-------
then used to derive operating costs and profits based on the historical
percentages in Table IX-17. Tables IX-18 and IX-19 then compare the
"before" and "after" affect of imposing control costs on the five
model plants.
3. Economic Impact on Model Plants
As shown in Table IX-18, which is based on the lower costs developed
in Table IX-12, control costs in the absence of product price increases
will reduce profits and cash flows significantly. Reduction in net earnings
after taxes ranges from 42 percent for HC FeMn to 114 percent for 50% FeSi.
Similarly, reductions in cash flows (i.e., the sum of depreciation charges
and after-tax earnings) range from approximately 20 percent for HC FeMn
to 54 percent for 50% FeSi.
However, if the profit figures are based on costs from Table IX-13
which include retrofit expenses and off-site items, the effect is more
drastic. In Table IX-19, silicomanganese and 50 percent ferrosilicon show
a net loss, while HC FeMn and HC FeCr show 57 percent and 53 percent re-
ductions in net income, respectively. Cash flow reductions range from 25 to
76 percent. Although application of aggregate corporate operating ratios
to the calculation of income statements for individual products may distort
the results for any or all of these products, the interpretation of this
analysis would remain the same with better data; i.e., control costs are
significant relative to the thin profit margins and can only be supported
by very substantial price increases.
4. Economic Impact on the Domestic Ferroalloy Industry
The preceding section concluded that pollution control for the model
plants would have to be supported by price increases to maintain even the
IX-50
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current low profit margins. In this section, the total economic impact of
emission control on the domestic ferroalloy industry is discussed. The
ability of the industry to pass control costs along to the user in the form
of higher prices is likewise considered.
The better control systems (baghouses and high-energy scrubbers)
installed by industry in recent years have average costs for amortization
and operation that total $9.30 (1971 dollars) per ton for ferroalloys
having relatively favorable dust-removal properties, such as the products
used for the models. Control costs for high-silicon alloys, which have
difficult dust-removal properties, average $61 per ton of product for
recent installations (see Table IX-20). Emission control costs range from
2 to 9 percent of sales for specific ferroalloys.
The ultimate total cost of emission controls to meet state implementa-
tion plans is estimated at approximately $30 million per year for the 2
million tons of ferroalloys produced. This estimate is based on a product
mix characteristic of recent industry experience and on unit control costs
derived from actual plant visits. These data are shown in Table IX-20.
Since annual costs run approximately 25 to 28 percent of required capital
costs, the ultimate capital costs will approach $120 million.
As of 1971 only about 20 percent of the total production capacity
(based on megawatt ratings) can be regarded as well enough controlled to
meet the state implementation plans. Such plants must include good hooding
enclosure and high collection efficiency of captured pollutants. The
amount of particulate emissions from all ferroalloy furnaces has been
estimated to be 150,000 tons annually. Installation and operation of the
most effective control systems on all furnaces would ultimately decrease
IX-51
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Table IX-20. PERCENTAGE OF PRODUCTION AND CONTROL COSTS
Control costs
Product
HC FeMn
SiMn
LC FeMn
HC FeCr
LC FeCr
FeCrSi
Up to 30% Si
50% FeSi
65% FeSi
75% FeSi
85-90% FeSi
Si Metal
MgFeSi
Ca alloys0
All other Si
Totals
Portion of productions3
net tons
348,000
194,000
138,000
148,000
126,000
86,000
124,000
494,000
26,000
106,000
10,000
116,000
58,000
14,000
12,000
2,000,000
Historical ,
$/ton
$ 5.00
9.00
7.15
6.15
-
11.25
8.00
10.00
10.00
20.00
61.00
61.00
10.00
61.00
20.00
-
Recent,
$/ton
$ 8.00
18.00
10.00
12.00
-
15.00
16.00
20.00
20.00
30.00
61.00
61.00
20.00
61.00
20.00
-
Average total
cost,
$
$ 2,262,000
2,619,000
1,183,000
1,343,000
-
1,129,000
1,488,000
7,410,000
390,000
2,650,000
610,000
7,076,000
870,000
854,000
240,000
$30,124,000
Based on Price Waterhouse Statistical Reporting Program, 1971,
adjusted from 1,632,835 net tons to 2,000,000 net tons.
The Ferroalloys Association.
°Excluding calcium carbide production.
IX-52
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the estimated emissions to 8,000 to 10,000 tons annually, based on 1971
production.
The domestic ferroalloy industry is faced with serious economic
problems in addition to air pollution control. Slackened demand for
many of the products, increased competition from foreign ferroalloy pro-
ducers, rising electrical power and coal costs, and higher wages have
combined to reduce profit margins significantly. A large proportion of
the industry has shut down in recent years as a result.
Foreign imports, mostly manganese and chromium products, accounted
for 19 percent of domestic consumption in 1971. Imports of silicon
products, historically on the order of 3 to 5 percent of domestic consumption
for this product class, jumped to 10 percent in 1971. Several factors account
for increasing foreign competition. Low transportation costs are available
to foreign producers, as their plants are located near the seaports. Some
countries, particularly in northern Europe, have cheap hydroelectric power.
As power costs vary from 15 to 40 percent of the product manufacturing cost,
depending upon the product, a cost difference of 4 to 5 mils per kilowatt-
hour or greater between U.S. power rates and overseas hydroelectric rates
can amount from $10 for HC FeMn to as high as $70 per ton for silicon, which
offers a considerable cost advantage to the foreign production.
High-quality metallurgical coal and coke, which are used in significant
quantities by the industry, have become expensive in recent years. Of
course, foreign producers have been paying higher prices for these coals,
too. Increased prices of ores, machinery, and parts have also been im-
portant factors in raising manufacturing costs for the domestic industry.
IX-53
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There are also qualitative factors that may contribute to the
stagnation of the industry. The expectation of increased costs for
emission control, the difference in government policies among various
countries toward taxation, subsidy payments for promotion of industrial
growth, advances in foreign technology leading to production efficien-
cies, and different latitudes in various countries with respect to
pollution control regulations all cannot be measured adequately in
numeric terms, but are postulated as important factors in the economic
setting of the industry today.
Of the groups analyzed, only silicon and ferrosilicon manufacturers
seem to be in a position to pay for emission control by raising product
prices. The quartz used to produce silicon alloys is plentiful domes-
tically,and demand for silicon products, particularly the silicon metals,
appears strong, as measured by an expected annual growth rate of 4 to 6
percent. Lastly, imports are still less than 10 percent of the market
measured in terms of domestic shipments. Some of the control costs for
silicon products could thus probably be passed on to the consumer. How-
ever, silicon and ferrosilicon manufacturers are also facing the greatest
costs.
Faced with low growth rate in demand by the steel industry for their
products and stiff foreign competition, ferromanganese and ferrochrome
producers will be forced to absorb most of their emission control costs.
Only through increased production efficiency in the form of higher
mechanization and larger plants can ferromanganese and ferrochrome
producers hope to retain current profit margins and simultaneously absorb
control costs. It is likely the smaller and more marginal plants (i.e.,
IX-54
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those faced with higher power costs, labor problems, and other cost-
associated problems) may either shut down in the face of expected air
pollution abatement costs, shift to other product lines, install more
efficient manufacturing facilities, or build in other countries which
have more lenient standards and lower costs.
IX-55
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X. RECOMMENDED RESEARCH AND DEVELOPMENT PROGRAMS
A. INTRODUCTION
Previous sections of this cooperative study have evaluated known control
technology, control technology now being tested in commercial operations,
and the economic effects of using various methods of emission control.
