EMISSION TESTING REPORT

         ETB TEST NUMBER  71-MM-06
              Emissions From

        Wet Process Clinker Cooler

         And Finish Mill Systems

                    at
 IDEAL   CEMENT   COMPANY

             HOUSTON, TEXAS
              Project Officer
              Clyde E. R1ley
       ENVIRONMENTAL PROTECTION AGENCY
           Office of A1r Programs
Research Triangle Park, North Carolina 27711

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                                   PREFACE

     The work reported herein was conducted by The Environmental Protection
Agency (EPA), Office of Air Programs, Emission Testing Branch  (ETB), Metal-
lurgical and Mechanical Section.  Mr. Clyde Riley served as the Project
Officer and directed the ETB field team consisting of Mr. Frederick Maerker
and Mr. Gene Smith.  Mr. Philip York served as Project Engineer and Mr. Howard
Crist performed the pollutant analyses at the EPA laboratories.

Approved:
    Environmental Protection Agency
        '   ,  // >
        .-JU_- >  CA _ -=>—
    Gene W. Smith
    Chief, Metallurgical & Mechanical Section
    March 29a 1972

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                              I.  TABLE OF CONTENTS
  II. List of Tables                                                2
 III. List of Figures                                               2
                                                                     «
  IV. Introduction                                                  3
   V. Summary of Results                                            3
  VI. Process Description                                           7
 VII. Location of Sampling Points                                  ':9
VIII. Process Operation                                             9
  IX. Sampling and Analytical Procedures                           12
   X. Appendices                                                   13
          A.  Particulate Results and Calculations                 13
          B.  Field Data                                           20
          C.  Laboratory Results                                   52
          D.  Test Log                                             55
          E,  Project Participants and Titles                      55

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                         II.  LIST OF TABLES
Table-Number                      Title                   Page
     1                   Summary of Results for             5
                          Clinker Cooler
     2                  Summary of Results for Finish      6
                          Mill Grinding System
    A-l                 Particulate Emission Data for     14
                          Clinker Cooler
    A-2                 Particulate Emission Data for     16
                          Finish Mill Grinding System
    C-l     .            Particulate Results, Clinker      52
                          Cooler
    C-2                 Particulate Results, Finish       52
                          Mill Grinding System
    C-3                 Results of Metals Analysis        53
                          Clinker Cooler
    C-4                 Results of Metals Analysis        54
                          Finish Hill Air Separator
    D-l                 Sampling Log                      55

                        III.  LIST OF FIGURES
     1                   Sampling Locations                 4
     2                  Baghouse Collector on Clinker     10
                          Cooler
     3                  Baghouse Collector on No. 2       11
                          Finish Hill Grinding System
                                   2

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                               IV.  INTRODUCTION

     Source sampling was conducted at the Houston, Texas wet process plant
of the Ideal Cement Company to determine particulate emissions from the
baghouse stacks of the clinker cooler and the finish mill grinding system.
Three particulate runs v/ere performed at each stack (for a total  of 6 runs)
between 18 May  and 20 May, 1971.  Sampling locations are shown in Figure 1.
     EPA Methods 1 and 2, Federal Register, December 23, 1971, were used
to determine the number of required sampling points per stack and the stack
gas velocity and volumetric flow rate.  Particulate emissions were determined
using EPA Method 5  of the Federal Register.

                         V.  SUMMARY OF RESULTS
     A summary of the particulate emissions data for the No. 2 clinker cooler
and finish mill grinding system is presented in Tables 1 and 2.  Clinker
cooler emissions (based on the probec cyclone and filter catches) ranged
from 0.0253 tcO.W48   Ibs/ton of feed.  Emissions from the finish mill
grinder baghouse were between 0.0120 and 0.0201 Ib/ton of feed-

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Clinker
Cooler #2
M
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                                      TABLE I
                       SUMMARY OF RESULTS FOR CLINKER. COOLER
Run Number
Diste
Percent Excess Air
Percent Isokinetic
Stack Flow Rate - SCFM* dry
Stack Flow Rate - ACFIi v/et
Volume of Dry Gas Sampled - SCF
Feed Rate - tons/hr
Parti cula to s
Probe, Cyclone, £ Filter Catch
mg
gr/SCF* dry
gr/CF @ Stack Conditions
Ibs/hr.
Ibs/ton feed
•*• i- •> r. j.f.\.
mg
gr/SCF* dry
gr/CF Q Stack Conditions
Ibs/hr
Ibs/ton feed
% Impinger Catch
1
5-18-71
NA
102.1
104,057
127,032
101.07
61.8


11.8
0.00180
0.00147
1.561
0.0253
26.3
0.00401
0.00323
3.538
0.0572
55.1
2
5-18-71
1 ; NA
98.5
100,432
.126,664
94.15
62.7
i
,
20.5
0.00335
0.00266
2.812
0.0448
38.1
0.00623
0.00494
5.323
0.0849
46.2
                                                                                3
                                                                              5-18-71
                                                                               NA
                                                                               98.8
                                                                            102,165
                                                                            128,672
                                                                              96.05
                                                                              63.7
                                                                              14.2
                                                                            0.00228
                                                                            0.00180
                                                                              1.941
                                                                            0.0305
                                                                             23.3
                                                                            0.00373.
                                                                            0.00296
                                                                              3.269
                                                                            0.0513
                                                                              39.1
* 70°F, 29.92" Hg
NA - Not Applicable

