EMISSION TESTING REPORT
ETB TEST NUMBER 71-MM-03
Emissions From
Wet Process Cement Kiln
And Clinker Cooler
at
IDEAL CEMENT COMPANY
SEATTLE. WASHINGTON
Project Officer
Clyde E. Rlley
ENVIRONMENTAL PROTECTION AGENCY
Office of A1r Programs
Research Triangle Park, North Carolina 27711
-------
PREFACE
The work reported herein was conducted by the Roy F. Weston Company,
pursuant to a task order issued by the Environmental Protection Agency (EPA),
under the terms of EPA Contract Number CPA 70-132 Task Order 1. Mr. G. E.
Benson served as the Project Engineer and directed the Weston field team con-
sisting of Messrs. H. F. Schiff, B. W. Cowan, and L. W. Johnson. Mr. Schiff
and Mr. Cowan performed the pollutant analyses at the Weston laboratories.
Roy F. Weston submitted to EPA a draft document from which EPA personnel
prepared the final report (Test No. 71-MM-03)
Approved:
Environmental Protection Agency
GeTie W. Smith
Chief, Metallurgical and Mechanical Section
Emission Testing Branch
March 29, 1972
11
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TABLE OF CONTENTS
Page
Acknowledgments 1v
List of Tables v
List of Figures v
Summary V1
Introduction 1
Process Description 2
Discussion of testing and Results 6
Abstract 12
Appendix A - Schematics of Test Locations 13
Appendix B - Sampling Procedures 16
Appendix C - Field Data and Notes 19
Appendix D - Laboratory Procedures 35
Appendix E - Sample Calculations 41
Appendix F - Test Log 43
111
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ACKNOWLEDGMENTS
The Office of Air Programs of the Environmental Protection Agency
gratefully wishes to acknowledge the valuable assistance of the follow-
ing members of the staff of Roy F. Weston, Inc., who made meaningful
contributions to the preparation of this report:
E. F. Gilardi, Concept Technology Division
Senior Project Manager
F. L. Cross, Concept Technology Division
Air Pollution Consultant
G. E. Benson, Concept Technology Division
Project Engineer
H. F. Schiff, Concept Technology Division
Assistant Project Scientist
B. W. Cowan, Concept Technology Division
Technician
L. W. Johnson, Concept Technology Division
Technician
We also wish to acknowledge the following personnel of the Ideal Cement
Company, Seattle, Washington, for their cooperation and assistance in the
preparation of this report:
F. Bauer,
Plant Manager
R. Owens, Quality Control
Supervisor
R. J. Castelli, Denver Office
Environmental Specialist
The following staff members of EPA-OAP have participated in the planning
and execution of this project and/or preparation of this report:
C. E. Riley, Emission Testing Branch
Technician
p- K. York, Source Control Branch
Chemical Engineer
J- Bazes, Emission Testing Branch
Chemical Engineer
1v
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LIST OF TABLES
Table No. Title Page
1 Summary of Particulate Data for Clinker Cooler vt1
2 Summary of Particulate Data for Kiln Stack Vt11
3 Particulate Emissions Data for Clinker Cooler 8
4 Particulate Emissions Data for Kiln Stack 11
D-l Results of Sample Recovery Procedure 38
D-2 Results of Emission Spectroscopy Analysis 40
F-2 Sampling Log 43
OF FIGURES
Figure No. U1U
1 Diagram of Baghouse Collector on Clinker Cooler 3
2 Diagram of Electrostatic Precipitator on Kiln 4
A-l Schematic of Clinker Cooler Exhaust Duct 14
A-2 Schematic of Kiln Stack Cross Section 15
B-l EPA-OAP Particulate Train 18
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SUMMARY
The Office of Air Programs of the Environmental Protection Agency
contracted with Roy F. Weston, Inc. to conduct OAP participate sampling
tests in the duct from the clinker cooler and in the kiln stack at the
Seattle, Washington plant of the Ideal Cement Company. Three sampling
runs were conducted at the clinker cooler duct and two simultaneous runs
were conducted at the kiln stack.
The clinker cooler particulate emissions, which were controlled by a
baghouse dust collector, were 42, 46, and 56 Ibs/hr. The measured particu-
late concentrations were 0.0513, 0.0571, and 0.0698 gr/scf, respectively
(particulate emission catch of front half of train).
The kiln emissions, which were controlled by an electrostatic precipitator,
were 85.9 and 94.0 Ibs/hr. The particulate concentrations were 0.0935 and
.1064 gr/scf (particulate emission catch of front half of train).
The isokinetic sampling ratios were between 89.9 and 105.7 percent.
A summary of the particulate emissions data is presented in the follow-
ing Tables 1 and 2. The complete summary results of the test may be found
in Tables 3 and 4.
v1
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TABLE 1
SUMMARY OF PARTICIPATE DATA FOR CLINKER COOLER
Run number
Date
Percent Excess Air
Percent Isokinetic
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
mg
gr/SCF* dry
gr/CF @Stack Conditions
Ibs/hr
Ibs/ton feed
Total Catch
mg
gr/SCF* dry
gr/CF (PStack Conditions
Ibs/hr
Ibs/ton feed
% Impinger Catch
1
3-18-71
NA
105.7
95,699
108,307
105.39
103.4
Catch
351.0
0.0513
0.0453
42.0
0.406
374.3
0.0547
0.0483
44.8
0.433
6.22
2
3-19-71
NA
105.3
94,971
105,121
104.21
102.8
386.0
0.0571
0.0516
46.4
0.452
400.6
0.0592
0.0534
48.2
0.468
3.49
3
3-19-71
NA
101.9
94,100
104,555
100.03
104.9
453.3
0.0698
0.0628
56.3
0.536
462.7
0.0712
0.0641
57.4
0.547
2.03
* 70°F, 29.92" Hg
NA--Not Applicable.
