, /,->,. V United States Air Pollution Training Institute EPA 450/2-80-076
' '' f- 4 "i; f' ' Environmental Protection MD 20 March 1980
Agency Environmental Research Center
Research Triangle Park NC 27711
Air
SEPA APTI
Course 444
Air Pollution
Field Enforcement
Student Workbook
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United States
Environmental Protection
Agency
Air Pollution Training Institute
MD20
Environmental Research Center
Research Triangle Park NC 27711
EPA 450/2-80-076
March 1980
Air
APTI
Course 444
Air Pollution
Field Enforcement
Student Workbook
Exercises 1—5 prepared by:
Charles W. Gruber
Cincinnati, Ohio
with
Pamela M. Giblin
Attorney at Law
Austin, Texas
Under Contract No.
68-02-3014
EPA Project Officer
James 0. Dealy
Exercise 6 prepared by:
Applied Science Associates, Inc.
Valencia, Pennsylvania
Under Contract No.
68-02-1315
EPA Project Officer
Michael C. Osborne
United States Environmental Protection Agency
Office of Air, Noise, and Radiation
Office of Air Quality Planning and Standards
Research Triangle Park, NC 27711
U.S. Environmental Protection Agency
Region V, Library
230 South Dearborn Street
Chicago, Illinois 60604
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Notice
This is not an official policy and standards document. The opinions, findings, and
conclusions are those of the authors and not necessarily those of the Environmental
Protection Agency. Every attempt has been made to represent the present state of
the art as well as subject areas still under evaluation. Any mention of products or
organizations does not constitute endorsement by the United States Environmental
Protection Agency.
Availability of Copies of This Document
This document is issued by the Manpower and Technical Information Branch, Con-
trol Programs Development Division, Office of Air Quality Planning and Standards,
USEPA. It was developed for use in training courses presented by the EPA Air Pollu-
tion Training Institute and others receiving contractual or grant support from the
Institute. Other organizations are welcome to use the document for training purposes.
Schools or governmental air pollution control agencies establishing training programs
may receive single copies of this document, free of charge, from the Air Pollution
Training Institute, USEPA, MD-20, Research Triangle Park, NC 27711. Others may
obtain copies, for a fee, from the National Technical Information Service, 5825 Port
Royal Road, Springfield, VA 22161.
U,S. Environmental Protection Agency
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* AIR POLLUTION TRAINING INSTITUTE
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TABLE OF CONTENTS
EXERCISE NO. 1
Section 1, Off-site Surveillance
(Opacity Violation of Incinerator)
Section 2, On-site Inspection
(Follow up of Section 1)
Page
1-4
1-9
EXERCISE NO. 2
Inspection of a Cement Plant
2-1
EXERCISE NO. 3
Trial of Opacity and TSP
Violations
3-1
EXERCISE NO. 4
Complaint Handling — Odor Complaint
Case Study
4-1
EXERCISE NO. 5
Complaint Inspection of an Asphalt
Concrete Batching Plant
5-1
EXERCISE NO. 6
Inspection of Combustion Sources
6-1
lv
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STUDENT EXERCISE NO. 1
OPACITY VIOLATION
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STUDENT EXERCISE NO. 1
HENDERSON COUNTY, STATE OF OHIO
SECTION I (LESSON 4) - OPACITY VIOLATION, OFF-SITE SURVEILLANCE
SECTION II (LESSON 5) - ON-SITE INSPECTION, FOLLOWING OPACITY OBSERVATION
GOAL. Practice in the application of principles taught during
the day.
OBJECTIVES. At the end of this exercise, the student should have
demonstrated his ability to:
1. Read and apply rules and regulations which are not
familiar to the student.
2. Objectively determine, from given data on a series of
opacity readings, that a violation, in fact, has
occurred and relate such observation to the Rules and
Regulations violated.
3- Write a notice of violation of a visible emission rule.
4. Determine the information to be obtained during the
on-site inspection.
5. Identify errors in a poorly conducted on-site
inspection.
6. Identify all potential violations discovered during
the on-site inspection.
?. Write a report documenting the on-site inspection.
INSTRUCTIONS. The Exercise has two sections:
Section I follows Lesson 4 and Section II follows Lesson 5.
Because of the time limitations, carefully abide by the
following instructions:
1. Work as a team of two or three to be assigned.
2. Read the case history and do the work called for in
the case study.
1-2
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3- Only one completed answer sheet is required for each
Team. All members should sign to record their
participation.
4. following each Lesson (4 and 5), forty (40) minutes
will be allotted to complete the answer sheets.
5- After 40 minutes, the instructor will call for reports -
question by question - at random from the various Teams.
The spokesman will respond.
6. Each point will be discussed.
?. At the completion of Section I and Section II, an
answer sheet will be available to each student to
compare against the work of his team.
8. Collection of the reports for review by the instructor
is optional. If collected, the Team Reports should be
returned the next day.
1-3
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STUDENT EXERCISE NO. 1
SECTION I - (LESSON 4)
OPACITY VIOLATION
HENDERSON COUNTY, OHIO.
OFF-SITE SURVEILLANCE
This case study of a multiple-chamber incinerator smoke violation describes
the observation of the emissions, entry of the facility, and inspection
of the equipment. Carefully read the following material. Do the assignment
required for each lesson. Use Section II, Rules and Regulations, as
applying to this source.
Inspector John Hubbard, who has been with his agency for six months, is
patrolling Sector 2, the southeastern part of Henderson County, Ohio on
July 15, 1978. At 8:10 A.M. he observes a plume of black smoke located
approximately one mile to the east of his vehicle. Traveling east, he is
soon able to park his car approximately 75 feet west of the source of the
plume. Hubbard notes a large sign painted on the side of the building
reading "Johnson Storage Co". The source turns out to be a small multiple-
chamber incinerator having an approximately 1 ft. diameter x 12 ft. high
steel stack equipped with a spark arrester. The incinerator is located in
the rear of a three-story brick building that appears to be a warehouse.
The wind is from the south at approximately five miles per hour.
The inspector gets out of his car and stands alongside of it. Using his
own watch and a stop watch, he begins to record his observations of the
emissions as of 8:15 on the agency observation form. The results of the
observation axe shown on the following page.
The incinerator is unattended during the entire observation. In fact,
no one is present in the yard, and the premises appear to be abandoned.
He notices two 50-gallon oil drums near the incinerator, but from his
vantage point, he cannot see the contents.
1-4
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At this point begin the exercise for Lesson 4. Except for the reference to
the appropriate regulations, do not read the case beyond this point as time
is limited and the actions and reactions to the questions will lose their
realism if such is done.
Each team is required to submit one copy of the following assignments,
completed and signed by each member of the team.
1. Complete the Visible Emission Observation Form using the data given
in the case narrative report. If any necessary information was
omitted 3n the description of Hubbard1s actions, make reasonable
assumptions which would validate the visible emission observation
results. Circle or underline assumed data.
2. Enter on the front of the "Notice of Violation" form only that data
which is valid to this point.
J. State the Rule violated and duration of the violation.
4. Decide on the on-site inspection strategy.
On the answer sheet write the three most Important pieces of information
to be obtained during the inspection.
4. State three important pieces of Information which are necessary to
complete the documentation of this opacity violation to be obtained
during the on-site inspection.
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STUDENT EXERCISE NO. 1
SECTION I (LESSON 4)
ANSWER SHEET
TEAM MEMBERS SIGN:
1. Completed Visible Emission Observation Form. Do not turn in.
2. Enter on the Notice of Violation Form that information Which is valid
to this point in time.
3. The rule violated was
Aggregate (length) of violation ._ minutes
4. The on-site inspection should produce the following information to
complete the documentation of this violation.
1.
2.
1-7
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COUP
fAUT
inonr
Henderson County Air Pollution Control
Henderson, Ohio
NOTICE OF VIOLATION
TNSTAIUNQ'CONTRACTOR
CITY"
YOU ARE HEREBY NOTIFIED THAT PURSUANT TO SECTION
OF THE HEALTH AND SAFETY CODE OF THE
STATE OF OHIO A MISDEMEANOR HA2i BEEN COM-
MITTED THROUGH THE
POINT OP OlSERVATIONi
WEATHER:
ARRlVALt JJ
• DEPARTURIt JJ
V.AS SOURCE EMIHING
VISIILE DISCHARGE AT
END OF OISERVATION?
_ns u NO n
M. N* OH
OPACITY
EMISSION JJJJ;to.
FROM! ^ONUOl
OPEN FIRE
P.rmlt
N«. _
WIND N JS W
VISIILi EMISSIONS OlSEftVED
•TAtT
TOTA
•
aaea
L
•TOP
•••BK
EHOBM
HIM.
'"-'— -
R. N«.
%»r
=3BaMBK
tOLOII
a- ' i qBMmsna
MIN.
SERVED TO.
TITLE,
JdT" TL-vu £*-
C/ DirMtor of
Daf • of Service
Sector
Bmforeemeiit
BedgoNo.
FRIONT
1-8
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STUDENT EXERCISE NO. 1 (CONT'D)
SECTION II (LESSON 5)
OPACITY VIOLATION
HENDERSON COUNTY, OHIO
ON-SITE INSPECTION
CONTINUATION OF HENDERSON COUNTY OPACITY VIOLATION
After completing his pre-entry surveillance, Hubbard drives to the front
of the plant and parks his car and enters the premises.
Inside, he meets a receptionist, identifies himself and his agency, and
asks to see the owner of the company. She replies that the owners are not
present, as the headquarters office of the company is located in Chicago,
Illinois, and asks what it is he wants. Hubbard replies that the incinerator
appears to be in violation. Thereupon, the receptionist directs him to
see the bookkeeper, Mr. Peterson.
She rings Mr. Peterson who presently arrives. After a quick introduction,
the inspector informs Mr. Peterson that he has observed smoke in excess of
allowable limits and that he is in violation of Henderson County APCD Rule
50. He then asks to see the incinerator. Mr. Peterson replies, "I didn't
know we are in any kind of violation. I don't see how that could be —
we have the necessary permit to operate. As I understand it, that's
supposed to be a smokeless incinerator."
As they walk through the plant to the rear, the first floor is comparatively
empty except for some apparently new equipment in the rear of the plant.
There appear to be a degreasing unit and five tanks (two of which have
buss bars, drains, etc., suitable for plating use). The inspector also
notices that part of the cement flooring is broken up as if to make way for
new plumbing, and that unassembled ventilation system parts, including
hooding, a blower motor and fan, are located near the tanks.
1-9
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The inspector asks Mr. Peterson What business the company is engaged in.
Mr. Peterson replies, "Hard chrome plating —we're the Hartley Division,
Compton Metals Company." In further conversation, the inspector learns
that the company moved to this location just three months ago.
They arrive at the incinerator at 9:09 A.M. No visible emissions are
observed. Mr. Peterson exclaims, "See, it's not smoking!" The inspector
explains that he observed a violation before he entered the plant, and asks
who lit the incinerator. Peterson replies, "I did. Mr. Allan, the Plant
Manager, asked that I clean out the debris left from the previous tenant.
I've been doing this sort of thing since we are still short of custodial
help." On further questioning, Mr. Peterson disclosed that he had charged
*.
two 50-gallon drums of paint cans, styrofoam packing materials, creosoted
wood timbers, rubber and plastic materials, cardboard and paper wastes,
and rubber and plastic gasket materials in the incinerator.
Hubbard inspects the interior of the incinerator and observes evidence
of paint cans and rubber and plastic residue. The interior appears to be
in good condition. He notes a slightly smouldering burning pile, 2 ft. in
diameter x 1 ft. high. The inspector also observes the following:
- A permit posted on the side of the incinerator made
out to "Johnson Storage Co.", 5678 S. Main St.,
Henderson, Ohio, Permit No. P-593^, dated
Sept. 15, 1977 authorises the operation of one (l)
ACME Multiple-Chamber retort type incinerator rated
at 75 Ibs./hour, equipped with 1-Larkin manual
secondary gas burner rated at 150 x 103 Btu/hour.
Incinerator to be used for Type 0" waste only. Secondary
burner must be in operation through all burning periods.
- Secondary burner not in operation.
- All air port doors were closed.
- Refractories and stack appear to be in good condition.
- Two sampling ports are noted in the stack.
The case study ends here, but not necessarily' the inspection.
At this point begin the exercise for Lesson 5«
1-10
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EXERCISE TOR LESSON 5
1. List at least five (5) important errors pertaining to different
principles of good on-site inspection and investigative practice.
2. List the number of potential violations and specify the Rule which
has "been violated.
3. Complete the Notice of Visible Emission Violation form, "both
front and back. Again make assumptions and circle or underline
where assumptions were necessary to complete the notice and report.
4. If so instructed, each Team is to turn in one answer sheet with the
completed Observation Form and Notice of Violation Form, signed
by all members of the Team.
1-11
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STUDENT EXERCISE NO. 1
SECTION II
LESSON 5
ANSWER SHEET
TEAM MEMBERS SIW
1. List at least five important errors pertaining to different principles
of good on-site inspection and investigative practice.
1.
2.
3-
6.
li-12
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STUDENT EXERCISE NO. 1
LESSON 5
ANSWER SHEET (OONT'D)
2. List the num"ber of potential violations and specify the Rule tdiich
has "been violated.
No. of
Rule Violations Description
3. Complete the notice of Violation Pbrm, front and "back.
4. If so instructed, each Team is to turn in one completed Answer Sheet,
signed "by all memters of the Team and one completed Notice of Violation
Form, front and "back.
1-13
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OPERATOR
Name & Address
HIS REMARKS
WAS MANAGEMENT CONTACTED YES
NO
NAME
TITLE
HIS REMARKS
(INCLUDING INSPECTOR'S FULL EXPLANATION OF VIOLATION)
CORPORATE OFFICER '
DRIVER'S LICENSE NO.
VACATION FROM
TO
REQUEST FOR COMPLAINT SIGNED
DATE
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CLASSIFICATION OF WASTES TO BE INCINERATED
Clarification of Waste*
Type Oaehption Principal Component*
Approximate
Composition
* by Weight
•0 Trash
•1 Rubbish
•2 Refuse
•3 Garbage
Animal
solids and
organ ie
waste*
5 Gaseous,
liquid or
Mmi-Uquid
Semi-solid
aad«olid
Highly combujcible
MM, paper, wood,
carboard cartons,
including up to 10%
treated papers,
plastic or rubber
scraps; commercial
and industrial
sources
Combustible waste,
paper, canons, rags,
wood scraps, combustible
door sweepings;
domestic, commercial,
and industrial sources
Rubbish and garbage;
residential sources
Animal and vegetable
wastes, restaurants,
hotels, markets;
institutional,
commercial, and
club sources
•
Circuses, organs,
solid organic wastes;
hospital, laboratory,
abattoirs, animal
pounds, and similar
sources
Industrial
process wastes
Combustibles requiring
hearth, retort, or grate
burning equipment
Trash 100%
Rubbish 80%
Garbage 20%
Rubbish $0%
Garbage 50%
Garbage 65%
Rubbish 35%
100% Animal
and Human
Tissue
Variable
Variable
RELATIONSHIP BETWEEN R AND OPACITY
•R" NO.
OPACITY
0
1
2
3
4
5
0
20
40
60
80
100
1-15
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SPECIMENS OF RULES AND REGULATIONS
HENDERSON COUNTY AIR POLLUTION CONTROL DISTRICT
REGULATION II PERMITS
Rule 1. DECLARATION OF POLICY AND THE PURPOSE
It is hereby declared to be the public policy of this
Henderson County Air Pollution Control District and the purpose
of this regulation to achieve and maintain such levels of air
quality as will protect human health, life, and safety or comfort.
Rule 2. DEFINITION OF TERMS
(a) Air Contaminant. Any smoke, soot, fly ash, dust, cinders,'
cinders, dirt, fumes, gases, vapors, mists, liquid, particu-
late or odorous matter, not including uncombined water vapors.
(b) Air Pollution. The presence in the ambient air of one or
more air contaminants or any combination thereof in such
quantity and of such characteristics and duration as to injure
or tend to injure human health or welfare, plant or animal
life, or property, or which would interfere with the enjoy-
ment of life or use of property.
(c) Effective Date of Regulation. This date shall be July 1, 1975,
notwithstanding any amendment, rescission, or renumbering of
of any of these regulations.
(d) Emission. Act of releasing or discharging any air pollutant
into the ambient air from any source.
(e) Opacity. A state which renders material partially or riiolly
impervious to rays of light and causes obstruction of an
observer's view.
(f) Person. Any individual, firm, public or private corporation,
association, business, trust, company, partnership, contractor,
supplier, installer, user, operator, or owner, or any political
subdivision or employee thereof, or any other entity.
(g) RJAgelmann Chart. The chart published and described in the
United States Bureau of Mines Information Circular 8333
(May, 196?).
(h) Source. Any operation, or real or personal property, or
person which emits or may emit any air pollutant.
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Specimens of Rules and Regulations (Cont'd)
Henderson County Air Pollution Control District
Rule 10. PERMITS RETIRED
(a) Authority to Construct. Any person "building, erecting,
altering or replacing any article, machine, equipment or
other contrivance, the use of which may cause the issuance
of air contaminants or the use of which may eliminate or
reduce or control the issuance of air contaminants, shall
first obtain authorisation for such construction from the
Air Pollution Control Officer. An Authority to Construct
shall remain in effect until the permit to operate the
equipment for which the application was filed is granted
or denied or the application is canceled.
(b) Permit to Operate. Before any article, machine, equipment
or other contrivance descri"bed in Rule 10(a) may "be operated
or used, a written permit shall "be obtained from the Air
Pollution Control Officer. No permit to operate or use shall
"be granted either "by the Air Pollution Control Officer or the
Hearing Board for any article, machine, equipment or contri-
vance described in Rile 10(a), constructed, or installed
without authorization as required by Rule 10(a), until the
information required is presented to the Air Pollution Control
Officer and such article, machine, equipment or contrivance is
altered, if necessary, and made to conform to the standards set
forth in Rule 20 and elsewhere in these Rules and Regulations.
(c) Posting of Permit to Operate. A person who has been granted
under Rule 10 a permit to operate any article, machine, equipment,
or other contrivance described in Rule 10(b), shall firmly affix
such permit to operate, an approved facsimile, or other approved
identification bearing the permit number upon the article, machine,
equipment, or other contrivance in such a manner as to be clearly
visible and accessible. In the event that the article, machine,
equipment, or other contrivance is so constructed or operated
that the permit to operate cannot be so placed, the permit to
operate shall be mounted so as to be clearly visible in an
accessible place within 25 feet of the article, machine, equip-
ment, or.other contrivance, or maintained readily available at
all times on the operating premises.
(d) A person shall not willfully deface, alter, forge, counterfeit,
or falsify a permit to operate any article, machine, equipment,
or other contrivance,,
1-18
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Specimens of Rules and Regulations (Cont'd)
Henderson County Air Pollution Control District
Rule 12. TRANSFER
An authority to construct, permit to operate or permit to sell
or rent shall not "be transferable, Aether by operation of law
or otherwise, either from one location to another, from one piece
of equipment to another, or from one person or corporation to
another.
Rule 19. PRO VISION OF SAMPLING AND TESTING FACILITIES
A person operating or using any article, machine, equipment or
other contrivance for which these rules require a permit shall
provide and maintain such sampling and testing facilities as
specified in the authority to construct or permit to operate.
REGULATION IV. PROHIBITIONS
Rule 50. CONTROL OF VISIBLE AIR CONTAMINANTS FROM STATIONARY SOURCES
(a) Emission Limitations
1. No person shall discharge into the atmosphere from any
single stationary source of emission whatsoever, any
air contaminant of a shade or density equal to or darker
than that designated as No. 1 on the Ringelmann Chart or
20 percent opacity, except as set forth in subsection
(a) (2) and section (b) of Rule 50.
2. A person may discharge into the atmosphere from any
single stationary source of emission for a period or
periods aggregating not more than three (3) minutes in
any sixty (60) minutes, air contaminants of a shade or
density not darker than No. 3 on the Ringelmann Chart or
60 percent opacity.
(b) Uncombined Water
It shall "be deemed not to be a violation of Rule 50 (a)•
where the presence of uncombined water is the only reason
for failure of an emission to meet the requirements of
Rule 50 (a).
1-19
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Specimens of Bales and Regulations (Cont'd)
Henderson County Air Pollution Control District
Rule 5L. NUISANCE
A person shall not discharge from any source tihatsoever such
quantities of air contaminants or other material which cause
injury, detriment, nuisance or annoyance to any considerable
number of persons or to the public or which endanger the
comfort, repose, health or safety of any such persons or the
public or which cause or have a natural tendency to cause
injury or damage to business or property.
Rule 52. PARTICULATE MATTER.
Except as otherwise provided in Rules 53 and 54, a person shall
not discharge into the atmosphere from any source particulate
matter in excess of 0.2 grain per cubic foot of gas at standard
conditions.
Rule 53. SPECIFIC CONTAMINANTS.
A person shall not discharge into the atmosphere from any single
source of emission whatsoever any one or more of the following
contaminants, in any state or combination thereof, exceeding
in concentration at the point of discharge:
(a) Sulphur Compounds calculated as sulphur dioxide (802):
0.1 per cent, by volume.
(b) Combustion Contaminants: 0.2 grain per cubic foot of gas
calculated to 12 per cent of carbon diox3.de (002) at
standard conditions. In measuring the combustion contaminants
from incinerators used to dispose of combustible refuse by
burning, the carbon dioxide (002) produced by combustion of
any liquid or gaseous fuels shall be excluded from the
calculation to 12 per cent of carbon dio3d.de (002).
Rule 54. DUST AND FUMES
A person shall not discharge in any one hour from any source
whatsoever dust or fumes in total quantities 3n excess of the
amount shown in the following tables (see next page)
To use the following table, take the process weight per hour as
such is defined in Rule 2(j). Then find this figure on the table,
opposite which is the maximum number of pounds of contaminants which
may be discharged into the atmosphere in any one hour. As an
1-20
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Specimens of Rules and Regulations (Cont'd)
Henderson County Air Pollution Control District
example, if A has a process which emits contaminants into the
atmosphere and which process takes 3 hours to complete, he will
divide the weight of all materials in the specific process, in
this example, 1,500 Ibs. by 3 giving a process weight per hour
of 500 rbs. The table shows that A may not discharge more than
1.77 Its. in any one hour during the process. Where the process
weight per hour falls "between figures in the left hand column,
the exact weight of permitted discharge may be interpolated.
Rule 57. OPEN FIRES
A person shall not turn any combustible refuse in any open outdoor
fire within Henderson County, except:
(a) When such fire is set or permission for such fire is given in
the performance of the official duty of any public officer,
and such fire in the opinion of such officer is necessary:
1. Pbr the purpose of the prevention of a fire hazard rtiich
cannot be abated by any other means, or
2. The instruction of public employees in the methods of
fighting fire.
(b) When such fire is set pursuant to permit on property used
for industrial purposes for the purpose of instruction of
employees in methods of fighting fire.
(c) When such fire is set in the course of any agricultural
operation in the growing of crops, or raising of fowls or
animals.
These exceptions shall not be effective any any calendar day on
which the Air Pollution Control Officer determines that:
1. The inversion base at 4:00 A.M., Eastern Standard Time,
will be lower than 1,500 ft. above mean sea level, and
2. The maximum mixing height will not be above 3,500, and
3> The average surface wind speed between 6:00 A.M. and
12:00 noon, Eastern Standard Time, will not exceed
five miles per hour.
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Specimens of Rules and Regulations (Cont'd)
Henderson County Air Pollution Control District
Rule 58. INCINERATOR BURNING
A person shall not "bum any combustible refuse in any incinerator
within the Henderson County, except in a multiple-chamber
incinerator as described in Rule 2(p), or in equipment found by
the Air Pollution Control Officer in advance or such use to "be
equally effective for the purpose of air pollution control as an
approved multiple-chamber incinerator.
Rule 60. CIRCUMVENTION
A person shall not "build, erect, install, or use any article,
machine, equipment or other contrivance, the use of which,
without resulting in a reduction in the total release of air
contaminants to the atmosphere,, reduces or conceals an emission
which would otherwise constitute a violation of Division 20,
Chapter 2 of the Health and Safety Code or of these Rules and
Regulations. This Rule shall not apply to cases in which the
only violation involved is of the Health and Safety Code, or
of Rule 51 of these Rules and Regulations.
1-23
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STUDENT EXERCISE NO. 2
INSPECTION OF A CEMENT PLANT
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INSPECTION OF A CEMENT PLANT
(FILM)
GOAL. To demonstrate off-site and on-site Inspection procedures
by depicting on film a permit status inspection of a
cement plant. The student's proficiency is tested by
completing inspection report forms to record conditions
shown in the film.
OBJECTIVES. At the end of this exercise, the student should be able to:
1. List the elements included in a facility inspection.
2. Describe the basic process of manufacturing
Portland cement (dry process).
3. Use existing agency data to prepare for an
inspection.
4. Properly obtain entry to a facility for the
purpose of conducting an inspection.
5. Interface effectively with plant management and
personnel so as to elicit their help and
cooperation.
6. List inspection points for cement plants.
7. Examine the appropriate inspection points for
permit compliance.
SELECTED READING: Inspection Manual for Enforcement of New Source
Performance Standards. Portland Cement Plants.
Reference 7.1
2-2
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INSTRUCTIONS FOR EXERCISE NO. 2
This unit centers around a film showing an FEO conducting a routine inspection
of a dry type cement plant. The student observes the movement of the FEO and the
results of his inspection. After the film is shown, the student is required to
complete his own inspection findings using the data gathering form starting on
page 2-4. When all students are finished, your completed findings will be com-
pared to those of the instructors, and the session ends with a discussion of the
lesson and student work.
NOTE: Most of the data you need to complete the form can be determined from
viewing the film, but some information you may need can be found in
this section.