Present knowledge indicates the various known control methods are not
each broadly applicable to controlling emissions from the manufacture of
all products. Existing controls result in the accumulation of substantial
amounts of wastes in the form of either dusts or drained slurries, without
proper disposal, the dry dusts can be entrained by wind, and the drainage
from slurries can become a water pollution problem. With the advent of
new source performance standards and the increasingly stringent levels of
control generally required under the Clean Air Act Amendments of 1970,
the problem of handling and disposing of collected dusts can become more
acute.
The technology of covered furnaces is applicable to the manufacture
of almost all products except some high-silicon ferroalloys. However,
the use of covered furnaces for different product lines has been noted
to vary to some extent from country to country; in Japan, for example,
covered furnaces have been used to produce silicon alloys containing up
>,
to 75 percent silicon. A worldwfde evaluation should be made of furnace
designs, operating techniques, manufacturing limitations and capabilities,
control technology, and economic factors. The goal of such an evaluation
would be to determine the extent to which covered furnaces can be applied
to the manufacture of high-silicon alloys.
X-l
-------
B. RECOMMENDATIONS
The following recommendations are presented for further research and
development.
1. Process Modifications
a. Determine the relationship of the cost of control to
particle size of emissions. This might include an
investigation of agglomeration techniques by sonic,
electrostatic, or other means that would increase
particle size and, presumably, decrease costs.
b. Examine methods that would decrease the rates of furnace
exhaust gas to be handled by control devices, since
costs normally decrease when the volumes decrease.
c. Examine the economics of raw materials (ores, coals,
etc.) used as ferroalloy charge stocks and their
effects on gaseous and particulate emissions. If
possible, develop data on the economic feasibility
of using raw materials that would result in the
lowest quantity of particulate emissions.
2. Applications of Control Techniques
a. Examine other types of available control techniques
and collection systems besides recognized venturi
or other liquid scrubbing systems, baghouse filters,
and electrostatic precipitators. This would include
examination of all available liquid-contacting
nozzle-ejector systems for effectiveness, reduction
X-2
-------
in costs, and applicability to a broader range of
dusts. Examine combination two-stage systems such
as electrostatic precipitator treatment preceding
a low-pressure venturi scrubber. Examine the
possible domestic application of other systems
developed outside the United States, such as multi-
stage scrubbers and the charging chute (shaft kiln).
b. Examine methods for reducing pressure drop across
baghouse collectors.
c. Develop a fiberglass fabric resistant to higher
temperatures or find other fabrics more suitable to
ferroalloy dust-filtering operations, with emphasis
on extended life of the fabric.
d. Develop a preconditioner additive for electrostatic
precipitators that may be more effective than the
currently used ammonia.
3. Waste Utilization
a. Search for new uses of particulates recovered from various
product lines and by various recovery methods. Uses for dry,
fluffy dusts and the settled-slurry fine particulates
should be included in this search. Examine the chemical
content and physical form of the recovery products and search
for additional uses in agriculture, industry, and other
areas not now in evidence. Examine collected materials
for other elements of possible economic value.
X-3
-------
b. Examine in greater depth the possibility of preparing,
by extrusion or other means, recovered participate for
recycling to the submerged-arc furnace. The problem
of possible wind entrainment is particularly severe
with dry dusts. Certain positive values, particularly
chromium and manganese, are contained in the dusts and
might be recovered for use. Although pelletized chromium-
and manganese-containing dusts may not be fully acceptable
as desirable charge stock, the stockpiling of these dusts
in the pelleted form would prevent their becoming entrained
by wind. Such stockpiles could be an important source
of raw material for furnace feedstock when other supplies
are not available.
4. Waste Heat Utilization
a. Investigate methods for using the sensible heat of
reaction gases as well as heat from the combustion of
carbon monoxide therein.
b. Develop methods for achieving greater utilization of the
heat produced within the furnace itself, possibly
through the use of water walls.
5. Emission Measurements
a. A much higher volume sampler is needed at the collector
outlet to more quickly obtain an adequate weight of
particulate. A sampler should be developed that is simple
to apply and that will accurately and quickly reflect the
results of control measures.
X-4
-------
b. Develop continuous-reading monitors of reliable accuracy
for hour-to-hour measurements of outlet particulate
concentrations.
X-5
-------
APPENDIX A
Description of EPA Source Tests
All the data compiled by EPA tests are a part of this Appendix.
Furnaces A through J were tested in the United States. Furnaces K
and L (ferromanganese and siliconnanganese) were tested in a plant
located in Norway. A brief description of the process and a flow
diagram showing test points are included for each plant tested. Re-
sults of each individual sample analysis from tests made on these
furnaces are shown in Tables A-2 through A-5. The source of the
samples shown in these tables is given in Table A-l. The amount of
submicron particulate matter in the gas stream flowing either to or
from an air pollution control system was obtained from the back half
(impinger catch) of the sampling train; this information is presented
in Tables A-6 through A-ll. Wherever inlets and outlets were tested
simultaneously, the percent collection efficiency (impinger catch only)
is shown for each furnace tested. These efficiency rates indicate
that the three types of control devices (baghouses, scrubbers, and
precipitators) used on these furnaces are effective in removing a high
percentage of submicron particulates.
Table A-l2 shows the actual gas flow rates and temperatures of
the furnace gas streams measured during each individual test run.
A-l
-------
FURNACE A
Ferrochrome Silicon
(Uncontrolled)
The initial atmospheric emission tests
made by the EPA contractor were conducted
May 18 to 19, 1971, on an uncontrolled
ferrochrome silicon furnace. The furnace
has a hood for collecting the furnace fumes,
and it was about 100-percent effective in
capturing the fumes. Two exhaust ducts
connected at opposite sides of the hood are
equipped with blowers that discharge the gas
into the open atmosphere through two stacks
terminating above the building roof. The
tap-hole hood was about 95-percent effective
in capturing generated tapping fumes. This
SAMPLE
POINT 1
Figure A-1. Uncontrolled ferrochrome silicon
-fitcnae.?
hood was vented into the uncontrolled furnace
exhaust duct. Figure A-1 shows the uncontrolled exhaust system and
test points. The charge material to the furnace was a mixture of
chrome ores, quartz, coke, and wood chips. The two exhaust stacks
were sampled simultaneously for approximately two hours to cover the
tapping cycle. Both the EPA train and the ASME particulate train
were used for comparison of results. The two tests with the EPA train
showed emissions to be 197 pounds per hour (0.14 gr/scf) and 438 pounds
per hour (0.32 gr/scf). The higher emissions for the second test were
caused by more furance gas blows than normal because one of the two
stoking machines broke down. However, the quantity of emissions for
A-2
-------
both tests was considered lower than normal for this alloy and has
been attributed to screened ores used in the furnace mixture. The
ASME train showed a slightly higher particulate emission rate than
the EPA train (28 percent for the first test and 2 percent for the
second test). The percentage of particulates collected in the
impingers (back half) of the EPA train was approximately 50 percent
during the first day's test at sample point 1 but varied from two
to five percent in all other samples. The EPA train was not com-
pared with the ASME train when the high fraction of sample was
obtained in the impingers.
The mass media particle size of the fumes emitted varied from
0.62 to 0.67 microns (see Table VI-16 and Appendix D)
Visible emissions ranged from 60 to 100 percent. One of the
two stacks serves not only the furnace hood but also the tapping
station. Consequently, the larger volumes of gases in this stack
dilute the concentration of particulates and results in fewer visible
emissions.
Chemical analysis was made of the exhaust gases coming from the
furnace and the particulates collected on the filter of the particu-
late sampling train. Sulfur dioxide ranged from 11 to 17 parts per
million. Carbon dioxide and carbon monoxide were 0.8 percent and
0 percent, respectively. Chemical constituents of the collected
dust are shown in Table VI-17.
