 a
            Tertiary crushing
              and screening                 3
            Recrushing and screening        4
            Fines mill                      4
          Screening, conveying,
            and handling                    a
 8.22    Taconite ore processing
          Fine crushing                     4
          Waste gas                         a
          Pellet handling                   4
          Grate discharge                   5
          Grate feed                        4
          Bentonite blending                4
          Coarse crushing                   3
          Ore transfer                      3
          Bentonite transfer                4
          Unpaved roads                     a
 8.23    Metallic minerals processing        a
 8.24    Western surface coal mining         a

         Wood  processing

10.1      Chemical wood pulping               a

         Miscellaneous sources
                                                     11.2
                                                              Fugitive dust
          a.
          b.
    Categories with  particle size data specific to process  included in the main body of the text.
    Categories with  particle size data specific to process  Included in Appendix C.I.
    Data for each numbered  category are shown in Table C.2-2.
 C.2-6
                                      EMISSION  FACTORS
                                                                                                               10/86
-------
                       Figure  C.2-2.  CALCULATION SHEET.
SOURCE IDENTIFICATION

Source name and address:
Process description:

AP-42 Section:

Uncontrolled AP-42
  emission factor:

Activity parameter:

Uncontrolled emissions:
                                    _(units)
                                    _(units)
                                     (units)
UNCONTROLLED SIZE EMISSIONS

Category name: 	
Category number:
                                                  Particle size  (vim)

                                               < 2.5         < 6
Generic distribution, Cumulative
  percent equal to or less than the size:

Cumulative mass j< particle size emissions
  (tons/year):
                                        < 10
CONTROLLED SIZE EMISSIONS*

Type of control device:
                                                    Particle size  (um)

                                           0-2.5       2.5-6        6 - 10

Collection efficiency (Table C.2-3):
Mass in size range** before control
  (tons/year):
Mass in size range after control:
  (tons/year):
Cumulative mass (tons/year):

*  These data do not include results for the greater than 10 vim particle size range.
** Uncontrolled size data are cumulative percent equal to or less  than the size.
   Control efficiency data apply only to size range and are not cumulative.
10/86
Appendix C.2
C.2-7
-------
             TABLE C.2-2.   DESCRIPTION OF PARTICLE SIZE CATEGORIES
 Category:   1
 Process:    Stationary Internal Combustion Engines
 Material:   Gasoline  and Diesel Fuel

      Category  1  covers size specific emissions from stationary internal
 combustion  engines.   The particulate emissions are generated from fuel
 combustion.

 REFERENCE:  1,  9
                     1/1
                     o
                     W!
                     V
                     Of
                     UJ
                     o.
yj
98
95
90
80
70
60
50
dn
i
-
-
-
-
i i i

	 —
- 	 -^
i i i " "
-
^^---"
-
.
-
-
-
i iii
i i i i
                                  2    345
                                  PARTICLE DIAMETER,
                                          10
      Particle
      size,  um
          Cumulative %
       less than or equal
         to stated size
         (uncontrolled)
              Minimum     Maximum     Standard
               Value       Value      Deviation
         1.0e
         2.0*
         2.5
         3.0£
         4.0
         5.0£
         6.0
        10.0
a
82
88
90
90
92
93
93
96
                               78
                               86
                               92
99
99
99
11
 7
 4
  Value  calculated  from data reported at 2.5,  6.0,  and 10.0 um.  No
  statistical  parameters are given for the calculated value.
C.2-8
                    EMISSION FACTORS
                                                10/86
-------
TABLE C.2-2 (continued).
Category: 2
Process:  Combustion
Material: Mixed Fuels

Category 2 covers boilers firing a mixture  of  fuels,  regardless  of the
fuel combination.  The fuels include gas, coal,  coke,  and  petroleum.
Particulate emissions are generated by  firing  these miscellaneous fuels.