2-3
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SUGGESTED INSPECTION POINTS AND DATA GATHERING QUESTIONS
CEMENT PLANT KILN AND CLINKER COOLER*
The plant perimeter
Control room instrument readings* (Points 1A, IB, & 1C! on flow diagram)
Delivery end of Kiln (Point 2B)
Clinker cooler enclosure (Point 3A)
Dust return spout and conveyor (Point
Clinker cooler "ba^iouse (Point 4)
*Refer to the drawings at the end of this form, for a
plant flow diagram indicating inspection points and for
actual control room instrument readings.
-v
2-4
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Bag cleaning compressor (Point 4)
Clinker cooler baghouse fan and motor (Point 4)
Clinker cooler "baghouse stack (Point 4)
Itilti-cyclone pre-heater (Shown in film - not shown on film diagram)
Kiln "baghouse enclosure and stack (Point 5)
Area "below kiln "baghouse (Point 5A)
Kiln "baghouse manometers*
*Refer to the drawings at the end of this form.
2-5
-------
Kiln baghouse hoppers and screw conveyor (Point 5A)
Kiln baghouse dust return system (Point 5A)
Kiln baghouse fan and motor (Point 5)
Plant Yard
2-6
------- An error occurred while trying to OCR this image.
------- An error occurred while trying to OCR this image.
-------
Illllilill
0 ,10 20
JLLUJ'MJJ
i ) | 2
tfjT
,
COOLER
DUST COLL INL!
TEMPERATURE
Illllllllll
3O 4O SO
J1 UK Mill
Si " °
III ' I'l °
'Ttij.ln! o
TT • r 1
|= SO
-EM i °
0
ET
Clinker Cooler Gas
Inlet Temperature
in Degrees Farenheit
(Temp. « chart number x 10)
(Recorder located in Control Room)
tCHES OF W^TER
10 15
BAGHOUSE
PRESSURE
Kiln Baghouse System Pressure
• (Overall baghouse pressure)
2-9
------- An error occurred while trying to OCR this image.
-------
Cement Plant Pile Information
Permit Application
Kiln Data
Kiln Baghouse Data
Clinker Cooler Data
Clinker Cooler Baghouse Data
- Summary of Source Operation - Kiln
Summary of Pitot Traverse Data - Kiln
Summary of Particulate Sampling Data -
Kiln
•
Summary of Source Operation - Clinker
Cooler
Summary of Pitot Traverse Data - Clinker
Cooler
Summary of Particulate Sampling Data -
Clinker Cooler
2-11
-------
STATE OF ILLINOIS
ENVIRONMENTAL PROTECTION AGENCY
DIVISION OF AIR POLLUTION CONTROL
2200 CHURCHILL ROAD
SPRINGFIELD, ILLINOIS (2706
MKE OF EQUIPMENT TO BE
CONSTRUCTED OR OPERATED
APPLICATION FOR A PERMIT,., . „
r-i r-i "'
U CONSTRUCT QU OPERATE memi,
PERM]
QAYF
Cement Plant r*}
FOR AGENCY USE ONLY .,
T H.
1,,
„
1C.
in.
NAME OF OWNER:
Ajax Cement Corporation
STREET ADDRESS OF OWNER:
100 Park AVenue
CITY OF OWNER:
New York
STATE OF OWNER:
New York
It. ZIP CODE:
10101
a. KAMI OF OPERATOR:
Ajax Cement Corporation
2b. STREET ADDRESS OF
. 123 River
OPERATOR:
Street
2c. CITY OF OPERATOR:
Clearview
2d. STATE OF OPERATOR
Illinois
2*. ZIP CODE:
60000
•.
3i. NAME OF CORPORATE DIVISION OR PLANT:
Riverview Plant
3c. CITY OF EMISSION SOURCE:
Clearview
4,
i.
ALL CORRESPONDENCE TO:
Donald Carson
3d. LOCATED WITHIN CITY
LIMITS:,-, r,
B YES U NO
3t>. STREET ADDRESS OF
123 River
3«. TOWNSHIP:
Smith
(NAME OF INDIVIDUAL)
ADDRESS FOR CORRESPONDENCE: (CHECK ONLY
Downr R : K! OPE RATOR
ONE)
TlmiSSION SttJSCF
EMISSION SOURCE:
Street
3f. COUNTY: 3g. ZIP CODE:
Jones 600,00
j*.
S. TELEPHONE NUMBER FOR ACiENCY TO CALL:
800/555-4567
7. YOUR ID NUMBER FOR THIS APPLICATION:,,,
RP2973 (c)
THE UNDERSIGNED HEREBY HAKES APPLICATION FOR A PERMIT AND CERTIFIES THAT THE STATEMENTS CONTAINED HEREIN ARE TRUE AND CORRECT, AND
FURTHER CERTIFIES THAT ALL PREVIOUSLY SUBMITTED INFORMATION REFERENCED IN THIS APPLICATION REMAINS TRUE, CORRECT AND CURRENT.
BY AFFIXING HIS SIGNATURE HERETO HE FURTHER CERTIFIES THAT DIE tS AUTHORIZED T» EXECUTE THIS APPLICATION.
AUTHORISED SIGNATURE^):
,-)
BY A.'fi+si.LJ C CL WC'TL
SIGNATURi
Donald Carson
YVPlfc bft TAINTED NAME OF SIGNER
2/9/73
DATE
BY
SIGNATURE
DATE
TYPED OR PRINTED Hint Or SIGNER
TITLE OF SIGNER
TITLE OF SIGNER
THIS FORM MAY
(A) THIS FORM IS TO PROVIDE THE AGENCY WTTH GENERAL INFORMATION ABOUT THE EQUIPMENT TO BE CONSTRUCTED OR OPERATED.
ONLY BE USED TO REQUEST ONE TYPE OF PERMIT - CONSTRUCTION OR OPERATION - AND NOT BOTH.
IB) CLEARLY IDENTIFY THE GENERIC NAME OF THE EQUIPMENT TO BE CONSTRUCTED OR OPERATED. SUCH IDENTIFICATION WILL APPEAR ON THE
PERMIT WHICH NAY BE ISSUED PURSUANT TO THIS APPLICATION. THIS FORM MUST BE ACCOMPANIED BY THE APPLICABLE ADDENDA.
(C) PROVIDE A NX1BER M HEM 7 ABOVE WHICH YOU WOULD LIKE THE AGENCY TO USE FOR IDENTIFICATION OF TOUR EQUIPMENT. YOUR IDENTIFICATION
NUMBER WILL BE REFERENCED IN ALL CORRESPONDECE. RELATIVE TO THIS APPLICATION. FROM THIS A6EMCY. TOUR IDENTIFICATION NUMBER MUST
IIOT EXCEED TEN (10) CHARACTERS. .
(0) THIS APPLICATION MUST BE SIGNED IN ACCORDANCE WTTH PCB REGS.. CHAPTER 2. PART 1. RULE 103UH4) OR 103(b)(5) WHICH STATES:
•ALL APPLICATIONS AND SUPPLEMENTS THERETO SHALL BE SIGNED BY THE OWNER AND OPERATOR OF THE MISSION SOURCE OR AIR POLLUTION
CONTROL EQUIPMENT, OR THEIR AUTHORIZED AGENT. AND SHALL BE ACCOMPANIED BY EVIDENCE OF AUTHORITY TO SIGN THE APPLICATION.*
IF THE OWNER OR OPERATOR IS A CORPORATION. SUCH CORPORATION MUST HAVE OK FILE WITH THE AGENCV A CERTIFIED COPY OF A RESOLUTION
OF THE CORPORATION'S BOARD OF DIRECTORS AUTHORIZING THE PERSONS SIGNING THIS APPLICATION TO (WISE OR ALLOW THE COKSTRUCTION OR
OPERATION OF THE EQUIPMENT TO BE COVERED BY THE PERMIT. 2-12
-------
OUTSIDE OF THE CWPORATE UMITS OF CHICAGO «T BE
In QUADRUPLICATE.
A CONSTRUCTION
PERMIT APPLICATION M ALL OTHER LOCATIONS NET BE SUBMITTED III TRIPLICATE.
10.
THE APPLICANT SHALL SUBMIT A PLOT PLAN AND MAP SMOKING DISTANCES TO THE NEAREST BOUNDARY OF THE PROPERTY ON MUCH THE OPERATION IS
LOCATED AND DISTANCES TO THE NEAREST RESIDENCES. LODGINGS. URSINE HOMES. HOSPITALS. SCHOOLS AND COMMERCIAL AND MANUFACTURING .
ESTABLISHMENTS. IF SUCH A PLOT PLAN AND NAP HAS ALREADY BEEN SUBMITTED, INDICATE THE ASSOCIATED AfiENCY 1.0. VtBER AND PEWIT
APPLICATION NUMBER. AfiENCY I J>. NO. APPLICATION NO.
11. THE APPLICANT SHALL SUBMIT A PROCESS FLOW DIAGRAM DEPICTING ALL EMISSION SOURCES AND ALL AIR POLLUTION CONTROL EQUIPMENT COVERED
BY THIS PERMIT APPLICATION. THE DIAGRAM SHALL INCLUDE LABELS FOR EACH EMISSION SOURCE AND EACH ITEM OF AIR POLLUTION CONTROL
EQUIPMENT. AND SHALL SET FORTH MAXIMUM FLOW RATES FOR (1) ALL PROCESSING EQUIPMENT. (2) ALL AIR POLLUTION CONTROL EQUIPMENT. (1)
ALL EMISSION SOURCES. AW (4) ALL STACKS AND VENTS. NUMBER OF SHEETS: •> DRAWING NUMBER(S): 1 ft 2
12- FOR EACH EMISSION SOURCE AND EACH ITEM OF AIR POLLUTION CONTROL EQUIPMENT IDENTIFIED ON THE PROCESS FLOW DIAGRAM. THE APPLICANT
SHALLCOMPLETE ANDSUBMIT THE APPLICABLE PEWIT APPLICATION FORMS. THE FLOV DIAGRAM SHALL INDICATE THROUGH *!» STACK OR VENT
JBrEHlSSION SOURCE OR ITS RELATED AIR POLLUTION CONTROL EQUIPMENT IS EXHAUSTED. IF irTTtXHAUSTED HITHIN A BUILDING. SO INDICATE.
„ IF THU IS AN APPLICATION FOR AN OPERATING PERMIT. AND THE APPLICANT IS INCORPORATING BY REFERENCE PREVIOUSLY GRANTED INSTALLATION
OR CONSTRUCTION PERMITS. HE SHALL tOMPLETE FORM APC-210, ENTITLED 'DATA AND INFORMATION - INCORPORATION |Y REFERENCE.* —
IF THIS IS AN APPLICATION FOR AN OPERATING PERMIT. AND THE STARTUP OF ANY EMISSION SOURCE DESCRIBED BY THIS APPLICATION PRODUCES
AN AIR CONTAMINANT IN EXCESS OF APPLICABLE STANDARDS, THE APPLICANT MAY REQUEST PERMISSION TO EXCEED SUCH STANDARDS BY COMPLETING
FORM APC-203. ENTITLED -OPERATION DURING STARTUP.*
15. IF THIS IS AN APPLICATION FOR AN OPERATING PERMIT. AND THE APPLICANT IS APPLYING FOR PERMISSION TO ^RATE AN EMISSION SOURCE
DURING MALFUNCTIONS OR BREAKDOWNS PURSUANT TO PCB REGS.. CHAPTER 2. RULE 105. THE APPLICANT NAY REQUEST SUCH PERMISSION BY
COMPLETING FORM APC-204, ENTITLED •OPERATION DURING MALFUNCTION AND BREAKDOWN.*
16.
IF THIS IS AN APPLICATION FOR AN OPERATING PERMIT AND ALL OR ANY PART OF THE PROCESS MUST BE CONTROLLED OR MODIFIED TO COMPLY
KITH APPLICABLE REGULATIONS. THE APPLICANT SHALL COMPLETE FORM APC-202. ENTITLED •COMPLIANCE PROGRAM I PROJECT COMPLETION SCHEDULE.
117. IF THIS IS AN APPLICATION FOR AN OPERATING PERMIT. DOES THE OPERATION COVERED BY THIS APPLICATION REQUIRE AN EPISODE ACTION
**" El*5 D* _____ :
I IS. MS EACH EMISSION SOURCE COVERED BY THIS APPLICATION. AS OF APRIL 14. 1972. IN COMPLIANCE WITH THE 'RULES AND REGULATIONS -.
GOVERNING THE CONTROL OF AIR POLLUTION/ ADOPTED 8f THE FORMER} IR POLLUTION CONTROL BOARD AND CONTINUED EFFECTIVE PURSUANT
TO SECTION 49{e) OF THE ENVIRONMENTAL PROTECTION ACT? [gj TES Q NO C\
119. IF THIS IS AN APPLICATION FOR AN OPERATING PERMIT. HAS THE OPERATION THE SUBJECT OF A VARIANCE-.PETITION FILED WITH THE ILLINOIS
POLLUTION CONTROL BOARD ON OR BEFORE JUNE 13. 1972? Q TES Q "°
IF 'YES/ CITE PCB NUMBER(S): DATE OF BOARD ORDER: _j
MAD THE APPLICANT ON OR BEFORE APRIL 14. 1972. COMMENCED CONSTRUCTION OF EQUIPMENT OR MODIFICATIONS SUFFICIENT TO ACHIEVE COMPLIANC
WITH THE APPLICABLE LIMITATIONS OF THE tULES AND REGULATIONS GOVERNING THE CONTROL OF AIR POLLUTION.* ADOPTED 1LTHE FORMER AIR
POLLUTION CONTROL BOARD AND CONTINUED EFFECTIVE PURSUANT TO SECTION 49(e) OF THE ENVIRONMENTAL PROTECTION ACT? QYES Q NO
IF IB.* EXPLAIN IN DETAIL AND NARK TOUR EXPLANATION AS EXHIBIT 0.
TOTAL NUMBER OF PACES IN EXHIBIT 0:
20. IF THIS IS AN APPLICATION FOR AN OPERATING PERHIT, THE APPLICANT SHALL SUBMIT AN ESTIMATE OF THE MAXIMUM ONE-HOUR AMOUNTS OF
PARTICU.ATE MATTER. SULFUR DIOXIDE. CARBON MONOXIDE. OXIDES OF NITROGEN. AND ORGANIC MATERIAL EMITTED FROM ALL SOURCES LOCATED
ON THE PLANT OR PREMISES. THIS ESTIMATE SHALL INCLUDE ALL EMISSION SOURCES LOCATED ON TM6 APPLICANT'S PREMISES ANO NOT JUST
THE EMISSION SOURCES DESCRIBED IN THIS APPLICATION.
MATERIAL
MAXIMUM ONE-HOUR
AMOUNTS
MATERIAL
MAXIMUM ONE-HOUR
AMOUNTS
HATER. ML
MAXIMUM ONE-HO
MRTICULATE
HATTER
SULFUR
DIOXIDE
NITROGEN
OXIDES
30 IB
450
270
OftUNIC
MTER1AL- .
CARBON
VMOXIDE
4.6
IB
15
LB
MAT IS THE SIZE (IN ACRES) OF APPLICANT'S PRBUSES?
500
LIST AND .IDENTIFY ALL FORKS. EXHIBITS. AND OTHER INFORMATION SUMITTD AS PART OF THIS APPLICATION. PLEASE NUMBER EVERY PAGE
AND STATE THE TOTAL NUMBER OF PAGES IR THIS APPLICATION.
2-13 .11
-------
STATE OF ILLINOIS
ENVIRONMENTAL PROTECTION ACINCY
DIVISION OF AIR POLLUTION CONTROL
*ZOO CHURCHILL ROAD
SPRINGFIELD. ILLINOIS CZ706
FOR AGENCY USE ONLY
DATA AND INFORMATION
PROCESS EMISSION SOURCE/*)
Cement Kiln
Ajax Cement Corporation
123 River Street
2. NAME OF CORPORATE DIVISION OR PLANT (IF DIFFERENT FROM Ok
4. CITY OF EMISSION SOURCE:
Clearview
GENERAL INFORMATION
1
Portland Cement Mfg.
Fuller/Gatx
6. NAME OF EMISSION SOURCE EQUIPMENT:
Rotary Kiln
8. WKL kUMMR: 8. SEMAi kUMtEfc:
PT-50 • F.G.1329
101 IfwlSftKPIo}):1*1™0" S°URCES KSCR18EO °" THIS '«*<««« TO -KNERAL- INSTRUCTIONS FOR OOPPUTIONOF rcmT
"• ^^^W&^fJSSS SJfiK&S^^ WJI l6™ |Y 'Hls m (1F UCH "^ m cwmb |Y «".**
2. AVERAGE OPERATION TIME OF EMISSION SOURCE:
24 HRS/OAY 7 DAYS/HK 52 IKS/YR
13. KWENTW^dATTHiroTPDT!
DEC/FEB 25 1 MAR/MAY 2 5 J JUN/AUG 25 j SEP/NOV 2!
RAW MATERIAL INFORMATION
1 '4*
NAMES OF RAH NATERIALS(B)
l.
Limestone
t.
Cement Rock
c.
Clay
t.
Iron Ore
t.
f.
C0?^
•
MAXIMUM RATE PCR
IDENTICAL Snu»CE
66,300 a/HR
20,000 u/HR
3'000 L./HR
. « r 000 IB/HR
Lt/HR
15,000 LB/HR
. AVERAGE RATE PER
IDENTICAL SOURCE
66,300
20,000
3,000
10,000 .
15,000
•
(A) THIS DATA AND INFORMATION FORM IS TO IE COMPLETED FOR MY STATIONARY EMISSION SOURCE CITHER THAN A FUEL COMBUSTION EMISSION SOU&C
AN INCINERATOR. A FUEL COMBUSTION EMISSION SOURCE IS MY FURNACE. IOILER, OR SIMILAR EOUIPMENT USED FOR THE PRIMARY PURPOSE OF I
OUCINC HEAT OR POWER BY INDIRECT HEAT TRANSFER. FOR SUCH AN EMISSION SOURCE. COMPLETE 'DATA MO INFORMATION ..FUEL COMBUSTION El
SOURCE.' FORM APC-?40. M INCINERATOR IS A COMBUSTION APPARATUS IN WHICH REFUSE IS BURNED. FOR SUCH M EMISSION SOURCE. COMPLC
•DATA MD INFORMATION - INCINERATOR.* FORM APC-2SO.
U) COMPOSITIONS OF RAH MATERIALS HJST BE DETAILED 70 THE CXTENT NECESSARY TO DETERMINE T»E NATURE MD 0UANTITV OF POTENTIAL EMISS10
I
2-14
-------
FOR AGENCY USE ONLY
IS.
MANES OF PRODUCTS
'PRODUCT INFORMATION
MAXIMUM RATE UK
IDENTICAL SflURCE
AVERAGE RATE P[R
IDENTICAL SOURCE
Portland Cement Clinker
106,000
LI/HR
91,250
"/HR
LB/HR
LB/HR
16.
HAKES OF WASTE MATERIALS
HASTE MATERIAL INFORMATION
MAXIMUM RATE PER
IDENTICAL SOURCE
AVERAGE RATE PER
IDENTICAL SOURCE
None - All returned to system
LB/HR
LB/HR
LB/HR
LB/HR
CONTAMINANT
W. ^ARTICULATE
MATTER
IB. CARBON
MONOXIDE
19. NITROGEN
OXIDES
MAXIMUM EMISSIONS FROM EACH IDENTICAL SOURCE*
CONCENTRATION OR EMISSION RATE
GR/SCF
i^BBMBI
PPM
(VOL)
(VOL)
D.
D.
LB/HR
••••MM^HB
LB/HR
b.
LB/HR
METHOD USED TO DETERMINE CONCENTRATION OR EMISSION RATE
c.
c.
c.
ORGANIC
MATERIAL
Pf«
(VOL)
C.
LB/HR
DIOXIDE
C.
(VOL)
LB/HR
5HWU9K-8?J«IL ASCRIBED IN THIS SECTION
27. EIIT MEI6HT WOVE GRADE:
mow
r AfPLi-
IADE:
FT
24. 6AS FLOW RATE THROUGH EACH
ttIT: M
28. MAXIMUM HEIGHT OF NEARBY
WILDINGS: „
25. EXIT GAS TENPERATU
29. EXIT DISTANCE FROK
FtANT BOUNDARY:
E= OmnE THESE SECTIONS ONLY IF EMISSIONS ARE EXHAUSTED WtNOUJ CflNTROL EQUIPMENT.
2-15 •
-------
STATE OF ILLINOIS
ENVIRONMENTAL PROTECTION AGENCY
DIVISION OF AIR POLLUTION CONTROL
2200 CHURCHILL ROAD
SPRINGFIELD. ILLINOIS (2706
DATA AND INFORMATION
*
AIR POLLUTION CONTROL EQUIPMENT
Kiln Baghouse
AGENCY USE ONLY
1. NAHC OF OWNER:
Ajax Cement Corporation
3. STREET ADl)R£SS OF EMISSION SOURCE:
2. NAME OF CORPORATE DIVISION OR PLANT (IF OIFFERENT FROM
123 River Street
4. CITY OF EMISSION SOUItCE:
Clearview
ADSORPTION STSTEM
'' AP*IM?10NS.^roK"lo?):ADSORI>TIWl
««R1BED '" THIS SECTION (REFER TO 'GENERAL INSTRUCTIONS FOR COMPLETION OF PERMIT
3. MODEL NAME AND NUMBEIt:
?. METHOD OF REGENERATION:
D REPLACEMENT
5. NUMBER OF BEDS PER SYSTEM
6. ADSORBANT HEIGHT Kft KB:
L6
STEAM
D OTHER (SPECIFY
TIME ON LINE BEFORE REGENERATION:
HIN/BED
9. EFFICIENCY OF CONTROL (ATTACH TEST REPORT OR tlPLAIN ESTIMATE)
AFTERBURNER
"«• «i: z: jz
LJ GAS LJ OIL ( I SULFUR!
i. INLET CAS TEMPERATURE:
•F
3. MODEL NAME AND NUHBEK:
5.
BURNERS PER AFTEBURHER •
7. OPERATING TEMPERATURE OF COMBUSTION CHAMBER:
LENGTH IN; CROSS SECTION IN x IN; OR
U YES LJ NO
10. EFFICIENCY OF CONTROL (ATTACH TEST REPORT OR EIPLAIN
PART I CU. ATE I CASEOUS
BTU/H
EACH
•F
I** OIA
ESTIMATE)
1
2-16
-------
m IGWY CSE WILT (
. . coNOENsm . • .
, ftOW DIAGRAM DESIGNATIONS OF CONDENSERS DESCRIBED IN IMIS SECTION (REFER TO 'CENERAL INSTRUCTIONS FOR COMPLETION Of PEWIT
tWLlCATlOHS.* F0«* APC-W1):
; NMUFACTURER:
3. MODEL NAME AND NUMBER:
D HATER (_ CPM) D'»I« ( SCFM)D OTHER (TYPE now HATE 1
INLET «F OUTLET »F
"MEAT EXCHANGE AREA PER CONDENSER:
FT*
6. CAS TEMPERATURES:
INLET »F OUTLET T
S. EFFICIENCY OF CONTROL (ATTACH TEST REPORT OR EXPLAIN ESTIMATE):
CYCLONE
Of rtWtlT APPLICATIONS t FDRn ArC'ZOl / • •
. MHUFACTURER:
Fuller
. MWER OF CYCLONES IN EACH MULTIPLE CYCLONE:
One unit of 3 cyclones
3. MODEL NAME AND NUMBER:
Z5600
S. EFFICIENCY OF CONTROL (ATTACH TEST REPORT OR EXPLAIN ESTIMATE):
. 95% bv wt. i
. BUCKS ION THE APPROPRIATE SKETCH (IN INCHES) OR PROVIDE A DRAWING WTH EQUIVALENT INFORMATION:
•nC£bnT
l\ , At
:" L\7^
r— — • I
— «
* ••
n-r
:
*• «j
•
ELECTRICAL PRECIPITATOf)
or%wa^wnSJs/SFORME»"5oih '"tclPIUTO(ts K5C"IBEC » THIS """* «KFEI1 TO '««RAL iioTRuaiONs FOR COMPLHIOK
COLLECTING ELECTRODE AKA PER CONTROL DEVICE:
FT*
3. MODEL NAME AKD NUMBER:
5. EFFICIENCY OF%CONTROL (ATTACH TEST REPORT OR EXPLAIN RESULTS):
^
• FILTER
«* APC^O?)*4'6"*710"4 °f niHK aSWI»t0 '" THIS ««•«" «K«R TO -SENERAL INSTRUCTIONS T0« COWLETION Of PERMIT APPLICATIONS.'
NANUfACTURER: " """ "
Fuller/Gatx
FIIHRINS AREA PER CONTROL DEVICE:
8.500 n?