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                                      TABLE 2
               SUMMARY OF RESULTS FOR FINISH HILL GRINDING SYSTEM
Run Number
Date
Percent Excess Air .\
Percent Isokinotic
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 @ Stack Conditions
Ibs/hr.
Ibs/ton feed
T.-^.-.l fate':
mg
or/ SCF* dry
gr/CF @ Stack Conditions
Ibs/hr
Ibs/ton feed
% Impinger Catch
1
5-19-72
NA
109.0 '
26,360
35,185
140.35
34.6


22.0
0.00241
0.00181
0.527
0.0152

32.9
0.00361
0.00270
0.791
0.0229
33.1
2
5-19-71
NA
102.9
26,252
35,679
131.99
33.9


26.9
0.00314
tL00231
6.683
0.0201

37.8
0.00441
0.00324
0.971
0.0287
28.8
                                                                              3
                                                                           5-20-71
                                                                             NA
                                                                            98.9
                                                                          26,244
                                                                          35,780
                                                                          126.82
                                                                           37.2
                                                                           17.1
                                                                         0.00208
                                                                         0.00152
                                                                         0.446
                                                                         0.0120
                                                                           27.9
                                                                         0.00339
                                                                         0.00248
                                                                         0.761
                                                                         0.0205
                                                                           38.7
* 70°F, 29.9?" Hg
NA - Not Applicable

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                          VI.  PROCESS DESCRIPTION

     Clay, crushed oyster shell, and silica sand are brought to the plant
by barge from deposits along the Gulf of Mexico.  These materials are ground
and blended ;in two rotating ball mills to form a slurry.
     The blended slurry is fed into the upper ends of two sloping, slowly
revolving kilns.  These kilns are gas-fired with a capacity of 5,250 bbls.
per day each and are 450 ft. long and 12 ft. in diameter with refractory lining
encased in a steel cylinder.  Fuel consumption is 1,300,000  BTU per barrel-
of cement produced.  During passage through the kiln; the raw materials are heated
to a temperature of approximately 2800°F .to produce-the element hydraulic calcium
silicates, known "in the trade' a^'*£^7rter'wc, '3Ms -Barbie- si zed clinker material
is then discharged from the lower end of the kilns at temperatures exceeding
2000°F and fed immediately into two air-quenching cooler units which reduce the
temperature of the material to about 150°F.  From these coolers, the newly-formed
clinker material is conveyed to storage silos.
     A small amount of gypsum (4.45% by weight) is added to the clinker material
and this mixture is fed into two finish grinding mills with a capacity of 47 tons
per hour each.  The mixture leaving the grinding mills is fed to two air-separa-
tors or classifiers where the coarse material  is returned to the mills and the
finished cement (90% through 325 mesh screen)  is pneumatically pumped to storage
silos.  Present plant production is approximately 4,000,000 barrels of cement
per year.
     The control equipment of interest in this report consists of a Mikro-
Pulsaire baghouse collector ori the No. 2 clinker cooler and a Norblo baghouse
collector on the No. 2 finish mill grinding system.

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     The Mikro-Pulsaire collector consists primarily of a series of
cylindrical filter elements enclosed in a dust-tight housing.   The felted
                       i
filter media is "Nomex" which is heat-resistant for temperatures up to 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  cylinder.  As
clinker 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 dust particles fall  by gravity during the cleaning
cycle to the hoppers below where the material  is removed by a  horizontal  screw
conveyor and then conveyed to the clinker storage silos.
     The Mikro-Pulsaire unit is designed to handle an air volume of 145,000
ACri! at 2:o°r for a performance of 99.0-:- psrcsnt efficiency.   The effective
                                    2
collecting surface area is 189720 ft  which gives an air-to-cloth ratio of
7.7:1.  The pressure drop across the filter varies from 4 to  6 inches of water.
The collector contains 2,016 bags with a minimum life expectancy of three (3)
years, and each bag costs $12.00.  The expected life of the baghouses is 40* years,
and the installed cost in September, 1970 was about $600,000.00 for both col-
lectors.
     The basic unit of the Norblo baghouse collectors on the  finish mill grinding
systems is a compartment which contains 108 cloth filter bags (6" diameter x
                                  p
8' 3" long) or a total of 1,296 ft  of free filtering area.  These bags are
arranged in two groups of 54 bags.  Each group has its own individual bag holder
and shaker controlled by an electric timer with reversing air flow.  Each com-
partment is 10' tall x 8' 6" x 5' above a 6' 6" tall 60° hopper.  The particulate
                                        8

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matter 1s collected on the Inside of the cloth filter bags (spun "Dacron")
and falls by gravity during the cleaning cycle to the hopper, where the
material (cement) is removed by a horizontal 'screw conveyor.
     The Norblo baghouse collector is designed to handle an air volume of
33,000 ACFM at 180°F for a performance of 99.9+ percent efficiency.  The
effective collecting surface area of each baghouse which contains 12 compart-
                  2
ments is 15,552 ft , giving an air-to-cloth ratio of 2i12:1.   The pressure
drop across the filter is approximately 3 inches of water.  The collectors
each contain 1,296 bags with an average life of five (5) years and each bag
costs $3.65.  The baghouses were installed in 1958 and the expected life is
40+ years.  Neither the total installed .cost nor the annual operating cost
of this unit were available.
                     VII.  LOCATION OF SAMPLING POINTS

