-------
Figure 8.3-4. Standard NEDS form for brick manufacturing - screening.
oo
I
M
N3
Slalej
1 2
County
3
4
s
(
AOCR
7
1
9
...
Plant ID
Numtwr
10
11
Po
ir
14
12
13
City
14
nt
IS
IS
SCREENING
Point
10
i
1
1
1
14
15
IS
J7I
si
• •
?• £
K
17
0?
w O
•1
It
17
o?
M
in
II
Y.ar ol 1
Record
It
17
0?
. o
: v
> a
it
17
Ytai ol 1
Record
IS
17
Uim
7nnr
!J]
ia
i]
tf
n
2JJ
SIC
II
3
n
t
n
s
Boiler 0
Capar.
10* 8T
11
n
\M
Dec-
Feb
11
n
n
71
n
NATIONAL EMISSIONS DATA SYSTEM (NEDS) POINT
ENVIRONMENTAL PROTECTION AGENCY """
OFFICE OF AIR PROGRAMS SZHTSL
Eitabl shment Name and Addiefi
27
71
o. £
i *
i . (C
77
tsirjn
U/hr
71
JNUAl
Mar-
70
71
77
n
71
74
n
?s
77
UTMCC
Horizontal
74
71
76
77
?«
71
10
11
17
OHOINATES
Vertical
km
71
71
10
11
17
11
!<
15
U
Height III)
33
34
35
16
1]
W
11
Diam It
17
11
31
<(
41
47
43
STACK OA
Temp(°FI
40
CONTROL EC
> > >
% n 5
•3 _ TJ fN ^ *
c « C O p e O
Pirt
71
TMR
June
Aurj
77
71
7<
?S
JPUT
Sept-
74
Paniculate
II
1
1
1
11
-
11
n
n
IS
n
X
s
ii
70
71
77
71
sec
III
?1
n
22
n
23
1
sec
71
77
73
74
71
?«
71
NO
OPEt
>
^
7S
77
71
HM
71
w
11
0
f,
1?
n
11
n
M
n
NO,
3S
n
in
n
17
n
Particulate
11
ALLOW
SOj
n
IV
74
n
75
«
IV
74
75
n
77
71
71
10
11
0
17
11
14
is
is
17
r
,u
u2
11
n
40
n
41
47
43
UIPMENT
Primary
HC
41
n
47
n
43
n
44
4!
41
41
41
4!
5C
A
Flo»Rate Ift^/min)
44
45
41
>
!o
01
•I
44
n
EMISS
SO3
W
/ABLE EMISSIONS (to
NO,
1?
SCO, UNIT
run. r-im.e»».
Sol
Is
£
"1_
so
n
51
n
ON ESTIMATES Itoni
NO,
45
nt/ywr
HC
11
- TONS RAW W
Hourly
Maximum Design
Rale
33
34
35
36
37
31
39
40
41
47
TERIAI
^
40
41
42
n
43
44
45
0
•?*!
o
u
43
44
45
n
4t
41
41
41
so
si
0
5?
.Q
S3
54
55
55
ESTI
Part
53
54
SS
56
57
51
59
with
common
stack
Sf
57
+
i*
MATED C
S02
V)
57
51
n
/yearl
HC
5?
CO
46
41
«
43
50
Fuel
He*t Content
10° BTU/icc
4G
41
41
49
50
n
51
52
u
5J
;L
VI
a
E
o
53
54
55
OMPL
SCHE
Year
S4
55
56
57
IANCE
3ULE
Mo
5«
51
5t
0
-------
Figure 8.3-5. Standard NEDS form for brick manufacturing - calcining.
Stat*
I
2
3
Cot
4
fltv
S
(
AOCFl
7
1
00
•
W
1
h-1
w
S
Plan! ID
Ngmh«r
10
11
Po
.1C
12
:
13
E
CALCINING
Point
10
14 15
tv
uin
cn
0 2
w O
•» U
o
uT
-| 1 JO '"AjT
I
o
O
16
T)
O
n
T3
\
rr
•p
5
tc
u
•p
o
5
£
17
Zone
i
e
%
o
F
1
11
19
H
•»
71
a.
&
77
_£_$ _Q
oiter Ovugn
Qfi BTU/hr
19 ?c ?i n
Ar
•c-
et>
P
19
4NI
M
M
Tfl
•n
Tfl
20
Ml
av
cul
7]
S
sc
21
.T
Ju
A
me
77
CC
c
III
22
X
71
Pr
71
HRV
fe
71
71
23
74
He
74
ma
74
u
>ru
'V
JPUT
Sepi
Nov
24 "
74
i
24
\f
r,
TM
K
77
CO
a
77
]':
?k 77
NO
OPEF
I
i
26 "
n
71
OR
71
71
KM
A1
7«
SOj
27 ?«
Fi
S
CC
77
ei.
Olid
MH
71
75
DIA
V
79
j
79
in
1A'
ert
VI
11
rES
cal
11
m.fy
02
30 31
o n
AL
ING
Z
29 30
NATIONAL EMISSIONS DATA SYSTEM (NEDS)
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF AIR PROGRAMS
Eitabliihment Name and Addieis
32 33 3435 36 37 3ll39|40l41 42 4344 4546 4741 45
i;
11
I£
32 33
14
34
35
36
37
CONTRC
Pfimafy
NO,
35 36 31
01 0 0 0 0
Paniculate
3ll32l33l34 35
ALLOV
29 30 31
rro
Wj
»EN
71
S
CVl
tie
30
TS
TO
U
:c
.
31
11
0
36
0
17
L
31 39
_L
STAC
40 41
3L > EO
li
•S
31 39 40
0
31
0
39
K I
)A
43
UIPMENT
Ptima.y
HC
41 42 43
000
SOj
40 41 42
JJ_ ':
(ABLE EMISSIONS (toni/ve«r
NO, 1
32 33 34 35 36 3! 3l|39|W
Ul
32
1?
•jr
M
33
n
r :
axir
34
- 1
Hoi
nui
•(»
fly
nO
36
16
IS
37
37
U
RJ
31
31
w
39
M
U
40
40
41
m
S
41
41
HC
42
:RI
~i
:
n
42
42
A
44
44
0 0
EMISS
41 44
43
.AI
ti
43
43
n
44
'5
44
44
45
?(_
n
45
46
46
47
Pf
4)
,3
41
1?
mufy
CO
41 49
50
"50
50
51
IT
52
53
54
ne Height
0 1 »clc ll
52)53|54
utlSeconda'v I
Ff c° I—
R I
0 0 0 C 0 0 0
ON ESTIMATES liont
NO,
45 46 41 41 49 50 51
45
0
>
:
o
"iT
45
46
HI
10
4C
47
F
dl
6fl
771
47
CO
41 49
"or
TU
41
41
ten
tic
45
49
50
r
50
n
51
[si]
51
55
_L_
ESTI>
Part
53 54 55
0
v«a()
52 53
52
U
52
5C
a
1
53
"sil
53
54
HC
55
OMPL
5CHE
Ye.f
54 55
1
54
55
POINTS
nput
N»m« of Person
Completing Form
56 57 51 59 60 61
Poir
comr
5*157
ti
h
non
t}
?'
^lATEO CC
SO,
56 57 51
56
no
57 5«
IANCE
3ULE
Mo
•* 5!
P
S6
57
*
60
/
li
n,mrc FORM APPROVED
i^"" OMBNO.I58-B0095
n-~. . , , -
62
0
''X
62
63
00
XX
C
64
0
X
3NTROL EFFICIEN
NO, HC
S9|60|61|62 63 64
J
59
n
COM
5
U
Ytir
SI 59
[sT]
f
5J.
_J
60
61
PLIAf'
TATU
PDAT
Mo
60 61
[M]
E
ma
ii
CO
62
63
ICE
:
Oiv
62 63
nt>
Taj
Kl
U
[H
61
u
64
0.
U
UJ
(4
*l
64
c"t»d Pe-io
i5|66|67|U
1
IF
PO
_LJ
NO
INT
CY 1%)
CO
65 66J67
65
u_
65
LJ
Is
RS
CO
ID
i.U J
ESTIMAl
METH
I |?i
urnju
fj1
65
MM
'S
ol
_1
no
3D
u
I
69
70
OS
I
75]
N
O
U
70
n
s
F
Til
_1
%
H
71
nn
TACK
7?|73|
— LJ
>DACa)
eit
77 n
lolo o o ^n
CONTROL REGULA
r«|S7|M 6s|70|n|7273
LLJ
UJ67
66 (7
U
Tl
61
[w
70
5
1
71
5
72 73
R"
z
74 n
OS S
m
75 77
. J
— 1_
74|7S|7i|-
_LJ — 1— 1
1
74 75TJ7 T7
I.I..1
TIONS
74 75
74 75
n 77
rtj77
*
J <
•H?
-' I
s
l»
*
71
T
ll U
Fffl
c
1 L
71 75^ K
r
|
a
71 75
p
cd
cd
"K
-------
Figure 8.3-6. Standard NEDS form for brick manufacturing - drying (raw material).
oo
u>
I
State,
1
2
County
3
4
5
6
AOCR
7
1
9
Plant IO
Number
10
11
Po
ir
14
12
15
13
Ci
DRYING-RAW MATERIAL
•
14
15
o
2
ill
»
re
•5
i
-
1
S
17
o
17
o
-
Record |
—
Year ol 1
Record r
11
17
5 i
16
17
Utm
1 11
11
19
31
70 71
r
21
rx
a.
£
Tmsioi i
Boiler Otiign
Capacity
106 BTU/h
II
11
% Ah
Dec-
41
11
70
71
JNUAl
Mar.
May
20
—
Particul
a
1
II
•J
II
-
19
20
II
11
0
70
S
19
70
—
7?
71
Procettj 1
23
24
H
71
u
jnl
l»
Primary
Pan
71
T»m
June
—
—
sec
Ml
71
n
77
n
71
T
sec
71
7?
23
74
V
JPUT
Sept-
Nov
24_
U
—
IV
74
0
7S
1
24
75
76
rM
ont
26
77
CO
n
27
OR
11
\i
76
77
NO
OPEF
A
_£!_
,,
1A1
1
—
SO,
£l
29
Oi
V
ill
30
1A1
erl
kn
»
NATIONAL EMISSIONS DATA SYSTEM (NEDS)
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF AIR PROGRAMS
Ellablithment Nome and Addict!
_3l|32i33|34|35|36l37|34|39|40|4ll42|43|44|4S|46|47[4«|49
rES
cal
iji
Primary
so?
7?
n
30
n
AL
ING
29
31
0
ALLOW
JU
Jl
n
1?
H
11
toh
14
4 r,
§8
17
n
11
n
Pur
14
n
1 (1
l»
U
rti
17
CONTR(
Primary
NO,
IS
o
Id
n
1!
n
ate
m
in
3L
in
n
(ABLE EMISSIONS Ito
NO,
Solid Watte
Operating Rale
76
77
?«
71
10
11
37
n
HI
21
S
T
1C,
EO
to"
Sz
i/i
11
0
n/V
- TQ|JSr|RAW MA'
Maximum Detiyn
33
34
35
36
37
31
39
4(1
fl
AC
41
K [
nt"
47
JA
Fl
41
UIPMENT
Primary
HC
41
(1
SO
(7
0
HC
'ER.J.AL
40
41
42
(1
41
0
f
44
44
0
EMISS
p
nw
«
L
4S
0
M
K
0
IF I
47
Pr
41
II
1,3
41
mi
41
mary
CO
41
II
41
II
50
.
Plu
II n
SO SI
111
Tie
0 t
S?
lo
So
Si
so
II
SI
0
ION ESTIMATES Itont
NO,
1||
0
nl
69
70
71
RM APPROVED
KB NO. 168-80095
t»
72
73
1
74
300 IF NO COMMON STACK
KXX POINT ID'S IF COMMON
il
64
EFFICIEN
HC
67
CO
TT
63
77
JCE
5
E
Osv
62 111
64
0
"nT
a.
u
M
65
6i
67
CY (%|
CO
65
lul
ii?|
66
t
0.
fifi
67
a.
61
61
69
(9
70
70
JTIMATION
METHOD
ffd 0 0
-------
Figure 8.3-7. Standard NEDS form for brick manufacturing - blending and mixing.
00
OJ
1
M
Ui
SI
1
"•»
2
County
3
4
5
(
AQCR
IT
i
3
Hint ID
Numh«r
10
u
Po
1C
14
12
11
C
14
)
11
IS
BLENDING AND MIXING
Point
10
14
-
IS
-
ty
IS
17
0 'S
k O
: ii
MC
16
17
0?
_ O
2 *
> i
16
17
Y«»r ol
Record
If
17
51
16
17
oS
. o
2k!
> X
16
17
0?
. o
: t
> n
16
-
17
—
Uim
Zone
11
13
}]
70
71
SIC
11
3
13
2
20
5
21
U
NATIONAL EMISSIONS DATA SYSTEM (NEDS) POINTS
ENVIRONMENTAL PROTECTION AGENCY ""*"
OFFICE OF AIR PROGRAMS "'™ °' Per'°"
Completing Form
Establishment Name and Addiesi
22
23
a. £
* 8
. £
22
Boiler Design
Capacity
IO6 BTU/hr
u1
13
XAt
D«-
fto
11
13
20
21
»JNUA
Mar-
Hit
20
21
22
23
24
25
26
21
UTMCO
Hori/onlal
24
25
Pr miry
Pl.t
23
. THH
June
Auq
22
23
24
25
JPUT
Sepi-
Nov
24
Particu ate
11
1
11
3
i
18
13
20
n
13
0
20
5
II
19
20
21
22
23
sec
III
21
0
22
U
23
3
sec
III
21
22
23
24
25
26
27
28
23
30
31
32
OROINATES
Vt'liu
21
•o «
C J
5 *
»
26
21
NO
OPE
5
i
25|27
21
MM
^A^
Jt
n
21
29
30
31
Pr mary
so? _,
29
U
30
0
AL
ING
5
23
30
31
U
32
33
34
35
36
Height 6O
ti
a
u
0
39
0
40
0
41
42
UIPME
Puma
HC
41
0
42
U
43
44
45
46
47
41
49
50
51
52
53
54
A
fclume Height
Flow Rale It^/min [lino slack It
44
45
46
47
41
49
50 51
NT
>• >
fo Ic
43
0
«
44
0
EMISS
SO,
31
'ABLE EMISSIONS Ito
NO,
32
Fu., ,.^?.?C W
Sol'd Wane
Operating Rate
25
27
21
23
30
31
32
33
34
35
36
37
U
0
33
40
41
42
41
44
n
45
u
H
U
CO
47
U
41
0
49
U
a
50
0
51
U
ION ESTIMATES (com
NO,
45
ns/year
MC
33
IT - TONS RAW
MOuny
Maximum Design
Rate
33
34
35
36
3;
31
33
40
41
42
HATER:
SJ
40
41
42
43
44 45
o
[AL
^<~c
0
U
43
44
4S
«
47
44
41
50
51
n
52
57
0
53
54
55
55
ESTI
Part
53
54
55
56
57
58
59
Poinli
with
common
stack
U
57
+
*
MATED C
SOj
Sfi
57
51
U
/ye«r)
HC
57
CO
46
47
4J
43
50
ruei
Hent Content
106 BTU/ICC
46
47
4t
49
50
51
52
D
5.1
;c
VI
Q.
E
o
1 )
53
54
55
OMPL
SCHE
Year
54
55
56
57
IANCE
3ULE
Mo
56
57
51
o
4
60
61
OURCE FC
Form O*
Ol
HM APPROVED
«BNO. 1S8-F(0095
Contact • Personal
62
63
64
65
66
67
61
69
70
1
72
73
I
74
75
76
77
0000 IF NO COMMON STACK
-/XXXX POINT ID'S IF COMMON STACK
60
61
DNTROL
NO,
59
60
61
U
a.
U
64
EFFICIEN
HC
62
63
64
U
65
66
67
CY(%)
CO
65
CO
53
COM
S
U
Year
51
59
60
61
PLIAN
rATir
POAT
Mo
60
61
62
63
CE
Day
62
63
64
a.
<
0
UJ
64
(5
ifl.
55
E!
i
u
S7
^_
61
(9
70
71
72
73
74
75
76
77
[Aclion
7!
_
!
7!
J-
AK
»|i
79
p
<*
K
J
J J
U
63
7:
TIMATION
METHOD
r* " _
O O '~l O
* z r i;
67
n
U
n
CON
Rt<] 1
K
u
67
u
13
ifl.
7;
n
71
7*
ii
XSaa
--.•
71
n
TBOL FIEGU
RtlJ
63
70
Comm«rm
51
52
53
54
55
%
57
51
59
60
61
67
63
64
(5
u
67
61
69
70
n
Sourc*
71
72
Conlid.
7?
73
L£
r< -5 -; -i.-rl
• 3|
74 nf.-ti-
LATIONS
R«tj3
73
_
74
75
76
c
ll ' •
< rr
T TK
77
73
74
75
76
77
COMMENTS
11
27
21
25
30
31
32
33
34
35
Jt
37
36
39
40
41
42
43
44
45
«
47
48
49
50
51
52
53
54
55
56
57
51
SS
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
7(
n
-
Atlli.n
71
Action
78
c
c
Z
<
'*«
-
4
!a
K
*
73
p
p
p
p
p
79
r
P
P
rt
K
6
6
6
6
S
of
r
7
7
-------
Figure 8.3-8. Standard NEDS form for brick manufacturing - curing and firing (kiln).
State,
1
7
County
3
4
5
(
00
w
^ 09 TUNNEL KILN,
11 TUNNEL KILN,
12 TUNNEL KILN,
13 PERIODIC KIU
14 PERIODIC KIU
15 PERIODIC KIU
IN-
2 - COAL
4 - RESI
5 - DIST
f> - NAT11
m
AOCH
7
1
9
Plant IO
Number
10
11
Po
.10
u
CAS FIRED
OIL FIRED
COAL FIREI
1, GAS FIRB
^, OIL FIRt
1, COAL Fit
:URING (KII
PROCESS FUI
DUAL OIL
ILLATE OIL
(AT. flAS
12
.D
.D
IEI
JO
:L
Po
U
13
)
ml
IS
"o
1
"o
m
"o
'o
m
I
16
T)
TJ
5
•c
0
•o
5
*
o
11
n
Ut
m
t
I
NATIONAL EMISSIONS DATA SYSTEM (NEDS)
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF AIR PROGRAMS
2j|?il«lKl>cljjhilj*linhllljl33l34l3Sl36l37lul39l40l4l|42|43|44|45|4.|47|4!|4S|»
4 *
Boiler Detign
Capacnv r
%
D
18
M
ۥ
19
19
Nl
W
20
20
JAL
ir-
S
21
5fi
21
THF
June
cc
HI
22 2
5
22 !
H<
U
>nr
DOS
nmary
(UPU
Se
1
3 24
T
PI-
n
25
fMC
onlal
OOR
> o
Ilo
N(
OPE
0
n
RA1
i
SO;
Solid
•»ien»
7 71
Dir
V
17
11
D2
AL
IN
gAl
en
V)
ES
cal
31
OR
°7
W 11
r
SI
ALLOV1
W
71
S(
ite
Rj
30
TS
Ul
:c
31
T
P
11
32
33
34
f.
t 1
36
D,
CONTR(
Primary
NO,
35 36 37
:E TABLE 8.
Particulate
3
Jl
JL
31
1
3s
/ABLE EMISSIONS (to
NO,
;; 33 34 : 5 36 3) 31
in
32
UN
F,R
17
m
M
33
^E
ro
n
r -
ixir
"1
L 1
11
M
- 1
MOt
nun
Ra
•isl
u
: i
rot
r'y
i O
If,
LN
CI
w
JS
HIS
I/
^:
LN
37
p
n
lin!
S:
31
It
39
Is
39
IT
S
T
40
EC
40
40"
ACK DA'
emo I°FI
41 42 43
JIPMENT
Primary
HC
41 2 43
50;
7T
it/year)
RO
[ 11
11
39
DU
i
r
-o
14
"40
CEI
LM
J4l|
Ab
-G
42
HC
42
D
i
'.
o
"1
F
AS
"4?
»
A
f
44
46
lo
01
EMISS
43J44
~43
1
;R!
F
[44]
5
44
:D
[Rl
47
te ll|3/rTlin)
Pnma
CO
47J4I
ry
"49
Plume Height
1 no stack ft
lo
ju
51
ON ESTIMATES lioni
NO,
D
45
:
:
45
;D
46
HI
in
k
CO
[4j«|49]
«'«
[iTI
15
IT
uel
Tl
^L
-0
4?
len
F
IL
[50]
[50
[R
F
"slj
1
:D
[RI
"sT
ESTI
Pan
year)
52JS3
1
:D
IF
(/i
a
1
13-
"sT
[si]
nr
SCHE
Year
[S4
-
16
54
1
M
-C
55
POINT S
Input
Name of Person
Completing Form
|56|57|St|S9|60|61
Wl
comr
tta
5«|5T
h
non
rk
«IATEDC(
SO;
[ssj
TT]
3ULE
Mo
S6|57
n
M
OA
sT
IT]
F
L
SI
V)
_^
X
Til
3NTROL
NO,
S
u
Yew
SO
[R
FI!
IT
C
JU
?EI
59
TATU
POAT
Mo
on-
m\
5
60
m«
Tii
IF
OURCE FORM AFWOVED
Forn, O*"8 N0' 'S»-R009S
00
XX.
[fi
uu
KX
c
I
p
EFFICIEN
HC
(2J63|(4
CO
D>¥
ntt
IF
1
[sT
a.
U
64
rir
on
f
31!
65
acl
MO
-------
GLOSSARY
Burning - See Firing.
Calcining - The heat treatment to which raw refractory materials
are subjected preparatory to further proc :ssing or use, for the
purpose oi eliminating volatile chemically combined constituents
and producing volume changes.
Curing - See Firing.
Firing - The controlled heat treatment of ceramic ware in a kiln
or furnace during the process of manufacture to develop the
desired properties.
Flashing - Firing a kiln under reducing conditions to obtain
certain desired colors on clayware.
Plasticity - The property of a material that permits it to be
deformed under stress without rupturing and to retain the shape
produced after the stress is removed.
Refractories - Materials used to withstand the thermal, chemical,
and physical effects in furnaces. Refractory materials include
firebrick, silica brick, magnesite brick, and chromite brick.
Vitrification - The progressive partial fusion of a clay as a
result of a firing process. As vitrification proceeds, the pro-
portion of glassy bond increases and the apparent porosity of the
fired product becomes increasingly lower.
8.3-17
-------
REFERENCES FOR SECTION 8.3
Particulate Pollutant System Study. Vol. Ill - Handbook of
Emission Properties. EPA-22-69-104, May 1971.
Compilation of Air Pollution Emission Factors. 2nd edition,
Environmental Protection Agency, Publication AP-42. February
1976.
Shreve, N.R. Chemical Process Industries. 2nd edition.
McGraw-Hill Book Co, New York, 1956.
industrial Process Profiles for Environmental Use, Chapter
19: The Clay Industry. EPA-600/2-77-023s, February 1977.
Aeros Manual Series Volume V: Aeros Manual of Codes. EPA-
450/2-76-005 (OAQPS No. 1.2-042), April 1976.
Loquercio, P. and W. J. Stanley. Air Pollution Manual of
Coding. U.S. Department of Health, Education and Welfare,
Public Health Service Publication No. 1956. 1968.
Aeros Manual Series Volume II: Aeros User's Manual. EPA-
450/2-76-029 (OAQPS No. 1.2-039), December 1976.
Vatavuk, W.M. National Emission Data System (NEDS) Control
Device Workbook. U.S. Environmental Protection Agency,
Publication No. APTD-1570, July 1973.
Standard Industrial Classification Manual. 1972 edition.
Prepared by Office of Management and Budget. Available from
Superintendent of Documents, Washington, D.C.
8.3-18
-------
8.6 PORTLAND CEMENT MANUFACTURING
1-4
PROCESS DESCRIPTION
The major use of Portland cement IF in making concrete,
which is a mixture of cement, aggregates consisting of sand
and gravel or crushed rock, and water. The product is used
in construction of highways, dams, buildings, and other
structures. Cement is produced by heating to the point of
fusion a finely ground combination of limestone, cement
rock, marl or oyster shells, and shale, clay, sand, or iron
ore. The fused product, called cement clinker, is ground to
a fine powder and shipped in bags or by bulk carrier.
Raw materials are received by truck, barge, or rail and
unloaded by a clamshell or discharged into a receiving pit
or hopper. Many cement plants are located near stone quar-
ries, which supply crushed stone of specified size. Quarry-
ing operations are described elsewhere. Other plants use
primary and secondary crushers and screens to produce stone
of specified size. The stone usually is unloaded directly
into a crusher hopper, crushed and screened, and then trans-
ferred to raw material piles or feed silos. The other raw
materials may be conveyed to open piles or directly to feed
silos. These materials may or may not be crushed.
8.6-1
-------
Raw materials from the silos are proportioned and fed
to a grinding mill. Depending on the type of grinding, the
cement production process is called dry or wet. In the dry
process, the raw materials may be dried separately before
grinding, but more commonly, grinding and drying are done
simultaneously. Some plants grind the raw materials sepa-
rately and then blend them in specified proportion. Exhaust
from the rotary kiln that follows this step supplies hot
gases for drying. Figure 8.6-1 is a flow diagram of a
typical dry process plant.
In the wet process, the slurry leaving the grinding
mill is 30 to 40 percent water; 70 to 90 percent of the
solids are smaller than 200 mesh. The raw materials may be
proportioned and blended before grinding or the slurries may
be blended after grinding. The blend may be vacuum-filtered
to about 20 percent water. Except for the difference in
grinding, the dry and wet processes are identical. Figure
8.6-2 is a flow diagram of a typical wet process plant.
The dry or wet mix is fed into the raised end of a
gently sloping rotary kiln, the far end of which is fired
with oil, gas, or coal. As the feed travels slowly down the
kiln, which may be as much as 350 feet long, it is exposed
to increasingly higher temperatures from the hot gases
traveling up the kiln. The feed is dried, calcined, and
8.6-2
-------
V WWT Q
1 PART O » PART. Q
RAH MATERIAL TRANSFER
.PART
C3
i
00
LEGEND
O EMISSION FACTOR3
©EMISSION F«CTOR NOT DEVELOPED
FOR THIS PROCESS
009 (66 0! DENOTES CON'RCL EOUIP
l CODE WITH ESI EFF SHOWN
* IN ( )
\ DENOTES FUGITIVE
I EMISSIONS
O DENOTES A STACK
ESP 010 (96)
BAGHOUSE 016(99 8)
IN POUNDS PER SCC UNI
CEMENT LOADOU
Figure 8.6-1. Dry process Portland cenont plant.
-------
t PWT.O
UK *TE«IAL
TO 8E CRUSHCO rua. Q , PWT. Q . PA«T. ©
LPRIWHT
cntSHCi
3-05-007-C*
p«N*i ausmm
O
n
^
VIUATIK . SECOP11W __— .
• xaa •• CRUSHER 1 '
3-05-007-11 1 VOWKT-1C 1
SCTSEKW I SECamART cMlilRt 1
9
t SECOHOABY I ' - T^-. ''AC.X)"
•PMT.O PAP.T O / FI.ESTOWSTE 8AGHOUSE 016 (99 8 _ _
\ . / OH PROCESS -,---ir,.r c,.« m B»U«USE 018 (99 8! •_, ,„„
DENOTES FUGITIVE FKESJO PA«lt>, SSSl M, SEPARATE «_^
Q OFNOTFI A STACK * fwi Q [' | | \\ Cll*Kt T«A«SF « | 1
1 IN POUNDS PER SCC UNIT CMirr SILOS *'" \A S = 5
LOAOIK ^l^^i^^ | | \$\ o d u
JTJr — 7 1 V\/\X \V "OT*" 1 1 " - -'
'"*>'° F[«AL PWOOCT CsSfBT KIL|. CL1™
CEMEHT LOADOUT "~' " ' '~J^ ^^^^
CLINKEB GRIKDING -^— _- . Ji-
f
-I
FINES TO
PROCESS
PART 0
R COOLER
't
AIR
Figure 8.6-2. Wet process Portland cement plant.
-------
eventually partly fused at a temperature of about 2900°F.
Residence time in the kiln is 1 to 4 hours.
The clinker is discharged from the kiln into a clinker
cooler and is cooled by a stream of air. At least part of
the clinker-heated air is used as combustion air for the
kiln. The cooled clinker is transferred to storage piles or
silos.
Clinker is withdrawn from storage, mixed with about 5
percent gypsum (which regulates the setting time of the
cement), then ground and mixed in a grinding mill. Milled
cement is classified by a cyclone separator, and the over-
size material is returned to the mill. Proper sized cement,
about 90 to 100 percent smaller than 325 mesh, is conveyed
to storage silos. From there the product cement is bagged
or shipped in bulk by truck, rail, or barge.
EMISSIONS4"6
Particulate is the major pollutant from cement plants.
Emission sources are identified in Figures 8.6-1 and 8.6-2.
4
For some of the sources, AP-42 provides emission factors,
which are listed on the process flow diagram. For other
sources of emissions, average emission rates obtained from
other documents are mentioned in the following source
descriptions.
8.6-5
-------
Particulate emissions occur from raw material unload-
ing, storage piles, crushing, screening, and conveying and
transfer operations. Unless confined, all of these are
fugitive emission sources. Emissions from raw material
unloading range from 0.03 to 0.4 Ib/ton; from storage, 3.0
to 5.0 Ib/ton; from primary crushing, about 0.5 Ib/ton; from
secondary crushing and screening, about 1.5 Ib/ton; and from
conveying and transfer operations, 0.2 to 0.4 Ib/ton.
In the wet process, no emissions occur from raw mate-
rial grinding and subsequent transfer into the kiln. In
the dry process, emissions occur from grinding and from
feeding the kiln.
The kiln and the cooler are the major sources of
particulate emissions. Burning of fuel in the kiln also
emits combustion products.
Particulate emissions from discharge of clinker onto
piles, wind effects, and retrieval activities range from 5.0
to 10.0 Ib/ton. Clinker grinding, transferring the cement
into silos, and subsequent bulk loadout or packaging all
generate particulates.
CONTROL PRACTICES
Options for reducing or controlling emissions from
unloading include the use of water sprays and enclosures,
with or without venting to a baghouse. The raw materials
8.0-6
-------
are stored in stockpiles or in silos. Although emissions
from conveying are minimal, conveyors are sometimes par-
tially covered to reduce the emissions. Emissions caused by
transfer of materials from one conveyor belt to another are
sometimes controlled by venting the transfer point to a
baghouse. Telescoping chutes, adjustable stacking con-
veyors, and stone ladders are the options available for
reducing emissions from discharging onto t1 e stockpiles.
All of these reduce the free-fall distance and, hence, the
fugitive emissions. Water spraying of the material before
discharge onto the pile reduces the emission potential.
Stone is commonly unloaded (dumped) directly into a crusher
hopper.
Primary and secondary crushers and screens are often
located below grade; this reduces the potential for fugitive
emissions. Suppression of dusts by water sprays at the feed
points of both primary and secondary crushing and screening
operations is common. Some plants vent the discharge
points to a baghouse.
Raw materials are usually retrieved from stockpiles
with a clamshell, front-end loader, or bulldozer and fed to
a belt system, which transfers them to the feed silos.
Emissions from retrieval and subsequent transfer to the belt
system usually are not controlled.
8.6-7
-------
In the dry process, emissions from the grinding circuit
are usually vented to a baghouse. Cyclones are an integral
part of the grinding circuit. In the wet process, the
grinding circuit generates no emissions.