3. PnOEL NAME AND NUMBER:
PP50
S. FILTERING MATERIAL:
Glass Fiber
&ISSING: ,-, __ __ ' ' II
U»AttR Q REVERSE AIR D PULSE AIR U PULSE JET UOTHEWSPrcirv . >
DKCEO-WMK SCFP>) DWTER SPRAY ( . .en
IRLET CAS: '
n»nRATuR£ 325 T; Kurcm 3.30 -r
B oua(LENCTH_20 rr: D,,72x4e];.) DoTnrt|Wr,r,j
*• trr'&'|"CQ2! cwr'ot 'm*w TK* *f"*: «* EFPLAIM ESTi»-t:c):
'•» " • • • - 2-17 - :tv j v ,
-------
ro* AGEMCY use ONLY
SCRUBBER
1. FLOW DIAGRAM OESISMAJ10NS OF SCRUBBERS DESCRIBED IN THIS SECTION (REFER TO -CENERAL INSTRUCTIONS FOR COMPLETION OF PERMIT APR
FORM APC-201):
2. MANUFACTURES:
4. SCRUBBER TYPE":
D HIW ENERGY (6AS STREAM PRESSURE DROP
O PACKED (PACKING TYPE ; MCKINC .SIZE
D SPRAY (NUCER OF ROZ2LES
O .OTHER (SPECIFY
J. MODEL NAME AM NUMBER:
IN HjO)
; NOZZLE PRESSURE
. IN; PACKED HE1SHT __
PS161
IN)
ATTACH KSCtlPTION AMD SKETCH KITH OIMENSIONEO DETAILS)
5. SCRUBBER 6EOMETRY:
.LENGTH IN DIRECTION OF CAS
IN; CROSS-SECTION
IN X
IN OR
IN 01A i
O CROSS
FLOW
COUNTER F:
i. LIQUID FLOU RATE INTO SCRUBBER:
CPU!
7. CHEMICAL COMPOSITION OF SCRUBBANT:
8. INLET GAS TEHPERATUKi:
J. EFFICIENCY OF CONTROL (ATTACH TEST REPORT OR EXPLAIN ESTIMT.
PARTI CULATE I CASEOUS 2
OTHER TYPES OF CONTROL EQUIPMENT
APPLICATIONS
EQUIPHMT ««"•« >" TH« SECTION (REFER TO "SWERAL HBTRUCTIOHS. FOR COMPLETION OF PEWIT
2. GENERIC
OF CONTROL EQUIPMENT:
3. MANUFACTURER:
4. MODEL B«ME AND NUMBER:
S. ATTACH DESCRIPTION AND SKETCH OF CONTROL EQUIPMENT KITH
DIMENSIONED DETAILS AND FLOW RATES.
6. EFFICIENCY OF. CONTROL (ATTACH TEST REPORT OR EXPLAIN ESTIMAT
PARTICULATE * S CASEOUS
MAXIMUM EMISSIONS FROM EACH IDENTICAL EXIT
CONTAMINANT
1. PARTICULATE
MATTER
12. CARBON
MONOXIDE
1. NITROGEN
OXIDES
<• ORGANIC
MATERIAL
i. SULFUR
DIOXIDE
i. OTHER
(SPECIFt)
CONCENTRATION JB EMISSION RATE
• .
6R/SCF
•• PPM
(VOL)
•• PPM
(VOL)
*. PPM
(VOL)
*• PPM
(VOL)
•• PPM
(VOL)
14.8
6.
7.5
b.
1351
b. 1
2.3
b.
225
t>.
3 LB/10HTU
S . "/HR
3 LB/10*8TU
2 U/HR
D
B
d
0
•
^
•
LB/10*BTU
IB/MR
LB/10*BTU
U/HR
LB/IO&BTU
LB/HR
LB/)0«BTU
U/HR
METHOD USED TO DnEIMINE CONCENTRATION OR EMISSION RATE
C' EPA - Method. - 5 .
c.
Coal Combustion Emission Factors A<
e.
Coal Combustion Emission Factors A<
Coal Combustion Emission Factors A'
c.
Coal Combustion Emission Factors A<
c.
EWAUST DATA
1. FLOW wIAGMPI KSIGISTum OF EXITS KSCMBlb l» THIS SECTION(REFCR
jo •a:;™*. iaTtacTio-5 n» CO^LETIT; v PEPMM APPL i CAT ions;"
FO»M APC-701):
«. EXIT oiAnu»: $. nn MEierr ABOVE CAAOC:
— 5 « » -1B "
2. CAS FLOW RATE THROUGH (EACH
|I1T: 63,000 *»"
1. MAXIIMi HEICHT OF NEAHY
fUILOINCJ: 5Q „
3.' CUT CAS TEMPERATURU
285
7. CUT DISTANCE FRO? NtAR
PUWTMUNOARY: 700
-------
STATE OF ILLINOIS
ENVIRONMENTAL PROTECTION AGENCY
DIVISION OF AIR POLLUTION CONTROL
2200 CHURCHILL ROAD
>i!gg2£3»< ' SWINSFULD, ILLINOIS K706
DATA MO MFOWAnON
PROCESS EMISSION SOURCE(A)
Cement Clinker Cooler
Ajax Cement Corporation
). STREET ADDRESS Of EMISSION SOURCE:
123 River Street
FOR AGENCY USE ONLY
2. NAME OF CORPORATE DIVISION OR PLANT (IF DIFFERENT FROM Orf.r»
«. CITY OF EMLSSION SOURCE:
Clearview
GENERAL INFORMATION
Clinker Cooling
7. EMISSION SOURCE EQUIPMENT MANUFACTURE: " ' ~
Fuller/Gatx
1C- IftlSffi.^^fr WSSI°" S°UR"S """"" W TH* F<
6. NAME OF, EMISSION SOURCE EQUIPMENT:
Clinker Cooler
~b. MODEL NUMBER: '"J. JEfelAL NUMBER:
770S/925H N/A
»« (REFER TO -6ENERAI' INSTRUCTIONS FOR COMPLETION OF PERMIT
1 ' IN WH«lgRiaTio«:iSSoli5SI?SK ^T^ScS!?*5 NOT CuvtRtu 8T 1H1! ™" "F **" WUKL" wt OWBI" BT FOW*™1A
U. AVERAGE OPERATION TIME OF EMISSION SOURtE: -•••.-
*4 MRS/DAY 7 OAYS/WK ^^ MICS/YR
-
13. PERCENT OP ANNUAL iHRduWuT: ~
DEC/FEE- 2 5 J MAR/MAY 2 5 JJUN/nuc25 j SEP/NOV
••
RAW MATERIAL INFORMATION
NAMES OF RAW MATERIALS(B)
Portland Cement Clinker
b.
MAXIMUM RATE PER
IDENTICAL SOU»CF
100,000 J/WR
LB/HR
J
LB/HR
LB/HR
LB/HR
AVERAGE RATE PER
IDENTICAL SOURCE
90,000 L
i
L
AM INCINERATOR
'
FOR ANY STATIONARY EMISSION SOURCE OTHER THAN A FUEL COMBUSTION EMISSION SOURCC
" ANY FURNACE. BOILER. OR SIMILAR EQUIPMENT USED FOR THE PRIMARY PURPOSE OF Pf
SUCH AN EMISSION SOURCE. COMPLETE "DATA AND INFORMATION —FUEL COMBUSTION f
APPARATUS IN WHCH REFUSE IS IURNED. FOR SUCH AN
«0 INFORMATION - INCINERATOR/ FORM
U) MFOSmONSOF MX MATERIALS.MUST IE DETAILED TO THE EXTENT KCQSARY TO DETERMINE THE NATURE MO OU4KTITT Of WTENTHL EMI. .,
"" 2-19 ———————^————
-------
C
FDR AGENCY USE ONLY
PRODUCT INFORMATION
DAMES OF PRODUCTS
«.
Cooled Cement Clinkers
6.
c. •
MAXIMUM RATE PER
IDENTICAL SOURCE
100,000 LB/HR
LB/HR
LB/HR
LB/HR
AVERAGE DATE PER
IDENTICAL SOURCE
90,000 L
L
I
fe
HASTE MATERIAL INFORMATION
16.
NAMES OF HASTE MATERIALS
None - Returned to System
b.
c.
0.
— — ^— _____ _
MAXIMUM RATE PER
IDENTICAL SOURCE
LB/HR
LB/HR
LB/HR
LB/HR
AVERAGE RATE PER
IDENTICAL SOURCE
L
•S
I
I
'•'. I
MAXIMUM EMISSIONS FROM EACH IDENTICAL SOURCE*
CONTAMINANT
1). PARTICULATE
MATTER
1 18. CARBON
I MONOXIDE
19. NITROGEN
OXIDES
20. ORGANIC
MATERIAL
21. SULFUR
DIOXIDE
22. OTHER
(SPICIFY)
CONCENTRATION OR EMISSION RATE
*.
6R/SCF
PPM
(VOL)
•' PPM
(VOL)
PPM
(VOL)
•' PPM
(VOL)
PPM
(VOL)
6. .
LB/HR
b.
LB/HR
b.
LB/HR
b.
LB/HR
b.
LB/HR
b.
LB/HR
METHOD USED TO DETERMINE CONCENTRATION OR EMISSION RATE
C.
C.
C.
e.
c.
c.
EXHAUST DATA*
23.
FLOW DIAGRAM DESIGNATIONS OF EXITS DESCRIBED IN THIS SECTION
REFER TO -GENERAL INSTRUCTIONS FOR COMPLETION OF PERMIT APPLl-
AT10HS, roW1 APC-ZOu:
16. EXIT DIAMETER: 27. EXIT HEIGHT ABOVE GRADE:
n FT
24. SAS FLOW BATE THROUGH EACH 25. EXIT CAS TEMPERATURE:
EX": ACFH
28. MAXIMUM HEIGHT OF NEARBY ' 29. EXIT DISTANCE FKH f
BUILDINGS: FT "•*"* BOUNDARY:
1IOTE
COMPLETE THESE SECTIONS ONLY IF EHISSIOKS AK EXHAUSTED WITHOUT CONTROL EQUIPMENT.
-------
STATE Of ILLINOIS
ENVIRONMENTAL PROTECTION AGCNCT
DIVISION Or AIR POLLUTION CONTROL
MOO CHURCHILL ROAD
JPRINGMEIO. ILLINOIS K706
DATA MO INFORMATION
AIR POLLUTION CONTROL EQUIPMENT
Clinker Cooler Baghouse
FDR «6£NCr USE ONLr
1. NAME OF OWNER:
Ajax Cement Corp.
2. NAHE Or CORPORATE OIVISION OR PLANT (IF 01FFERCHT FROM
3. STREET ADDRESS OF EMISSION SOURCE:
123 River Street
4. CITT or EMISSION SOURCE:
Clearview
MBORPTION STSTEM
"ri£!*T.l?1,^ WSORPTION SYSTEMS DESCRIBED IN THIS SECTION (REFER TO 'SENERAL INSTRUCTIONS FOR COMPLETION OF
rUKW APC*ZU1 :
2. MANUFACTURER:
3. MODEL NAME AND NUMBER:
1. METHOD OF REGENERATION:
REPLACEMENT Q
S. NUMBER OF IEDS PER STSTEM
6. WSORBANT HEIGHT P» IED:
LI
STEAM
D
OTHER
TIME ON LINE BEFORE RtGENERATItiN:
MIN/BED
». EFFICIENCY Or CONTROL (ATTACH TEST REPORT OR EXPLAIN ESTIKAU, .
°"ClllBtD '" TH»S ACTION (REKR TO 'CtNERAi INSTRUCTIONS FOR COMPLETION OF PERMIT
I. MODEL MME AND MMBER:
FUEL:
DGAS D
OIL
t SULFUR)
S.
•MNERS PER AFTERBURNER
BTU/HF
EACH
PERATURE:
7. OPERATING TEMPERATURE OF COMBUSTION CHAMBER:
COMBUSTION CHAMBER DIMENSIONS
LENGTH ,
CAum: USED?
IN; CROSS SECTION
IN X
11 DIA
D
TES
DNO
10. EFTICIENCT Of CONTROL (ATTACH TEST REPORT OR EXPLAIN ESTIMATE).
MRTICULATE I CASEOUS z
2-21
MCE 1 01
-------
. MEAT EXCHANGE AREA PER CONDENSER:
8. EFFICIENCY OF CONTROL (ATTACK TEST REPORT OR EXPLAIN ESTIMATE}"
TO -«««* INS.RUCTIONS FOR COMPLETION
me or COOLANT AND COOLANT FLOW PER CONDENSER:
D WATER ( CPU) DAIR {
3. MODEL NAME AND NUMBER:
1 " »—•••••••.
.SCFM) D OTHER (TYPE
MANUFACTURER:
»f«ER OF CTCLONES IN EACH MULTIPLE CYCLONE:
3. MODEL NAME AND NUMBER:
5. EFFICIENCY OF CONTROL (ATTACH TEST REPORT OR EXPLAIN ESTIMATE):
DIMENSION THE APPROPRIATE SKETCH (IN INCHES) OR PROVIDE A DRAWING KITH EQUIVALENT INFORMATION'
r
MANUFACTURER:
COLLECTING ELECTRODE AREA PER CONTROL DEVICE:
FT?
3. MODEL MMf AND NUMBER:
S. EFFICIENCY OF CONTROL (ATTACH TEST REPORT OR EXPLAIN RESULTS):
FILTER
'UIHS KS"'Bl° '" THIS «««»" ««•
INSTRUCTIONS FOR COMPLETION OF KRMIT AW.ICATIOMS.
MNUTACTURI
Fuller/GATX
FILTERING AREA n» OWTROL DEVICE:
"&
3. MODEL NAME AND NUMBER:
Plenum Pulse - 156-10-1625
ITERIAL:
U«EVERSEAIR
PULSE JIT LJoTHE«( SPECIFY
COOLING:
BLEED-IN A1R(_
INLET MS:
STRAY (
BDUO(LtNCTH_25r; 0>t 24 ,..,
TEH-ERATURE 35Q >f; 2-22 HEW
120
I. CFFICIENCY OF
99.9% -f
(«H«CH TEST
-------
FOR AGENCY USE DM'
SCRUBBER
I. FLOW DIAGRAM DESIGNATIONS Of SCRUBBERS DESCRIBED IK THIS SECTION (REFER TO 'GENERAL IHSTRUCTIONS FOR COMPLETION OF PERMIT APPUUm
FORM APC-Z01): '
2. MANUFACTURER:
1. MODEL MK AND NUMBER:
«. SCRUBBER TYPE:
D HIGH ENERGY (CAS STREAM PRESSURE DROP
D PAOCED (PACKING TYPE ; PACKING SIZE
LJ SPRAY (NUMBER OF NOZZLES ; IIOZZLE PRESSURE"
D OTHER (SPECIFY
IN HjO)
. IN; PACKED HEIGHT
WIG)
IN)
ATTACH DESCRIPTION AND SKETCH UITH DIMENSIONED DETAILS)
5. SCRUBBER GEOMETRY:
LENGTH IN DIRECTION OF GAS FLOW
.IN; CROSS-SECTION IN X IN OR IH DIA; D CROSS FLOW D COUNTER FLOW
6 LIQUID FLOW RATE INTO SCRUBBER;
6PM
7. CHEMICAL COMPOSITION OF SCRUBBAM:
B. INLET GAS TEMPERATURE:
9. miCIENCY OF CONTROL (ATTACH TEST REPORT OR EXPLAIN ESTIMATE):
PART I Cut ATE I CASEOUS I
OTHER TYPES OF CONTROL EQUIPMENT
C'Zwl ) I
ASCRIBED IN THIS SECTION (REFER TO 'GENERAL INSTRUCTIONS TOR COMPLETION OF PEWIT
2. GENERIC NAME OF CONTROL EQUIPMENT:
3. MANUFACTURER:
4. MORI NAME AND NUMBER:
5. ATTACH DESCRIPTION AND SKETCH OF CONTROL EQUIPMENT KITH
DIMENSIONED DETAILS AND FLOW RATES.
6. EFFICIENCY OF CONTROL (ATTACH TEST REPORT OR EXPLAIN ESTIMATE):
PART ICUL ATE I SASEOUS t
MAXIMUM EMISSIONS FROM EACH IDENTICAL EXIT
CONTAMINANT
CONCENTRATION £R EMISSION KATE
METHOD USCO TO DETERMINE CONCENTRATION OR EMISSION RATE
1. PART ICULATE
MATTER
SR/SCF
>• D LI/10&BTU
.30 g) LI/HR
Source Test - EPA Method 5
2. CARBON
N3NOXIOE
PW
(»OL)
b.
7.5
«-B/HR
3. NITROGEN
OXIDES
PPM
(WL)
D U/106BTU
135 Q "/HR
MATERIAL
PPM
(TOL)
b.
2.3
U/106BTU
U/H(1
SW.FUR
DIOtlK
(WU
b.
225
1»/>0*BTU
LI/HR
OTHER
(SPECIFY)
(VOL)
b.
LI/10*BTU
LI/HR
tIMAUST DATA
I FLOW i,IAGB*'i OtS«C.14TIO-(S OF EXITS DESCRIBED IU THIS SECTIONlREFrR
T-- T: OF P£PMIT APPLICATIONS."
Z. CAS FLOW RATE THROUGH EACH
UIT: 57,200 «ew
3. EXIT CAS TEMPERATURE:
290
ElIT
s. EXIT HEIGHT Aeon GRADE:
51
i. MAXIMUM HEIGHT OF MEARBY
WILDINGS: c
FT
2-23
7. EXIT DISTANCE FROM NEAREST
PUNT MUNDARY: gQQ r
-------
SUMMARY OF SOURCE OPERATION
PLANT: Ajax Cement Corporation/ Clearview Plant
LOCATION: 123 River Stree, Clearview, Illinois
DATE OF TEST: June 6, 1977
TYPE OF PROCESS/EQUIPMENT: Portland Cement Kiln
Material Processed or Produced: Portland Cement Clinker
Operating Schedule: 24 Hr./Day ^£5* payAear
Maximum Operating Capacity (Include Units): 53 T/hr
Normal Operating Capacity: 45 T/hr
Operating Capacity During Test: Test 1 SOT; Test 2 43T; Test 3 47T
Fuel Type: Crushed Coal % Ash: % Sulfur: 1>5
Amount of Fuel Consumed During Test: 22.5 T
Pollution Control System Description: Primary multicyclone;
secondary positive pressure, reverse air cleaned baghouse with
collected dust returned to system
Pressure Drop Across Collector:
Additional Information:
* less normal down-time
2-24
-------
SUMMARY OF PITOT TRAVERSE DATA SHEET 1 o:
Ajax Cement Corp, Clearview SOURCE: Kiln _ _ DATE:/<
A. Stack Dimensions
B. Area of Stack, Sq. Pt. 19.6 ft.2
C. Barometric Pressure, *Hg 29.75
D. Gage Static Pressure in Stack, "H2O 0.15
E. Stack Gas Temperature, Dry Bulb, °F 285°
F
F. Percent Moisture 12%
G. Dry Gas Composition: %02 8.7%
*C02 i2.6%
*CO o.2%
78.5%
% other
H. Density of Dry Stack Gas, 9 STP, Lbs./Cu. Ft. 0.079
I. Density of Moist Stack Gas, 9 STP, Lbs./Cu. Ft. 0.075
J. Density of Moist Stack Gas, 9 Stack Conditions,
Lbs./Cu. Ft. 0.053
Total Number of Traverse Points 12
Pitot Tube Calibration Factor 0.82
Average Square Root Velocity Head of all
Traverse Points 0.80
Average Gas Velocity, Feet/Min. 3200
0. Stack Gas Flow Rate:
1. ® Stack Conditions, Wet, ACFM 63,000
2. ® Standard Conditions, Wet, SCFM 44,750
3. 9 Standard Conditions, Dry, DSCFM 39,500
5TP - 70°F, 29.92 "Hg.
"Wet" or "Moist- - Refers to the condition of the gas with actual water
content.
2-25
-------
SUMMARY OF PARTICULATE SAMPLING DATA SHEET 1 of 2
PLANT; Ajax Cement Corporation SOURCE: Kiln DATE: 6/6/77
A. Sample Number
B. Number of Points Sampled 12 12 12
C. Total Duration of Sample, Min. 60 60 60
D. Nozzle Diameter, In. .260 ,,260 .260
E. Nozzle Area, Sg. Ft. .000369 .000369 .000369
F. Calibration Factors
1. Probe Pitot Tube .82 .82 .82
2. Gas Meter 2.07 2.07 2.07
G. Barometric Pressure, "Hg. 29.75 29.75 29.75
H. Gage Static Pressure in Stack, "H20 .16 .15 .14
I. Stack Gas Temperature, °F (Ave) 275 285 295
J. Average Square Root Velocity Head
of Points Sampled
K. Average Gas Meter Temperature, °F 88.2 91.8 89.6
L. Average Gas Meter Pressure, "H2O .716 .743 .785
M. Gas Meter Volume, Actual, Cu. Ft. 63.2 63.9 62.9
JN. Gas Meter Volume, @> STP, Cu. Ft. 62.3 62.5 61.9
0. Liquid Volume of Water Condensed, ML. 171 190 160
P. Vapor Volume of Water Condensed at
STP, Cu. Ft. 8.5 8.9 7.8
Q. Total Gas Sampled Through Nozzle,
e STP, Cu. Ft. 70.8 71.4 69.7
R. Percent Moisture in Stack
2-26
-------
SUMMARY OP PARTICIPATE SAMPLING DATA SHEET 2 of 2
S. Particulate Concentration
1. Grains/Dry Standard Cubic Feet 0.04 0.05 0.04
2. Lbs./Hr. 14.0 16.0 15.0
T. Percent Isokinetic IQI 102 98
STP « 70°F, 29.92 "Hg.
"Wet" or "Moist" - Refers to the condition of the gas with actual
water content.
2-27
-------
I
SUMMARY OF SOURCE OPERATION
PIANT: Ajax Cement Corporation, Clearview Plant
LOCATION: 123 River Street/ Clearview, Illinois
DATE OF TEST: June 6, 1977
TYPE OF PROCESS/EQUIPMENT: Portland Cement Clinker Cooler
Material Processed or Produced: Portland Cement Clinker
Operating Schedule: 24 Hi'./Day 365* DayAear
Maximum Operating Capacity (Include Units) : 50 T/hr.
Normal Operating Capacity: 45 T/hr.
Operating Capacity During Test: Test 1 40T; Test 2 47T; Test 3 44T
el Type: Coal % Ash: 8.0% % Sulfur: 1.5%
Amount of Fuel Consumed During Test; 15,000 Ib/hr.
'Dilution Control System Description: Negative pressure, pulse cleaned
baghouse with collected dust returned to system
»ressure Drop Across Collector: B"
Additional Information:
* less normal down-time
2-28
-------
SUMMARY OF PITOP TRAVERSE DATA
SHEET 1 Of
PLANT:
Ajax Cement Corp., Clearview SOURCE: Clinker Cooler pAT£: 6/6/7'>
A. Stack Dimensions
B. Area of Stack, Sq. Ft.
C. Barometric Pressure, "Hg
D. Cage Static Pressure in Stack, MH20
E. Stack Gas Temperature, Dry Bulb, °F
F. Percent Moisture
G. Dry Gas Composition: %02
*C02
%CO
other
diameter
15.9 ft.
29.80
0.22" W.C.
290
11%
9.2%
12.1%
0.2%
78.5%
0.079
0.075
0.053
12
0.82
0.81
Density of Dry Stack Gas, ® STP* Lbs./Cu. Ft.
|l. Density of Moist Stack Gas, €> STP, Lbs./Cu. Ft.
Density of Moist Stack Gas, 9 Stack Conditions,
Lbs./Cu. Ft.
K. Total Number of Traverse. Points
Pitot Tube Calibration Factor
Average Square Root Velocity Bead of all
Traverse Points
Average Gas Velocity, Feet/Min.
Stack Gas Flow Rate:
1. 9 Stack Conditions, Wet, ACFM
2. e Standard Conditions, Wet, SCFM
3. 9 Standard Conditions, Dry, DSCFM
TP « 70°F, 29.92 "Hg.
Wet" or "Moist" - Refers to the condition of the gas with actual water
content.
3600
57,200
40,100
35,700
2-29
-------
SUMMARY OF PARTICULATE SAMPLING DATA
SHEET 1 of
Cement
SOURCE; Clinker Cooler
DATE:
f r
r
D.
E.
F.
Sample Number
Number of Points Sampled
Total Duration of Sample, Min.
Nozzle Diameter, In.
Nozzle Area, Sq. Ft.
Calibration Factors
1. Probe Pitot Tube
2. Gas Meter
Barometric .Pressure, "Hg.
Gage Static Pressure in Stack,
Stack Gas Temperature, °F (Ave)
Average Square Root Velocity Head
of Points Sampled
Average Gas Meter Temperature, °F
Average Gas Meter Pressure, "H2O
Gas Meter Volume, Actual, Cu. Ft.
Gas Meter Volume, @ STP, Cu. Ft.
Liquid Volume of Water Condensed, ML.
Vapor Volume of Water Condensed at
.STP, Cu. Ft.
Total Gas Sampled Through Nozzle,
@ STP, Cu. Ft.
Percent Moisture in Stack
12
60
.260
.82
12
12
60
60
.260
.260
,000369 .000369 .000369
.82
.82
2.07
29.80
.11
280
.80
88.2
.716
51.6
49.7
130
6.1
55.8
2.07
29.80
.12
290
.81
91.8
.743
51.9
50.0
138
6.2
56.2
2,07
29,80
.12
300
.82
89.6
.785
53,3
51.4
141
6.4
57.8
2-30
-------
j
SUMMARY OF PARTICULATE SAMPLING DATA
SHEET 2 Of 2
.09
.08
.09
30
25
32
105.6 102.6 105.9
S. Particulate Concentration
1. Grains/Dry Standard Cubic Feet
2. Lbs./Hr.
T. Percent Isokinetic
STP « 70°F, 29.92 MHg.
"Wet" or "Moist" - Refers to the condition of the gas with actual
water content.
2-31
-------
STUDENT EXERCISE NO. 3
CASE STUDY EXERCISE
TRIAL OF OPACITY AND TSP VIOLATIONS
-------
LESSON 11
CASE STUDY
TRIAL OF OPACITY MI) TSP VIOLATIONS
GOAL. This lesson (exercise) is intended to provide a
"background against which the students may tesl
their own ability to develop a trial strategy,
"both for prosecution and defense, and to provide-
court room testimony.
OBJECTIVES, At the end of this lesson, the student should "be
able toj
1. Differentiate between good and poor trial
strategy.
2. Differentiate between testimony well given
and poorly given.
