EMISSION TESTING REPORT
ETB TEST NUMBER 71-MM-01
Emissions From
Wet Process Cement Kiln
And C1Inker Cooler
at
MAULE INDUSTRIES, INC,
HIALEAH. FLORIDA
Project Officer
Clyde E. R1ley
ENVIRONMENTAL PROTECTION AGENCY
Office of A1r Programs
Research Triangle Park, North Carolina 27711
-------
PREFACE
The work reported herein was conducted by The Environmental Protection
Agency (EPA), Office of A1r Programs, Emission Testing Branch (ETB), Metal-
r—"
lurglcal and Mechanical Section.jMr. Clyde Riley served as the Project
Officer and directed the ETB field team consisting of: Messrs. Robert Martin,
Ray Mobley, Allan Riley, Dana Ludwlg, and Howard Crist. Mr. Philip York and
Mr. Tom Jacobs served as Project Engineers. Mr. Howard Crist and Mr. Allan
Riley performed the pollutant analyses at the EPA laboratories.
Approved:
Environmental Protection Agency
Gene W. Smith
Chief.Metallurglcal & Mechanical Section
March 27, 1972
HNM
-------
TABLE OF CONTENTS
I. List of Tables and Figures
II. Introduction
III. Summary of Results
IV. Process Description
V. Location of Sampling Points
VI. Process Operation
VII. Sampling and Analytical Procedures
Appendix A Particulate Results
Appendix B Gaseous Results
Appendix C Field Data
Appendix D Standard Sampling Procedures
Appendix E Laboratory Report
Appendix F Test Lon
Appendix 0 Project Participants and Titles
Page
3
5
9
12
13
14
15
25
26
68
69
76
77
L
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I. LIST OF TABLES AND FIGURES
Table No.
I
II
III
A-1
A-II
A-III
B-I
B-II
E-I
E-II
E-III
E-IV
E- V
F- I
Ti tle Page
Results For Clinker Cooler Stack No. 1 6
Results For Kiln Stack No. 1 7
Gaseous Results For Kiln Stack No. 1 8
Clinker Cooler Stack No. 1 Particulate 16
Emission Data
Kiln Stack Mo. 1 Particulate Emission Data 19
Particulate Calculations 22
Carrier Gas Data 25
NOV Emission Data 25
A
Stack Sample Analysis 70
Analysis of Impinger Particulate 72
Metals Emission Data 73
Results of Emission Spectrographic Analysis 74
Analysis Results of Impinqer Particulate 75
Sampling Log 76
Figure No.
1
Title
Electrostatic Precipitator on Kiln
Page
10
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II. INTRODUCTION
Under the Clean A1r Act, as amended, the Environmental Protection
Agency 1s charged with the establishment of performance standards for new
Installations or modifications of existing Installations In stationary
source categories which may contribute significantly to air pollution.
The development of realistic performance standards requires accurate
data on pollutant emissions within the various source categories. In the
cement Industry, the Maule Industries, plant located 1n Hlaleah, Florida,
was designated by EPA as representative of a well controlled operation, and
was thereby selected for the emission testing program. This report presents
the results of the tests conducted at the Maule plant.
The recently constructed Maule cement plant has been in operation for
over two years. The plant has two parallel wet process units, each consist-
ing of a kiln, electrostatic precipitator and stack; and a clinker cooler,
electrostatic precipitator and stack.
The gases from each of the separate rotating kilns are directed through
one of two parallel electrostatic precipitators, then emitted into the atmos-
phere through a connecting stack.
As the clinker falls from the rotating kiln onto a cooler-bed, air is
drawn through the red-hot clinker. The resulting dust-laden gases are then
directed through one of two electrostatic predpltators prior to discharge
through a connecting stack. Three particulate samples were collected at this
stack.
Sampling at the kiln stack consisted of continuous monitoring for C02,
02, and CO, plus the collection of three particulate and four nitrogen oxides
samples.
-------
The following sections of this report treat (1) the summary of results,
(2) the description of the process, (3) the location of sampling points, (4)
process operating conditions, and (5) sampling and analytical procedures.
' 4
-------
III. SUMMARY OF RESULTS
Tables I, II, and III present a summary of results from the particulate
and gas emission testing.
The clInker cooler partlculate emissions contained 1n the front-half
catch (probe, cyclone, & filter) ranged from 0.0798 pounds per ton of feed
to 0.106 pounds per ton of feed. The total catch (Includes 1mp1nger portion)
ranged from 0.0885 pounds per ton of feed to 0.112 pounds per ton feed.
The kiln stack partlculate emissions contained 1n the front-half catch
ranged from 0.634 pounds per ton feed to 1.799 pounds per ton feed. Results
from the kiln stack testing are not as consistent as the clinker cooler re-
sults. This 1s possibly due to several upset conditions encountered 1n the
kiln operation during the testing.
Nitrogen oxide levels ranged between 85 ppm1 and 265 ppm during the
coarse of the partlculate testing.
The average concentrations of (XL, Op, and CO at the kiln stack are pre-
sented 1n Table III.
* Standard Conditions - 70°F, 29.92 1n.Hg
-------
TABLE I
RESULTS_FOR CLJNKER COOLER STACK NO. 1
Run Number
Date
Percent Excess Air
Percent Isok1net1c
Stack Flow Rate - SCFM* dry
Stack Flow Rate - ACFM wet
Volume of Dry Gas Sampled - SCF*
Feed Rate - tons/hr
Parti culates
Probe, Cyclone, & Filter Catch
mg
gr/SCF* dry
gr/CF @ Stack Conditions
Ibs/hr
Ibs/ton feed
Total Catch
mg
gr/SCF* dry
gr/CF @ Stack Conditions
Ibs/hr
Ibs/ton feed
% Impinger Catch
1
2-25-71
NA
106.2
19,473
23,898
74.90
41.2
128
0.0263
0.0214
4.381
0.106
134
0.0276
0.0224
4.596
0.112
4.5
2
2-25-71
NA
110.0
17,369
21 ,360
69.25
41.2
127
0.0282
0.0229
4.203
0.102
138
0.0307
0.0249
4.551
0.110
8.0
3
2-25-71
NA
103.7
18,996
23,216
71.41
41.2
94
0.0203
0.0166
3.286
0.0798
104
0.0224
0.0183
3.647
0.0885
9.6
*70°F, 29.92" Hg
NA - Not Applicable
-------
RESULTS
Run Number
Date
Percent Excess Air
Percent Isok1net1c
Stack Flow Rate - SCFM* dry
Stack Flow Rate - ACFM wet
Volume of Dry Gas Sampled - SCF*
Feed Rate - tons/hr
Participates
Probe, Cyclone, & Filter Catch
mg
gr/SCF* dry
gr/CF @ Stack Conditions
Ibs/hr
Ibs/ton feed
Total Catch
mg
gr/SCF* dry
gr/CF @ Stack Conditions
Ibs/hr
Ibs/ton feed
% Impinger Catch
TABLE II
FOR KILN STACK NO. 1
1
2-26-71
181
96.1
55,031
126,208
48.84
40.3
172
0.0542
0.0236
25.53
0.634
189
0.0596
0.0260
28.07
0.696
9.0
2
2-26-71
181
94.5
54,413
122,704
47.49
40.3
272
0.0882
0.0391
41.08
1.019
321
0.104
0.0461
48.54
1.204
15.3
3
2-26-71
181
96.2
52,018
118,324
46.17
40.3
488
0.163
0.0715
72.51
1.799
518
0.173
0.0759
76.99
1.910
5.8
* 70°F, 29.92" Hg
-------
TABLE III
GASEOUS RESULTS FOR KILN STACK NO. 1
Gas Composition (Vol. %
Run No. OJ 0^ CO N_2
10.5 13.0 <1 76.5
Gas Composition (ppm dry)*
Sample No. NO
^
1 265
2 85
3 147
4 215
(1) Represents average values of results from continuous monitoring,
* Standard Conditions - 70°F, 29.92 in. Hg
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IV. PROCESS DESCRIPTION
Clay and crushed limestone are conveyed to the plant from an open pit
quarry adjacent to the plant. These materials are ground and blended with
shale and pyrlte 1n a rotating ball mill to form a slurry.