The rotary kiln is equipped with a cyclone followed by
an electrostatic precipitator (ESP) or baghouse to control
particulate emissions. A large part of the sulfur oxides
(SO-) from burning of fuel is retained in the cement clinker
by the lime. In addition, about 50 percent of the S02 that
enters the baghouse is removed by reaction with the cement
dust cake on the bags. Oxides of nitrogen are not con-
trolled. The cooler usually is equipped with a cyclone
followed by a baghouse or electrostatic precipitator.
Emissions from discharge of clinkers onto a storage
pile or into a storage pit are sometimes reduced by use of
telescoping chutes, which reduce the free-fall distance. At
least one plant discharges the clinker into an enclosed
structure vented to a baghouse. Some plants use open-ended
structures with sidewalls for storage of clinker; usually,
however, these partial enclosures are not sufficiently
confining to prevent fugitive emissions from windage and
loading onto the pile. A clamshell or front-end loader
retrieves the clinkers from the pile, or an elevator lifts
the clinker from the pit, and transfers it onto a belt
8.6-8
-------
system, which conveys the clinkers to the storage or feed
silos for the grinder. Emissions from clinker retrieval and
subsequent transfer to the belt system usually are not
controlled. Some plants vent the silo loading points to a
baghouse.
Emissions from clinker grinding are usually controlled
by a baghouse. Conveying and transfer of the cement is
accomplished by belt or pneumatic conveyoi and is usually
well confined and controlled both for prevention of product
loss and for particulate control. Air from the the pneu-
matic transport system is typically exhausted to fabric
filters.
Cement storage silo vents (for the discharge of dis-
placement air as cement is fed to the silos) are either
uncontrolled, covered by fabric "socks," or exhausted to
fabric filters, which are part of the pneumatic conveying
systems. The trend is toward exhausting to fabric filters.
Cement loading for bulk truck, rail, and ship/barge
transport is typically by gravity feed systems, which are
partially enclosed (in truck and rail loading) or unconfined
(in ship/barge loading). Some plants exhaust the cement
dust, which is emitted with displaced air during loading and
packaging, to fabric filters,- others use no controls. Load-
ing or packaging aspiration systems, which consist of a
8.6-9
-------
filling spout with an outer concentric aspiration duct
vented to a fabric filter, are being used increasingly.
CODING NEDS FORMS
7-9
The emission sources associated with cement production
are :
Source
Raw material unloading
Raw material p^'les
Primary crushing
Secondary crushing
Screening
Raw material transfer
Raw material grinding
Kilns
(Inprocess fuel)
Residual oil
Distillate oil
Natural gas
Coal
Clinker cooler
SCC
3-05-OOX-07
3-05-OOX-08
3-05-OOX-09
3-05-OOX-10
3-05-OOX-ll
3-05-OOX-12
3-05-006-13
3-05-OOX-06
(3-90-004-02)
(3-90-005-02)
(3-90-006-02)
(3-90-002-01)
3-05-OOX-1A
Pollutants
Particulates
Particulates
Particulates
Particulates
Part iculates
Particulates
Particulates
Part iculates,
combustion products
Particulates
8.6-10
-------
Source SCC Pollutants
Clinker piles 3-05-OOX-15 Particulates
Clinker transfer 3-05-OOX-16 Particulates
Clinker grinding 3-05-OOX-17 Particulates
Cement silos 3-05-OOX-18 Particulates
Cement loadout - 3-05-OOX-19 Particulates
The codes for X in the SCC's are: 6 for the dry
process and 7 for the wet process.
Standard NEDS forms for each of the sources, Figures
8.6-3 through 8.6-16, show entries for the SCC's and other
codes. Entries in the data fields give information common
to cement plants. Information pertinent to coding the
source is entered on the margins of the forms and above or
below applicable data fields. Entries for control equipment
codes, other optional codes, emission factors, and required
comments minimize the need to refer to the code lists.
Typical data values for operating parameters, control equip-
ment efficiencies, and other source information are shown on
the form (or in the text) only to aid in rapid, approximate
checks of data submitted by the plant in a permit applica-
tion or similar report. Data entered in EIS/P&R and NEDS
must be actual values specific to and reported by the
plant, rather than typical values. Contact the plant to
validate or correct questionable data and to obtain unre-
8.6-11
-------
ported information. See Part 1 of this manual for general
coding instructions.
The emission source labeled "raw material piles"
includes loading onto piles, wind effects while the materi-
als are stored, and retrieval activities. Raw material
transfer operations that are not included under unloading,
storage piles, primary and secondary crushing, and screening
are grouped under the emission source labeled "raw material
transfer." Figures 8.6-3 through 8.6-8 illustrate the
standard NEDS forms for these six sources. Emission factors
for these sources have not yet been developed. When a plant
furnishes emissions data for these sources, code the values
given. Enter "Emission Estimates Given by Plant" in the
comments field on Card 7. Where there is no control device
or where water sprays are used, enter zeros in the stack
height and diameter fields, 77 in the temperature field, and
zeros in the common stack field. Enter appropriate height
in the plume height field. Where water sprays are used,
enter 061 or 062 as a control equipment code. In the com-
ments field on Card 6 identify other equipment used to
reduce emissions. For example, enter "stone ladders" where
these are used for transfer onto storage piles.
Figure 8.6-9 shows the standard NEDS form for the
grinding mill in a dry process plant. Rotary kilns and
8.6-12
-------
clinker coolers are the major sources of particulate emis-
sions in both dry and wet processes. Coal is the fuel used
most commonly for firing the kilns. Figures 8.6-10 and
8.6-11 show standard NEDS forms for these two sources.
The emission source labeled "clinker piles" includes
discharge (loading) onto piles, wind effects while the
clinkers are stored, and retrieval activities. The source
labeled "clinker transfer" includes the operations involved
in transferring the retrieved clinkers to the silos. Figures
8.6-12 and 8.6-13 show standard NEDS forms for these two
sources.
Figures 8.6-14 through -16 show standard NEDS forms for
clinker grinding, cement silos, and cement loadout opera-
tions.
8.6-13
-------
CODING EIS/P&R FORMS10
The EEC's for use in EIS/P&R forms are:
Source
Raw material unloading
Raw material piles
Primary crushing
Secondary crushing
Screening
Raw material transfer
Raw material grinding
Kiln
Clinker cooler
Clinker piles
Clinker transfer
Clinker grinding
Cement silos
Cement loadout
As of April 1978.
BEG
700
700
650
650
575, 577
700
653, 654
230
no code*
700
700
653, 654
no code*
700
8.6-14
-------
Figure 8.6-3. Standard NEDS form for Portland Cement Manufacturing - raw material unloading.
00
•
OX
I
tn
1 ;
1
1
S
t
»OCB
7
i
s
fttut ID 1 t
Numltfr j
10
It
F"
m
^
J
c
1
V
r
"5
o
0
T
•o
U.m
3
g
N
D
F
S
2
Oil*
C
n6
A
*-C
-»I
r
4
' D
fl r
SINV
M
M
1
7? " 71
a
17
o
0
I
Ju
A
a.
pf
F
(H
u1
T,!
M
T|
mj
jPl
Sf
N
T",
U
«i*
h
1
ot
TM
n
O
to
K
1
pr
:
:
••ft
OH
71
T?T
5
TM
U
0
•
\l\tl
'"-'
11 I'
FM*
«4 IS
n!n
[ojolojolo]
SOi
TTTrT^ ...
±LLo
p,,.
,.i
U 4,]U
"o ojols
( ( ', f 1 V ft T f
NO,
LL
i
i
5n>T«
i £
!w i: j*
>rV K
^~p--
J
b!
5p.
_LOJ
ss
Tl
,.
c
y
si
SI
\*
so.
LULiO
—
.:%
^
0
PC
.oq
^
tt
Inp
to'
f 0
SO
X
61
m
tl
/
•)N tnoi
NO,
H'V!
,
..,
F°'m
u
XX
00
«
13
XX
00
U
FFFIC
MO
.'•ill
L
CO
12
1
t.'i e
L_J
?T
c
P
I
V
TT
01
F
CV
'-
ss
Ik
•ci P
NT I
NO C
« (7
I'iL,
^0
V(
a j-
fio
U
~
D'S
AMMT
LIHTRj
(Ml
D
TVT
~10|u
-%
T
0
70
IF
N
70
-
C
ST
71
V
—
1-1-
n
Of
AC
•:
71
M(
K
71
5
)N
-^
SI
15
•s
— '-i
•V
AC
•4
— .
1_JP__j__
71
K
k
T *
tf
— .!U_
* 1 r^
i i
' t-
! 1 .i '
i
RAW MATERIAL L_
UNLOADING
-,I
'
V
C
i;
-ill
m'">
^
1
1?
n
20
•i
IS
10
T
?j 7T 71 •*!
S
n
n
CC
Ml
n
_
sec
Ml
77
-t
r
SOi
?S ?S ." ?1
IV
b'4
TT
S
~
a
s
cr
T~
U
jl.d
^ V
F,
ALLOV
"j 10 11
Nl
V*'
„-
1
n >
1.
i,1
U
Jt
-
AMI t e
j? 33 j
10
6
7?
Nb
V i
JJ
a
FO
nn
V SSION5
NO,
lLJli'& );
MAT
Huu
Rj
* OF
EF
o
Y
I/I
77
P
u
U
IL
is
RO
'cT^l-H--'1 \?
UN
M
;E*
r i>
10
LC
>S
.'JJ_l-
41
AC
ti
,-|,,|.,|.,
.J
rEO
1,
0
7 F
L\>2
OR
»r
_LOJ
LQ
...
WE
•••
r f
— Tl —
HJ-.5JM
:
_
-ROCE51
J
M
0
U1
,i
Jv
0
s
»/•
S3
s
_
»
' : 'i l
*
[sT
_i
—
%
-
''•
j
-
L L
.LJ_L
<,, sTjsJt< ss «
'4 -s -s - 'I
4.j
I.
1'J
-------
Figure 8.6-4. Standard NEDS form for Portland Cement Manufacturing - raw material piles.
oo
en
„.,.
11
-mi
KX
«
^
P
iN
|f)
•n
11
If
11
10
u
n
»
^
C.ti
li
Ik
o
X
•*
^1
Ik
"5
f-
"P
K
Tr
o
i:
s
II
O<">
"IT
I
3
R
%
D
n
S
2
A
•K
11
*I
a
c
4
OJK
1^1
M
H
1
nn
JA
»*
;i
~ri}-n
0
r
n
•»i
?;
B^_
^J
/
»f
m
*i
Hi
?!
Hf
"f
JPL
ii
U
hr
.,
1
^.
fM
n
CO
50
T*
5
F
°
-
*c
r
:
f
'
L_
j<
?
a
o->
^1
rif
,.
in
Al
krf
,o-«
n o
X
•;
—
^L
ss
..
0
•=;
»
17
A1IONAL twi««u™> UHIH j' Ji <."• i" "-K-.
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF AIR PROGRAMS
Hf
o ^
0
0
TT
i»
n
0
"TT
i it
)
NO
iTTH
0
NO
-
0
0,
I*
0
t'
rm
ni
ji
1
c. Q
S^
;
11 ;^
0
n
0
••
STACK OA
T»mpl"n
M tl « Til
f.J.JII
1 r'
111 1 i
i;
0|0 iu'
1 1.
V
*•
0
(1
51
™
0
s:
0
H»
*•*
;•
O~
<
{)
•yirt*
1)
Pvt SO-
^-.JT^F]
L
5?
- r
J
s<
-
L
^
^fl
54
LJ
l*fc
1 !
* ol P*»to
51 5< W
.!_.
0
3
SI
II
b
t , •
THo
H
41
NO.
1U-
LJ
1C
LU.
41
TAH
r:
Lu,
1 i !
Fo'm "
"1
<,?
- -
1
CO
f.'
41
M
MC
11
,
u
Jn
c
4«
•£
^
t '
45
7^
i
t*
CO
i'
L J
It,
"
P
(I
47
4r
IE
T)
41
7T
r»o
U
ti
11
7f
CO1
•y i
il S*
«ji
—
^
Tnl
—
r
.._J
: j
l»
"1
/'
-
(T
"1
-^
S«
r~
:
n 1
,1,:
—
L
n
rj
Cf
?T
'J
^
c
'«
-q
75
;i
« ]
"^TTT
""*]""
*
s
\
RAW MATERIAL PILES
I
l«.
1
14
-
I
1'
1
II
1
1)
!
li
« t'
II 1
3
u
*•
,
n
9 ?fl
3 b
J ,'C
- -
,
n
« I
sec
in
n
0
sc
j>
-
a i
U
c
so->
-
IV
1 71
0
-
"
i
?5
H
-
NO.
SCC UNIT - T
Oc — "••"
*.
—
'1
F
;i
T:
n
Fi
«
,„
-
JI
i
6
ONS PLAC
-
il
FOR
'*
*.
]jl U
EC
TJ
MC
IN
-
-
Hk^
-)
M
_.
DRY PROCESS
£pp)J!
-4 -4- -I—
Ji
—
-
2*
!1
—
10
-
ii
?J
3
J
i;
o"
__.
1
1!
-I
U
QJ
o
._
7 FOR WET P
ii
—
i;
—
1!
-
I1
~
—
'"
,. »T
uhi
— —
'I-
50
n
f _,r^-rit.
ii
•>.'
S)
—
5<
)5
--
Si
y
^a
i)
so
S!
i>
U
4*
>5
««
<,:
ss
4t
• -
t;
H
C
I?
.')
'«
J
fc
nn
V
Sn
' 1
ri
Til
-
-
-77177]
4
77
-
^?
-
"
44
4'
-
-
H
5"
n
n
lilil
_i_
T
•i
-
i
-
-------
Figure 8.6-5. Standard NEDS form for Portland Cement Manufacturing - primary crushing.
CO
I
»-4
AOC"
n[n
NATIONAL EMISSIONS DATA SYSTEM (NEOS)
ENVIRONMENTAL PROTFCTION AGENCY
OFFICE OF AIR PROGRAMS
POINT souncf
Inpul Fofrrt
own HO i •*
[7Tl7
Up
S u
• »
* 8
Sffi
ANNUAL tHHUpUl
Mf lu»*
M*v AU-J
• ^ 1 r m*< u
; * v
X NO.
"TTiFMiTisfr
"olbioi
XXXX POINT ID'S IF COMMON STACK |
0000 IF NO COMMON STACK
I S'f.'/i M I) c Tl'noi E"
-l- Ll iPJ
SO,
Fnp^,
±11 to
^•Ri7!?'
•>ho!
f
IT ?o
,i
a
?]
n
so-.
n
K
71
'•)
jal ii
t1
NO.
!'
Jj
it JJ
.'k
nr
J'
re
M
U
rr
»
n
U
t.Us
ot
<••
S!
6'
, .'
,
;
P
-
S
i
_
-------
Figure 8.6-6. Standard NEDS form for Portland Cement Manufacturing - secondary crushing.
Staff.
1 J
Cawntv
1
<
^
(
»QCR
1
1
J
*•." 10 |
f
10
jum
11
J^ 1
^Inj
"11
c.
m
NATIONAL EMISSIONS OAf A SYSTEM (NEOS)
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF AIRPflOGRAMS
INT sounct
Irtpul Fcxm
N»m^ 0' P»'to«
Compl'""<> FO
00
*
eri
r
««tv
ffl
Contact Pf-to**"
., ,l , . _-_^—-r—T-- f,)1Jll,,,Nt
1, I- fv
* I r.,~v.| '? lr .1 S? I f-—»l 51
^ U"r Ji *° L. "UL^r
XXXX POINT ID'S IF COMMON STACK
0000 IF NO COWON STACK
H
SECONDARY CRUSHING
%
A
V
C
0
1
IT
t
ID
3
M
11
0
n
b
sec
HI
:i .'.' i
0
U
IV
3[)>j'M
1
,
F
n
bi
nl
-L
St
00-
Ul
Jl.tJ
M
>
^'i
n
i
M i
in
I
^
11
IU
jr
r,
\j
V
11
Ff
»
•
«
s?
u
ii
(S
«
1
S!
1
1
P
C
1
1
"^
1
—f
r 5
ftt-';
V
cnw/tr^m
-------
Figure 8.6-7. Standard NEDS form for Portland Cement Manufacturing - screening.
00
Snw,
1 1
Covnir
3
1
5
t
| «.n
AQCR! NU~
iTTjTjioIji
JLLLL-
ID |
X-(
fl
c.
fl
NATIONAL EMISSIONS DAf A SYSTEM (NEDS!
ENVIRONMENTAL PROTECTION AGtNC i
OFFICE OF
SCREENING
Pjn.cu's-'
irair
1 1
V
ni.'i
1
so->
^sl?1;
!
>i
x\»
\
ji
NO.
:;
o|
331,-
1
J>
Jb
j!ia
11
«b
77
r—T—-r- -T—T-TT vrr., r,»1 t-\l t'l
BSiW^
t±t
11
iittWr
tl'rhli±j:
... II.
6 FOR DRY PROCESS; 7 FOR WET PROCESS
±±1
-H H- {-
utr-4-
-------
Figure 8.6-8. Standard NEDS form for Portland Cement Manufacturing - raw material transfer.
NATIONAL EMISSIONS OAf A SYSTEM (NEDS)
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF AIR PROGRAMS
FORM I
own NO i so m»«s
E,loh'.(hrr.rn. Njmt »nd Ad.1-f«
nn^raraniDMS^
XXXX POINT ID'S IF COMMON STACK
•' 0000 IF NO COMMON STACK
¥
-i LL1P I
MATERIAL HANOLfD .
RAW MATERIAL
TRANSFER
6 FOR DRY PROCESS; 7 FOR WET PROCESS
-------
Figure 8.6-9. Standard NEDS form for portland cement manufacturing - raw material grinding,
dry process.
oo
•
CTV
ro
AOCfl
fl«m ID
NATIONAL EMISSIONS OAtA SYSTEM (NEOSI
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF AIR PROGRAMS
POINT souncf
Input Fo"*i
FORM APMlOvf D
OWP NO IM*«CV»«.
D«t«
C.I,
* JS
COOHl'IflAT ES
STACK. DM •
T>mo l"r
008 018
vln
ololo
r ,n-».y
NO.
isl^
g]o
00
XXXX POINT ID'S IF COMMON STACK I
0000 IF NO COMMON STACK
iliil
99+
. ON"ioi 6f SIOENCY I
NH,
fvr,'.i')'i i •,
SO; N0
olnli'l'i'TTi !-.Ji,h7jM
±rl:loLi_LL
RAW MATERIAL GRINDING
DRY PROCESS
"o
1
•v
U
t:
0
V
5
if
i
IB
3
p
n
i
0
70
5
71
S
0
cc
III
0
71
n
6
SCH
;< zb ?i :' 71 .*) 10
i
1
y
3
b
r
'F*
S
On
IL
W
U
"
»
v'/
71
,"
ID
11
0
f
]t
~
10
j;
TT
6
M
10
ii
1
UCEjp,
10
ii
1,'
0"
1
Ii
-
_1
11
UJ
d
lHTrfTT[Trr«T"sTTs7
::Hl.Q-.lo
"n|-,> sMu i.'lt!
irrtft
H :l
W
0
il
•).'
S)
il
>s
•A
V
•-*
—
il
M
1,1
s:
u
(1
65
no
i,;
^
bi
P
7?"
;j
M
'5
•6
•"
<
cd
T
6
L-J-*
ID
irrir
;i :7 7)
n ;:'n ;i ia
}'. !6
-
—
-
" •
7^
"I
7^1
"
~
TH
-
r
M
c:
•^
"«
fc
-
H
5?
-
11
-
M
-
T;
-
;j
-
•i
74
._
Ul"4^
^1
-------
Figure 8.6-10. Standard NEDS form for Portland Cement Manufacturing - kiln.
NATIONAL EMISSIONS DATA SYSTEM (NEDS)
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF AIR PROGRAMS
POINT 5OUHCF.
'npul Form
FOF1M APITIOVrD
OWB NO ISBHIW9S
KILN-10.2 LB/TON
IN-PROCESS FUEL
CQAL-26S LB/TON ,
R.OIL-108S LB/10J GAL
D.OIL- 98S
GAS- 0
6 - DRY PROCESS!
7 - WET PROCESS]
Po-ni
ID
14
16 f9
GAL
1
KILN
:ss FUEL
«!
; S
16
17
:> 5
_ o
« J
>- X
16
17
to 5
II
11
7(1
?i
27 7
HCC-T
t
1
1
II
11
n
q
7(1
s
n
Ml
21
n
n
n i
0
n
sec
24
ALLOW
SOl
25
IV
C 24
(1
n
75
6
j ,
75
2 1
78
.")
30
31
32
SCC UNIT - TOI
Fuel Prrjreji.
Op.-' .It'i-t HJIC
26
'1
2R
, L
71
30
31
.!<'
33
J4
J3
36
3/
3D
HC
« CEMENT PROD
Vjn.rnu'ii Ocu^f1
33
34
35
36
J7
id
39
40
JC^
u
4!
41
^
4i
''
J
^
!_
i;
U
3
F0_
Ts"
!t
} f
r _
4J
- 1 - THAI : ? - OIL AND GAS
fi
f
l! U
' t
14
.en.
I'l
50
n
CO,,™,,
51
V
53
54
55
5t
5'
58
51
«,i)
SI
L_
6'
U
64
1
55
»
67
58
tt
Id
&
\\
P
^
3
72
73
74
75
76
II
o
<
18
cd
7i "air
f 6
p 1.
P S
P B
P 6
'# 21
?'.
1
)IL
—
»
—
6
-
NA
TL
-
RA
L
W
S
—
Is.
67
6.1
69
I1)
71
77
73
74
75
76
;;
_.
<
78
-
79
p
P
p
-------
Figure 8.6-11. Standard NEDS form for Portland Cement Manufacturing - clinker cooler.
00
*
&>
I
t\3
00
NATIONAL EMISSIONS OAt A SYSTEM (NEDS)
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF AIR PROGRAMS
POINT souncf
Input fntm
OMB NO !••*(
XXXX POINT ID'S IF COMMON STACK
0000 IF NO COMMON STACK
"*"M
FSTIM'.Tri) I ONItlOL FfCKJFNCV (M
«l:'l?iln ho hi h- Ji|3«hlL!il"U!
S CEMENT PRODUC^q 4_'-
•
CLINKER COOLER
M : 1
50
n
51
*>r
b)
b«
ib
M,
>/
^
r
SI
so
f->«
SI
S!
U
(4
6S
gi
",!
S«
'"I
;(^
«
P
\
n
7»
*s
;6
"
5
<
-
r,
r
<)
91
T
b
•;
e
Pfl'^t
ID
1.
6 FOR DRY PROCESS; 7 FOR WET PROCESS
COW^F*-'T<'
O
JiJi
_L
-
y
1
16
-
$|
10
11
ir
-------
Figure 8.6-12. Standard NEDS form for Portland Cement Manufacturing - clinker piles.
CO
ro
n»*i ID
NumlM"
NATIONAL EMISSIONS OAtA SYSTEM (NEOS)
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF AIR PROGRAMS
POINT SOUOCE
Input Fo'Tt
FORM API-noVEO
OMB NO 1 "*8 RCV9S
Htrrtf of P*rlO"
Complftinq Form.
Eujh'i
_LJ
6 FOR DRY PROCESS; 7 FOR WET PROCESS
^e
^;
10
__.
'.1
~
(ji
—
sij^rU)
II
-It
i-
~~
>>5
(i
b'
M
SI
-
-
-
-
--
<.
P
N
r
!_!.
-------
Figure 8.6-13. Standard NEDS form for Portland Cement Manufacturing - clinker transfer.
POINT SOUHCE
FORM AP*f*OV€0
CO
*
en
i
ro
ui
i ;
OH-tV
3
4
S
i
Htnl ID
I
1
»
9 10 II ITTl3_
1 — 1 o?
^ 5
(Jtm • f
C.tv 2o«f > tt
r, u 5 UTM COOHPI
m > a. Sic «; '"'" .
|t]n U TT 't H JO H 7! 73 74 75 7S 77 7S T>
_J 3241 __
J
"3 ? Boilpf Dwqn c ^
; I innn'Tkri" «•«.." 3*
* II II 11 7C 71 .'! .'! '4 75 K •'' " *n
0 0
\ ANNUAL TIIHUPUT NH"N'>'
OT'1/.T"
S 3 0« M». I Ju"' Sf 01 ^ S
v * f,t, M>. 1 Aui N.I. f D
** fVl.cul.lf S°'>
sec SCC UN
"5 £ Fypl P.
; | I ir Ml IV do
U 17 |! 1? ?0 n 1! 73 71 ft It '1 71 71
CLINKER TRANSFER 3050016
t -3
^o' '•? ii in " COW/F
14 :r. i' n is rj_ 7c 71 ,•? 7i n .". 7?|;;'"' '
'TV.-- .Ii
NATIONAL EMISSIONS DATA SYSTEM (NEDS)
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF AIR PROGRAMS
lo 31 37 33 31 !i IS 17 31 3? <0 41 >! <1 " >i "> " " !1 -"P'l1- M S< —
IAIES STACK I:AI ••
_. _L_. -. _ --i-
I ON ll'?V I- t I ' " N I
srj!"?_pr F|-"| I' 1-1 -
o o oloio oooo ololo LoiQlojojQJ QJMS lMP_ I L
E vr/ I'l'i ' ', r i VA Tf j nor* /- >' '
' 1 1
i »,,i,ruijilf 50; NO. "
rolT 3? 35 1« 3' K '' 31 39 '0 TTTrT -111 J«Ji, I/JU n]M vL' 5!]M. '.
ffrftmTrttlt lot .1 jimottti
NO. '" C° ' '"
~fo Jo I LJo L LI Li o
IT - TONS CEMENT PRODUCED _-_
".Hf HJI-* 'j C* "• '" L
00 0
J . _,^ „ .. - ..
i 11 31 i: r v v. w '.! " Ji '« " '• " " '•• '•" ' '' '-'.J " ,s >i.V
t-^l '. I.Hf 1 llr-
inpul Fo-m
T . . 8, . Olt| -^T-
,3
;<|sj
. 'J ,' XXXX POI
[";;«."'/ oooo IF
stj^t" M L « u M "
flZl 1 11 1
1 .„. N,. H, |
TCF *^R-. <;lMUihl
Hiol^li
CO
« 'i '1 1' 1C H K'Ul
o _L
. ,,%-^ . > ^'-' (.'i '
"iT
i^^tS^
JTJ__LL_
I !
- I- j-t-
bJ
OJ |
~"i7T
JU
S4 (S
- -
- -
K (1
NT I
W C(
>K i;
M
:o
<»!'.:
-.'t
* 7
C
«* ^'
I
-I
OMB NO .V.XW
Z
i
•10n»l C
U S? 70 71 7? 71 7(
D'S IF COMMON
DMMON STACK
t! S' 70 71 7: 7! 7
" ' ~J ""'ip 1
JLll^_J p +— '- -^l-
41 ii ;0 ! 77 7]
P
LLLL^LLJ.
O 1
75 % 77 -! 'H*1
STACK S
*1 r
1 75 "6 7; « •']
-------
Figure 8.6-14. Standard NEDS form for Portland Cement Manufacturing - clinker grinding.
00
•
01
ro
fistic
AOC« Numt^_
NATIONAL EMISSIONS OAt A SYSTEM (NEOS)
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF AIR PROGRAMS
POINT sounct
Input fo*f"
I PPMO"
FO*T> —
FORM '
OMB NO 1Sf< '
11
14
. DRY PROCESS |
- WET PROCESS
Euah'i^hmfnt Njm* andArtrf"**
XXXX POINT ID'S IF COMMON STACK
0000 IF NO COMMON STACK
fSTII.'»nOi:0'linOL EF'ICIfNCV 111
j^no iin:uni'i»iK|i-
CEMENT PRODUCED ./,
v.i.-mu»i O'4-y'1
6 FOR DRY PROCESS; 7 FOR WET PROCESS
CLINKER GRINDING
-------
Figure 8.6-15. Standard NEDS form for Portland Cement Manufacturing - cement silos.
O3
i
ro
W»nt ID
tin
NATIONAL EMISSIONS OAtfl SYSTEM INEOS)
ENVIRONMENTAL PROTECTION AGENCY
Of F1CE OF AIR PROGRAMS
POINT SOURCE
Input FO*TI
OMB NO 1SBROO9S
N*mr o' Perion
Co"->p(fttfH) form_
nw
J..
STACK (;*' -
Mnqht 1M)
O.amlM
T.rT,Dl°n
flo~".,if Ili3/i
fc.,,rr.f H».nh'
'mini IIJTO *'y ^ "
nh1! fit h^lyBi
C*o«"v
mr> RTU'h-
018 :
CEMENT SILOS
\ ANNUAL TMRUpUT
Qpf HA rifJ'
olo
Kii
otg
Co A i act PtMO"*i
XXXX POINT ID'S IF COMMON STACK |
/ 0000 IF NO COMMON STACK
99+
i;riMnr(t>i v< IHOL Ef1'Of NCY I
NO,
I'Li'^li'UL
_M.XiP-
_L
^pZpt
ojoJoiQLL
~( ' ,'j-Pl -AN-
TA
1"
F
i ,
,
u
t
t?l
E<
a
•i
••'
Si
$4
C
, t
''
0-
M
Ron I
ilMl'TS
i_l — ^i_
L»
n
TIL
"xi
;t
3
A
'k
i!.
c
C
-5l
JJ
crt
SCC UN T - TONS CEMENT PRODUCED ^-.
T
!•'
i-
r
iO
0
ii
s'
S)
M
>S
Sd
'
^^
SI
",0
SI
s?
u
(i
IS
(I
SI
n
"
V
-1-
±
c
•)
11
n
M
T5
•s
3
<
•I
'•'
r
cd
3-'
b
*
6 FOR DRY PROCESS; 7 FOR WET PROCESS
fl
-------
Figure 8.6-16. Standard NEDS form for Portland Cement Manufacturing - cement load out.
CO
•
en
I
ro
oo
AOCR
NATIONAL EMISSIONS OAf A SYSTEM INEDS)
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF AIR PROGRAMS
POINT ID'S IF COMMON STACK I
0000 IF NO COMMON STACK
CEMENT
LOADOUT
SCC UNIT -TONS' CEMENT PRODUCED
Fu*< •t"K«l» Miju'ty -,~- i
Solom-mr
Otf "•"<
t
11
t)
0
M<*
to
— 1
F
I/
j* '
n
11
50
TT
ii
ir
»
S4
•>i
%
V
^J
il
VI
<,!
S?
u
(4
kj
»«
^
M
SI
;o
«.
"1
P
V
'3
<
«
P
3
6
T
6 FOR DRY PROCESS; 7 FOR WET PROCESS
-------
GLOSSARY
Barrel - One barrel of cement weights 376 Ib; there are 5.32
barrels per ton of cement.
Clamshell - A crane with a bucket having two hinged jaws.
Clinker - The fused product of the kiln, cement chunks.
Stacking cr" veyor - A belt conveyor that discharges at the
storage pile. Use of conveyors that rise and fall with
the storage pile reduces the distance that the material
must drop.
Stone ladder - A fixed column containing a series of steps
that allow the falling material to cascade in short
drops. As the storage pile increases, the material
discharges through ports in the sides of the column and
emissions are reduced.
Telescoping chute - A column that can be raised or lowered
to maintain a constant distance between the coal being
discharged and the top of the storage pile.
8.6-29
-------
REFERENCES FOR SECTION 8.6
1. Kreichelt, T.E., D.A. Kemnitz, and S.T. Cuffe. Atmos-
pheric Emissions from the Manufacture of Portland
Cement. U.S. Dept. of Health, Education, and Welfare,
Cincinnati, Ohio. PHS Publication No. 999-AP-17.
1967.