A-3
-------
FURNACE B
Chrome Ore/Lime Melt Furnace
(Uncontrolled)
On May 20, 1971, a chrome ore/lime melt fur-
nace was tested. Dried and screened chrome ore
mixed with lime is charged into an open-arc tilt-
ing electric furnace with a pouring spout at the
top. The furnace is periodically tilted and the
melt falls by gravity into a large ladle,
where subsequent ladle reaction with ferrochrome
silicon produces a low-carbon ferrochrome (see
Flow Diagram, Figure V-3, page V-7). Two test
runs were made with results of 50 pounds per hour
(0.14 gr/scf) and 61 pounds per hour (0.175 gr/
scf). At the same time an ASME sampling train
SAMPLE
POINT
\
TAP
LADLE
TILTING
OPEN-ARC
ELECTRIC
FURNACE
Figure A-2. Uncontrolled chrome
ore/lime melt furnace.
was used with test results of 60.4 pounds per hour and 72.3 pounds per
hour. Capture of the fumes by the hooding and exhaust system was
judged very poor. With the use of a high-volume filter to determine
the particulate concentration and an estimate of the volume of the
uncaptured gases escaping the exhaust system, it was shown that emis-
sions escaping the exhaust system varied from 9 to 65 pounds per
hour.
Chemical analysis was made of the gases coming from the furnace
and the particulates collected on the filter of the particulate sampling
train. The analysis showed no sulfur dioxide or carbon monoxide, and
only 0.1 percent carbon dioxide. Chemical analysis of the collected
particulate sample is shown in Table VI-18.
Particle size was determined by the use of a cascade impactor.
A-4
-------
FURNACE C
Silicomanganese Furnace
(Scrubber)
A series of tests were conducted be-
tween July 27 and August 4, 1971, on a
furnace making silico manganese, 2-percent-
carbon grade. The furnace fumes are con-
trolled by two Research Cottrell flooded
disc scrubbers discharging into a common
stack. Figure A-3 shows the flow diagram
of the furnace and scrubber system. Three
test runs were made at each scrubber pres-
sure drop setting of 57,47 and 37 inches H20
pressure. Figure A-4 shows the collection
efficiency curves as a result of these
tests. The mass emission rates in pounds per hour were 9.8 (0.01
gr/scf), 16.7 (0.02 gr/scf)> and 44 (0.05 gr/scf) for pressure drops
of 57 inches H20, 47 inches H20, and 37 inches H20, respectively. The
percent efficiencies were 99.1 (57 inches H20), 99.1 (47 inches Ufl),
and 96.3 (37 inches H20). The efficiencies were the same for 57 inches*
HpO and 47 inches hUO, but the concentration of dust into the scrubber
when testing at 47 inches HJ) was 60 percent higher. Even though pres-
sure drop varied across the scrubbers, velocities and temperatures
remained relatively constant. The average scrubber inlet particulate
loading was 1355 pounds per hour.
Particulate emission rates were also determined for tapping. Tap-
ping time varied for each tapping test from 28 to 32 minutes. There
Figure A-3. Scrubber system serving Silico-
manganese furnace.
A-5
-------
are two tap holes with exhaust systems, but only one tapping station
was in use. Therefore, it was necessary to test both stacks simul-
taneously to obtain the total tapping emissions. Tapping losses for each
tapping period were 59 pounds (32 minutes), 27 pounds (30 minutes), and 17
pounds (28 minutes). The average tapping losses (34 pounds) exceed the con-
trolled losses (average over three different pressure drops) by 22 pounds.
Gas analysis made at the scrubber outlet showed sulfur dioxide
emission levels generally below 1 ppm. Carbon monoxide was negligible,
and carbon dioxide varied between 2 and 3 percent.
The filter catch of the EPA particulate sampling train was analyzed
for chemical constituents by use of a microscope, qualitative electron-
beam X-ray microanalysis and atomic absorption. The quantities of
sample materials were very small, making analysis difficult. The glass
fiber of the filter became intermixed with the particulate matter im-
bedded in the filter, and no accurate silicon analysis could be made.
Details concerning the specific elements can be found by referring
to Table VI-18.
Several samples were obtained by a cascade impactor to determine
particle size. The mass median diameter (MMD) of the particulates at
the scrubber exhaust varied from about 0.2 to 0.7 micron. The MMD
of particulates from the furnace varied from 0.6 to 5.0 microns.
Because of the short sampling time and the varying loading of the gas
stream from the furnace outlet, the MMD particle size reported may not
reflect a true average particle size from the furnace. However, most
of the samples analyzed showed a MMD of less than 1 micron. Table VI-17
A-6
-------
and Appendix D shows the particle size of samples collected.
No emissions were visible from the scrubber when it was operated
at 57 and 47 inches H?0 pressure drop, but a slight trace of emissions
was reported at 37 inches H20.
A-7
-------
0.08
100
0.07
0.06
0.05
a
to
z
1 0.04
te
a
i—
LLl
t 0.03
0.02
EFFICIENCY
0,01
99
98
I
UJ
o
97
27 37 47
VENTURI PRESSURE DROP, in. H20
Figure A-4. Scrubber efficiency as function of pressure drop.
A-8
57
96
-------
FURNACE D
Ferrochrome Silicon
(Baghouse)
CLEAN AIR TO ATMOSPHERE (
Three test runs were made on Aug-
ust 31 to September 1, 1971, on an air
pollution control system with a 12-
compartment push-through baghouse con-
trolling the fume emissions from a FeCrSi
furnace. An air curtain is provided
around the periphery of the hood over
the furnace with the air provided coming [j\rr
from the exhaust system serving the tap-
ping station hood (see Figure A-5). The
larger particle sizes in the exhaust
system serving the furnace settle out
I 1 II 1 I iTTl TiTTll 1 1 1 I 1 1 1 11 1 I I I
12-COMPARTMENT
BAGHOUSF
SPARK
IRJJESTOJ
AIR
COOLER
Figure A-5. Baghouse serving ferrochrome
silicon furnace.
in the spark arrester. A very small amount settled out in the spark
arrester hopper; at the time of the tests, it had not been emptied
after several months of operation. The effluent gas stream then passes
through two indirect forced draft air coolers, although it had not
been necessary to use these as coolers. The dust-laden gas then is
directed into a 12-compartment baghouse with a total of 1728 (11-1/2
inch X 30 foot) fiberglass bags. Mechanical shakers clean the bags in
each compartment once every 78 minutes.
Three EPA particulate sampling trains were spaced equal distances
apart at the baghouse-roof monitor outlet in order to obtain a represen-
tative sample. Simultaneous sampling with the three samplers showed
that particulate emissions to the atmosphere varied considerably in
A-9
-------
three test runs, ranging from 18.1 to 37.9 Ib/hr with an average
of 30 Ib/hr. The average grain loading was only 0.009 grains per
standard cubic foot. The collection efficiency of the baghouse was
96.5 percent. The percentage of participates collected in the im-
pinger (back half) of the EPA train was high for an unknown reason
and quite consistent for nine samples, ranging only from 63 to 74
percent. The impinger water residue from the sampling train was
analyzed by the Sulfaver-Turbidimetric procedure and found to be
33 percent sulfate ion (SO }. Optical emission spectrography has
shown most of the material in the water residue to be Fe, Na, Ca,
Si, Al, Mg, and K. The sample volume through the sampling train
was 88.72 standard cubic feet of dry gas with an SO concentration
of 0.69 mg/cubic foot. The impinger water thus contained enough
S02 to potentially ionize 91 mg sulfate ion. Total material col-
lected in the impinger weighed 20.4 mg. With the possibility that
particulates may have formed from the reactants in the impinger portion,
the amount of particulate matter reported going into the atmosphere
should be based on the fraction collected in the front half (filter and
probe) of the EPA train. In this case, the emissions for the three test
runs would be 11.0 Ib/hr (0.0035 gr/scf), 9.4 Ib/hr (0.0025 gr/scf), and
5.8 Ib/hr (0.0014 gr/scf), resulting in a collection efficiency of 98.7%.
Particle size determinations were made by use of a cascade im-
pactor. The mass median diameter (MMD) for the baghouse exhaust was
approximately 0.7 to 0.8 microns. The MMD for the furnace exhaust was
0.3 and 3.2 microns during taps and between taps, respectively.