REFERENCE: 1
  o
  UJ
  t—
  «t
                        95

                        90

                        80

                        70

                        60
                        50
                        40

                        30

                        20

                        10
                2345
                PARTICLE DIAMETER,
                                                     10
      Particle
      size, ym
         1.0
         2.0£
         2.5
        4.0
        5.0C
        6.0
        10.0
   Cumulative %
less than or equal
  to stated size      Minimum     Maximum     Standard
  (uncontrolled)       Value       Value      Deviation

        23
        40
        45              32          70            17
        50
        58
        64
        70              49          84            14
        79              56          87            12
  Value calculated  from  data  reported at 2.5,  6.0,  and 10.0 ym.   No
  statistical parameters are  given for the calculated value.
 10/86
               Appendix C.2
C.2-9
-------
TABLE C.2-2  (continued).
Category:   3
Process:    Mechanically  Generated
Material:   Aggregate, Unprocessed  Ores

     Category  3  covers material  handling and processing of aggregate and
unprocessed ore.  This broad  category includes emissions from milling,
grinding, crushing,  screening, conveying,  cooling,  and drying of material.
Emissions are  generated  through  either  the movement of the material or the
interaction of the material with mechanical devices.

REFERENCE:  1-2,  4, 7
                   •t.
                   H-
                   l/l
                   a.
                   UJ
                   I
           90

           80

           70
           60
           50
           40
           30

           20

           10

            5

            2
                                 I     1   I   l  II1TT
                                 2345        10
                                 PARTICLE DIAMETER, ^m
                      Cumulative %
                   less  than or equal
      Particle       to  stated size
      size,  ym       (uncontrolled)
                             Minimum
                              Value
                          Maximum
                           Value
          Standard
          Deviation
         1.0C
         2.0£
         2.5
         3.0
         4.0£
         5.0*
         6.0
        10.0
a
 4
11
15
18
25
30
34
51
                               15
                               23
                                           35
65
81
   Value  calculated  from data reported at 2.5, 6.0, and 10.0 ym.
   statistical  parameters are given for the calculated value.
13
14
                                                       No
C.2-10
                    EMISSION FACTORS
                                                                           10/86
-------
TABLE C.2-2 (continued).
Category:  4
Process:   Mechanically Generated
Material:  Processed Ores and Non-metallic Minerals
     Category 4 covers material handling and processing  of processed  ores  and
minerals.  While similar to Category 3, processed ores can be  expected  to  have
a greater size consistency than unprocessed ores.  Particulate emissions are
a result of agitating the materials by screening or  transfer,  during  size
reduction and beneficiation of the materials by grinding and fine milling,  and
by drying.
REFERENCE:  1
      Particle
      size, vim

        i.oa
        2.0a
        2.5
        3.0?
        4.0
        5.0£
        6.0
       10.0
a
                     I/O
                     o
             95

             90

             80

             70

             60
             50
             40
             30

             20

             10

              5

              2
              1
            0.5
                                               t  i i  i i
                       2345

                       PARTICLE DIAMETER,
   Cumulative %
less than or equal
  to stated size      Minimum
  (uncontrolled)       Value

         6
        21
        30               1
        36
        48
        58
        62              17
        85              70
                                                     10
                                         Maximum
                                          Value
                                           51
                                           83
                                           93
Standard
Deviation
   19
   17
    7
  Value calculated from data reported at 2.5, 6.0,  and  10.0  um.  No
  statistical parameters are given for the calculated value.
10/86
                      Appendix C.2
                                                       C.2-11
-------
TABLE C.2-2  (continued).
Category:
Process:
Material:
Calcining and Other Heat Reaction Processes
Aggregate, Unprocessed Ores
     Category  5  covers the use of calciners and kilns in processing a variety
of  aggregates  and  unprocessed ores.   Emissions are a result of these high
temperature  operations.