3-2
-------
CASE STUDY EXERCISE
TRIAL OP OPACITY AND TSP VIOLATION
I. CASE HISTORY
The Columbia Smelting Company, a large corporation engaged in
metals refining, smelting, and production has "been sued by
the State of Columbia for violations of the state's rules
^ y \
and regulations governing opacity and suspended particulate
matter. You are a field enforcement officer assisting in
preparing the case for trial. The attached investigator's
report is one of the violations alleged in your plaintiff's
original petition in State v. Columbia Smelting Company.
The effective and successful prosecution of this case will
mostly depend on how thoroughly both the attorney and the
witnesses prepare the trial. Thorough preparation requires
a trial outline containing the following:
1. A thorough analysis of your case.
2. Your trial strategy plan detailing the facts and
points of law you want to establish, the evidence
and witnesses you want to introduce, and the order
and manner of introducing them.
3. Anticipation of the defense attorney's possible
strategies and efforts to undermine your case and
deciding how to block or neutralize his defense.
* Rule 103.1 Assume plant built prior to Jan. 31, 1972.
*» Rule 105.2
3-3
-------
II. BAGKGBDUND ON STATE VS. COLUMBIA SMELTING GO.
Prior to the initiation of action against Columbia Smelting Co.
(COSMO), the State Air Centre 1 Board had been conducting routine
investigations of the plant suid had reviewed the emissions
inventory data submitted by the company. Most of the investiga-
tions revealed violations of the State's suspended, particulate
and opacity regulations. In fact, during the year immediately
preceding the filing of the suit, GOSMD had received five notices
of violation from the State Air Control Board.
After the second notice of violation, COSMD was called in for a
conference to determine when compliance could be achieved.
COSMD's general manager insisted that the company was doing
everything it could and that the State's tests were probably
defective. After the third notice of violation was issued,
COSMD said it would look into the matter. When compliance was
not forthcoming after the fifth violation, the State decided to
file suit.
3-4
-------
III. INSTRUCTIONS
The objective of the exercise is to give each student team
an opportunity to develop strategy for prosecution and defense
and then to test the strategy by mock trial method. Only one
witness will be heard, the FED.
The students will work in groups of three to six depending on
the number of students in the class. Each Team will be assigned,
by lot, to prosecute or defend the violation. A Team will be
assigned either opacity or TSP.
After receiving the above assignment, each Team will organize
into roles and select one member for each of the following:
Prosecution Defense
1 Chief Prosecutor 1 Defense Attorney
1 TOD I Technical Advisor
1 Chief of Enforcement 1 Assistant Defense Attorney
If more persons are added, they are assigned by the team leader
to any appropriate role.
IV CASE PREPARATION
Each team is to study the investigator's report, the background
of the case, the history of the violations, and the applicable
regulations. Each team will then plan the prosecution or the
defense strategy for either the opacity or the TSP violation as
assigned. Each team will then organize their strategy into a
series of five questions to be asked on direct examination by
the prosecution and five questions to be asked by the defense on
cross-examination. Extra questions should be prepared in case the
opposition objects and the objection is sustained. The FED is to
be the only witness heard during the demonstration.
3-5
-------
In addition to the questions, the prosecution and defense should
each prepare a one minute opening statement,
In order to save time, it is assumed that five questions establish-
ing the identity and qualifications of the FED have 'been asked with
the responses as shown:
1. Q. Please state your name and address.
A. Viy name is George Plohm. I live at
1269 Elm St., Kingsman, Columbia.
2. Q. What is your position of employment?
A. I am a field enforcement officer for the
Columbia Air Control Board.
3- Q. How long have you been employed in your present
capacity?
A. 5 years and 6 months.
4. Q. What are your duties as a field enforcement
officer?
A. Plohm recites his duties as an FID.)
5- Q. Please describe your educational background,
your training and qualifications as a field
enforcement officer.
A. Graduation, Columbia Two year Technical College
Associate degree in Environmental Studies.
Inservice Training Program, Columbia. Air Control
Board, three months at beginning of employment.
Two years as assistant FED.
Three and one-hs.lf years as senior FED.
Certified Smoke Reader. Date of last
certification 9/20/78.
V. DEMONSTRATION
After sixty minutes of preparation, the opacity team, chosen by lot,
begins with the FED as the prosecuting witness taking the stand.
It is to be assumed that the FED has been sworn as a witness. The
prosecution begins with an opening statement, no longer than one
minute duration.
3-6
-------
After this opening statement, it is assumed that the witness (the FED)
will have been asked the five stated questions and that he gave the
indicated answers.
Now the prosecuting attorney will begin to interrogate his witness
(the FED) and he will be permitted to ask five questions not counting
questions objected to and sustained. Because of time constraints, a
maximum of eight minutes will be allowed for direct examination.
At the-end of-the five-prosecution-questions,-^the-defense will begin
his five questions of cross-examination. Same rules regarding
objections and time will apply.
While objections are allowed, each side is asked to make restrained
use of this privilege to conserve time.
The judge will be the legal instructor who will rule on the objections.
At the end of the cross-examination, the following takes place:
(a) The prosecutor sums up his case in two minutes.
(b) The defense attorney sums up his case in two minutes.
(c) The prosecutor has a rebuttal, if he wishes, for one minute.
TSP violation. Repeat the procedure for opacity.
After both cases are "heard", the teams who were not put on the stand
will have their "chief attorneys" give their strategy stressing where
it differed from that taken by the demonstrating teams.
V. DISTRIBUTION OF ACTUAL CASE HISTORY AND INJUNCTION
After this presentation of the actual trial questions, the instructor
(judge) calls for open student discussion or questions.
VI. DISCUSSION AND SUMMARY
When discussion is exhausted or time begins to run out, the instructor
"critiques" the mock testimony and summarizes the lesson.
3-7
-------
Case Study (
Trial of an Opacity and
Suspended Particulate Matter Violation
The City of Kingsman
and State of Columbia
Plaintiffs
v.
The Columbia Smelting Company (COSMO)
Defendant
3-8
-------
SECTION II - INVESTIGATOR'S REPORT
STATE OF COLUMBIA AIR CONTROL BOARD
NAME: COLUMBIA SMELTING COMPANY DATE OF INVESTIGATION 1/15/79
(company or person occupying permises) TIME: 1110 to 1430
ADDRESS: 5300 N. Sylvania CITY: Kingsman, Columbia
PREMISES USED FOR: Iron Casting and Foundry
REASON FOR REPORT: Request to investigate for compliance
TYPE OF POLLUTANT: Particulate 5 Smoke TYPE OF AIR SAMPLE TAKEN: Hi-Vol.
(sheltered)
PERSON CONTACTED AT
PREMISES INVESTIGATED: Mr. Norris Gallo TITLE: Chief Engineer
STATEMENT OF PERSON CONTACTED: Mr. Norris Gallo stated that afterburners are
being used to control emissions from the cupola stacks. Mr. Gallo said that
a wet scrubber for the shake-out system is being installed. Consideration is
being given to installation of bag-houses on the new shotblast machines and
to elimination of sand blasting.
INVESTIGATOR'S FINDINGS: At the time of this investigation, the sky was
clear with variable wind bearing 160° to 190° at 4-10 mph. A grayish white
smoke with an average opacity of 80% was emanating from the cupola stacks.
The primary source of emissions appeared to be coming from the cupola stack;
however, some emission was observed emanating from open doors of buildings
located adjacent to the cupola stacks.
High volume sampling results are as follows:
1/15/79 Downwind 698 ug/M3
1/15/79 Upwind 52 ug/M-*
RECOMMENDATIONS: Recommend that COSM install, operate, and maintain
abatement controls in such a manner so as to comply with the regulations of
the State Air Control Board.
BY: ^-^^-^ 9* .^asScs^c^ TITLE F.H.S. DATE 1/16/79
George P*ohn
3-9
------- An error occurred while trying to OCR this image.
------- An error occurred while trying to OCR this image.
-------
STATE AIR CONTROL BOARD
PLUME OBSERVATION RECORD FORM
Date:
1/15/79
Observer: George Plohn
Start time: 1340
Observation point: 33rd Street
Distance from stack: 900 feet
Wind speed: 8 mph direction: 190'
Type of background: Cloudy Sky
Color of Emission: Grayish White
Type of installation: Cupola
Observation ended: 1346
Remarks
Name of s;ource: Columbia Smelting Co.
Add re s s: 3300 N. Sylvania
Kingsman, Columbia
Smoke Density Tabulation
No. Units X Equiv. No. 1 Units
24
JLJnits No. 0
JJnits No. %~
Units No. l"
JJnits No. 1%
Units No. 2
"Units No. 2h
"Units No. 3"
"Units No. 3%~
JJnits No. 4~
"Units No. 4%~
"Units No. 5"
"Total Units "
96.0
Total Equiv. No. 1 Units
Average Smoke Density
Equiv. No. 1 Units x 20%
Total Units
80%
Signed:
3-12
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STATE AIR CONTROL BOARD
SAMPLING DATA AND PLANT OPERATIONAL STATUS
Date: 1/13/79
Firm name: Columbia Smelting Company _ _
Location of plant: 3300 N. Sylvania _ _
Type of operation: Manufacturing Plant _ _
SAMPLING DATA: *
Type of Sample
Location Duration
Hi-Vol. (Sheltered) ' Upwind From: 1130 to 1430
Hi-Vol. (Sheltered) Downwind From: mp_ to 1410
Special conditions: Sky clear with variable wind bearing 160° to 190'
at 4 - 10 mph.
I certify that the above sample(s) is (are) representative of conditions at
the time of the investigation:
Signature:
Title: Environmental Health Specialist
PLANT OPERATIONAL STATUS (During the sampling period)**
process Per Cent Capacity Abatement Controls
Foundry 100% Afterburners
Special Conditions:
I certify that the above statement is true to the best of my knowledge
and belief:
Signature:
Title: Chief Engineer
* To be completed and acknowledged by Air Control Program representative.
** To be completed and acknowledged by plant representative. It is
understood that all the above information will be considered confidential
3-13
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7 SECTION III - RULES AND REGULATIONS
STATE OF COLUMBIA
RULES AND REGULATIONS
FOR THE
CONTROL OF AIR POLLUTION FROM
SMOKE, VISIBLE EMISSIONS, AND PARTICULATE MATTER
Rule 103. Visible Emissions.
103.1 No person may cause, suffer, allow, or permit visible emissions
from any stationary flue to exceed an opacity of 30% averaged
over a 5-minute period. No person may cause, suffer, allow, or
permit visible emissions from any stationary flue beginning
construction after January 31, 1972, to exceed an opacity of
20% averaged over a 5-minute period. Visible emissions during
the cleaning of a firebox or the building of a new fire, soot-
blowing, equipment changes, ash removal and rapping of pre-
cipitators may exceed the limits set forth in Rule 103.1 for a
period aggregating not more than five minutes in any sixty
consecutive minutes, nor more than six hours in any ten-day
period.
103.2 No person may cause, suffer, allow, or permit visible emissions
from a waste gas flare for more than five minutes in any
2-hour period except as provided in Rule 12.1 of the General
Rules.
103.3 No person may cause, suffer, allow or permit excessive visible
emissions from any building or enclosed facility.
103.4 No person may cause, suffer, allow, or permit excessive visible
emissions from motor vehicles for more than ten consecutive
seconds.
3-14
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103.5 No person may cause, suffer, allow, or permit excessive visible
emissions from any railroad locomotive, ship, or any other
vessel, except during reasonable periods of engine start-up.
103.6 No person may cause, suffer, allow, or permit visible emissions
from any stationary flue having a total flow rate of 100,000 acfm
or more to exceed an opacity of 15% averaged over a 5-minute
period unless an optical instrument capable of measuring the
opacity of emissions is installed in the flue. Records of all
such measurements shall be retained as provided for in Rule 9 of
the General Rules. The provision shall not apply to flues
having gas streams containing moisture which interferes with
proper instrument operation, if so determined by the Executive
Secretary.
103.7 Contributions from uncombined water shall not be included in
determining compliance with Rule 103. The burden of proof
which establishes the applicability of Rule 103.7 shall be upon
the person seeking to come within its provisions.
Rule 104. Particulate Matter From Materials Handling, Construction, and
Roads.
104.1 Rule 104 shall apply only in Standard Metropolitan Statistical
Areas where the Federal air quality standards for particulate
matter are exceeded.
104.2 No person may cause, suffer, allow, or permit any fine material
to be handled, transported, or stored without taking at least
the following precautions to prevent particulate matter from
becoming airborne:
104.21 Application of water or suitable chemicals or some
other covering on materials stockpiles, and other
surfaces which can create airborne dusts under
normal conditions.
104.22 Installation and use of hoods, fans and filters to
enclose, collect, and clean the emissions of dusty
materials.
104.23 Covering or wetting at all times when in motion, of
open-bodied trucks, trailers, or railroad cars
transporting materials in areas where the general
public has access which can create airborne parti-
culate matter.
104.3 No person may cause, suffer, allow or permit a building struct-
ure to be used, constructed, altered, repaired or demolished
without taking at least the following precautions to prevent
3-15
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particulate matter from becoming airborne:
104.31 Use of water or chemicals where feasible for control
of dust in the demolition of buildings or structures,
in construction operations, or in the clearing of
land.
104.32 Use of adequate methods to prevent airborne parti-
culate matter during sandblasting of buildings or
other similar operations.
104.4 No person may cause, suffer, allow, or permit a road to be used,
constructed, altered, or repaired without talking at least the
following precautions to prevent particulate matter from
becoming airborne:
104.41 Application of asphalt, oil, water or suitable
chemicals on heavily traveled dirt streets as
necessary.
104.42 Paving of public or commercial parking surfaces
having more than five parking spaces.
104.43 Removal as necessary from paved street and parking
surfaces of earth or other material which have a
tendency to become airborne.
104.5 Alternate means of control may be approved by the Executive
Secretary of the State Air Control Board.
Rule 105. Particulate Matter
105.1 No person may cause, suffer, allow, or permit emissions of
particulate matter from any source to exceed the allowable
rates specified in Table 1 and/or Figure 1.
105.11 If a source has an effective stack height less than
the standard effective stack height as determined
from Table 2 and/or Figure 2, the allowable emission
level must be reduced by multiplying it by
Effective Stack Height
Standard Effective Stack Height
105.12 Effective stack height shall be calculated by the
following equation:
3-16
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h - h + 0.083vD
1.5 i- 0.82
e «• «• i *• * n
e
u ift
Where:
he * Effective stack height in feet
h * Physical stack height above ground level in feet
ve* Stack exit velocity in feet per second
De * Stack exit inside diameter in feet
Te • Stack exit temperature in degrees Rankin
105.2 No person may cause, suffer, allow or permit emissions of
particulate matter from a source or sources operated on a pro-
perty or from multiple sources operated on contiguous properties
to exceed any of the following net ground level concentrations:
105.21 One hundred (100) micrograms per cubic meter (ug/m3)
of air sampled, averaged over any five consecutive
hours.
105.22 Two hundred (200) micrograms per cubic meter (ug/m3)
of air sampled, averaged over any three consecutive
hours.
105.23 Four hundred (400) micrograms per cubic meter (ug/m )
of air sampled, averaged over any one hour period.
105.3 Rules 105.1 and 105.2 shall not apply to solid fossil fuel fired
steam generators.
105.31 No person may cause, suffer, allow, or permit emissions
of particulate matter from any solid fossil fuel fired
steam generator to exceed 0.3 Ib. per million B.T.U.
heat input.
Rule 106. Transient Operations.
106.1 Rules 103 and 105 shall not apply to portable hot-mix asphaltic
concrete plants, portable rock-crushers, and other transient
operations engaged in public works projects which are not
operated at the same premise for more than six months if all the
following conditions are met:
106.11 The plant is located at least one mile outside the
nearest corporate limits of any city or town.
106.12 The plant is located at least one mile from any
occupied facility or recreational area other than that
located on the same property as the plant.
3-17
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106.13 The plant is equipped with cyclones, or wet scrubbers,
or water sprays at the material transfer points open
to the atmosphere, or other equipment or systems ap-
proved by the Executive Secretary, properly installed,
in good working order and in operation.
106.2 The time requirement for Rule 106.1 may be extended by the
Executive Secretary upon written request.
106.3 All emissions from sources operating under provisions of Rule
106 shall be controlled so as not to permit: or create a nuisance.
106.4 Rule 106 shall not apply to portable hot-mix asphaltic concrete
plants after December 31, 1974.
Rule 107. Agricultural Process.
107,1 Rules 103, 104, 105 and 108 shall not apply to any person
affected by Section 3.10 (e) of the State Clean Air Act.
107.2 No person affected by Section 3.10 (e) of the State Clean Air Act
may cause, suffer, allow, or permit emissions of particulate
matter from any or all sources associated with a specific process
to exceed the allowable levels specified in Table 3 and/or
Figure 3, excep't as provided by Rule 107.3.
107.3 Any person affected by Section 3.10 (e) of the State Clean Air
Act who does not wish to be controlled by the process weight
method, established by Rule 107.2, may select an alternate method
of control which the Executive Secretary finds will provide
emission control efficiency and measurement to achieve the same
goal as Rule 107.2.
107.4 Any person affected by Section 3.10 (e) of the State Clean Air
Act who does not select an alternate method and notify the
Executive Secretary, in writing, prior to any plant investigation
by the staff of the State Air Control Board, shall be controlled
by the process weight method established by Rule 107.2, unless
the Executive Secretary, at his discretion, chooses to accept
proposals for an alternate method at that time.
107.5 Nothing herein is intended to affect the limitations on burning
set out in Rule 101.
107.6 Persons affected by Rule 107 shall be in compliance with the
provisions set forth herein by February 15, 1973.
3-18
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Rule 108. Persons affected by this regulation shall be in compliance with
the provisions contained herein no later than December 31, 1973.
Not later than six months after the effective date of this
regulation, any person affected by this regulation shall submit
to the State Air Control Board a written report on his compliance
status, including but not limited to, the minimum time required
to design, procure, install and test abatement equipment or
procedures. Progress reports shall be submitted to the Board
every four months commencing in July of 1972 until compliance is
achieved.
All persons shall continue to be governed by the provisions of
Regulation I, which became effective on March 16, 1967, and
amended on January 23, 1968, September 12, 1969, and May 18,
1971, and Regulation II, which became effective February 22,
1968, and amended on September 12, 1969, until December 31, 1973,
at which time this regulation shall supersede the previous
Regulations I and II.
3-19
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STUDENT EXERCISE NO. 4
COMPLAINT HANDLING
ODOR COMPLAINT CASE STUDY
-------
LESSON 13
COMPLAINT HANDLING
ODOR COMPLAINT CASE STUDY
GOAL. To teach the principles of processing nuisance complaints
with emphasis on the field investigation process.
OBJECTIVES. At the end of this exercise, the student should be able to:
1. Differentiate between good and poor complaint investiga-
tion procedures.
2. Document the procedure for investigeition and case
development.
3« Design an odor surveillance plan for a suspected source.
4. Differentiate between a public and a private nuisance.
5. Define the various steps in getting action from the
source management to abate the cause of the complaint.
INSTRUCTIONS! No formal lecture on Complaint Handling will be given. The
conduct of this lesson is a self-study of an actual odor
complaint case by each student and then developing the
answers to the questions at the end of the case narrative.
For reference, Chapter 13, Complaint Haindling is included in
the Student Manual for a reference to be used during the
self-study exercise.
The case is to be read and notes made the evening of the
second day of the course.
On the third day of the course, during the period following
Test No. 1, the instructor will call on students at random
to respond to the questions posed at the end of the case
narrative. Thus, each point will be discussed.
At the end of the discussion, a summary of complaint handling
will be presented to the lecturer.
After all points are discussed, an Answer Key, describing the
"Collection of Data" and "Analysis of Data and Establishment
of the Case" will be passed out to the students. Also
distributed will be the "Disposition of the Case" giving the
record of the State Agency with respect to the case.
4-2
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LESSON 13
ODOR COMPLAINT CASE STUDY
SECTION I - CASE HISTORY
The following narrative is a case history of an odor complaint from the
inception of the complaint to the final resolution of the problem. Odor
complaints are usually challenging in that there are few, if any, agencies
that have good objective standards upon which the existence of a violation
can be based.
We will preface this exercise by stating that the only legal mechanism
available to this agency is an ordinance that forbids air pollution and
defines it as "The presence in the outdoor atmosphere of any air contaminant
which is or may be inimical to health, safety or welfare; or which is or
may be injurious to human, plant or animal life or property; or which
unreasonably interferes with the comfortable enjoyment of life or property".
As in any air pollution problem, it is necessary that the inspector be
observant, thorough, and particularly that he be capable of exercising
"common sense". Although there may necessarily not be a "right" or a
"wrong" way for handling odor complaints, a preferred set of procedures
has evolved from experience.
Review the following information and determine to your satisfaction whether
the inspector handled this complaint properly. Note both what was properly
done and what, if anything, was improperly handled.
4-3
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THE COMPLAINT INVESTIGATION
Field Enforcement Officer, Harry Prank, has been with the agency just over
four months. He has completed his basic orientation and has had several
training courses. He has had, however, little practical field experience.
Due to the rapid expansion of the program and a shortage of personnel,
Harry has been shoved into the field and told to do the best that he can.
On July 6, Mr. Rust of Orangeland called the regional office and complained
that he and his wife had nearly become ill on the previous evening as a
result of malodorous emissions from a paint plant (ALcoat Company) located
near their home. Harry was assigned to the investigation.
Harry immediately went to the agency's files to determine whether or not
there had been any previous complaints concerning operations of the Alcoat
Company, His search of the records indicated that a similar complaint from
a resident in the Orangeland area had been received approximately one week
earlier. However, due to a shortage of personnel, no one had yet investi-
gated that complaint.
The agency's files also showed that the Alcoat Company had received a permit
to construct a coating plant in the complaint area approximately eighteen
months previously. The permit file indicated that the company would utilize
catalytic combustion units to control the emission of solvent vapors from
their paint coating and baking lines. The plant construction had been
completed and the plant had been operating for approximately four months.
Another inspector checked the plant prior to the beginning of operation:
his report had indicated that the plant was operating satisfactorily and
that there were no malodors apparent in the vicinity of the plant at that
time. The inspector had noted, nevertheless, that a faint solvent odor
could be detected outside of the plant.
Harry next visited the complainant at his home. He observed that the
Orangeland development consisted of approximately one hundred homes located
on a 130 to 140 acre tract. Adjacent to the development was a small
4-4
-------
( industrial park which apparently contained several manufacturing plants.
- As he approached the Rust residence, Harry was not able to detect any
malodors. In his conversation with Mrs. Rust, Harry was told that the
Rusts first became aware of the malodors approximately two weeks earlier
and that the odor episodes had occurred frequently since that time.
Mrs. Rust further stated that several of her neighbors had also complained
about the malodors to her. She offered to supply their names and addresses.
Mrs. Rust pointed out the Alcoat plant to Harry. He noted that the plant was
located approximately six hundred yards away from the residential Orangeland
area.
After leaving Mrs. Rust's residence, Harry drove directly to the Alcoat
plant. As he approached the plant, he noted that it had five stacks. Three
of the stacks had no visible emissions but two were emitting white vapor
plumes. He parked and entered the plant.
Inside he was greeted by the receptionist. He identified himself and asked
to see the plant manager. The receptionist placed a call and then told Harry
that the plant manager was not available but that the plant engineer,
Mr. Erb, would see him. Harry met Mr. Erb, again identified himself,
recorded Mr. Erb's full name and position title, and advised Mr. Erb of
the nature of the problem and of his agency rules and regulations pertaining
to such a problem.
Mr. Erb told Harry that, to the best of his knowledge, the plant and its
associated air pollution control equipment was operating satisfactorily
and that there was no problem. He did indicate, however, that he, himself,
had noted a slight odor as he drove by a metal-plating company approximately
one mile south of his plant. He also stated that some of his workmen had
informed him that several of the Orangeland residents were having trouble
with their septic tanks and that might be the source of the odor.
Mr. Erb offered to show Harry the plant and took him through the manufac-
turing facility. Harry observed that the company coated strips of metal
with paint. The paint was baked on the strips and then quenched, after
4-5
-------
C which the metal was recoiled for shipment to fabricating plants. The
baking ovens were each vented to separate catalytic combustion units
and the quenching operations each had a separate stack; there was also
a small oil-fired boiler.
Harry could detect strong paint solvent odor in the plant, but Mr. Erb
informed him that this was to be expected in the immediate vicinity of
so much fresh paint.
After the plant inspection and a further brief conversation with Mr. Erb,
Harry left. On his way back to his office, Harry passed the metal-plating
plant mentioned by Mr. Erb. He could not detect any malodors as he drove
by the plant.
Upon returning to his office, Harry prepared a report which detailed his
investigation. He concluded that, possibly, the Rusts were mistaken and
could discover no problem that would warrant further action by the agency.
Harry thought that that would be the end of the case, but it wasn't.
( Over the next several days, fourteen additional complaints concerning
malodorous emissions in the Orangeland area were received. The complaints
were brought to the attention of Harry's supervisor who reviewed Harry's
investigative report. He noted various errors in the investigative
technique and discussed these with Harry.
4-6
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EXERCISE
1. Assuming that Harry neither did not saw anything more than that
stated in the preceding material, prepare a critique of his
investigative technique. Indicate all errors and deficiencies
in his technique.
2. Assuming that the investigation indicated that the Alcoat Company
was indeed the source of the odors, explain how you would go about
establishing a bona fide air pollution case. Remember that there
are no specific odor control regulations and that the burden of proof
in establishing air pollution as defined in the agency's ordinance
rests with the agency. An odor problem of this type is effectively
a public nuisance and the manner of establishing the existence of
/ the problem would be similar to that used to establish the existence
of a public nuisance.