     The locations of the sampling ports are shown schematically in Figures
2 and 3.  At each stack, sampling was conducted along each of two perpendi-
cular stack diameters.  The number of sampling points was dependent upon the
distance of the sampling ports from disturbances in the gas flow, as described
in Method 1 of the Federal Register,, Vol. 36 s No." 247, December 23, 1971.   The
number of points sampled was 22 points per diameter (for a total of 44 points)
at the clinker cooler stack,and 12 points per diameter (each  point sampled
twice, for a total of 48 points) at the finish mill stack.  The sampling time
at each point throughout the testing v/as three minutes.
                                                                        i
                           VIII.   PROCESS OPERATION
      Operating conditions of this continuous  process  were normal  throughout
 the testing.

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PULSAJRE
COLLECTOR
                           10
                                  .LEGEND-.

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 'NORBLO
&AJS HOUSE
 COUUECTCR
    FROM A»R
    SEPARATORS
             r« SIDE View                         WesrSioe

FI6URE.  3 B/\GHoose COLLECTOR ON Mo.S  FINISH
                               FROM
                     *.  X  Kt>  AFTER

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               EX.  SAMPLING AND ANALYTICAL PROCEDURES

     Complete details of the equipment and procedures used for particulate
sampling are described in Method 5, Federal Register, December 23, 1971.

     The procedures for analyzing the particulates conform to Method 5
with the added exception of the impinger catch being analyzed for particu-
late residue including organic matter.

     Quantitative analyses results of material collected on the glass fiber
filter and in the residue samples are reported in Appendix C.
                                 12

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                           X.  APPENDICES
                             APPENDIX A
                           'IftSSETS. • Affl)
     Complete results of the participate sampling are presented in Tables
A-l and A-2.  Example calculations using the data from run Mo. 1  of the
clinker cooler follow the data tables.
                                13

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                   PARTICULATE  EMISSIofToATA FOR CLINKER COOLER
Run No.
Test Date
Dn
Tt
Pb
Vm
Tm
Xta
vw
wgas
X M
Md
X C02
x o2
2- CO
XSJ
9
X EA
^d
MW
V
Ts
N
Pst
V
1
Q '
"a
. ' ""*****--
* I - '
Sampling nozzle diameter, 1n.
Net time of test, min.
Barometric pressure, in.
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 at
standard conditions*, SCF
Total H20 collected in Impingers
and silica gel , ml
Volume of water vapor collected
at standard conditions*, SCF
X Moisture 1n the stack gas by
volume
Mole fraction of dry gas


Excess A1r Percent
Molecular weight of stack gas,
dry basis
Molecular weight of stack gas,
wet basis
P1tot tube coefficient
Average velocity head of stack gas,
Average stack temperature, °F
Net sampling points
Static pressure of stack gas in. Hg
Stack gas pressure in. Hg absolute
Stack gas velocity at stack conditions fpsn
2
Stack area, in.
Dry stack gas volumetric. flow rate at
standard conditions*, SCFfl
Stack gas volumetric flow rate at stack
.conditions, ACFM
^Percent 1sok1nstic
• 1
5-18-71
0.193
132
29.82
2.28
107.40
104
101.07
34.5
.*.. 1.64
1.59
0.984
< 1
20.95
78.0
NA
29.00
28.82
0.85
1.44
175
44
0.02
29.84
4493
4072
104,057
127,032
102.1
2_
5-18-71
0.193
132
29.85
2.06
101.95
115
94.15
35.0
1.66
1.73
0.983
20.95
78.0
' NA
29.00
28.81
0.85
1.43
196
44-
0.02
29.87
4480
4072
100,432
126,664
98.5 .
3
5-18-71
0.193
132
29.80
2.15
103.79
113
96.05
34.0
1.61
1.65
0.983
20.95
78.0
NA
29.00
28.82
0.85
1.44
194
44
0.02
29.82
4551
4072
102,. 165
128,672
S3. 3
*.70°F, 29,92 in, Hg                    14
 NA -• Not Applicable

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                                   TABLE A -  1
                 PARTICULATE  EMISSION  DATA FOR CLINKER COOLER
Run No.
T.
c
mf
1
mt
'c
Can
Gil
Cao
Cat
Ct L

Cau

C,,,
aw
Cax
Ptf

Unit Feed Rate-
Tons/hr
Partlculate - probe,
and filter, mg
Partlculate - total ,
% Impinger catch
Partlculate - probe,
and filter, gr/SCF*
Particulate - total ,
Partlculate - probe,
and filter, gr/cf at
conditions
Particulate - total ,
stack conditions
Particulate - probe,
and filter, Ib/hr.
Particulate - total ,
Partlculate - probe,



cyclone

mg

cyclone,

gr/SCF*
cyclone,
stack

gr/cf at

-cycltme.