The blended slurry 1s fed into the upper end of one of the two sloping,
slowly revolving kilns. These gas-fired kilns are 421 ft. long, 12 ft. 1n
diameter at the feed end and tapering to 10.5 ft. at the discharge end with
refractory lining encased in a steel cyclinder. Fuel consumption is approxi-
mately 1,420,000 BTU per 356 Ib. barrel of clinker produced. During passage
through the kiln, the raw materials are heated to a temperature of about
2800°F to produce the element hydraulic calcium silicates, known in the trade
as "clInker". This marble-sized clInker material 1s discharged from the lower
end at the kiln at temperatures exceeding 2000°F and fed Immediately Into air-
quenching cooler units which reduce the clInker temperature to about 150°F.
From these coolers, the newly-formed clInker material Is conveyed to a storage
silo.
A small amount of gypsum (4.45% by weight) is added to the clInker material
and this mixture is fed Into the finish grinding mill. The mixture leaving
the grinding mill 1s fed to an air-separator or classifier where the coarse
material 1s returned to the mill and the finished cement (90% through 325 mesh
screen) 1s pneumatically pumped to storage silos. Present plant production is
approximately 2,340,000 barrels of cement per year.
The control equipment of Interest 1n this report consists of two Koppers
electrostatic predpitators, one on the No. 1 kiln and the other unit on the
No. 1 clInker cooler (Refer Sketch).
9
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KKULE.
ELECTROSTATIC PRECIRJT^TOR 0NKILN
»
_ Pl^urc /.
V4l A Lg A H F LOR I
VACUUM
--- f> EXHAUST SA5ES
- i> SOLIDS
-------
The electrostatic predpltator 1s designed for a performance of 98.8
percent efficiency with an Inlet loading of 8.0 gr/ACF at 525°F and an out-
let loading of 0.016 gr/ACF to treat a gas volume of 120,000 ACFM containing
?
30 to 40 percent water. The collection surface area 1s 46,200 ft. which
gives a gas-to-surface ratio of 2.59:1. The linear gas velocity is 4.05
ft. per sec. and the residence time 1s 8.6 sec. There are 22 gas passages
1n the predpltator and each passage 1s 9 1n. wide and contains 42 emitting
electrodes. The operating voltage of the Inlet field 1s 35,000 with a cur-
rent of 500 mllHamperes, and the operating voltage of the other three (3)
fields is 53,000 with a current of 750 mllHampeares.
The electrostatic predpltator on the clinker cooler 1s designed for a
performance of 99.2 percent efficiency with an Inlet loading of 1.0 gr/ACF
at 300°F and an outlet loading of 0.008 gr/ACF to treat an air volume of
48,000 ACFM containing less than 1 percent water. The collection surface
2
area 1s 22,400 ft. which gives an air-to-surface ratio of 2.14:1. The linear
air velocity is 2.38 ft. per sec., and the residence time 1s 10.5 sec. There
are 16 air passages in the predpltator and each passage Is 9 in. wide and
contains 30 emitting electrodes. The operating voltage of the inlet field is
35,000 with a current of 500 mllHampeares, and the operating voltage of the
other two (2) fields is 45,000 with a current of 500 mHHampeares. The
approximate total cost of all four predpltators 1n 1968 was $1,250,000.00 and
the annual operating costs for these units was not available.
11
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V. LOCATION OF SAMPLING POINTS
The two sampling ports for the clinker cooler stack were positioned
approximately 16 feet (2.6 stack diameters) above the breeching inlet and
20 feet (3.3 stack diameters) below the stack outlet. The identification
and distribution of sampling point locations used for the three particulate
runs was selected from the Federal Register, "Standards of Performance for
New Stationary Sources" (23 December, 1971).
The four sampling ports located on the kiln stack were approximately
80 feet (10 stack diameters) above the breeching inlet and 100 feet (12.5
stack diameters) below the stack outlet. The identification and distribu-
tion of sampling point locations was also selected from the Federal Register.
For the gaseous sampling the probe was positioned consecutively at one
of the four ports located on the kiln stack and extended approximately four
feet into the stack.
12
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VI. PROCESS OPERATION
Process operation was frequently interrupted by kiln upsets and
ring formations within the kiln. This was attributed to the recent inno-
vation of insufflating the captured dust from the kiln electrostatic pre-
cipitator back into the kiln process. It was estimated by the Project
Engineer that the kiln stack opacity ranged from 20 to 30 percent during
the testing period.
No major upsets or interruptions occurred while testing the clinker
cooler. The Project Engineer estimated the clinker cooler stack opacity
to range between 5 and 10 percent during the testing period.
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VII. SAMPLING AND ANALYTICAL PROCEDURES
For particulate sampling the train specified 1n Method 5 of the
Federal Register. "Standards of Performance For New Stationary Sources"
(23 December, 1971) with Impingers as described was used.
The equipment and procedures used for collecting and analyzing the
nitrogen oxide samples at the kiln stack are described in Method 7 of the
Federal Register.
Carbon dioxide, oxygen, and carbon monoxide were analyzed continuously
1n the field with an Infrared analyzer.
The procedures for analyzing the particulates conform to Method 5
specified In the Federal Register, In addition, the 1mp1nger catch was
analyzed for particulate residue Including organic matter.
Quantitative analyses of material collected on the glass fiber filter
and in the residue samples are reported in Appendix E •
,14
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APPENDIX A
PARTICULATE RESULTS
Table A-1 lists the complete results for the clInker cooler participate
test. Table A-II 11st the complete results for the kiln stack partlculate
testing. Table A-III 11st the equations used for the calculations. Also
shown 1n Table A-III are example calculations from Run 1 at the clInker
cooler stack.
Standard conditions are taken as 70°F and 29.92 1n. of Hg.
15
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TABLE A-I
CLINKER COOLER STACK NO. 1 PARTICULATE EMISSION DATA
Run No.
Test Date
"„
Tt
pb
V
vm
Tm
V|"std
V«
"gas
*M
Md
»z
Sampling nozzle diameter,
1n 1n.
Net time of test, 1n m1n.
Barometric pressure, 1n.
Hg absolute
Average Orifice pressure
drop, 1n. H20
Volume of dry gas sampled,
ft3 at meter conditions
Average gas meter temperature,
°F
Volume of dry gas sampled,
ft3 at standard conditions*
Total HpO collected, ml,
1mp1ngers and silica gel
Volume of water vapor collected
ft3 at standard conditions*
% Moisture in the stack gas by
volume
Mole fraction of dry gas
1
0.370
132
30.02
1.49
77.95
95
74.90
32.7
1.55
2.03
0.980
20.95
2
2-25-71
0.370
132
30.02
1.23
73.28
104
69.25
28.4
1.35
1.91
0.981
20.95
3
2-25-71
3.370
132
30.02
1.35
74.48
96
71.41
28.5
1.35
1.86
0.981
20.95
*70°F, 29.92 1n. Hg,
-------
TABLE A-I (Continued)
Run No.
% CO
%N2
MW,
MW
S
P*
Ts
NP
Pst
Ps
Vs
As
Q*
"a
% I
Molecular weight of dry
stack gas
Molecular weight of wet
stack gas
P1tot tube coefficient
Average velocity head of
stack gas, 1n. H20
Average stack temperature, °F
Net sampling points
Static pressure of stack, 1n. Hg
Stack presure in. Hg absolute
Stack velocity at stack conditions
fpm
2
Stack area, 1n.
Dry stack gas volume at standard
conditions*, SCFM
Stack gas volume at stack
condition ACFM
Percent 1sok1net1c
1
79.05
29.00
28.78
0.85
0.055
180
44
0.02
30.04
876
3929
19,473
23,898
106.2
2
79.05
29.00
28.79
0.85
0.043
182
44
0.02
30.04
783
3929
17,369
21 ,360
110.0
3
79.05
29.00
28.80
0.85
0.052
178
44
0.02
30.04
851
3929
18,996
23,216
103.7
*70°F, 29.92 1n. Hg, dry basis
,17
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TABLE A-I (Concluded)
Run No.