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TABLE 2
SUMMARY OF PARTICULATE DATA FOR KILN STACK
Run Number
Date
Percent Excess Air
Percent Isokinetic
*
Stack Flow Rate - SCFM dry
Stack Flow Rate - ACFM wet
*
Volume of Dry Gas Sampled - SCF
Feed Rate - tons/hr
Particulates
Probe, Cyclone, & Filter Catch
mg
gr/SCF dry
gr/CF PStack Conditions
Ibs/hr
Ibs/ton feed
Total Catch
mg
*
gr/SCF dry
gr/CF @Stack Conditions
Ibs/hr
Ibs/ton feed
% Impinger Catch
1
3-24-71
67.8
93.5
107,179
286,431
39.69
101.7
241
0.0935
0.0350
85.9
0.844
262
0.1016
0.0380
93.4
0.918
8.01
2
3-24-71
67.8
89.9
103,085
288,505
36.68
101.7
•
253.5
0.1064
0.0380
94.0
0.924
281.8
0.1183
0.0422
104.4
1.027
10.04
* 70°F, 29.92" Hg v111
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INTRODUCTION
Under the Clean Air Act, as amended, the Environmental Protection
Agency is 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. A
performance standard is a standard for emissions of air pollutants which
reflects the best emission reduction systems that have been adequately
demonstrated (taking into account economic considerations).
The development of realistic performance standards requires accurate
data on pollutant emissions within the various source categories. In the
cement industry, eight plants exhibiting well controlled operation have
been selected for the emissions testing program. This report presents the
particulate emissions data for the Seattle, Washington plant of the Ideal
Cement Company.
Between March 15 and March 25, 1971, Roy F. Weston, Inc. conducted
particulate source sampling at the following locations within the plant:
1. Outlet duct from the clinker cooler baghouse collector.
2. Stack from the kiln electrostatic precipitator.
The clinker cooler performs the function described by its name; i.e.,
cools the clinker (the main constituent of cement) which is discharged from
the kiln. The kiln acts to calcine the raw materials (which are fed to the
kiln in the form of a slurry) in a wet process operation.
The following sections of this report include (1) a process description,
(2) a discussion of the testing procedure and results, (3) an abstract of
the report, (4) analytical procedures and results, and (5) sample calculations.
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PROCESS DESCRIPTION
Clay, crushed limestone and silica sand are brought to the plant by
barge from British Columbia and Post Angles, Washington. These materials
are ground and blended in a rotating ball mill to a slurry.
The blended slurry is fed into the upper end of a sloping (3/8 inch
per foot), slowly revolving (one revolution per minute) kiln. This gas-
fired kiln is 500 ft. long, 15 1/2 ft. in diameter at the feed end and
tapered to 14 ft. at the discharge end with refractory lining encased in
a steel cylinder. Fuel consumption is approximately 1,240 cu. ft. of gas
per barrel of cement 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 is then discharged from the lower end of the kiln at
temperatures exceeding 2000°F and fed immediately into air-quenching cooler
units which reduce the temperature of the material to about T50°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 is fed to an air separator or classifier where the
coarse material is returned to the mill and the finished cement (90% through
325 mesh screen) is pneumatically pumped to storage silos. Present plant
production is approximately 2,500,000 barrels of cement per year.
The control equipment of interest in this report consists of two Mikro-
Pulsaire baghouse collectors (parallel) on the clinker cooler and a Buell
electrostatic precipitator on the kiln (see Figures 1 and 2).
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TOP VIEW
<*>
w/
1
WA
^
I
M-L
LL
SAMPLE
PORTS
y
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144 BAGS PER
COMPARTMENT
CLINKER
- . cnr»i E.R.
i JO CLINKER
U STORAGE
FIGURE I DIAGRAM OF BAGHOU5E COLLECTOR ON
CLINKER COOLER
KEY
•* VACLAUM
— EXHAUST^'
-SOLID
-------
EXPANSION
JOIMT
EXPANSION
JOINT
SEE FIG. A-E
FOR LOCATION OF
SAMPLUJ6 PORTS
»•
KILN r
1
n
|
b
-4*-^
1
1
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FIGURE 2 DIAGRAM OF ELECTROSTATIC PRECIPITATOR ON KILN
KEY
•• VACUUM
^ EXHAUST
— SOLID
STACK
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The baghouse collectors consist primarily of a series of cylindrical
filter elements enclosed in a dust-tight housing. The felted filter media
is "Nomex" which is heat resistant for temperatures as high as 425°F and
is supported on a stainless steel wire frame. Dust laden air is admitted
to the housing and clean air withdrawn from inside the filter cylinders.
As dust particles accumulate on the filter elements, periodic cleaning is
accomplished by introduction of a momentary jet of high pressure air through
a venturi mounted above each filter cylinder. A continuous flow of air
through the collector is maintained, since only a fraction of the total
filter area is cleaned at one time. The particulate matter falls during
the cleaning cycle to the hopper below where the material is removed by a
screw conveyor.
These Mikro-Pulsaire collectors are designed to operate with a pressure
drop of 7 in. of water and have 864 filter bags per unit that are 4 1/2 in.
in diameter x 8 ft. long. Each collector has six compartments and is 16 ft.
tall x 36 ft. long x 13 ft. wide with a 60° hopper below. Each collector is
designed for a performance of 99.99+ percent efficiency with a gas volume of
62,500 ACF at 350°F. The collection surface area is 8,040 square feet, which
2
gives an air to surface ratio of 7.79 CFM/ft . The approximate installed
cost of both baghouses was $425,000 in 1966. Annual bag usage is about 50 bags
($12.00 each) and labor and maintenance is approximately $600.00.
The electrostatic precipitator is of the horizontal flow type and consists
of two sections with three treatment stages in each section This unit is
designed for a performance of 99.83 percent efficiency with an inlet loading
of 12 gr/ACF at 700°F and an outlet loading of 0.02 gr/ACF and a gas volume
-------
to the predpltatori of 400,000 ACFM containing 30-40 percent water. The
collection surface area is 151,200 square feet which gives an air-to-surface
ratio of 2.64 CFM/ft2. The linear gas velocity is 5.28 feet per second and
the residence time is 8.5 seconds. The particle drift velocity is 0.281 feet
per.second. There are 35 gas passages per section and each passage is 9 inches
wide, 24 feet high, and 45 feet long. The precipitator contains a total of
3,990 emitting electrodes constructed of stainless steel. The approximate
cost of installation in 1966 was $2,325,000.00 and the annual operating cost
is about $10,400.00.