2. Process Flow Diagrams and Air Pollution Emission
Estimates. Cincinnati, American Conference of Govern-
mental Industrial Hygienists. Committee on Air Pollu-
tion. 1973. pp. 52-54.
3. Considine, D.M. (ed). Chemical and Process Technology
Encyclopedia. New York, McGraw-Hill Book Co. 1974.
pp. 237-240.
4. Complication of Air Pollution Emission Factors. 2nd
edition, 3rd Printing. Environmental Protection
Agency, Research Triangle Park, N.C. Publication AP-
42. February 1976. pp. 8.6-1 8.6-4, C16.
5- Inspection Manual for the Enforcement of New Source
Performance Standards: Portland Cement Plants.
Environmental Protection Agency, Research Triangle
Park, North Carolina. EPA 340/1-75-001. January ly75
6. Technical Guidance for Control of Industrial Process
Fugitive Particulate Emissions. Environmental Protec-
tion Agency, Research Triangle Park, North Carolina.
EPA-450/3-77-010. March 1977.
7. Aeros Manual Series Volume II: Aeros User's Manual.
U.S. Environmental Protection Agency, Research Triangle
Park, North Carolina. Publication No. EPA-450/2-76-029
(OAQPS No. 1.2-039). December 1976.
8.6-30
-------
8. Aeros Manual Series Volume V: Aeros Manual of Codes,
U.S. Environmental Protection Agency, Research Triangle
Park, North Carolina. Publication No. EPA-450/2-76-005
(OAQPS No. 1.2-042). April 1976.
9. Standard Industrial Classification Manual, 1972 Editxon,
Prepared by Office of Management and Budget. Available
from Superintendent of Documents, Washington, D.C.
10. Loquercio, P. and W.J. Stanley. Air ?ollution Manual
of Coding. U.S. Department of Health, Education, and
Welfare. Public Health Service Publication No. 1956.
1968.
8.6-31
-------
8.9 COAL CLEANING
PROCESS DESCRIPTION
Coal IF Cleaned to remove impurities s ch as dirt,
clay, rock, shale, iron, wood, and some sulfur. These
.mpurities are present in coal in its natural state or are
added accidentally when the coal is mined. Their removal
increases the heating value of the coal and reduces emissions
of sulfur oxides when the coal is burned.
Coal cleaning plants are usually located at the mine.
Their capacities range up to 2000 tons per hour, with an
average of about 500 tons per hour. There are three basic
types of coal preparation plants: (1) complete preparation
plants, which clean both coarse and fine coal; (2) partial
preparation plants, which clean only coarse coal; and (3)
coal crushing plants, which crush the coal to specified
sizes. The complete preparation plant is discussed here,
since its operations include those of the other two types.
Figure 8.9-1 shows a typical coal cleaning plant. Coal
is usually carried by belt conveyors to the crusher where it
is prepared for the cleaning plant or for shipment. The
crusher is designed to discharge the slate and rock to a
.9-1
-------
WET CLEANING
PROCESS
o
CHKMON TnOM THERMAL DRYERC
TYPE OF
; DRYER
FLUID BED
FLASH
MULTILOUVERED
V
EMISSIONS
LB/TON
CONTROL .,,.,
DEVICE °01
«
20 |
16 ^_
' 3 ;
-*-
CYCLONE
1-FLU ID!ZED BED
2-FLASH
3-MULTI LOWERED
4-ROTARY
5-CASCADE
6-CONTINUOUS
CARRIER
7-SCREEN
PART.
LEGEND.
Q EMISSION FACTOR'
0EB!5S!ON FKTOR NOT DEVELOPED
FOR THIS PROCESS
009 (66.0) DENOTES CONTROL EOUIP
. CODE WITH EST. EFF SHOWN
O
IN ( )
DENOTES FUGITIVE
EMISSIONS
DENOTES • STACK
IN POUNDS PER SCC UNIT
Figure 8.9-1. Coal cleaning plant.
8.9-2
-------
refuse pile. A bar screen following the crusher separates
the oversize fraction and returns it to the crusher. The
crushed coal is conveyed to storage silos. Coal to be
cleaned is conveyed to vibrating screens, which separate the
coal into several size fractions. The large and small sizes
of screened coal are moved by conveyors to separate cleaning
circuits.
Impurities are separated by wet and dry processes. In
the United States, approximately 93 percent of the coal
produced is cleaned by the wet process, in which water or a
mixture of water and hematite is the medium and separation
is effected by gravity, centrifugal force, air, or a pulsa-
tion column. In the dry process, air is the medium and
separation is done on "air tables." In both processes
separation is based on differences in specific gravities of
the various materials.
Wet separation is followed by recovery of the medium
(hematite) and by mechanical dewatering of the coal, after
which the smaller coal particles are sometimes dried ther-
mally, depending on product specifications. The dried coal
is usually mixed with a larger coal fraction, and the
mixture is conveyed to storage piles or silos or is loaded
directly into railroad cars, trucks, or barges.
The fluidized-bed dryer (sometimes called "fluid-bed")
is commonly used for drying the fine coal. In this device
8.9-3
-------
the coal is suspended in a fluid state above a perforated
plate on a rising column of hot combustion gases. The
entrained coal is separated from the hot gases by cyclones.
Other types of dryers used for coal drying are flash, multi-
louver, rotary, cascade, continuous carrier, and screen
dryers. The three most common are the fluidized bed, flash,
and multilouver.
EMISSIONS3'4
Although combustion products are emitted from the
dryer, coal particulate is the major pollutant in coal
cleaning operations. Emission sources are identified in
4
Figure 8.9-1. For some of the sources, AP-42 provides
emission factors, which are listed on the process flow
diagram. For other sources, average emission rates obtained
from other documents are mentioned in the following source
descriptions.
Most coal cleaning plants are located near the mouth of
the coal mines. Coal is conveyed from the mine to the
cleaning plant by semi-covered belt conveyors or by elevator,
Emissions from conveying are minimal. When coal is dis-
charged (transferred) onto a storage pile or into a breaker
or crusher hopper, fugitive emissions occur because these
transfer operations usually are not enclosed and vented.
Where coal is received in barges or rail cars, emissions
8.9-4
-------
occur during unloading. Fugitive emissions that occur in
raw coal storage and retrieval, crushing, screening, and
transfer activities are in inverse proportion to the surface
moisture of the coal. Emissions from storage are caused
primarily by wind.
The separation and mechanical dewateri^g operations of
wet cleaning plants do not emit air pollutants. Substantial
amounts of coal particles are entrained in gases leaving the
thermal dryer. Combustion of fuel (usually coal) for the
dryer generates sulfur dioxide, nitrogen oxides, carbon
monoxide, and hydrocarbons.
In dry process plants, dust particles are emitted in
the air table exhaust. An air table designed to handle 70
tons of coal per hour may emit up to 50 pounds per hour of
particulates.
Fugitive particulates are also emitted from storage and
loading of cleaned coal. Since a wet process plant produces
coal with a relatively high surface moisture content, emis-
sions are lower than those from a dry process plant.
3 4
CONTROL PRACTICES '
Emissions from unloading, storage, and transfer of raw
coal are usually not controlled. Most plants, however, use
stone ladders, telescoping chutes, or adjustable stacking
conveyors for loading onto the storage piles. All of these
8.9-5
-------
reduce the free fall distance and, hence, the fugitive emis-
sions. Control options for transfer operations include
spraying the material before the transfer or the use of an
enclosure or hood vented to a particulate control device.
Increasing use of water within coal mines to implement new
health and safety regulations produces coal with relatively
higher surface moisture content and thus reduces fugitive
emissions.
Emissions attributed to crushing do not occur from the
crushing operation, but from the feed and discharge points,
which are transfer sources. Sometimes the crusher is
housed in a building but not vented. In these cases the
degree to which emissions are reduced by baffle effects and
internal settling is not known; it is possible that all of
the dust generated in crushing is eventually emitted to the
atmosphere.
Although emissions from conveying are minimal, con-
veyors from the crushers to the screens are usually partially
covered to protect the coal from wind. The screens are
usually equipped with water sprays to wash some of the fines
from the larger coal and to reduce the emission potential.
Use of sprays at this point also reduces emissions from
subsequent transfer and conveying operations, which are not
controlled.
8.9-6
-------
Where a fluidized-bed dryer is used, a cyclone is an
integral part of the system. Particulate emissions from the
dryer are controlled also by several types of scrubbers,
most commonly a venturi scrubber. Particulate removal
efficiencies for venturi scrubbers are reported to be 99
percent.
Cyclones also are an integral part of the air table in
a dry process plant. Particulate emissions are typically
controlled also by fabric filters, which are reported to
reduce emissions to less than 0.01 grain per dry standard
cubic foot.
Emissions from the discharge of cleaned coal onto
storage piles, and from storage, retrieving of coal, and
loading for shipment are usually not controlled. In the
transfer of raw coal, however, stone ladders or telescoping
chutes are sometimes used to reduce emissions.
CODING NEDS FORMS
The emission sources in a coal cleaning plant are:
Source SCC Pollutants
Unloading 3-05-010-08 Particulates
Raw coal storage 3-05-010-09 Particulates
Crushing 3-05-010-10 Particulates
Coal transfer 3-05-010-11 Particulates
Screening 3-05-010-12 Particulates
Air tables 3-05-010-13 Particulates
8.9-7
-------
Source
Thermal dryer
Fluidized bed
Flash
Multilouvered
Rotary
Cascade
SCC
3-05-010-01
3-05-010-02
3-05-010-03
3-05-010-04
3-05-010-05
Continuous carrier 3-05-010-06
Screen 3-05-010-07
(Inprocess fuel
for all dryers)
Coal
Residual oil
Cleaned coal
storage
(3-90-002-99)
(3-90-004-99)
Pollutants
Particulates, products
of combustion
Particulates, products
of combustion
Particulates, products
of combustion
Particulates, products
of combustion
Particulates, products
of combustion
Particulates, products
of combustion
Particulates, products
of combustion
Particulates
Particulates
3-05-010-14
Loading 3-05-010-15
Standard NEDS forms for each of the sources, Figures
8.9-2 through 8.9-10, show entries for the SCC's and other
codes. Entries in the data fields give information common
to coal cleaning plants. Information pertinent to coding
the source is entered on the margins of the forms and above
or below applicable data fields. Entries for control
equipment codes, other optional codes, emission factors, and
8.9-8
-------
required comments minimize the need to refer to the code
lists. Typical data values for operating parameters,
control equipment efficiencies, and other source information
are shown on the form (or in the text) only to serve as
quick, approximate checks of data submitted by the plant in
a permit application or similar report. Da :a entered in
EIA/P&R and NEDS must be acutal values specific to and
reported by the plant, rather than typical values. Contact
the plant to validate or correct questionable data and to
obtain unreported information. See Part 1 of this manual
for general coding instructions.
The emission source labeled "storage" includes loading
on to piles, wind effects while the coal is stored, and
retrieval activities. Transfer operations that are not
included under unloading, storage, crushing, screening, and
loading are grouped under the emission source labeled "coal
transfer".
Emissions from coal unloading, raw coal storage,
crushing, coal transfer, and screening are usually not
controlled. Figures 8.9-2 through 8.9-6 illustrate the
standard NEDS forms for these five sources. Emission
factors for these sources have not yet been developed. When
a plant furnishes emissions data for these sources, code the
values given. Enter "Emission Estimates Given by Plant" in
the comments field on card 7. Where there is no control
8.9-9
-------
device or where water sprays are used, enter zeros in the
stack height and diameter fields, 77 in the temperature
field, and zeros in the common stack field. Enter appropriate
height in the plume height field. Where water sprays are
used, enter 061 or 062 as control equipment code. Identify
other equipment used to reduce emissions in the comments
field on card 6. For example, enter "stone ladders" where
these are used for transfer onto storage piles.
Thermal dryers are major sources of particulate emis-
sions in the wet process, and air tables in the dry process.
Figures 8.9-7 and 8.9-8 illustrate standard NEDS forms for
these sources. Note that a fluidized-bed dryer includes
primary cyclones as part of the equipment. Coal is the most
common fuel used for drying; oil is used rarely.
Emissions from the handling of cleaned coal are minimal
in the wet process because of relatively high surface
moisture content. Figures 8.9-9 and 8.9-10 illustrate the
standard NEDS forms for cleaned coal storage and loading,
respectively. The emission source labeled "cleaned coal
storage" includes loading on to piles, wind effects, and
retrieval activities.
8.9-10
-------
CODING EIS/P&R FORMS
The BEC's for use in EIS/P&R forms are:
Source Ul£
Unloading 70°
Raw coal storage no code*
Crushing rD°
Transfer 70°
Screening 575,577
Air tables 582
Thermal dryer
Fluidizcd bed 464
Flash 464
Multilouvered 464
Rotary 452
Cascade 464
Continuous carrier 464
Af.A
Screen ^D4
Cleaned coal storage no code*
Loading 70°
* As of .3 -nuary 1978.
8.9-11
-------
Figure 8.9-2. Standard NEDS form for coal cleaning - unloading.
oo
! ,J
Sffi
NAlliAAl I MISSIONS OAF A SYSHM IKE OS)
[NU'.O ."INTAt PHimCT(0*i
Of MCE IH AIR PROGRAMS
FORM AfPRGVf D
O»8 NO IbSRIX
ftffl
JITTTITI
1-ANTHRACITE-
2-BITUMINOUS
Ulf.' ,MHIH"' Ii i.
ME
*4r^bM-' yU:
J3"
o|o|oToiotoTp_
onflo
Contact Pr -.on.il
fiVA'eO 1. >*1rIOL tf f lCl£(«CV (
r,,.^ H..T>^<
e i.uvr". ( .r.f •- • F". Mfj^^
';7Tu'";!T];-T-)r.,t77rj: r^rann;
ilTjli-ii&mSi
ffi
UNLOADING J.rjj3"|Sll
TUO
LU
nT't
tfflffii-
To
aft
tilt!
010
SQ6 UNIT - TONS COAL SHIPPED,, /
.4-4—-
,,.
:,ho
"F>
i
i
„
-,i
^
"
MW
1
, ^
t
1
J
-,«
'*
s
3
V
I
„
-,'J
.„
f i
U
tl
ss
M
I'
^
=i
;o
5
ji
;i
P
v
n
13
><
'i
;t
;;
«(
'i
oj
79 n
P 6
£ 6
P 6
P 6
? S
11 ">;
!-
iT7
-
S'l'e
-H
rf-
• i
F
1 1
rn
ti
fi
fi
SI
,S
filr
s;
M
ss
10
II
12
'J
.«
'i
It
''
<
,«
cd
u n
P 7
-------
Figure 8.9-3. Standard NEDS form for coal cleaning - raw coal storage.
CD
NAIIDNAl l MISSIONS OA1 A SYSUMlrUDS)
uMSNIAL PHOTfCMON AGtNCY
UiHCE (H AIR PROGRAMS
FOHM APPfiO^ f ':
OM6 NO IW RQO1S
1-ANTHRACITE
2-BITlimNOUS
11
-JT:! I ; i ' l-'^^-r-I-l [•''.'!-•!>-\>^\*].T:.pT:!Tj."t.ni''
mM±^
RAW COAL STORAGE : i :3|o]_5
'r-i-l •-
- T ¥
I+H4
otoli
SCt UNIT - TONS COAL SHIPPED 4
-i-1
-1-4-!
4 f
..I :q ..
I" Jo
/EXAMPLE COMMENT
-
jK
±
4f
ft
i .'.
:r
-------
Figure 8.9-4. Standard NEDS form for coal cleaning - crushing.
00
vo
I
Bfi
NA1IUNAI EMISSIONS DATA SVSTEM (NEDS)
ENVinOiMMlNTAL PROTECTION AGENCY
OFFICE OF AIR PROGRAMS
1-ANTHRACITE
2-BITUMINOUS
0000 IF NO COMMON STACK
XXXX POINT I.D.'S IF COMMON STACK
CRUSHING
TJT
SCC,UNIT - TOHS COAL SHIPPED
>••
TirtxJ
«.,
.' 1'.
ft
tL
j
,
4]
0
1)
i
H
1}
0
1U
I',
'
M
"*'
1*
,-
;,
:i
n
•,1
j."
•j
it
'/t
i
j
r
;..
^
VJ
j-i#
tl
••\
..;
U
kl
Si
M
8'
ii
i',
n
s
1
^
••I
V
j
s
;?
;i
M
IS
;t
7;
|
4
7i
C4
19 HI
6
6
6
6
6
M \\
sr
,-,
';
Si
v
w
•^
SI
M
ti
(7
Si
M
ii
H
«;
H
M
10
/I
12
H
:i
;i
ik
;i
«
.1
cd
n •
P 7
P 7
P 1
P 7
-------
Figure 8.9-5. Standard NEDS form for col cleaning - coal transfer.
oo
VD
I
LTI
NATIONAL I MISSIONS DATA SYSftH (NCOS)
PROTECTION AGINCY
Of MCE Or AIR PROGRAMS
0000 IF NO COMMON STACK
XXXX POINT I.D.'S IF COMMON STACK
i4Uun:;^M.J44-Ti^^
so'UNIT -"TONS COAL SHIPPD,
TRANSFER MSMSOiro
F1"F]
1[J
i ""
r
- t
;0
-QJ
1"
l"T~ri
hP
LL
~j"[T;T
I
I
--
«rrni
n
h
3
4
3
4
H
-1
-J
4
hi
i!
nt>
f'
Jl
>i
.•i
^
.
I
/v
n
u
1 i
Ji
j,
5
's
e
-
p
P
d
±*
6
6
6
~T-01
...
bi
V-'
',3
«.;
-
i.
._
:,
^
-1
-
iG
S7
1
"1
71
;H|
-------
Figure 8.9-6. Standard NEDS form for coal cleaning - screening.
00
*
VD
I
"Ti
ft
MA1IUMAL EMISSIONS DAT A StSU* Wf OS)
ENVIRONMENTAL PROTECTION ACINCY
OFFICE OF AIR PROGRAMS
ffi
1-fcNTHRACITE-
2-BITUHINOUS
ffi
"a .if"
ffi
. J
(31(4 (Slit U
xOOOO IF NO COMMON STACK
POINT I.D.'S IF COMMON STACKljl
INIHOI £f f ICltlnCV (M
SCREENING I
ilM
J±t
T?!
7T-.I,.
'
UTSMiini
irrs
Bffi
ESTIMATION
UEThOt)
MM8
OlO
SCC UNIT - TONS COAL SHIPPED,
O. '•
^n.:
iH™±!4:
-H-:-f-
na:..
J-Hffi
:o
,i a c
5 1
1:i
3B1
—.-,
.-.-.
M
V
,-
, .
,
—
,.
r
<.)
iO
t.
y
fi
(4
•,s
K
h'
M
SI
ID
/I
72
(J
•4
I't
n
;i
<
it
*tt
n m
P 7
P 7
-------
iI-6'8
TV,E Of om«
FLUID BED
FLASH
"UlTI-
LOUVEHED
CONTINUOUS
CARPIEP
ftOTAUr
CASCADE
IPP i UMOHTIlOLlEO PA«T
COOC EKISSItWS l»/TO«
04 1 20
OS 1 16
06 2S
07 NOT AVAILABLE
OB < NOT AVAILABLE
09 j HOT AVAILABLE
o •-•
d -H
t/i m
LTH:
ffiOJS
_i"J,° [S
-
i__~i _ ^''
i : 1 T T | ~
—I—|—t—L—1.^,'
: ( : [ I .. i
TO
>-(
0)
CO
1-1
a.
o
in
i-n
O
O
o
o
M
(D
00
I
rt
fl>
ro
i-!
-------
Figure 8.9-8. Standard NEDS form for coal cleaning - air tables
CO
I
h-'
CO
NATIONAL EMISQIQSS DATA SYSTEM (MOS)
ENVIRON.V.FNTAL PROTECTION AGENCY
OFFICE OF AIR PROGRA.VS
POrV -.-Prc^ ED
'.>•<> NO 1 SB P',035
-UL
U
- I I , !
riiTJiiia^^
,,.0000 IF NO COMMON STACK
XXXX POINT I.O.'S IF COMMON STACK
1 - ANTHRACITE
2 - BITUMINOUS
! i ; j ,- - .. ! .- - i J-.-j^j- .,,'_> ' i i "' ' X AAAA rUlH I l.U.i It l,UTr*jn 3 I m.h |< ; ,^
o7o^ioTip{To^ 1 * ! ioiTioi io;
_ _ __
JSCCSHT- TONS COAL SHIPPED
AIR TABLES
:.y:.. ..;. _:., L -_. ,•._.: T:_: :,_;'.. 4.
— H'O-i^nKLi:!! : ;_; . - i Ij_: f i--f-[-p
---;— . -r — »- j- r -( - - — t— pl-r-^| T— j- '
;;.L". -:-!-,, ;-.-,-!
"PH fi — — :^ — L ;" -T-r
. l i_: >.^_: :_„. . : _ •„. __l
_ ^____^_ , _
TrTT"1 ''-•":' ;i"rr' T';l'"T~.Tr:r.'F:rnT,-T T'^TTT^"rVi--R" ;1, .-. j
^^
' ' I I ' , ^ . L_ 4—_i. ^— -. , . ^—i J 1 i 1 - f —--•» • • * ..- ..-j
TITnn ; • iTt.LLi.Lii.i.Tj_£niij-Lj_!-i-iL:
-------
CO
Ficiure 8.9-3. Standard -.IEDS form for coal cleaning - cleaned coal storage.
if
MftllDNAl I MISSIONS OATASYSTlMINf OS)
CNvmUhiMlNIAl PROTf CTION AGENCY
OFFICt Of AIR PROGRAMS
KJIWT ioum:c
IIHM.I Fo«m
FORM APPWOVt o
OMNO IMH009S
efflff
l-ANTHRACITE-
2-BITUMINOUS
S1.V> K UAL-
'i-^'-U '••••"•• "•
jl ;i] >:T4lt"M»I"l<»
±t±i±i±
-,.
1Jl>l.
r
3H3
i;l73l)4l;i
ESI.V*' -0 • .WilOL tf HCiENCV IM
CO
CLEANED COAL STORAGE
3J01
01
±1±
nT't
_ i
J [_J l__L -J 1 —L--L ' i "*-* >—-—
"SCGlWIT - TONS COAL SHIPPED
IMS!
COMHOL
7ti '•
i :
144
j .iJlLLi
U 15
n
t>
,,
lalTI-l
0
•J
1
K-
ili;
1
'jJTV
!
• r
.
,
s
-
--V
i
vt
,\
1>
i)
k4
Si
oi
s;
M
»'!
;a
»
f
;i
f
3
,'?
/j
'4
">
rt
r;
c
(»
c
/D
'
'
p
itti'|'iMiHl"il"l';l"l'4l7>T'^ —
-------
Figure 8.9-10. Standard NEDS form for coal cleaning - loading.
00
I
NJ
O
NATIONAL EMISSIONS DATA SYSTEM (NCOS)
ENVIRONMENTAL PROTE CriON ACENCY
OFFICE OF AIR PROGRAMS
SCC,UNIT - TONS COAL SHIPPED
LOAD1K6 .. II
315
50
n
xt
.Ll
...
ii
1.,
.
41
0
-
1J
<
tl
1)
0
n
r« -
i;
v-
la
,'"
:i
;j
n
-,,
i,"
•j
ti
;«
•*
i'
u
i!
V»
a
-•i
.1
a
u
Sb
M
C
ii
»'l
;o
c
M
P
^
^
;?
;a
M
'S
71
n
4
;s
;j
cd
n
6
b
b
6
6
•M il
S?
SI
'*
S-.
V
S!
''d
•,)
in
«i
u
«i
(4
«
«
s;
H
H
re
/!
71
7J
,'4
Ji
K
;;
^
;i
cd
75 n
P 7
P 7
P I
,P 7
-------
GLOSSARY
Air table - A device that uses a pulsating air column to
separate coal from reject material.
Cleaning circuit - The equipment that separates impurities
from coal.
Coal cleaning - All operations involved in removing impuri-
ties from coal.
Dry coal cleaning - Use of air to separate impurities from
coal.
Grizzly - A device used to remove large fragments of rock
and other materials from coal. This is a form of a
scalping screen, except, that it consists of a series
of heavy steel bars spaced parallel to each other.
Hematite - A mineral Fe203 constituting an important iron
ore and occuring in crystals or in a red earthy form.
Hematite is mixed with water to produce mixtures having
different specific gravities for use in a wet washing
plant.
Scalping screen - Used to remove large rock, slate, timbers,
etc. , from coal; the scalper consists of heavy wire
screen with large openings that permit the coal pieces
to drop to another series of screens for segregation.
Stacking conveyor - A belt conveyor that discharges at the
storage pile. Use of conveyors that use and fall with
the storage pile reduces the distance that the coal
must drop.
Stone ladder - A fixed, rectangular column with a series of
steps inside that allow the falling material to cascade
in short drops. As the storage pile increases, the
coal discharges through ports in the sides of the
column and emissions are reduced.
Telescoping chute - A column that can be raised or lowered
to maintain a constant distance between the coal being
discharged and the top of the storage pile.
Wet coal cleaning - Use of liquids of varying specific
densities to separate impurities from coal.
8.9-21
-------
REFERENCES FOR SECTION 8.9
1. Keystone Coal Industry Manual. New York. McGraw -
Hill, Inc. 1975.
2. Coal Preparation. Leonard, J.W., and D.R. Mitchell.
(ed.). New York. The American Institute of Mining,
Metallurgical, and Petroleum Engineers, Inc. 1968.
3. Background Information for Standards of Performance:
Coal Preparation Plants. Vol. 1: Proposed Standards.
Environmental Protection Agency, Research Triangle
Park, North Carolina. Research Triangle Park, EPA
450/2-74-0219. October 1974.
4. Compilation of Air Pollutant Emission Factors, Second
Edition. Environmental Protection Agency, Research
Triangle Park, North Carolina. AP-42. February 1976.
5. Aeros Manual Series Volume II: Aeros User's Manual.
U.S. Environmental Protection Agency, Research Triangle
Park, North Carolina. Publication No. EPA-450/2-76-029
(OAQPS No. 1.2-039). December 1976.
6. Aeros Manual Series Volume V: Aeros Manual of Codes.
U.S. Environmental Protection Agency, Research Triangle
Park, North Carolina. Publication No. EPA-450/2-76-005
9OAQPS No. 1.2-042). April 1976.
7. Standard Industrial Classification Manual, 1972 Edition.
Prepared by Office of Management and Budget. Available
from Superintendent of Documents, Washington, D.C.
8. Loquercio, P. and W.J. Stanley. Air Pollution Manual
of Coding. U.S. Department of Health, Education and
Welfare. Public Health Service Publication No. 1956.
1968.
8.9-22
-------
8.15 LIME MANUFACTURING
PROCESS DESCRIPTION1"4
The manufacture of lime involves the calcining of limestone
(CaCO-. or CaCO 'MgCO_) to release carbon die
-------
UGEHD:
£} OHSSIOH FACTOR*
eEMISSIOII FACTOR HOT DEVaOPED
FOR THIS PROCES.
009 (66.0) DENOTES COKTROl EQUIP.
I CODE WITH EST. EFF. SHOWN
f IM)
\ DENOTES FUGITIVE
/ EMISSIONS
o
DENOTES A STACK
PHOOBCT TWWSFER
(WO CONVEYING
COimOL FWRIC
DEVICE
f PART0
FILTER 018 (99)
* IK POUNDS PER SCC UNIT
3-05-016-07
RAW MATERIAL
TRANSFER AND
CONVEYING
PART0
3-05-016-03
CALCINING-
VERTICAL KILN
RAH
MATERIAL.
3-05-016-02
SECONDARY
CRUSHING/
SCREENING
9
MET SCRUBBER 001 (95-99)
FABRIC FILTER 017 (99)
ESP 010 (95)
GRAVITY COLLECTOR 000 (<80)
CENTRIFUGAL COLLECTOR 009 (<80)
FABRIC FILTER
018 (99)
jPAJtrQ 4 PARj Q
FABRIC FILTER
018 (99)
CaO
'PART
3-90-OOX-99
IN-PROCESS FUEL
4-OIL
6-NATURAL GAS
VERTICAL
ROTARY
3-05-016-10
RAW MATERIAL
STORAGE PILES
. QUICKL
FABRIC FILTER 017 (99)
CYCLONE 008 (90-95)
WET SCRUBBER 002 (80-95)
CALCININ6-
ROTARY KILN
3-90-OOX-99
IN-PROCESS FUEL
2-COAl
4-01L
6-NATURAL GAS
3-05-016-14
PACKING/
SHIPPING
FABRIC
FILTER 018 (99
DOLOm
PRESSU
HYDRAT
LIME
9 9
FABRIC
9
HIGH CALCIUM QUICKLIME
MO DOLOWTIC QUICKLIME
Figure 8.15-1. Lime Manufacture
SPRAYS
WET SCRUBBERS
FABRIC
FILTER 018 (99)
HIGH C
AND 00
HYDRAT
-------
secondary crushers and screens reduce the stone to the desired
feed size for the calcining kilns.
In the United States, limestone is calcined in either verti-
cal or rotary kilns. The limestone feed size for most vertical
kilns is 6 to 8 inches; consequently, only primary crushing is
required. However, some vertical kilns need a smaller feed size
of 3 to 5 inches. Material for these kilns must undergo second-
ary crushing Rotary kilns, which are the most prevalent kilns
in use, also need the smaller feed size.
Vertical kilns, which are fueled by oil or natural gas, have
four distinct zones from top to bottom: stone storage zone,
preheating zone, calcining zone, and cooling and discharge zone.
The flow of stone in the kiln is countercurrent to the flow of
cooling air and combustion gases. The stone is charged at the
top and preheated by the hot exhaust gases from the calcining
zone. Air blown into the bottom of the kiln cools the lime
before it is discharged. This air is heated sufficiently by the
time it reaches the calcining zone to be used as secondary com-
bustion air. The lime is discharged to cars on tracks or to
conveyor belts, and either prepared for shipping or further
processed by hydration.
The rotary kiln, which is supported by rollers, is a long
inclined horizontal steel cylinder lined with refractory brick.
Most rotary kilns rotate at a speed of about 1 rpm. The lime-
stone flows countercurrent to the heat, the pebble-size limestone
entering at one end and the hot gases entering at the other.
8.15-3
-------
Rotary kilns have three distinct zones: the feed and drying
zone, the central or preheating zone, and the calcining zone.
Rotary kilns are fueled with coal, oil, or natural gas. Product
coolers are commonly used after the kiln to recover heat from the
calcined lime.
In both vertical and rotary kilns, the temperature in the
feed end is kept below 1000°F, and the temperatures in the pre-
heating and calcining zones are between 2000° and 2400°F; higher
temperatures are found in shorter kilns. At these temperatures,
limestone dissociates to quicklime and carbon dioxide.
CaC03 + CaO + C02
Most of the calcined lime or quicklime is screened, milled,
and transferred pneumatically or by conveyor to storage silos,
where it is kept until it is shipped. Fines from calcination can
be briquetted, fed to a hydrator, or pulverized, as the market
demands.
About 10 percent of all the lime produced is converted to
hydrated (slaked) lime.
CaO + H20 + Ca(OH)2
In the hydration process, water is added to crushed or ground
quicklime in a mixing chamber (hydrator). The slaked lime is
dried by the heat of the hydration reaction, and is conveyed to
an air separator in preparation for final shipment. Dolomitic
pressure-hydrated lime has an additional milling step prior to
shipment. Atmospheric hydrators are operated continuously;
pressure hydrators are operated in a batch mode.
8.15-4
-------
For shipping, the quicklime and hydrated lime products are
packaged in bags and handled in bulk by truck, rail, ship, or
barge.