T
c
mf
T
"t
'c
Can
an
Cat
at
cau
au
caw
aw
cax
ptf
IT
"tt
Unit Feed Rate -
Tons/hr
Participate - probe, cyclone and
filter 1n mg
Partlculate - total 1n mg
% Implnger catch
Partlculate - probe, cyclone,
and filter gr/SCF*
Partlculate - probe, cyclone,
and filter, gr/cf at stack
conditions
Partlculate - total, gr/cf at
stack conditions
Partlculate - probe, cyclone,
and filter, Ib/hr.
Partlculate - total, Ib/hr.
Partlculate - probe, cyclone,
and filter, Ib/ton feed
Partlculate - total Ib/ton feed
1
41.2
128.
134.
4.5
0.0263
0.0214
0.0224
4.38
4.60
0.106
0.112
2
41.2
127.
138.
8.0
0.0282
0.0229
0.0249
4.20
4.55
0.102
0.110
3
41.2
94.
104.
9.6
0.0224
0.0166
0.0183
3.28
3.65
0.0798
0.0885
*70°F, 29.92 1n. Hg, dry basis
18
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TABLE A-II
KILN STACK NO. 1 PARTICULATE EMISSION DATA
Run No.
Test Date
°n
Tt
Pb
Pm
vm
Tm
\td
Vw
wgas
% M
Md
% co2
% o2
Sampling nozzle diameter,
1n 1n.
Net time of test, 1n m1n.
Barometric pressure, 1n.
Hg absolute
Average Orifice pressure
drop, 1n. H20
Volume of dry gas sampled,
ft at meter conditions
Average gas meter temperature
°F
Volume of dry gas sampled,
ftj at standard conditions*
Total HJ3 collected, ml,
1mp1ngers and silica gel
Volume of water vapor collected
ft3 at standard conditions*
% Moisture 1n the stack gas by
volume
Mole fraction of dry gas
1
2-26-71
0.370
60
30.02
2.69
50.31
91
48.84
449
21.28
30.35
0.696
10.5
13.0
2_
2-26-71
0.370
60
30.02
2.56
49.03
92
47.49
406
19.24
28.84
0.712
10.5
13.0
3_
2-26-71
0.370
60
30.02
2.35
47.69
92
46.17
398
18.87
29.01
0.710
10.5
13.0
*70°F, 29.92 1n. Hg,
-------
TABLE A-II (Continued)
Run No.
% CO
XN2
% EA
MWd
MW
S
Ps
Ts
NP
Pst
ps
vs
As
Q*
°a
% I
Excess A1r percent
Molecular weight of dry
stack gas
Molecular weight of wet
stack gas
P1tot tube coefficient
Average velocity head of
stack gas, 1n. H^O
Average stack temperature, °F
Net sampling points
Static pressure of stack, 1n. Hg
Stack pressure 1n. Hg absolute
Stack velocity at stack conditions
Stack area, 1n.
Dry stack gas volume at standard
conditions*, SCFM
Stack gas volume at stack
condition ACFM
Percent 1sok1net1c
1
76.5
181.
30.20
26.50
0.85
0.29
390
12
0.04
30.06
2593
7010
55,031
126,208
96.1
2
76.5
181.
30.20
26.68
0.85
0.32
395
12
0.04
30.06
2521
7010
54,413
122,704
94.5
3
76.5
181.
30.20
26.66
0.85
0.33
400
12
0.04
30.06
2431
7010
52,018
118,324
96.2
*70°F, 29.92 1n. Hg, dry basis
-------
TABLE A-II (Concluded)
KILN STACK PARTICULATE EMISSION DATA
Run No.
Tc
•f
"t
lc
can
Cao
cat
c.u
caw
c.x
ptf
ptt
Unit Feed Rate -
Tons/hr
Parti cul ate - probe, cyclone and
filter 1n mg
Parti cul ate - total 1n mg
% Implnger catch
Partlculate - probe, cyclone,
and filter gr/SCF*
Partlculate - total 1n gr/SCF*
Partlculate - probe, cyclone,
and filter, gr/cf at stack
conditions
Partlculate - total, gr/cf at
stack conditions
Partlculate - probe, cyclone,
and filter, Ib/hr.
Partlculate - total, Ib/hr.
Partlculate - probe, cyclone,
and filter, Ib/ton feed
Partlculate - total Ib/ton feed
1_
40.3
172
189
9.0
0.0542
0.0596
0.0236
0.0260
25.53
28.07
0.634
0.696
2
40.3
272
321
15.3
0.0882
0.104
0.0391
0.0461
41.08
48.54
1.019
1.204
3
40.3
488
518
5.8
0.163
0.173
0.0715
0.0759
72.51
76.99
1.799
1.910
*70°F, 29.92 1n. Hg, dry basis
21
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TABLE A-life
PARTICULATE CALCULATIONS
1. Volume of dry gas sampled at standard conditions: 70°F, 29.92 1n.
Hg, ft3
17.7 x Vm (Pb
T7. 7X77. 95 (30.02+
"std
(Tm + 460)
( 95 + 460)
— =74.90 ft3
2. Volume of water vapor at 70°F and 29.92 1n. Hg, ft3
Vw » 0.0474 x Vw = 0.0474; x 32.7s 1.55
gas
3. Percent moisture 1n stack gas
100 x V,
w,
fgas
vmstd 4 V
TOO* 1.55
74.90 +1.55
= 2.03
gas
4. Mole fraction of dry gas
*
100 - %M _ 100 -
M.
0.980
100
100
5. Average molecular weight of dry stack gas
44
MWd - (XC02. x J-) +
(XCO + «N2) x
28
100
-------
TABLE A-III(Continued)
6. Molecular weight of stack gas
MW = MW
d .x,Md + 18 (1 - Md) = 29.00X .980 + 18 (1 - .980 ) " 28.78
\§ ' •> • u *j . j.
1/2
7. Stack velocity at stack conditions, fpm
, .Vs = 4,360 x
4,360 x 5.91
8. Stack gas volune at standard conditions, SCFM
0.123 x Vs x As x Md x Ps 0.123 x 876 x 3929 x .980 x 30,04 crcM
Qs = = . . _ =19,473SCFil
^APS x (ls + 4£
1
30.04 x 28.78
>o)
1/2 m
1
Ps x MW
876 fPm
(Ts + 460)
' ( 180 * 460 )
9. Stack gas volume at stack conditions, ACFM
ft = .05645 x Qs x (Ts+460) _ .05645 * 19,473 x( 180+460) ^
- 23,898
x Md
30.04 x .980
10. Percent 1sok1netic
1,032 x (Ts + 460) x Vmstd 1,032 x ( 180 + 460) x 740
%I
Vs x Tt x Ps x Md x (Dn)2 876 X 132 x 30.04X .980 x( .370)'
11. Particulate: probe, cyclone and filter, gr/SCFury Basis
Can= 0.0154 x -5— = 0.0154 x 128 * 0.0263gr/SCF
vmstd 74.90
12. Partlculate total, gr/SCF* Dry Basis
m* . __
Cao = 0.0154 x —^- = 0.0154 x 135 . = 0.0278 gr/SCF
vmstd 74.90
106.
* 70°F, 29.29 1n Hg.
-------
TABLE A-
13. Parti cul ate: probe, cyclone and filter, gr/CF at stack conditions
17.7 x Can x Ps x Md
81 (Ts + 460) ( 180 + 460)
14. Particulate : total, gr/CF at stack conditions, •"
C . 17'7 X Cao X PS X Md . V'7 x-0278 x 3Q.Q4X .980 .