DISCUSSION OF TESTING AND RESULTS
Schematic drawings of the sampling locations are shown in Appendix A. The
clinker cooler duct was not an ideal sampling location, however, it was the
only available location. A temperature-controlled damper was located approxi-
mately four feet in front of the sampling ducts. Immediately preceding the
damper was the fan. Three sampling runs of 144 minutes duration were conducted
in the duct from the clinker cooler baghouse.
Sampling was conducted at a total of 36 points--12 points at each of three
sampling ports. No sampling problems occurred. The isokinetic sampling rates
were 105.7, 105.3 and 101.9 percent for the three runs.
Sampling was conducted in the kiln stack 150 feet above grade. Two simul-
taneous particulate runs were conducted. Sampling was done at 12 points—three
points at each of four ports located 90° apart. The sampling trains were operated
at ports 180° apart.
Tests at the kiln stack were begun on March 16 but discontinued due to
sampling equipment difficulties. OAP type unitized trains were obtained and
-------
sampling at the kiln stack was begun again on March 23. Heavy rainfall made
sampling difficult. The sampling platform and equipment were electrified
and several members of the sampling crew received shocks. The electrical
shocks and the rain forced abortion of the sampling after five minutes of
the tests. With the concurrence of the GAP observer, the tests were con-
tinued on March 24 at the point where they had been discontinued.
Two simultaneous one-hour duration runs were completed between 11:30 a.m.
and 5:30 p.m. The sampling was extremely difficult to complete. The sampling
ports were below the stack platform top railing, and two ports were further
blocked by vertical members of the stack platform railing. The port locations
made necessary the use of two different lengths of probe to sample the three
points at each port. Operating two trains simultaneously caused further
problems due to coordination. Anything that delayed the sampling with one
train also delayed the other. The stack platform width was approximately
30 inches around the stack. The sampling equipment and the four sampling
platforms erected at ports cluttered the platform and made movement around
the stack difficult. Winds with velocities of 40 and 50 mph made it difficult
to retain heat in the sampling boxes.
When changing probes and moving the sampling boxes inside and outside the
railing and from port to port, the box temperatures decreased quickly. Fifteen
to twenty minutes were necessary to reheat the boxes after the sampling at
almost every point. After completion of the two simultaneous particulate
sampling runs, no further sampling was conducted at the kiln stack. For de-
tails of the sampling procedure see Appendix B. Data sheets and notes
recorded in the field are presented in Appendix C.
7
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The kiln stack emissions which were controlled by an electrostatic
precipitator were 93.4 and 104.4 Ibs/hr. The participate concentrations
were 0.1016 and 0.1183 gr/scf. The isokinetic sampling rates were 93.5 and
89.9 percent.
A complete summary of all participate testing data is presented in
Tables 3 and 4. According to the Federal Register, "Standards of Per-
formance for New Stationary Sources V (December 23, 1971), the
standards for particulate emissions, in terms of Ibs. per ton of feed to
the kiln, for cement plants are based upon measurement of the weight of
particulate matter collected in the probe, cyclone and filter section. At
the time of testing the Ideal, Seattle Plant (March 1971), these standards
had not been officially established. Thus, emissions data were obtained
measuring (a) the weight of particulates collected by the probe, cyclone
and filter alone and (b) measuring the total weight of particulates collected
(to include the impinger catch). These are reported for both schemes in
Tables 3 and 4. A sample calculation is presented in Appendix E in which
the data for run No. 1 of the clinker cooler are utilized.
Particulate samples were recovered from the sampling train and analyzed
for the elements Sb, As, Be, Cd, Cr, Cu, Fe, Pb, Mn, Ni, Sr, V, and Zn. Details
of the sample recovery procedure as well as the results of the subsequent
analyses are presented in Appendix D.
Nitrogen oxides and carbon monoxide grab sampling was to be conducted
simultaneously with the particulate sampling. During trial runs of NO
X
sampling, a stream of water was pulled into the sample flask with the stack
gas stream. This and other equipment difficulties, together with a test
crew member's illness, made NO and CO sampling impossible.
A
8
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TABLE 3
PARTICULATE EMISSIONS DATA FOR CLINKER COOLER
Run No.
Test Date
Dn
\
Pb
U
P
V
m
Tffl
Vm
mstd
Vw
W
V
wgas
% M
Md
% co2
el f>
'•' C2
% to
% N2
% EA
MHd
U
m
r
P
s
Ts
"p
Pst
ps
%J
A
s
<>s
^
a
2 T
Sampling nozzle diameter, in.
Net time of test, min.
Barometric pressure, in.
. H*v absolute
Average Orifice pressure
drop, in. H,,0
Voluge of dry gas sampled,
ft at meter conditions
Average gas meter temperature, °F
Volume of dry gas sarnn'ied at
standard conditions*, SCF
Total ILO collected in irr.pingers
and sfl ica gel , ml
Volume of water vapor collected
at standard conditions*, SCF
% Moisture in the stack gas by
volume
Mole fraction of dry gas
Excess Air Percent
Molecular weight of stack gas,
dry basis
Molecular weight of stack gas,
wet basis
Pitot tube coefficient
Average velocity head of stack qas,
in. H20
Average stack temperature, °F ,
Net sampling points •
Static pressure of stack gas in. Ho
Stack gas pressure in. Hg absolute ;
Stack gas velocity at stack conditions
2 '
Stack area, in. i
Dry stack gas volumetric flow rate at
ii^vi,;' •" " ''."•in!".' ' r \'~.' ''-,•'' i'-'v,'^ .-'-C stCiCK
conditions, ACFM
Pprcpnt. isnkinetic
1
3-18-71
0.189
144
30.23
1.30
103.81
68.7
105.39
12
0.57
0.54
0.99
0.03
20.95
^
78.0
-
29.0
28.9
0.85
1.23
141
36
0.05
30.28
fpm 4012
3888
95,699
103,307
105.7
2
3-19-71
0.189
144
29.88
1.29
104.06
69.8
104.21
10
0.47
0.45
0.99
0.03
20.95
*1
78.0
-
29.0
28.9
0.85
1.19
121
36
0.05
29.93
3894
3888
94,971
105,121
105.3
3_
3-19-71
0.189
144
29.92
1.27
101.92
81.2
100.03
8
0.38
0.38
0.99
0.03
20.95
*1
78.0
-
29.0
28.9
0.85
1.17
124
36
0.05
29.97
3873
3888
94,100
104,555
101.9
* 70°F, 29.92 in. Hg
-------
I Feed P.ate-
1
103.4
2
102.8
3.