Ib/hr.
cyclone,
1
61.8

11.8

26.3
55.1
0.00180

0.00401
0.00147

.
0.00328

/l^SETI

3.538
0.0253
£
62.7

20.5

38.1
46.2
0.00335

0.00623
0.00266


0.00494

2.812

5.323
0.0448
3_
62.7

14.2

23.3
39.1
0.00228

0.00373
0.00180


0.00296

1.941
••
3.269
0.0305
and filter, Ib/'ton feed
Ptt
Partlculate - total ,
Ib/ton feed
0.0572
0.0849
0.0513
*70°F, 29.92 1n. Hg, dry basis
                                         15

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                                  IMDLC M - £.
                                  I f \ i-S W W f\   *-

          PARTICULATE EMISSION DATA FOR FINISH MILL GRINDING SYSTEM
Run No.
Test Date
D
n
Tt
P.
b
P
m
V
m
Tm
V
mstd
V
w
V
wgas
% M

Md
% co2
% 0?
Z CO
% N
% EA
MW.
d
MW

c
P
APS
T
s
X
P
Pst
PC
s
Vc
s
Ac
o 1
S '
Qa

% I


Samplina nozzle diameter, in.

Net time of test, min.
Barometric pressure, in.
Hg absolute
Average Orifice pressure
drop, in. hLO
Volume of dry gas sampled,
ft at meter conditions
Average gas meter temperature, °F
Volume of dry gas samnled at
Standard conditions*, SCF
Total H20 collected in impingers
and silica 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 gas,
Average^stack temperature, °F
Net sampling points

Static pressure of stack gas in. Hg
Stack gas pressure in. Hg absolute
Stack gas velocity at stack conditions
Stack area, in.
Dry stack gas volumetric flow rate at
standard conditions*, SCFM.
Stack gas volumetric flow rate at stack
' . conditions, ACFM
^"Percent isokinetic
1
5-19-71
0.250

144
30.00

3.84

149.51

111
140.35

90.5

4. 29

J2L97

t).-9TO
< 1
20.95
<1
78.0
NA
29.00

28.67

0.85
0.81
229
24

0.04
30.04.
3490
1452
26,360

35,185

109.0
2
5-19-71
0.250

144
30.00

3.29

139.57

106
131.99

81.0

3.84

2.83

0.972
* ^
20.95
<1
78.0
NA
29.00

28.69

0.85
0.81
243
24

0.04
30.04
3539 i
1452
25,252

35,679

102.9
3
5-20-71
0.250

144
30.10
i
2.94

130.70

93
126.82

72.0

3.41

2.62

0.974
< 1
20.95
<1
78.0
NA
29.00

28.71

0.85
0.81
249
24

0.04
30.14
3549
1452
2.6,244

35,780

93.9
* 70°F, 29.92  in. Hg                      16
NA - Not Applicable

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                               TABLE A -  2
         PARTICULATE EMISSION DATA FOR FINISH  MltlT^RINDING SYSTEM
Run No.
v
I
Can
Oil
Cao
Cat
a I

Cau

c,w
av/
Cax
P
ct

ptt


Unit Feed Rate-
Tons/hr
Parti cul 3 te - probe- ,
and filter, mg
Participate - total ,
% impinger
Parti c-jl ate
and filter,
Particulate
Particulate
and filter,
conditions
Particulate
stack condi
Particulate
and filter,
Particulate

Harticd] ate
and filter,
Parti cul ate
catch
- probe,
gr/SCF*
- total ,
- probe,
qr/cf ot

- total,
tions
- probe,
Ib/hr.
- total ,

- probe,
Ib/ton f
- total ,

cyclone
mg

cyclone,

qr/SCF*
cyclone,
stack

gr/cf nt

cyclone,

Ib/hr.

cyclone,
eecl
Ib/ton fee
1 ,
34.6 |
22.0
32.9
33.1
0.00241

0.00361
0.00181 -


;Q,ISB2T€i

*0r527

0.791

0.0152

Cb.0229



0.
i
0.
0.


0.

0.

0.

0.

0.
2
33.9
26.9
37.8
28.8
00314

00441
00231


00324

683

971

0201

0287



0

0
0


0

0

0

0

0
3_
37.2
17.1
27.9
38.7
.00208

.00339
.00152


.00248

.446

.761

.0120

.0205
*70°F, 29.92 in. Ho, dry basis
                                        17

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                           PARTICULATE CALCULATIONS
Example:  Run No.  1, Clinker Cooler               ^^
1.  Volume of dry gas sampled at standard conditions:   70°F.  29.92  in.  Hg,  SCF
              17.7 x Vm (Ph+  ^rn_)  17.7X 107.4(29.82+ *'28
                             T 3.6	
        m
         !std
           TFm + 4W
                        104* 460J
                                                                     =  101.07 ft*
2.  Volume of water vapor at 70°F and 29.92 in.  Hg,  SCF
       Vw    = 0.0474 x Vw = 0.0474 x34.5 =  1.64   SCF
         gas
3.  Percent moisture in stack gas
               100 x V..
       % M  =
                      'aas '   100 xl.64
                m
    + V   101.07" 1.64
std    wgas
                       = 1.59
4.  Mole fraction of dry gas
          =  100 - ?'•'•  =  TOO -!.$•?  = 0.984
           '     ICO          100
5.  Average molecular weight of dry stack gas

