United States
Environmental Protection
Agency
Air and Energy Engineering
Research Laboratory
Research Triangle Park NC 27711
Research and Development
EPA/600/S7-86/050 Apr. 1987
Project Summary
Metallurgical Coke Industry
Particulate Emissions:
Source Category Report
John Fitzgerald, John Jeffery, and Paul Wolf
The objective of this study was to
develop particulate emission factors
based on cutoff size for inhalable par-
ticles for the metallurgical coke industry.
After a review of available information
characterizing particulate emissions
from metallurgical coke plants, the data
were summarized and rated in terms of
reliability. Size specific emission factors
were developed from these data for the
major processes used in the manufac-
ture of metallurgical coke. A detailed
process description is presented with
emphasis on factors affecting the gen-
eration of emissions. A replacement for
Section 7.2 (Coke Manufacturing) of
EPA report AP-42, A Compilation of
Air Pollutant Emissions Factors, was
prepared, containing the size specific
emission factors developed during this
program.
This Project Summary was developed
by EPA's Air and Energy Engineering Re-
search Laboratory, Research Triangle
Park, NC, to announce key findings of
the research project that Is fully docu-
mented In a separate report of the same
title (see Project Report ordering In-
formation at back).
Introduction
The purpose of this program was to
summarize the best available information
on emissions of inhalable particulate
matter in the metallurgical coke industry.
The main objective of the program was to
develop reliable size-specific emission
factors for the various processes used in
the production of metallurgical coke. Both
uncontrolled and controlled emission
factors are presented in the report. The
uncontrolled factors represent emissions
which would result if the particulate con-
trol device (baghouse, ESP, etc.) were
bypassed, and the controlled factors
represent emissions emanating from a
particular type of control system. The
size-specific emission factors are gen-
erally based on the results of simul-
taneous sampling conducted at the inlet
and outlet of the control device(s), utilizing
a variety of particle sizing techniques.
Other objectives of this program were to
present current information on the metal-
lurgical coke industry as well as prepare
a replacement for Section 7.2 in EPA
report AP-42, "A Compilation of Air Pol-
lutant Emissions Factors."
The above objectives were met by a
literature search that included:
• Data from an inhalable particulate
characterization program,
• Fine Particle Emissions Inventory
System (FPEIS),
• AP-42 background file at EPA's
Office of Air Quality Planning and
Standards (OAQPS),
• State and local air pollution control
agencies, and
• Various industry sources.
The emission data contained in the
reference documents were reviewed,
analyzed, summarized, and ranked ac-
cording to the criteria established by
OAQPS as published in the EPA report,
"Technical Procedures for Developing
AP-42 Emission Factors and Preparing
AP-42 Sections," April 1980. After the
data were ranked, emission factors were
calculated using the highest quality data
available. The quality of the data used to
develop each emission factor is indicated
by the emission factor rating.
Process control system operating data
and general industry information were
also obtained and summarized as general
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background information. It was not part
of this program to provide detailed
engineering analyses, product specifica-
tions, or detailed evaluation of trends in
the industry.
Summary of Results
Paniculate emissions from the produc-
tion of coke originate from: (1) coal
preparation, (2) coal preheating, (3) charg-
ing coal into incandescent ovens, (4) over
leakage during coking, (5) pushing coke
out of the oven, (6) quenching hot coke,
and (7) combustion (underfire) stacks.
Coal preparation consists of pulverizing,
screening, blending of several coal types,
and oil or water additives for bulk density
control. Particulate emissions are some-
times controlled by evacuated or un-
evacuated enclosures. A few domestic
plants preheat coal before charging, using
a flash drying column heated by combus-
tion of oven or natural gas. The air stream
that conveys the coal through the column
is typically passed through conventional
wet scrubbers for particulate removal prior
to atmospheric discharge.
Oven charging can produce emissions
of particulate matter and volatile organic
compounds from coal decomposition.