104.9
TABLE 3 (Concluded)
PARTICULATE EMISSIONS DATA FOR CLINKER COOLER
Run Mo.
T Uni
c Tons/hr
mf Particulate - probe, cyclone 351.0 386.6 453.3
and filter, ing
mt Particulate - total, mg 374.3 400.6 462.7
I % impinger catch 6.22 3.49 2.03
C Particulate - probe, cyclone, 0.0513 0.0571 0.0698
an and filter, gr/SCF*
C Particulate-total.gr/SCF* 0.0547 0.0592 0.0712
90
C . Particulate - probe, cyclone, 0.0453 0.0516 0.0628
and filter, gr/cf at stack
conditions
Cau Particulate •• total, gr/cf at 0.0483 0.0534 0.0641
stack conditions
C Particulate - probe, cyclone, *2.0 46.4 56.3
aw and filter, Ib/hr.
C Particulate - total, Ib/hr. 44.3 48.2 57.4
C* X>
rcu"i.'i\.uiciLcj - ijfouc, v-ycionc:, 0.406 0.0452 0.536
and filter, Ib/ton feed
Particulate - total, Ib/ton feed Q.433 0.468 0.547
*70°F, 29.92 in. Hg, dry basis
10
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TABLE
PARTICIPATE EMISSIONS DATA FOR BIN STACK
SL^lJto-
', e:>t: Date
Dn
Tt
A
U
Pm
111
Vm
HI
Tm
Vm
mstd
Vw
W
V,
. wgas
% M
Hd
s co2
% °2
% CO
% Up
% EA
HWd
u •
Mil
cp
AP
TS
NP
Pst
ps
V
s
A
"*
-------
;d Rate--
ate - nrobe, cyclone
1
101.1
241
2
101.7
253.5
TABLE 4 (Concluded)
PARTICULATE EMISSIONS DATA FOR KILN STACK
Run No.
T Unit Fei
c Torts/hr
mf Particu
and filter, mg
mt Particulate - total, mg 262 281.8
I % ircpinger catch 8.01 10.04
C Particulate - probe, cvclone, 0.0935 0.1064
an and filter, gr/SCF*
Cao Particulate - total, gr/SCF* 0.1016 0.1183
C . Particulate - probe, cyclone, 0.0350 0.0380
aL and filter, gr/cf at stack
conditions
Cau Particulate - total, gr/cf at. 0.0380 0.0422
stack conditions
C Particulate - probe,• eyeIC;-,L, 85.9 94.0
aw and filter, Ib/hr.
C Particulate - total, Ib/hr. 93«* 104.4
ax
•t-P i-dk uitiilalt1 - uiobe, cyclone, 0.844 0.924
and filter, Ib/ton feed
Ptt Particulate - total, Ib/ton feed °«918 1»027
*70°F, 29.92 in. Ha, dry basis
ABSTRACT
This source sampling report 1s one of nine studies concerning partlculate
and gaseous emissions from selected cement plants at vartous toctttons. The
objectives of this study were to evaluate air pollution*control equipment per-
formance and efficiencies and to determine emission constituents typical of the
cement Industry. Schematics of test locations, field and processed data, and
descriptions of sampling and laboratory analytical procedures have been Included
as part of the evaluation.
12
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APPENDIX A
SCHEMATICS OF TEST LOCATIONS
13
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FIGURE A-l
IDEAL CEMENT COMPANY
SEATTLE, WASHINGTON
SCHEMATIC OF CLINKER COOLER EXHAUST DUCT
EXHAUST-
1
7;
i
t
r
X 69'
X 63*
X 571
X 51'
X 45'
X 39'
X 33*
X 27'
X 21 '
X 15'
X 9" /
X 3'
| |
1 K
DISTANCE TO
SAMPLING POINTS
D
A
M
P
E
R
•3"SAMPLING PORT
FLOW FROM
BAGHOUSE DUST
COLLECTOR
TOP VIEW
SIDE VIES
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FIGURE A-2
IDEAL CEMENT COMPANY
SEATTLE, WASHINGTON
SCHEMATIC OF KILN STACK CROSS-SECTION
(71
3" SAMPLING PORTS
3" SAMPLING PORTS
NOTE: INCHES, INSIDE STACK,DENOTE
THE DISTANCE FROM THE INSIDE
OF THE WALL TO THE SAMPLING
POINT.
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APPENDIX B
SAMPLING PROCEDURES
The participate sampling train used by Roy F. Weston, Inc. 1s shown
1n Figure B-l. A glass or nonreactlve metal probe with button hook nozzles
(whose size depended on the velocity of the gases) headed the train. The
equipment following the probe consisted of a glass cyclone and flash, (for
certain runs a glass cyclone by-pass was used), a pre-weighed glass fiber
filter, and four Greenberg-Snrith Implngers. The Implngers were placed 1n
an 1ce bath, while the preceding glass pieces were contained In a hot box
maintained at a temperature of 240°F. The first Implnger was modified by break-
Ing off the glass tip, the second was unmodified, and the third and fourth w@re
modified. The first two Implngers each contained 100 ml of distilled watGt%
the third was empty, and the fourth contained a pre-welghed quantity of silica
gel. A leakless vacuum pump, a dry gas meter, and a calibrated orifice measured
with an Inclined manometer completed the train.