Lime manufacturing plants have capacities between 50 and 650
tons per day. Plants usually operate 24 hours per day for 6 or 7
days a week. Stack heights for lime plants range from 250 to 400
feet.
EMISSIONS1""3'5
Particulate is the major pollutant from lime plants, espe-
cially from the calcining kiln. Emission sources are identified
in Figure 8.15-1. For some of the sources, AP-42 provides emis-
sion factors, which are listed on the process flow diagram. For
other sources, average emission rates obtained from other docu-
ments are mentioned in the discussion that follows.
Particulate emissions arise during raw material unloading,
open storage piles, crushing, screening, and conveying and
transfer operations. All of these operations, unless confined,
are fugitive emission sources. Emissions from raw material un-
loading range from 0.03 to 0.4 Ib/ton; from raw material storage
piles, 3.0 to 5.0 Ib/ton (includes loading onto pile, vehicular
traffic, loading out, and wind erosion); from primary crushing,
about 0.5 Ib/ton; from secondary crushing and screening, about
1.5 Ib/ton; from raw material conveying and transfer operations,
0.8 Ib/ton; and from packaging and shipping of quicklime and hy-
drated lime products by truck, rail, ship, or barge, 0.25 lb/
ton.
8.15-5
-------
The major source of particulate emissions in lime manu-
facture is the calcining kiln. Emissions vary with kiln type and
composition of limestone burned. Rotary kilns emit considerably
more particulates than do vertical kilns because the charge
material is smaller, the rate of fuel consumption is higher, and
air velocity through the kiln chamber is greater. The in-process
fuel also emits sulfur oxides and small amounts of nitrogen
oxides and carbon monoxide.
Product coolers following the rotary kiln are emission
sources only when some of their exhaust gases are not recycled
through the kiln as combustion air. Current practice is against
the venting of product cooler exhaust, however, because recycling
makes better use of the fuel. Cyclones, baghouses, and wet
scrubbers have been used to control particulates from coolers.
Emissions from milling and screening the calcined material are
minor because the operations are enclosed.
Few particulates are emitted during hydration, because water
sprays or wet scrubbers are usually installed to prevent the loss
of product in the exhaust gases. Emissions from pressure hy-
drators may be greater than from the more common atmospheric
type; control is more difficult in pressure hydrators because the
exhaust gases are released intermittently over short time inter-
vals. Particulate emissions from pressure hydrators after wet
scrubbers are about 2 Ib/ton of hydrate produced. Emissions
froir atmospheric hydrators after wet scrubbers are about 0.1
Ib/ton of hydrate produced.
8.15-6
-------
Minor amounts of particulates are emitted from the air
separator following the hydrator and the milling operation fol-
lowing the pressure hydrator because the processes are enclosed.
Some particulates are entrained in the lime silo ventilation.
Additional particulate emissions are generated during the packing
and shipping operations, and product transfer and conveying.
CONTROL PRACTICES
Emissions from unloading are generally not controlled.
Building enclosures may be used to reduce emissions. Liquid
sprays are also sometimes used to suppress emissions during un-
loading. Occasionally, the unloading area is vented to a bag-
house.
The limestone is nearly always stored in stockpiles, a
source of fugitive particulate emissions, but in some cases it
may be stored in silos. Liquid spraying of the material before
discharge onto the storage pile is often practiced to reduce the
emission potential. Telescoping chutes, adjustable stacker con-
veyors, and stone ladders are possible ways to reduce emissions
from loading onto the raw material storage piles. All of these
devices reduce the free-fall distance and, hence, the fugitive
emissions.
Emissions from conveying are minimal, but the belts are
sometimes partly covered to reduce any emissions that occur.
Emissions caused by transfer of materials from one conveyor belt
to another are most often controlled by enclosures or water
.15-7
-------
sprays, with an increasing trend toward control by venting the
transfer point to a baghouse.
Primary crushers and secondary crushers and screens are
often located below grade; this reduces the impact of the emis-
sions. Suppression of dusts by water sprays at the feed points
of these operations is very common. Emissions from primary
crushers are sometimes controlled by wet scrubbers or fabric
filters. An increasing number of plants are venting the dis-
charge points of secondary crushing and screening to a fabric
filter.
Emissions from kilns are controlled in most plants by pri-
mary collectors, consisting of centrifugal or gravity collectors,
which have,efficiencies between 25 and 80 percent (70 percent
average). These collectors are usually followed by secondary
collectors, such as wet scrubbers (95 to 99 percent efficient);
electrostatic precipitators (95 percent efficient); or fabric
filters (99 percent efficient).
Nitrogen oxides, carbon monoxide, and sulfur oxides are all
formed in the kilns, but the last is the only gaseous pollutant
emitted in significant quantities. Not all of the sulfur in the
kiln fuel is emitted as sulfur oxides because some fraction
reacts with the materials in the kiln. Sulfur oxide emissions
may be incidentally reduced by the various equipment used for
secondary particulate control; otherwise, gaseous emissions are
uncontrolled.
8.15-8
-------
Some or all of the exhaust from the product cooler is re-
cycled to the kiln as combustion air. The portion that is not
recycled is typically controlled by a fabric filter, cyclone, or
wet scrubber.
Emissions from the atmospheric or pressure hydrator are re-
duced by water sprays or wet scrubbers. The emission rates after
control are 2 Ib/ton and 0.1 Ib/ton of lime produced, respec-
tively.
Particulates entrained in the air displaced during loading
of the silos are retained by fabric socks on the vents. In
pneumatic systems the lime silo transport air is often exhausted
through a fabric filter.
During packaging and processing for bulk shipment, the
emissions that arise are frequently controlled by aspiration
through fabric filters. Many lime plants are using a gravity-
feed fill spout mechanism that has outer concentric aspiration
ducts to vent the dust to a fabric filter. This device has been
markedly successful in reducing emissions during packing and
shipping.
Transfer and conveying of the finished quicklime and slaked
lime can be a considerable fugitive emission problem if these
sources are not properly enclosed and exhausted. Nearly all
plants completely enclose the conveyor systems, which are most
often belt-type, and many of them also enclose transfer points
and exhaust the emissions to fabric filters.
8.15-9
-------
CODING NEDS FORMS1'8"10
The emissions sources associated with lime manufacturing
are:
Source
Raw material unloading
Raw material storage piles
Primary crushing
Primary screening
SCC
3-05-016-08
3-05-016-10
3-05-016-01
3-05-016-16
Secondary crushing/screening 3-05-016-02
3-05-016-07
Raw material transfer and
conveying
Calcining, vertical kiln
In-process fuel
Calcining, rotary kiln
In-process fuel
Product cooler
Hydrator (atmospheric)
Pressure hydrator
Lime silos
Packing/shipping
Product transfer and
conveying
3-05-016-03
3-90-OOX-99
3-05-016-04
3-90-OOX-99
3-05-016-11
3-05-016-09
3-05-016-12
3-05-016-13
3-05-016-14
3-05-016-15
Pollutant(s)
Particulates
Particulates
Particulates
Particulates
Particulates
Particulates
Particulates, com-
bustion products
Particulates, com-
bustion products
Particulates
Particulates
Particulates
Particulates
Particulates
Particulates
Standard NEDS forms for each of the sources, Figures 8.15-2
through 8.15-15, show entries for the SCC's and other codes.
Entries in the data fields give information common to lime manu-
factaring plants. Information pertinent to coding the source is
entered on the margins of the forms and above or below applicable
8.15-10
-------
data fields. Entries for control equipment codes, other optional
codes, emission factors, and required comments minimize the need
to refer to the code lists.
Typical data values for operating parameters, control equip-
ment efficiencies, and other source information are shown on the
form (or in the text) only to aid in quick, approximate checks of
data submitted by the plant in a permit application or similar
report. Data -ntered in EIS/P&R and NEDS muc. c be actual values
specific to and reported by the plant, rather than typical values.
Contact the plant to validate or correct questionable data and to
obtain unreported information. See Part 1 of this manual for
general coding instructions.
The emission source labeled "raw material unloading" in-
cludes emissions released when raw materials that have been
previously sized are received from truck, ship, barge, or rail.
Raw materials that must be crushed and screened are unloaded
directly into primary crusher hoppers; emissions from unloading
this unsized material are included in primary crusher emissions.
There is no emission factor developed for primary screening.
The emission factor assigned to secondary crushing/screening
includes emissions from both operations.
The emission source labeled "raw material storage piles"
includes loading onto piles, wind effects while the materials are
stored, and retrieval activities. Raw material transfer opera-
tions that are not included under unloading, storage piles,
primary crushing, primary screening, and secondary crushing and
8.15-11
-------
screening are grouped under the emission source labeled "raw
material transfer and conveying." Figures 8.15-2 through 8.15-7
illustrate the standard NEDS forms for these six sources. When
a plant furnishes emissions data for these sources, code the
values given. Enter "Emission estimates given by plant" in the
comments field on Card 7. Where there is no control device or
where water sprays are used, enter zeros in the stack height and
diameter fields, 77 in the temperature field, and zeros in the
common stack field. Enter appropriate height in the plume height
field. Where water sprays are used, enter 061 or 062 as a con-
trol equipment code. In the comments field on Card 6 identify
other equipment used to reduce emissions. For example, enter
"stone ladders" where these are used during loading onto raw
material storage piles.
Figure 8.15-8 shows the standard NEDS form for calcining
with the vertical kiln. The in-process fuel is either oil or
natural gas.
Figure 8.15-9 shows the standard NEDS form for calcining
with the rotary kiln. The in-process fuel may be coal, oil, or
natural gas. AP-421 provides emission factors for control for
primary, and for secondary particulate control. These numbers
serve as guides; actual plant values must be entered. Secondary
particulate controls such as venturi scrubbers may reduce sulfur
oxides as well. When this is the case, also enter the scrubber
as a secondary S02 control device using 053 as the control device
code.
8.15-12
-------
The standard NEDS form for the product cooler used after the
rotary kiln is shown in Figure 8.15-10. The emission factor from
AP-42 and the control device apply only when the cooler gas is
not completely recycled back to the rotary kiln. The coder must
determine whether or not this is the case.
Atmospheric and pressure hydrator emissions are reduced by
water sprays or wet scrubbers; Figures 8.15-11 and 8.15-12 show
standard NELo forms for these sources.
Particulate emissions from lime silo ventilation air and
packing/shipping are generally vented to fabric filters. Product
transfer and conveying include all emissions from pneumatic or
mechanical (conveyor) transport of the lime from the kiln through
the packing/shipping operation. These emissions are also usually
controlled by venting to a fabric filter. See Figures 8.15-13,
8.15-14, and 8.15-15 for standard NEDS forms for these sources.
8.15-13
-------
CODING EIS/P&R FORMS
The BEC's for use in the EIS/P&R forms are:
Source BEC
Raw material unloading 712
Raw material storage piles 700
Primary crushing 650
Primary screening 575
Secondary crushing/screening 650, 575
Raw material transfer and conveying 700
Calcining, vertical kiln 229
Calcining, rotary kiln 229
Product cooler 330
Hydrator (atmospheric) No code*
Pressure hydrator No code*
Lime silos 730
Packing/shipping 711, 712
Product transfer and conveying 700
As of November 1978.
8.15-14
-------
Figure 8.15-2. Standard NEDS form for lime manufacturing - raw material unloading.
00
Ul
I
e ,
'!•'
1
i
4
11
">
1
il'l.
1 1
n
i
pi >• .
,,|.
1
NATIONAL fMISSIONS DATA SYSHM INFOS)
ENVIRONMLNlftL PROTfCTION AGLNCY
IHFICE OF AIR PROGRAMS
l_
Sn
i«|nr?(l:i
•ii1:?lV)Ti,liU>Uo
I I I i I
iYp.pTq^jlTH
iitiit
STAO' DA ! fl
I
T ..!.,. !''! ' I '. „ » ... I'll ,-,,.,! •! ^ , HJ
J443
oiol oTF
oioioioo
ofoTo"o1oTo~
6l|Sb
iS H
.0000 IF NO COMMON STACK
XXXX POINT ID'S IF COMMON STACK
•7 S» S»
(
I;,
1.0
a
0
3 •-
5;
0
0
f 1'
•Jin
1
•,;
;,
w|-.,
10
•4..
..M.,
I io
t:
MC
S)
SJ
k°
i!
ri
4.,U-
lo
sjj,.,!«
! 1
;i
a
n
14
:s
'i
q
.'S
7}
p
Cff
sr
j
, tillVi ttS ,
I C5TIMA II,IN
VEIHOL.
i-jiiIi;jM7n!'jn. ,:' >!
j. l±mfci:
,1 . .
RAW MATERIAL UNLOADINGJ i \3
... „. SCC UNIT - TONS PROCESSED
1
,.j,T|i s,r^.i
1 I ! lo!
Of>tHt
«hi
1
,«Ll
!t|\l
•oPni-Vi"
>.•!
Siliv
1
n\.
a
'"• L"'
.iliii.
! !
COf'THOL MtGULATlONS
M,, 1
11
•»
bl
»J
*"r L /
05
70
71
1!
He.) J
73
;4
:s
c
4
* I
i1" '
f J
P
>.
^»
1 ! !
.1 i.L 1 I
,
Ul-i-
Ti.
"1 - N I-
.LiilJ.
l±lJ
j m±Ltm-i:
- J-"). r^i,;,.;;,
' . ' ' ; . i i
ss U
t_ _^_
dtrilr
ii , ' ' i ii( , s t I
J Li iJiL -J L. Li i. nrrmjj±m±LL ,1:1
-------
Figure 8.15-3. Standard NEDS form for lime manufacturing - raw material storage piles.
Ti; irrrvrr vi > i > i«i_i.
f MISSIONS DATA SYS I EM (Nf US)
MLNI Al PHOTfCTlUN AGENCY
OFFICE OF AlBPnOGRAMS
Input
fCI>M AITI- . i
O"8 SO IV( H.o
DJU_
oo
L.
312171*13
CO'JHin-\ATt I
STACK. OAlfl
T •"
if 7i]!4!"i'Ji7'!7ln|n wI«iTi,T)i" « iijiJi/Tii'
.-fi" rr m-JTrrrl~rr r
X
r ^
•OTsTfTT..
00
Ct ii
V. i» M
oToioro
j '.'ONIHOL EFUC'Er.CV IM
U 14
. I ,|PVAHS Ifuni
ffltfiffilffi
i_, ' I .>-«'. t f 'IS ...
•ffiffi!
RAW MATERIAL STORAGE PILES J ;3
on 16
t t
i|.si..i,Tirijrn i; .'rijjjwnTrisnTni jii44'i!iv]»>r«iTi\ Hi^r^rmMhiii: sj •,;f;s'stn
-|J IJJ iomiJ rioLLl |-trlg|-m 11 roll111-
SCC UNIT - TONS PROCESSED
COMfi if. .,C
^r«ius
tjfOAl f
iiTTV tilt i'»? 1
LSTIMAl <,)
MET MOO
.* -
J.
rrli .
-t - T' T-|
4
PJ-
o.
.11 r
ttt
•I4
1
i-
1
Jj
1
J
VI
u
in.
n
(.1
:,j
M
IS
o»
(.)
Si
>S
;o
2
C
;i
(*
j
1
>-•
il
n
•j
j^
:.
r
<
'$
75
»
P
P
»
p
, i
i.
6
6
•^
5
6
-------
Figure 8.15-4. Standard NEDS form for lime manufacturing - primary crushing.
oo
t-1
t_n
r>t*l*,
1 _?
Coun.y
1
1
s
I
AOCH
I
1
1
N"
1C 11
ID
f
C,
"I-
NATIONAL EMISSIONS DATA SYSTEM (NEDS)
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF AIR PROGRAMS
PRIMARY CRUSHING
0000 IF NO COMMON STACK
POINT ID'S
i : i ! i , I ' i *~^~"~7"'
-------
Figure 8.15-5. Standard NEDS form for lime manufacturing - primary screening.
oo
I
M
00
Si.i.
'!•
1
Cou"'»
1
1
•
(
AOCfl
7
1
9
n.-i 10
Ntimh«»
10
11
17 1)
ng
NATIONAL EMISSIONS DATA SYSTEM (NEDS)
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF AIR PROGRAMS
POINT SOURCE
tnoul form
FORV »»»«ci. E:
ovt NC ;K "cess
Datt _^__^_^__
Namp o' Pf ion
Comnlftinq FOM
PRIMARY SCREENING
0000 IF NO COMMON STACK
UTM COORDINATES
XXXX POINT ID'S IF COMMON STACK [S'_
Flaw Rat* (fi^/m-n) "
«4|IST<5 » ') « 501 51 52
ESTIMATED CONTROL EFf ICIENCV (M
SANNUAL THBUPU1
iTTirinM« is K j:
Ol i i i ;'*!••
ALLOWABLE EMISSIONS lioni/vftll
CONTROL REOULATICSS
it 4,- U II M SI 5!
A-nUJ,SCC UNIT - TONS PROCESSED
Furl P'tx-'U '"-
I i I ' •'!«;
I I I ! *l«
-------
Figure 3.15-6. Standard NEDS form for lime manufacturing - secondary crushing/screening.
CD
(Jl
I
i i
&
NATIONAL EMISSIONS DATA SYSTEM INEOSI
ENVIIIONMENIAI PROHCIION AGENCY
orncEOF
OMtNO
O..t
vcl'f
•.nf-RW
— 1 _r\ J -.* * -.
3121 71 if 2
KIM i r-'".ti,jt*,A 11 s
-.r-l •-.:•'
Bfflf
TfllsTiil Spl r.p^.^il i 'M«Ri;i PT5R«Ui'
-fr| TTi"i 11 ' ri" 1 'rixril
fcf
018 >
?.
.-.[••I ,
rr
*. *•*, .I'AI t *•!'». I-
i1"t:n"
ooiooio
CPM'ATINC
oboo
dloloroio
QlO
iuiily.
,0000 IF NO COMMON STACK
XXXX POINT ID'S IF COMMON
sM-^Mlv^'lul"!"!"^!"-!'''-!*'
-tWrri I I 1 1 tr
99
NO. I MC
US IB/TON
uTiL nli« ."iT:; ;; ::
SECONDARY
atUSHlK/SCKCNINC
sec
105
J.6
L'lVCl •*.»!(.£
SI..IUS
til)
f * Ti*.-.*ttON
MITMOO
ojoTo
CONtKOl KIGUIATIONS
"M > I »•• 1
ulu
l,.i
1
UNIW.JONS PROCESSED
S..IIIIM.II
<* >•!
:',',
I
-
\t
I
-
n
)(
--
,t
1
•n
-
7;
-
,"
Q
-
7,
-
^
,,
-
•'
.
,
A
•
i,
-
__,
*
it f
• s
,;
-
~
"".
,,
.,..
,i
^
a
.i(
-
v-
-
.,
-
.,
~
H
\;
• |
(
is
1
0-
13
HIM
n
*ll
U
u
(1
IV
u
1'
-
','
—
11
_
10
•"
1
p
)
•'•'
II
;i
H
1!
i
4
1
C0
« u
_ •
«
r t
•
<
iT^TT
-------
Figure 8.15-7. Standard NEDS form for lime manufacturing - raw material transfer and conveying.
FQHM APf'f- ,j . CT
OMB NO !bd
00
U1
I
NATIONAL EMISSIONS OATASVSHM INtOS)
ENVIRONMENTAL PHOUCTION AGENCY
OfFICE OF AIR PROGRAMS
COVPl tfcf.
^ SCHf-UULt I &TAIUS
UPOA't
. -. SCC UNIT - TONS PROCESSED
RAW MATERIAL TRANSFER ..
AND CONVEYING I.]
-------
Figure 8.15-8. Standard NEDS form for lime manufacturing -
calcining, vertical kiln in-process fuel.
CO
NAlllKJAl IMISSIONS DATA SYSrtM {N( US)
ENVIROHMLN1AL PHOTfCTION AGENCY
OFFICE OF AIRPnOCRAMS
FO»f/ At'l'l-u 'I l,
OMB NO tStt MOQ9*>
o o o> o>
oo co r
V V "">
o o o o o
o
S3
ee. LU
o —i
I— _i
o o
UJ O O£
_J DC LU
=> ^
u. a
I— m a-
LU < l^
L_
lillt
3217
3HS
riliili'Ti.Ti'TnTH
it I I I i
STACK DAIS
T.,,,,. :''i <
ti (i. i; Ml 'i
•- AN\UAI
':l L.L.
oj olo
lQ tot Q
,0000 IF NO COMMON STACK
XXXX POINT ID'S IF COMMON STACK
'/o TLij 'ION THOL fcfFIClENCV (%(
HC
8 lb/ton
as
CALCINING, VERTICAL KILN I
IN-PROCESS FUEL ;.\'~
JXL
'X'9
-—
rT— -
fl '.ilbl U'|»i'
L'c •.
rot
tST'M41l.1N
METMCIj
UU3
COMHOL PECULATIONS
"..,r..,"scc UNIT - TONS "PROCESSED FOR FUEL: 1000 GALLONS FOR OIL-, 10 FT FOR GAS
^¥
',];:[:;
\-\-
. ,_t ..
..LI .
:i;:F
-U
:iT
li
ri.-p-
r
llj
i>
--
i'.;iii
I
•4
-j
0.
'"'
1
.,
-•
ko
;
•'
i
..i.
• •
i
L
i
4-OIL; 6-NATURAL GAS
r ' L L i i i_
i.j ititt±axi±:
L
11
J..
Li.
IL
-------
ZZ-ST'8
O O
O -I
CONTROL DEVICE
GRAVITY COLLECTOR
CENTRIFUGAL COLLECTOR
WET SCRUBBER
FABRIC FILTER
ESP
CODE
006
009
001
017
010
EFFIC.
<80
<80
95-99
99
95
n
pi
(SO
H
O
rf
ft)
09
C
OO
t_n
I
VD
rt
ft)
ft)
i-t
W
3
o
I
>d
H
o
o
(D
HI
(D
O
i-i
H-
m
§
HI
ft)
o
rf
C
H
-------
HI
H
O
O
CJ
o
p.
I
00
(4-1
3
C/5
O
o
r-l
I
' r-l
•
oo
0)
oo
96 01 08
S6 01 08
66
'3IJJ3
ZOO
800
no
3000
aaaamjos JJM
3N01DA3
aanu oiaavj
3DIA30 10M1N03
8.15-23
-------
Figure 8.15-11. Standard NEDS form for lime manufacturing - hydrator (atmospheric).
CO
Ul
I
NATIONAL EMISSIONS DATA SYSTEM (NEDS)
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF AIR PROGRAMS
" iii"l'MnI:tl''"hh!n!-'i
xiipnmxt
i j-
i i j i j i.JOipiOjO
_o:i—--••'--•7
s i ^" i '•'" :"— i S'i- i
1 A'W •
iiTT
,0000 IF NO COMMON STACK
N STACK K ,-_,]
-t_
-L-L -i- LI j^LLj_Lj.-L.j_Lj_i_L_L±njLn i~1ii±
., .-
!^:cj=i^a:^ ^ i^o
LLLi;L:r.i:i:;::z:iX:Xrm-r[njXiiTi.!
,_. _ j. j _^ j_ 4.?: i___Ljjj
HYDRATOR
ri-r-hi-l-i-H-i-iH-i-i-rt-i i-M^-lt'J-:i;i±jrfttlifflti:jT j-i7t!:id^H±S:^
-------
Figure 8.15-12. Standard NEDS form for lime manufacturing - pressure hydrator.
oo
Ul
I
N>
Ul
NATIONAL fMISSIONS DATA SYSTLM (NEDS)
ENVIRONMENT AL PROTf CTIUN AGENCY
OFFICE OF AIRPnOCnAMS
mi',! , ,uf't C
tfioul Fnim
QM8 NO
0*ie
E
L-
;i :i .'i :s
3|2|7
I < •!*•»•
I llUJ'iH
UTM COOHOtNATi ^
:ii)o[.M
itc
S
STACK. DA I A
gg
in mi- M,..f)hi
H-'vi tl/t- '(
«)*™
{,? (3 6l|SS 46 6) U 69 ;o 71 12 13
'5 7i );
.0000 IF NO COMMON STACK
XXXX POINT ID'S IF COMMON STACK
tf FICHNCV t-,>
2 Ib/ton
. tSUMATf S (mni.v
PRESSURE HYDRATOR
i i '
.
5L5
Ul
s , i .pTJTT"'""^'!
!!!!l--.):ti:
L!±rirrtn±Ll±te
MM
»d ''I^fTTRhi
±n±t
~T;—T~T~TI~
34Hf£
SCC UNIT - TONS HYDRATED LIME PRODUCED
siTvi tslii
LSTtMA TJO
M6TMOU
O O t-» O
S ^ -, u
COI.IHOL HtC
Hf I I hf. t
U l- 4-4 -
.t.1.1- U-
JJITLII
Iflfflf^
-i-Hi-j
1:1 ft
:::t- -
I...1.
1.1-J
-r-»-
,.}'<]»
"i fi l-t-l-l i-H-f
:_L±t±tJxrJ±l:
i i i i Ill.
,
i ''
'" 1
i
, ',
•••
f,v.
,,..
-1
i
. .1 .
\
~
"lit
"I'l }
^ a i ,J .
1,
c.
—
•_i
—
~
-
11
-
—
-
—
—
-
t '.
—
_,
S
,.,:,
i
-
-
N
—
'"[
_ t
_l_
i
.
i
'I"
L
-(•'
!
t'
-i
_ i __
I
i._
,-j.
— -(-
_[.,
i
».•
~
nTn|,'J^
— 1 ~ t - \
__!_l- 1
1 -• 1 .
_L ;.;
i>
h
sV-i-jM'Ji ' • 'r:
_ ] i _ ' _i,_ , . - _ , - * —
-H±b: -!^
_j.. .1 i J . ;- ' -j
-------
oo
Figure 8.15-13. Standard NEDS form for lime manufacturing - lime silos.
5
jfivii
i f,..
iiMij
S \ \ J._i
, , I ,
L! J.!. .LL
NATIONAL EMISSIONS DATA SYSTEM (NE DS)
ENVIRONMENTAL PROTECTION AGtNCY
OKiCE OF AIR PROGRAMS
fQtltJt AiTi- < , { ti
OMB NO lb*i HOG -- .
t±Efl
0000 IF NO COMMON STACK
XXX POINT ID'S IF COWN ?T4"K;ji .
-------
Figure 8.15-14. Standard NEDS form for lime manufacturing - packing'shipping.
oo
I
N3
-4
Sl-t"
•1'
1
L'>«rt" r
j t {IT
J_
»,•( -i
'Is
1
n,.-.
lolu
1
NAI mrjAi. EMISSIONS DATA SYSTEM INI osi
ENVIRONMENTAL PROTECTION AGENCY
Of fICE OF AIR PROGRAMS
OMB NO lb*i HOO9S
O«tc __„__
it 11
3! a TIM
WFffiW
UTMCOOHOIN'ATfl
"iiji'.Sil
li M 15 !M!1
<3 «l»:UtU; it ;•)
[TtT;T ioUi s:_ siTi?
STACK OA1A
nliih1, h,
•a ii
OJO
NiV
QPI'HM TtN^j
OJO
,, 13
M -« 1' H S> H>
P^ifltl
•.Hit
com/v. >n
-0000 IF NO COWON STACK
XXXX POINT ID'S IF COWON STACK
iMATEO 'JONTHOL EFFICIENCY IM
& T£ S Horn, vf J'i
- L
>:i sayiliriitsTr^'Tn -.'TTlT
PACKING/SHIPPING
.! rr
..--. SCC UNIT - TONS PROCESSED
>-'•'- • ••• -, „ •, \-". k-,i
c14iT»iTj|M;
L J—1—^| I. | 1 :
SCHtDULt
M vi isTjT ».' >
ESTIMATION
METHOD
tlioi
CO'-THOL REGULATlOrfS
t-l J
TT-J-
11 tltllj ill.
- i_
^
_rt_
.,,
<
il
^^
«
r.,.
-.11
l>
ij
k<
ii
at
k/
u
i!i
;o
I
;i
P
c
^
?J
u
75
,-i T
1
J
— j"1
j
—I
cd
0, i.
° 6
'I6
Pi S
j
.". -'I
U 1 4] 4|
.LJJ-i-iJ LLl U
L..Li
.L±l
tiiSI
-------
Figure 8.15-15. Standard NEDS form for lime manufacturing -
product transfer and conveying.
00
N>
00
NATIONAL EMISSIONS DATASYSHM (Nf OS)
ENVIRONMENlAt PROTfCTION AGENCY
Of AIR PnOGflAMS
FOMM AWM(/, I'D
OM» NO I Ml HU09S
iffi
tj
PRODUCT TRANSFER AND CONVEYING
UTMCOOHlHNATtS
"?il.i[«r.'i
IIIIX
! -1 xTHT-iT vnun7:
STACK DA 1 A
018
•. ANNUAL TMnOfUT
I'-'i
tft
71 nl u I;.'
In
OjO
jjjj_Lt±t
ojo
00
i< i; w 55
.0000 IF NO COWWN STACK
XXXX POINT ID'S IF COffWN STACK
''.-JMnOL Ef fICIfNCV tM
j'.IO'. t SMWiftS liimi.vfJil
^Li@i3! I'-D' ''I ''IliE&SIll
j.±l±jrlp.n m rio
iffi
IT]
i:l.i±-T-til]
M:
I !
.l.L.L-
~.';W\:.> 17 ii|;:]iS] »f"M:'! ^ ''T^l "T'-'i ';["1 rs|u]'t;{i\fI7]':3] -,\]v
JJ-LiflLlJIIJ [QilLLllMiBirk
Ji iCHfcDOLi
.JiS
V!u
aTw
iKi
±
lo
ESTIMATION
MSTHOO
5 ? V S
I'l'l
CO'.TMOL HEGULATIOK5
iT>T£T»T»5ui
. n:
I ... ,--1- i- -f- -
-^-H-h»
."
4
!rtH4\
iTitrti:
r-
t±i;
( , •-
•,j ^'j
«"t
(i
Ttl
12
'o
(4
(S
«
- — J
H
»
»i
;o
3
Jl
;i
P
j
c
o
(-
;z
n
'i
;<
'i
r
<
rs
ej
i..
6
6
S
6
6
:LT
-------
GLOSSARY
Clamshell - A crane with a bucket having two hinged jaws.
Density:
Densities,
Product Ib/ft3
Lime, hydrated - 200 mesh 20-25
Lime, quick, lump,
1-1/2 in. x 0 in. 70-80
Lime, quick, lump, 1/2 in. x 0 in. 70
Lime, quick, ground 60-65
Stacker conveyor - A belt conveyor that discharges at the storage
pile. Use of conveyors that rise and fall with the storage
pile reduces the distance that the material must drop.
Stone ladder - A fixed column containing a series of steps that
allow the falling material to cascade in short drops. As
the storage pile increases, the material discharges through
ports progressively higher in the sides of the column so
that emissions are reduced.
Telescoping chute - A column that can be raised or lowered to
maintain a constant distance between the coal being dis-
charged and the top of the storage pile.
8.15-29
-------
REFERENCES FOR SECTION 8.15
1. Compilation of Air Pollutant Emission Factors. 2nd edition.
U.S. Environmental Protection Agency, AP-42, February 1976.
2. Engineering Science, Inc. Exhaust Gases from Combustion and
Industrial Processes. PB-204-861, Washington, B.C., October
1971.
3. Midwest Research Institute. Particulate Pollutant System
Study, Volume III. Handbook of Emission Properties. Con-
tract No. CPA 22-69-104, May 1971.
4. Industrial Gas Cleaning Institute, Inc. Air Pollution
Control Technology and Costs in Seven Selected Areas.
Stamford. PB-231-757, December 1973.
5. Technical Guidance for Control of Industrial Process Fugi-
tive Particulate Emissions. EPA-450/3-77-010, March 1977.