The baghouse exhaust flow rate was too low to measure accurately
with a pitot tube. Because air is induced into the baghouse and
A-10
-------
mixed with the cleaned furnace gases after passing through the cloth
filters, it was necessary to measure the induced air by use of a vane
anemometer. The volume of gases from the baghouse was determined by
adding the measured volume of dirty gases from the furnace going into
the baghouse to the measured volume of induced air. Induced air was
found to be over half the volume leaving the baghouse. These volumes
were verified by use of a heat balance. Another method for determin-
ing the amount of dilution air is measuring the concentration of CO
into and out of the baghouse. The C02 readings into and out of the
baghouse were 1.2 and 0.5 percent, respectively, which also compared
very closely. Including induced air, the baghouse outlet volume was
383,000 SCFM.
The quantity of particulates contained in the air induced into
the bottom of the baghouse was determined by use of an ambient air
3
particulate sampler to be 1400 mg/nM , which means that this con-
centration of dust was added to the cleaned gases exiting the baghouse.
Subtracting the amount of dust in the induced ambient air from the
total outlet emissions would only reduce the emissions by slightly
less than one pound per hour.
The baghouse was in good operating condition during the tests,
and no emissions were visible.
A-ll
-------
FURNACE E
HC Ferrochrome Furnace
(Electrostatic Precipitator)
Three test runs were made on
September 21 to 23, 1971, on a
HC ferrochrome furnace equipped
with an electrostatic precipitator
for controlling furnace fumes. The
precipitator is preceded by a gas
conditioning tower because of the
Figure A-6. Electrostatic precipitator
serving HC 'srrochrome furnace.
high resistivity of the ferroalloy fume. The gas conditioner, similar
to a scrubber tower in construction, removes approximately 40 percent
of the furnace fume. Resistivity of the fumes is reduced by spraying
170 gallons per minute of water into the gas conditioner. Water
adsorbing on the dust particles forms a liquid surface film through
which electrolytic conduction of the accumulated charge can occur.
Since this type of dust does not readily adsorb moisture, a small
amount of ammonia is added to enhance the moisture adsorption capacity.
The dry precipitator consists of three sections in series with discharge
electrodes of negative polarity and positively charged collecting
surfaces at ground potential. The furnace hood is equipped with
water-cooled, vertically operated doors to minimize the excess air
required for effective furnace emission collection. Two tapping holes
120 degrees apart are both vented to the air pollution control system.
The tests showed that the air pollution control system removes
15.4 tons per day of dust and fumes. Average emissions from the pre-
cipitator to the atmosphere were 21 pounds per hour with a concen-
A-12
-------
tration of 0.0183 grains per standard cubic foot. The average inlet
loading to the conditioning tower and precipitator was 1312 Ib/hr and
1.87 gr/scf. The collection efficiency was 98.1 percent. The fraction
of particulates collected in the water impinger section of the EPA train
varied from 8 to 20 percent in the outlet sample and from 0.7 to 3.2
percent in the inlet sample.
Particle size distributions of furnace fumes and precipitator ex-
haust fumes are shown in Table VI-16 and Appendix D. Average size (mass
medium diameter, MMD) of individual particles from the furnace was typically
from one to two microns. Frequently, there was little difference between
the sizes measured before and following the air pollution control system.
The MMD of the fumes at the precipitator outlet varied from 0.38 to 2.54
microns.
Chemical analysis was made of the gas and the filter catch of the
sampling train. The average sulfur dioxide analysis from the furnace
was 8 ppm. Carbon monoxide varied from 200 to 500 ppm. The percent
of carbon dioxide varied from 1.6 to 2.4 percent. The major con-
stituents found on the filter using atomic absorption methods of
analysis were found to be Cr, Mg, Al, and Si02. The major conclusion
is that the sample is a mixture of oxides: Si02, Cr^O.,, MgO, and
A120_. The sum of the percent values, after conversion to equivalent
oxide values, is 84 percent, which indicates adequate closure in the
sense that all the major constituents have been taken into account.
The remaining 16 percent could well be accounted for by water of hy-
dration or by the presence of chlorine, carbon, and titanium. Analysis
of a dust sample collected by the precipitator unexpectedly found 4.22
percent sodium and 5.95 percent potassium (see Table VI-17).
A-13
-------
Chemical analysis made by the company of the collected dust samples
showed a difference between the dust collected in the conditioning
tower and that collected in the electrostatic precipitator. This is
shown in Table A-13. It was speculated the conditioning tower collects
the larger dust particles, which are primarily from the mix charge
materials, while the electrostatic section collects the fumes from
the furnace reactions.
Table A-l TYPICAL DUST AND FUME ANALYSIS FOR
FURNACE E28
1
Product
Cr203
FeO
Si02
A12°3
MgO
CaO
C
Conditioning tower
dust, %
28.3
7.6
10.2
25.7
15.8
3.9
6.0
Precipitator
fume, %
5.4
6.7
24.2
7.1
38.8
12.3
2.3
A-14
-------
FURNACE F
Silicon Furnace
(Baghouse)
A series of three test runs were conducted
on January 17 to 20, 1972, on a three-baghouse
system (3744 bags, 11-1/2" diameter X 30' long)
serving a silicon furnace. Figure A-7 shows a
plan view of this system. Baghouse B was se-
lected for sampling simultaneously with four
EPA particulate samplers as the cost would be
high to test all three parallel-operated bag-
houses. The trains were equally spaced in the
roof monitor. A representative
sample was obtained from all 8 com-
partments by traversing over the
monitor 24 sampling points. The
inlet sample was obtained at the
furnace outlet exhaust duct. The
three tests showed the emissions
from Baghouse B only were 11.27,
HOOD OVER Si
FURNACE
ROOF
MONITOR
TRAVERSE
POINTS
BAGHOUSE B
BAGHOUSE A
SAMPLE POINT
TRAVERSE
POINTS
TOTAL
28 POINTS
SECTION OF
FURNACE
EXHAUST DUCT
Figure A-7. Plan view of baghouse system on
silicon furnace.
13.82, and 10.3 pounds per hour. Based on the measured gas flow rates
into all three baghouses, and assuming all three baghouses were equally
as efficient in particulate removal as Baghouse B, the total amount of
emissions to the atmosphere for each test run would calculate to be
28.6, 30.9, and 23.5 pounds per hour. The concentration of particulate
emissions to the atmosphere from Baghouse B was 0.006, 0.006, and 0.004
grains per cubic foot. The three baghouses collect 14.6 tons per day
A-15
-------
of participates from the submerged-arc furnace producing a silicon pro-
duct. The collection efficiency of the baghouse averaged 98.9 percent
for the three test runs.