During sampling, gas stream velocities were measured by Insertion of a
calibrated type "S" pltot tube Into the stack beside the participate sampling
probe. A type "K" thermocouple and a direct reading pyrometer measured gas
temperatures within the gas flow Itself. Temperature measurements were made at
the heated cyclone, after the silica gel Implnger, and at the Inlet and outlet
of the dry gas meter. Immediately after positioning on each traverse point,
readings were made and sampling were adjusted.
Each sampling location was divided Into equal cross-sectional area. The
centrold of each area was chosen as a sampling point. The number of sampling
points was determined by the configuration of the sampling location (e.g.
circular, square, or rectangular) and Its distance from bends, constrictions,
16
-------
fans, etc. In general, the closer a sampling location was to a bend con-
striction, fan, etc., the greater was the number of sampling points used.
After the completion of sampling, the cleanup of the train proceeded as
follows: The filter was placed 1n a Petrl dish. The probe, cyclone, flask,
and the front half of the filter holder were washed with acetone Into a sam-
ple bottle. The volume of the first three 1mp1ngers was measured, and these
1mp1ngers, the back half of the filter holder, and all connectors were washed
first with distilled water and then with acetone. The silica gel was weighed
to the nearest tenth of a gram.
17
-------
FIGURE
B-l
EPA-OAP PARTICULATE TRAIN
oo
PITOT TUBE
AND
MANOMETER
GLASS
FIBER
FILTER
CYCLONE
MPINGERS IN ICE BATH
DRY TEST METER
ORIFICE
AND
MANOMETER
-------
APPENDIX C
FIELD DATA AND NOTES
19
-------
r^xl
•I
i
.5
PMB
\
<
-4"
f
r
t
t
*7"
\
I
45"
\f
* -
rs.
2;
T
n"
/ fl-
-------
PRELIMINARY FIELD DATA
SUek Geometry
punt dJU (L
Test No.
location
A. Dtst. from Instde of far wall to outside of
near wall. In., . sb
B. Nail thickness. In.. • 2 "
Inside 4tav*M>-of stack • A-B
.1 **.
Consents:
Sketch of stack cross-section
showing sampling holes
Calculations:
Calculator
(12/07)
Point
/
i
3
t.
$
i
7
8
?
10
If
11-
&*^^^&£fo€k
01st. from outside
of samnle port. In.
2'V
9"
1^"
ll"
7"- 5"*
= D"
= />'
27" •= 79"
>V
V"
-S"/"
= 3J>"
r 47"
5^" _ ^5-9"
^j" _ ^5"
i^L_L_2C-^
^
i±L.
ffl /
02
3
30.23
i«?jT
if.72.
163. 367
IlL
&S.7
74.0
1 .37
le> s; 3?
Mo;
to
-8
Vr.# . ^g
.377
990
A*ca
23.87
za.i?
ts±i
3, fit
30.22
'VI
I 21
itc.n
Plant
• Date 'Z-St,
Sailing location
&L.JL .
STACK DATA FOR NOMOGRAPH:
1. Metar tH /, ^ £)
1n
2. Avg. nter teupt (ambient + ?0" "7
3. Moisture (volume) _ J 3
4. Avg. static press. O > XS" 1n. HjOX.073 « * , OJ? In. Hg.
5. Bar. press sampling point30,2^ In.Hg +
In. Hg.
(static press In.Hq)
6. Bar press of nater
. 5.
t 2..~\ In. Hg.
1, Hg
57"
In. Ha
8. Avg. stick temperature
./'^
9. Avg. stack velocity UP) / / Z. In
C factor (1) .,*$ (?)
*' * f
,)V\
fiHI
(2lt M.
clock)
-ttv
LJ&L.
M^-
MNPlC
POINT
/
1
?J
i-
?
f
7
,4
Q
/..•*?
o.ez.
0.73
/o. 75-
(j.«9
,^
.3
O.D8
1 .7.
O- ^
n.R(*
0.1V
0.5C
.-L,
2,
I .3
L 7-
hfiS~
()./>•>>
O.3Z-
VELOCITY
HEAD
IN. H--,
^
VELOCITY
ft. /sec.
s
3
i
2
J
L
!>
6
7
$
< DISTANCE
FROM WALL
DISTANCE
FROM WALL
INCHES
Area Square ft.
Effluent
Flow Rite, CFH
Effluent
Flow Rate, SCFH
Operator^
•1}
1.1
Lll
21
-------
VEIHf IK'ORTABT - fill IN All 6LAHKS
Fin Mo. /
location (&JL.
CpiMtor
i PATHOtCGiCAt. INCIURArORS-
I read and record evsry 5 ra1mitss.
Trr|) *f ^5"^
Bar. Press. "85 3f3- 2"3 '
Asswra Hotsttn; ii _^ '_
Hc-ter Box Setting. 'F
?rrbc Tip D1a.. In. _
Probe length _
,_ in H«i> j °r : lyvig
7,?p
-------
-------
Yzc
/"
y
2.
3
1
3
c,
/ 0
.37?
FJ/
y
/ / •
5-; 3-7
M
^ 9 A
C / / !-'
Vcth
v r o
101,
v
, «^
24
-------
PREL1M1KART FIELD DAT*
SUcli QtoMtry
runt
Test No.
location
Date
A. 01ft. frag Inside of far will to outside of
mir mil. In.. . 2. Q g _
B. Nail thickness. In., • / 3 " _
Mtnt
Date "3 -
Sampling location
'3n*u~.M)
STACK DATA FOR NOMOGRAPH:
1. Meter aH /.
Inside diameter of stack - A-B t <)£"
Stack Area •
Cements: A -
Sketch of stack cross-section
showing sampling holes
Calculations:
2. Avg. meter tempt (ambient t 20' ~^~ & °F
•J. Moisture (volume) 3 6 i
4. Ayg. static press. £
In. Ho.
Calculator
Point
)
L-
3
i,
5
I
t Dia. for
circular stack
Ll.U
It,. 7
ll.Z
•7?:-S
K.^.3
t-5. (,
01st. from outside
of samnle port, 1n.