(Ts + 46°) ( 180 + 460)
15. Participate: probe., cyclone, and filter, Ib/hr
Caw = 0.00857 x Can x Qs= 0.00857 x .0263 x 19,473 =4.33 Ib/hr
16. Particulate: total, Ib/hr
Cgx = 0.00857 x Ca£) x Qs = 0.00857 x.0278 x 19,473 = 4.61 Ib/hr
17. Particulate: probe, cyclone, and filter, Ib/ton feed
P ., Caw 4.38
*tf±-JZ- = ATI - 0.106 lb/ton feed
18. Particulate: total, lb/ton
Ett = Sf£~ = » 0.112 lb/ton feed
24
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APPENDIX B
GASEOUS RESULTS
The results of the testing for carrier gas composition are shown 1n
Table B-I. Gas concentrations were determined directly from an Infrared
analyzer continuously monitoring the kiln stack gases. An average value
1s shown for each day. Nitrogen oxide emission data with the mathematical
equation is shown in Table B-II.
GASEOUS RESULTS
TABLE B-I
Carrier Gas Data
Date
2-23-71
2-24-71
K1ln Stack
No. 2
No. 1
Run No.
Date
mg N02
Tf - Flask Temperature, °F
Vf - Flask Volume, liters
P1 - Initial Flask Vacuum, "Hg.
Pf - Final Flask Vacuum, "Hg.
ppm N0?
std. cond.*
ppm N02 stack cond.
* 70°F, 29.92 1n. Hg.
CO
— 2
10.5
12.5
Gas Composition
0,
—2
13
10.5
(Vol. %
CO
<1
<1
dry)
N
—2
76.5
77.5
TABLE B-II
NOX EMISSION
1
2-26-71
0.82
81
2.061
1. 24
0
265
DATA
2
2-26-71
0.26
89
2.057
24
0
85
3
2-26-71
0.45
89
2.059
24
0
147
4
2-26-71
0.67
82
2.081
24
0
215
189
61
104
153
ppm NO,
29.54 x mg N02 X (Tf + 460)
V. X (P< - P.)
25
-------
APPENDIX C
FIELD DATA
This section presents the actual field data from the testing of
(1) the No. 1 clinker cooler stack (C-1), and (2) the No. 1 Kiln stack
(C-2).
26
-------
PRESURVEY - PROCESS INDUSTRY & POWER PLANTS
NAME OF COMPANY 7/^UjL\ dMuMj^U^ LfL^u4 DATE OF PRESURVEY 2- //- ?/
ADDRESS
NAME OF CONTACT //.
>
PROVIDE FLOW DIAGRAM OF EACH PROCESS TO BE SAMPLED, INCLUDING FEED COMPOSITIONS M
RATES, OPERATING TEl-iPERATURES AND PRESSURES, PRODUCT RATES, AMD PROPOSED SAMPLING SITES:
^
Cfr**^—' >W^<^^
/ifamA i
COMMENTS:
-------
"?
s:
W '
PROVIDE DIAGRAM OF EACH SAMPLING SITE. INCLUDE THE FOLLOWING INFORMATION:
DIMENSIONS TO NEAREST OBSTRUCTION IN ALL DIRECTIONS FROM SAMPLING
PORT.
COMPLETE DESCRIPTION OF ALL PORTS INCLUDING ALL DIMENSIONS. DESCRIPTION
OF ANY UNUSUAL FEATURES ABOUT ENVIRONMENT; HEIGHT, ODORS, TOXIC CONDITIONS,
TEMPERATURE, DUST, ETC.
V w^1 S d -J
jU- ^j^A
th&
4
-------
3.
-------
OPERATING HOURS OF PLANT PERSONNEL
OPERATING SCHEDULE FOR EACH PROCESS TO BE SAMPLED
ARE PROCESSES BATCH OR CONTINUOUS?
LIST FEED RATES AND COMPOSITION FOR EACH PROCESS
LIST ANY CONTROL EQUIPMENT, INCLUDING SIZE
S
LIST EXPECTED CONSTITUENTS OF STACK GAS FOR EACH SAMPLING SITE
STACK DATA: HEIGHT
O.D. AMOUNT OF INSULATION
MATERIAL OF CONSTRUCTION^.
PRESSURE
WET Bl
AVERAGE PITOT TUBE READING
DISTANCE TO NEAREST UPSTREAM KESTR.,
DISTANCE TO NEAREST DOWNSTREAM RES'
LB TEMPERATURE
TON
UCTION
ARE PORTS EXISTING?
, SIZE
NO, WHO WILL PROVIDE THEM?_
DIAMETER
WALL THICKNESS
GAS TEMPERATURE
I.D.
TYPE OF RESTRICTION
TYPE OF RESTRICTION
-------
5.
SCAFFOLDING OR OTHER 1-iEAHS OF SUPPORT PRESENT?
£J NO, WHO WILL PROVIDE IT?
SOURCE OF ELECTRICITY AVAILABLE? £J YES, MAXIMUM AMPERAGE PER CIRCUIT 2-
DISTANCE
MHO WILL PROVIDE EXTENSION CORDS?
&* £*•
LOCATION OF FUSE BOX
PARKING FACILITIES AVAILABLE FOR TRAILER OR VAN?
SIGNATURE REQUIRED ON -PASSES? _ /Y\A)~
NEARBY RESTAURANTS AND MOTELS
^
WAIVERS?
LIST ANY SPECIAL SAFETY EQUIPMENT OR RULES
COKKE
SURVEY BY C ^ $Jl>\ ___
-------
C - 1
NO. V CLINKER COOLER STACK FIELD DATA
.32
-------
Sketch of stack cross-section
showing sampling holes
Calculations:
Calculator
PRELIMINARY FIELD DATA
Stack Geometry
Test No.
Location
% •
Date
A. Dist, from inside of far wall to outside of
near wall, in., » _ ?& f/ _ _____
j, v .
B. Wall thickness, in*, ° 3 V
Inside diameter of stack « A-B
Stack Area -
Comments:
Point
s
I
A&JL
^~
'
% Oia. for
circular stack
&rlAJrU?t^ A.
r™.
01 st. from outside
of sample port, in.
Ld ))
S
•
33
NCAi'-28 (12/67)
-------
3
V
,5"
7
n
/(,
17
20
3,5"
S-7
//. 6.
LL.2.
1. 3
°. 7
t.i.S'
73.
f L • 5
i\fi&
.80 +24\ S"
.) 5-
,2z>
/S,V
LL.&
(. t*?>
3 ^
^ ssi"
y 71
r 73
-------
VELOCITY TRAVERSE FIELD DATA
Test
Location $&, /
Date I- 1
- ?/
Operator
Meter AH
/, ~ ___ _
"A'P, in. HpO Average
AP, in. H^O Average
Comments:
35
NCAP-29 (12/67)
-------
. VELOCITY TRAVERSE FIELD-DATA
Plant
Test
Location A/t>.I
Date Z
Operator
Meter AH
Clock
Time
Point
1
3
_4__.
7_
__.2._
1_
IP
li
11
13
(i)
AP, fnTH20
,n
.Us
,11
0)
-A
_R»
w
', inf H00
/
17
2L
z\
.01
(2±
'/AP, i"rJ7~H:^
Stack
-fry
Tempt.
°F
(1)"A'P, in. H20 Average
(2) AP, iru M20 Avernqe
_____ /.
Comments:
3'6
NCAP-29 (12/67)
-------
Plant yfWUAjq O>W- Date_
Sampling location /V^t!
STACK DATA FOR NOMOGRAPH:
1. Meter AH /. J & _ in
2. Avg. meter tempt (ambient + 20
3. Moisture (volume) _ -O . _ __%
4. Avg. static press. c£ „ Z ^ In. H2OX.073 = + , ^)/^ 1n. Hg.
5. Bar. press sampling point 3&.D D _ 1n.Hg ^ . 0 / (static press in.Hq)
1n. Hg.
6. Bar press of meter 3 °,^ -{n. Hg.
7. ps/pm - *- y in- Hg . /.
s m 6. /\ ThT Hg - :
8. Avg. stack temperature / /)^
9. Avg. stack velocity (AP) ^)/ ^>7 1n H20. Max< velocity A/? in!
C factor (1) // 2 (2)
37
-------
RUT Ho.