Two other particulate samplers were used at the baghouse outlet
for the purpose of comparison. A Boubel high-volume source test sampler
was used adjacent to an EPA sampler, and a high-volume ambient air sampler
was suspended at the outlet of the same baghouse compartment. Comparison
of filter catch only for all three samplers found the EPA train collected
59 percent and 67 percent more than the Boubel and high-volume samplers
respectively, during one test. The other two times, the EPA train was
compared only with the high-volume sampler and was found to be 53 per-
cent and 17 percent higher.
An ASME sampler at the baghouse inlet was compared with the EPA
sampler, and the EPA train collected 19 percent more particulates based
on pounds per hour of emissions. The difference may be attributed to
the fact that the ASME testing was started about halfway through the
EPA test. The ASME train continued to be used for a sampling period
equal to the amount of time that the EPA train was used.
The operating condition of the baghouse sampled appeared good
even though there was a small bag leak in one of the end compartments
during the first two tests. The results of testing reflect this higher
emission. Emissions from the baghouse for test runs one and two were
10 to 35 percent higher than those for test run three. Disregarding
the area containing the leaky bag, the baghouse system appeared to be
capable of reducing particulate emissions to approximately 0.004 gr/scf
or approximately 23 Ib/hr.
A-16
-------
Laboratory analysis of the 12 outlet samples of participates
from the impinger train (percent of total) varied from 22 to 77
percent and averaged half the total weight.
The plan and side view of the baghouse in Figure A-8 shows where
the sampling points were traversed when using four EPA samplers
simultaneously. Each sampler determined the quantity of particulate
emissions from two baghouse compartments.
A-17
-------
SAMPLER i4 REQUIRED)
SAMPLER PLATFORM
SIDE VIEW
/ OPEN GRATING LOCATED
/ AT BOTTOM FOR DILUTION
1 AIR AND WALKWAY
i «rr5r° ° ° °
\ ^T-fro §o
; \oo6
' V3 O O
r S S S S S S S S S S S f S f J
;
J
J
k
2 1
4 3
6 5
8 7
10 9
12 11
14 13
IB 15
17 18
20 19
22 21
24 g 23
1-
"*)
a (
~B > SAMPLING POINTS
-c)
-A
-B
„ ^ ROOF OF
"L BAGHOUSE
-A
-
-A
-B
-C
A'
PLAN VIEW
Figure A-8. Eight-compartment, open-type baghouse
showing sampling points.
A-18
-------
FURNACE G
SiMn Furnace
(Scrubber)
The test conducted on February
1 and 2, 1972, was on an Aeronetics
scrubbing system. As dust-laden gas
(1100-1200 F) flows from the ferro-
alloy furnace, a standard heat-
exchanger (see Figure A-8) transfers
heat from the gas to high-pressure
water that then enters a two-phase
jet nozzle. The pressure and temper-
ature of the scrubbing water entering
CLEAN GAS
TWO-PHASE
fJET NOZZLE
CHEMICAL
ADDITIVES
HEAT
EXCHANGER
SLUDGE
DIRTY GAS
Figure A «). Aeronetics scrubbing system.
the jet nozzle at a rate of 82 gallons per minute averages 320 pounds per
square inch and 375°F. A two-phase mixture (steam and water) occurs
as the high-pressure heated water passes through the jet nozzle which
is located at the inlet of the mixing duct. The mixture thus leaves
the nozzle at high velocity, and as it passes through the long venturi
section, dust-laden gases are intermixed with the moisture. Concurrently,
transfer of momentum of the mixture to the furnace gas stream results
in a pressure rise across the mixing section, which produces the force
to move the fumes from the furnace into the scrubbing system. The tap-
ping hood is served by an exhaust fan that discharges into the top part
of the furnace cover and helps to supply combustion air to the furnace
for the conversion of carbon monoxide to carbon dioxide. The conversion
process in turn provides heat necessary to drive the scrubber exhaust
system. The tapping-hood exhaust system was estimated to be 40-percent
A-I9
-------
effective In capturing tapping fumes.
The emission concentration, including the entire catch of the
EPA sampling train, varied from 0.05 to 0.11 grain per standard
cubic foot and averaged 0.086 gr/scf. Considering only the front
half (probe and filter) of the EPA train, the mass emission rate and
concentration varied respectively from 5.8 to 13.6 pounds per hour
and from 0.04 to 0.10 gr/scf. The gas cleaning efficiency varied
from 92.6 to 97.6 percent. Two of the tests at the control inlet showed
lower-than-normal emission factors for this product; the effeciency
would thus be correspondingly lower. Particle sizing of the particu-
lates in the scrubber outlet and inlet was obtained during the test
by using a Brink cascade impactor. The mass median diameter of the
particulate samples varied from 2.41 to 5.1 in the inlet and from
0.18 to 0.50 micron in the stack outlet.
A-20
-------
FURNACE H
50% FeSi Furnace
(Scrubber)
Tests were made on February 15, 16,
and 17, 1972, on a covered 50 percent
ferrosilicon furnace served by two par-
allel-installed Chemico scrubbers opera-
ting at 80 to 85 inches H20 pressure
drop. The total volume of furnace exhaust
gas is approximately 7000 scfm. Three
test runs were made at the sampling point
located in the common outlet duct of the
BLOWER
5 HOODED
^TAPPING
STATION
BLOWER
Figure A-10. Covered ferrosilicon
furnace with scrubbers.
two scrubbers. Three test runs were also made in the three outlet ducts
of the secondary, uncontrolled exhaust system. The secondary uncontrolled
exhaust system captures the fugitive furnace fumes that escapes from the cover
and discharges them directly to the atmosphere. Also tested was the uncontrolled
tapping station. Figure A-10 shows a schematic diagram of the furnace with the
five exhaust stacks and test points. The blowers on the scrubber exhaust
were injected with kerosene to prevent binding of the rotors. Any resi-
dual kerosene carryover is combusted when flared. All three test runs
at the scrubber outlet were of short duration because the filter in
the sampling train became quickly loaded. The filter location was changed
over to the impinger outlet in the sampling train during test runs 2 and 3
with very little extension of testing time.
The results of the particulate loading in the collected aas before flarina
were 86.1, 11.2, and 8.25 pounds per hour. The corresponding grains per standard
A- 21
-------
cubic foot were 0.856, 0.115, and 0.085. Analysis of the filter catch
showed a high percentage of combustibles that should have been burned
by the flare. When the flare was off, a very distinct emission was
visible. No visible emission occurred with the flare on. An attempt
was made to determine the inlet loading to the scrubbers by collecting
water samples coming out of the scrubbers. The results did not come
close to typical inlet loadings for this size furnace; thus the
efficiency of the scrubber cannot be precisely determined. However,
emission factors indicate that the scrubber is about 98.5 percent
efficient, and the efficiency is even higher if the combustibles are
not included.
Losses from the secondary hooding varied from 136 to 569 pounds per
hour and averaged 342 pounds per hour. Tapping losses averaged 20 pounds
per tap. The average tapping time was 15 minutes.
As an experiment, an IKOR sampler was used for cnmnarisnn of particulate
loading during the samolina of the secondary hnnriinn <=tacks and thp tarmina
35 J
stack. This instrument gives instant readout, and it showed wide
fluctuation of the particul ate loading in the secondary hooding stacks.
Carbon monoxide concentrations appeared stable in the scrubber
exhaust but varied considerably in the fugitive fume exhaust ducts,
ranging from 50 to 75 ppm with peaks up to 130 ppm.
Because the test of the scrubber outlet was somewhat influenced
by kerosene injection into the blower, tests were repeated on July 18 and
19, 1972, without injecting kerosene. Three test runs were made; each lasted
approximately one hour. The results were 3.9, 3.6, and 3.6 pounds per
hour and on a pounds per megawatt basis were 0.09, 0.08, and 0.07.