REFERENCE:   1-2, 8
     90


  W  80
  c/>
  a  70
  UJ
  5  60

  "  50
  V
  g  40
  LU
  a  30
  UJ
  *•  20
  UJ
  >

  S  10


  I   5


      2
                                             IIIIFT
       1
                                      J_
                              J_
                                             I
                                                 I I  I I
                                  2    345
                                  PARTICLE DIAMETER,
                                         10
      Particle
      size,  ym
         1.0'
         2.0
         2.5
         3.0'
         4.0
         5.0£
         6.0
        10.0
a
a
   Cumulative %
less than or equal
  to stated size      Minimum     Maximum      Standard
  (uncontrolled)       Value       Value       Deviation

         6
        13
        18               3          42            11
        21
        28
        33
        37              13          74            19
        53              25          84            19
  Value  calculated  from data reported at 2.5, 6.0, and 10.0 vim.
  statistical parameters are given for the calculated value.
                                                       No
C.2-12
                    EMISSION FACTORS
                                                                          10/86
-------
TABLE C.2-2 (continued).
Category:
Process:
Material:
Grain Handling
Grain
     Category 6 covers various grain handling  (versus grain processing)
operations.  These processes could  include material transfer,  ginning and
other miscellaneous handling of grain.   Emissions  are generated by mechanical
agitation of the material.

REFERENCE:  1, 5
                    *f
                    _j
                    ZD
                    IE
             30

             20

             10

              5

              2

              1
            0.5

            0.2
            0.1
            0.05

            0.01
                                               I  I  i I I
                       2345
                       PARTICLE DIAMETER,
                                                     10
      Particle
      size, ym

        i.oa
        2.0a
        2.5
        3.0a
        4.0a
        5.0a
        6.0
       10.0
          Cumulative %
       less than or equal
         to stated size      Minimum     Maximum
         (uncontrolled)       Value       Value

               .07
               .60
                1               0           2
                2
                3
                5
                7               3          12
               15               6          25
Standard
Deviation
    3
    7
  Value calculated from data reported at 2.5, 6.0, and  10.0 urn.
  statistical parameters are given for the calculated value.
                                                      No
10/86
                                 Appendix C.2
                                                              C.2-13
-------
TABLE C.2-2 (continued).
Category:
Process:
Material:
7
Grain Processing
Grain
     Category 7 covers grain processing operations  such  as  drying,  screening,
grinding and milling.  The particulate emissions  are  generated during
forced air flow, separation or size reduction.

REFERENCE:  1-2
                       80

                       70

                       60
                       50
                       40

                       30

                       20

                       10
                                 T  III IT
                                 I  1  l  I
                                 2345       10
                                 PARTICLE DIAMETER, \m
      Particle
      size,  urn

         i.oa
         2.0a
         2.5
         3-°
         4.0
         5.0
         6.0
        10.0

          Cumulative  %
       less  than or equal
         to  stated size      Minimum     Maximum
         (uncontrolled)        Value        Value

                8
                18
                23               17           34
                27
                34
                40
                43               35           48
                61               56           65
Standard
Deviation
    7
    5
   Value  calculated from data reported at 2.5, 6.0, and 10.0 ym.  No
   statistical parameters are given for the calculated value.
C.2-14
                    EMISSION FACTORS
                                                                          10/86
-------
TABLE C.2-2 (continued).
Category:  8
Process:   Melting, Smelting, Refining
Material:  Metals, except Aluminum

     Category 8 covers the melting, smelting, and  refining  of metals  (in-
cluding glass) other than aluminum.  All primary and  secondary  production
processes for these materials which involve a physical  or chemical  change are
included in this category.  Materials handling and  transfer are not included.
Particulate emissions are a result of high temperature  melting, smelting, and
refining.

REFERENCE:  1-2
                   l/l
                   o
                   on
                   UJ
                   O-
99
98

95

90

80

70

60
50
40
                                 2    345
                                 PARTICLE DIAMETER,
                             10
                     Cumulative %
                  less than or equal
      Particle      to stated size      Minimum     Maximum     Standard
      size, um      (uncontrolled)       Value       Value      Deviation

        1.0a              72
        2.0a              80
        2.5               82              63           99            12
        3.0a              84
        4.0a              86
        5.0a              88
        6.0               89              75           99             9
       10.0               92              80           99             7
  Value calculated from data reported at 2.5, 6.0, and  10.0 um.  No
  statistical parameters are given for the calculated value.

10/86                            Appendix C.2
                                                   C.2-15
-------
TABLE C.2-2  (continued).
Category:
Process:
Material:
Condensation, Hydration, Absorption, Prilling and Distillation
All
     Category  9  covers  condensation, hydration,  absorption,  prilling, and
distillation of  all materials.  These  processes  involve the  physical separa-
tion or combination of  a wide variety  of  materials  such as sulfuric acid and
ammonium nitrate fertilizer.   (Coke ovens are  included since they can be con-
sidered a distillation  process which separates the  volatile  matter from coal
to produce coke.)