Cat*
Ssirpls Bex No. •
Hster Bcs No.
/, z.
T~
:r.:.~ j Meie:-,.
\jLL-
tiiizfa
*L f ... [
.._|-
t
i
i PARTICULATS F1£L;3 DATA
j :
1 VFR? IMPORTANT - FILL IN ALL BLANKS
Read and record at the start of
each test point.
PATKOLOG3CAL INC!KERATCRS-
reed and ratord ev*ry i 'minutes.
Ambient Temp °F_
Bar. Press. "Hg
AssumedflbTsture
Master Bex .Setting, °F
probe Tip Dia., In. f 3
Frobe Length
A 01
**>
Pitot:
/3-Z/7/V
I .Dry Cis Temp.
Probe Hester Setting Q &
•Avg. & P_
T
Pump
Vacuum
Box
In. HG -T
i £
bi
! /^*
>•»...
r~
.jt__I
_^
*/
3/0. ¥8
3A r
WO
/t
ZJ
'..//_.
I «-_
U-2L
j '/y'
M£
Ji^>
/>
4_»*.
r ^f
T v*
C2._ZL_^
. ' 7
7,c cual'_;'" In-e'i j Out'lTt" I Gauge
""
IET.
I A>8
| Stack.
!?res.-
a
•09
C { A AC > /«
~T /
', 58
sf'.
tIL*
-. -_. ,. -
l/ez^.j 3.0 ! 5 | i
t
i JL/--
^
1
tcmmcnts:
-------
Clock
Time
Dry Gas
Meter, CF
Pi tot
in. H20
Orifice &H
in H00 .
Desired 1 Actual
Dry Gas Terr.p.
Inlet Outlet
Pump
Vacuum
In. Hg
Gauge
Box
Temp
°F
Impingsr
Temp
op
Stack
Press
in. Hg
Stack
Temp
A?
78
^L
2£-
/f 5V
S7
? .
jot
rf
M
9o
> V
To
, fl-
. J
•z.3
95"
/ 00
7*
ASO
#?
*
3V? .
y.7
.25*
ft
v.*/
7.
x So
3SZ , 17
/ f
/so
*« t?
/ 10
/&
/S
34 $0
Z.o
3.7
t to
/ f
9?
/S
ts
36 Y . 33
. 10
/o
• /a i.
CO
"
370.
/So
*
10
///
372.62,
I1? //V
. V/
2o
32-
9?
ft.
/*•*
96
*
377.
-------
Pisnt
Run- Mo,
Location
Date
"2.
PARTICULATE FitLU DATA
i • VESY IMPORTANT - 'fill IX ALL BLANKS
! Reed end record at the stsrt of
; e.-ich test point.
i P ATi !GLCG I CA1. I ?! fj II. .7 .UTOur..
S?ir,ple Box fio. : •
Meter 3ox No.
!•»•-••
•~ Factor i i
Ambient Temp °F____^£
Bar. Kress. "Hy 3 ^.
Assumed Moisture » __xf
Heater Sox Stttlng, 3F__
Probe Pip Dla., In.
Prcbs Lergth ^
jfobt iieater Setting VC
avg. i-. P ,oT_ Avg. ,',
Point
t:
P. .
Vfl'.p
!•/ o^t/urs-U-^'tot } Orif;ce ^H ! Di^y Go? Te;rp. I Vacuum !&cx ! Implnger Stack j Stac's i
Clock !/ Dry Gas ; in. HvQ. j J"i_H'-J i 1! ! In- ^3 iler.p.i T&mo -Pre*-; j Temp ;
Time "WHeter, CF i £p"; , OesTrei-J "'[ Actul'l 'fTnlet j Outlet 1 G^s^gs j °F | °F pn. Hg | °F :
__ ..^ _._^ p....- .. i -•
a.1
J S
302.. f 7
''
•2..0 j /o e> j 9 "7 j f_
z .9
2.3
I 2=f?_L
T- v^^ i"
9J^ I /Z.
A^-T f ^ . i •. // !
"
1
(leo .
F_T7!
'SI
I 2.3
3.-
3.2. j //r i /go
f } /O t
2. o
2.. «? ; //
//r
.-_! '
i£ 2Jl_//4 f _/j
/ <90
zco
»o
"7^>
-f0
i
—i
. /YTQi
ygb
i_.
^ i «.
-------
-------
FUin Ho.
Location
Pate
Hiter 3cx do.
. '"*t«r * K _.L_:A_£
I Clock
Dr c^^i
in. i
r.-.STiC'JLATL FltLG DATA
^J_l^2M»!iI - FILL IN ALL 3LANKS
Rend e?id record r.v the start of -
Kt.c"i tf?st point.
PATHOLOGICAL INClMERATCRS-
rcad an a'r.
Bar. Press. >:Hg
•9?
As5U!7
Punic
f «4Mlf> . j . |
Vact'uin 5cv ' Imcvager !St>.
> ' ' ~* i
ir. H.r.0
"" '"~
• _'"_ii'js-' i L_ j!r.. H^ ;-£irp.
P'OesiTvc" ""Actuf T'l Inlet j OijtTat G2ug£ -! JF • j °F ^ jxn^Hg
-. . • : 4--. . -^-^-.. r_ -+- .-7^-. t.i,.;-
3t. 3
1 r7y _. s '«-^ _ : 7_» !
r ^7f Tf7" "1 jr-£" i ~
hCA?-37-{12/67} j
-------
Pur,?)
Vacuum
In. Hg
Gauge
-------
PARTICIPATE CLEANUP SHEET
Date:
Plant:
Run iiiimber:
Open-tor: _
L
Sample box number:
Location of sample port:
Barometric pressure:
Ambient, temper a turu:
>, 02^
Impinger H20
Volume after sampling 3J?/y ml lontainer No..
Impir.ger prefilled withl£i_ml ! xtra No.
Volume collected It, ml
Ether-chloroform extraction
' of impin9er water
Impinger water residue
"9
mq
Impi ncjers and back half of
filter, acetone wasV.
Container Mo
txtra No.
Weight results
mg
Dry probe and cyclone catch:
Container No.
Extra No.
Weight results
Probi, cygfene, ftesk, and
front half of filter,
ac-Dtone wash:
Container No.
Extra t!o.
Weight results
71.*
Filter Papers and Dry Filter Particulate
Filter number Container no. Filter number Container no
I : _.
Filter particulate
weight
Total particulate weight
_mg
mg
Silica Gel
Weight after test:
Weight before test:
Moisture weight collected:
Container number: 1.
'1O0.6
2.
4.
Moisture total
gm
Sample number:
Method determination^
Comments:
Analyze for:
44
-------
Date:
7/
PA/ITICULATE CLEANUP SHEET
Plant:
Run iiuniber:
Operator:
Sample box number:/ ffi *S
Jmpiager HgO
Volirne after campling %2f ml Container No.
Impinger prefilled with/^_m] Extra No.
Voli Tie collected
Location of sample port:
Barometric pressure: _ 3 b-C>
Ambient temperature:
, )
Ether-chloroform extraction
' of imf'ingcr water
Impinger water residue //.
mg
Impincjers and back half of
fUter, acetone wash:
Container !!o. 3 J/
Extra No. . Weight iesults
rng
Dry probe and cyclone catch:
Container No
Extra No.
Height results
mg
Prole,
f-ont half of fiU<-T
acetone wash:
Container No.
Extn; iio.
Height
Filter Papers ai;d Dry Filter Particulate
Filter number Container no. Filter number Container
i
Filter particulate
weigh t •S'2. ^ rng
Total parti cul ate v/einht
Silica Gel
Weight after test:
Weight before test:
Moisture weight collected: ff.tf
Container number: 1. 2.