HMd * (%C02 x TO
                 x
                                             (%CO
       (  0   x  ^ ) + (20.95X T   )  + (  78   x     )  -  29.00
6.  Molecular v/eight of stack gas
       HW = Ml!d x Md + 18 (1  - Md) =29.00 x0.984 +  18 (1  -0.984  )=   28.82
7.  Stock gas velocity at stack conditions,  fpm
                     	'          r  _,   j1/2
       V. = 4,360 x\P>P, x fL +Tt-f:)'      ('  x T¥  |
        5          ^   --     S           I—  ^       —I
                       r     i     ~i1/2
            4,360 X30.2..1:.—I—'.	 £4493 fpm
                       129.84  "28.82J
                                         18

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                       PARTICULATE CALCULATIONS(Contlnued)
 8.   Stack g£S volumetric flow rate at standard conditions*, SCFM
              0.123 x Vc x Ae x M. x Pc   0.123 :<4493   x 4072   xO. 984x29. 84
        n              S    S    U    S _     •__•_
                              __ __ _   _ ___  __
                    (Ts + 450J '         "         (  175 + 460)
 9.   Stack gas volumetric flow rate at stack conditions,  ACFM

        n    _^^45 x 0  x...(Tc * £60)   .05645 X104»057X( 175+ /ipO)  12; Q32  ACR1
        ya "        7  x M  "        "  " "29.84 x 0.984                  '
10.   Percent isokinetic'
     1,032 x (T  + 46C)  x Vm
                             td_ =  1.032 x (175 * 460) x 101.07 A
                                                                   2
             Vs x Tt x Ps x Md x (Dn)      4493 x ^32 x 29..84X 0.984x{0.193)

11.   Participate:  probe, cyclone and  filter, gr/SCF* Dry Basis
                        mf
        Cfln = 0.0154 x -yi - = 0.0154 x jn:8_ =0.00180gr/SCF
                         mstd           101.07

12,   Particulate total. nr/SCF* Prv Basis
                         mt
        C_ = 0.0154 x n-—-— = 0.0154 x 26.3   _ft nn.n,    /prp
                                        1UO7" "°-00401  gr/SCF
13.   Pcrticulate:   probe,  cyclone and filter,  qr/CF at stack conditions
              17.7 x Can x Ps x Hd _  17.7x 0.00180 XJ29.84 x 0.984 =  0<00147  gr/CF
                     s
14.  . • Pa'rticulatc:   total, gr/CF at stack conditions
              17.7 x Cao x PS x Nd    17.7 x 0.00401  x 29.84 x 0.984
            = ~~       "           =                       =
Ccvj = —rr~TTOf	= —rr^iFTiEm	=        = o.00328 gr/CF
15.   Particulate:   probe, cyclone, and filter, Ib/hr
      .  C   = 0.00357 x C,, x Oc = 0.00357 x 0.00180 x 104,057 = 1.561  Ib/hr
         «tw              an    'S
16.   Particulate:  total, Ib/hr                                  .          i
        C,v = 0.00357 x C   x Qr - 0.00357 x 0.00401 x 104,057 = 3.538  Ib/hr
         C. /\           '•   t* J    — *
17,  • Pamcul.ate:c probe, cycloncj ?.nd fil"-:r, Ib/ton feed
         '*        *        *6          lb/tonfeed
"v.   FdriJLUiuC-..-:  total; )b/to» '•'."' .
      -   pt^_:^_:=  3.538 = Q_0572       1b/lon

--.70'C'FS  29.92 in. H
-------
APPENDIX B




Field Data
      20

-------
                     PRESURVEY - PROCESS INDUSTRY & POWER PLANTS
 NAME  or COMPANY
 ADDRESS
                                                      DATE  OF  PRESURVEY
                                      (P& Ji   CITY  ^U^Cs^ ___ STATE
-NAME  OF CONTACT
                                                         T^ A^HONE
PROVIDE FLOW DIAGRAM OF EACH PROCESS TO BE SAMPLED,  INCLUDING  FEED COMPOSITIONS AND
RATES, OPERATING TEMPERATURES AND PRESSURES, PRODUCT RATES,  AMD  PROPOSED SAMPLING SITES
COMMENTS:
/I P.
 . 1       5
                                 7
                                              21

-------
                                                                                5.
 SCAFFOLDING  OR OTHER HEAiiS  OF  SUPPORT PRESENT?
       LJ   YES
             NO, WHO WILL  PROVIDE  IT?
"SOURCE  OF  ELECTRICITY AVAILABLE?   /2>fES, MAXIMUM AMPERAGE PER CIRCUIT_
                                   LJ  NO
• PI STANCE   / D b JH      WHO  KILL  PROVIDE EXTENSION CORDS?
 LOCATION OF FUSE BOX
PARKING FACILITIES AVAILABLE FOR TRAILER OR VAN?
SIGNATURE REQUIRED ON PASSES?	
NEARBY RESTAURANTS AND HOTELS
                                                             WAIVERS?
 LIST ANY SPECIAL SAFETY  EQUIPMENT  OR  RULES
                                            22