REFERENCE:   1, 3
        «t
        	I
        s:
                       99
                       98

                       95

                       90

                       80

                       70
                       60
                       50
                       40
                           I
                              I
                                 I  i  l i  i i
                                 2    345
                                 PARTICLE DIAMETER,
                                         10
                      Cumulative  %
                   less  than or equal
      Particle       to  stated size      Minimum     Maximum     Standard
      size,  urn       (uncontrolled)       Value       Value      Deviation

         1.0a              60
         2.0a              74
         2.5                78              59          99           17
         3.0a              81
         4.0a              85
         5.0E              88
         6.0                91              61          99           12
        10.0                94              71          99            9
  Value  calculated  from data reported at 2.5,  6.0, and 10.0 \im.
  statistical  parameters are given for the calculated value.
                                                       No
C.2-16
                    EMISSION FACTORS
                                                                          10/86
-------
C.2.3  How To Use The Generalized Particle Size Distributions For
       Controlled Processes

     To calculate the size distribution and the size specific emissions for a
source with a particulate control device, the user first calculates the
uncontrolled size specific emissions.  Next, the fractional control efficiency
for the control device is estimated, using Table C.2-3.  The Calculation Sheet
provided (Figure C.2-2) allows the user to record the type of control device
and the collection efficiencies from Table C.2-3, the mass in the size range
before and after control, and the cumulative mass.  The user will note that
the uncontrolled size data are expressed in cumulative fraction less than the
stated size.  The control efficiency data apply only to the size range
indicated and are not cumulative.  These data do not include results for the
greater than 10 ym particle size range.  In order to account for the total
controlled emissions, particles greater than 10 um in size must be included.

C.2.4  Example Calculation

     An example calculation of uncontrolled total particulate emissions,
uncontrolled size specific emissions, and controlled size specific emission is
shown on Figure C.2-1. A blank Calculation Sheet is provided in Figure C.2-2.
           TABLE C.2-3
TYPICAL COLLECTION EFFICIENCIES OF VARIOUS
PARTICULATE CONTROL DEVICES.3'
           (percent)

Type of collector
Baffled settling chamber
Simple (high-throughput) cyclone
High-efficiency and multiple cyclones
Electrostatic precipitator (ESP)
Packed-bed scrubber
Venturi scrubber
Wet-impingement scrubber
Fabric filter
Particle size, ym
0 - 2.5
NR
50
80
95
90
90
25
99
2.5 - 6
5
75
95
99
95
95
85
99.5
6-10
15
85
95
99.5
99
99
95
99.5
  The data shown represent an average of actual efficiencies.  The efficien-
cies are representative of well designed and well operated control equipment.
Site specific factors (e.g., type of particulate being collected, varying
pressure drops across scrubbers, maintenance of equipment, etc.) will affect
the collection efficiencies.  The efficiencies shown are intended to provide
guidance for estimating control equipment performance when source-specific
data are not available.
  Reference:  10
NR = Not reported.
10/86
                                Appendix C.2
                                                C.2-17
-------
References  for Appendix  C.2


1.    Fine Particle  Emission  Inventory  System,   Office of Research and
      Development, U.  S.  Environmental  Protection Agency, Research Triangle
      Park,  NC,   1985.

2.    Confidential test data  from various  sources, PEI Associates, Inc.,
      Cincinnati, OH,  1985.

3.    Final  Guideline  Document:   Control of  Sulfuric  Acid Production Units,
      EPA-450/2-77-019, U.  S.  Environmental  Protection Agency,  Research
      Triangle Park, NC,  1977.

4.    Air Pollution  Emission  Test,  Bunge Corp.,  Destrehan,  LA., EMB-74-GRN-7,
      U. S.  Environmental Protection Agency,  Research Triangle  Park, NC, 1974.