AIR POLLUTION REGULATIONS
APPLYING TO THIS AREA
USE THE RULES AND REGULATIONS OP HENDERSON COUNTY,
OHIO AS APPLYING TO THE AREA OF THIS CASE STUDY.
SEE EXERCISE NO. 1
4-7
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-------
STUDENT EXERCISE NO. 5
COMPLAINT INSPECTION OF AN
ASPHALT CONCRETE BATCHING PLANT
FILM & WORKBOOK
-------
r
LESSON 15
COMPLAINT INSPECTION OF AN
ASPHALT PLANT
FILM & WORKBOOK
GOAL.
To demonstrate a complaint inspection of an asphalt concrete
"batch plant. The student's proficiency is tested "by completing
inspection report forms to record conditions demonstrated in
the film.
OBJECTIVES. At the end of this lesson, the student should be able to:
1. Describe the process of manufacturing asphalt concrete
in a batch plant.
2. Use existing agency data to prepare for an inspection.
3. Properly obtain entry to a facility for the purpose
of conducting an inspection.
4. List inspection points for asphalt plants.
5. Interface effectively with plant management and
personnel so as to elicit their help and cooperation.
List the information which must be obtained from a
complainant.
6.
7.
8.
Interview complainants so as to obtain necessary
information and maintain good will.
Prepare inspection report forms and other appropriate
notices.
SELECTED READING:
Inspection Manual for Enforcement of New Source
Performance Standards.
Asphalt Concrete Plants, Reference 27.
INSTRUCTIONS. Use the same format as Lesson 6.
The film portrays a response to a citizen complaint and/
an inspection of the suspected source.
As in Exercise No. 2, there are various documents to be reviewed
and a Data Gathering Form to be filled out as the film
progresses.
At the conclusion of the film, the instructor will call on
students at random for their "Response Data" and lead a
discussion of the various inspection points.
Proceed to review documents in preparation for viewing the
film.
5-2
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SUGGESTED INSPECTION POINTS AND DATA GATHERING QUESTIONS
ASPHALT CONCRETE BATCH PLANT*
Entering plant premises
Interviewing plant manager
Reviewing .data provided
The plant yard
General plant survey
The cold feed conveyor/bucket elevator transfer point
*Refer to the flow diagram at the end of this form for
indicated inspection points.
5-3
-------
The rotary dryer
The hot elevator
The nixing tower
The underside of the baghouse
The baghouse exterior
The interview with the complainant
5-4
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Asphalt Plant Pile Information
Permit Application
- . Parmetric Evaluation Form
Summary of Source Operations
Summary of Pitot Traverse Data
Summary of Particulate Sampling Data
Production Record - October
5-6
-------
STATE Of ILLINOIS
OWUWWEKTAL PROTECTION AGEHCY
Binsio* OF AIR POLLUTION CONTROL
tWO CHURCHILL ROAD
C2706
APPLICATION FOR A WCT^j
D CONSTRUCT B OPERATE .
HA* OF EQUIPMENT TO BE - . ,
CONSTRUCTED OR OPERATED Asphalt Batch Plant
fOR A6ENCY USE ONLY ,
PTRMIT HO. ,„_.,_
ft)
Scenic Valley Asphalt Corp.
100 Main Street
Clearview
Id. STATE OF OWNER: ],. ZIP aK:
Illinois 60000
Scenic Vallev Asphalt Corp.
Clearview L """"EYES DNO
a. NAME Of OPERATOR:
Same *~~
2b. STREET ADDRESS OF OPERATOR:
Same
Same
2d. STATE OF OPERATOR: 2«. ZIP CODE:
•;
Jb. STREH ADDRESS OF EMISSION SOURCE:
loo Mair> Street
3«. TOHNSHIP: Jf. COUNTY: 39. ZIP CODE:
Smith Jones 60000
4. ALL CORRESPONDENCE TO: (NAME OF INDIVIDUAL)
Gary Johnson .
«. ADDRESS FOR CORRESPONDEN£L: (CHECK ONLY ONE)
»:
OPERATOR
EMISSION SOURCE
S. TELEPHONE NUMBER FOR ACENCY TO CALL:
7. YOUR ID NUMBER fOR THIS APPLICATION:/,,
100M1977 (c)
"
AUTHORIZED SICNATURE(S)
6/2/77
wu
IY
Gary
DATE
TVPED Oft PR1NTLD hAHE Of SICNEK
General Manager
mm UK
NIHL u>
(I) CLEARLY IDENTIFY
PERMIT WICH MAT
-------
9. AN OPERATING PERMIT APPLICATION HUST BE SUBMITTED IN DUPLICATE.
A COWR5!TTON PERMIT APPLICATION FOR CONSTRUCTION INTBoTTSuNTY OUTSIDE OF THE CORPORATE LIHITS OF CHICAGO MUST K
SUBMITTED IN QUADRUPLICATE.
A CONSTRUCTION PERMIT APPLICATION ID AU OTHER LOCATIONS MUST BE SUBMITTED IN TRIPLICATE.
THE APPLICANT SHALL SUBMIT A PLOT PLAN AMD MAP SHOVING DISTANCES TO THE NEAREST KUNDMY OF THE PROPERTY OH WICH THE OPERATION IS
LOCATED AC DISTANCES TO THE NEAREST RESIDENCES. LODGINGS. NURSING HOMES. HOSPITALS. SCHOOLS Ad COMMERCIAL AND MANUFACTURING
ESTABLISHES. IF SUCH A PLOT PLAN AMD NAP HAS ALREADY BEEN SUBMITTED. INDICATE THE ASfOTIATED AGENCY 1.0. WOER AND PEWIT
APPLICATION NUMBER. AGENCY I.D. MO. APPLICATION HO.
11. THE APPLICANT SHALL SUBMIT A PROCESS FLOW DIAGRAM DEPICTING ALL EMISSION SOURCES AND ALL AIR POLLUTION CONTROL EQUIPMENT COVEKiU
BY THIS PERMIT APPLICATION. THE DIAGRAM SHALL INCLUDE LABELS FOR EACH EMISSION SOURCE AW EACH ITEM OF AIR POLLUTION CONTROL
EQUIPMENT. AND SHALL SET FORTH MAXIMUM FLOW RATES FOR (1) ALL PROCESSING EQUIPMENT. (2) ALL AIR POLLUTION CONTROL EQUIPMENT. (3)
ALL EMISSION SOURCES. AND (4) AU STACKS AND VENTS. NUMBER OF SHEETS: 1 DRAWING NUMBER(S): 1
FOR EACH EMISSION SOURCE AND EACH ITEM OF AIR POLLUTION CONTROL EQUIPMENT IDENTIFIED ON THE PROCESS FLOW DIAGRAM. THE APPL1CAM
SHALL COMPLETE AND SUBMIT THt APPLICABLE PERMIT APPLICATION FORMS. THE FLOW DIAGRAM SHALL INDICATE THROUGH WHICH STACK OR VENT
SOURCE OR ITS BELATED AIR POLLUTION CONTROL EQUIPMENT is EXHAUSTED. IF ][T"Tr~EXHAusT£D WITHIN A BUILDING, so INDICATE
1 3" IF THlS IS AN APPLICATION FOR AN OPERATING PERMIT, AND THE APPLICANT IS INCORPORATING Tf REFERENCE PREVIOUSLY GRANTED INSTALLATION
' OR CONSTRUCTION PERMITS. HE SHALL COMPLETE FORM APC-210, DfTHLED *OATA AND INFORMATION - INCORPORATION BY REFERENCE.* —
14. IF THIS IS AN APPLICATION FOR AN OPERATING PERMIT. AKO THE STARTUP OF ANY EMISSION SOURCE DESCRIBES BY THIS APPLICATION PRODUCES
AN AIR CONTAMINANT IN EXCESS OF APPLICABLE STANDARDS. THE APPLICANT HAY REQUEST PERMISSION TO EXCEED SUCH STANDARDS BY COUPLET IN;
FORM APC-203. ENTITLED "OPERATION DURING STARTUP.*
15. IF THIS IS AN APPLICATION FOR AN OPERATING PERMIT, AND THE APPLICANT IS APPLYING FOR PERMISSION TO OPERATE AN EMISSION SOURCE
DURING MALFUNCTIONS OR BREAKDOWNS PURSUANT TO PCB REGS.. CHAPTER 2. RULE 105. THE APPLICANT MAY REQUEST SUCH PERMISSION BY
COMPLETING FORM APC-204, ENTITLED 'OPERATION DURING MALFUNCTION AND BREAKDOWN.*
~6. IF THIS IS AN APPLICATION FOR AN OPERATING PERMIT AMD ALL OR ANY PART OF THE PROCESS MltST BE CONTROLLED OR MODIFIED TO COMPLY
WITH APPLICABLE REGULATIONS, THE APPLICANT SHALL COMPLETE FORM APC-202, ENTITLED "COMPLIANCE PROGRAM t PROJECT COMPLETION SCHEDUU
17. IF THIS IS AN APPLICATION FOR AM OPERATING PERMIT, DOES THE OPERATION COVERED BY THIS APPLICATION REQUIRE AN EPISODE ACTION
IE. WAS EACH EMISSION SOURCE COVERED BY THIS APPLICATION, AS OF APRIL 1*. »72, IN COMPLIANCE WITH THE 'RULES AND REGULATIONS •
GOVERNING THE CONTROL OF AIR POLLUTION.* ADOPTED BY THE FORMER AIR POLLUTION CONTROL BOARD AND CONTINUED EFFECTIVE PURSUANT
TO SECTION 49(c) OF THE ENVIRONMENTAL. PROTECT ION ACT? [£] YES PI MO
15.
IF THIS IS AN APPLICATION FOR AN OPERATING PERMIT. MAS THE OPERATION THE SUBJECT OF A VARIANCE PETITION FILED WITH THE ILLINOIS
POLLUTION CONTROL BOARD ON OR BEFORE JUNE 13, 1972? TH YES g NO
IF "YES." CITE PCB NUMBER(S): BATE OF BOARD ORDER:
HAD THE APPLICANT ON OR BEFORE APRIL 14. 1172. COMMENCED CONSTRUCTION OF EQUIPMENT Oft MODIFICATIONS SUFFICIENT TO ACHIEVE COMPLIA
WITH THE APPLICABLE LIMITATIONS OF THE "RULES AND REGULATIONS GOVERNING THE CONTROL OF AIR POLLUTION." ADOPTED BY THE FORMER AIR
POLLUTION CONTROL BOARD AND CONTINUED EFFECTIVE PURSUANT TO SECTION 49(c) OF THE ENVIRONMENTAL PROTECTION ACT? QYES [_] NO
IF *NO," EXPLAIN IN DETAIL AND MARK TOUR EXPLANATION AS EXHIBIT 0.
TOTAL WMBER OF PAGES IN EXHIBIT 0:
20. IF THIS IS AN APPLICATION FOR AN OPERATING PERMIT. THE APPLICANT SHALL SUBMIT AN ESTIMATE OF THE MAXIMUM ONE-HOUR AMOUNTS OF
PARTICIPATE MATTER. SULFUR DIOXIDE. CARBON MONOXIDE. OXIDES OF NITROGEN. AND ORGANIC MATERIAL EMITTED FROM ALL SOURCES LOCATED
ON THE PLANT OR PREMISES. THIS ESTIMATE SHALL INCLUDE ALL EMISSION SOURCES LOCATED ON THE APPLICANT'S PREMISES AND NOT JUST
THE EMISSION SOURCES DESCRIBED IN THIS APPLICATION.
MATERIAL
MAXIMUM ONE-HOUR
AMOUNTS
MATERIAL
MAXIMUM ONE-HOUR
AMOUNTS
HftTBML
MAXIMUM ONE-t
'ARTICULATE
UTTER
SULFUR
DIOXIDE
NITROGEN
OXIDES
^JL
LB
-t!
J*£
WTERIAL- .
CARBON
KONOXIDE
03
• 17
U
21. WHAT IS THE SIZE (IN ACRES) OF APPLICANT'S PREMISES?
50
LIST AND IDENTIFY ALL FORMS, EXHIBITS. AND OTHER INFORMATION SHMITTED AS PART OF THIS APPLICATION. PUASE NUMBER EVERY PAGE
AND STATE THE TOTAL HHBER OF PAGES IN THIS APPLICATION. *
5-8 • • -
-------
r
STATE OF ILLINOIS
tWURONMENTAL PROTECTION AGENCY
DIVISION OF AIR POLLUTION CONTROL
2200 CHURCHILL ROAD
SPRINGFIELD. ILLINOIS (2706
DATA AND INFORMATION
PROCESS EMISSION SOURCE (A)
ft* ACENCT USE OKU •
or PLANT OWNER:
Scenic Valley Asphalt Corp.
2. NAME OF CORPORATE DIVISION OR PLANT (IF OlFFERtNT FROM
100 Main Street
4. CITY OF EMISSION SOURCE:
Clearview
CENERAL INFORMATION
XESS:
Asphalt Paving Material Batching
6. NAME OF EMISSION SOURCE EQUIPMENT:
Asphalt Batching
"'"UJlRn i^mfc^r "" • " •<«•
6.
NUMBER:
Cedar Rapids
H
9. SERIAL NUMBER:
C254171
D""JBED °" ™" FORM <«"« TO -6ENERAL' INSTRUQIONS FOR COMPLETION OF'PERMIT
10 HRS/DAY 6 DAY5/WK "30
WO/YK
13. HKW1 U AMIAL
OCC/FEB 0 I MAR/MAY 15 t JUN/AUC 60 I 5EP/NDV 25
RAW MATERIAL INFORMATION
U.
NAMES OF RAW MATERIALS(B)
NAXinUM RATE PER
IDENTICAL SOU°CF
AVERAGE RATE PER
IDENTICAL SOURCE
Aggregate - Various sizes depending
— on mix desired
>00.000
U/HR
937
Asphalt
30.000
15,000
LB/HR
.,LB/HR
LB/HP
E«SSION SOURCE OTHER THAN A .UU .,::•_, I |-n IHISSION SOURCE OR
' WIL"' °* SIMILM fW">«'" KEO «• THf. MtlHAI-^ »uM-aU OF PRO-
' ttH>Lm *WT* *"° '"FORMATION -Full CW^TION EMISSION
l$ •**'• «« SUCH *"
* WHKMTW
8UC NG HEAT OR
SOuicE ^FWW A
^WTi AND
») CONPOsmONS OF ^ HATERIAIS MUST BE DHAILfO TO THE EXTENT KO3SAKT TO DnERniNE THE fATUtt MO OWMCTm OF POTENTWi W1SSIOKS.
. 5-9 -
-------
MAXIMUM KATE PIS
IDENTICAL SOURCE
NAMES OF PRODUCTS
AVERAGE RATE PER
IDENTICAL SOURCE
Hot-Mix Asphalt Paving Cement
HASTE MATERIAL INFORMATION
MAXIMUM RATE PER
IDENTICAL SOURCE
"AMES OF HASTE MATERIALS
AVERAGE RATE PER
IDENTICAL SOURCE
Water Vapor
25,000 LB/HR
.MAXIMUM EMISSIONS FROM EACH IDENTICAL SOURCE*
CONTAMINANT
I?. PARTICULATE
MATTER
IS. CARBON
MONOXIDE
19. NITROGEN
OXIDES
20. ORGANIC
MATERIAL
DIOXIDE
OTHER
(SPECIFY)
CONCENTRATION OR EMISSION RATE
6R/SCF
t.
PPM
(VOL)
PPM
(VOL)
*.
PPM
(VOL)
•^HB^BH
PPM
(VOL)
LI/HR
b.
b.
U/KR
^••••IMM
LB/HR
"••—^™™
LI/HR
b.
U/KR
•••••MMI
LB/HR
METHOD USED TO DETERMINE CONCENTRATION OR EMISSION RATE
c.
c.
c.
c.
c.
EXHAUST DATA*
23• ?IP>' DIAGRAM DESIGNATI
cK&yg ai
EXIT DIAMETER:
27. EXIT HEIGHT ABOVE MADE:
RATE THROUGH EACH
ACFM
EIGHT OF NEARBY
: FT
25. EXIT CAS TEMPERATURE:
1
29. EXIT DISTANCE FROM NEA
PLANT BOUNDARY: . |
COMPLHE THESE SECTIONS ONLY IF EMISSIONS ARE EXHAUSTED WTHOUT CWTKOl EQUIPMENT.
"~~~~^~™"~"~1^"™^™111™~"llto~~^"~" 5-10 ———
-------
STATE OF ILLINOIS
ENVIRONMENTAL PROTECTION AGENCY
DIVISION OF AIR POLLUTION CONTROL
2200 CHURCHILL ROAD
SPRINGFIELD. ILLINOIS C2706
DATA AND INFORMATION
AIR POLLUTION CONTROL EQUIPMENT
FOR AGENCY USE ONLT •
1. NAPE OF OWNER:
Scenic Valley Asphalt Corp.
2. NAME OF CORPORATE DIVISION Oft PLANT (IF DIFFERENT FROH
3. STREET ADDRESS OF EMISSION SOURCE:
100 Main Street
4. CITY OF EMISSION SOURCE:
Clearview
ADSORPTION SYSTEM
AP*iw*?Si5s."Fo»JAAPc.1o?):*KORPT10N $YSTWS ttSMIB" IH THIS
<*F» T0 '««•*•• INSTRUCTIONS FOR COMPLETION or PERMIT
3. MODEL NAME AND NUMBER:
7. METHOD OF REGENERATION:
O REPLACEMENT
S. NUMBER OF BEDS PER SYSTEM
t. ADSORBANT HEIGHT KR (ED:
IB
STEAM
O OTHER (SPECIFY
B. TIME ON LINE BEFORE REGENERATION:
M1N/BED
9. EFFICIENCY OF CONTROL (ATTACH TEST REPORT OR EXPLAIN ESTIMATE)
AFTERBURNER
'" ™IS UCTI0" <""" T° "ttNtRAL «KT«UOIOW FOR COMPLETION OF PERK1T
U GAS Q OIL ( _ J SULFUR)
6. INLET GAS TEMPERATURE:
3.
S.
7.
LENGTH _^ U,; CROSS SECTION
U ns U NO
10.
BURNERS PER AFTERBURNER «
OPERATING TEMPERATURE
IN I
EFFICIENCY OF CONTROL
PARTICIPATE
OF COMBUSTION CHAMBER:
IN; OR
(ATTACH TEST REPORT OR
S CASEOUS
BTU/KF
EACH
EXPLAIN ESTIMATE):
I
5-11
MCE 1 0
-------
1
1
FOR MENCY US.E ONLY
CONDENSER
'" ^ICMIO^.^FO^APc'-M?):0*'1*""5 KSCR1BE° '" ™IS $£CTIW . l«TRUCT10flS FOR COMPLETION OF PERMIT
D WATER ( CPM) Q'AIR (
INLET -F OUTLET
FT*
1
SCFM) D OTHER (TYPE FLOW RATE ,
^"F INLET . «F OUTLET 't
8. EFFICIENCY OF CONTROL (ATTACH TEST REPORT OR Em.A!tl ESTIMATE):
.
eraow Prittarv Control
LI IONS. RM APC-ZOl :
Iowa Manufacturino Corn.
4. NUMBER OF CYCLONES IN EACH MULTIPLE CYCLONE:
6. DIMENSION THE APPROPRIATE SKETCH (IN INCHES) OR PROVIDE A 0
- ^^
r — 60—1
3. MODEL NAME AND NUMBER:
Sinqle Stage 24 OH
S. EFFICIENCY OF CONTROL (ATTACH TEST REPORT OR EIPLAIN ESTIMATE):
AP-42 65
RAWING WITH EQUIVALENT INFORMATION:
nT
J :
ELECTRICAL PREC1PITATOR
'' OF^EWT^PUCATIONS^So^APC-ZO^ "ttC">IUTORS «CRIBED IN THIS SECTION (REFER TO '6ENERAI INSTRUCTIONS FOR COMPLETION
'.. MANUFACTURER:
I. COLLECTING ELECTRODE AREA PER CONTROL DEVICE:
3. MODEL NAME AND NUMBER:
5. EFFICIENCY Of .CONTROL (ATTACH TEST REPORT OR EIPLAIN RESULTS):
FT* »
FILTER Secondary Control
' row SpMOl)*""1*"0* °f FILT£K KSC">BtB Jlt THli ««»0" <«"» « -SENERAL INSTRUaiONS FOR COMPLETION OF PERMIT APPLICATIONS."
• MANUFACTURER :
Western
FILTERING AREA PER CONTROL DEVICE:
1 3200
IT COAMING: __
U SHAKER Q REVERSE AIR U PULSE AIR B PULSE JTT
D BLEED- IN A|R( 5CTV) D MATER SPRAY (
INLET 6AS:
TEMPERATURE 300 'f; OfV PTIKT 16
n-ito
3. MODEL NAME AND NUMBER:
S1132
S. FILTERING MATERIAL:
"2 Fiber Glass
DoTHER(SPECIFY , ) .
__ 36x24
«••«) H DUCTUCNGTH 70 FT: 01* M D OTNTifwrC |t»)
_ ». EFFICIENCY OF CWTPOL ('HACM nST «£»)»: OP E»P' (IN ESTIMTCi-
5-12 flv t ^
-------
rot AGENCY ust OM.»
SCRUBBER
4 SCRUBBER TYPE:
CD HIGH ENERGY (us STREAM PRESSURE DROP
D wctto (PACUNC TYPE
1—I SPRAV (NUMBER Of NOZZLES
D EITHER (SPECIFY
IN H20)
; PACKING SIZE
; NCIZIE PRESSURE
IN; PACKED HEIGHT
PSIC)
IN)
ATTACH DESCRIPTION AND SKETCH WITH DIMENSIONED DETAILS)
5 SCRUBBER GEOMETRY
LENGTH Id DIRECTION Of GAS FLOW
LIOUIC FLOW RATE INTO SCRUBBER
CHEMICAL COHPOSITIOh OF SCRUBBAM
OTHER TTPES OF COKTWL EpUIPMENT
2. 6ENERIC NAME OF OSKTRO.
3. HUtUFACTURER:
4. WDEL NAME AND NITCER
i. ATTACn DESCRIPTION AND SnETCh OF CONTROL EQUIPMENT
DIMENSIONED DETAILS AND FLOW RATEsT tOUIP"«T
*• fr"««CT OF CONTRA (ATTACH TEST REPORT OR EXPLAIN ESTIKATE)
PARTJCU.ATE j 6AS£0US ,
5-13
EMISSIONS FHW EACH IDENTICAL EXIT
CONCENTRATION JJR EMISSION RATE
»CTHOD USED TO DCTEM1NE CONCENTRATION OR EMISSION RATE
EPA Method - 5
e- Emission Factors for Natural Gas
Combustion (AP-42)
EXIT HEIGHT ABOVC MADE
30
fT
*• **.^FL* UTE THROUGH EACH
28,000
6. MAIJMUK HEIGHT OF NEARBY
•UIL01NGS: ,. „
3. EXIT GAS TEMPERATURE:
250
'• EXIT DISTANCE F«0« NEAREST
PLANT IDUNDARY:
------- An error occurred while trying to OCR this image.
------- An error occurred while trying to OCR this image.
-------
SUMMARY OF SOURCE OPERATION
PLANT: Scenic Valley Asphalt Corp.
LOCATION: 100 Main Street, Clearview. Illinois
DATE OF TEST: July 7, 1977
TYPE OF PROCESS/EQUIPMENT: Permanent Asphalt Plant
Material Processed or Produced: Asphalt paving material
[Operating Schedule: 10 Hr./bay 180 Dav/Year
(Maximum Operating Capacity (Include Units) •
|Hormal Operating Capacity: 120 T/hr.
2.52.5 T/hr.
Operating Capacity During Test: Test 1 118T; Test 2 13QT: Test 3 123T
[Fuel.Type: Natural Gas % Ash: N/A % Sulfur: N/A
Amount of Fuel Consumed During Test: Not measured.
pollution Control System Description: Primary cyclone; secondary positive
pressure, pulse-cleaned baghouse with dust return to fines storage bin.
Pressure Drop Across Collector:
Additional Information :
6" W.C.
5-16
-------
SUMMARY OP PITOI TRAVERSE DATA SHEET 1 of
PLANT: Scenic Valley Asphalt Corp. SOURCE: Baahouse StacV DATE: 7/7/7
A. Stack Dimensions 2' x 4'
B. Area of Stack, Sq. Ft. 8
C. Barometric Pressure, "Kg 29.65
D. Gage Static Pressure in Stack, "i^O 0.18"
E. Stack Gas Temperature, Dry Bulb, °F 280
F. Percent Moisture 10%
G. Dry Gas Composition: %C>2 17.1
%C02 2.1
%CO < 0.1
90*2 80.8
% other -
H. Density of Dry Stack Gas, @ STP, Lbs./Cu. Ft. 0.08
I. Density of Moist Stack Gas, @ STP, Lbs./Cu. Ft. 0.07
J. Density of Moist Stack Gas, @ Stack Conditions,
Lbs./Cu. Ft. • 0.054
K. Total Number of Traverse Points 12
L. Pitot Tube Calibration Factor 0.82
M. Average Square Root Velocity Head of all
Traverse Points 0.77
N. Average Gas Velocity, Feet/Min. 3500
0. Stack Gas Flow Rate:
1. @ Stack Conditions, Wet. ACFM 28,200
* ' ^^**«W™«i«^^^^B«*"^^^«^^^**™^^^™
2. @ Standard Conditions, Wet, SCFM 20,300
3. @ Standard Conditions, Dry. DSCFM 18,250
STP * 70°F, 29.92 "Hg.
"Wet" or "Moist" - Refers to the condition of the gas with actual water
content.