Moisture total
9"
Sample number:
Method determination:
Conments:
Analyze for:
45
-------
PARTICULATE CLEANUP SHEET
Date:
Run number:
Operator: _
Sample box number
Location of sample port:
Barometric pressure:
Ambient temperature:
CA+&^
Impinger H20
Volime after sampling HQ ml
Impinger prefilled wltttftffijnl
Volume collected IjjLml
Container Mo. ?A Ether-cMoroform extraction
Extra No. _ ' of finger water - mg
Impinger water residue J 3,£) _ mg
Imp'ngers and back half of
filter, acetone wa;.h: ..
Dry probe and cyclone catch:
Container tio
Extra No.
Weight results_
mg
Container No.
Extra No.
Height results
mg
Pro'je,
lQiiifr, and
front half of filter,
a-.etone wash:
Container No._ ?C
Extra iio.
Weight results
Filter Papers and Dry Filter Particulate.
Filter number Container no. Filter number Container no.
i •
Filter particulate
weight
m
Total particulate weight
mg
Silica Gel
Weight after test: 2/f, f
Weight before test: 300
Moisture weight collected: _fji±f
Container number: 1. 2.
Moisture total
qni
3.
4.
Sanple number:_
Method determination^
Comments:
Analyze for:
-------
PLANT
SAMPLING SUMMARY"SHEETS
LOCATION
SAMPLED SOURCE
Train Data
Run
No.
/
t-
3
• Date
-2-Z5->
i-25-y
l-tS-J
Nozzle
dia.
in.
*^>o &
J~"^r
/.3 "/*>
,2>>c>
HTet
time
mm.
13 L
I3L.
/32
Bar.
pres.
"Hg.
fa at
J>&s^ if
_5*i5, ~l)if
Orifice
diff.-AH
"H2.0
/'#?
L 22>
/,3^
Volume sampled
meter cond.
cu. ft.
77- 3S
*?~< y
Total
moisture
ml .
•**. 7
Zt.*f
z*«s
Moisture
std. cond.
cu. ft.
/.jrjr
/.3S
/.~J>g
% Moisture
by volume
/, 63
/. 91
l.tib
Mole
fraction
dry gas
, f/J2>
,7*1
_,_£.^Z_
Molecular
wt. of dry
stack gas
11.**
2?. o*
I?, *^
(. <&\r )
• Molecular
wt. of moist.
stack gas
21. 72
2?. 7/
2?'*°
Stack Data
Run
No.
/
I
^
Stack
area
in2
39Zf
3? Z?
,o S*
Static
press.
"Hg.
.&
,£>L.
L
Stack
press.
11 Hg. Abs.
3&.i*f
2°. oy
?>O.Qif
Stack
temp .
°F
/*&
/^^
J7%
Calculation Data
•"Run
No.
(
L
o
Average
*J Velocity x temperature °R
^"x $/
*>fl$
vT, y<-
:> 33
%^t
Stack _.-•..
gas volume
scfm
/^ 4/^3
;^.3£*
/ f, ??t
1 /
Percent
isokinetic
/^^.z
1J2>,*>
Jt>3, 7
47
-------
C - 2
NO. 1 KILN STACK FIELD DATA
48
-------
PRELIMINARY FIELD DATA
Stack Area
Comments :
/^
_Sketch of stack cross-section
showing sampling holes
Calculations:
f
• Calculator
Point
/
£
^3
% Dia. for
circular stack
4^-
W
-------
A-/
^•v/\A^_
PRELIMINARY FIELD DATA
Stack Geometry
Plant
T
f
*x to'
Sketch of stack cross-section
showing sampling holes
Calculator £.
NCAi'-28 (12/67)
Test Mo._
Location_
Date
i
/
A. Dist. from inside of far wall to outside of
/' 2 $ 2^
near wall, in., =
B. Wall thickness, in., =
_5 2'jL
Inside diameter of s;tac.k_= J\,-B
JSSs8-8 -
>y>
Comments :
Point
/
I
3
i •
i
r
i
jl_
% Dis. for
circular stack
4.V
yv,7
Zt.7
Dist. from outside
of samnle port, in.
*.3 y-3/i.37f
^2^^- ^£"
27."/ •> ^^X/
50
-------
VELOCITY TRAVERSE FIELD DATA
Plant
Test
Location
Date
frt. Akck
Operator
Meter AH
Clock
T i iiic
L-4T—
Point
(i)
AP, fnT
__.].
-J
-J_r:._>
u
(1)
A P,in.H00
Af\ in. H*
F"
•>
.*_] C_-,,
10
/z,
u_^3i
Stack T«iinpt.cF
•^P, in. H.,n
1—
j_Jbt/^..
i
.4
( 1 ) -fiP , in. H , 0 A v c ra g y 3
(2) AP, in. H^O Averagu
r ,
Comments :
NCAP-29. (12/67)
-------
VELOCITY TRAVERSE FIELD DATA
Plant
Test
Location
Date
M./
Operator
Meter AH
f
f,
Clock
„ T i inc
A3* 6
[.
Point
A/
I
a
£ L
i
3
C i
4-
^
1>l
<,
o
(1)
AP, fn7H20
.2?
,3?
,34
r -/J
' ,30
.£_3^ ._„
^_/^ ;
, ^>^/ X
•,35^
-£J7
, 36
, 3^
LU.
i^A~^.invH00
&x
^
lil
AP, in, H00
(2)
TATT'Tr;. 'TU^
i. "r " '
i
1
i
]~
" ~~1
.
'
.... - .... .
.-->-•• - - — .— - . ™._.._
Stack Tempt.°F
. _
.. — j_. .|
t/&D \
—
—
4
£/
jr -i
|
1
I
f "
(
i
i
/I
t "i
J> i
i
(1) "A P,. i n. H20 Av c r a g c
(2) AP, in,. H20 Averaqfj
Comments:
52
NCAP-29 (12/67)
-------
Plant //Uuja O^^Ut^l^<^L Date_
Sampling location /Yo, /
STACK DATA FOR NOMOGRAPH:
1. Meter AH /. .d? _ in
2. Avg. meter tempt (ambient + 20° / O £> *F
3. Moisture (volume) _ .3 £> _ X
4. Avg. static press. & , in. Hg.
5. Bar. press sampling point 30 ,d 2^ _ in.Kgft .fc>^> (static press in.Hq) =
3g, & ^ In. Hg.
6. Bar press of meter _/ ^ in. Hg.
7
7'
= 5- V in-
6.
"
8. Avg. stack temperature
9. Avg. stack velocity (&P) £,3Z- in H20. Max< velocity^? 1nH,0
\ . i
C factor (1) , L (p __ (2) __
5} •
-------
Plant Guj?^ _ Date
Sampling location
STACK DATATOR" NOMOGRAPH:
1. Meter AH /, g _ _in
2. Avg. meter tempt (ambient + 20° / Q Z) °F
3. Moisture (volume) _ J3
4. Avg. static press. & . */ (c in. H2OX.073 = + / 6 .3 in. Hg.
5. Bar. press sampling point 3^ ^^ _ in.Hg £> ^ 3> (static press in.Hq)
3^), z) ? in. Hg.
3"'~ i
^. *' L/ in. Hg.
7-
in. Hg
8. Avg. stack temperature
9. Avg. stack velocity UP) _ .33 _ 1n H20. Max< velocity ,32 inHJ
- • — " "—- — — jf-
C factor (1)
-------
Plant
Rur» No.
Location
Date
Curator
S-3jr.ple BC4: No.
tfeter Bex No*
i
•''sl.vr .-« H i
FAftTICUL.^7 FIELD DATA
j VER/ IMPORTATiT - FILL IN ALL S'.ANKS
'j Read and record st the st^irt of
i ; each test point...
! ' .. • i .i
! PATHOLOGICAL IriCIKERATORC- [
\ : read and record every 5 minutes.
i
•<-
Ambient T2mpT°F__
Bar, Press. "Hg_
Assured 'M
1
j Poinl
Pi tot;
Clock j Dry Gas I in. HgO
Tif^ I i«eter, CF j aP i
.......