5.    I. W.  Kirk, "Air Quality in Saw and  Roller Gin  Plants", Transactions of
      the ASAE, 20:5,  1977.

6.    Emission Test  Report, Lightweight Aggregate Industry, Galite Corp.,
      EMB-80-LWA-6,  U. S. Environmental Protection Agency,  Research Triangle
      Park,  NC, 1982.

7.    Air Pollution  Emission  Test,  Lightweight Aggregate Industry, Texas
      Industries, Inc., EMB-80-LWA-3, U. S.  Environmental Protection Agency,
      Research Triangle Park,  NC, 1975.

8.    Air Pollution  Emission  Test,  Empire  Mining Company, Palmer,  Michigan,
      EMB-76-IOB-2,  U. S. Environmental Protection Agency,  Research Triangle
      Park,  NC, 1975.

9.    H. Taback , et al., Fine Particulate Emission from Stationary Sources in
      the South Coast  Air Basin,  KVB, Inc.,  Tustin, CA 1979.

10.   K. Rosbury, Generalized Particle  Size  Distributions for Use  in Preparing
      Particle Size  Specific  Emission Inventories, U.  S.  Environmental
      Protection Agency,  Contract No. 68-02-3890, PEI Associates,  Inc., Golden,
      CO, 1985.
                                                *U.S. GOVERNMENT PRINTING OFFICE:1986-726-611
C.2-18                         EMISSION FACTORS                           10/86
-------
TECHNICAL REPORT DATA
(Please read Instructions on the reiersi before completing)
1
4.
7
9.
12
15
REPORT NO. |2
AP-42, Supplement A j
TITLE AND SUBTITLE
Supplement A to Compilation Of Air Pollutant Emission
Factors, AP-42, Fourth Edition

AUTHOR(S)
PERFORMING ORGANIZATION NAME AND ADDRESS
U. S. Environmental Protection Agency
Office Of Air And Radiation
Office Of Air Quality Planning And Standards
Research Triangle, KG 27711
. SPONSORING AGENCY NAME AND ADDRESS
3. RECIPIENT'S ACCESSION NO.
5. REPORT DATE
October 1986
6. PERFORMING ORGANIZATION CODE
8. PERFORMING ORGANIZATION REPORT NO.
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
13. TYPE OF REPORT AND PERIOD COVERED
14. SPONSORING AGENCY CODE
. SUPPLEMENTARY NOTES
EPA Editor: Whitmel M. Joyner
16. ABSTRACT
        In this Supplement to the Fourth Edition of AP-42, new  or  revised  emissions
   data are presented for Bituminous And Subbituminous Coal Combustion; Anthracite Coal
   Combustion; Fuel Oil Combustion; Natural Gas Combustion; Wood Waste Combustion In
   Boilers; Lignite Combustion; Sodium Carbonate; Primary Aluminum Production;  Coke
   Production; Primary Copper Smelting; Ferroalloy Production;  Iron And Steel Production
   Primary Lead Smelting; Zinc Smelting; Secondary Aluminum Operations; Gray Iron
   Foundries; Secondary Lead Smelting; Asphaltic Concrete Plants;  Bricks And Related
   Clay Products; Portland Cement Manufacturing; Concrete Batching; Glass  Manufacturing;
   Lime Manufacturing; Construction Aggregate Processing; Taconite Ore Processing;
   Western Surface Coal Mining; Chemical Wood Pulping; Appendix C.I, 'Particle Size
   Distribution Data And Sized Emission Factors For Selected  Sources"; and Appendix C.2,
   "Generalized Particle Size Distributions".
17. KEY WORDS AND DOCUMENT ANALYSIS
a. DESCRIPTORS
Stationary Sources
Point Sources
Area Sources
Emission Factors
Emissions
18. DISTRIBUTION STATEMENT
b. IDENTIFIERS/OPEN ENDED TERMS

19. SECURITY CLASS (This Report]
20 SECURITY CLASS (This page)
c. COSATI Held/Group

21. NO. OF PAGES
460
22. PRICE
EPA Form 2220-1 (Rev. 4-77)   PREVIOUS EDITION is OBSOLETE
-------
U.S. Environmental Protection Agency
Region V, Library
230  South Dearborn Street
Chicago. Illinois  60604
-------