5-17
-------
SUMMARY OF PARTICULATE SAMPLING DATA
SHEET 1 of
r
PLANT; Scenic Valley Asphalt Corp. SOURCE: Baahouse Outlet DATE: 7/7/71
A. Sample Number
B. Number of Points Sampled
C. Total Duration of Sample, Min.
D. Nozzle Diameter, In.
E. Nozzle Area, Sq. Ft.
F. Calibration Factors
1. Probe Pitot Tube
2. Gas Meter B@
G. Barometric Pressure, "Hg.
H. Gage Static Pressure in Stack, "H20
I. Stack Gas Temperature, °F (Ave)
J. Average Square Root Velocity Head
of Points Sampled
K. Average Gas Meter Temperature, °F
L. Average Gas Meter Pressure, "H20
M. Gas Meter Volume, Actual, Cu. Ft.
N. Gas Meter Volume, €> STP, Cu. Ft.
0. Liquid Volume of Water Condensed, ML.
P. Vapor Volume of Water Condensed at
STP, Cu. Ft.
Q. Total Gas Sampled Through Nozzle,
@ STP, Cu. Ft.
R. Percent Moisture in Stack
12
12
12
60
60
60
.260
,260
.260
,000369 .000369 .000369
.82
2.07
.18
270
.76
88.2
.716
.82
.82
2.07
2.07
29.80 29.80 29.80
.18
.18
280
290
.77
.78
91.8
89.6
.743
.785
44.80 45.74 47.09
44.00 45.04 46.57
102.1 105.6 108.3
4.77 5.06 5.23
48.75 50.10 51.80
9.8 10.1 10.1
5-18
-------
SUMMARY OP PARTICULATE SAMPLING DATA SHEET 2 of 2
i
5, Particulate Concentration
1. Grains/Dry Standard Cubic Feet .05 .04 .05
2. Lbs./Hr. 8.0 6.3 6.0
T. Percent Isokinetic 105.6 108.6 107.9
STP = 70°F, 29.92 "Hg.
"Wet" or "Moist" - Refers to the condition of the gas with actual
water content.
5-19
------- An error occurred while trying to OCR this image.
-------
STUDENT EXERCISE NO. 6
INSPECTION OF COMBUSTION SOURCES
LECTURE AND FILM
-------
United States
Environmental Protection Agency
Contract No. 68-02-1315
Applied Science Associates, Inc.
Box 158 Valencia, Pennsylvania 16059
INSPECTION OF COMBUSTION SOURCES
a training module
for fuel burning equipment inspectors
TRAINEE'S WORKBOOK
Zita Glasgow, Project Manager
Applied Science Associates, Inc. Box 158
Valencia, Pennsylvania 16059
and
Michael C. Osborne, Project Officer, U.S. EPA
Prepared for the
United States Environmental Protection Agency
Control Programs Development Division
Air Pollution Training Institute
Research Triangle Park, North Carolina 27711
March 1974
-------
us
EPA
This is not an official policy and standards document.
The opinions, findings, and conclusions are those of the authors
and not necessarily those of the Environmental Protection Agency.
Every attempt has been made to represent the present state of the art
as well as subject areas still under evaluation.
Any mention of products or organizations does not constitute endorsement
by the United States Environmental Protection Agency.
6-11
-------
ACKNOWLEDGEMENTS
The project reported in this volume was developed under a contract
from the Environmental Protection Agency, Contract No. 68-02-1315.
Mr. George Purifoy, Program Scientist, served as principal investigator.
Ms. Zita Glasgow, Staff Scientist, served as project director.
Mr. Joseph Cherico of the Allegheny County Health Department's Bureau
of Air Pollution Control, and Mr. Richard W. Gerstle, Vice President of
PEDCO-Environmental Specialists, Inc., served as technical consultants.
The author is indebted to numerous people for their cooperation
and participation in the project. Silvermine-Films, Inc. provided the
film making expertise for the project. Mr. Joseph Cherico played the
role of the Field Enforcement Officer in the film and assisted in obtain-
ing permission from industries to film at their facilities. The roles
of the plant Representatives were played by Mr. D. E. Kordes, Mr. G. Edward
Scutt, and Mr. Al Taylor. The New Jersey State Bureau of Air Pollution
Control and the Pennsylvania Bureau of Air Quality and Noise Control
assisted in the field test of this material.
6-iii
-------
AIR POLLUTION TRAINING INSTITUTE
MANPOWER AND TECHNICAL INFORMATION BRANCH
CONTROL PROGRAMS DEVELOPMENT DIVISION
OFFICE OF AIR QUALITY PLANNING AND STANDARDS
The Air Pollution Training Institute (11 conducts training for personnel working on
the development and improvement of state, and local governmental, and EPA air
pollution control programs, as well as for personnel in industry and academic insti-
tutions; (2) provides consultation and other training assistance to governmental
agencies, educational institutions, industrial organizations, and others engaged in
air pollution training activities,- and (3) promotes the development and improve-
ment of air pollution training programs in educational institutions and state, regional,
and local governmental air pollution control agencies. Much of the program is now
conducted by an on-site contractor, Northrop Services, Inc.
One of the principal mechanisms utilized to meet the Institute's goals is the intensive
short term technical training course. A full-time professional staff is responsible for
the design, development, and presentation of these courses. In addition the services
of scientists, engineers, and specialists from other EPA programs, governmental
agencies, industries, and universities are used to augment and reinforce the Institute
staff in the development and presentation of technical material.
Individual course objectives and desired learning outcomes are delineated to meet
specific program needs through training. Subject matter areas covered include air
pollution source studies, atmospheric dispersion, and air quality management. These
courses are presented in the Institute's resident classrooms and laboratories and at
various field locations. , r
Q&tsllJ&z&t&tte'*'
Robert G. Wilder A ifcan j. Schueneman
Program Manager " KChief. Manpower & Technical
Northrop Services, Inc. Information Branch
6-iv
-------
TABLE OF CONTENTS
OVERVIEW OF THE COURSE 1
CHAPTER 1. ELEMENTS NECESSARY FOR GOOD COMBUSTION . 3
Introduction 3
The Composition of Fuels 3
Air Supply for Combustion 4
Elements of a Good Combustion System 7
Definitions of Some Components in the
Combustion System and Their Functions 9
CHAPTER 2. OPERATION OF EQUIPMENT TO BE INSPECTED . 11
Introduction 11
The Spreader Stoker 11
Pulverized Fuel Firing Units 15
Cyclone Furnace 18
Oil Burning Furnaces 22
Air Pollution Control Equipment 26
SELF-EVALUATION QUESTIONNAIRE I 30
CHAPTER 3. INSPECTION POINTS AND OBSERVATIONS WHICH
SHOULD BE MADE 35
Introduction 35
Observe Plume Before Entering the Plant 36
Inspect Fuel Preparation System 36
Inspect Furnace Interior 38
Inspect Control Panel Instrumentation 39
Inspect Fans and Duct Work 46
Inspect Ash Disposal Systems 46
Inspect Air Pollution Control Systems 46
SELF-EVALUATION QUESTIONNAIRE II 48
CHAPTER 4. SOURCES INSPECTED IN THE FILM 51
Introduction 51
Your Job While Viewing the Film 51
Information About the Sources to be Inspected
in the Film 53
REFERENCES 78
6-v
-------
Table
LIST OF TABLES
Page
1.1 BTU Values When the Three Important Combustibles
in Fuel Unite With Oxygen at the Combustion
Temperature 5
2.1 National Bureau of Standards Grades for Fuel Oil . . 23
3.1 Plume Characteristics and Operating Parameters ... 37
3.2 Guides for C02 Concentration in Flue Gas Leaving
Furnace 42
3.3 Guides for ©2 Levels in Combustion ..,..,.... 42
6-vi
-------
LIST OF FIGURES
Figure
1.1
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
3.1
3.2
3.3
3.4
3.5
3.6
4.1
4.2
Diagram of the basic elements of a combustion
Traveling grate Spreader Stoker with front ash
Spreader Stoker installation with gravity
fly-ash return
Circular burners for firing pulverized coal ....
Direct-firing system for pulverized coal
Cyclone Furnace operation
Bin, direct-firing, and direct-firing pre-drying
bypass systems for coal preparation and feeding
to the Cyclone Furnace (schematic)
Firing arrangements used with Cyclone Furnaces . . .
Circular register burner for oil burning
Cell burner for pulverized coal, oil and
Air pollution control equipment
Opacity chart
Opacity chart
Steam-flow/air-flow pens calibrated to coincide . .
Steam-flow/air-flow pens modified to show parallel
traces
C02 concentration recorded continuously
The control room
C©2 concentration
Pag
8
12
13
16
17
19
20
21
25
25
27
41
41
43
43
45
45
56
56
(Continued, next page)
6-vii
-------
LIST OF FIGURES (cont.)
Figure
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
> 4.18
4.19
4.20
4.21
4.22
4.23
Condition of steam-f low/air-flow .
Emissions as shown by opacity chart ... V ...
Readings on "bus .section" of electrostatic
Equipment associated. with the forced air fan
A portion of the Spreader Stoker grate '.''.'.
Pressure drop gauge for air pollution control
The oxygen recorder, the opacity recorder and the
steam-flow/air-flow recorder ....
Gauges showing conditions of the fuel delivery
.pass.
57
57
1 58
58
59
59
59
60
65
65
66
67
67
68
68
69
• 69
74
75
76
77
6-viii
-------
OVERVIEW OF THE COURSE
This course is intended for personnel in air pollution control
agencies who are responsible for inspecting fuel-burning equipment.
Fuel-burning equipment, as treated in this course, consists of equip-
ment designed to burn fossil fuels in order to generate heat. The
heat generated is then used in various thermal processes such as steam
generation and electric power generation. At the end of this course
you will be able to distinguish between good operating practices which
will result in reduced air pollution and poor operating practices which
may result in an increase in air pollution.
The course has two interdependent components—the Workbook and a
Film. The Workbook contains information about the:
Elements necessary for good combustion (Chapter 1).
Operation of equipment to be inspected (Chapter 2).
Inspection points and observations which should be
made (Chapter 3).
Sources inspected in the film (Chapter 4).
The Film shows the inspection process as it would actually be carried
out by an experienced Field Enforcement Officer (FEO). As you view the
Film you will make the same visual inspection points asKthe FEO in the
Film. You will see what he sees and then for some points decide whether
or not satisfactory or unsatisfactory operating practices are evident.
The Film is divided into three parts:
Part I: Inspecting a plant which has a pulverized coal
burner. This part of the film contains a
sequence about the Cyclone Furnace.
Part II: Inspecting a plant which has a spreader stoker
furnace.
Part III: Inspecting a plant which has an oil burner for
residual or distillate oils.
PA.C.pm.112.5.74
6-1
-------
CHAPTER 1. ELEMENTS NECESSARY FOR GOOD COMBUSTION
Introduction
Combustion is the chemical combination of oxygen with the combus-
tible elements of a fuel. It can take place rapidly, as for example in
a fireplace or a boiler furnace. Or it can take place very slowly, taking
years in the process. A discussion of combustion which takes place over
a long period of time may be helpful in understanding what goes on during
the process. Vegetation, left to rot, will after a while disappear be-
cause it will have gone through the process of decay. During this process,
a chemical action takes place. The matter which forms the waste is oxi-
dized. In other words, it forms various compounds which pass away mostly
in the form of gases. During this process some heat is given off, but be-
cause the process is so slow, it goes unnoticed. Assume this heat is given
off in a confined space where the gases cannot escape, as for example with
hay in a barn. The increase in temperature might cause an increase in the
temperature of the hay, until perhaps the gases given off ignite and the
hay and barn catches fire. Essentially the same process occurs in large
combustion systems, such as boiler plants. The combustion system feeds
fuel which mixes with air and ignites when the temperature is high enough.
The fuel then burns at rates necessary to generate the amount of thermal
energy needed.
The Composition of Fuels
There are just three combustible chemical elements of significance—
carbon, hydrogen, and sulfur. The most important combustible in all fuels
is carbon. Carbon is present in fuels in varying quantities. Coal, coke,
and oil are valuable and useful as fuel because of their high carbon
content.
Next to carbon, hydrogen, a gas, is the most important constituent
of fuels and plays an important part in the combustion process. It is
6-3
-------
foujd in small quantities in most fuels, hut it is important because of
the high heat output from its combustion.
Sulfur is present in most fuels in small quantities. Sulfur is usually
of minor significance as a source of heat, but it can be of major signifi-
cance in pollution problems.
Air Supply for Combustion
Oxygen necessary for combustion is found in air. Air is composed of
largely two gases, oxygen and nitrogen. There is approximately four times
the volume of nitrogen to that of oxygen. Nitrogen is an inert gas and
has no direct value as an aid to combustion, but it is a source of pollu-
tion. At extremely high temperatures the nitrogen molecules and the atmos-
pheric oxygen molecules combine to form oxides of nitrogen. (NOX). NOx
emissions from large plants may produce a brownish haze or cloud in the
vicinity of the plant.
When oxygen unites with the carbon in a fuel, two important gases re-
sult from this chemical action. One is carbon monoxide (CO) and the other
is carbon dioxide (C02). If sufficient air is at hand when this chemical
action takes place then C02 is formed. If there is an insufficient supply
of air, CO is formed. The heat output from C02 is nearly three and one
half times greater than that from CO. It is obvious that to obtain the
greatest heat output when carbon is going through the combustion process,
a sufficient supply of air must be available. Hydrogen, the next most
important combustible, unites with oxygen and forms water vapor or
steam (H20).
The heat value of sulfur is small but the oxidation of sulfur forms
sulfur oxides (SOX). Sulfur oxides are produced in significant quantity
by the combustion of most coals and fuel-oils and are a serious cause of
pollution. Sulfur oxides can be controlled by using low sulfur fuels in
the combustion process.
In the combustion process, the uniting of carbon, hydrogen, and sul-
fur can take place only at what is known as "the temperature of combus-
tion" or the "ignition temperature". This temperature varies with each
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constituent of any given fuel. Ignition temperature is the temperature
which must be attained or exceeded in the presence of oxygen to cause
combustion. The important point is that combustion cannot take place
completely below this temperature.
The heat of combustion is measured as the quantity of heat evolved
by burning a standard unit of fuel (BTU/kilogram for coal and BTU/liter
for oil). Heat contents of fuel differ because of variations in percent-
ages of carbon, hydrogen, and sulfur. Table 1. 1 shows the heat produced
for 1 kilogram (kg) of carbon, 1 kg of hydrogen, and 1 kg of sulfur.
Table 1.1 BTU Values When the Three Important Combustibles
in Fuel Unite with Oxygen at the Combustion Temperature
1 kg carbon (complete combustion
forming C02) = 32,288 BTU
1 kg carbon (incomplete combustion
forming CO) = 14,207 BTU
1 kg hydrogen - 136,868 BTU
1 kg sulfur " 8,882 BTU
Source: Cotton, J. C. Combustion and modern coal-
burning equipment. London: Pitman & Sons,
1946.
As we said earlier, the oxygen required for combustion is largely
drawn from the air supply. However, oxygen is only one of several gases
in air. It contains 23.2 percent of oxygen by weight. About 2-2/3 kg of
oxygen are needed to complete the combustion of 1 kg of carbon, while 8 kg
of oxygen are required to completely burn 1 kg of hydrogen. It is obvious
that a great deal of air is needed in order to provide the required amount
of oxygen for combustion.
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For complete combustion to take placr, it is necessary that ea-.:rs pat-
tide of the substance being burned be ir, intimate contact with the oxygen.
With solid fuels this is a problem because of the small surface of the fuel
exposed to the air.
If sufficient air reaches the combustion chamber and the firebed and
is intimately mixed with the fuel, complete combustion will take place. If
the air supply is in any way restricted in quantity then there will be in-
complete combustion. Uuburned particles of carbon in the form of hydro-
carbons will pass out through the stack as visible emissions. There will
also be a considerable waste in heat generated due to the formation of CO
instead of C02-
In order to ensure that sufficient air has reached the combustion
chamber, several types of combustion air are of interest. Primary air is
air which is introduced with the fuel at the burner or over the fuel bed.
Secondary air is introduced through specifically arranged inlets.
In order to ensure that sufficient air reaches the combustion ;;iaa.bv,,
it is usual to supply air in quantity in excess of what is theoreti .ally
required. The actual amount of excess air necessary varies with each
installation.
Increasing the excess air decreases the amount of unburned coabusti.xle
matter and increases the combustion efficiency. At the same time excess
air dilutes and cools the combustion gases. Each kilogram of excess air
introduced into the chamber absorbs useful heat. Because excess air is a
factor in the emission of all air contaminants optimum excess air require-
ments should be established for each installation.
In summary, there are three main requirements for complete com".uec,ii,»tt,
They are:
1. Air from which the correct amount of oxygen can be drawn.
2. An intimate mixture of fuel and air.
3. A sufficient temperature at the point where combustion
is taking place.
It can be seen that efficient combustion can take place only under
certain conditions.
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Elements of a Good Combustion System
A combustion system feeds fuel, intimately mixes the fuel with air
and ignites and burns the fuel in a firebox at rates necessary to gen-
erate the amount of thermal energy required., Figure 1.1 presents a dia-
gram of a simplified combustion system. The fuel may consist of liquids,
solids or gases. The combustion systems discussed in this course use
coal and oil. In some systems the fuel cannot be used in the same con-
dition it is when it arrives at the plant. For example, some liquid fuels
have to be preheated before they can be used in combustion. Solid fuels
may have to be crushed, ground, classified, washed or otherwise conditioned
before combustion. The fuel must also be mixed with air in the proper
ratio in order to provide for complete combustion. Depending on the type
of equipment, the air-fuel mix may occur prior to feeding the fuel into
the firebox, as the fuel is fed into the firebox or in the firebox itself.
Whichever process is used, sufficient turbulence must be permitted to allow
thorough mixing of fuel particles with combustion air.
During this combustion process a definite amount of heat is given
out and this heat is used, in the case of a boiler, to heat the water which
surrounds the combustion chamber. In all solid fuels there is a residue
which is unburnable, and it is therefore a useless part of the fuel known
as ash. Ash remains as a waste product after combustion and is periodi-
cally or continuously removed from the firebox for disposal. The gaseous
products of combustion and any light pieces of fly ash entrained in the
gases are carried out the stack. The draft which draws the products of
combustion into the flue may be natural or mechanical. In large opera-
tions fans are used. To meet the objective of a clear stack, some form
of particulate removal equipment is used to remove the fly ash from the
flue gases. In some cases, devices called scrubbers which also control
sulfur oxides (SOX) are used.
The entire combustion system is typically monitored from a control
board. The conditions which show up on the control panel vary from plant
to plant. Control panel instrumentation is discussed later in this Workbook.
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Definitions of Some Components in the Combustion System and Their Functions
AIR HEATERS: Air heaters reclaim some heat from the flue gases to heat
the air required for fuel combustion. -«,,
BOILERS: Shells, drums or tubes which contact hot gases on one side and
water on the other. Heat is transferred from the hot gases through the
boiler walls to the water on the other side.
ECONOMIZER: In large units, the economizer absorbs heat from the flue
gases. The heat is in turn used to heat the feedwater before the water
enters the boiler. Economizers allow for economic use of the heat gen-
erated from fuels and thus warrant their name.
FANS: Move air or gas through the combustion system. The fan usually
consists of a bladed rotor or impeller and a housing. The draft created
by the fan may be either forced or induced. Forced draft fans "push"
air and induced draft fans "pull" air.
FEEDWATER: Water supplied to the heat exchanger units for heating or
steam production.
FURNACE: Firebox where combustion takes place. Usually of refractory
cement, water tube or firebrick construction. Furnaces are rated in terms
of million BTU/hour of capacity, or when combined with a boiler, in kilo-
grams of steam generated/hour, or boiler horsepower. Since the furnace
and boiler are usually built as an integrated unit, no sharp distinction
is usually made.
REHEATERS AND SUPERHEATERS: Heat steam to higher temperatures to effect
higher thermodynamic gain and improve turbine efficiency. Units are essen-
tially banks of tubes exposed to the hot gas stream.
SOOT BLOWERS: Jets of high pressure steam or air which are blown across
the surfaces of the furnace to remove soot deposits. Soot blowing sched-
ules vary depending upon the fuel burned and the size of the operation.
Frequencies of soot blowing varies from every 2 hours to every 24 hours.
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CHAPTER 2. OPERATION OF EQUIPMENT TO BE INSPECTED
Introduction
This chapter describes systems for coal and oil burning and air pol-
lution control equipment associated with these systems. You will read
about the spreader stoker system of firing coal, about the systems which
burn coal in pulverized form, and the Cyclone Furnace firing of coal.
You will also read about equipment which burns residual and distillate oils,
Air pollution control equipment covered in this chapter include electro-
static precipitators, inertial separators and wet scrubbers.
The Spreader Stoker
Mechanical stokers were developed early in the history of the steam
boiler as an improvement over hand firing. Today several types of stokers
are available. Among these several types, the spreader stoker is the most
generally used in the capacity from 34,000 to 181,000 kilograms (75,000
to 400,000 pounds) of steam per hour. It responds rapidly to load swings
and can burn a wide range of fuels with low maintenance, high daily effi-
ciency and simplicity of operation.
As the name implies, the spreader stoker projects coal into the
furnace over the fire with a uniform spreading action. Fine fuel parti-
cles are burned in suspension, and the larger pieces fall and burn on a
grate. Figure 2.1 illustrates this method of firing.
The spreader stoker combines suspension and fuel bed firing. The
coal is fed from the hopper onto a rotating flipper mechanism, which
throws the fuel into the furnace. The modern spreader stoker installa-
tion consists of a coal hopper, a feeder distributor unit that regulates
the flow of coal in proportion to the load, and a distributor rotor that
throws the coal into the furnace and distributes it on the grate. The
grate is specifically designed to meter the flow of air into the furnace.
Air ports cast in the grate provide uniform air flow to the entire active
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grate, and forced draft fans provide both undergrate (primary) air and
overfire (secondary) air. The fuel introduced into the furnace ignites
rapidly, starting to release hydrocarbons the instant the fuel enters
the high temperature zone. Because partial suspension burning results
in a great carry-over of particulate matter in the flue gas, dust col-
lectors are frequently, required. Large coarse particles in these dust
collectors may be skimmed off and reinjected into the furnace for fur-
ther burning. The overfire-air may be adapted to return fly carbon to
the high temperature zone just above the fuel bed. Figure 2.2 shows a
spreader stoker installation with a gravity fly-ash return.
Coal Hopper
Feeder
Stoker
Chain
Figure 2.1 Traveling-grate Spreader Stoker with front ash discharge.
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APES OF SPREADERS
There are various types of spreader stokers. The main difference
among them is in the grate design and operation. The stoker grates may
b,; of the stationary, dumping, and continuous discharge type.
With stationary grates, the ash is removed manually by a hoe or rake
through doors at the grate level. This limits application to boilers of
;,000 to 13,690 kilograms (20,000 to 30,000 pounds) of steam per hour
capacity.
Dumping-grate designs have grate sections for each feeder and the
undergrate air plenum chambers are correspondingly divided. These models
are constructed in individual sections to allow .temporary shut-off of fuel
from the feeder mechanism, and of air from the undergrate air plenum cham-
bers on the particular section to be cleaned. The remaining grate section
or sections can remain in operation. The frequency of ash removal depends
on the burning rate and the percent of ash in the fuel. The ash is depos-
it .id into a basement ash pit or a shallow ash pit'if the grate is 3.65
meters (12 feet) or less.
The advantage of continuous ash discharge is that there are no
interruptions for ash removal. Also, because of the thin fast burning
fuel bed, burning rates are approximately 70% greater than with stationary
and dumping grates. Continuous discharge grates may be as large as
48,77 square meters (525 square feet) of grate, and corresponding to steam
capacity, somewhat over 181,000 kilograms (400,000 pounds) of steam per
hour. Above this size the spreader stoker is not effective.
There are three types of continuous cleaning grate stokers, namely,
continuously reciprocating, intermittently vibrating, and traveling grate.
The reciprocating grate consists of alternate rows of continuously recip-
rocating grates imparting a forward movement of the ash for automatic dis-
charge at the front or feeder end of the stoker. The vibrating grate
stoker has a vibration generator on the grate frame. It is periodically
energized to remove the accumulated ash to the ash pit. The traveling
grate stoker consists of an endless chain of grates slowly moving through
the furnace permitting the ash to reach a depth of several centimeters
(inches) before being automatically discharged into the ash pit. The
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depth of ash accumulating on the grate can be controlled by speeding up
or slowing down the rate at which the grate travels.
The grate types described above can be placed in two categories,
agitating and non-agitating. The agitating types are the reciprocating
and vibrating. The non-agitating are the stationary, intermittent dump-
ing, and the continuously traveling grate.
FUELS AND FUEL BED
As we stated earlier, an outstanding characteristic of the spreader
stoker is its ability to burn a wide range of fuels. Except for anthra-
cite it can handle everything from semianthracite to lignite. Even
though the spreader stoker can burn a wide variety of coals, fuel sizing
is critical to good operation. Ideally the coal should range in size
from 1.90 centimeters (3/4 inches) or less to about 5 centimeters (2 inches)
If the coal is too coarse, the large lumps will not be completely oxidized
on the grate. As a result clinkers will tend to form in the areas contain-
ing the large sizes. If there are too many fines in the coal, the fly ash
carry-over will be excessive creating an increase in emissions from the
stack.
The ideal fuel and ash bed for the coal-fired spreader stoker is
evenly distributed and from 5 to 10 centimeters ( 2 to 4 inches) thick.
There should be an absence of clinkers in the bed so that there is a uni-
form air flow through all portions of the grate. The ash discharged into
the ash pit should be about popcorn size. Any ash as large as a man's
fist is too large.