Heater Sox Setting, °F
Prcbe Tip- Ois.» in. r
Probe Length
Proba Heater Setting __
Avg. i P__t
2.7
Orifice AH
JCLik:0_
Desired
FU.TO i
] Or/ GcS Temp, iVacuum
!_..JF Jin. Hg
inletpJutlet jGauge
3ox Impir.ger iStscb Stack L
T^.M., TC.VA . h->-^«:«;' .r Ter.o r
i-.-i.p. j '^••;;-' ! ; —-' * i -^^r \
m r M ^fJT * • :~l *" ~ ~'i- "•tT'SF I
.._ ;1__6^ .J
1 _
Cc-r,OT?r.ts: ,, A ,
•Cowtifa*
NCAP-37-{l?/67) \f \ i
-------
Plant
Run, No.
Location
p » rs tor
Samp Is 3c-x *Q. ;
__Mftter.B.ojj-Mo» ±
Meter 4 H
C Faster
~~- ! ":
Clock
j Point -
Ub.
T
j PI tCt
Drv Gas j in. H?C
-t=r-, CF j ^i;"
T
.-jL_
•r~AT
C - /
;&
i--!
?ART!CULATE HELD DATA
VERY IMPORTANT - FILL IN ALL BLANKS
Read and recced at the sti^t of
each test point* :
PATHOLOGICAL INCINERATORS- \
: read and record every 5 rc~» nutes.
Terrtp °F_
Bar. Press. "Hg
Asstaned Rertsture t~-
Heater Box Setting.
Probe Tip Die., In,__,,j
Prpbe Length ^
rrobc Hester Settittg
Avg. A ? •• Avg.
Orifice ^H
•In H0C
! Dry Gas Temp.
DesI red ' Aclult"' Inlet Outlet
_X_5
Pump j
Vacuum iBox
!— 5 - ^ '** .
n. ns ..yrv.
Iinpinger J^tack
Stack
l£ r-O-LiJZJL _| ^ 1. ? ^r<
ieHCT2^7_t_j_ .?r r ?. 7 ; yy s
AHTT.f4 /. / j_LA^_ 4—M i- *•£ .
>< nft1* } ^~? 7.3_ . ; JL.J j
77 i r *7. ^ r \ Tl^ i 3.J? i ! « i
'h'^y i' i.?
•Hrr"
JuJ*~-
,j—
^fe^- /w
KCAP-37'(12/67)
3 XT
-------
f;un No,
f S* -r I 1 • ' "*
• i ~ c. i ^JfT1 n ^ r j' *' *": i i •* r • •
— ' , ~ \* J . ^.IttjJ * I f ^ X, Ui ui! I * *,' O.-
'. ;• C
-------
Date:
Run number:
Ope-ator: __
Sample box number:
PARTICIPATE CLEANUP SHEET
Plant:
Location of sample, port:
Barometric pressure:
Ambient temperature:
Impinger
Volume after sampling
Impinger prefilled wi
Volume collected
Container No. t/A Ether-chloroform extraction
Extra No. - ' of 1m')1n9er water
Impinger water residue
»*
mg
Impingers and back half of
filter, acetone wash:
Container Mo.
Extra No.
Weight results_
mg
Dry probe and cyclone catch:
Container No.
Extra No.
Weight results
mg
Prcbe, ayelencri^>ilr'> and
front half of filter,
ecetone wash:
Container No.
Extra Mo.
Weight results
fr
ing
Filter Papers and Dry Filter Particulate
filter number Container no. Filter number Container r.o.
Filter particulate
weight fp^ mg
Total particulate weight
Silica. Gel
Height after test:
Height before test:
Moisture weight collected: l
Container number: 1.
Moisture total
2.
gin
Sample number:
Method determination:
Comments: 2
Analyze for;
-------
Date:
Run number:
Operator:
PANICULATE CLEANUP SHEETv
Plant:
_
. e, 05^10110, f^»4, and
front half of filter,
acetone v/ash:
Container No.
Extra Mo.
Weight •'csults
/J> 0
_mg
Filter Papers and Dry Filter Particulate
Filter number Container no. Filter number Container
Filter particulate
weight
Total particulate weight
_mg
mg
Silica Gel
Weight after test:
V'aight before test:
Moisture v/eight collected:
Container number: 1.
Moisture total
2.
3.
gm
Sanple number:
Method determination^
Comments:
Analyze for:
rr
-------
Date:
PARTICULATE CLEANUP SHEET
Plant: '•
Run number:
Operator:
C.£ KJL
Sample box number:
Locaton of sample port:
Barometric pressure: 3
Ambient temperature:
\
Impinger H20
Volume after samjpling
Implnger
Volume collected
Container No.^>9- Ether-chloroform extraction
Extra No. - Of Impinger water
Implnger water residue 3
jug
mg
Implngers and. Bat
filter, ace£one_
r '
Container No.
No.
Weight results,
mg
Dry probe and
'-
Container No._
Extra No.
Weight results
mg
Probe, cysliBQ^ f-teok, and
front half of filter,
acetone wash:
Container No. L C -—^
Extra Mo. We1ghf>esults_
b 6
SHica Gel
WHght after test:
Weight before test: Let*
Moisture weight collected: 17.
Container number: 1. 2.
Moisture total
3.
mg
Filter Papers and Dry Filter Particulate
Filter number Container no. Filter number Container no.
I
/ T^"?1/ ^ . .„.,..., _..«7.,,. Filtrr nnrtimlitr
i . weight S?2.
Total particulate weight *$~/ff
mg
mg
Sair.plc number: [
Method determination:
Comments:
Analyze for:
-------
FIELD DATA
Location
Date
Time
e&J'
Comments:
Operator
&Lj&A.y>
V ef}g**-£Jt«-
7
Test
/
•
(co2) .._
- Reading 1 -
/L.g
— . . _ . -
(Q2)
. Reading 2
JiO ,^
(CO)
Reading 3
2. 'ft'p&M
f r
NCAP-31 (12/67)
-------
FIELD DATA
Location
Date
Time
Comments:
Operator
Test
(cp2) . .
Reading 1 -
(o2)
Reading 2
(CO)
Reading 3
NGA.P-31 (12/67)
-------
PLANT
SAMPLING SUMMARY SHEETS
u^f LOCATION
SAMPLED SOURCE /I/O, /
Train Data
Run
No.
/
I
J?
-
Date
t-U,-?/
1-26-7/
Z-tt-7f
Nozzle
dia.
in.
.37^
,3>*
,3^0
~K'et
time
tm'n.
to
6 0
io
Bar.
pres.
"Hg.
3£.*£
?&. i>2.
\£>,f>L~
Orifice
diff.-AH
"HzO
l,L1
L -56
/. *£
Volume sampled
meter cond.
cu. ft.
jf 0.-V
3> •
*/ ?- i* 1
Meter
temp.
oF
9S
9^
72-
Volume sampled
standard cond.
cu. ft.
4^;^
V7, Yt
tjt./*f
Moisture and Gas Data
Run
No.
/
JL
J?
Total
moisture
ml.
4^Vf
fyo(*
•?f ?
Moisture
std. cond.
cu. ft.
I/. I?
ft, IV
/$- $"<>
% Moisture
by volume
_J.^^14_
13. 1S
25. t&
Mole
fraction
dry gas
, f£>C>
. >/ 6
, >/ *>
Molecular
v/t. of dry
stack gas
:^.^£
2* . 2&
2>o. Z&
Molecular
wt. of moist.
stack gas
H,3
IL, i C
Stack Data
Run
No.
/
2.
J>
Stack
area
in^
'7^>/»
ID/ D
. ?£>/ *
Velocity
head
"H20
,2?
3Z-
• ,c>l^
Static
press.
"Hg.
,0^
.Vi
• *tf
i
Stack
press.
"Hg. Abs.
.3 A tC
^>o °(
3* L>
3?^
/^/^
Stack .-.
gas volume
scfrn
js^ ^^^
jrv./xC
jTA fO fc
s
Percent
isokinetic
9^. X
W . ?