6. Minnick, L.J. Control of Particulate Emissions from Lime
Plants. In: 63rd Annual Meeting of the Air Pollution
Control Association, St. Louis, June 1970.
7. Vatavuk, W.M. National Emission Data System (NEDS) Control
Device Workbook. U.S. Environmental Protection Agency,
APTD-1570, July 1973.
8. Aeros Manual Series Volume II: Aeros User's Manual. EPA-
450/2-76-029 (OAQPS No. 1.2-039), December 1976.
9. Aeros Manual Series Volume V: Aeros Manual of Codes. EPA-
450/2-76-005 (OAQPS No. 1.2-042), April 1976.
10. Standard Industrial Classification Manual. Office of
Management and Budget. Available from Superintendent of
Documents, Washington, D.C., 1972.
11. Loquercio, P. and W.J. Stanley. Air Pollution Manual of
Coding. U.S. Department of Health, Education, and Welfare.
Public Health Service Publication No. 1956. 1968.
8.15-30
-------
8.19 SAND AND GRAVEL QUARRYING AND PROCESSING
PROCESS DESCRIPTION1"5
Sand and gravel have many uses in landscaping and construc-
tion, and are also used in concrete aggregate, road base materi-
als, and blacktop. Figure 8.19-1 shows a typical sand and gravel
operation.
Sand and gravel deposits are found in banks, pits, and
subterranean beds. The three methods of excavation are: (1) dry
pit, in which sand and gravel are removed from above the water
table; (2) wet pit, in which raw material above or below the
water table is extracted by means of a dragline or by barge-
mounted dredging equipment; and (3) dredging, in which sand and
gravel are recovered from public waterways, including lakes,
rivers, and estuaries. Dry pit extraction accounts for 50 per-
cent of the total that is produced; wet pit, for 30 to 40 per-
4
cent; and dredging, for 10 to 20 percent. Light-charge blasting
is sometimes needed to loosen the deposit. Before blasting,
holes must be drilled for the explosives.
The loosened deposit is transported to the plant by earth-
movers, or it is shoveled and loaded into a truck or barge and
transported to the processing plant. In a wet pit, the material
may be transported by suction pumps. The processing plant is
usually close to the excavation area. The material is unloaded
8.19-1
-------
PART
' PART
G
PART
0
PART
Q
3-05-025-03
MATERIAL TRANSFER AND CONVEYING
f f f
\ \ I
EXCAVATING
*
DRILLING AND
BLASTING
f
V—
T"
^^ ^ y
3-05-025-04
HAULING
I ^ 7PART<->
( / ^
m >-x i
^ .^ 1
3-05-025-02 _— — ' L- — "7.DrrM
AGGREGATE r— ' <-^ ^oLKLLH
STORAGE f ~~ —.•'I
LEGEND:
EMISSION FACTOR3
/-\
\-J
EMISSION FACTOR NOT DEVELOPED
FOR THIS PROCESS
009 (66.0) DENOTES CONTROL EQUIP.
CODE WITH EST. EFF. SHOWN
IN ( )
-
O
DENOTES FUGITIVE
EMISSIONS
DENOTES A STACK
IN POUNDS PER SCC UNIT
OVERSIZE
PARTICULATES(0.1)
PRIMARY CRUSHER 3-05^-025-0!
CRUSHING AND
SCREENING
SCREEN
SECONDARY CRUSHER
RECYCLE
3-05-025-02
AGGREGATE STORAGE
FINE SAND
FINES
TO
DISPOSAL
Figure 8.19-1.
8.
gravel processing.
-------
directly onto the primary screen (scalping screen), or it is
stockpiled and later transferred to the screen by a front-ena
loader.
At the plant, the sand and gravel are crushed and screened
to reduce and segregate the material by size, then it is stored
and loaded. The sand and gravel are reduced and classified by a
wet or a dry process, many plants use both.
In the wet process, sand and gravel are washed and screened
for use as concrete aggregate. The material is first screened
(scalping), and the material passing through the screen is
crushed in a jaw crusher (primary crushing). Oversize material
from the first screen is removed, reduced in size, and recycled
to the screen. The output (gravel) from the primary crusher is
again screened (secondary screening). The oversize material goes
to a secondary crusher (gyratory or roll crusher) where it is
reduced to a size of 3/4 to 1 inch and recycled to the screen.
The material passing through the screen goes to a washer or
rotary scrubber and is screened a third time to remove unwanted
soil. Additional screens and classifiers are used to separate
the material further into specified fractions.
Dry processing prepares sand and gravel that are to be used
for road base, blacktop (bituminous aggregate), or similar pur-
poses. The dry process is the same as the wet process, with the
exception of the washing steps. After processing and classifica-
tion are complete, the material is loaded for shipment or is
stockpiled in storage areas until it is loaded onto trucks for
shipment.
8.19-3
-------
Material is transferred throughout the plant by conveyors
and bucket elevators.
Individual sand and gravel operations range in size from
less than 1000 tons produced annually to more than 3.5 million
tons. Plants usually operate 8 hours a day, 5 or 6 days a week.
Many sand and gravel plants operate on a part-time or seasonal
basis to meet fluctuating demands. During periods of high de-
mand, which is caused by intense construction activity, plants
may operate for longer hours. The exhaust flow ranges from 500
to 750 scfm per ton/h of aggregate produced at those plants that
have control devices.
EMISSIONS1"3/6
Sand and gravel quarrying and processing generate particu-
late emissions, but since these materials are usually moist when
handled, the emissions are much lower than in crushed stone
plants that use similar operations. Emission sources are identi-
fied in Figure 8.19-1. For crushing and screening, AP-421
provides an emission factor that is listed on the process flow
diagram. For other sources of emissions, average emission rates
obtained from other documents are mentioned in the following
source descriptions.
Particulates are emitted during excavating, drilling,
blasting, and hauling. When wet pit and dredging methods are
used, the emissions from excavation are minimal. When the dry
pit method is used, emissions are slightly greater only when the
material is relatively dry. Drilling and blasting have little
8.19-4
-------
impact on overall emissions because they are performed infre-
quently. Significant amounts of particulate emissions are gen-
erated during hauling when the trucks or earthmovers travel cver
unpaved or dirt-covered paved roads. The dusts that arise come
mainly from the roads, although the material in the vehicles also
contributes to the emissions, which range from 1.7 to 4.5 lb/
vehicle mile.7 The level of the emissions is affected by the
composition or the road surface, the wetness of the road, and the
volume and speed of the traffic.
A state agency has estimated that sand and gravel processing
releases overall emissions of 0.06 lb of dust/ton of material.
The primary dust sources listed in the report are the discharge
of the secondary crushers, the transfer of dry material, and the
final screening of dry material. As much as 75 percent of the
dust was estimated to come from the crushers. Based on this
information, AP-42 lists an emission factor of 0.1 lb of dust/ton
of product for crushing and screening operations. Emission rates
may vary, because they are affected by the moisture content of
materials processed, amount of size reduction, and type of equip-
ment used.
Fugitive emissions arise from outdoor storage. Most storage
piles are left uncovered, but silos and bins may be used. Dust
emissions occur at several points in the storage cycle: during
loading of material onto the pile, during movement of trucks and
loading equipment in the storage area, during disturbance by
strong wind currents (wind erosion), and during loading of
8.19-5
-------
material from the pile. An overall emission factor of 0.33/
2
(P-E/100) Ib/ton placed in storage has been reported in AP-42
(Section 11.2), where P-E is Thornthwaite's precipitation-evapora-
tion ratio. Although such factors as age of the pile, moisture
content, and proportion of aggregate fines influence emission
rates, the precipitation-evaporation index is the best guide to
the variability of total emissions from aggregate storage piles.
Fugitive emissions are generated during material transfer
and conveying, particularly when the material is dry. The emis-
sions are small when the sand and gravel are moist.
Particulates are also emitted during loading of the product
for shipment. Front-end loaders usually transfer the material
into trucks.
CONTROL PRACTICES1"5
Particulates generated during excavation and drilling are
not controlled. Emissions from blasting are not amenable to
capture by a hood or similar device and are, therefore, fugitive.
Emissions from hauling, when controlled, are most commonly
reduced by wet suppression. Water or water plus chemicals are
applied by trucks to the roads during dry weather. The frequency
and extent of wet suppression determines its effectiveness.
Emissions from haul roads can also be reduced by lowering vehicle
speeds, stabilizing the soil, and paving the roads. The material
being hauled need not be controlled because it is usually too wet
to generate significant amounts of particulate emissions.
8.19-6
-------
Emissions from crushing and screening, aggregate storage,
and material transfer and conveying are not commonly controlled
because the material is usually wet and emissions are minor.
When the material is dry, emissions can be controlled by wet
suppression. Initial applications of water are made at the truck
dump and at the outlets of crushers where new surfaces are ex-
posed. Emissions from dry material processi ig could also be
controlled with low- to medium-efficiency cyclones, wet scrubbers,
and fabric filters; but these devices are seldom used.
Emissions from aggregate storage can be reduced by wet sup-
pression and by using stone ladders, telescopic chutes, and
hinged-boom stacker conveyors. A stone ladder is a vertical pipe
with steps inside that reduce the free-fall distance of the sand
and gravel. The enclosure also protects the material from wind.
A telescopic chute is a retractable chute that is raised or
lowered according to the height of the stockpile. A stacker
conveyor is equipped with a hinged boom that adjusts the conveyor
height as the level of the stockpile changes.
CODING NEDS FORMS
The major sources of emissions and their SCC's are:
Source SCC Pollutant(s)
Hauling 3-05-025-04 Particulates
Crushing and screening 3-05-025-01 Particulates
Aggregate storage 3-05-025-02 Particulates
Material transfer and
conveying 3-05-025-03 Particulates
8.19-7
-------
Standard NEDS forms for the sources, Figures 8.19-2 through
8.19-5, show entries for the SCC's and other codes. Entries in
the data fields give information common to sand and gravel pro-
cessing. Information pertinent to coding the source is entered
on the margins of the forms and above or below applicable data
fields. Entries for control equipment codes, other optional
codes, emission factors, and required comments minimize the need
to refer to the code lists. Typical data values for operating
parameters, control equipment efficiencies, and other source in-
formation are shown on the form (or in the text) only to aid in
rapid, approximate checks of data submitted by the plant in a
permit application or similar report. Data entered in EIS/P&R
and NEDS must be actual values specific to and reported by the
plant, rather than typical values. Contact the plant to validate
or correct questionable data and to obtain unreported informa-
tion. See Part 1 of this manual for general coding information.
In general, for emission sources that do not discharge
through a stack or vent and are not housed in a building, enter
zeros in the stack height, diameter, and common stack fields, and
77 in the temperature field, unless temperature data are fur-
nished. Enter appropriate plume height. Where liquid sprays are
used to reduce particulate emissions, enter 061 or 062 as a con-
trol equipment code. In the comments field on Card 6, identify
other equipment used to reduce emissions. For example, enter
"stone ladders" where they are used. For sources that do not
discharge directly through a stack and are not hooded but are
8.19-8
-------
housed in a building, enter the roof vent data in the stack da<
fields. Enter "roof vents" in the comments field.
Figure 8.19-2 is a standard NEDS form for hauling. Wet
suppression by water or water plus chemicals is sometimes used to
reduce emissions. The SCC unit for this source is expressed in
vehicle miles.
Crushing and screening are the major sources of particulates
from sand and gravel processing. The emission factor associated
with all crushing and screening is 0.1 Ib per ton of product. A
standard NEDS form for crushing and screening is shown in Figure
8.19-3.
Emissions from aggregate storage include loading onto
piles, wind effects while the materials are stored, and retrieval
activities from raw material storage piles and sized product
piles. A standard NEDS form is shown in Figure 8.19-4.
Particulate emissions generated during material transfer and
conveying operations throughout the process are reported under
the source labelled "material transfer and conveying." The
emissions are usually not controlled. A standard NEDS form is
shown in Figure 8.19-5.
Emission factors for aggregate storage and for material
transfer have not yet been developed. When a plant furnishes
emissions data for these sources, code the values given. Enter
"Emission estimates given by plant", in the comments field on Card
7.
8.19-9
-------
The emission factors assigned to the SCC numbers for sources
other than hauling are expressed as pounds emitted per ton
product.
CODING EIS/P&R FORMS
The Basic Equipment Codes (EEC's) for use in EIS/P&R forms
are:
Source BEC
Hauling No code*
Crushing and screening 650
Aggregate storage 700
Material transfer and conveying 700
*
As of November 1978.
8.19-10
-------
Figure 8.19-2. Standard NEDS form for sand and gravel processing - hauling.
00
; i s
NATIONAL EMISSIONS DATA SYSTEM (NEDS)
ENVIRONMfNTAI PROTECTION AGENCY
OFFICE OF AIR PROGRAMS
POINT SOURCE
InfMft fotm
FORM APPROVED
OMB NO IU ROMS
lilt; 20
HAULING
zi :s 10
w "I"
061 or 062
\i
i,
Dec M*> Junr S*oi
fro M-v Au«
00000
3) =
«t X
II
JUIi'lioh:
ALLOWAbLt EMISSIONS (lorn
IS H ?0 .'I !? 21
2) IS 25 ]0 II
;; 33 is Ji H ;: n
!' 40
-------
Figure 8.19-3. Standard NEDS form for sand and gravel processing -
crushing and screening.
00
ACCf I Numn*"
NATIONAL EMISSIONS DATA SYSTEM INEOS)
ENV RONMENTAI PROTECTION AGENCY
OFFICE OF AIR PROGRAMS
POINT SOURCE
IftfMil Form
I Pnion
linO, ftU*l
FORM APPROVED
OMB NO 1SI ROOK
0...
IB 19
CRUSHING AND
SCREENING
5
Zo«->* > M (I S? U M (i H » Ji 6» .-0
1
N C
I N
-------
Figure 8.19-4. Standard NEDS form for sand and gravel processing -
aggregate storage.
GO
•
M
I
CO
NATIONAL EMISSIONS DATA SYSTEM (NEDS)
ENVIRONMENTAl PROTECTION AGENCY
OFFICE OF AIR PROGRAMS
POINT SOURCE
Input fotm
FORM APPROVED
OMB NO IMROOtt
N«m« of Pe-s
Completing f
n/mnt Njmt and A Jrt. «
n \n
HOHMAi
TT|T
Contact P«
ESTIMATED CONTROL EFFICIENCY t\\
EMISSION ESTIMATES l
nlu
AGGREGATE STORAGE
ALLOWAtLt EMISblONS tllrf.. y«».l
NO.
Uil
40 41
COMPLIANCE
SIATLJS
UPDATE
XSo+cef
y*- I
LLU
CONTROL REGULATIONS
a 2 B« 3
SCC UNIT - TONS PRODUCT
MOo", i~ r
..mumO**.^
N C
ElR
-------
Figure 8.19-5. Standard NEDS form for sand and gravel processing -
material transfer and conveying
CO
>£>
I
NATIONAL EMISSIONS OATA SYSTEM INEOS)
ENVIRONMENTAI PROTECTION AGENCY
OFFICE OF AIR PROGRAMS
POINT SOURCE
Input fotm
OMb KG 1S8 ROO9b
i I! 20 1\ '>
MATERIAL TRANSFER
AND CONVEYING
1:4
= 0
Cxuc.i.
10*. BTuf"
UTM COOHOiNA T
13 Jl J? » I! 3! 3f
S * 3" II 39 40 *1 »? U «
r ;i » in In 12 ii
44 15 44 i; 4! w it 51 i7 U S4 SS 54li7 M :i
TTIsV
77 II
0 0 0 OTO
OPERATING
II 4.' 1)141 <', U|«I II !•)
ololo|o|olololololololo|o|o|o|oiolo|ololo'to
• 0000 IF NO COmON STACK S,
XXXX POINT ID'S IF COWON STACK
ESTIMATED CONTROL If f IOEMCV IM
NO. MC CO
i4 5) illil 58 41
.01 1 10
t.'lll (I ii U ('
EMISSION ESTIMATES
Pj'lrt.,1
i: :i n
SO;
U H 70 !l 72 7) Ii
ALLOWA«Lt EMISSIONS lion* i
NO.
!0 Jl
3.' ]J J« Jl it !' It
!' 40111 1? 4] 44
it :.' a\ii so 41 i:
J, SCHEDULE
COMPLIANCE
S1-TU5
UPDATE
(2 U
M VI n
ESTIMATION
METHOD
75 JO
ij 771
I loi 1 i i
CONTROL REGULATIONS
R*q
«7 U,
$9 70 M 72
SCC UNIT - TONS
U) (I
N C
-------
GLOSSARY
Gravel - Loose, rounded fragments of rock that are larger and
coarser than sand. Also called pebbles.
Sand - Separate grains or particles of rock material, easily
distinguishable by the unaided eye but too small to be
classified as pebbles or gravel.
Scalping - The removal, by screen or grizzly, of undesirable fine
material from broken ore, stone, or gravel.
Stacker conveyor - A belt conveyor with a hi-ided boom that dis-
chrrges at the storage pile. Use of conveyors that
rise and fall with the storage pile reduces the dis-
tance that the stone must drop.
Stone Ladder - A fixed, rectangular column with a series of steps
inside that allow the falling material to cascade in
short drops. As the height of storage piles increases,
the stone discharges through ports in the sides of the
column and emissions are reduced.
Telescoping chute - A column that can be raised or lowered to
maintain a constant distance between the stone being
discharged and the top of the storage pile.
Thornthwaite's precipitation-evaporation ratio - An approximate
measure of average surface moisture used in estimating
fugitive emissions from outdoor storage.
8.19-15
-------
REFERENCES FOR SECTION 8.19
1. Compilation of Air Pollutant Emission Factors. 2nd edition.
Environmental Protection Agency. AP-42, February 1976.
2. Midwest Research Institute. Particulate Pollutant System
Study. Volume III. Handbook of Emission Properties. EPA
Contract No. CPA 22-69-104. Kansas City, Mo., May 1971.
3. PEDCo Environmental, Inc. Background Information for the
Nonmetallic Minerals Industry. Draft. EPA Contract No. 68-
01-1321, Task No. 44. Cincinnati, June 1976.
4. Newport, B.D., and J.E. Moyer. State of the Art: Sand and
Gravel Industry. EPA-660/2-74-066, June 1974.
5. Engineering Science, Inc. Exhaust Gases from Combustion and
Industrial Processes. PB-204-861. Washington, D.C., October
1971.
6. Midwest Research Institute. Particulate Pollutant System
Study. Volume I. Mass Emissions. EPA Contract No. CPA
22-69-104. Kansas City, Mo., May 1971.
7. Technical Guidance for Control of Industrial Process Fugitive
Particulate Emissions. EPA 450/3- 77-010, March 1977.
8. Aeros Manual Series Volume II: Aeros User's Manual. EPA
450/2-76-029 (OAQPS No. 1.2-039), December 1976.
9. Aeros Manual Series Volume V: Aeros Manual of Codes. EPA
450/2-76-005 (OAQPS No. 1.2-042), April 1976.
10. Standard Industrial Classification Manual, 1972 edition.
Prepared by Office of Management and Budget. Available from
Superintendent of Documents, Washington, D.C.
11. Loquercio, P., and W.J. Stanley. Air Pollution Manual of
Coding. Public Health Service Publication No. 1956. U.S.
Department of Health, Education and Welfare, 1968.
8.19-16
-------
8.20 STONE QUARRYING AND PROCESSING
PROCESS DESCRIPTION1"
Crushed and broken stone have many applications, including
uses in road base, concrete aggregate, bituminous aggregate, and
in cement and lime manufacture. Total production in 1977 was 914
million tons.
Natural rock deposits are converted into crushed and broken
stone through a series of physical operations. Drilling and
blasting are quarrying operations; crushing and screening are
among the plant operations. Figure 8.20-1 gives a process flow
diagram for stone quarrying and processing.
Stone processing plants are of two types: stationary and
portable. Stationary plants are usually located at or very near
the quarry, and the broken rock is hauled to the processing units
by truck. A portable plant, which is designed to be moved from
one quarry site to another, consists of one or several chassis
upon which processing units are mounted. The processing steps
are the same at stationary and portable plants; but in the latter,
the units are squeezed into a restricted space.
The removal of overburden by earthmoving equipment leaves a
large denuded area that is worked into benches or ledges to form
an open quarry (pit). Blastholes are drilled into the exposed
8.20-1
-------
PART ( 2
-\
I
3-05-QZO-06
SCREENING/ CONVEYING/ HANDLING
PART
3-S5-02Q-10
DRILLING
BLASTING
HAULING
3-05-020-01
PRIMARY CRUSHING
* TYPICAL SPRAY LOCATIONS
* CAPTURE POINTS
LEGEND:
(3 EMISSION FACTOR8
0 EMISSION FACTOR NOT DEVELOPED
FOR THIS PROCESS
009 (66.0) DENOTES CONTROL EQUIP.
, CODE WITH EST. EFF. SHOWN
O
IN ( )
DENOTES FUGITIVE
EMISSIONS
DENOTES A STACK
A PART
a IN POUNDS PER SCC UNIT
FINISHING (TERTIARY)
SCREENS
SECONDARY
SCREEN
TERTIARY
CRUSHERS
3-05-020-03
SECONDARY CRUSHING/
SCREENING
COMBUST ION I/
PRODUCTS
TO STORAGE
OR SHIPMENT
TO STORAG-
OR SHIPMENT
Figure 8.20-1. Stone quarrying and processing operations.
TO STORAGE
OR SHIPMENT
3-05-020-12
DRYING
3-90-006-99 NATURAL GAS
3-90-004-99 RESIDUAL OIL
3-90-005-99 DISTILLATE OIL
IN-PROCESS FUEL
8.20-2
-------
rock face, and the rock is blasted out of its deposit with ex-
plosives. When the fragmentation is insufficient, the rock is
broken a second time, often with drop-ball cranes. The broken
rock is loaded by loaders or shovelers into trucks (20- to 75-ton
capacity) and hauled to the processing plant. The haul roads are
usually unpaved. In portable plants, the rock is fed directly
into a primary-crusher hopper.
Primary crushing is the first stage in stone processing.
The crusher (commonly a jaw or cone type) reduces the rock to a
size of 3 to 12 inches. This material is discharged onto a belt
conveyor that carries it to a surge pile for temporary storage.
A series of vibrating feeders located under the surge pile
reclaims the stone by placing it on a belt for conveyance to a
scalping screen. This unit consists of two screens that separate
the material into three fractions before secondary crushing:
oversizes, which are retained on the top screen; undersizes,
which are retained between the screens; and throughs, which pass
through both the screens. The oversize is discharged to a sec-
ondary crusher for further reduction. The undersize, which
requires no further reduction at this stage, bypasses the sec-
ondary crushers and thus reduces its load. The throughs, which
contain unwanted fines and screenings, are removed from the
process flow and stockpiled for sale as a product or disposal as
landfill. Secondary crushers are usually cone type, but impact
crushers are used at some plants.
8.20-3
-------
After secondary crushing, the product, which is 1 inch or
less in size, is transported to a secondary screen for further
sizing. Sized material from this screen is conveyed or dis-
charged directly to a tertiary crusher, usually of the cone or
hammer-mill type. The product from the tertiary crusher is
shuttled back to the secondary screen, the two units forming a
closed circuit with a fixed maximum size, until the material has
been sufficiently reduced to pass through the secondary screen.
The throughs from this screen are discharged to a conveyor and
carried to a screen house or tower containing finishing screens
for final sizing. Occasionally, fines mills are used to produce
a finer consistency. After final sizing, end products of the
desired grade are dumped directly into finished-product bins, or
are moved by conveyor or truck to open areas for stockpiling.
The product is usually loaded into open trucks by front-end
loaders.
Sometimes the stone must be washed to meet particular end-
product specifications, as for concrete aggregate. The material
falls onto fine mesh screens in washing units, where it is sprayed
heavily with water. Unwanted fines are discharged to a settling
pond. Normally dryers are not used, but for some stones, such as
dolomite, drying may be necessary. The dryers are usually direct-
fired, rotary units.
Plant capacities range from less than a hundred to several
thcasand tons per hour.
8.20-4
-------
EMISSIONS ~5
Virtually every operation in stone quarrying and processing
is a particulate emission source. The emission sources are
identified in Figure 8.20-1. Emission factors, listed on the
process flow diagram, are given in AP-42. Average emission
rates for other sources were obtained from other documents and .
are mentioned in the following source descr ptions.
Unlike emissions from boilers and incinerators, emissions in
this industry have not traditionally been confined and discharged
through stacks or similar outlets. It is possible for emissions
from drilling, crushing, screening, and conveying to be captured
with enclosures and hoods and collected in a control device.
Emissions from blasting, stockpiling, and hauling, however, are
not amenable to capture by a hood or similar device and are,
therefore, fugitive.
Emissions at stone quarries and processing operations are
affected by the moisture content of the rock, type of rock
processed, type of equipment, and operating practices. Little
information is available on the quantities of these emissions.
During drilling operations, emissions arise when cuttings
and dust are removed from the bottom of the hole. An estimate
4
for this source for granite is 0.0008 Ib/ton of stone produced.
Blasting occurs between once a week and several times a day, de-
pending on the plant capacity and the size of individual shots.
Emissions during blasting are affected by the size of shot, type
of rock, and wetness. Estimated emissions from this source (for
8.20-5
-------
4
granite) are 0.16 Ib/ton of stone produced. Emissions from
secondary breakage, usually done by drop-ball cranes, have been
2
judged by visual observation to be insignificant. Emissions
from loading are also considered to be minor.
At most quarries the haul roads are unpaved. Traffic on
these roads generates a large portion of the fugitive particulate
emissions from quarrying and processing operations. The amount
2
ranges from 1.7 to 4.5 Ib/vehicle mile. The level of these
emissions is affected by the composition of the road surface, the
wetness of the road, and the volume and speed of the traffic.
During crushing, emissions come from the crusher feed and
discharge points. Sometimes the crusher is housed in an unvented
building, but the degree to which internal settling (baffling)
reduces the emissions in these cases is not known. The emission
factors are based on the feed rate to the primary crushers.
Emissions are affected by the moisture content of the rock, the
type of rock processed, and the type of crusher. Primary crush-
ing releases fewer emissions than secondary, tertiary, or fines
mills processing, because the material itself is less fine.
Emissions from screening depend on the sizes of the material
screened, the amount of agitation, and the type and moisture
content of the rock. The emission factors for secondary and
tertiary crushing include the emissions from secondary and fin-
ishing screens, respectively. Emissions from the scalping screen
are included in the emission factor for screening/conveying/han-
dling. Most of the emissions from material handling occur at
8.20-6
-------
transfer points, because transport of material on the conveyor
creates little disturbance of air, and emissions due to wind are
judged to be minimal. The transfer points include transfers
from one conveyor to another, into a hopper, and onto a storage
pile. Only those transfer points that are not accounted for
elsewhere are included in screening/conveying/handling. The
amount of uncontrolled emissions depends on the sizes of the
material handled, the belt speed, and the free-fall distance (the
vertical distance between the belt and the top of the pile or
belt to which the material is transferred).
Washing generates no emissions. Particulate emissions from
a dolomite dryer are reported to range from 2 to 50 Ib/ton of
product after a cyclone-type collector.
Emissions from open storage occur during loading onto the
piles, action of the wind, and retrieval activities. No data on
emissions during product loading are available.
CONTROL PRACTICES2"4
Emissions from drilling have not commonly been controlled.
Two methods are available: liquid injection, and collection by
aspiration to a particulate control device.
Liquid injection is a wet-control technique in which water,
sometimes with a wetting agent (liquid detergent), is forced into
the compressed air stream that flushes the drill cuttings from
the hole. The injection of fluid into the air stream produces a
8.20-7
-------
mist that dampens the stone particles and causes them to ag-
glomerate. As particles are blown from the hole, most of them
drop as damp pellets at the drill collar instead of becoming
airborne.
In the collection systems, a shroud or hood encircles the
drill rod at the collar; and a vacuum pulls the emissions through
a flexible duct into a control device for collection. Control
2
devices most commonly used are cyclones or fabric filters.
No effective method is available for controlling particulate
emissions from blasting. Good blasting practices can minimize
noise, vibration, and air shock. Scheduling blasting to occur
during conditions of low wind and low inversion potential can
substantially reduce the local impact of the emissions. Emis-
sions from the loading of broken rock by loaders or shovels are
difficult to control. Using water trucks equipped with hoses to
wet down the rock is a potential control technique.
Watering of the haul roads during dry weather is the most
common method for reducing emissions from hauling. Water is
applied to the road by water trucks that are equipped with either
gravity-fed spray bars or pressure sprays. The amount of water
required, frequency of application, and effectiveness of this
method depend on the weather and the conditions of the roadbed.
Other methods for reducing emissions from the roads include soil
stabilization, paving, and lower vehicle speeds. Paving is
probably the most effective way to reduce emissions, but it is
very costly.
8.20-8
-------
The plant processes either have water sprays to reduce emis-
sions or, less frequently, hoods to capture and direct them
through a control device. Combinations of the two methods are
often used at different stages throughout the process.
Wet suppression is an attempt to prevent fine particles from
becoming airborne. At critical points, the material is sprayed
with water or water plus wetting agents. The initial application
is usually made at the truck dump into the primary crusher.
Spray bars are located either on the periphery of the dump hopper
or above it. Applications of water are also made at the outlet
from the primary crusher and from all subsequent crushers, where
new dry surfaces are exposed by the fracturing of the stone.
Water treatment may also be required at the feeders located under
surge piles. If the material is properly treated at these points,
further applications of water at screens, conveyor transfer
points, conveyor and screen discharges to bins, and conveyor
discharges to storage piles may not be necessary; sprayed stone
exhibits a carryover effect that permits it to be handled through
a number of operations without significant emissions. No data on
the effectiveness of wet suppression have been developed, but a
well designed system can eliminate visible emissions.
Collection systems consist of enclosures and hoods that
confine and direct the emissions to a control device. Good
systems enclose the process equipment as completely as practi-
cable, yet allow access for routine maintenance and inspection.
8.20-9
-------
The fabric filter is the most commonly used control device,
although cyclones and scrubbers are sometimes used. Depending on
the layout of the plant, emission sources may be vented to one
central control device or to units at strategic points. The
fabric filter is more than 99 percent effective, but the degree
of control depends on the efficiency of the enclosures and hoods.
Fines mills are usually vented to a fabric filter.
In combination systems, wet suppression is used on the pri-
mary crusher inlet and outlet, screens, and other transfer points,
whereas the outlets of secondary and subsequent crushers are
vented to a control device.
During conveying, emissions are reduced by the carryover
effect from wet suppression at transfer points. Conveyor covers
are the most effective measure for controlling these emissions,
but they are not common because of high cost.
The carryover effect from spraying after final crushing or
screening reduces emissions during loading onto open storage
piles. Emissions are also reduced by such equipment as stone
ladders, telescopic chutes, and hinged-boom stacker conveyors. A
stone ladder is a section of vertical pipe with steps inside to
check the fall of the stone. This ladder reduces the free-fall
distance of the stone and protects it from wind. The telescopic
chute is a retractable device that receives material from the
conveyor or truck and allows it to fall freely to the top of the
pile. As the level of the stockpile goes up or down, the chute
8.20-10
-------
is gradually raised or lowered. Similarly, the stacker conveyor
is equipped with an adjustable hinged boom that raises or lowers
the conveyor according to the height of the stockpile.
Watering is the most effective technique for reducing wind-
blown emissions from storage piles. A water truck equipped with
a hose or other spray device is sometimes used. One plant uses
spray towers around the stockpiles. Emissions from washing are
minimal. Dryers are usually equipped with cyclones.