-------
PRELIMINARY FIELD DATA
   Stack Geometry
             Plant  I<*«ai
Test Mo..
Location
                                      (K>inU
\
v









Dist. from outside
of samnle port, in.
^
**3sA*c-t)
-/







i

               23

-------
     /
  L
  3
  V
 5
 6
 7
 S
n
! *>
I ^-
;/*
                          3A5"
                          73.$
                          85. V
                                                     - X
                                                      2.5
                                                      4^5
io.5
13.6
'5.75
                                                   2.2.025
                                                     4-5 .7 5
                                                     71 , i
                                                              .
                                                              *•
                                                              •3
                                                                      (o
                                                                        3/S
                                                                      '7.6
               41
               53V*
               5-7 78
               Go '/4
               G3. o
               65%
               6-7 -'/z,
              J>% s/s
               •71.%
               13  ?/g
                   '/8
                                           24

-------
                              VELOCITY TRAVERSE  FIELD DATA
Plant 	
Test	
Location   ^V)^K(
Date   s/n/7i
                       <^€w\ev\l  -
                              CooUv  -
Hrio v* n *' t\ v*- »V\G.£V LL£V Ss tori, 1"^ l*^» * S-V
W p ^, I vi V U ) » — 1 ") /
1
i
i
i
i
i
'
5
.1
4
(
i
1
1
Meter
Clock
T i me













Point
1
2
3
4
5
(j
•7
,H_e£i 	 __•
(D
AP5 Tn7H20
IA .
'
t.4
.
lA
U
/-4
8 1-4
0>
10
II
12
13
,.4
/:5
{)\
p'-' ' Hi
A") -in U fl
"! » 1"» r'-?U
14
15
-10
n
. (6
'9
20
	 *L
! 22
. |_ -
1
!
!
t.t
/.6
^;5
./.5
/c5
i -,

;.5
(2}_
*'^:, in. H,,0







^-5 ' '
(.1








Stack Ta^pt.cF •
f^G 2.^5
2.^5^ 2.0*5 '.

-------
                            .   VELOCITY  TRAVERSE FIELD DATA
Plant J-ciea.1 Ccmevvt
Test-
Location Kli«vc.e<
- C.coVe»- — PoH- ?£
         Date    5/'i/-7i
         Operator   Mae^u-ey.  gor.«Vvav Ri.\ey


         Meter  AH __2^-_o|	      	
Clock.
1 Ills-

i-
1
I
i
i



_
"





D o •? n •••
1 O 1 1 1 v
1
2
3
4
5
G
7
8

lo
U
12.
13
(1)
/ P Tri (-1 n
t»r j III. \\j\J
I.I -
1.4
\&
].(,
).^
t.u
1-0
1.1
; u
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1.5
f.5
l.l,
iU ;
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uP, '
14
15
it .
n
. is
'9
20
21
E2




(2)
in. H00

i.o>
,!,{,
.i.e.
i.V.
1.5
1.5
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;
Stack Tumpt.'F
Ti) 1 "12")
i&5 ; I"i8
i
t / ~1 • "7 n
j
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t
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!~?7 | <^5
1
(75 j ("70
ng> | 1^5 ^
• ^ 1 !
(^5 )
r
i
J £iQ
 (]}"A!-J in, MpO  Average__
        ,/^r
         in, H00  Average
             /..          ~
2t)
                                              26
KCAr-^9 (12/07).

-------
                   II   I /      •"/    y/    "r"             v-~   / *-,
           Plant  f)L<££*y (&W-.J   /V-^t-t&W     Date  J5 ~~ ( /



           Sampling location
                                                   A +£> /E*U
!-          STACK DATA  FOR NOMOGRAPH:

!

!'          V.   Meter AH      oiin H_0
-
                                  no
           2.   Avg.  meter  tempt  (ambient + 20°     '
           3.   Moisture  (volume)	•" 2-°	%
           4.   Avg.  static  press. +   Q.3	in. H9OX.073 = HQ.o-^2.	in. Hg.
                                                                          -
j           -r«   nvy.  ^bubi^ pitoo.  •   - '; ~^        111.  n«v

i     .                                               £-
           5.   Bsr.  press  sampling point   29. £c)    jn.Hg(-b> _ °-02-   (static  press  in.Hg)


                                  in. Hg.
           6.   Bar press  of meter    9-8*) _ in. Hg.
•t


'           7   p /p  -   5-_J±lL_   ™- "9
I           /.   K$/Pm -
                        C.   2.^.6S>     in. Hg
           8.   Avg.  stack  temperature    ^QO	°F.