Pulverized Fuel Firing Units
in this system, coal is pulverized to particles, at least 70 percent
of which pass through a 200-mesh sieve and is fired in burners similar to
those used for liquid fuel. The pulverized coal method permits continuous
use of raw coal directly from bunkers where it is stored in the condition
received at the plant. Any size coal may be used. Raw coal is dried and
pulverized simultaneously in a mill and is fed to the burners as required
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by the furnace load. A small portion of the air required for combustion
(15% to 20%) is used to transport coal to the burner. This is known as
primary air. A predetermined air-coal ratio is maintained for any given
load. Secondary air, the remainder of the combustion air (80% to 85%)
is introduced at the burner. (See Figure 2.3) The pulverized coal ejected
into the furnace then burns in suspension.
PULVERIZED COAL
AND PRIMARY AIR
PRIMARY AIR
VANES
FUEL OIL
o
Figure 2.3 Circular burners for firing pulverized coal
There are two basic systems of pulverized fuel preparation and firing,
the bin system and the direct-firing system. The direct-firing system is
the one being installed almost exclusively today.
The basic equipment components of a direct-firing pulverized coal
system are the pulverizer and the burner. The pulverizer grinds the coal
to the fineness required. The burner accomplishes the mixing of pulver-
ized coal and primary air with secondary air in the right proportion and
delivers the mixture to the furnace for suspension burning. Other neces-
sary components are the raw-coal feeder which controls the rate of coal fed
to each pulverizer; the primary air fan which supplies air for drying and
conveying the coal-air mixture to the burner; and the coal and air
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conveying lines. Figure 2.4 illustrates these components and their rela-
tionship. Completeness of combustion is a function of the uniform distri-
bution of fuel and air, turbulence imparted to the fuel and air mixture,
type of firing used, and the fineness of pulverization.
Cold (Tempering) Air _
from forced Draft Fan
Hot Air from
Boiler Air Heater
_ Boiler
^" Front Wall
Pulverized Fuel
and Air Piping A
Pulverizer
Figure 2.4 Direct-firing system for pulverized coal
PRIMARY AIR SYSTEM
The rate of fuel feed in the direct-firing method is automatically
controlled by the boiler load demand. Air flow to the pulverizer is pro-
portioned to fuel rate to provide the air for drying the coal. In order
to pulverize and circulate fuel pneumatically within a pulverizer, some
moisture must be removed leaving the coal dry and dusty. Preheat air to
the pulverizer is usually required for drying. The use of preheat air
also permits control of the temperature of the fuel-air mixture to the
burners for the most stable ignition. In addition to acting as a drying
agent, the air flow provides the velocity required for transporting the
fuel to the burners. The velocity in the conveyor lines must be suffi-
ciently high to prevent settling and drifting of coal. At the burners
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the air-coal mixture must be uniform and the velocity suitable so as to
prevent flashing back of the flame, and to allow stable ignition at all
times. To meet these conditions velocity must be varied with changes in
ratio of air to coal in the mixture.
BURNERS
Pulverized fuel burners are installed in three different planes, de-
pending on the type of boiler, the available combustion space and the kind
of burner. The direction of firing may be classified as either horizontal,
vertical, or tangential. One manufacturer uses an adjustable burner which
is tilted upward or downward to control the furnace outlet temperatures.
In many instances, burners are of the combination type, and are designed to
burn either pulverized fuel, oil, or gas, or all three. The most fre-
quently used burners are the circular and cell types..
FURNACE TYPES
Pulverized-coal fired units are usually one of two basic types, wet-
bottom or dry-bottom. The temperature in a wet-bottom furnace is main-
tained above the ash fusion temperature, thus the slag is melted so that
it can be removed from the bottom as a liquid. The liquid is quenched and
accumulates in storage tanks under the furnace. The dry-bottom furnace
maintains a temperature below this point so that the ash will not fuse and
is removed as dry ash. Whether a furnace is dry-bottom or wet-bottom af-
fects emissions. About 80% of the ash otiginally in the c'oal leaves a
dry-bottom furnace entrained in the flue :gases. In wet-bottom or -slag-tap
furnaces, as much as 50% of the ash may be retained in the furnace.
Cyclone Furnace
In pulverized coal fired units discussed above, the furnace has a
double function. It must maintain the high temperatures necessary for
complete combustion and at the same time cool gases resulting from com-
bustion so that when they enter the heat exchangers they are below the
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temperatures at which slagging occurs. Excessive slag on surfaces re-
duces the transfer of heat to produce steam. The furnace consequently
has to be relatively large to allow these conflicting functions to occur.
The Cyclone Furnace was developed to obtain more efficient combustion by
separating these functions. The idea was to provide a small combustion
chamber where high turbulence and temperature may be maintained and to
use the main boiler furnace primarily to cool the combustion gases.
The Cyclone Furnace (Figure 2.5) is a water-cooled horizontal cylin-
der in which fuel is fired and heat is released at an extremely high rate
for the volume of the furnace. Coal is crushed in a simple crusher so
that approximately 90 percent passes through a 4-mesh screen. The fuel
is introduced at the burner end of the Cyclone, and air for combustion is
admitted tangentially. Combustion occurs at heat-release rates of
14,000 to 25,200 BTU per cubic meter (500,000 to 900,000 BTU per cubic
foot) per hour at gas temperatures sufficiently high to melt a high per-
centage of the ash into a liquid slag. The slag is discharged from the
bottom of the furnace through a slag tap opening.
Emergency Standby
Oil Burner
Secondary Air
Crushed Coal Inlet
Tertiary Air
Primary Air
Radial Burner
Oil Burner
Replaceable
Wear Liners
urners
Re-entrant
Throat
Slag Top Opening
Figure 2.5 Cyclone Furnace operation
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COAL PREPARATION
The Cyclone Furnace is capable of successfully burning a wide range
of coals varying in rank from low volatile bituminous to lignite. The
Cyclone is able to use any size of fuel available. Fuel oils and gases
are also suitable for firing.
There are two types of coal preparation and feeding, (See Figure 2.6)
the bin or storage system, and the direct-firing system. With the bin
system coal is crushed in a central preparation plant to a size suitable
for firing and delivered to the bunker. Because the crushed coal is rela-
tively large in particle size, the hazards associated with pulverized-
coal systems do not exist.
The direct-firing system has a separate crusher located between the
feeder and the burner of each Cyclone Furnace. The crusher is swept by
hot air which helps to dry the coal. This improves crusher performance
and ignition with high moisture coals.
The pre-drying bypass system is a variation of the direct-firing
system. It incorporates a mechanical dust collector between the crusher
and the Cyclone Furnace. The dust collector is vented to the boiler fur-
nace. This system is used when firing extremely high moisture coals be-
cause the moisture is removed from the coal during crushing and then vented
to the boiler furnace instead of the Cyclone Furnace.
The two general firing arrangements used for the Cyclone Furnace are
one-wall firing and opposed firing. These are shown in Figure 2.7.
One-Wall Firing Opposed Firing
Figure 2.7 Firing arrangements used with Cyclone Furnaces"
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EXCESS AIR
The excess air required for satisfactory combustion is less than
10 percent. However, when there are several Cyclones and where auto-
matic controls are used, excess air is usually maintained between 10%
and 15% to assure no individual Cyclone is operating with insufficient
air.
ASH REMOVAL
By the Cyclone Furnace method of combustion the fuel is burned
quickly in suspension. Most of the ash is retained as a liquid slag
and tapped into the slag tank under the boiler furnace. Up to 70% to
80% of the total ash is retained and only 20% to 30% leaves the furnace
as dry ash in the flue gas. Air pollution control equipment is placed
ahead of the stack to prevent the ejection of large quantities of this
ash to the atmosphere.
Oil Burning Furnaces
The chief advantages of fuel-oil over coal in the generation of
steam are that it can be easily moved from the storage tank to the place
of use, the burning equipment is simple and easy to operate, and it has
very little ash content compared to coal. The important properties of
oil are: (1) specific gravity, (2) heating value, (3) viscosity, (4) flash
point, (5) fire point, (6) sulfur content, (7) ash content, and (8) pour
point.
Specific gravity is the ratio of the weight of a volume of oil to
the weight of the same volume of water at 60F. Heating value is expres-
sed in BTU per liter (gallon) or per kilogram (pound) at 60F. Viscosity
is defined as the measure of resistance to flow. Flash point is the tem-
perature at which sufficient vapor is given off to form a momentary flash
when flame is brought near the oil surface. The sulfur and ash are, of
course, undesirable elements in fuel oil. Pour point represents the
lowest temperature at which oil flows under standard conditions.
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The National Bureau of Standards has established specifications for
five grades of fuel oil. The descriptions of these grades are given in
Table 2,1. The grades are numbered from light to heavy. Distillates are
lighter oils and residuals are heavier oils. Generally, grade., of oil
heavier than No. 2 must be heated to reduce viscosity.
Table 2.1. National Bureau of Standards Grades for Fuel Oil
NUMBER
DESCRIPTION OF FUEL OIL
1.
2.
3.
5.
6.
Distillate oil for use in burners requiring
volatile fuel.
Distillate oil for use in burners requiring
a moderately volatile fuel.
Distillate oil for use in burners requiring
a low-viscosity fuel.
Residual oil for use in burners requiring a
medium viscosity fuel.
Residual oil fqr use in burners equipped
with pre-heaters, permitting a high
viscosity fuel.
Fuel-oils of No. 1 and No. 2 grades, the distillate fuels, are usually
used to heat homes and domestic hot water. No. 2 fuel-oil is used in small
apartment houses and in industrial processes. The firing rate is usually
not more than 75 to 95 liters (20 to 25 gallons) per hour.
Distillate oils of No. 2 and 3 grades are fired in large apartments,
small industrial plants, and other commercial establishments up to 189
liters (50 gallons) per hour. Fuel-oils No. 5, light and heavy, are used
in installations burning more than 189 to 378 liters (50 to 100 gallons)
per hour respectively. Fuel-oil No. 5 possesses greater heating value.
Fuel-oil grade No. 6 is used in power generating stations, marine vessels,
and other large installations, and is fired at rates greater than 189 liters
(50 gallons) per hour. The sulfur content of No. 1 distillate will vary
from .04 -.124%, and of No. 2 distillate from .104 -.307%. The sulfur
content in grade 6, residual oils, will range from 0.9 - 3.2% by weight.
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'.Jhen oil viscosity is not satisfactory, preheaters must be used,
particularly with grades 5 and 6 oil. Oil preheaters are used to
improve viscosity, and may be mounted directly on the burner, at the
supply tank or any place in between. Preheaters operate with either
electricity or steam. Typical oil preheat temperatures necessary to
obtain a suitable viscosity for atomization are usually between 150°
and 200°F.
The principal air contaminants affected by burner design and
operation are oxidizable materials: carbon, carbon monoxide, alde-
hydes, organic acids, unburned hydrocarbons, soot, and other partic-
ulates. The principal causes of smoke and incomplete combustion are:
1. Burner and fuel not compatible.
2. Burner not properly adjusted or operated.
3. Burner improperly maintained.
OIL BURNERS
The burner is the principle equipment component for the firing of
oil. Burners are normally located in the vertical walls of the furnace,
but may be installed in the horizontal wall. The types of burners most
frequently used are circular and cell burners similar to those used in
pulverized coal burning systems. (See Figures 2.8 and 2.9.)
In order to burn fuel-oil at high rates it is necessary for the oil
to be "atomized", or dispersed into the furnace as a fine mist. Atomi-
zation allows an intimate mixture of air and fuel. It exposes a large
amount of oil particle surface for contact with the air to assure prompt
ignition and rapid combustion.
Burners are classified according to the method used for securing
atomization: (1) air-atomizing burners, (2) steam-atomizing burners,
and (3) mechanical-atomizing burners. The cost of supplying compressed
air has limited the use of air-atomizing burners in industrial installs-
tions.
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Steam atomizers, as a class, possess the ability to burn almost any
fuel oil, of any viscosity at almost any temperature. These burners may
be sub-divided into two groups: (1) internal-mixing or premixing oil and
steam inside the body or tip of the burner before being sprayed into the
furnace, and (2) external-mixing in which oil emerging from the burner is
caught by a jet of steam or air.
In the mechanical atomizer the pressure of the fuel itself is used
as the means for atomization. Good atomization results when oil, under
high pressure is discharged through a small orifice, often aided by a
slotted disk. The disk gives the oil a whirling motion before it passes
on through the hole in the nozzle where atomization occurs. Finally,
because oil fuels are low in ash, scheduled cleanouts may be a couple
of times a year.
Air Pollution Control Equipment
To meet the objective of a clear stack, some form of particulate-
removal equipment is required to remove fly ash from flue gases from
units where fuel is burned in suspension.
Air pollution control equipment may be classified into two groups,
equipment controlling particulate matter, and equipment controlling
gaseous emissions. Because oil fuels are low in ash and sulfur, plants
using oil typically do not have associated air pollution control equip-
ment. In this Workbook devices for the control of particulate matter
on the equipment just presented have been grouped into three classes:
inertial separators, wet collection devices, and electrical precipi-
tators. Figure 2.10 shows illustrations of each type. Fabric filters
(baghouses) are not discussed because they are not currently being used
to control emissions from fossil fuel fired combustion sources.
INERTIAL SEPARATORS
Inertial separators are the most widely used devices for collecting
medium and coarse-sized particulates, above 10 to 20 microns. Collection
efficiency is usually not high, although suitable for medium-sized par-
ticulates. Ordinary inertial separators are generally unsuitable for
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Electrostatic Precipitator
Inertial Separator
Wet Scrubber
Figure 2.10 Air pollution control equipment
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for fjne dusts ranging from 5 to 10 microns. Below 10 microns the
efficiency drops below 90 percent.
Inertial separators operate by the principle of imparting centrifugal
force to the particle to be removed from the flue gas. This force is pro-
duced by directing the gases in a circular path. The spiral of the circu-
lar motion of the gases force the particulates toward the outlet where
they drop into a dust-tight bin and are removed by mechanical conveyors,
pneumatic or steam ejection systems. The single cyclone separator is an
inertial separator without moving parts. It separates particulate matter
from a carrier gas by spiraling the entering gas downward at the outside
and upward at the inside of the cyclone outlet. The particulates, because
of their inertia, tend to move toward the outside wall. A multiple-cyclone
separator consists of small-diameter cyclones operating in parallel, having
a common gas inlet and outlet. Another type of inertial separator supplies
the centrifugal force by a rotating vane.
A common cause of poor cyclone performance is leakage of air into the
dust outlet. A small air leak at this point can result in a substantial
decrease in collection efficiency.
WET COLLECTION DEVICES
Wet collection devices use a variety of methods to wet the contaminant
particles in order to remove them from the gas stream. A good wet scrubber
is one that can effect the most intimate contact between the gas stream and
the liquid for the purpose of transferring the suspended particle from the
gas to the liquid.
Because the wet scrubber employs a liquid stream to collect particu-
late matter, it can usually perform additional process functions besides
dust collecting. Simultaneous removal of dust and gaseous pollutants such
as sulfur oxides by use of a suitable scrubbing liquid can be accomplished
with a wet scrubber.
There are a variety of different types of wet collection devices.
The simplest type of scrubber is a chamber in which spray nozzels are
placed. Gases are sprayed with a liquid as they pass through the
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chambers. In some types of scrubbers the water spray is generated by a
rotating element such as a drum or disk. The collection efficiency of a
scrubber varies according to the type and size of particulate nrtter.
ELECTRICAL PRECIPITATORS
The electrical precipitators work on the principle that substances
with the opposite electric charge attract each other. The particles
entrained in the flue gases are given a negative charge. The negatively
charged particles in the presence of positively charged collecting plates
are attracted to the plates. The collected dust accumulates on the plates
and is discharged by rappers. The rapping of the plates discharges the
collected dust into storage hoppers.
The use of electrical precipitators has grown because of the many
inherent advantages in the method. High efficiency can be attained
because very small particles can be collected. There is no theoretical
lower limit to the size of the particle that can be collected. Precipi-
tators are easy to maintain over long periods of time because they have
no moving parts. They can be used in extremely high temperatures and will
collect a variety of types of particulate matter.
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SELF-EVALUATION QUESTIONNAIRE I
Below are statements which describe the basic parameters and the
proper operating practices of the fuel-burning systems covered in Chapter
Two. Read each statement and check the system or systems it best describes.
Some statements are descriptive of more than one system. First, try to
answer each without referring back to the text. Then, for those you are
uncertain about or cannot answer, you may refer back to the text.
Basic Design Parameters and
Proper Operating Practices
Cyclone
Furnace
Spreader
Stoker
Pulverized
Zoal Burner
Oil
Burner
1. An important advantage is
its ability to burn fuels
with a wide range of burn-
ing characteristics.
2. Permits continuous use of
raw coal directly from
bunkers where coal is stored
in condition received at the
plant.
3. Permits suspension burning
of fuel in the furnace.
4. Able to use coal of any size
available.
5. Requires the fuel to be
atomized.
6. Can burn either coal or oil.
7. Uses circular burners and
cell burners
8. All ash particles are formed
in suspension.
9. Three systems of fuel
preparation and feed are
bin, direct-firing, and
direct-firing pre-drying
bypass.
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10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Basic Design Parameters and
Proper Operating Practices
Requires coal in a fine
powder form (70% will pass
a 200-mesh screen) .
The proper size coal ranges
from 1.90 centimeters (3/4
inches) and under to 5 centi-
meters (2 inches) .
Moves coal from the supply
hopper over an adjustable
spill plate to fall onto a
rotor equipped with curved
blades for distributing the
coal over the furnace area.
Requires hot primary air to
dry the coal and convey it
to the furnace.
Two basic types of furnaces
are wet or slag-bottom and
dry-bottom.
Requires that certain grades
of fuel be heated before
they can be used.
Burners may be arranged
vertically, horizontally,
and tangent ially.
Requires few ash cleanouts.
About 70-80% of total ash
is retained and only 20-30%
leaves as dry ash in flue.
Molten ash drains toward
furnace bottom and is re-
moved through tap holes,
quenched and is accumulated
in storage tanks under the
furnace .
Ash discharged in pits is
fairly large; ranging from
popcorn size to the size of
a man's fist.
Cyclone
Furnace
*
Spreader
Stoker
•V*
Pulverized
Coal Burner
Oil
Burner
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Basic Design Parameters and
uood Operating Practices
Cyclone
Furnav.'
Spreader
Stoker
Pulvt ri/c
-------
Answer the following questionr.
29. The three types of grates which may be used on a spreader stoker
are
Identify the type of grate described by each statement.
30. a. Requires manual ash removal and is limited
to boilers of 9,000 to 13,690 kg (20,000 to
30,000 Ibs.) of steam per hour capacity.
31. b. Has grate sections for each feeder and
the undergrate air plenum chambers are
correspondingly divided permitting tem-
porary discontinuance of fuel air supply
to a grate section for ash removal with-
out affecting other sections of the
stoker.
32. c. No interruptions for removing ashes.
Its maximum size is usually up to
about 48.77 square meters (525 square
feet) of grate and produces over
181,000 kg (400,000 Ibs.) of steam
per hour.
6-33
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Eelow are statements which describe the basic theory, collection
and associated disposal system of the air pollution control equipment
covered in Chapter Two. Read each statement and check the equipment
it describes. There should be only one check mark for each statement.
First try to answer without referring back. Then if necessary, refer
back.
Basic Theory and Associated
Disposal Systems
Electrostatic
Precipitators
Inertial
Separators
Wet
Scrubbers
33. Collects particles by
contact with a liquid
droplet.
34. Executes centrifugal
force on the particles
to be separated.
35. Most efficient for large
particles (above 10 to
20 microns).
36. No theoretical lower
limit to the size of
the particle that can
be collected.
37. Collection efficiency
varies according to size
and type of particulate
matter.
38. Charged particles are
attracted to collecting
plates.
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CHAPTER 3. INSPECTION POINTS AND OBSERVATIONS WHICH SHOULD BE MADE
Introduction
The purpose of an inspection by you, the Field Enforcement Officer
(FEO), is to determine whether a source is operating in compliance with
acceptable emission regulations. The initial decision regarding compli-
ance is usually made by an experienced engineer. He makes his decision
by considering process design and operating characteristics, and by con-
ducting emission stack tests under various furnace operating conditions
considered representative of the range of normal operation. This review
by the engineer is crucial because it is the foundation for future enforce-
ment actions. Thus, once these initial evaluations have been made, your
major responsibility as the FEO is to check that the source is still opera-
ting either as specified in the permit application, or under the same con-
ditions as when the source satisfactorily passed the emission source tests.
The purpose of a source inspection is to make the following determinations:
Determine whether the source meets equivalent opacity
regulations.
Determine whether the source is operating in accordance
with permit conditions.
Determine whether operating and maintenance procedures
conform with good practice.
Determine whether good operating and maintenance pro-
cedures are used regularly based on a spot check of
operations since the last inspection.
Determine whether the air pollution control equipment
is operating properly.
The above determinations about a source are made on the basis of an
analyses of plant operating records and on the basis of visual observations
made during inspection. This chapter covers the visual inspection points
and observations which should be made during the inspection tour. It tells
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you what to look for and provides guidelines for deciding whether or not
the conditions you observe on the spot are satisfactory or unsatisfactory.
The following inspection points are covered:
Observe plume before entering the plant.
Inspect fuel preparation system.
Inspect furnace interior.
Inspect control panel instrumentation.
Inspect fans and ductwork.
Inspect ash disposal system.
Inspect air pollution control systems.
Observe Plume Before Entering the Plant
The first task in the inspection process is to determine the plume's
equivalent opacity. Opacity standards will vary according to local regu-
lations, but generally satisfactory conditions are a clear stack or emis-
sions equivalent to less than 20 percent.
In order to "read" the plume for smoke density, you, of course, must
be a qualified smoke reader. Because the judgment about opacity is being
made by a human, it is subject to a certain amount of error in measurement.
A standard error of measurement for qualified smoke readers is 15 percent.
Thus, if a reading of 30 percent is reported, the actual opacity level may
range from 15 percent to 45 percent.
Also, note the plume color. When the opacity is high, the. color may
be a clue to factors to investigate. Table 3.1 presents factors to investi-
gate when opacity is unsatisfactory.
Inspect Fuel Preparation System
COAL FIRED BOILERS
Check the outside coal pile for evidence of windblown dust. Satisfac-
tory conditions exist if no windblown emissions are visible when a small
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amount of coal is filtered through the fingers and falls to the ground.
Check with plant representative to determine if additives are used to
suppress windblown dust.
Table 3.1 Plume Characteristics and Operating Parameters
PLUME COLOR
White
Gray
Black
Reddish
Brown
Bluish
White
POSSIBLE OPERATING FACTORS TO INVESTIGATE
Excessive combustion air; loss of burner
flame in oil fired furnace.
Inadequate air supply or distribution.
Lack of air; clogged or dirty burners,
or insufficient atomizing pressure;
improper oil preheat; improper size or
type of coal.
Excessive furnace temperature, burner
configuration, or excess air.
High sulfur content in fuel: Fuel
should be sampled.
Check the delivery procedure to determine if excessive fines are
stirred up as coal is transferred onto the conveyor system. Conditions
are unsatisfactory if the dust blows beyond the plant boundaries into the
surrounding neighborhood. Windblown emissions which do not go beyond the
plant boundaries are not considered a violation.
Check the conveyor system as the source of windblown dust emissions.
Satisfactory conditions exist if the system is covered. Unsatisfactory
conditions exist when the conveyor is uncovered or when it vibrates to
the point that it creates fugitive dust emissions.
For spreader stoker operations check the coal size. A satisfactory
range is from 1.9 centimeters to 5 centimeters (3/4 inches to 2 inches).
OIL FIRED BURNERS
Check the oil preheat and atomization pressure gauge for each nozzle,
These readings should later be compared with those on the original permit,
A sample of the oil may be taken to analyze for sulfur content.
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Inspect Furnace Interior
When inspecting the furnace interior, use specially design filters
for eye protection. In addition, never open furnace doors, manipulate
controls, change valve settings, or in any way interfere with boiler opera-
tion. During the inspection process, plant personnel should open the door
for inspection purposes.
SPREADER STOKER GRATE CONDITIONS
Check the evenness of the coal distribution on the bed. The coal
should be evenly distributed across the width of the grate. The fuel bed
thickness should be about 5 centimeters to 10 centimeters (2 inches to
4 inches).
Check the grate to determine if it is unbroken and in good condition.
The entire grate may not be observed while the furnace is in operation.
If your inspection coincides with the time that a section is down, then
of course you can check the grate. However, during operation a small
portion of the grate may be visible and you can make some judgments about
the entire grate based on the visible portion. If the portion you see is
about 30 centimeters square (2 feet square) in size, you may assume the
entire grate is in the same concition as the visible section.
SPREADER STOKER BOTTOM ASH
On spreader stokers you should also check the bottom ash in the ash
pits. The cooled ash should be about popcorn size, with no pieces larger
than a man's hand. It should be white to brown in color with no blackness
or clinkers.
FLAME CHARACTERISTICS
The most important indication of good combustion is a clear, steady
flame. The flame should look clean. There should be no black tips to
the flame and no evidence of smoke or haze. Any streaks or unevenness of
the flame indicates unsatisfactory conditions.
Color of the flame is a secondary indication of the adequacy of com-
bustion. Good flame color varies with type of equipment arid type of fuel
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used. For grate systems, such as the spreader stoker, you should note
whether the flame is clear and steady. The flame should be yellowish-
orange with no dark smoke. Dark smoke means soot and particulate emissions
are high. Do not mistake the coals falling onto the live fire bed for
unsatisfactory conditons.
For burner systems, such as pulverized coal and oil, a mixture of
yellow and blue flames attached to ports indicates correct proportion of
air and fuel. Some pulsing of the flame is normal, but a totally blue
flame lifting off the ports indicates too much air. Dazzling or bright
white flame indicates that the flame temperatures may be sufficiently high
to create excessive NOX emissions.