Staged, or sequential, charging tech-
niques used on virtually all batteries draw
most charging emissions into the battery
collector main, and on to the byproduct
plant. During the coking cycle, volatile
organic emissions from the thermal dis-
tillation process occasionally leak to the
atmosphere through poorly sealed doors,
charge lids, offtake caps, and cracks which
may develop in oven brickwork, the off-
takes, and collector mains. Door leaks
are controlled by diligent door cleaning
and maintenance, rebuilding of doors,
and, in some plants, by manual application
of sealant Charge lid and offtake leaks
are controlled by an effective patching
and luting (sealing) program.
Pushing coke into the quench car is
another major source of particulate emis-
sions, volatile organic compounds, and
combustion products if the coke mass is
not fully coked. Most batteries use push-
ing emission controls consisting of
hooded, mobile scrubber cars; shed en-
closures evacuated to a gas cleaning
device; or travelling hoods with a fixed
duct leading to a stationary gas cleaner.
Quenching generates emissions from the
quench tower consisting of particulate
from the coke mass and dissolved solids
from the quench water which become
entrained in the steam plume rising from
the tower.
The combustion of gas in the flues
produces emissions through the underfire
or combustion stack. If coke oven gas is
not desulfurized, SOX emissions accom-
pany the particulate and combustion
emissions. If flues are damaged, coal
fines and decomposition products from a
recently charged oven may leak into the
waste combustion gases. Electrostatic
precipitators and fabric filters are typically
used for control of particulate in com-
bustion stack gases.
The total mass controlled and uncon-
trolled emission factors for metallurgical
coke manufacturing are presented in fhHe
1 The size-specific controlled and uncon-
trolled emission factors are presented in
Table 2.
Table 1. Emission Factors For Coke Manufacturing3
Particulate emission Particulates
Operation factor rating kg/Mg
Ib/ton
Coal Crushing with Cyclone
Coal Preheating
Uncontrolled
With Venturi Scrubber
With Wet ESP
Wet Coal Charging*
Larry Car (Uncontrolled)
Larry Car with Sequential Charging
Larry Car with Scrubber
Door Leaks (Uncontrolled)
Coke Pushing
Uncontrolled
With ESP*
With Venturi Scrubber11
With Baghouse*1
With Mobile Scrubber Car"
Quenching
Uncontrolled (Dirty Water/
Uncontrolled (Clean Water,
With Baffles (Dirty Water,
With Baffles (Clean Waterf
Combustion Stacks
Uncontrolled (COG)
Uncontrolled (BFG)
With ESP (COG)
With Baghouse (COG)
Coke Handling with Cycloneh
C
C
C
E
E
E
B
C
D
D
C
D
D
B
B
A
A
D
D
0.055
1.75
0.125
0.006
0.24
0.008
0.007
0.27
0.58
0.225
0.09
O.O45
0.036
2.62
0.57
0.65
0.27
0.234
0.085
0.046
0.055
0.003
0.11
3.50
0.25
0.012
0.48
0.016
0.014
0.54
1.15
O.45
0.18
O.09
0.072
5.24
1.13
1.30
0.54
0.47
0.17
0.091
0.11
0.006
a Emission factors expressed as units per weight of coal charged.
Charged coal has not been dried.
0 Emissions captured by coke side shed.
dEmissions captured by traveling hood.
e Emissions captured by quench car enclosure.
' Dirty water > 5OOO mg/L total dissolved solids.
9 Clean water < 1500 mg/L total dissolved solids.
h Handling defined as crushing and screening.
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Table 2. Size Specific Emission Factors For Coke Manufacturing
Process
Coal Preheating,
Uncontrolled
Controlled
with Venturi
Scrubber
Coal Charging.