96. .3
63
-------
OXIDES OF NITROGEN FIELD DATA
Date
Plant
Sample Collected By
No.
Power Stat Setting
Field Data
Clock time
Flask number
Volume of flask less _
correction (444«r)i^<
T/dUSrt***'*?"*-* • .
^reMiH"0 before sampling
In Hg.
Jisa&uu.**f. ..
Veyourc after sampling
[ In Hg.
Flask temperature, °F
Wl
^
~£OX&>
~$0i \f
*f
I
o
l&
Remarks:
NCAP-35 (12/67)
//
64
-------
OXIDES OF NITROGEN FIELD DATA
Date
Sample Collected By
Run No.
Power Stat Setting
Field Data
Clock time
Flask number
Volume of flask less A
correction (•W*er))"*-<
\&cw^~ . . , .
PpoMtirc before sampling
In Hg. <•
'L>B&UU-***n. ..
tw**tfre After sampling
In Hg.
?,' c
rlask temperature, °F
a:eo
/
po?4/
- a£
^6^9
At
0
$*
11
*
Remarks:
'
NCAP-35 (12/67)
65
-------
OXIDES OF NITROGEN FIELD DATA
Date _
Plant
» - 2.1 - ?/
Sample Collected By
Run No. ti
Power Stat Setting (o
-------
OXIDES OF NITROGEN FIELD DATA
Date 2-
Plant
Sample Collected By
Run No.
Power Stat Setting
Field Data
Clock time
Flask number
Volume of flask less n
correction (4fter))^H
•HJSSUIC before sampling
In Hg.
l/WmAt.'Y»~
Vessurc after sampling
[ 1n Hg.
Flask temperature, °F
V.3o
11
*fr
^
o
*&o
33
*
Remarks:
//:
//
NCAP-35 (12/67)
67
-------
APPENDIX D
STANDARD SAMPLING PROCEDURES
The sampling procedures are Identical to those outlined in the Federal
Register, "Standards of Performance for New Stationary Sources" (23 December,
1971).
68
-------
APPENDIX E
LABORATORY REPORT
This section presents the participate results which were performed
by the ETB laboratory. Also presented 1n Tables II, III, IV, and V 1s
quantitative data reported on certain allquots of the participate samples,
69
-------
TABLE E - I
STACK SAMPLE ANALYSIS
Maule Industries Cement Plant
Hialeah, Florida
. March, 1971
— — — -
Sample No
1A
1C
ID
Total
2A
2C
2D
Total
\
3A
3C
3D
Total
i
4A
4C
>' 4D:
Total
5A
5C
5D
Total
6A
6C
6D
Total
Water Blai
Acetonp "
ik
'^T',
Parti c."1
mg
6
71
57
134
11
75
52
138
10
55
38
104
17
104
68
189
49
138
134
321
30
206
282
518
0
i
-
.
Nitrogen
Dioxide
U jnn
0.82
0.26
0.45
0.67
T A
1
Run No.
i
1
2
L o c a t i
o n
Clinker-Cooler Stack
No. 1 (Outlet)
Clinker-
No. 1 ((
i
i
1
-Cooler Stack
)utlet)
I
2
4
5
6
Clinker-Cooler S1
No. 1 (Outlet)
i
1
Kiln Stack No. 1
(Outlet)
Kiln Sta
(Outlet)
Kiln Sta
(Outlet)
ck No. 1
ck No. 1
tack
-------
TABLE E - I (Continued)
STACK SAMPLE ANALYSIS
Maule Industries Cement Plant
Hialeah, Florida
March, 1971
Legend: A - impinger water
C - acetone rinse of probe cyclone, flask, and front half
of filter
D - glass fiber filter particulate
Note; Samples 1, 2, 3, and 6 were obtained without a cyclone and
flask in the sampling train. One N02 sample was void for run
and one for run 6.
The following additional samples were obtained for future reference
and analysis:
(1) finished product (cement)
(2) clinker
(3) slurry (kiln feed)
(4) material removed by electrostatic precipitator of kiln No. 1
(5) material removed by electrostatic precipitator of clinker-
cooler No. 1
(6) raw feed to grinding mill
71
-------
TABLE E - II
ANALYSIS OF IMPINGER PARTICULATE*
Sampling Location Sample Wt. Sulfate Calcium Potassium Iron Magnesium
mg mg mg mg ug ug
Clinker Cooler 10^ 0.4 0.30 0 30 12
Stack No. 1
Kiln Stack No. 1 49^ 17 0.4 0.11 30 34
(1) Clinker cooler stack Run No. 3 1mp1nger catch.
(2) K11n stack Run No. 2 1mp1nger catch.
* Analyses performed by EPA
72
-------
TABLE E - III
METALS EMISSION DATA*
Element
Be
Cd
As
V
Mn
N1
Sb
Cr
Fe
Cu
Sr
Pb
Weight of
sample-mg
Sample Cone.
Cl Inker Stack #1^
7.2
BDL
BDL
200
300
1304
0
1376
23,880
231
3854
BDL
134
(ug/gm Sample)
KILN Stack #1^
BDL
BDL
BDL
139
130
2204
0
3273
10,430
256
2853
815
189
Metal wt.%
wt. metal
X 100
wt sample
(1) ClInker stack Run No. 1 total catch.
(2) Kiln stack Run No. 1
total catch.
73
-------
TABLE E - IV
Results of Emission Spectrooraphlc Analysis
Performed on the
Results given in
Metals
Na
K
Ca
Al
Fe
Mg
B
SI
Cu
Ba
Mn
Pb
Sn
Cr
N1
Ti
Co
Implnger Participate*
weight percent
Cl Inker Cooler
Run No. 2
1.0
0.2
1.0
0.02
0.4
0.4
0.1
2.0
0.02
0.01
<0.01
^0.01
0.02
0.02
0.04
0.01
<0.01
K1ln Stack
Run No. 3
0.2
0.2
0.5
0.1
0.04
0.1
-------
TABLE E - V
Analysis Results of Imolnqer Participate*
Type of Analyses: Category Visual Absorption Spectrography
Results 1n weight percent
Analysis For Cl Inker Cooler Stack Kiln Stack
Run No. 2 Run No. 3
S04* 1.0 50.0
13.0
H2S04 - 18.0
Add as
H
Cl
Water
soluble
(D(2)
*»
(1) Estimate 20 percent of sample 1s organic material.
(2) Organic Components Present -a. methyl s111 cone
b. aliphatic esters
c. aromatic hydrocarbons
* Analyses conducted by Battelle Laboratories for EPA.
75
-------
APPENDIX F
TEST LOG
Table F -
I presents the actual time during which
TABLE F - I
Sampling Log
sampling was conduct
(Clinker Cooler)
Run Date
1 2-25-71
2 2-25-71
3 2-25-71
1 2-26-71
2 2-26-71
3 2-26-71
Sampling Port
A
B
B
A
A
B
A
B
C
D
0
C
B
A
A
B
C
D
Began
09:15
10:44
13:15
14:44
16:15
17:39
11:35
12:01
12:25
12:55
13:45
14:10
14:37
15:00
15:30
15:55
16:20
16:45
Ended
10:21
11:50
14:21
15:50
17:21
18:55
11:50
12:16
12:40
13:10
14:00
14:25
14:52
15:15
15:45
16:10
16:35
17:00
Elapsed T1me(M1n)
66
66
66
66
66
66
15
15
15
15
15
15
15
15
15
15
15
15
,76
-------
Name
Howard Crist
Robert Jacobs
Dana Ludwlg
Robert Martin
Raymond Mobley
Allan Rlley
Clyde R1ley
Gene Smith
Philip York
APPENDIX
PROJECT PARTICIPANTS AND TITLES
Title
Analytical Chemist, ETB
Chemical Engineer, SCB
Technician, ETB
Technician, ETB
Technician, ETB
Technician, ETB
Technician, ETB
Chemical Engineer, ETB
Chemical Engineer, SCB
77
------- |