2.6 +/J-S.I
2S.7 = *>
S'7f5' = ?&
/57.S = ITt
fUJ =• />?
l8Lb - 111-
r 6
?
r
4 ,
3
\ 8'
9.
5. Bar. press sampling point !??.?& In.Hg * 29. '/>Z-(static press tn.l! 2- In. Hg.
|^ 1n.Hg(& , c<- (static press In.Hg)
t 7. ? i. in. Hg.
6. Bar press of meter f
. 5-
1n. Hg.
6\
8. Avg. stack temperature
*F.
9. Avg. stack velocity UP) . £7/ In HjO.
C factor (D__i_^ _ (2)
25
-------
*n &aJA
Ta/
21.71
3 8,
3 ?.(,?
.5*
^,75
£
6i>
3o,3?^
^V
/.7^
?6,C,?"7
Vet
3,52
PA;
.3/.V
W"
- .01 j*,
A'*, /y
//».i
26
Jt
-------
fun No. '' !—
location
tut* .?4-7> _ >/
upjritor Wu_j«-
Ittplc Box No.;
rtfeter 'lox No. ^^
* H £-£j2
I VERY iH?QrlTANT - Fill 1H Ai.i. SimS - A/nigs* ',-jsf °f 4*-3*
B»r. Cross. "Hg J0. j V
Muter 8i.< Setting. «F
Probe Tip D:».. In. _
Probe Ler.;t?i
Prciie Heater Setting "^7 Q
i I "iPetd tr.d retort.' »< the st«rt of
j V«Mti tm point.
i I 'MMbsiCM. iNClliERATORS-
-* md told record en-.ry 5 minutes.
__ . ..
I 0-tflcc »H Dry C«s Tirrii. IvacuLnlcox ! jjir^.gcr !j-..-c- I ;f
-|X*S-
-I-.Q"
.!M£
r
r~
..«:i_j--^-T-
!?:• l.n^;. '-.^: U-r-?^-I^^-!^S-!S'1?'^^
"V" ~Jr^/^&. ::.s»~l"i^~.LT^l:"^8n:i^:j.'.' ^ •\;^:i±^tiL.;?f:^!3s?fcJi^.
......uJQL&3- ... 23 J.... M.V !.jai.-..Ja,...^D. J.—fci...Liifirf.1. ..-,..-;-•*?•.. SSJ'.JteL.
^ |tfti««- -:-^.gfa_L.,..a.au- • ^.^ai-^s-ffr-'-gf 3. ^.Toafe.^. :...j>..;s.fer.JaiSL
^.T; ~(JL.-Ji4::J:rQ^
^L£..5SOi _..(?_. —l..*B ...^:...^;_^_:-Jff....:HSa..K-t_ .•-«•> ,rf? -HiJ-
zigal^-iiO-j.-^^i
K«*—. •_
7.-:-aa-i£g^-r!-.;irr«. m-;-^.
I '"")Llfai'"i?—''"Si£'l]Z7 ~""^' '••1jJ-' •;—:—r--r-.—-r- • "jr-j Jj^^i Zl''' '1 ' "gg JHZH
S^^|: ^F^^-§?f£S^^fS^^'
In.-^^iVsirV ;!,;.-;
-------
.
*
M
Z
^7.7?
3 3, J«.
7
3*7
/«.«-
*?%
.7/
3/Vf
5?^
0
^dD^
7-37^
3/3
!-:-S^
'
7
A
23
/
-------
L
i
Z
3
/^Tb
, ^"*
^*>',
^ 7f
^r
(,t
3 o: 3 ^
^57
1.71
^6, & ?7
/?u/> V«L VW Vc*i McJ> Mb
1
2
^N
3
3,52
/£*?
t
31. £
- »••*
.^?
3/,
-------
PRF.SURVEY - PROCESS INDUSTRY & POWER PLANTS
DATE OF PRESURVEY
NAME OF COMPANY C
ADDRESS
NAME OF CONTACT
PROVIDE FLOW DIAGRAM OF EACH PROCESS TO BE SAMPLED, INCLUDING FEED COMPOSITIONS AND
RATES, OPERATING TEMPERATURES AND PRESSURES, PRODUCT RATES, AND PROPOSED SAMPLING SITES:
xibfi
'/*
*'
3-
/£$*'*>
30
-------
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. , , t .
, j*kj_
Hldff^h
31
-------
/jro
O
32
4
t
i.
-------
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
LIST EXPECTED CONSTITUENTS OF STACK GAS FOR EACH SAMPLING SITE
STACK DATA: HEIGHT
, WIDTH /? ^ /5 '
O.D. AMOUNT OF INSULATION
MATERIAL OF CONSTRUCTION,
PRESSURE 4/-~£ *h.#ri<>
WET BULB TEMPERATURE
AVERAGE PITOT TUBE READING
DISTANCE TO NEAREST UPSTREAM, RESTRICTION 6
DISTANCE TO NEAREST DOWNSTREAM RESTRICTION^
ARE PORTS EXISTING? """ ^
/t
H
. SIZE jfW
fin. H"ft MTliL_Dpnt"ni:
DIAMETER
WALL THICKNESS 2 f
"
GAS TEMPERATURE
TYPE OF RESTRICTION
TYPE OF RESTRICTION
33
-------
SCAFFOLDING OR OTHER MEANS OF SUPPORT PRESENT?
), WHO WILL PROVIDE IT?_
SOURCE OF ELECTRICITY AVAILABLE? /Z^YES, MAXIMUM AMPERAGE PER CIRCUIT^
[J NO
DISTANCE fS*" 20* WHO WILL PROVIDE EXTENSION CORDS?_
LOCATION OF FUSE BOX
PARKING FACILITIES AVAILABLE FOR TRAILER OR VAN?
SIGNATURE REQUIRED ON PASSES?_
NEARBY RESTAURANTS AND MOTELS
WAIVERS?