Moving the materials from stockpiles into open dump trucks
may generate significant fugitive emissions. Controls are not
currently used, except for some attempts to wet the material
before loading and to empty the loaded buckets as close to the
2
truck beds as possible. Some plants spray the loaded truck to
reduce emissions during transport.
CODING OF NEDS FORMS3'
The emission sources associated with stone quarrying and
processing are:
Source SCC Pollutant(s)
Drilling 3-05-020-10 Particulate
Blasting 3-05-020-09 Particulate
Hauling 3-05-020-11 Particulate
Primary 3-05-020-01 Particulate
crushing
Secondary 3-05-020-02 Particulate
crushing and screening
Tertiary 3-05-020-03 Particulate
crushing and screening
8.20-11
-------
Source SCC Pollutant(s)
Fines mill 3-05-020-05 Particulate
Screening/conveying/handling 3-05-020-06 Particulate
Open storage 3-05-020-07 Particulate
Drying 3-05-020-12 Particulate,
combustion
products
(In-process fuel)
Natural gas 3-90-006-99
Residual oil 3-90-004-99
Distillate oil 3-90-005-99
Standard NEDS forms for each of the sources, Figures 8.20-2
through 8.20-11, show entries for the SCC's and other codes.
Entries in the data fields give information common to stone
quarrying and processing. Information pertinent to coding the
source is entered on the margins of the forms and above or below
applicable data fields. Entries for control equipment codes,
other optional codes, emission factors, and required comments
minimize the need to refer to the code lists. Typical data
values for operating parameters, control equipment efficiencies,
and other source information are shown on the form (or in the
text) only to aid in rapid, approximate checks of data submitted
by the plant in a permit application or similar report. Data
entered in EIS/P&R and NEDS must be actual values specific to and
reported by the plant, rather than typical values. Contact the
plant to validate or correct questionable data and to obtain
unraported information. See Part 1 of this manual for general
coding instructions.
8.20-12
-------
Use appropriate SIC and IPP codes. SIC Code 1400, which has
been used in the standard NEDS forms included here, is for mining
in general. The SIC codes are: 1411 for dimension stone (build-
ing stone); 1422 for limestone; and 1429 for all others.
Except for a few items, coding of portable plants is simi-
lar. Follow the special procedures described in Section 3.1.2 of
the Aeros Manual.
In general, for emission sources that do not discharge
through a stack or vent and are not housed in a building, enter
zeros in the stack height, diameter, and common stack fields, and
77 in the temperature field, unless temperature data are fur-
nished. Enter appropriate plume height. Where liquid sprays are
used to reduce particulate emissions, enter 061 or 062 as a
control equipment code. In the comments field on Card 6, identi-
fy other equipment used to reduce emissions. For example, enter
"stone ladders" where they are used. For sources that do not
directly discharge through a stack and are not hooded but are
housed in a building, enter the roof vent data in the stack data
fields. Enter "roof vents" in the comments field.
Emissions from drilling are sometimes controlled. Code the
operation when it is controlled or when emission data are avail-
able. Use 061 or 062 as a control equipment code for liquid
injection systems and the appropriate codes for cyclones and
fabric filters. Emissions from blasting are not controlled.
Code the source when emission data are available. Standard NEDS
forms for drilling and blasting are shown in Figures 8.20-2 and
8.20-3, respectively.
8.20-13
-------
Haul roads are usually watered to reduce the emissions.
Note that the SCC unit for this source is vehicle miles. A
standard NEDS form is shown in Figure 8.20-4.
Emission factors for secondary and tertiary crushing include
emissions from associated screening operations. Other screening
operations are included in the source labeled "screening/con-
veying/handling," which also includes transfer operations not
accounted for in other sources. Code the primary, secondary, and
tertiary crushing operations as shown in Figures 8.20-5, 8.20-6,
and 8.20-7. Where combination systems are used, for those units
(usually secondary and subsequent crushers) that use fabric
filters, code the fabric filter as a primary control device and
enter "wet suppression" in the comments field. For emission
sources equipped only with wet sprays, code 061 or 062 as a
primary control device. Efficiencies of wet suppression can only
be estimated by plant inspection (observation) during dry weather.
Where fines mills are used, code them as shown in Figure 8.20-8.
Wet suppression affords some reduction in emissions from
screening/conveying/handling where the material is sprayed before
these operations. Assign 061 or 062 as a primary control device
code to wet suppression or combination systems that are designed
to reduce emissions from screening/conveying/handling. Figure
8.20-9 shows a standard NEDS form.
8.20-14
-------
A standard NEDS form for open storage is shown in Figure
8.20-10. In the comments field, identify the equipment that is
used to reduce emissions during loading onto the piles. Where
the piles are regularly sprayed to reduce emissions from the wind
and during retrieval activities, assign 061 or 062 as the primary
control device code. Where dryers are used, code them as shown
in Figure 8.20-11.
CODING EIS/P&R FORMS9
The EEC's for use in EIS/P&R forms are:
Source
Drilling
Blasting
Hauling
Primary crushing
Secondary crushing/screening
Tertiary crushing/screening
Fines mill
Screening/conveying/handling
Open storage
Drying
EEC
No code*
No code*
No code*
650
650
650
651, 654
575, 577
700
452
* As of October 1978.
8.20-15
-------
Figure 8.20-2. Standard NEDS form for stone quarrying and processing - drilling.
CO
•
to
o
I
I-1
CTl
Jl< Mi
ffi
NAUUMAl t MISSIONS 0AIA SYS rtM(N! OS)
ENWRUNMtNlAl PHOU CHUN ACINCY
UK ICE OF AIR PROGRAMS
El*
11410101011
fflttffi
STACK DAI A
wifflwiwiitmw
ffi
TmrvfT
MUI
ulw
(4HIKI
,1 0^ I ,•,,.,., I =^ IP,...., I =« Iv^;.-,
I < I •-•. I s I "' I J I t'« :
Mj'li.l '';''''^i4'''''' '**''li'
nr^r. .i.-n7, i r,i rn-iLTTin.!.^".^;
DRILLING
11:
T
H
I
1J11U
''•'".
_ .-
i L._
-
•1
—
—
-:f
(i
1-
.i
'
-
—
-
i>
.liii
1
\
Q
o
-
5
it
-•
0
^
-
"
-
•jr,
4
r
..I
i
,|,
1
i
I
1
.,;
'<
C.
11
u
.*>•
11
lit
I!
ij
kl
IS
•»
k)
S4
ii
/I
A
;i
P
a
n
ii
74
7S
(k
7T
4
11
cd
^n •
P 6
' 6
' S
f 6
r •
'j S)
M
•1
..'
(J
(4
li
U
i;
u
n
10
;i
n
n
74
)i
)k
;;
[i
-.1
,.i
H 10
f 7
f 7
\f 7
F 7
-------
Figure 8.20-3. Standard NEDS form for stone quarrying and processing - blasting.
00
o
I
NAIIUNAl (MISSIONS DAT A SYSUMINt OS)
£*VinONMlNlAl PHOTFCTION AtiiNCY
Of AIB PROGRAMS
4iTi;rr»ra!i[n|ii
Jlkl I I I I I in|
r- ' o '•• ,
'ill '.I '- I ••....«, I JZ I P...-«, 31 \''—,-,
* 1 - J * J ""'• 1 * I **• 1 * I C''_
^'•1'*r1rtIiTiiTT^-'1^J^'':T'H»lH>Jl';llM'n*['.
ifflifimraffDMa
-------
Figure 8.20-4. Standard NEDS form for stone quarrying and processing - hauling.
00
•
N)
O
I
M
00
NAl 11) NAl [MISSIONS DAT A SVST LM (Nf OS)
INVIRONMtNl Al PROTECTION ACiNCY
OFFICE Of AIR PROGRAMS
f OKM Ai>f*
-------
Figure 8.20-5. Standard NEDS form for stone quarrying and processing - primary crushing,
00
O
I
M
VO
rorw Awwu
OtWNO IMAUDK
NAHUJlAl I MISSIONS DATA SYSTEM IN( OS)
ENVIRONMENTAL fHOTf CTION AGENCY
OHICE OF AIR PROGRAMS
ffiffiffi
0000 IF NO COmON STACK S
XXXX POINT ID'S IF CONON STACK
"1 "l'T'*F1 "l"!"!^]''!"
rTTTTTl I M
: ,. ,, o .„.,.
'*" J« I 1*1 ^'l 1 * I ***"
.sii'. •'tTR'M'T'1 iTti'l' l.'l i lit ''T'»l i»'''''l'''T''
.
oTo1oTo1o1o1oToTo1oi6lo|o
BHfflSSfflilHBffi
-f
1-
1
. . ,;; : ;
LI
-
i
;
-
f-
•
T
f
i
-
-
-i
0
;
iii. i i
t
f r
H
n
~-
'""!».
[4=
MI.
^u
i
i
T
-
1 1 1
c
.^
-
>***«
„,
!
5
1
I
-------
00
•
NJ
O
I
10
O
Figure 8.20-6. Standard NEDS form for stone quarrying and processing -
secondary crushing/screening.
5C
UJ O
-
go§
i
><_><-> U1Z
^•"oS
NA1IUNAL IMiSSlONSOATASYSItM(NtOS)
(NVlHUNMiNIAL PHOTf CTIUN AGENCY
tittffiffffi
0000 IF NO COMMON STACK °
XXXX POINT ID'S IF COMMON STACK
SECONDARY CRUSHING/ I
SCREENING!
tt
ill
t
", .. SCC UNIT - TONS RAW MATERIAL
Afi
- -i-
.i _'
H
!
u V
1
.Jv.
1
I
1
1
'4
.
t
•)J
V*11
(D
"»«
€1
-tn
i;
»j
u
u
0*
II
M
ii
II
J
C
«*»
It
p
I
V
»
»
n
n
>i
n
i
i
n
n
«4f
•
ni«
T
'.« it
>I
U
k)
)0
I!
12
11
II
IS
X
;i
i
it
i«
•i •
r i
r t
r i
f /
-------
Figure 8.20-7. Standard NEDS form for stone quarrying and processing -
tertiary crushing/screening.
00
O
I
to
Is.... I ...... I
BffiB
NAllllttAI I MISSIONS DAT A SYMIM INI US)
lNl Al PHOTICTIUN ACtNCY
OH ICE OF AIR PROGRAMS
fOMM APf'fc^ ,1 \,
OM« NO Ibtt HUO90
o o o
_i mo
U. ^ Lu I/I
.
> UJ Z
) O
Q _J
HTM (At')Hi>
ffi
STACK DA I A
iconl*. f,
;[n[u[>i[tt[n
i'lulu
ojoioToio
010
- --
imij.i
I'l
QMototototoMototo
0000 IF NO COMMON STACK &,
XXXX POINT ID'S IF COMMON STACK
W|H|H| Hi MlMlUlM
'•ICllHf.1 I'M
".•I'.il'J {.'Mil
I iol I io
6 Ib/ton
Jm-ft4
. ( ' 'I.. ,.JM, ,• , » ,r
TERTIARY CRUSHING/ I .
SCREENING ; '
t i
fl.5
L 1 I
s
f
b U
j
^
'i
-
0
';
u
-
.1"
J
- -
"V
"
.
'
-
J
s
-
>.•
o
cc
"
-
\
"
u
HP
NIT
1-
1
i
1
i>l •
II
Jl |
1
"•
'5!
TO
,
1
•'
NS
*
0
R
(
1 i
1AV
,,
t.
H
,
-
"i."
t
IAT
t:
-
,,
i'
ER
(
Q
-
4~.
IA
41
"
L
It
-
»N
0
(
0
^
-:
i
~
,,n.,
i
:A>,
\ •
\
..
"^
;J
n
."
M
--
-
- '
•,;
Q
-
Ti
"..
-
Ll
.-
T;j
,;
"
-
[
:
—
«ter
1 1
.-
Sffl
Him
OfO
ill ml
CON1HOL HfGULATtONS
H«. /
nlnln
, •*
I
A
. I '(]~,1
\
\
Sj
...r
t;
>ti
t?
•u
i«
fci
.ft
ft!
SI
.4
10
j
;i
P
S
i;
;i
II
n
i.
n
3
'i
H
tij
H
6
6
h
6
«
-------
Figure 8.20-8. Standard NEDS form for stone quarrying and processing - fines mill.
00
N)
o
(SJ
UNAl tMISSIONS DAIASYSUMINtDS)
f NVlRONMtttlAl PROUCTION AGENCY
OHlClOf AIR PROGRAMS
FOHM A*W*^Vt O
OMB »«O tM ROOM
00
CTiCT. p
25
00
fflffi
miranmr
STACK UAIA
uTiiT 17[<¥"]'•'I'>Ii'H ^I*; "1M
-
hOt'l.'fi
(Jl-tx* I"...
S i.- ».->I |2 11-...-.,I |t I- -V-.
M kl
a u
0000 IF NO COWON STACK
10's I
STACK
tSriUATtD CONTROL Ef FICltNCV I
6 Ib/ton
* t i I 'MA 11 S Horn- »«.»• I
FINES MILL .!
111
T'
.Til
o
*.t COVWUANCE
»t»luS
:i\n
ESTIMATION
MCTHOO
SEE
CONTROL HCCULATIOM
" ' I ,1**''7
»|M3HE
Ml H| K
Liu
'.:,. ..SCC UNIT - TONS STONE PROCESSED
it-I-
-
I
.,, .;
I
(J
-
i;
,Jta
1
- !
I
1
t]
,
.<
1 —
,
I
}J
1,1-
Vi
.*>•
fi
-in
t»
M
fc4
is
M
61
U
*i
M
;i
P
I
;i
u
»
n
n
n
i
it
VS
n n
«
' <
&
6
i
-------
CO
to
o
I
NJ
U)
Figure 8.20-9. Standard NEDS form for stone quarrying and processing -
screening/conveying/handling.
NAMUNAl I MISSIONS DATA SYSItM INI US)
tWVIHONMtNTAl PBOTf CTIUN AGINCY
IHHCE OF AIR PROGRAMS
0000 IF NO COMON STACK S
XXXX POINT ID'S IF COMMON STACK
.,i !>' I-......i I-/ i- -. I* i *•-.'-<
SCREENING/COHVEYIMG/
'.1 /
- T
I
.,
V
r
\
.j-.
I
!
V
L
•41
_
(
5)
S'j
f i
t?
«
o
M
ii
u
.V
;o
3
;i
t
I
(_
;;
u
it
7S
;.
/7
3
1
ft
(1
Cl)
M
6
k
«
t
1
.J^L
,ft
4,
,-l
111
.
>1
(1
SI
,.,
ikUrlu
1 I
I 1
I j
i I
hi
13
II
;;
f]
><
>S
>»
<
I
.,1
'1 H
P 7
P t
P 7
P /
-------
Figure
8.20-10. Standard NEDS form for stone quarrying and processing - open storage.
00
*
to
o
I
NAllUMAl tMlSSIOMSDATASrSItMINfOS)
INVlRUMMtlHAl PROTrCllUN AGtNCY
OHICEOF AIRPIIOCRAMS
FOHM AfMlv
DM* NO IM
a... .
I kill
L_L
iffittffi
HIM CuOHtn'v 'i '-
STACK OAJA
I £ I „ „ .• ,.,„ I y, , . I I j f'-" - *"
irtlffffi™
oToTg
Kt>HI->'.t
UHFH»* Il»»^
win
n\n M n KJII
^ilal'^
|o|olo
CONTROL Ef FlOtNCV (
1ft
10 lb/ton
» IMATtS tlOAt-T«J<
OPEN STORAGE
Ji SCHtuotl
T'
:""SCC UNIT - TONS PRODUCT STORED
(.e COV'UANCE
---- "
it Is/
silw lulu
ESTIMATION
METHOO
\ IO* O <-t O
OloloTQ
yn.
nmn
Tm
CONTROL REGULATIONS
n\n\n
,J •„
n
r~
„'
...
,i
S;
rth.
1
I
1
't
(
11
wr-
u
nn«
II
Tit
t?
tj
k<
iS
M
>l
u
.4
»
3
c
trt
;i
P
i
n
n
H
n
)«
n
s
;
<
it
i)
cd
•
L i L
111!!
tl
U i)
.a
ii
.;
(i
ii
>s
u
i>
u
bt
10
n
1!
n
n
!5
H
;;
4
.1
v«l
n •
f i
r J
r i
f i
-------
00
•
NJ
O
I
to
cn
Figure 8.20-11. Standard NEDS form for stone quarrying and processing -
drying in-process fuel.
I 2
SEE
NA11UNAL tMISSIONS DATA SYSUMWtDS)
f NVlROftMtNlAl PROUCTIUN AGfcWCY
UHICIOF AIR PROGRAMS
FOHM AWfriuvf O
OM»HO 1MROOK
f
Staas
Ilirfi
006
« C
Kiin
(jWKATiN.,
STACK DA I A
sfi
tolil
M u it
,0000 IF NO COMMON STACK I
XXXX POINT ID'S IF COMMON STACK
HIM
iiltt
tsri(.'.«iLi< cowmen. EFHOENC* IM
. t >t>M- TtS lux-t r'J«<
!(ltt
DRYING
*
IN
, s,
-PROCESS FUEL ; \1\9 Q
ft
rl
1
^Ua^^TO^^
irin
COMHOL HtCULATtONS
7, .."SCC UNIT - TONS STONE DRIED
>
4-
1 ^
i-n-'l
tlM
li
Tl
T
4
1
i ^.-
„.
i.
ki
M
tl
u
•4
;Q
j
C
;i
P
!
ii
n
M
15
It
n
|
•t
IS
IS
cO
10
6
G
6
6
6
OIL; 5-DISTILLATE OIL; 6-NATURAL GAS
_L
-------
GLOSSARY
Grizzly - A device used to remove large fragments of rock. This
is a form of a scalping screen, except that it has a series
of heavy steel bars spaced parallel to each other.
Stacker conveyor - A belt conveyor with a hinged boom that dis-
charges at the storage pile. Use of conveyors that rise and
fall with the storage pile reduces the distance that the
stone must drop.
Stone ladder - A fixed, rectangular column with a series of steps
inside that allow the falling material to cascade in short
drops. As the height of storage pile increases, the stone
discharges through ports in the sides of the column and
emissions are reduced.
Telescoping chute - A column that can be raised or lowered to
maintain a constant distance between the stone being dis-
charged and the top of the storage pile.
8.20-26
-------
REFERENCES FOR SECTION 8.20
1. Pit and Quarry Publications, Inc. Pit and Quarry Handbook
and Purchasing Guide. 63rd edition. Chicago, 1970.
2. PEDCo Environmental, Inc. Control Tech iques for the
Crushed -.ad Broken Stone Industry (Drafu). EPA Contract
Nos. 68-01-4147 and 68-02-2603, Cincinnati, May 1978.
3. Compilation of Air Pollution Emission Factors. 2nd edition.
Environmental Protection Agency, AP-42, February 1976. pp.
8.6-1 to 8.6-4, C16.
4. Technical Guidance for Control of Industrial Process Fugi-
tive Particulate Emissions. EPA-450/3-77-010, March 1977.
5. Air Pollutant Emission Factors. U.S. Department of Health,
Education and Welfare. APTD-0923, PB-206924, April 1970.
6. Aeros Manual Series Volume II: Aeros User's Manual. EPA-
450/2-76-029 (OAQPS No. 1.2-039), December 1976.
7. Aeros Manual Series Volume V: Aeros Manual of Codes. EPA-
450/2-76-005 (OAQPS No. 1.2-042), April 1976.
8. Standard Industrial Classification Manual. 1972 edition.
Prepared by Office of Management and Budget. Available from
Superintendent of Documents, Washington, D.C.
9. Loquercio, P., and W.J. Stanley. Air Pollution Manual of
Coding. U.S. Department of Health, Education and Welfare.
Public Health Service Publication No. 1956. 1968.
8.20-27
-------
10.1.2 SULFATE (KRAFT) WOOD PULPING
PROCESS DESCRIPTION1'2
Wood is the most important source of fiber for paper pulp.
The pulp, or cellulose fibers, are extracted from the wood by
dissolving the lignin that binds the cellulose fibers together.
The pulp is used as raw material in the manufacture of paper,
cardboard, tissue, toweling, and related products.
The kraft process accounts for about 65 percent of all pulp
produced in the United States. This process, also known as the
sulfate process, is shown in Figure 10.1.2-1. Wood chips are
cooked (digested) in an aqueous cooking liquor at high tempera-
ture and pressure. Regeneration or recovery of the cooking
chemicals is also part of the kraft process.
The wood that is used as raw material may be purchased as
chips from other forest product manufacturers, or it may be
produced directly from logs or wood at the pulp mill. "White
wood," from debarked logs, is the preferred material. The logs
are cut at a 45-degree angle to the grain in a high-speed chipper,
producing a chip that measures about 1 inch by 1 inch by 3/16 inch,
The chips are screened for size and sent to a storage area.
When they are needed, the chips are conveyed from storage
and placed in a digester. Cooking liquor, containing sodium
sulfide and sodium hydroxide also known as "white liquor, is
10.1.2-1
-------
I UQlwl
OXIDATION
i-07-OOI-M I I(M« J
iiquo> oiim
TOUCH
3-90-00«-"9
4 - RESIWMM OH
5 - OISIIUHIE OH
6 - HATIIRM GAS
LCGfMI:
Q EMISSION FACTOK*
0 EMISSION FACTOR NOT OEVELOPEO
F0« THIS PROCESS
009 (66.0) DENOTES CONTKH. EQUIP.
COK KITH EST. EFF. SHOWN
IN ( )
-
O
MNOTES FUGITIVE
EHISSIONS
OEIIOTES A STACK
IK POUNDS PEK SCC UNIT
Figure 10.1.2-1. Sulfate (kraft) wood pulping.
10.1.2-2
-------
added. The cooking time varies from 2 to 5 hours, at a tempera-
ture of about 350°F and a pressure of 100 to 125 psig. When cook-
ing is completed, the contents of the digester are forced into
the blow tank, where the gases are relieved and the pulp and liquor
are separated. Flash steam and gases released from the digester
are vented through a turpentine condenser, where heat is recovered
and the condensable vapors, in the form of t .rpentine, are removed.
Gases from the blow tank are also sent to a separate condenser.
The noncondensable gases, which are a source of malodors, are
primarily reduced sulfur compounds. They are either confined and
treated or released directly to the atmosphere. The ususal
treatment, where one is applied, is to carry the gases to the
lime kiln and introduce them with the air for combustion.
The pulp from the blow tank is separated from the spent
cooking liquor, which is known as black liquor, by screening and
washing. If the pulp is to be bleached, that operation is done
at this time. The pulp is sent to the paper machine for futher
processing, or it is stored until needed.
The black liquor that is removed during washing contains
about 96 percent of the alkali from the chemical solution that
was originally charged to the digester. In some older kraft
pulping plants, this weak black liquor is conveyed to a liquor
oxidation tower where it is pumped against the flow of flue gas
from the recovery furnace. This step is designed to oxidize the
reduced sulfur compounds that are a source of malodors. In newer
plants, the oxidation tower is eliminated, and oxidation is per-
formed at a later stage in the recovery process.
10.1.2-3
-------
The liquor is then pumped to a multiple-effect evaporator,
which uses steam to bring the liquor from a solids concentration
of 15 percent to one of 50 percent. Using the heat from the
recovery furnace flue gas, the liquor is further concentrated to
between 55 and 70 percent solids in either a direct-contact or a
cascade (closed) evaporator. The direct-contact evaporator may
include a cyclonic scrubber in older plants, or an ESP in newer
ones. The concentrated black liquor is then burned in the re-
covery boiler furnace, and the heat from the combustion of the
organic constituents is used to generate steam. The inorganic
compounds that remain after burning are removed from the recovery
furnace and dissolved in water in a smelt dissolving tank. The
green liquor that is formed is then passed to a causticizer tank
and treated with slaked lime, to convert the sodium carbonate to
sodium hydroxide that can be recycled back to the digester. The
lime slurry from the causticizer, after passage through a vacuum
filter, is dewatered and calcined in a lime kiln and stored for
reuse.
Kraft mills operate continuously for about 350 days a year,
with downtime only for routine maintenance. Their production
capacities range between 150 and 2700 tons of pulp per day.
EMISSIONS
Both particulate and gaseous pollutants are emitted from
kraft pulp mills. The emission sources are identified in Figure
2
10.1.2-1. For some of the sources, AP-42 provides emission
factors, which are listed on the process flow diagram.
10.1.2-4
-------
Emissions from debarking, chipping, screening, and storage
are minor.
The emissions from the digester and blow tank contain re-
duced sulfur compounds that pass through the condensers.
Small amounts of sulfur dioxide are emitted during the
washing and screening of the digested pulp. Section 10.1.2 of
AP-422 lists an emission factor of 0.1 Ib per ton of air-dried,
unbleached pulp.
Liquor oxidation towers, when used, are sources of sulfur
dioxide and small amounts of reduced sulfur compounds. The
multiple-effect evaporator emits small amounts of sulfur dioxide
and reduced sulfur compounds.
The direct-contact or cascade evaporator receives flue gas
from the recovery furnace; therefore these two units are con-
sidered one emission source. This is the major emission source
in kraft pulping mills from which particulates, sulfur dioxide,
carbon monoixde, and reduced sulfur compounds are released. The
particulates are generally less than 1 ym in diameter. Sulfur
dixoide emissions result mostly from the oxidation of reduced
sulfur compounds in the recovery furnace. Carbon monoxide emis-
sions are considerable. Sodium sulfide in the black liquor
reacts with carbon dioxide in the flue gas to produce hydrogen
sulfide, which along with several other organic sulfur compounds,
is responsible for the characteristic odor of sulfate pulping
mills.
10.1.2-5
-------
The smelt dissolving tank and lime kiln are sources of
particulate emissions. The lime kiln also emits CO and SO-.
The causticizer tank and vacuum filter are not emission sources.
Some nitrogen oxides are emitted from the recovery furnace
and lime kiln, but the amounts are relatively small. Nitrogen
oxide emissions from each of these sources are about 1 Ib per
2
air-dried ton (ADT) of pulp produced.
CONTROL PRACTICES1'2
The minor emissions from debarking, chipping, screening, and
storage are not controlled.
In most cases, the gases released from the digester are
vented to a condenser for recovery of the crude turpentine. The
emissions from the blow tank are also sent to a condenser.
Noncondensable, odorous gases from the digester and the blow tank
may be vented to a stack, but are most often sent to the lime
kiln where the reduced sulfur compounds are destroyed by thermal
oxidation.
The multiple-effect evaporator, which is a source of small
amounts of SO- and reduced sulfur compounds, is usually uncon-
trolled.
The few emissions from the liquor oxidation tower are
either vented without treatment to a stack, or sent to the
multiple-effect evaporator.
The reduced sulfur compound and SO- emissions from the
washing and screening operations are not controlled.
10.1.2-6
-------
Several new mills have adopted recovery systems that eliminate
the conventional direct-contact evaporators. In one system,
preheated combustion air, rather than flue gas, is used for the
evaporation. In another, the multiple-effect evaporator system
is extended to replace the direct-contact evaporator altogether.
Both systems can reportedly decrease the reduced sulfur emissions
from the recovery furnace by more than 95 percent when compared
2
with uncontrolled systems using direct-contact evaporators .
In conventional systems, flue gas emissions from the re-
covery furnace are vented to the direct-contact or cascade evapo-
rator, and particulates are controlled by the evaporator control
devices. Particulates are controlled in a variety of ways.
Control is especially important in mills where either a cyclonic
scrubber or a cascade evaporator serves as the final liquor
concentrator, because these devices are only 20 to 50 percent
efficient for particulates. An electrostatic precipitator is
most often used after the evaporator to provide an overall parti-
culate control efficiency of 96 to >_99 percent. In a few mills,
however, a venturi scrubber is used after a direct-contact
evaporator to provide 80 to 90 percent particulate control. In
either case, auxiliary scrubbers with an average efficiency of 90
percent may be included after the precipitator or the venturi
scrubber to provide additional control of particulates. Carbon
monoxide and sulfur dioxide emissions are not controlled, al-
though the SO2 is incidentally reduced by the particulate control
devices.
10.1.2-7
-------
Particulate emissions from the lime kiln are controlled by
venturi scrubbers having an efficiency of 99 percent. Smelt
dissolving tanks use a mesh pad, together with a scrubber, if
needed to remove mists. The efficiencies of these systems have
been reported as 75 and 80 percent, respectively.
Although odor control devices are not generally used in kraft
mills, control of the reduced sulfur compounds that produce the
odors can be accomplished by process modifications and by improved
operating conditions. For example, black liquor oxidation systems
can considerably reduce odorous sulfur emissions from the direct-
contact evaporator.
CODING NEDS FORMS
5-8
The sources of criteria pollutants associated with sulfate
(kraft) pulping are:
Source
Washers/screens
Liquor oxidation tower
Multiple effect
evaporator
sec
3-07-001-02
3-07-001-09
3-07-001-03
Recovery furnace/direct- 3-07-001-04
contact evaporator
Smelt dissolving tank
Lime kiln
In-process fuel
3-07-001-05
3-07-001-06
3-90-OOX-99
Pollutants
SO,
SO,
so2
Particulates,
S02, CO
Particulates,
O \J •-)
Particulates,
S02, CO
10.1.2-8
-------
Standard NEDS forms for each of the sources, Figures
10.1.2-2 through 10.1.2-7, show entries for the SCO's and other
codes. Entries in the data fields give information common to
sulfate (kraft) pulping. Information pertinent to coding the
source is entered on the margins of the forms and above or below
applicable data fields. Entries for control equipment codes,
other optional codes, emission factors, and required comments
minimize the need to refer to the code lists. Typical data
values for operating parameters, control equipment efficiencies,
and other source information are shown on the form (or in the
text) only to aid in rapid, approximate checks of data submitted
by the plant in a permit application or similar report. Data
entered in EIS/P&R and NEDS must be actual values specific to and
reported by the plant, rather than typical values. Contact the
plant to validate or correct questionable data and to obtain
unreported information. See Part 1 of this manual for general
coding instructions.
The digester and blow tank are sources of reduced sulfur
compounds, but a NEDS form is not required for these sources
because no significant amounts of the criteria pollutants are
emitted.
Emissions from washing and screening and from the liquor
oxidation tower, when used, are usually uncontrolled. Figures
10.1.2-2 and 10.1.2-3 are standard NEDS forms for these sources.
The multiple-effect evaporator is a source of SO,, emissions.
These are usually vented through a stack with no control devices.
Figure 10.1.2-4 is a standard NEDS form for this source.
10.1.2-9
-------
The major sources of particulate emissions are the recovery
furnace/direct-contact evaporator, lime kiln, and smelt dis-
solving tank. In some mills, a cyclonic or a venturi scrubber or
a cascade evaporator serves as the direct-contact evaporator,
with no further controls. When this is the case, the process is
considered to have no control equipment. An electrostatic
precipitator, however, is sometimes used after the direct-contact
evaporator, and would be coded as the primary control equipment
for particulates from the furnace. If an auxiliary scrubber is
used with the ESP, the scrubber would be coded as a secondary
control equipment for particulates.
The wet scrubber reduces S02 emissions by about 40 percent,
and when it is used it is coded as a secondary control device for
S02 because it is designed to control particulates and only inci-
dentally controls S02. The CO that is emitted from the furnace
and the evaporator is not controlled, and is unaffected by the
ESP or scrubber control devices. Figure 10.1.2-5 is a standard
NEDS form for the recovery furnace and direct-contact evaporator.
A mesh pad or mist eliminator is used on the smelt dissolv-
ing tank as a primary control device for particulates. This may
be followed by a wet scrubber as a secondary control device.
Figure 10.1.2-6 is a standard NEDS form for this source.