The presence of black spots indicates poor atomization. Clogged or
dirty burners may cause improper atomization. You should check the fre-
quency of cleaning burners to be sure it is the same as on the original
permit. In addition, the flame should not impinge on walls and arches of
the firebox.
FIREBOX WALLS
From a visual inspection of the furnace interior through observation
"peep" holes, firing doors or access doors, recognize that a smooth clean
wall indicates a satisfactory condition. Heavy accumulations of ash on
the walls is undesirable because it may build up to the extent that it
interferes with heat transfer. Ash may also build up to the extent that
it interferes with turbulence.
Inspect Control Panel Instrumentation
There is usually a control panel where instruments provide data on
such elements as the stack opacity, the air-flow/steam-flow relationship,
C02 concentration and 02 levels. Instrumentation varies from plant to
plant, but opacity and steam-flow/air-flow meters are included in most
boiler installations.
THE OPACITY CHART
The chart on which a record of the density of emissions from the stack
is recorded may be called a smoke chart, a density chart, or an opacity
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chart. A single opacity chart is capable of displaying the opacity per-
centages for a 24-hour period. Figure 3.1 shows an opacity chart. The
24 hours, with 15-minute intervals, are marked off around the outer rim of
the circular chart. The numbers radiating from the center indicate percent-
ages. A pen continuously records the percent of opacity. By studying the
chart you can determine the percentage of opacity for any point in a dav.
For example, at 2:00 a.m. and at 5:15 A.M. the opacity percentage in »
Figure 3.1 rose above 20 percent opacity. But, from 6:00 a.m. until 10:00
a.m. the stack was satisfactory. What was the stack reading at 2:00 p.m.?
Not all opacity charts are round. Figure 3.2 shows a meter which
records opacity on a horizontal chart. It too, is marked off in 15-minute
intervals. The heavier lines indicate 30-minute intervals with the lighter
line showing the 15-minute point in between. Only about an hour is visible
through the window. In order to see the entire 24-hour period, the chart
must be removed from the meter.
An opacity chart shows unsatisfactory conditions if there are any
deviations above 20 percent for more than 3 minutes. Deviations above
20 percent for less than 3 minutes in any one hour are usually allowable.
For example, soot blowing schedules, which are allowable, may account for
deviations. When soot blowers are in operation particulate matter con-
centrations in exit gases increase markedly. The frequency of soot blowing
schedules varies depending upon,the fuel burned and the size of the opera-
tion. Soot blowing once every shift for a duration of 30 minutes, if per-
formed sequentially is usually allowed. Large plants may have continuous
systems. By increasing the frequency of schedules or by lengthening the
total operation, a plant can be technically in compliance.
STEAM-FLOW/AIR-FLOW RECORDERS
The amount of total combustion air used in a boiler can be established
by metering the flow of air through the unit. A given total air-flow,
measured by a meter, has a straight line relationship to the steam output.
The steam-flow/air-flow meter is one of the most widely used flow meters.
It measures not only steam-flow from the boiler, but also the relative rate
of combustion air-flow to the furnace. Some boilers have maximum design
rates, and you should compare the steam-flow rate for the individual boilers
6-40
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wicl the maximum design value listed on the permit. Rates above the max-
imum design values will lead to excessive emission. Low loads may cause
smoking if the correct amount of combustion air is not maintained.
The steam-flow and air-flow pens are adjusted on the basis of actual
•
tests, and are set so that calibrated, they both coincide. That is, they
follow the same path around the dial, one on top of the other, (See
Figure 3.3) or are modified to follow parallel paths. Figure 3.4 shows a
steam-flow/air-flow chart calibrated to record measurement about 1 inch
apart. The air-flow and steam-flow are usually recorded in different
color inks.
Ask the operator when the steam-flow/air-flow meter was last calibra-
ted. Also, inquire if the pens read "true" values or if the pen trace has
been modified. Modified instrumentation may include a scale factor. If ]
t1
more than a year has passed since calibration, or if there is doubt about
the accuracy of the reading, request that it be calibrated.
For steam-flow/air-flow recorders, compare chart values with the
following guides:
Air-flow should read between 10 and 25 percent higheJ^
than steam-flow for coal fired operations.
Air-flow and steam-flow should read approximately the
same value for oil operations.
Air-flow above steam-flow shows too much air or too little fuel. Air-
flow below steam-flow shows too little air or too much fuel. In other words,
the air to fuel ratio is incorrect and combustion is less efficient.
However, because calibrations differ from plant to plant, you can make
some determination of conditions by looking at the relationship of the two
pens. From a visual inspection, you can tell whether conditions are satis-
factory or not. If the steam-flow and air-flow pens trace essentially the
same paths, conditions are ideal. That is, if the air-flow trace goes up,
the steam-flow trace should follow it and vice versa. However, ideal situ-
ations rarely exist and some deviation is allowable. From an air pollution
standpoint, it is better to err in the direction of too much air. While
this reduces combustion efficiency, it does not critically affect air pol-
lution. However, when steam-flow is above air-flow, this does indicate an
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Figure 3.3 Steam flow/air flow pens calibrated
to coincide
Figure 3.4 Steam flow/air flow pens modified
to show parallel traces
6-43
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air pollution problem. Instantaneous peaking of steam-flow above air-flow
is allowable. Figure 3.3 shows instantaneous spikes of steam-flow at about
2:15 p.m. and 2:30 p.m. Of course, any extended period of steam-flow above
air-flow is undesirable. An extended period is defined as three minutes.
If you study Figure 3.3 carefully you will note that steam-flow rises above
air-flow on several occasions. The traces may coincide or parallel each
other. Do the pen traces in Figure 3.3 show satisfactory or unsatisfactory
conditions? How about Figure 3.4?
C02 MEASUREMENTS
C02 measurements may be on the control panel board or may be taken
manually. Figure 3.5 shows an automatic (X>2 recorder. Rate C02 measure-
ments according to the guides in Table 3.2. These values are onlyvguides
and individual boilers may depart somewhat from these guides depending on
the original design.
Table 3.2 Guides for CC»2 Concentration
in Flue Gas Leaving Furnace
Spreader stoker:
Pulverized coal
burner :
Cyclone furnaces:
Residual oil:
Distillate oil:
10 to 12 percent
12 to 14 percent
12 to 14 percent
12 to 14 percent
10 to 12 percent
OXYGEN MEASUREMENTS
02 measurements are sometimes on the control panel. Rate 02 measure-
ments according to the guides in Table 3.3. Again, these values are only
guides and individual boilers may depart somewhat from these guides.
Table 3.3 Guides for 62 Levels in Combustion
Spreader stoker:
Pulverized coal
burner:
Cyclone furnace:
Residual oil:
Distillate oil:
3 to 9 percent
3 to 6 percent
3 to 6 percent
3 to 6 percent
3 to 6 percent
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Inspect Fans and Duct Work
Inspect breechings and air ducts through air heaters, economizers and
super heaters for cracks and holes. Check the fan to be sure it is opera-
ting properly; that no obstructions are impeding the air flow, that all
blades are intact, that vibration is not excessive and that there are no
holes or cracks in connections to duct work.
Inspect Ash Disposal Systems
Check both furnace bottom ash and control equipment ash hoppers for
correct ash handling procedures. Ash from hoppers should not drop signifi-
cant distances into trucks used for transfer of ash. Visible dust emis-
sions should not be present during loading of ash into trucks. Ash should
be moistened before transport to minimize fugitive dust emissions. Trucks
which convey ash to disposal area should be covered or sufficiently wetted
to prevent windblown emissions beyond the plant boundary,
Inspect Air Pollution Control Systems
INERTIAL SEPARATORS
Inertial separators and electrostatic precipitators are the devices
most commonly used for particulate emission control. The most important
guide- to their performance is the condition of the plume. If the plume
opacity is greater than it was under similar boiler load conditions at an
earlier time, either the collection efficiency of the controls has decreased
or the fuel quality has decreased.
Visual checks should include checking the pressure drop gauge and check-
ing the exterior of the air pollution control device for cracks or air
leaks. Be sure to check around doors or other openings used for cleaning
out collected fly-ash. Air leaks caused by holes will change the air flow
pattern and decrease the device's efficiency.
A simple U-shaped tube half filled with water may be used as a pres-
sure-drop-gauge. One leg is connected to a duct in which the pressure is to
be measured. The other leg is open to the atmospheric pressure outside the
duct. The gauge then shows the difference between the pressure within the
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duct and atmospheric pressure. The pressure in the duct could be more or
less than atmospheric pressure. The difference in levels is measured in
centimeters (inches) of water. What is the pressure drop in centimeters
(inches) on the pressure-drop-gauge in Figure 3.6?
Inertial separators commonly operate with pressure drops of 5 to
15.24 centimeters (2 to 6 inches) of water depending on design. Greater
pressure drops indicate plugged cones or hoppers; lesser pressure drop
may be due to erosion of internal components which would substantially
reduce the collection efficiency.
ELECTROSTATIC PRECIPITATORS
Your task in inspecting the electrostatic precipitator is to record
data from each section to compare with data on the original permit. You
should check the spark-rate meter for each section. The meter should read
approximately 100 sparks/minute for the most efficient operation. This
value, however, varies significantly from one installation to another.
You should also read and note the secondary or precipitator current and
voltage for each section and compare with original permit data.
As part of your inspection, you should also (1) check to determine
if new sources are being vented through the precipitator; (2) check main-
tenance records regarding wire breakage; and (3) check frequency of ash
removal to determine if schedule complies with original permit.
WET SCRUBBERS
Wet scrubbers are used to a limited extent in combustion processes,
primarily for controlling S02- Inspection procedures include recording
scrubber liquid-to-gas ratio, recording pressure drop rate and obtaining
records of the acidity levels of liquid to compare with original permit.
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SELF-EVALUATION QUESTIONNAIRE II
Below are statements describing conditions you might find during a
fuel-burning equipment inspection. Read each statement and check whether
or not it describes a satisfactory or unsatisfactory condition. Try to
answer each question without referring back to the text. Then, refer back
for guidance if needed or to confirm your answers.
Conditions Found During a
Fuel-Burning Equipment Inspection
Rate Conditions
Satisfactory
Unsatisfactory
1. The opacity of the plume is
30 percent and the color is
white.
2. The opacity of the plume is
10 percent and the color is
gray.
3. On the smoke chart, you note
at 2:00 p.m. that opacity was
at 70 percent for about a
minute.
4. You are inspecting a spreader
stoker and find a C02
concentration of 15 percent.
5. During ash disposal the ash
is wetted down as it is dumped
into trucks.
6. The pressure drop on an inertial
separator is seven inches.
7. On an electrostatic precipitator
bus section the voltage meter
reads zero.
8. The fuel bed thickness in a
spreader stoker is about 5 to
10 centimeters (2 to 4 inches).
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Conditions Found During a
Fuel-Burning Equipment Inspection
Rate Conditions
Satisfactory
Unsatisfactory
9. Flames from a pulverized
coal burner are impinging on
the wall.
10. The flame in the spreader
stoker has black tips.
11. The coal for a cyclone furnace
arrives at the plant in pieces
about 12.70 centimeters
(5 inches) in diameter.
12. Soot blowing is performed
sequentially once every shift
for a duration of 30 minutes.
13. During dumping onto the con-
veyor system, a small amount
of fines are stirred up and
they blow beyond the plant
boundary.
14. The flame in the spreader
stoker is a clear yellow-
orange.
15. Looking through the flame of
a spreader stoker, the larger
pieces of fuel are seen fall-
ing onto the fuel bed.
16. The oxygen level for a resi-
dual oil fired boiler is
8 percent.
17. Steam-flow pen traces are
above air-flow traces for
three minutes in an hour.
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CHAPTER 4. SOURCES INSPECTED IN THE FILM
Introduction
The Film you will see as part of this module simulates the inspection
of fuel-burning equipment sources typical of those you will be inspecting
on the job. The Film is divided into three parts:
Part I: Inspecting a plant which has a pulverized
coal burner. This part also includes infor-
mation on the inspection of a Cyclone Furnace.
Part II: Inspecting a plant which has a spreader
stoker.
Part III: Inspecting a plant which has an oil burner
for residual or distillate oils.
Your Job While Viewing the Film
While you are watching the Film, you will be required to make decisions
about the adequacy of conditions at the plants depicted in the Film. That
is, you will have to rate some of the conditions shown in the Film and re-
cord your decision on a form which will be provided for that purpose. The
Data Collection Forms for each part of the Film are included in this chapter.
These are completed while viewing the Film. The Film will show a FEO in-
specting some component of a plant operation. Then the narrator will ask
you to make an evaluation about what you have just seen. You will record
your evaluation on the Data Collection Form. For example, as the FEO is
checking the ash disposal method, you will also watch the method of ash dis-
posal used at the plant being inspected. The narrator will explain the pro-
cedure as you watch it. Then he will ask you to rate the ash disposal method
as being satisfactory or unsatisfactory. A statement directing you to record
your decision will appear on the screen for several seconds to allow you
enough time to enter your decision on the form. At the completion of each
part of the Film the projector will be stopped to allow you to make some
additional decisions and to check your decisions against the decisions made
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by the "seasoned" FF.O in the Film. You will not be required to make a
decision on each and every inspection point shown in the Film. Some data
gathered during inspection has to be compared to the original permit after
the inspection has been completed. The Steps below outline your task while
watching the Film.
Step 1. Before viewing Part I of the Film, read the
information about the plant to be inspected
and look at the photographs of the plant. By
studying these photographs you will get a pre-
view of the inspection points covered in the
Film.
Step 2. Review the "Data Collection Form: Pulverized
Coal Burner" to see which inspection points
you will have to make decisions about.
Step 3. View Part I of the Film and record your
decisions on the Data Collection Form.
Step 4. The projector will stop after Part I is com-
pleted. After viewing Part I, review the photo-
graphs of the plant for additional information
on any inspection point you are uncertain about.
Step 5. Check your decisions against those of the
"seasoned" FEO. The course Instructor will pro-
vide you with the FEO's results.
Step 6. Follow Steps 1 through 5 for Part II of the Film.
Step 7. Follow Steps 1 through 5 for Part III of the Film.
Film.
6-52
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Information About the Sources to be Inspected in the Film
PART I: PULVERIZED COAL BURNING FURNACE
The plant in Part I of the Film is the Riverdale plant of a large
power company. The plant uses a pulverized coal burner system. The air
pollution control equipment are electrostatic precipitators. This plant
has been issued an operating permit.
During the course of the Film you will be directed to perform the
following ten inspection tasks:
1. Record opacity percentage.
2. Rate condition of steam-flow/air-flow as satisfactory
or unsatisfactory.
3. Rate condition of emissions as shown by opacity chart.
4. Rate the C02 concentration as satisfactory or
unsatisfactory. (A CC>2 concentration guide is pre-
sented opposite the Data Collection Form.)
5. Rate condition of flame.
6. Rate condition of furnace walls.
7. Rate condition of fan.
8. Rate adequacy of ash disposal.
9. Rate adequacy of conveyor system.
10. Rate extent of windblown emissions.
In addition to the above, you will observe the inspector recording
data from the electrostatic precipitator for comparison with the original
permit.
The Data Collection Form to be used while viewing the Film is on
page 55. Photographs of some of the inspection points follow the Data
Collection Form. You may want to refer back to chapter 3 to review some
of the guidelines for deciding whether or not the conditions you will
observe are satisfactory.
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CHECK THIS TABLE BEFORE RATING CO2 CONCENTRATION
SPREADER STOKER: 10 TO 12 PERCENT
PULVERIZED COAL
BURNER:
12 TO 14 PERCENT
CYCLONE FURNACES: 12 TO 14 PERCENT
RESIDUAL OIL 12 TO 14 PERCENT
DISTILLATE OIL 10 TO 12 PERCENT
6-54
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~ DATA COLLECTION FORM: PULVERIZED COAL BURNER
_ 1. RECORD PERCENT OF OPACITY HERE:
RATE CONDITION OF:
2. STEAM FLOW
3. OPACITY CHART
4. C02 CONCENTRATION
5. FLAME CONDITION
6. FURNACE WALLS
7. FANS AND DUCT WORK
8. ASH DISPOSAL
9. CONVEYOR SYSTEM
10. WINDBLOWN EMISSIONS
CHECK ONE
SATISFACTORY
UNSATISFACTORY
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Figure 4.3 Condition of steam flow/air flow
Figure 4.4 Emissions as shown by opacity chart
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Figure 4.5 Slag deposits on furnace walls
Figure 4.6 Readings on "bus section" of electrostatic precipitator
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Figure 4.10 The system for coal delivery
6-60
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View Part I of the Film and Complete
the Data Collection Form: Pulverized
Coal Burner Before Proceeding to the
Next Section of this Workbook.
6-61
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PART II: SPREADER STOKER FURNACE
ihe plant in Part II of the Film is a food processing plant. It uses
a spr-.ader stoker to generate heat for producing steam. The spreader stoker
is responsive to rapid changes in loca, a condition required for food pro-
cessing. The air pollution control equipment are inertial separators.
Multi-cyclones are the type of inertial separator used.
During the course of the Film you will be directed to perform the
following inspection tasks:
1. Record opacity percentage.
2. Rate condition of flame and rate condition of fuel bed.
3. Rate condition of grates.
4. Rate condition of furnace walls.
5. Rate adequacy of fuel delivery and rate adequacy of
coal size.
6. Rate condition of emissions as shown by opacity chart.
7. Rate condition of steam-flow/air-flow.
8. Rate condition of cyclone exterior.
9. Rate condition of bottom ash.
In addition, you will also observe the FEO taking a manual C02 reading,
recording the percent of oxygen in the combustion air, and reading a pres-
sure-drop-gauge on an inertial separator. You will rate these conditions
immediately after viewing Part II of the Film:
10. Rate the C02 concentration.
11. Rate the 02 level.
12. Rate pressure drop differential.
The Data Collection Form to be used while viewing the Film, and the
guides for C02, 02, and pressure drop are on the next two pages. Photo-
graphs of some of the inspection points follow the Data Collection Form.
You may want to refer back to chapter 3 to review some of the guidelines for
deciding whether or not the conditions you will observe are satisfactory.
6-62
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CHECK THIS TABLE BEFORE RATING CO2 CONCENTRATION
SPREADER STOKER: 10 TO 12 PERCENT
PULVERIZED COAL
BURNER: 12 TO 14 PERCENT
CYCLONE FURNACES: 12 TO 14 PERCENT
RESIDUAL OIL 12 TO 14 PERCENT
DISTILLATE OIL 10 TO 12 PERCENT
CHECK THIS TABLE BEFORE RATING O2 LEVEL
SPREADER STOKER: 3 TO 9 PERCENT
PULVERIZED COAL
BURNER: 3 TO 6 PERCENT
CYCLONE FURNACES: 3 TO 6 PERCENT
RESIDUAL OIL 3 TO 6 PERCENT
DISTILLATE OIL 3 TO 6 PERCENT
CHECK THIS GUIDE BEFORE RATING PRESSURE DROP
INERTIAL SEPARATOR-2 TO 6 INCHES
6-63
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DATA COLLECTION FORM: SPREADER STOKER
1. RECORD PERCENT OF OPACITY HERE:
RATE CONDITION OF:
2. FLAME AND
FUEL BED
3. GRATES
4. FURNACE WALLS
5. FUEL DELIVERY AND
COAL SIZE
6. OPACITY CHART
7. STEAM-FLOW/AIR-FLOW
8. CYCLONE EXTERIOR
9. BOTTOM ASH
CHECK ONE
SATISFACTORY
UNSATISFACTORY
RATE CONDITIONS AFTER VIEWING FILM
10. C02 =10.5%
11. OXYGEN=6.7%
12. PRESSURE DROP=2 IN.
6-64
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Figure 4.13 Slag deposits on furnace walls
6-66
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Figure 4.14 The coal delivery system
Figure 4.15 The doors to the basement ash pit
6-67
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Figure 4.18 Percent of oxygen in combustion air
Figure 4.19 Pressure drop gauge for air
pollution control cyclones
6-69
-------
View Part II of the Film and Complete
the Data Collection Form: Spreader
Stoker Before Proceedine to the Next
Section of this Workbook.
6-70
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PART III: OIL BURNING FURNACE
The plant in Part III of the Film is the Mid-town Station which pro-
vides steam heat to buildings in a mid-city area. The plant uses No. 6
residual oil. The plant has no air pollution control equipment.
There are two boilers at this plant and the oxygen and opacity record-
ers show readings from both. Look at Figure 4.20. You will note that oxy-
gen levels are being recorded for two boilers. You will also note that
opacity levels for both boilers are being recorded on the same chart. The
numbers up the side from 1 through 5 are Ringlemann numbers. A number 1
corresponds to 20 percent opacity. The air-flow/steam-flow recorder pre-
sents data for boiler number 1. The two bottom traces are the air-flow
and steam-flow lines.
During the course of the Film you will be directed to perform the
following five inspection tasks:
1. Record opacity percentage.
2. Rate condition of emissions as shown by opacity chart.
3. Rate condition of steam-flow/air-flow.
4. Rate condition of firebox interior.
5. Rate condition of fan.
In addition to the above, the FEO will observe several readings on the
control panel which he will later compare with the original permit. After
viewing the Film you will:
6. Rate the oxygen level for boiler No. 1.
7. Rate the oxygen level for boiler No. 2.
The Data Collection Form to be used while viewing the Film is on
page 73. Photographs of some of the inspection points follow the Data
Collection Form. You may want to refer back to chapter 3 to review the
guidelines for deciding whether or not the conditions you will observe
are satisfactory.
6-71
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CHECK THIS TABLE BEFORE RATING O2 LEVEL
SPREADER STOKER:
PULVERIZED-COAL
BURNER:
CYCLONE FURNACES:
RESIDUAL OIL
DISTILLATE OIL
3 TO 9 PERCENT
3 TO 6 PERCENT
3 TO 6 PERCENT
3 TO 6 PERCENT
3 TO 6 PERCENT
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DATA COLLECTION FORM: OIL BURNING EQUIPMENT
1. RECORD PERCENT OF OPACITY HERE.-
RATE CONDITION OF:
2. OPACITY CHART
3. STEAM-FLOW/AIR-FLOW
4. FIREBOX INTERIOR
5. FORCED DRAFT FANS
AND DUCT WORK
CHECK ONE
SATISFACTORY
UNSATISFACTORY
RATE CONDITIONS AFTER VIEWING FILM
6. BOILER #1:02 =11%
7. BOILER #2= 02 =7%
6-73
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Figure 4.23 Firebox interior
6-77
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REFERENCES
1'. Danielson, J. A. Air pollution engineering manual:
Air pollution control district, County of Los Angeles.
DREW, Cincinnati, 0: Public Health Service Bulletin
No. 999-AP-40, 1967.
2. de Lorenzi, 0. Combustion engineering. New York, NY:
Combustion Engineering—Superheater, Inc., 1947.
3. Devitt, J. W., Gerstle, R. W., and Kulujian, N. J.
Field surveillance and enforcement guide: Combustion
and incinerator sources. Research Triangle Park,"NC:
Environmental Protection Agency, Publication No.
APTD-1449. June 1973.
4. Devitt, J. W., Gerstle, R. W., and Kulujian, N. J.
Field operations and enforcement manual for air
pollution control. Research Triangle Park, NC:
Environmental Protection Agency, Publication No.
APTD-1102.
5. Steam; Its generation and use. New York, NY:
Babcock and Wilcox Company, 38th Edition, 1972.
6. Perry, R. H. Perry's chemical engineers handbook.
New York, NY: McGraw Hill, Fourth Edition.
6-78
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TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1 REPORT NO.
EPA 450/2-80-076
3. RECIPIENT'S ACCESSION-NO.
4. TITLE ANDSUBTITLE
APTI Course 444
Air Pollution Field Enforcement
Student Workbook
5. REPORT DATE
March 1980
6. PERFORMING ORGANIZATION CODE
7 AUTHOR(S)
8. PERFORMING ORGANIZATION REPORT NO.
C. W. Gruber, P. M. Giblin
9. PERFORMING ORGANIZATION NAME AND ADDRESS
10. PROGRAM ELEMENT NO.
B18A2C
11. CONTRACT/GRANT NO.
68-02-3014
12. SPONSORING AGENCY NAME AND ADDRESS
U.S. Environmental Protection Agency
Manpower and Technical Information Branch
Air Pollution Training Institute
Research Triangle Park, NC 27711
13. TYPE OF REPORT AND PERIOD COVERED
Student Workbook
14. SPONSORING AGENCY CODE
EPA-OANR-OAQPS
15. SUPPLEMENTARY NOTES
EPA Project Officer for this manual is J. 0. Dealy, EPA-ERC, MD-17, RTF, NC 27711
16. ABSTRACT
This document is part of an overall package of training materials to be
used in presenting the Air Pollution Training Institute Course 444. The
course is designed for governmental air pollution control personnel who
do field inspection and enforcement work. The workbook contains printed
materials needed to do classroom exercises recording visible emission
violations and preparation of a notice of violation thereon; conducting
inspections of industrial facilities; preparation of cases for prosecution
in court and acting as a witness in a court case; and handling public
complaints about air pollution.
This student workbook is used in conjunction with the Instructor's Guide
(EPA 450/2-80-077) and the Student Manual (EPA 450/2-80-075).
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.IDENTIFIERS/OPEN ENDED TERMS C. COSATI Field/Group
Education
Manuals
Air Pollution
Training course
Student Workbook
13 B
5 I
68 A
13. DISTRIBUTION STATEMENT Unlimited
Available from National Technical Infor-
mation Service, 5285 Port Royal Rd.,
VA 22161
19. SECURITY CLASS (This Report)
Unclassified
21. NO. OF PAGES
204
20. SECURITY CLASS (Thispage)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
6-79
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