/L
£s**Jlj>? )
LIST ANY SPECIAL SAFETY EQUIPMENT OR RULES
COMMENTS:
34
-------
APPENDIX D
LABORATORY PROCEDURES
The following 1s a detailed outline of the laboratory procedure used
1n determining the weights of particulates and water collected In the various
segments of the EPA-OAP sampling train.
All glassware used for evaporation and residue determinations In the
following steps was prepared for use by the following procedure. The
beakers were first soaked 1n 40% nitric add for several hours. They were
then washed and rinsed with distilled water followed by oven-drying. After
drying, the beakers were desiccated to constant weight and kept 1n a desiccator
until used. Beakers were weighed to + 0.1 mg.
A. Filter
1.) Preparation
The filters are oven-dried e 105*C for a minimum of four
hours, and then desiccated to constant weight. Filters are
weighed to + 0.1 mg. After weighing, the filters are placed
1n plastic petrl dishes until used.
2.) Partlculate weight determination
Filter and any loose partlculate matter are transferred to
a tared glass weighing dish, and desiccated to constant weight.
The weight gain 1s then recorded.
B. Acetone washings prior to filter
1.) The acetone washings are received 1n glass bottles and their
volume 1s measured. They are then transferred to the tared
beakers prepared as described above.
35
-------
2.) The acetone washings are allowed to evaporate to dryness
at ambient temperature and pressure. The beakers are covered
with ribbed cover glasses to facilitate evaporation without
allowing dust or other foreign matter Into the beakers. When
dry, the beakers are desiccated to constant weight. Beakers
are weighed to nearest 0.1 mg.
3.) A blank of the acetone (measured amount) 1s evaporated also
as described above. Any residue resulting from this blank 1s
used to correct for the amount of acetone used 1n the washings.
The net weight 1s the required participate residue.
C. Implnger water plus water rinsings
1.) The volume of Implnger water has been measured 1n the field
and recorded. Final volumes of these samples are measured 1n
the laboratory 1n order to determine the volume of washings used
and to correct for this water using a blank (by the same proce-
dure used 1n part B-3 above).
2.) At this point an organic extraction of the Implnger water 1s
1n order. However, this step was omitted since no organic material
was considered present.
D. Acetone washings - back
1.) The volume of acetone washings 1s first measured and then the
liquid 1s transferred to tared beakers (prepared as above) and
allowed to evaporate to dryness at ambient temperature and pres-
sure. Upon drying, the beakers are desiccated to constant weight.
A blank of the acetone used 1s also evaporated any corrections due
36
-------
to the acetone are made 1f necessary. Beakers are weighed to
nearest 0.1 mg.
E. Silica gel
1.) Preparation
The silica gel 1s placed In a wide mouth plastic bottle
and capped. The bottle plus silica gel 1s then weighed to the
nearest 0.1 gm.
2.) After sampling, the bottle plus used silica gel 1s weighed
to the nearest 0.1 gm and the weight of water collected Is deter-
mined.
Results of the sample recovery procedure are presented 1n Table D-l wherein
total partlculate weights are reported for each run. These values were obtained
by adding the weights of the probe, cyclone, filter and 1mp1nger catches.
An emission spectroscopy analysis was conducted on the partlculate samples
collected from each stack to determine the concentrations (vg/g) of the follow-
ing elements: Sb, As, Be, Cd, Cr, Cu, Fe, Pb, Mn, N1, Sr, V, and Zn. The results
of these tests are presented In Table D - 2. In general, of the components
tested for, Iron was present 1n the highest proportion (reaching concentrations
as high as 3.32), followed by zinc, strontium and lead.
37
-------
TABLE D - 1
RESULTS OF SAMPLE RECOVERY PROCEDURE
Clinker Cooler
Description of Sample
1.
2.
Filter
Probe, Flask
Cyclone Acetone
Front half Wash
Filter holder
RPW #
Filter
Net wt.
RFW #
Beaker
Net wt.
#
gm.
#
gm
Total
3.
H
Implnger HpO + H20 wash
Imp, conn.
back 1/2 filter holder
, Implngers, Connectors
hart 1/9 f 4 1 ^ov
l/Q^^ If. III WCI A«*A^j%nA
holder ^,*.-h
wash
Blanks H,0
z
RFW #
Beaker
Net wt.
gms.
RFW #
Beaker
Net wt.
RFW 1
Beaker
Net wt.
Sample
#
Run 1
1419
F56
0.0077
1417
117
0.3433
351.0
1416
Run 2
1423
F65
0.0297
1422
122
.3569
386.0
1420
Run 3
1427
F67
0.0197
1426
119
0.4336
453.3
1424
K1ln Stack
Run 1
....
....
0.159
....
....
0.082
241
....
* Run 2
1430
....
0.1643
1429
no
0.0892
253.5
Note: Implnger
water lost 1n
transit. Value
assumed to be
that forRun# 1
fblank)
#
gm.
#
gm.
Volume
0.0153
1418
124
0.0080
1414
121
0.0024
420
0.0047
1421
104
0.0093
1415
120
0.0025
435
0.0031
1425
105
0.0063
....
0.021
....
..._
....
....
0.0023
500
0.021
1428
111
0.0073
ml.
Total Partlculates, mg
(obtained by adding weights
374.3
400.6
462.7
262
281.8
* See TABLE D - 1 (Continued)
38
-------
TABLE D - 1 '(Continued)
ENVIRONMENTAL PROTECTION AGENCY
Reply to
•Attnof-. ETB, DAT .H. , Date: April 20, 1971
Subject: Participate Analysis of Samples Collected at Ideal Cement, Seattle, Washington.
TO: Gene Riley
Sample _ _ Participate, Mg _ Location
Impinger water
Probe, cyclone, flask
21
82
Kiln stack
& filter holder
Filter 159
Total 262
Water blank (Seattle) 2.3 Mg/500 ml
Water blank (Tijeris) 2.1 Mg/500 ml
The sample results reflect correction for the blank. The above sample
was one of a pair of samples collected simultaneously by Roy Weston
Company. They are analyzing the companion sample for comparison with
the above results.