A standard NEDS form for the lime kiln is shown in Figure
10.1.2-7. A venturi scrubber is used to reduce particulates from
the kiln. Emissions of SO^ and CO are not controlled. When
10.1.2-10
-------
emissions from other sources are vented to the kiln, enter a
comment in the comments field stating this.
The SCC units are expressed as air-dried tons of unbleached
pulp.
CODING EIS/P&R FORMS9
The EEC's of the process equipment in a kraft mill are:
Device EEC
Washers/screens 450
Liquor oxidation tower 292
Multiple-effect evaporator 308
Recovery furnace and direct- 206/303
contact evaporator
Smelt dissolving tank 287
Lime kiln 231
10.1.2-11
-------
Figure 10.1.2-2. Standard NEDS form for sulfate (kraft) wood pulping - washers/screens.
to
I
to
NATIONAL [MISSIONS OAIA SYSUM IfcCOS)
iMFNTAL PROTECTION AGENCY
OFHCt OF
Njmv ol (V .on
Ct «npVu»y Fo.rr
FOUV Af'PnovEO
OV& NO 108 KOG05
D.*ie „
MM
! :
1 Lt
«M
_LLL
BHS
_oiioloo1^IoloioooioTo ooloroolo oooolooloio
i'. 'X 47 iJ «l It
JZL
,0000 IF NO COmON STACK
POINT ID'S IF COHCN STACK
CS71«.'.AT£D cyjlPOL if FICI£«CV (-.1
r .ir-tip -::pi:>
ffiimr
0.01
so-.
. ESTiV.ATES Horti v*»l
^W-Jrn:
frmr
HASHERS/SCREENS
IP 3
i.nslrcT.'i
cm
1 >l
. -1.,
3 517
iiLU-
1
_ L_
s
n
?>
~
cc S(
III
;,
0
-
1
1
?4
n
:c
o.
~
-s
Ul
,
2^
^
ALL
C'-l-.
rJ>.f?i[jT
~
IT-*
rL
s
.
-
-
t;
J
IP
.IT
tl
XT
ABLE
17
-
^OfiY TON
-%
R 1TP
1,1
,|
i-
u
Et'iSSICNS u..
NO,
Mfiqsrai;
b
:9
S UNBLEACHED P
ji
«a
Ib
,.
iE
3;
ii
-
10
ULP,-:
;i
4.
0
7TO
1 ro
1 o|
t
•j
j;
;
0
4,'
si
«
f u. !
K
!t
-
r
U in
Sj
s>
jS
0
ills.'
Jo
'-
S3
~LH l
JULE
@K
w
£
U
•£
S3
T.-.TIJ
fOAI
tO
c,
5
E
(2
63
C
CO'
(i
«
«
C!
TROt ftEGU
t«
70
Co-nn-.e"li
~,ils
j_
!
I
1
!
U
14
Vj
-
•*
bJ
'.t
S3
hi
61
U
63
64
(S
it
tl
6i
65
JC
71
1
71
P
7?
;
c
72
t-ATlONS
73
74
75
7k
77
73
74
75
75
J7
5
fed
71J7SJ80
|?| 5
5
/'!
ca
T: K
f 6
~ 6
» 6
f 6
P 6
-
31 3.'
r
«
",
-
if,
!J
-
V<
;c
!]
j-
!'.
j:
-
45
-
^
j-
-
:i
M
5:
',?
U
54
*^
V
V
V
SI
to
(1
J?
It
f.
-
K
it
6'
k?
H
(0
71
;<
73
'«
?i
!l
''
i
;E
cd
fe »
P 7
P 7
P 7
-------
Figure 10.1.2-3. Standard NEDS form for sulfate (kraft) wood pulping - liquor oxidation tower
APPHOvrO
OMB NO (rjH R0095
0.1!
to
I
M
U)
POINT ;,ouncE
NATIONAL EMISSIONS OAT A SYSTEM (NEOS)
ENVIRONMENTAL PROTECTION AGENCY
OFIICt OF AIR PROGRAMS
,0000 IF NO COtfON STACK
/XXXX POINT ID'S IF COHON STACK
LIQUOR OXIDATION TOWER '___
M*^
^ ,
3: 3i
"V
,
j(
:&
i)
!C
-'
t;
0
t.
i'
uel
1 ^
"1
^
iO
0
it
i.'
u
'4
«
«.
51
•i
ii
0"
63
(I
it
t:
a
u
f>
d:
(1
i«
M
70
?
i-
71
P
5
»
?(
'5
't
;;
8
<
It
ed
'S K
"• €
* G
• f,
ul 6
P 6
-------
Figure 10.1.2-4. Standard~NEDS form for sulfate (kraft) wood pulping - multiple-effect evapprator,
lir
n:
intifrHii
NATIONAL EMISSIONS DATA SYSTEM (NCOS)
ENVIRIHiMrNiAl PHOrFCTION AGENCY
QFFICl OF AIH PROGRAMS
FOH.V, APPROVED
OVfc NO 1M K009S
ZUilLUJLL-LJ
SSI3L
.iltipflii
J± u
010
ril
OjO
;-|.irn
T±j
iiR
olmo
0[Q|0
_
wjsi .a \iih
TTTT
.0000 IF NO COMMON STACK
XXXX POINT ID'S IF COMMON STACK
COMPOL EFFICIENCY I
--t-i-S
Et.tlS'llON fSTl
0.01
I II 10
ESTIMATION
METHOD
63!
U
I
I-1
MULTIPLE-EFFECT EVAPORATOR
cSCC UNJT-AI*-WY TONS UNBLEACHED PULP,':
STATUS
CONTROL REGULATIONS
Hf^i 1 I fl^q 2
H, .,F^.B«, |
H1^ fal L- -,tc t
T, rrrj^nkl
-------
Figure 10.1.2-5. Standard NEDS form for sulfate (kraft) wood pulping -
recovery furnace/direct-contact evaporator.
NATIONAL EMISSIONS DATA SYSTEM (NEDS)
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF AIR PROGRAMS
OVf ',0 • ?" F-C09S
0000 IF NO COMMON STACK
XXXX POINT ID'S IF COWON STACK
ESP SCRUBBER.
Oil 1-002
CS7.MAT6D CO'iTPOL EFTlC'Er-'CV (M
EMISSION ESTIVATE5
ALLOWABLE EMISSIONS llcni/y
•§
*!
ji
is"
is
5
333
fM ISI CSI
3
rf* «
? » " 2
' 5 8
i \r\ —
0 °
«i
l^j o
s
8
at
_J M
I
s.g s
is ,;
sec SCC UNIT-AfrR-ORY TONS UNBLEACHED PULP-C
I I Furl P.^ri,
S. lirt Wji
^l^'PsRilsofiilv
-rrrrrr
ffi
- ^^-4^ '"'- I ,r"';
^ "
.L
I S. l.rt Wj-.ir
IV I OP-..'..V, B,ir
ziiiTin0iu»i«i5i«
3Trm»
-RECOVERY FURNACE/DIRECT-CONTACT EVAP.
CCKWLNIS
UJ_J_
-I-
-------
9T-Z'T*OT
UNCONTROLLED
H MESH PAD
t/>
WET SCRUBBER
n
ro
NJ
I
ft
(V
0)
h|
a
w
o
en
l-h
o
»-!
3
HI
O
M
Cfl
C
H-
Hi
0)
ft
(D
Hi
ft
O
o
Ul
3
(D
H-
cn
01
o
h-1
-------
Z.T-2'TOT
CONTROL
UNCONTROLLED
SCRUBBER
DEVICE
CODE
001
EFF. ,
X
93
PART.,
LB/TON
45
3
S02.
LB/TON
0.3
0.2
CO.
LB/TON
10
10
p-
H
(D
ro
I
co
rt
W
Hi
O
M
3
HI
O
0")
rt
(D
HI
rt
O
O
P-
3
05
I
p-
(T)
p-
M
3
-------
GLOSSARY
Sulfate or kraft process - A chemical process used to convert
wood to papermaking fibers by using an aqueous solution of
sodium sulfide and sodium hydroxide as the cooking liquor.
Digester - A device in which wood chips react with chemicals, at a
specified pressure and temperature, to separate the wood
fibers by dissolving the lignin.
White liquor - An aqueous solution of sodium sulfide and sodium
hydroxide, used for cooking wood chips in the digester.
Black liquor - Spent or used solution from the digester. It
contains about 15 percent solids as it leaves the digester.
Green liquor - The solution of inorganic compounds generated from
the recovery furnace.
10.1.2-18
-------
REFERENCES FOR SECTION 10.1.2
1. Industrial Gas Cleaning Institute. Air Pollution Control
Technology and Costs: Seven Selected Emission Sources.
PB-245-065. Stamford, Conn., December 1974.
2. Compilation of Air Pollutant Emission Factors, 3rd edition.
Environmental Protection Agency. AP-42, August 1977.
3. Lund, H.F., (ed). McGraw-Hill Book Company, Industrial
Pollution Control Handbook. New York, 1971. pp. 18.17-
18.27.
4. Standards of Performance For New Stationary Sources. I^raft
Pulp Mills. Federal Register, Volume 43, No. 37, February
23, 1978.
5. Vatavuk, W.M. National Emission Data System (NEDS) Control
Device Workbook; U.S. Environmental Protection Agency
APTD-1570, July 1973.
6. Aeros Manual Series Volume II: Aeros User's Manual. KPA
450/2-76-029 (OAQPS No. 1.2-039), December 1976.
7. Aeros Manual Series Volume V: Aeros Manual of Codes. EPA
450/2-76-005 (OAQPS No. 1.2-042), April 1976.
8. Standard Industrial Classification Manual, 1972 edition.
Prepared by Office of Management and Budget. Available from
Superintendent of Documents, Washington, D.C.
9. Loquercio, P., and W.J. Stanley. Air Pollution Manual of
Coding. U.S. Department of Health, Education, and Welfare.
Public Health Service Publication No. 1956. 1968.
10.1.2-19
-------
10.1.3 ACID SULFITE PULPING
PROCESS DESCRIPTION1"3
About 15 percent of the 35 million tons of paper pulp pro-
duced annual"y in the United States j r manufactured by the sul-
fite pulping process. The lignin that binds the cellulose fibers
of the wood together is dissolved by an acid sulfite digestion
liquor composed of sulfurous acid and bisulfite salts. The pulp
(extracted cellulose fibers) is then used as the raw material for
the manufacture of such products as paper, cardboard, tissue, and
toweling. The sulfurous digestion or cooking liquor is in solu-
tion with various bisulfites that act as buffers: calcium,
especially in older mills; ammonium; sodium; or, increasingly,
magnesium. The lignin is removed from the cellulose as soluble
lignosulfonotes. Figure 10.1.3-1 is a flow diagram of a sulfite
pulping process using magnesium.
Wood for raw material may be purchased as chips from other
forest product manufacturers, or may be formed from logs or wood
at tho pulp.ng mill. "White wood," from debarked logs, is the
prefeired material. Wood is transported to the mill by rail,
barge, trucl , or ship, and is stored in piles or in water. Logs
are washed io remove dirt and are then debarked in drum or hy-
draulic bari ers. The debarked logs are reduced to chips to
10.1.3-1
-------
3-U/-002-XX
RECOVERT SYSTEM
BASE
«g 0
HH3
Na
XX
21
22
23
1 ®
| S02 (9)
1 FLl
1
1
1
1
1
1
1
1
T
*
1
CONTROL
DEVKF
E GAS f«
WATER/
MAGNESIUM |
"bULFITE '
1
1
1
1
1 SCRUBBER Ut>3
DIRECT
— -p*- ^503 CONTAC
SO^W EVAPORAl
(^ "1 STRONG RED
L. — —1 i iramo
S02
ABSORBER
ACID
FORTIFIER
MULTIPLE-
EFFECT
EVAPORATOR
3-07-002-VV
DIGESTER AND PULP
BLOW PIT OR OUHP TANK
PULP
BASE
HH3
Ra
Ca
tw
31
32
33
HOT t
T
t
IATER )
t
WASHING AND
SCREENING
SULFUR
BURNER
AIR
MAKEUP
SULFUR
WEAK RED LIQUOR
Hg(OH)2
RED LIQUOR CONCEN1PATE
WATER
PROCESS (DIGESTER & BLOW PIT OR DUMP TANK)
ALL BASES EXCEPT Ca
C« BASE
MgO WITH RECOVERY SYSTEM
MgO W/PROCESS CHANGE it SCRUBBER
Nf»3 H/PROCESS CHA06E t SCRUBBER
Na W/PROCESS CHANGE & SCRUBBER
VV
03
12
13
14
15
3-07-002-34
WASHING AND
SCREENING
UNBLEACHED
PULP
*THESE LINES MAY
GO DIRECTLY TO
THE SO? ABSORBER
LEGEND:
(3 EMISSION FACTOR3
0 EMISSION FACTOP NOT DEVELOPED
FOR THIS PROCESS
009 (66.0) DENOTES CONTROL EQUIP.
» CODE HI Til FST. EFF. SHOWN
I "I ( )
x, DENOTE'.. Flit,! TIV'
.-' EMISSION
Q DENOTES A STACK
III POUNDS PFP Sfr UNIT
Figure 10.1.3-1. Magnesium - Based Sulfite Pulping Process
1.3-2
-------
achieve a uniform size and to allow proper penetration of the
cooking liquor. The chips are screened, washed, and stored in
piles.
Sulfurous acid for the digestion liquor is made by burning
sulfur and dissolving the resulting SO.-, in water. Some of the
acid is converted to bisulfite (by adding calcium, ammonium,
sodium, or magnesium) to bring the mixture to the desired pH.
The liquor and the wood chips are mixed together in a digester at
high temperature and pressure. When cooking is complete, the
mixture is discharged into either a blow pit or dump tank, de-
pending on how pressure is released. The spent sulfite liquor
(red liquor) is separated out and the pulp is washed free of the
remaining liquor with hot water. The pulp may be bleached during
subsequent papermaking operations.
Treatment of the spent liquor depends on the base that is
used. Figure 10.1.3-1 shows a magnesium system. Other systems
are similar although some older mills do not practice any chem-
ical recovery. In a magnesium system, after being separated from
the pulp, the liquor is partially concentrated in multiple-effect
evaporators. It is then further concentrated in a direct-contact
evaporator using hot flue gas from the recovery furnace. The
concentrated liquor, at 55 to 60 percent solids, is burned in the
recovery furnace (without extra fuel), where the magnesium is
converted to magnesium oxide (MgO) and the sulfur species is oxi-
dized to S02.
10.1.3-3
-------
The magnesium oxide is a solid, occurring in the form of
fine particulates. It is separated from the flue gas by a me-
chanical collector, usually a cyclone that is part of the process
equipment, and slurried in water to become magnesium hydroxide
[Mg(OH)2l. It is then sent to the S02 absorber. The hot flue
gas is also sent to the S02 absorber, after traveling through the
direct-contact evaporator and picking up water vapor. In the
absorber the gas stream is dissolved in the Mg(OH)_ solution,
regenerating the sulfurous acid and magnesium bisulfite liquor.
Makeup acid, which passes through a sulfur burner and an acid
fortifier, is added as needed.
In calcium-based systems, the furnace is used for heat
recovery to produce steam. The solids leaving the furnace are
calcium oxide and calcium sulfate; some SO,, is present in the
flue gas. The solids are discarded after collection by an ESP or
a cyclone control device, and the cleaned flue gas enters the
atmosphere. In some cases, the flue gas is sent to the S0~
absorber, which may be a limestone-packed tower or a series of
three or four venturi scrubbers.
In ammonium-based systems, the products of the liquor com-
bustion in the recovery furnace are SO0 water, and nitrogen.
~ i
Very few solids are present; they are collected by a mechanical
dust collector and discarded. The S0« is absorbed from the flue
gas by an ammonia solution to make the digestion liquor.
10.1.3-4
-------
Sodium-based systems are often operated next to a kraft
plant, and the spent liquor is burned with the black liquor from
the kraft pulping. In other cases, it is burned alone in a
kraft-type furnace and the sodium that is recovered as a sulfide
smelt is reused after chemical treatment- or it is shipped to a
1-4
nearby kraft mill and used there. The SO2 is absorbed from
the flue gas by sodium carbonate that is recrvered from the
smelt. Makeup sulfur dioxide is added to produce sodium bisul-
fite liquor for digestion.
EMISSIONS1"4
Particulates and SO2 are the major pollutants from sulfite
pulping. Emission sources are identified in Figure 10.1.3-1.
4
For some of the sources, AP-42 provides emission factors, which
are listed on the process flow diagram. For other sources of
emissions, average emission rates obtained from other documents
are mentioned in the following source descriptions.
No significant emissions are generated by debarking, chip-
ping, screening, and storage. The digester and blow pit or dump
tank are a source of S02 emissions as well as acid mists and
water vapor. The pH of the digestion process affects the SO~
emissions from these operations and from subsequent washing
operations. Sulfurous acid, which has a high vapor pressure, is
present in a greater proportion at low pH. The high vapor pres-
sure causes S02 to be released from the solution, resulting in
more emissions. Solutions with higher pH levels have less poten-
tial for S02 emissions.
10.1.3-5
-------
The digester relief and discharge techniques also affect
emissions. When contents are blown out under high pressure,
large amounts of SO,,, which are difficult to capture and treat
efficiently in scrubbers, are released. When the pressure in the
digester is relieved and the contents are pumped into a dump tank
the volume of emissions is much less and is more easily captured
and controlled.
Some sulfur dioxide is emitted from the washing and screen-
ing operations. When the other emission sources are well con-
trolled, this can be a large percentage of the total S0? emis-
sions from sulfite pulping.
The multiple-effect evaporator is a source of S02 emissions,
and the recovery furnace is a source of both S02 and particu-
lates. Particulate emissions are minimal where ammonia is used,
although some gaseous ammonia may be emitted. Where magnesium is
used, magnesium oxide particulates are released from the recovery
furnace. Where calcium is used, particulates composed of calcium
oxide and calcium sulfate are released. The calcium is not
reused. Where sodium is used, some particulates in the form of
sodium carbonate and sodium sulfide are emitted from the recovery
furnace; however, most of the material is retained in the smelt.
Particulates and S02 from the recovery furnace pass through the
direct-contact evaporator, picking up additional reduced sulfur
compounds in the evaporator. These may be released as emissions
or pent to the S02 absorber.
10.1.3-6
-------
Where chemical and heat recovery are practiced, the sulfur
oxide is scrubbed from the flue gas in the S02 absorber. The
emissions from the absorber are particulates and SO2.
The sulfur burner and acid fortifier, which provide makeup
acid for the digester, generate SO2; however, the exhaust is sent
to the SO« absorber and is not considered an emission source.
Estimates of S02 emissions from dif ferer c. process equipment,
without controls, are given below:
Equipment SO,., emissions, Ib/ton of pulp
(dry weight)
Blow pit 100-500
Dump tank 10-25
Multiple-effect evaporator 5-10
S02 absorber 10-25
Recovery furnace (NH3 base) 250-500
Small amounts of nitrogen oxides and carbon monoxide may be
emitted with the flue gas from the recovery furnace. The gas is
generally sent to the S02 absorber before being vented to the
atmosphere.
CONTROL PRACTICES1"
Emission factors from various sources, with and without
4
controls, are listed in Table 10,1.3-1.
Emissions from the digester and blow pit or dump tank are
either sent to a scrubber or to the SO,, absorber for recovery of
SO- to be used as digestion acid.
Sulfur dioxide generated during washing and screening of the
digested pulp is not controlled.
10.1.3-7
-------
TABLE 10.1.3-1. EMISSION FACTORS FOR SULFITE PULPING'
Source
Digester blow pit
or dump tankc
Recovery system'
Acid plant?
Other sources1"-
Base
All
MgO
MgO
MgO
MgO
NH..
NH3
Na
Ca
MgO
NH3
Na
NH,
Na
Ca
All
Control
None
Process change6
Scrubber
Process change and scrubber
All exhaust vented through re-
covery system
Process change
Process change and scrubber
Process change and scrubber
Unknown
Multiclone and venturi scrubbers
Ammonia absorption and mist
eliminator
Sodium carbonate scrubber
Scrubber
Unknown*1
Jenssen scrubber
None
Emission factor
Particulates,
Ib/ADUT
Negd
Neg
Neg
Neg
Neg
Neg
Neg
Neg
Neg
2
0.7
4
Neg
Neg
Neg
Neg
Sulfur dioxide,
Ib/ADUT
10-70
2-6
1
0.2
0
25
0.4
2
67
9
7
2
0.3
0.2
8
12
a Data taken from Reference 4. All emission factors represent long-term average
emissions.
b Factors expressed in terms of Ib of pollutant per air dried unbleached ton of pulp (ADUT)
c These factors represent emissions that occur after the cook is completed and when the
digester contents are discharged into the blow pit or dump tank. Some relief gases
are vented from the digester during the cook cycle, but these are usually trans-
ferred to pressure a'ccumulators, and the SO2 therein is reabsorbed for use in the
cooking liquor. These factors represent long-term emissions; in some mills, the
actual emissions will be intermittent and for short time periods.
Negligible emissions.
e Process changes may include such measures as raising the pH of the cooking liquor,
thereby lowering the free S02; relieving the pressure in the digester before the
contents are discharged; and pumping out the digester contents instead of blowing
them out.
f The recovery system at most mills is a closed system that includes the recovery
furnace, direct-contact evaporator, multiple-effect evaporator, acid fortifier,
and SO, absorption. Generally, there will only be one emission point for the
entire recovery system. These factors are long-term averages and include the high
S02 emissions during the periodic purging of the recovery system.
9 Acid plants are necessary in mills that have no or insufficient recovery systems.
h Control is practiced, but type of control is unknown.
1 includes miscellaneous pulping operations such as debarking, chipping, washing,
and screening.
10.1.3-8
-------
Sulfur dioxide emissions from the multiple-effect evaporator
are controlled by a scrubber or are vented to the SO2 absorber
for reuse in digester acid.
Particulates generated in the recovery furnace are con-
trolled by an ESP or by mechanical dust collectors, such as
cyclones. Sometimes these devices are used together. When the
captured particulates are recycled to the process, as in magne-
sium-based pulping, the cyclone is considered process equipment;
ESP's or scrubbers that follow the cyclone are control devices.
Calcium oxide, calcium sulfate, and whatever particulates
result from ammonium-based combustion are discarded. Most of the
particulates in a kraft furnace (which is used for sodium-based
liquor), are removed as molten smelt from the bottom of the
furnace. Particulates entrained in the flue gas are partly
removed by mechanical means (usually cyclones), and sometimes
also by an ESP or scrubber. In processes using ammonia, sodium,
and calcium, the cyclone, ESP, and scrubber are considered
control equipment.
After the particulates have been removed, the exhaust gas
(containing S02) may be sent directly to a stack, or vented to
the direct-contact evaporator for heat recovery and then ex-
hausted through a stack. The latter is practiced in some older
plants. Usually, however, the recovery furnace gas is sent
through the direct-contact evaporator to provide heat for
evaporation and is then sent to the S02 absorber to recover SO,,.
10.1.3-9
-------
These absorbers remove most of the SC^. Efficiencies of more
than 95 to 98 percent are reported for Mg(OH)2 venturi-type
absorber s.
CODING NEDS FORMS
The sources of emissions in a sulfite pulping mill are:
Source SCO Pollutant(s)
Digester and blow pit or 3_07_002_vv so
dump tank L
Washing and screening 3-07-002-34 S02
Recovery System 3-07-002-XX S02> particulate
The numbers assigned to the letters in the SCC's vary ac-
cording to the buffering agent used. The specific codes are
shown in Figure 10.1.3-1.
Standard NEDS forms for each of the sources, Figures 10.1.3-
2 through 10.1.3-5, show entries for the SCC's and other codes.
Entries in the data fields give information common to sulfite
pulping. Information pertinent to coding the source is entered
on the margins of the forms and above or below applicable data
fields. Entries for control equipment codes, other optional
codes, emission factors, and required comments minimize the need
to refer to the code lists. Typical data values for operating
parameters, control equipment efficiencies, and other source
information are shown on the form (or in the text) only to aid in
10.1.3-10
-------
rapid, approximate checks of data submitted by the plant in a
permit application or similar report. Data entered in EIS/P&R
and NEDS must be actual values specific to and reported by the
plant, rather than typical values. Contact the plant to validate
or correct questionable data and to obtain unreported informa-
tion. See Part 1 of this manual for general coding instructions.
Figure 10.13-2 is a standard NEDs form for the digester and
blow pit or dump tank. A different SCC -lumber is assigned to the
blow pit or dump tank according to the base that is used. The
scrubber on the digester and dump tank or blow pit, which is a
primary control device for S02, is coded as 053. If the emis-
sions are sent to the S02 absorber, it is the control device and
is coded as 050 or 051.
Emissions of SO 2 from washing and screening are fugitive.
A standard NEDs form for this source is shown in Figure 10.1.3-3.
The recovery system employed by sulfite pulp mills involves
multiple pieces of process equipment including a multiple-effect
evaporator, recovery furnace, direct-contact evaporator, and S02
absorber. The controls applied to and procedures for venting
exhaust gases from each piece of equipment may vary from one mill
to another. In many mills the recovery system is a closed system
that includes all of the process equipment noted above. As such,
there may be only one emission point for the entire system. Figure
10.1.3-4 is a standard NEDS form which treats the entire recovery
system as only one emission point. The emission factors in
Table 10.1.3-1 are also expressed on this basis.
Alternatively, if each piece of equipment is separately vented
to the. atmosphere, to a specific control device or to some other
process it may be nore appropriate to treat each piece of
10.1.3-11
-------
equipment as a separate emission point. In these cases, separate
point ID's should be assigned and a. NEDS form coded for each piece
of equipment as necessary. The SCC for the recovery system,
reflecting the appropriate chemical base, should be used in each
case. Indicate in a card 6 or card 7 SCC comment, the process
equipment that is represented by the emission point. If no
common stack is shared with some other piece of equipment in the
recovery system, enter (jxtxfxfr in points with common stack field.
If a common stack exists, indicate appropriate point ID's in
this field instead. Code control equipment codes as appropriate.
Specific information for each process is given below.
The multiple-effect evaporator is coded according to the
base used, either Mg, NH-j, or Na. The wet scrubber control
device is coded as 053. When the emissions are instead sent to
the S02 absorber, code 050 or 051 as the control device. No
NEDS form for the multiple-effect evaporator need be coded in
this case. Include a comment with the SC^ absorber point, that
it includes multiple-effect evaporator off-gases.
The recovery furnace generates SC^ and particulate emissions.
Particulates are generally removed from the gas stream by a
mechanical dust collector, usually a cyclone. For processes
using Ca, NH , and Na, this cyclone is a control device; for
processes using Mg, the cyclone is considered process equipment.
10.1.3-12
-------
An ESP, where used, is a control device. Where the ESP follows a
cyclone in Ca, NH^, and Na processes, the ESP is a secondary
particulate control device. After particulate removal the gases
may be vented to a stack, to the direct-contact evaporator, cr to
both the evaporator and the SCU absorber. In the last two cases,
the emissions are included on the NEDS forms for the direct-
contact evaporator or the 862 absorber. The coder need not include
a point for the recovery furnace in this case. Indicate by a
comment ^n the direct-contact evaporator or SC>2 absorber emission
point, that off-gases from the recovery furnace are included.
The direct-contact evaporator receives flue gas from the
recovery furnace. In some older plants, the gas is vented to a
stack after passing through the evaporator. In most plants, the
gas is sent to the 862 absorber for SC>2 recovery. Where this is
the case, the emissions from the direct-contact evaporator are in-
cluded on the NEDS form for the S02 absorber. The coder should
include a comment on the SO^ absorber emission point that direct-
contact evaporator emissions are included. No emission point for
the evaporator needs to be defined in this case.
For the SC>2 absorber, the SCC number is assigned according to
the base used, either Mg, NHo , or Na . No add-on SC>2 controls are
used on the S02 absorber. A comment should be included indicating
any other processes that are vented to the S02 absorber.
CODING EIS/P&R FORMS
The BEG numbers for use. in EIS/P&R forms are:
Device B_EC
Digester and blow pit or dump tank 287
Washing and screening 575
Multiple-effect evaporator 308
S02 absorber 350
Recovery furnace 206
Direct-contact evaporator 303
10,1.3-13
-------
Figure 10.1.3-2. Standard NEDS form for sulfite pulping - digester and blow pit or dump tank.
I-1
o
M
»
LO
1
H-1
*-
Si
1
llf
1
Co..
3
4
o»y
5
t
>
»OCf
1 !
w«m 10
Number
10
11
tr
12
14
nt
>
1
13
C
15
DIGESTER AND BLOW PIT
OR DUMP TANK
AIL BASKS EXCEPT CM
r. BASE
MHO WITH RECOVERY SYSTEM
H«0 W/PROCESS CHANGE I SCRUBBER
Mlj W/PHOCESS CHAra t ICRDBMR
'I. U/PROCr.SS CHAWS t SCRUBBER
•
0}
11
1]
n
u
15
Po
__l
7i
_.
M
)
W
U
o
t
*
17
*
o
*
C
r
i
o
i
^ o
to tr
•- c
lip
_L
1
o
o
r
77
e
if
»
L'i
20
1C
20
Z|D 1
B"iler C
( .f..
dec
frl.
Tit:
II
t
1
—
1 M
k
_!_
P.I.I
15
t
73
«
...
'
20
7
21
2!
2<
£
I
JA
21
71
S
21
"o
sec
-
u
. T
J.,
A
r;
22
cc
III
/7
P
III
-
23
.'!
Q
in
.HI
2!
23
S(
?
_.
24
H
24
i
U
O*'l
h
»v
Oiu
iria
N»v
"
X
t\
l>
26
IM
on
2i
O
Cl
3J
NATIONAL EMISSIONS DATA SYSTEM (NEDS)
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF AIR PROGRAMS
FliahMSmenl Njrie IntJ Artdfcif
33 34 35 X 3) 31 33 « 41 (2 43 44 45 4( :) 4t « 50 i
H
33
so: 1 •*"
w Jill- 3!
G
f
J
30
31
ALLOV
«D
fto
EN
-
30 Jl
U
lie
fii
1C
TS
-
t
f»
Jl
II
u
3:
UAG
^
ON
"F
-
u
Pa.
3!
tlAi
35
M
5-
llfU
14
n 1
35
tl
31
0
J7
11
CONTROL
NO. 1
f* £J Jt
(*1
35
U
18
(1
3!
|U
31
LE EMISSIONS (in
NO.
33
S
V
Tl
33
34
UN
r>Kir
M
35
8L
Hrjt
not
n.,
J5
J)
H 37
EA
. a
lk
CH
3;
li
a
n
ED
3S
(Ml
n
S
1
40
EC
S
to
3? 4r)
0
3?
U
40
'AC* DA
41 42 43
IUIPMIN
MC
tl 42 4-
TA
Flow Flute (It^/m.n)
14 45 H JT U> n 50
0000
EMIS3
SO,
4i 72]7ip
rtWyMr)
n
p
40
UL
'
I
40
41
P.*
i?
.fc?
f
It
-". ;»MOMI
1 1
HC
12
:
:
0
4.1
o
j;
43
43
13
44
4
f
4;
fo
r
45 K.
p
41
.m^ry
CO
41 V)
52
1! rwl
SI 5?
cO
1°
V
51 52
ooooooo
ION ESTIrjIATSS lion
'JO.
45 41 rjjj 41 50 «
45
'
0
1:
JO
MM!
CO
.'<
»lv
10
'.6
«
47
r
.11
''B
J
*
.on
TU
u
-
44
41
"••
50
50
5
sc
n
SI
-«
51
()
/VF
52
52
57
I
POINT
Inpu
Nam* of Perjoi
Omplrhnq Forr
« S< 55 K S? i8 S? W (1
.;
£
10
ESTl
P*i
«[ 54(55
t
y,
(jOI
IM
i/no
I
TCOC
so-.