A-22
-------
FURNACE J
Calcium Carbide
(Scrubber)
Tests were made on February 22, 23,
and 24, 1972, on a scrubber outlet stack,
four fugitive-fume hood stacks, and a
tapping stack all serving a covered cal-
cium carbide furnace. The fume collec-
tion system consists of a pair of
identical Buffalo Forge (centrifugal)
scrubbers, with only one on line and the
other one used as a spare. The tapping
operation is continuous, and the hood
Figure A-l L Covered calcium carbide furnace
with scrubber.
over this area directs all fumes directly to the atmosphere. The molten
product pours directly into molds, then is cooled and dumped from the
molds in an automatic operation. Figure A-11 shows a schematic diagram
of the furnace with the six exhaust stacks and test points.
Three test runs conducted at the scrubber outlet Were very con-
sistent and averaged only one-half pound per hour of particulate emis-
sions for the collected gas. The outlet particulate concentration averaged
0.036 grain per standard cubic foot. Fugitive fumes (fumes uncaptured by the
scrubber exhaust system) amounted to an average of 58 pounds per hour. The
average particulate concentration of these fumes was 0.06 grain/scf.
The average tapping particulate emissions of three test runs was 48
pounds per hour with an average concentration of 0.20 grain/scf.
Samples of the scrubber effluent water showed that an average of 689
A-23
-------
pounds of participate rratter per hour was collected by the scrubber,
indicating a scrubber efficiency of 99.9 percent. No solids measure-
ment was taken on the inlet water.
Flue-gas conditions were stable in the scrubber exhaust, but were
very erratic and unstable at other locations. Carbon monoxide levels
in the fugitive-fume ducts were extremely variable across the area of
the traverse; they ranged from 50 ppm to more than 500 ppm. The levels
of carbon monoxide in the tapping exhaust were more stable, generally
in the range of 35 ppm with occasional peaks up to 150 ppm.
A-24
-------
FURNACE K
Ferromanganese
(Scrubber)
This furnace, rated at 27 MW, was
tested August 12 to 21, 1972, by EPA
personnel in a plant located in Norway.
Figure A-12 shows only one scrubber system,
but an identical system is located on the
opposite side of the furnace. This furnace
operating at its rated loading of 27 mw was
tested under two conditions, first with only
SCRUBBER
one scrubber system in operation, and then WATER
FLARE/
HIP
Figure A-12 .Covered ferromanganese furnace
with sealed electrodes served by three
Venturis in series.
both scrubber systems in operation. The
design is based on the use of water jets only, which eliminates need for the
exhaust fan found in conventional fan-scrubber systems. The last two stages
act as ejectors inducing the movement of gas through the entire exhaust system.
The cleaned gas containing a high percentage of carbon monoxide is either flared
or sold as a fuel to a nearby chemical plant.
Six test runs were conducted with only one scrubber system in operation. The
concentration of particulates for the collected gas in the scrubber outlet
ranged from 0.009 to 0.037 gr/scf and averaged 0.018 gr/scf. The average pounds
per megawatt -hour was 0.031.
Two test runs were conducted with both scrubber systems in operation. The
concentration of particulates in the scrubber outlet was 0.010 and 0.016 and the
average pounds per megawatt -hour was 0.024.
Normally only one scrubber system is used. The company will not
A-25
-------
Install two systems on future furnaces.
Excluding incidents of uncontrolled tapping, no emissions were
visible from the furnace except for a few instances during test runs
1 and 2 when emissions were less than 10 percent opacity from fugitive
fumes.
A-26
-------
FURNACE L
Silicomanganese Furnace
(Scrubber)
This covered furnace equipped with
sealed electrodes is located in Norway.
It is used to make silicomanganese or
ferromanganese. During the tests made by
EPA personnel on August 23 and 24, 1972,
the furnace was making silicomanganese and
operating between 22.5 and 23 megawatts.
The air pollution control system serving
the furnace consists of a two-stage
venturi scrubber, two 200-HP exhaust fans,
2ND
STAGE
VENTURI
Figure A- 1 3, Covered silicomanganese
'furnace witn sealed electrodes served by
two-stage venturi scrubbers.
and two 150-HP booster fans. The pressure drop across the first-
stage venturi is approximately 2 inches f^O and across the second
stage approximately 50 inches I-^O.
Because of operating difficulties in the control system during
the fourth test run, data are limited to the first three test runs.
The particulate concentration for the collected gas in the scrubber-
outlet gas stream ranged from 0.00811 to 0.0113 grain per standard cubic
foot and averaged 0.01 gr/scf (probe and filter catch only). On a
pound-per-megawatt basis the average emission was 0.009. No emissions
were visible from the stack.
A-27
-------
Table A-2. KEY TO SAMPLE NUMBERS FOR TABLES A-3 THROUGH A-12
' Furnace
: kilowatts
during
Furnace test
A 9,800
9,300
B 7,200
C 29,000
28,000
20,000
23,000
23,000
28,000
28,000
27,500
27,500
28,000
28,000
27,500
27,500
! ! !
1 ! i
1 Test
Furnace Control point
Product type equipment location
FeCrSi Open None Uncontrolled
stack
Uncontrolled
stack
Uncontrolled
stack
Uncontrolled
stack
Cr ore/ Open None Uncontrolled
lime melt stack
Uncontrolled
stack
SiMn Open Scrubber Outlet
Outlet
Outlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Sample
number
IE
1W
2E
2W
3
5
6
7
8
9
10
11
12
(discarded)
13
14
15
16
17
A-28
-------
Table A-2 (continued). KEY TO SAMPLE NUMBERS FOR TABLES A-3 THROUGH A-12
Furnace
kilowatts
during
Furnace test Product
27,500
27,500
28,000
28,000
27,000
27,000
27,500
27,500
28,000
28,000