Sequential
or Staged
Coke Pushing,
Uncontrolled
Controlled
with Venturi
Scrubber
Mobile
Scrubber Car
Quenching
Uncontrolled
(Dirty Water)
Uncontrolled
(Clean Water)
Paniculate
emission Particle
factor size
rating (pm)
D 0.5
1.0
2.0
2.5
5.0
10.0
15.0
D 0.5
1.0
2.0
2.5
5.0
10.0
15.0
£ 0.5
1.0
2.0
2.5
5.0
10.0
15.0
D 0.5
1.0
2.0
2.5
5.0
10.0
15.0
D 0.5
1.0
2.0
2.5
5.0
10.0
15.0
D 1.0
2.0
2.5
5.0
10.0
15.0
D 1.0
2.5
5.0
10.0
15.0
B 1.0
2.5
5.0
10.0
Cumulative
mass%
< stated
size
44
48.5
55
59.5
79.5
97.5
99.9
100
78
80
83
84
88
94
96.5
100
13.5
25.2
33.6
39.1
45.8
48.9
49.0
100
3.1
7.7
14.8
16.7
26.6
43.3
50.0
100
24
47
66.5
73.5
75
87
92
100
28.0
29.5
30.0
30. 0
32.0
35.0
100
13.8
19.3
21.4
22.8
26.4
100
4.0
11.1
19.1
30.1
Cumulative
9 mass emission
factors
kg/Mg
0.8
0.8
1.0
1.0
1.4
1.7
1.7
1.7
0.10
0.10
0.10
0.11
0.11
0.12
0.12
0.12
0.001
0.002
0.003
0.003
0.004
0.004
0.004
0.008
0.02
0.04
0.09
0.10
0.15
0.25
0.29
0.58
0.02
0.04
0.06
0.07
0.07
0.08
0.08
0.09
0.010
0.011
0.011
0.011
0.012
0.013
0.036
0.36
0.51
0.56
0.60
0.69
2.62
0.02
0.06
0.11
0.17
Ib/ton
1.5
1.7
1.9
2.1
2.8
3.4
3.5
3.5
0.20
0.20
0.21
0.21
0.22
0.24
0.24
0.25
0.002
0.004
0.005
0.006
0.007
0.008
0.008
0.016
0.04
0.09
0.17
0.19
0.30
0.50
0.58
1.15
0.04
0.08
0.12
0.13
0.13
0.16
0.17
0.18
0.020
0.021
0.022
0.022
0.024
0.023
0.072
0.72
1.01
1.12
1.19
1.38
5.24
0.05
0.13
0.22
0.34
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Table 2. (continued)
Process
Cumulative
Paniculate Cumulative mass emission
emission Particle mass % factors
factor size < stated
rating dun) size kg/Mg Ib/ton
With Baffles
(Dirty Water)
With Baffles
(Clean Water)
15.0
1.0
2.5
5.0
10.0
15.0
1.0
2.5
5.0
10.0
15.0
37.4
100
8.5
20.4
24.8
32.3
49.8
100
1.2
6.0
7.0
9.8
15.1
100
0.21
0.57
0.06
0.13
0.16
0.21
0.32
0.65
0.003
0.02
0.02
0.03
0.04
0.27
0.42
1.13
0.11
0.27
0.32
0.42
0.65
1.30
0.006
0.03
0.04
0.05
0.08
0.54
Combustion Stack.
Uncontrolled
D 1.0
2.0
2.5
5.0
10.0
15.0
77.4
85.7
93.5
95.8
95.9
96
100
0.18
0.20
0.22
0.22
0.22
0.22
0.23
0.36
0.40
0.44
0.45
0.45
0.45
0.47
John Fitzgerafd, JohnJeffery, and Paul Welfare with GCA/Technology Division,
Bedford. MA 01730.
Dale L. Harmon is the EPA Project Officer (see below).
The complete report, entitled "Metallurgical Coke Industry Paniculate Emissions:
Source Category Report." (Order No. PB 87-140 331/A S; Cost: $ 13.95, subject
to change) will be available only from:
National Technical Information Service
5285 Port Royal Road
Springfield, VA22161
Telephone: 703-487-4650
The EPA Project Officer can be contacted at:
Air and Energy Engineering Research Laboratory
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
United States
Environmental Protection
Agency
Center for Environmental Research
Information
Cincinnati OH 45268
Official Business
Penalty for Private Use $300
EPA/600/S7-86/050
OQ003Z9
CHICAGO
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