Howard L. Crist
Chemist
Emission Testing Branch
Division of Applied Technology
39
-------
TABLE D - 2
RESULTS OF EMISSION SPECTROSCOPY ANALYSIS
Sample type
Sample location
and run No.
Sample weight, mg
Volume of gas
sampled, scf
Part 1cul ate
Clinker Cooler
Run f 1
374.3
105.39
Partlcula
K1ln
Run # 1
262.0
39.69
Sb
As
Be
Cd
Cr
Cu
Fe
Pb
Mn
N1
Sr
V
Zn
Concentration, yg/g
100
< 192
2
40
850
500
33,000
300
400
500
2,000
< 4
4,000
< no
< 276
2
170
100
200
15,000
4,000
200
200
< 276
60
8,000
40
-------
APPENDIX E
SAMPLE CALCULATIONS
Example: Run No. 1 on Clinker Cooker (for data, see Table 3, page )
1. Volume of dry gas sampled at standard conditions: 70°F, 29.92 in. Hg, SCF
17.7 x V (P.+ Pm ) 17.7 x 103.81(30.23+1.30 )
III D •\~-7~f- ' • - in * '
V - _ _. „. _ Jiii -, ___ , _____ . .. - ' u»6« ins ™
mstd V'm +nj53^ (68.7*46077^ 105'39
2. Volume of water vapor at 70°F and 29.92 in. Hg, SCF
V - 0.0474 x V = O.n-174 x 12 - 0.57 SCF
'gas
3. Percent roisture in stack cjas:
100 x V
V + V 105.39*0.57
o.54
l!1std "gas
4. Hole fraction of dry gas
M. » IT:: - %'. = TOO -0.54
d _.._ -- -- 1_
5. Average molecular weight of dry stack gas
3l
(0.03 x TUO" ^ + (20.95X TtJO ^ + < 78 x TW ^ "29.0
6. Molecular woiqht of stack gas
MH - !';l,'d x Fld + 18 (1 - Md) - 29.0 x 0.99 + 18 (1 - .99 ) •-•• 28.9
1
7.. Stack qas velocity at stack conditions, fpn
V " d *3 {"' P x'« - '' ^' * ^" "^" '''' '')
<- >' * v^'*''v''-i
4,3GO x27.f ^_ J]='-
L.30.28 28.9.'
1/2
41
-------
SAMPLE CALCULATIONS. RUN HO. 1. CLINKER COOLER (Continued)
8. Stack gas volumetric flow rate at standard conditions*, SCFM
0.123 x Vs x As x Md x PS 0.123 X4012 x 3888 XQ.9ix30.28
° --- +-~ — ^ = — : — ss — - - -95.699
S
9. Stack gas volumetric flow rate at stack, conditions, ACFM
n .05645 x PC x (T.; * 460) . .05645 x 95.699 x( 141 + 4FO) _.108
Q B - j - r*Ti - 5 - -- - - - -- IUO,
x fd 30.28 x 0.99
ACFM
10. Percent isokinetic
1,032 x (T + 460) x V
stii B 1.C32 x (W + 460) X105.39 = 105>7%
Vs x Tt x Ps x Md x (Dn)f 4012 x 144x30.28x0.99x(0.189)2
11. Particulate: probe, cyclone and ^iHer\ gr/SCF* Dry Basis
f
C = 0.0154 x -V— - O.OU: SfJSAo.0513 3r/SCF
mstd
12. Particular.? total, nr/Sf.F* Pry Basis
m.
cao = °'0154 x V " = °'0154 x 374>3-0.0547qr/SCF
mstd 105.39
13. Particulote: probe, cyclone and filter. ar/CF at stack conditions
17.7 x C x P x M . 17.7 xO.051 3x30.28x0.99
= __ _!"...* _ 2. = __-__«____«._____--__.»,
-
r __ _
Sit (Ts
14. Particulate: total, gr/CF at stack conditions
17>? X Cao x Ps x Hd 17.7 x Q.Q547 x 30.28 x 0.99
Cau = (Ts + 460) = ( 141 + 460) * " 0.0483 gr/CF
15. Particulate: probe, cyclone, and filter, Ib/hr
C,,, = 0.00857 x Can x Q = 0.00857 x0.0513'x 95,699 =42.0 Ib/hr
a Vi an b
16. Particulate: total, Ib/hr i
Cax = 0.00857 x Cao x Qs = 0.00857 XQ.0547 .x 95.699 = 44.8
17. Particulate:c probe, cyclono, and filter, Ib/ton feed
Ptf r ,-r'lvl- - -- 0.406 Ib/ton feed
18. Parciculace: tucdl, lu/tuii
C,v 44.8
p = _ax__ =lW^-= . lb/ton feed
c 42
* 70°F, 29.92 in. Hg
-------
APPENDIX F
TEST LOG
Table F - 1 presents the actual time during which sampling was conducted.
Table F - 1
Sampling Log
(Clinker Cooler)
Run Date
1 3-18-71
2 3-19-72
3 3-19-71
1 3-23-71
l(cont.)3-24-71
Sampling Port
A
B
C
C
B
A
A
B
C
(K1ln
E
E
N
N
W
W
S
s
Began
13:20
14:19
15:16
09:14
10:10
11:14
14:22
15:16
16:13
Stack)
10:25
10:50
12:30
12:50
14:00
14:15
16:00
16:20
Ended
14:08
15:07
16:04
10:02
10:58
12:02
15:10
16:04
17:01
10:30
11:00
12:40
12:55
14:05
14:25
16:10
16:25
Elapsed Time (ro1n)
48
48
48
48
48
48
48
48
48
5
10
10
5
5
10
10
5
43
-------
TABLE F - 1 (Continued)
Run Date Sampling Port Began Ended Elapsed Time (nrin)
2 3-23-71 W 10:25 10:30 5
2(cont.)3-24-71 W 10:50 11:00 10
S 12:30 12:40 10
S 12:50 12:55 5
E 14:00 14:05 5
E 14:15 14:25 10
N 16:00 16:10 10
N 16:20 16:25 5
44
------- |