28,000
28,000
28,000
28,000
D 20,000 FeCrSi
20,000
20,000
20,000
22,000
22,000
22,000
22,000
20,000
i ! 1
Test
Furnace Control point
type equipment location
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
None Tapping
Tapping
Tapping
Tapping
Tapping
Tapping
Open Baghouse Outlet
Outlet
Outlet
Inlet
Outlet
Outlet
Outlet
Inlet
Outlet
Sample
number
18
19
20
21
22
23
24
25
26E
26W
27E
27W
28E
28W
29N
29C
29S
30
31N
31C
31S
32
33N
A-29
-------
Table A-2 (continued). KEY TO SAMPLE NUMBERS FOR TABLES A-3 THROUGH A-12
Furnace
kilowatts
during
Firnace test Product
20,000
20,000
20,000
E • 32,000 FeCr (HC)
33,000
33,000
34,000
34,000
34,000
33,000
34,000
34,000
F Silicon
Test
Furnace Control point
type equipment location
Outlet
Outlet
Inlet
Open Precipitator Outlet
Inlet
Inlet
Outlet
Inlet
Inlet
Outlet
Inlet
Inlet
Open Baghouse Inlet
Outlet
Outlet
Outlet
Outlet
Inlet
Outlet
Outlet
Outlet
Outlet
Inlet
Sample
number
33C
33S
34
35
36 E
36W
37
38E
38W
39
40 E
40W
41
42E
42EC
42WC
42W
43
44E
44EC
44WC
44W
45
A-~30
-------
Table A-2 (continued). KEY TO SAMPLE NUMBERS FOR TABLES A-3 THROUGH A-12
Furnace
kilowatts
during Furnace Control
lace test Product type equipment
•
i 7,800 SiMn Open Scrubber
7,800
7,800
7,800
7,800
7,800
40,500 FeSi (50%) Covered Scrubber
39,500
39,500
50,200 None
50,200
48,700
48,700
« 01
i
Test
point
location
Inlet
Outlet
Outlet
Outlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Outlet
Outlet
Outlet
Fugitive
fume
Exhaust
ducts
Fugitive
fume
Exhaust
ducts
Fugitive
fume
Exhaust
ducts
Fugitive
fume
Exhaust
ducts
Sample
number
46
47E
47EC
47WC
47W
48
49
50
51
52
53
54
55
56
57N
57S
58N
58C
-------
Table A-2 (continued). KEY TO SAMPLE NUMBERS FOR TABLES A-3 THROUGH A-12
Furnace
kilowatts
during
Furnace test Product
48,700
52,300
52,300
52,300
50,000
50,000
50,000
40,500
39,500
42,000
J 24,000 CaC2
23,800
Test
Furnace Control point
type equipment location
Fugitive
fume
Exhaust
ducts
Fugitive
fume
Exhaust
ducts
Fugitive
fume
Exhaust
ducts
Fugitive
fume
Exhaust
ducts
Fugitive
fume
Exhaust
ducts
Fugitive
fume
Exhaust
ducts
Fugitive
fume
Exhaust
ducts
None Tapping
Tapping
Tapping
Covered Scrubber Outlet
Outlet
Sample
number
58S
59N
59C
59S
60N
60C
60S
61
62
63
64
65
A-32
-------
Table A-2 (continued). KEY TO SAMPLE NUMBERS FOR TABLES A-3 THROUGH A-12
Firnace
Furnace
kilowatts
during
test
Product
Furnace
type
Control
equipment
Test
point
location
Sample
number
23,500
22,800
22,800
22,800
23,000
23,000
23,000
23,000
21,500
21,500
None
A-33
Outlet
Fugitive
fume
Exhaust
ducts
Fugitive
fume
Exhaust
ducts
Fugitive
fume
Exhaust
ducts
Fugitive
fume
Exhaust
ducts
Fugitive
fume
Exhaust
ducts
Fugitive
fume
Exhaust
ducts
Fugitive
fume
Exhaust
ducts
Fugitive
fume
Exhaust
ducts
Fugitive
fume
Exhaust
ducts
66
67NE
67NW
67SW
68NE
68NW
68SE
68SW
69NE
69NW
-------
Table A-2 (continued). KEY TO SAMPLE NUMBERS FOR TABLES A-3 THROUGH A-12
Furnace
Furnace
kilowatts
during
test
Product
Furnace
type
Control
equipment
Test
point
location
Sample
number
21,500
21,500
24,000
23,800
23,800
None
Fugitive
fume
Exhaust
ducts
Fugitive
fume
Exhaust
ducts
Tapping
Tapping
Tapping
69SE
69SW
70
71
72
A-34
-------
Table A-3.
['ARTICULATE EMISSION CONCENTRATIONS AND RATES FROM UNCONTROLLED TEST POINTS
urnace
A
B
C
D
[
F
G
H
J
Sample
nuniier
IE
1W
2E
2W
3
4
9
11
13
15
17
19
21
23
25
30
32
34
36E
Probe and
cyclone
gr/scf j
0.052
0.023
0.069
0.046
0.117
0.137
0.180
0.386
0.98
0.98
0.99
1.25
0.17
0.56
0.23
0.13
0.06
0.06
0.48
36W j 0.59
38E
38W
40E
40W
41
43
45
46
48
50
52
0.40
0.39
0.43
0.35
0.085
0.052
0.085
0.078
0.47
0.31
0.42
Ib/hr
30.1
18.5
42.7
34.3
41.8
47.6
161.0
319.0
439.0
823.0
875.0
1123.0
134.0
407.0
189.0
199.0
81.5
84.7
322.0
415.0
292.0
253.0
315.0
253.0
297.0
193.0
286.0
266.0
65.0
43.7
59.5
Probe,
and
gr/scf
0.220
0.047
0.376
0.249
0.141
0.175
1.05
0,423
2.22
1.92
2.10
2.06
0.965
1.66
1.91
0.66
0.12
0.40
0.892
1.09
0.819
0.835
1.107
0.782
0.815
0.538
0.742
0.723
2.15
1.38
1.33
cyclone,
filter
Ib/hr
126
37
232
188
50
61
940.4
349.8
1918.0
1611.0
1857.0
1846.0
752.6
1209.0
1553.0
996.4
173.2
594.4
597.0
761.0
600.0
538.0
811 .0
573.0
2840.0
1980.0
2490.0
2470.0
296.1
194.8
188.1
Impi nger
gr/scf
0.005
0.040
0.012
0.014
0.014
0.003
0.01
0.04
0.01
0.03
0.02
0.01
0.02
0.03
0.01
0.79
0.40
0.59
0.03
0.02
0.01
0.01
0.01
0.01
0.009
0.007
0.004
0.025
0.04
0.02
0.02
Ib/hr
3
31
8
10
5
1
8.9
33.9
8.0
25.0
18.0
10.0
13.3
22.0
9.0
1194.6
583.5
882.9
20.0
16.0
6.0
6.0
6.0
5.0
30.0
30.0
20.0
90.0
5.5
2.8
2.8
Total per
sample point
(includes water
: residue)
; gr/scf : Ib/hr
i
' 0.225 129
0.087 , 68
| 0.388 ' 240
, 0.263 198
, 0.154 55
0.178 62
1.06 949.3
i
; 0.464 383.7
' 2.23 1926.0
1.95 1636.0
2.12 1875.0
i 2.07 1856.0
0.982 765.9
1.690 1231.0
1.920 1562.0
1.448 2191.0
0.520 75t>.7
0.990 1477.3
0.922 617.0
i 1.113 777.0
, 0.827 606.0
0.845 . 544.0
1.114 817.0
0.789 578.0
!
0.824 2870.0
0.545 2010.0
0.746 2510.0
0.748 2560.0 i
2.19 301.6
1 .40 197.6
•1.35 190.9
Total from
furnace
gr/scf
0.15
0.29
0.15
0.18
1.06
0.46
2.23
1.95
2.12
2.07
0.98
1.69
1.92
1.45
0.52
0.99
1.07
0.84
0.95
0.82
0.55
0.75
0.75
2.19
1.40
1.35
Ib/hr
197
438
55
62
949
384
1926
1636
1875
1856
766
1231
1562
2191b
757b
1477b
1394
1150
1395
2870
2010
2510
2560
302
198
191
Estimated
emissions
not
captured,
percent
0.5
0.5
53
52
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5b
0.5b
0.5b
0.5
0.5
0.5
5
5
5
5
2
2
2
9C
6C
Does not include tapping fume losses unless otherwise indicated.
Includes tapping fura losses.
cNo inlet sarples obtained with EPA sampler. Percent loss based on emission factor and samples obtained of
fugitive fu ,e hood.
A-35
-------
Table A-4. r.wr:-." ire EMISSION C(«CEKTRATIO:IS KIO RATES TO ATMOSPHERE FROM CONTROLLED TEST POINTS
n
c
D
E
r
c
H
J
Sairple
5
C
7
8
10
1?
14
16
18
?0
??