5) M
l.lo .;;.
UI^^Tru
3
53
53
y
:
i i
OMI'l
SCHE
54
54
—
',4
J
*
""
',S
1 -
1ANU
7ULE
Mo
•*
*
5)
51
~
oc
XX
S1
1
ONTMOl
NO,
5« (0 (1
T?
0
{_Ow
r>
t
it
"
5J
~
iS
r
iS
K
0
"tlAI
T/. TU
Mo
to
otn
M
61
M
-
50U"CE '
Form C
t2|t3|l<
00 IF
XX POI
(2 H (
HC
(2 i) (1
CO
S2 S3 M
ICE ~~
;
D.y S
(2 U ((
nil
S2 U 64J
f
r? fi (1
Com act Prr
15 d: 67 t
NO COMMC
NT ID'S
55 «. f I
1CV I",
CO
55 «](l ,
OCM APPROVED
)WB NO 158 R009S
83 70 71 " »
IN STAC
IF CCW
SS 7» 7
trio! IIP
ESTIMATION
Ul TMOO
- f* V
i O O O O N
(5 K, (I (| t; 7C 7!
0 0
CON
CS U C) 6!
65 U V G?j
<* U I' (,'
0 0
THOL c€
.» 70 71
LI 1 1
si 70 Til
P
r.i if 7i
K
HON
Saacy
4
C
Ir
P
ST
q
)• n
1
:• I'l
A
'4
74
"1
ACK
3
•5 -6 ;-
M ,t
< cC
P 1
H
c
f t
1 • -- £,
1 1 • i
-It -I IT
1 I
't 'i !:
f 6
P 6
» 6
P S
P ;
^ •» ft
• ^
-------
Figure 10.1.3-3. Standard NEDS form for sulfite pulping - Knotters/ Washers/Screens, etc,
UJ
i
Uim
Zone
NATIONAL EMISSIONS DATA SYSTEM (NEDS)
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF AIR PROGRAMS
Eitjt.Mhmenl Nome and Aifrtren
POINT SOURCE
Input Form
FORM APPROVED
O«B N
Njme ul Pfiion
Complelinj Foim_
UTM COORDINATES
STACK DATA
yfYlc Heiqhl
no ilacU h
so hi
CONTROL EQUIPMENT
ANNUAL THRUPUT
StC'
No.
0°
Pfimit'v
HC
with
Ilork x
-0000 IF NO COMMON STACK I.
POINT ID'S IF COMMON STACK
ESTIMATED CONTROL EFFICIENCY i\]
NO,
EMISSION ESTIMATES Uont/y«arl
NO,
WASHING AND SCREENING
ALLOWABLE EMISSIONS lioni/vll'l
NO,
sec SCC UNIT MfUDRY TONS UNBLEACHED PULP?
fu.l P.oc.ll Mou.l,
^COMPLIANCE
COMPLIANCE
ESTIMATION
METHOD
CONTROL REGULATIONS
R'92
-------
Figure 10.1.3-4. Standard NEDS form for sulfite pulping - recovery system.
o
w
1
St
1
,„
7
Cou-i
1
i
j
V
t
CONTROL
7
AOCX
1
J
r
*
10
11
ir
TJ
in
ITJTj
II
"1
)
fb
r
ib
EQUIPMENT
DEVICE
VENTURI
PACKED TOWER
TRAY TOWER
RECO
MRO
Nil]
Nn -
- 21
- 22
n
CODE
VERY
053
050
051
SYSTEM
"o
_l
-
1
IS
u1
o
•
1)
o
o
•
"
,
o 5
. o
: y
if
1
f
tl
li
t:
5
c
c
!;
j
iT
-
b O
*Q
l(.
-
if
-
C
it
i;
1
n
I!
70
:i
SIC
T
Roil
IP'
f
r
17
_
3
i
i
. A
P
1
7C
1
T
NATIONAL EMISSIONS DATA SYSTEM (NEDS)
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF AIR PROGRAMS
.'<
c.
..A
JNUA
:c
r?ra
1
1°
a
t
n
2
.v
P
.V
0
7)
;f
7A
;>:.;/
1 1
U
|
TMCO
S|J7
i
'1
:i
!0
fMlOINA
Eiillis
-
i:
-
T
i)
ji
35
H
Hr.oM I'll
1!
'.-
'b
?
j;
0
1!
IS
33
ih'
F
!C
u
<7
13
S'ACK. DA
Tt-ul^FI
10
1
ii
l.'
l)
a
IA
r
n
I'j
i
IS
F
:>
!'.
:9
te llp/m
rai?
CON1POL IOUIPVINI
; t0~ to fu
:.:..-»
oTolo
. THH
Aun
:r
7'.
F4
IT
1"
1
f -dn'f
71
:;
7)
scciC
III
'I
i
-
/:
3-
...
in
;'
F
;i
,-<
0
0
(J
o c
71
:i
:i
0
n \
HA
O
7«
.'?
Ml
At
I INC,
!1
iO
Jl
•S
s:
0
J!
0
u
0
IS
0
0
i
Jl
ALLO.
;b
C W
IV
;i
-
.»
"
/
;«
IT
n
:;
A
s
Or-
.'«
M
n
nl.fl
:»
.'9
10
II
it
!)
11
3b
is
»ABLC EMISSIO
"O.
j;
T.QKY TON
tn-i ft vf
n
JS.
11
j;
uw
3b
H
Ji
NS
[^
1
Ji
0
;i
0
<0
0
HC
11
0
0"
-.Oj
'J
llo
ilk
0
]•
10
>n.l
67
S3
(1
S5
Of
17
u
<3
7f
71
;:
73
c
it
P
i
;5
7t
71 '
"" i/OOOO IF NO COMMON STACK
rr/f XXXX POINT ID'S IF COMMON STACK ,
•J«
jTIMATlOC
1 SO,
r
HC
RT
1
;c
n
e
57
M
b(
s;
OWLIANC
son nuLC-
V,.,, Iw,,
bl
it
0
5?Ul
1
61
JNTPOl
MO.
5«
CO
Cl
,0
s?
H
SI
HC
{:
U
fl
Si
U
SI
CO
Sb
CO
*(,
u
it
bi
sclsi
TATll
to * i
so
(i
s;
SI
JLL
t
(7
(3
ti
0.
u
S(
U
0,
V.
S
(«
55
10
71
;;
n
X
75
:»
-
'i
-
* r *
•
i
i
t ;?
f
rt
Ki
l
'H
• 7«I d
.ll'l
f
*
f r5
P
c
>
j
«
5 "!
F
C
3
C
r ;;
f
f *i
r
'
»
r
*
*f
r
»
p
*
J
n
3|
u
4
r
s
rt
K
««
ff
T
T
'
-------
Figure 10.1.3-5. Standard NEDS form for sulfite pulping - acid plant.
I
I—'
-J
Sni».
1 ?
Coo«'V
3
1
s
4
»OCB
I
1
J
PUnl IO
Nun*h"
10
U
,?n
1
O
u|u
Lu
NATIONAL EMISSIONS DATA SYSTEM (NEDS)
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF AIR PROGRAMS
POl'JT SOU»CE
t"Oul Fo»m
CONTROL EQUIPMENT
DEVICE
(PART.)
CYCLONE
ESP
(S02)
VENTURI
PACKED TOWER
CODE
0000 IF NO COMMON STACK I
XXXX POINT ID'S IF COMMON STACK \y\
^'! '! ;i ."i
ACID PLANT
ww
mi3 - 31
Nn - 32
Ca - 33
Po
_ 1
II
-
1
I1.
-
:§
T (f
ii.
H
i
in
—
U
11
.'(
i — i —
in
71
j.*1
11
1
;i
/
n
COMWf NTS
rt
—
?!
-
r*
?•>
'0
11
i.'
1!
V
!•!
if.
:;
"'
-
!1
!C
11
i;
i1
t:
^
-
\i
i .
-
^
—
:i
-
•,n
si V
dtti:
J_LL11TZ irTTH
-------
GLOSSARY
Lignin - A group of polymeric molecules which holds the cellulose
fibers together.
Red liquor - Spent sulfite digestion liquor.
Smelt - Molten sodium salts obtained from the sodium based
recovery furnace.
10-1.3-18
-------
REFERENCES FOR SECTION 10.1.3
1. Hendrikson, E.R., J.E. Roberson, and J.B. Koogler. Control
of Atmospheric Emissions in the Wood Pulping Industry. Vol.
1. Environmental Engineering, Inc., and J.E. Surine Co.
Contract No. CPA 22-69-18, U.S. Dept. of Health, Education,
• an£ Welfare. March 15, 1970. pp. 3.62-3.71.
2. Babcock & Wilcox. Steam-Its Generation and Use. 38th
edition. New York, 1972. pp. 26.11- 26.14.
3. Kirk-Othmer Encyclopedia of Chemical Technology, Volume 16.
2nd edition. John Wiley & Sons, New York, 1963. pp. 712-
721.
4. Compilation of Air Pollutant Emission Factors. 3rd edition.
Environmental Protection Agency. AP-42, August 1977.
5. Aeros Manual Series Volume II: Aeros User's Manual. EPA
450/2-76-029 (OAQPS No. 1.2-039), December 1976.
6. Aeros Manual Series Volume V: Aeros Manual of Codes. EPA
45/2-76-005 (OAQPS No. 1.2-042), April 1976.
7. Standard Industrial Classification Manual. 1972 edition.
Prepared by Office of Management and Budget. Available from
Superintendent of Documents, Washington, D.C.
8. Loquercio, P., and W.J. Stanley. Air Pollution Manual of
Coding. U.S. Department of Health, Education, and Welfare.
Public Health Service Publication No. 1956. 1968.
10.1.3-19
-------
10.1.4 NEUTRAL SULFITE SEMICHEMICAL (NSSC) PULPING
PROCESS DESCRIPTION1'3
Wood pulping extracts cellulose from wood chips by dissolving
the lignin that binds the fibers together. The pulp is then used
as the raw material for the manufacture of paper, cardboard,
tissue, and towel products. Neutral sulfite semichemical (NSSC)
pulp is the variety that is produced by the partial chemical
dissolution of the lignin followed by mechanical disintegration.
About 10 percent of the 35 million tons of pulp produced in the
United States annually is made by the NSSC process.
Figure 10.1.4-1 shows the process flow in an NSSC pulping
mill. The wood chips used in pulping are purchased from forest
product manufacturing firms and delivered to the mill by truck or
rail, or they may be produced from logs at the pulp mill. In
this case, the logs are transported to the mill by rail, barge,
truck, or ship, and are stored in piles or in water until needed.
The logs are washed to remove dirt and debarked in drum or hydraulic
barkers. The debarked logs are then reduced to chips to provide
a size that is uniform, easy to handle, and allows even penetration
of cooking liquor during pulping. The chips are screened to
remove oversized pieces (which are recycled) and slivers; then
the chips are washed to remove dirt and sawdust. The chips are
then conveyed to storage piles until needed for pulping.
10.1.4-1
-------
9
1 } ' Na SO, r ~ , !
CHIPPING -^ SCREENING/ ^ \ ^ ? "^ ^^ ™) ™T°
J • / i f rnMRUvnnH .n.
(^ ^Y^ 3-07-003-04 r-U INTEGRAL 3-07-003-03
U S02 ABSORPTION TOWER 1 HcYCLONE FLUID-BED
DIGESTER T SOLID \S REACTOR
'SO- O Na,SO., [
i 2 ^^ , £ 4 ^C~T • ~^
3-07-003-01 1 °53 (99-5> 2 r\ 1^
— ' • x SCRUBBER \^y
DIGESTER AND DUMP TANK f } VENTURI SULFUR * <-n ^ CONCENTRATED
OR BLOW PIT /^r-"' BURNER •" SUL1-UK iu2 v^i LIQUOR
| PRESSURE i ! f
DUMP TANK RELIEF*
OR BLOW PIT 3-07-003-02
LJ EVAPORATOR
HOT WATER
— ^
* PRESSURE RELIEF MAY BE 1 | Tn ,FUFR
VENTED DIRECTLY TO SO- I lu itwtl<
ABSORPTION TOWER '
PULP TO
MECHANICAL
DISINTEGRATION
LEGEND:
(^) EMISSION FACTOR3
O EMISSION FACTOR NOT DEVELOPED
FOR THIS PROCESS
009 (66.0) DENOTES CONTROL EQUIP.
CODE WITH EST, EFF. SHOWN
4 IN ( )
N DENOTES FUGITIVE
-' EMISSIONS
O DENOTES A STACK
3 IN POUNDS PER SCC UNIT
Figure 10.1.14-1. Process flow diagram for NSSC pulping.
10.1.4-2
-------
In the first part of the pulping process, the wood chips are
cooked under pressure in either a batch or a continuous digester
to partially delignify the wood. The cooking liquor is sodium
sulfite (Na2SO.,) , mixed with either sodium carbonate (Na^CO ) or
bicarbonate (NaHCCK). The sulfite ion reacts with the lignin in
the wood while the sodium carbonate or bicarbonate acts as a
buffer to maintain a neutral solution (pH near 7). The sodium
sulfite may be purchased, or it may be produc ad at the mill by
burning sulfur and dissolving the flue gas in a sodium carbonate
solution in an S02 absorption tower for the reaction.
Following digestion, the mixture is discharged into a dump
tank or blow pit to bring it to £itmospheric pressure. A dump
tank is used to receive the mixture when the pressure in the
digester is partially relieved by a pressure relief system; a
blow pit receives the mixture when the pressure is relieved as
the material discharges from the digester.
The material must be washed to remove the liquor from the
pulp. The cooling liquor is drained and the pulp is washed with
water, usually on a multistage drum filter. The washed pulp may
then be further disintegrated mechanically by grinders before
bleaching or manufacture into paper. Some mechanical disinte-
gration of the pulp is done in the blow pit by blowing the
material onto a plate to break up the fibers. This combination
of chemical delignification and mechanical disintegration can
yield as much as 60 to 80 percent pulp. For coarser products,
such as cardboard, the mechanical disintegration is not necessary.
10.1.4-3
-------
The spent liquor from the washers is sometimes discarded to
the sewer system. At mills that adjoin kraft pupling mills, the
spent liquor may be combined with the liquor from kraft processing
for chemical recovery. (See the section on kraft pulping for a
complete description of this chemical recovery process.) A third
way to dispose of the spent liquor is to concentrate it in an
evaporator and send it to a fluid-bed reactor for combustion.
This particular concentration and combustion process is unique to
NSSC pulp production. In the fluid-bed reactor, the inorganic
solids are converted to sodium carbonate and sodium sulfate,
which are withdrawn as pellets. An integral cyclone collects the
entrained solids and returns them to the bed, where any remaining
organic fraction undergoes further combustion. The solids cannot
be reused in the NSSC process, but they are often sold to a kraft
mill -as process chemicals.
EMISSIONS1"3
The major pollutants from NSSC pulping are sulfur oxides
(SCO , hydrogen sulfide (H2S) , and particulates. The digester
and dump tank or blow pit, evaporator, fluid-bed reactor, and S02
absorption tower are the four emission sources. The fluid-bed
reactor also emits combustion products including CO and NOx/ but
2
these are considered to be negligible.
Emissions from the production of wood chips (debarking,
chipping, screening, and storage) are insignificant. Pressure is
periodically relieved in the digester during the cooking cycle to
maintain the desired pressure in the vessel, resulting in
10.1.4-4
-------
intermittent gas release. Intermittent gases released from the
digester contain SO2 and H2S; however, their quantities are
insignificant compared to those from the dump tank or blow pit.
The main emissions from the digester and dump tank are released
mainly from the digester when the digester and dump tank are
used. When the digester and blow pit are used, these emissions
are released from the blow pit as shown in Figure 10.1.4-1.
Emissions from the pulp washer and mechanical disintegration are
considered insignificant.
Mills that purchase sodium sulfite for the digestion liquor
have no SO,, absorber, and therefore no emissions from that
point. Emissions of S02 and H2S from the SC>2 absorption tower
vary according to the operating conditions and efficiency of the
absorber.
Mills that send the spent liquor to a sewer have no evap-
orator or fluid-bed reactor exhausts. Liquor sent to a kraft
mill recovery system contributes to the emissions of that system.
The quantities of these emissions are not known, since they
depend on the operating and process variables at the kraft mill.
It is known that the NSSC effluent lowers the pH of the kraft
black liquor and, as a consequence, can cause generation of
H Q 1'2
ri~ o.
Because of the scarcity of data on the many variations in
NSSC mills, no emission factors are currently available.
10.1.4-5
-------
CONTROL PRACTICES1 3
Intermittent emissions from the digester are not controlled.
Emissions from the pressure relief system of the dump tank or
blow pit are usually controlled by a scrubber, usually a venturi
scrubber; or the pressure relief may be vented directly to the
2
sulfur absorption tower at the mill when it is in use.
Emissions from the evaporator are relatively small and are
usually uncontrolled.
A wet scrubber is commonly used to control both the partic-
ulate and gaseous emissions from the fluid-bed reactor. The
integral cyclone is considered process equipment rather than a
control device because it is a part of the reactor. Efficiencies
as high as 99 percent can be expected for both the particulate
and S0~ control. The CO and NO emissions from the reactor are
2. X
negligible and are not controlled.
Emissions from the S0_ absorption tower are usually uncon-
trolled.
4-6
CODING NEDS FORMS
The emission sources associated with NSSC pulping are:
Source SCC Pollutant(s)
Digester and dump
tank or blow pit 3-07-003-01 SO2
Evaporator 3-07-003-02 S02
Fluid-bed reactor 3-07-003-03 Particulates, S02/
combustion
products
S02 absorption tower
3-07-003-04 SO.
10.1.4-6
-------
Standard NEDS forms for each of the sources (Figures 10.1.4-
2 through 10.1.4-5) show entries for the SCC's and other codes.
Entries in the data fields give information common to NSSC
pulping. Information pertinent to coding the source is entered
in the margins of the forms and above or below applicable data
fields. Entries for emission factors, required comments, control
equipment codes, and other optional codes minimize the need to
refer to the code lists. Typical data values for operating
parameters, control equipment efficiencies, and other source
information are shown on the form (or in the text) to aid in
rapid, approximate checks of data submitted by the plant in a
permit application or similar report. Data entered in EIS/P&R
and NEDS must be actual values specific to and reported by the
plant, rather than typical values. Contact the plant to obtain
unreported information and to validate or correct questionable
data. See Part 1 of this manual for general coding instructions.
Emissions from the digester and dump tank or blow pit are
usually vented to a venturi scrubber. Code this operation as
shown in Figure 10.1.4-2. When there is a different type of
scrubber, enter the appropriate code. When the gases are vented
to the SO,, absorption tower, code the tower as a control device
using code 050 or 051.
Emissions from the evaporator are not controlled. Code the
evaporator as shown in Figure 10.1.4-3. The integral cyclone on
a fluid-bed reactor is part of the reactor and not a control
device. Emissions from the reactor are usually controlled with a
10.1.4-7
-------
scrubber, which controls both particulates and S02. Figure
10.1.4-4 shows a standard NEDS form for the fluid-bed reactor
Code 001 in the particulate and S02 primary control device
fields.
The S09 absorption tower is not controlled. Code this
source as shown in Figure 10.1.4-5.
CODING EIS/P&R FORMS7
The EEC's for use in EIS/P&R forms are:
Source BEG
Digester and dump tank or blow pit 287
Evaporator 302
Fluid-bed reactor 206
S0~ absorption tower 351
10.1.4-8
-------
Figure 10.1.4-2. Standard NEDS form for NSSC pulping -
digester and dump tank or blow pit.
>,_ \_ TTi lisTa ji_i]ij
NATIONAL IMISSIONS DATA SYSItM (NtOSI
ENVIMfiNMCNIM PIlOTf CIION AGENCY
of Ain
ill mill II IIIH
— t—I—t —I T—
03 Ui
CONTROL EQUIPMENT
DEVICE
VENTURI
C00£
053
iiri
SI AC* OAT A
oiQJOioioo
M,. M .,.11. I/™., I ll „,-•.,..
iiiis[ts[t^i*jti['^n^v
±ttrrrij.fi...
L O
S
.0000 IF NO COMMON STACK \
' POINT ID'S IF COMMON STACK
o[o|oioroLrjo
"C CO I
i or r WA t iwr.
ffi
nfTo )il;;lM|'ii|iiTis]' pi])'!"1!"
J
a
1)
-
i
)
3
,
it
-
i
u
(5
11
;t
7
I
i'.
-
s
,M
0
•.c
;i
t
-c
H
/;
5
c
Ml
-
-
3L
3
y
_
L
.V
, i!
0
-
t
UP
;s
1
''
1-
1 1
•^
A
f u
V-
1 O
V
-
Ml
;.
• •r.
i'
'
~u
-!
1 ^
-
X!
T*
11,
'
'i1
-
1
,
,j
11
-
un
;;
).-
J
!:
-
M
3L
11
trtl
,
,l
^
1:
,n
,
;l
-
LU
,*
-
P
)-,
.'?
JL
i
ID
10
.1
II
-
r
0
1,
L-
I*
',•
u
:•
i,
0
iO
•\
,,
f
w
1
-
».l
I J
M
:
IV
•''
-
'J!
0
si
"•
•
•>r
"
W"
1-
-.1
s
M
_
••'
. ,
"I
'.i
'*
~
\
-
-,,
'-'
~
,b
~
U-
-
,
SSI
SI
-
l,<-
to
in
._
,,
~
^
-
-.,
,1
;i
-
tl
«. II t« i» It II i? )) II )5 >l I) It >»
-------
Figure 10.1.4-3. Standard NEDS form for NSSC pulping - evaporator,
H1
O
I
h-1
o
E
M"l
MllT
NATION/H EMISSIONS OftTA SYSTEM (NEDS)
ENVinONMlNTM PROTECTION AGENCY
OfflCt Of AIR PflOGRAMS
WO !!,« TOWS
a
i
'
s
SIC _
nffli
fln»n,,« ll,l|m.M
as
;lU!UL _
01010 0
At TumMUT
ME!
^
1LQ.
S";
11 ..- i'
orofo
M
l/11
lOO IF NO COHHON STACK
xxxx POINT ID'S IF comJN STACK
I^TIMAUO CONTMOl t rnCICNCV IM
MIS-jiON tSli'/ATiS IIO/M.V.*-!
F^l^u'.l. SOj I NO. MC
gSHHffflaafEfflira
CO
t;TiT ^ i
0
ESTIMATION
Ml THOO
EVAPORATOR
f
) 1
it '."i
1.9
i,.>»^
7
s
o"
,f
CC
1
st
?!
5
0
c
0
U'
?*
I
11
-
507
A
ri
i IP-
IB
-
r°
-
RY
e*t
—
T
*
,,
-
»i
t
ON
-
s w
--
o.
s
8LEA
-
;
v] 'fj)i|ifll»iii?r7i
|oU
CHEO P
;
—
—
±d
ULRsj
MJ
-
—
4
J
3
T
-
_qj
i
1
;
CO
—
—
.XI
—
-
_
L_d
i.
-
-
so
6
-
0
-
5CMI 1
0
',»
!••
'UlE
iTlsT
i
'A
SI
It
!i
-
r.T.'.
iili
CQ.^
iilH
rn
IT
(1
Kt»«
fl
(>
i;
t)
U
«.
n
(i
IS
U.
f
c
tl
11
—
—
ON If*
1
I'.
-
-
—
01
n
it
«t
M
:
tft
II
P
CU
l;
V
;?
LA
1]
1)
TIC
»••
''
NS
J
'5
'I
11
"
5
|
4
'f
5
'*•
^
?
1*
!0
%
cd
!J
6
«
G
6
t±EI
V tl
—
1C
II
IJ
1!
II
Ii
-
11
i;
._
<
ii
vn
11 10
p J
f J
-------
Figure 10.1.4-4. Standard NEDS form for NSSC pulping - fluid-bed reactor,
NATIONAL EMISSIONS DATA SYSTEM (NEDS)
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF AIR PROGRAMS
f~ NT SOURCE
form
f O«M APPROVED
owe NO
Om
FLIUD-BED REACTOR
-------
Figure 10.1.4-5. Standard NEDS form for NSSC pulping - SO2 absorption tower,
i
M
NJ
NATIONAL EMISSIONS DATA SYSTEM (NEDS)
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF AIR PROGRAMS
m
isse
010!
0|0
OToTo
00
1
IPI
0000 IF NO COMMON STACK
"XXXX POINT ID'S IF COMMON STACK
l £FF(CIEVCV l\l
•.O,
ALt-O-VABLE EMISSIONS
-------
GLOSSARY
Black liquor - Spent (used) kraft digestion liquor.
Blow pit - The receiving pit for digested pulp released under
pressure.
Dump tank - The receiving pit for digested pulp released from the
digester after the pressure in the digestion vessel has been
reduced by the pressure relief system.
NSSC pulp - Neutral sulfite semichemical pulp.
10.1.4-13
-------
REFERENCES FOR SECTION 10.1.4
1. Compilation of Air Pollutant Emission Factors. 2nd edition.
Environmental Protection Agency, AP-42, February 1976. pp.
8.6-1 to 8.6-4, C16.
2. Hendrikson, E.R., J.E. Roberson, and J.B. Koogler. Control
of Atmospheric Emissions in the Wood Pulping Industry.
Volume 1. Environmental Engineering, Inc., and J.E. Sirrine
Co. Contract No. CPA 22-69-18, U.S. Dept. of Health,
Education, and Welfare, March 15, 1970. pp 3.54-3.61.
3. Environmental Pollution Control—Pulp and Paper Industry,
Part 1: Air. EPA/625/7-76-001, October 1976.
4. Aeros Manual Series Volume II: Aeros User's Manual. EPA-
450/2-76-029 (OAQPS No. 1.2-039), December 1976.
5. Aeros Manual Series Volume V: Aeros Manual of Codes. EPA-
450/2-76-005 (OAQPS No. 1.2-042), April 1976.
6. Standard Industrial Classification Manual. 1972 edition.
Prepared by Office of Management and Budget. Available from
Superintendent of Documents, Washington, D.C.
7. Loquercio, P., and W.J. Stanley. Air Pollution Manual of
Coding. U.S. Department of Health, Education, and Welfare.
Public Health Service Publication No. 1956. 1968.
10.1.4-14
-------
TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1 R'IPCRT NO
EPA-450/4-80-007
J
LE AND SUBTITLE
ineering Reference Manual for Coding NEDS and
TTs/P&R Forms: Volume III
5. REPORT DATE
6. PERFORMING ORGANIZATION CODF
7 Al'"HOR(S)
National Air Data Branch
8. PERFORMING ORGANIZATION REPORT NO.
9 PERFORMING ORGANIZATION NAME AND ADDRESS
U.S. Environmental Protection Agency
Office of Air Quality Planning and Standards
Monitoring and Data Analysis Division
Research Triangle Park. NC 27711
12. SPONSORING AGENCY NAME AND ADDRESS
U.S. Environmental Fiotection Agency
Office of Air, Noise and Radiation
Office of Air Quality Planning and Standards
Research Triangle Park. NC 27711
:. RECIPIENT'S ACCESSION" NO.
10 PROGRAM ELEMENT NO.
11 CONTRACT/GRANT NO.
13. YPE OF REPORT AND PERIOD COVERED
14 SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES
Associated Volume I is a general
additional process compendiums.
introduction to the manual. Volume II presents
16. ABSTRACT
This manual provides specific engineering guidance and background information
for the evaluation and reporting of source/emissions data in NEDS or EIS/P&R format.
The manual is designed to assist coders of NEDS and EIS/P&R data who may not be
imiliar with a wide variety of industrial processes.
Volume III consists of compendiums of information about specific industrial
processes. Each compendium presents a process description and process flow diagram
which identifies the points in the process at which pollutants are emitted, describes
common control measures and presents codes necessary for preparation of NEDS and
EIS/P&R forms. Specific guidance for the coding of process information is given,
with example preceded NEDS forms. Each compendium also includes a glossary of
technical terms and a list of pertinent technical literature.
Volume II consists of process compendiums for additional industries.
17.
a.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
NEDS
CDHS
EIS/P&R
Point Sources
Air Pollutants
Emissions
Cod-ng forms
b.IDENTIFIERS/OPEN ENDED TERMS
COSATI Field/Group
fl
,
RIBUTION STATEMENT
lease Unlimited
19. SECURITY CLASS (ThisReport)
Unclassified
21. NO. OF PAGES
20. SECURITY CLASS (This page)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
-------
INSTRUCTIONS
1. REPORT NUMBER
Insert the EPA report number as it appears on the cover of the publication.
2. LEAVE BLANK
3. RECIPIENTS ACCESSION NUMBER
Reserved for use by each report recipient.
4. TITLE AND SUBTITLE
Title should indicate clearly and briefly the subject coverage of the report, and be displayed prominently. Set subtitle, if used, in smaller
type or otherwise subordinate it to main title. When a report is prepared in more than one volume, repeat the primary title, add volume
number and include subtitle for the specific title.
5. REPORT DATE
Each report shall carry a date indicating at least month and year. Indicate the basis on which it was selected (e.g., date of issue, date of
approval, date of preparation, etc.).
6. PERFORMING ORGANIZATION CODE
Leave blank.
7. AUTHOR(S)
Give name(s) in conventional order (John R. Doe, J. Robert Doe, etc.]. List author's affiliation if it differs from the performing organi-
zation.
8. PERFORMING ORGANIZATION REPORT NUMBER
Insert if performing organization wishes to assign this number.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Give name, street, city, state, and ZIP code. List no more than two levels of an organizational hirearchy.
10. PROGRAM ELEMENT NUMBER
Use the program element number under which the report was prepared. Subordinate numbers may be included in parentheses.
11. CONTRACT/GRANT NUMBER
Insert contract or grant number under which report was prepared.
12. SPONSORING AGENCY NAME AND ADDRESS
Include ZIP code.
13. TYPE OF REPORT AND PERIOD COVERED
Indicate interim final, etc., and if applicable, dates covered.
14. SPONSORING AGENCY CODE
Leave blank.
15. SUPPLEMENTARY NOTES
Enter information not included elsewhere but useful, such as: Prepared in cooperation with, Translation of, Presented at conference of,
To be published in, Supersedes, Supplements, etc.
16. ABSTRACT
Include a brief (200 words or less) factual summary of the most significant information contained in the report. If the report contains a
significant bibliography or literature survey, mention it here.
17. KEY WORDS AND DOCUMENT ANALYSIS
(a) DESCRIPTORS - Select from the Thesaurus of Engineering and Scientific Terms the proper authorized terms that identify the major
concept of the research and are sufficiently specific and precise to be used as index entries for cataloging.
(b) IDENTIFIERS AND OPEN-ENDED TERMS - Use identifiers for project names, code names, equipment designators, etc. Use open-
ended terms written in descriptor form for those subjects for which no descriptor exists.
(c) COSATI FIELD GROUP - Field and group assignments are to be taken from the 1965 COS ATI Subject Category List. Since the ma-
jority of documents are multidisciplinary in nature, the Primary Field/Group assignment(s) will be specific discipline, area of human
endeavor, or type of physical object. The application(s) will be cross-referenced with secondary Field/Group assignments that will follow
the primary posting(s).
18. DISTRIBUTION STATEMENT
Denote releasability to the public or limitation for reasons other than security for example "Release Unlimited." Cite any availability to
the public, with address and price.
19. & 20. SECURITY CLASSIFICATION
DO NOT submit classified reports to the National Technical Information service.
21. NUMBER OF PAGES
Insert the total number of pages, including this one and unnumbered pages, but exclude distribution list, if any.
22. PRICE
Insert the price set by the National Technical Information Service or the Government Printing Office, if known.
EPA Form 2220-1 (9-73) (Reverse)
-------