           9.   Avg.  stack  velocity  UP)  ~i 5	in H20.



                     C factor  (1)  15	(2)     /.^?c3
                                              .    27
       \

-------
 Ho.
1.3
     .
   -
                       Pi tot
                      in. K'>
                         4P*"
                                       -Af;TICl;!..A'rF FIELD DATA
                                                                                                        <^
                                 VERY
                                   td .^^a rsccr=: si the start  of
                                • Giich test po'ir.t .
                                • r&:sd an-J rcccrd every 5 r.rlnutas. •'
                                              3ar. Press.  "Hg  2.^.82


                                                  ?r,.od Moisture S
                                                    'C'. 40  A.M.
                                                     T
                                              Haater Bos Setting,
                                              Fr'cbe Tip Dia.,  In-	,

                                              Probe Length  _

                                              Probi Heater  Setting

                                              Avq.  A P	      Awg
                                                 7      r
     Orifice   AH
        •• ..  u  r*
! Dry  Ga^ Temp,  i Vacuum |5-ox
I   "   T-        ! --r.   >•/,
1    I .~?      !    t.~T    !  loo  i    IOD  i   S..^  "1 2..2-r"0 j
j^c;
i  , r-;T:n
                                                _:!?::* _' _i°to_.. '	^6  !  4.O
                                                   o
                                                   J5_^	 j ^ _T_^  '

-------
f>  VN
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        D-y  Gas
       Meter,  CF
                             Pilot
                                  in.
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                                          Orifice  -5
                                             in MoO
                                            Desired   j  Actual
                                                                 Dry Gas Temp.
                                                                   Inlet
                                                                     Outlet
                                                                      >}ur,;p
                                                                    Vacuum
                                                                    In.  Hg
                                                                    Gauge
Box
Temp.
 °F
                                                                               4.Q
Impinger
  Temp
   °F
Stack
Press
in. Hq
                                                              ion
                                                                        » 7.
                              1.
                                          i.55
                                                     2.55
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                                                                                       2.46
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                87
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                                           2.. 15
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                                                      2.3,
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           \  /
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                                                   2fZ $

-------
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V —• •. * >•*»•>!           ^

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Xitar  i h .JJZ^i.	

r  Factor  -i^- /.Z5
                                                         PAsmC.L-.ATE  FfaD DATA
                                                 i


                                                  VERV  I^^ORTAM - FILL. IA ^'.L glANKS

                                                  Road  and  record i:-c the start r>f
                                                 • each  test point.

                                                  PATHOLOGICAL InC:f;E?VVTOrri--
                                                  read  ar.d  rc-ccrd i.".try 5 :nir,utes.
                                                         JI '. t O A.M.
                                                                                  Ambient Tenp CF

                                                                                  Bar. Press.  "Hg
                                                                                  Assrrr.ed Moisture. 3
                                                                                                                    2.0
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                                            i •. Z.4 P.rA..
                               RioiaJneS v  !    ^_*-*     '
                                                                                                                           -..^£5.
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            Q85~."Z6    T    r."65   T     J/3     !    zTi   I    i,"^    I

-------
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Time
49
51
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87
60
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33.80 -
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in. H20
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1.5
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1-5
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2.25
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(.85
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'2.0
2.C5
2.05
2.1
2.1
2.4
2.35
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2.0
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2.1
2./
2.1
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AH
Actual
2.5
•2.25
2.25
'^.25
2.25
2.25

1.35
°if i.to
l.l
a^e-i-9
i.&S
t-9
2.0
2.o5
2.. 05
2.1
2-1
2.4
2..S6
2..L
2.1
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2.. O
2.0
•2. .Co
2.1
2.1
2.1
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2~ffib
7
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°F
Inlet
/ M
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III

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lit
II 1
HI
I 1 1
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112
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113
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117
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• '7
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in
10
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<«p.
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11 i*
110
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3.5
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dox
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24o
•255
235
2-* 5
245
245

24-5
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'
22.5
221^
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240
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230
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TO
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74
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74
'70
70
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-------
   • i 2
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      it ion
                                                     PARTICI..ATE FIELD DATA
                          MBjLI^^IMi - ['IkLlfL^J^^

                          Pii^d and  r?cc.*d :. Ku  ;
                                                                                                                             op
                                      	£.j[ _ __
                                ^	| "" )'86~ j   I
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           T~2.r
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                                                                                                          74
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                                                                                                 235
                                                                                                 Z25
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	2._«	|	2.1	j	M_2	;	HO       -5. (, _ 255 \   —11     I	{ |94
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95. 125
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102.52,5
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Pi tot
in. H20
AP
I.L,
1.65
f, ^
1.55
i.55
1.55

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1.2.
1.3
i-35
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Orifice
in Hr>
Desired
2-4
•2.3
Z.4
2.3
•2.3.
2..-S

1.25
(."?
I.S
2.0
Z.i
2/2.
2.2.
2.2-
2. 1
2.0
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2.2.
2.1
2.1
2.2
2.. 25
2.. '3
2.4
2.4
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AH
Actual
2.. 4
2.. 3
•2.4
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1.26
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2..0
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H5
-.15
M5
I/G


// ^f"7
^~









Temp .
Outlet
HI
HI
HI
H2.
VI Z-
t it

(IZ.
* i 2-
1
i
i
1
<
(
i t
I i
ll \
t i 1
ll 1
i l 1
i i I
V I 1
i I >
il t
\ \l
ill
i 1 1
112 j