21
29H
29C
MS
31H
3K
31S
3X1
33C
335
35
37
39
42E
42EC
42WC
42W
44E
4irr
44UC
44U
47E
47EC
47WC
47W
49
SI
S3
S4
55
S6
54
es
66
Scrubber 57" PD
Scrubber 57" PU
Probe
0.010
0.007
Scrubber 57" PD 0.011
Scrubber 57" PD 0.003
Scrubber 57" PD 0.009
i
Scrubber 47" PD
Sarplc
Scrubber 47" PD . 0.015
Scrubber 47" PO O.Ola
Strui,b»r 17" PD
0.011
Scr..bl'er 37" PO 0.013«
Tr.rubber 37" PD 0.037
Scrubber 37" PD
Ba'jhousc*
Gaghouse3
Bjghouse*
Baghouse*
Baghousea
Baghouse*
Bd^ltouse*
Eaghouse
Bughouse*
PreclpHator
Precipitator
PrecipHator
8aghouseb
Baghouse*
Baghouse
Baghouse
Baghouse
P-jllOtKP1"
Baghouse
Baghouse
Ba;houseb
Baghouse
Baghouse
Hajhouse1'
Scrubber
Scrubber
Scrubber
Scrubber
Scrubber
Scrubber
Scrubber
Scrubber
Scrubber
O.OCO
0.0035
0.0042
0.0023
0.0038
0.0028
0.0020
0.0023
0.0014
0.0016
0.029
0.009
0.010
0.007
0.0032
0.0015
O.OOIS
0.0067
0.0014
0.0023
0.0014
0.0026
0.0018
0.0017
0.0015
0.040
0.093
0.102
0.668
and filter
| Ib/hr
10.0
6.8
11.2
8.1
8.4
discarded
15.2
17.7
11.8
13.5
35.4
70.6
11 .5
13.8
7.6
12.5
9.2
6.6
7.6
4.6
5.3
36.3
12.5
14.2
4.2
1.9
0.9
0.9
5.2
1.0
1.4
0.9
1.5
1.1
1.0
0.9
S.8
12.4
13.6
67.0
Inplnger
gr/scf
0.007
0.004
0.001
0.002
0.002
0.002
0.002
0 002
0.0006
0 008
0.005
0.008
0.010
0.007
0.008
0.007
0.006
0.004
0.004
0.003
0.002
0.003
0.003
0.007
0.002
0.0005
0.0001
0.004
0.003
0.002
0.003
0.001
0.004
0.002
0.002
0.009
0.008
0.005
0.188
Ib/hr
6.1
3.7
1.6
1.6
l.S
2.0
1.7
1.8
0.6
7.3
4.5
28.3
30.5
21.9
27.2
23.0
19.0
12.8
11.5
12.4
3.1
3.2
3.0
2.4
0.6
0.2
0.1
1.6
1.3
1.1
1.
0.6
2.4
1.3
1.4
1.3
1.0
0.6
19.0
! Total per
sample point
, (Includes water
residue)
gr/scf
0.017
0.011
0.012
0.010
0.011
-•
0.017
0.020
" 0.013 '
0.0144
0.045
0.08S
0.012
0.014
0.009
0.01?
0.010
0.008
0.006
0.005
0.005
0.031
0.012
0.013
0.014
0.005
0.002
0.002
0.011
0.004
0.004
0.004
0.004
0.006
0.004
0.004 ,
0.049
0.101
0.107
0.856
0.115
0.085
0.043
0.031
0.034
Ib/hr
It.l
10. i
12.8
9.7
9.9
"
17.2
19.4
13.6
14.1
42.7
75.1
39.8
44.3
29.$
39.7
32.2
25.6
20.4
16.1
17.7
39.4
15.7
17.2
6.6
2.5
1.1
1.0
6.8
2.3
2.5
2.3
2.1
3.5
2.3
2.3
7.1
13.4
14.2
86.1
11.2
8.3
0.6
0.4
0.5
i
Totll Into
atmosphere
«r/$cf
0.02 '
0.01
0.01
0.01
0.01
0.02
0.02
0.01 '
0.01
0.05
0.09
0.01
0.01
0.005
0.03
0.01
0.01
0.01
0.01
0.01
0.05
0.10
0.11
0.86
0.12
0.09
0.04
0.03
0.03
Ib/hr
16.1
Efficiency
10.5
12.8
9.7
9.9
17.2
19.4
13.6
14.1
42.7
75.1
37.9
32.5
18.1
39.4
15.7
17.2
11.2
13.9
99.0
97.5
99.0
99.0
99.4
98.1
96.4
95.2
98.0
95.0
98.9
97.2
98.6
98.8
99.1
98.5
10.2
7.1
13.4
14.2
86.1
11.2
8.3
0.6
0.4
0.5
99.1
97.6
93.2
92.6
'three samplers used during each run designated N, C, and S. Total enfs:fons are based on results of each sanpl*.
Total for ejch rjn i; the average of tt, C, and S.
brour samplers used d^ing p,ich run designated E. EC. WC, and V. Ea:h s*r.pler covers emissions from two compartmen
Total emissions for each tcit run are the su-*i'3tion of the result* of E. EC, KC, and U.
A-36
-------
Table A-5. PARTICIPATE LOSSES FROM THE FUGITIVE FUME HOOD*
1
Sample
Furnace number
H 57N
57C
57S
58N
58C
58S
59N
59C
59S
SON
60C
60S
0 67NE
67NW
67SE
67SW
68NE
68NU
. 68SE
68SW
69NE
69NW
69SE
69SW
I
; Probe and filter
; gr/scf
0.095
Sample
0.110
0.423
0.337
0.565
0.054
0.358
0.740
0.078
0.077
0.163
0.161
0.037
Sample
0.050
0.079
0.018
0.046
0.029
0.079
0.021
0.037
0.039
|
• Ib/hr
40.6
rejected -
! 45.5
i 186.1
: 157.7
' 225.4
22.3
159.9
275.5
36.0
36.8
63.3
15.8
20.4
rejected -
29.2
8.1
9.5
13.2
15.7
: 9.1
10.8
9.9
20.1
Impinger
gr/scf
0.008
Ib/hr
3.6
Total
sample
gr/scf
0.103
per
point
i
! Ib/hr
1
! 44.2
glass probe broke ;
0.015
0.028
0.016
0.035
0.061
0.064
0.014
0.033
0.031
0.008
0.003
0.004
6.0
12.2
7.2
13.9
25.1
28.6
5.1
15.5
14.4
3.1
0.4
2.1
0.125
0.451
0.353
0.600
0.115
0.422
0.754
0.111
0.108
0.171
0.164
0.041
51.5
198.3
164.9
, 239.3
47.4
188.5
280.6
j 51.5
I 51.2
! 66.4
I
: 16.2
, 22.5
| Total Into
: , atmosphere
!
gr/scf i Ib/hr
0.11 293.06
.
i
0.47 602.5
j
i
!
' 0.43 516.5
j
I
0.13 169.1
0.09 69. 0C
glass probe broke
0.002 '
0.007
0.001
0.005
0.015
0.007
0.003
0.001
0.030
1.1
0.8
0.7
1
1.4
8.5
0.7
1.7
0.5
15.7
0.052
0.086
0.019
0.051
0.044
0.086
0.024
0.038
0.069
30.3
8.9
10.2
' 14.6
24.2
9.8
12.5
10.4
35.8
i
0.05 64.0
0.05 68.5
Fumes not captured by air pollution scrubber system.
Fugitive fume hood discharges uncontrolled fumes to atmosphere through three stacks. Total
Into atmosphere is summation of samples N, C, and S. Total of 293 Ib/hr would be higher If sample
57C were added.
Fugitive fume hood discharges uncontrolled fumes to atmosphere through four stacks. Total Into
atmosphere is summation of samples NE, NW, SE, and SW. Total of 69 Ib/hr would be higher if sample
67SE were added.
A-37