///.D
~>
3)
X







i'ur.;p
Vacuum
In. Hg
Gauge
4.0
4.0
4.0
•5.0.
3.^
3 3

2. i
2.^
3.0
3- \
3.3
3.0
3.7
'2>.1
3.5
3 5

13.5
?>.5
3.5
3-5
3.T
3.8
4.0
4-.0
4.o
4-0
4.0













Box
Temp.
°F


2|o


2.3O

235
2.2.5
2.4-5
2-10
2.-S5
2bO
2.15

25o
215

2-"35
!_2l6
245

2- "50

2.10
Z-40

'2-20










•


!
' Impinger
Temp
°F


T7

•
1^

TT
71
G9
fo9
&6
C-8
Gl

oe
08

70
'70
6>9

(»"7

6T
67

6g














Stack
Press
in Hg






\
\ .
.
i
1



I
]
/


1
I
1
j
I
I
1

/












,
!
Stack
Tcrr,o
CF
,l9Cj
I^C?
T5>C:
196
•9G
1^6-

101 -
'fe~1
CS'7
^8"T
\€>'l
l^o
'^0
t^C
2iO
2(4 -
2'4
2'4
ZoO
2ofc
202.
(<=)^
i-=5o —
18!
161
ist
181
• 80


Af^—

\9^









-------
                               PARTICULATE CLEANUP SHEET
                                            Plant: c.H<£&.fjs 63-»u^r/"
Run rumber: /
Operator: C- f /£-&>
Sample box number: / \p-H.&Aj^
Location of sample port: '
Barometric pressure:
Ambient' temperature:
tfiju^ 6^4-v.
M.W
96*

impinger H20 . •
Volume after sampling
implnger prefilled wi
Volurr.e collected
                                 Container No. __//)'_   Ether-chloroform extraction
                                                       ' of
                                 Extra No.
/ ^m
                                                       Impinger v/ater residue   /I/,
Impii.gers and back half of
  fi"ter, acetone v/asf:~
         Contalner No. )J3
         Fxtra No.      .      Wfiiqht,re-suits
Prob'j, cyclone, flask, and
  front half of filter,
  acetone wash:

         Container /no.
         l-xtra Mo.-
                                                      V'eight  results
                      I D
                                                                  Filter particulate
                                                                    weight	Q __
                                 Total particulate v;eiqht
                                                                                         nig

Dry probe and cyclone catch:
Container No.
Fxtra Ho. ,•' 'Vfeight results
• /
mg

           Filter Papers and Dry i-'ilter Particulate
  Filter number   Container no.    Filter number  Container  no.
                                                                 nig
Silica Gel
  Weight after test:
                   V.       '
  Weight before test:        2$^
  Hcisture weight collected:
  Container number:         1.
                                                                  Moisture total
                    3.
Sample number:  .
Metiiod determination:
Corn,ir,£.nts:
                       Analyze
                                                                  ni

-------
                                PARTICIPATE CLEANUP  SHEET
Dater 	
Run number:
Operator: __
                      2
 Samp'ie box number:	l_
Plant:	
Location of sample port:
Barometric pressure:     2. 9, ,3
Ambient temperature:	J'a "*
 lmpii>ger
 Vo-luiae after sampling
 Impinger prefilled wi th££Vjn]
 Volume collected
                                 Container Mo.
                                 Kxtra No.
ft
          Ether-chloi^oform  extraction
           • of impinger water
                                       mg
                                                       Impinger v/ater residue  J J, L.  'ing
 Impingers and back half of
   filter, acetone
                                 Container' No.
                                ...£x±.ra N^>. ...,.-..
                                                   ...,., JJeight  results
                                             mg
 Dry probe and cyclone catch:
                                 Container .No,,_
                                 Extra t!o.
                                                       Wei-ght  results
                                             mg
 Probe, cyclone, flask, and
   front half of fliter»
   acetone wash:
                                 Container No. A £•-
                                 Extra f!o.	V/eight  r-esults
                                             mg
            Filter Papers and Dry Filter Particulate
   Filter number   Container no.    Filter number  Container  nc>
    /-;?
-------
 Date:
            -/;->/
                               PANICULATE CLEANUP SHEET
                                           Plant:
 Run  lumber:
 Oper.ttor: _
 Sample  box number:     /
                                           Location of sample port:
                                           Barometric pressure:
                                           Ambient temperature:
 Impinger  H20
 Volune  after  sampling  2 /t( ml   Container No.. _5/|   Ether-cJhloroform extraction
~
Impinger prefilled W1th2i£,m]    Extra No.
Volu.r.e collected        / 0 ml
                                                      ' of 1l
                                                                   water

                                                     Impinger water residue    ^ t /
                                                                                        «ng
                                                                                        mg
 Impingers  and back half of
   filter,  acetone v/ashr
                                 Container No.
                                 Extra No.
                                                  .    Weight results_
                                                                                       jng
Dry probe and cyclone  catch
                                 Container No,
                                 Extra No.
                                                     Weight results
                                                                                       _mg
 Probe,  cyclone, flask, and
   front half of filter,
   acetone wash:
                                 Container No.
                                 Extra t!o.
                                                     Weight  results
            Filter Papers and Dry Filter Particulate
   F'ilter  number   Container no.    Filter number  Container no.
                                 Total particulate weight
mq
                                                                 Filter particulate
                                                                  w e i g h t,     /"}. ff     mg
                                                                                 3	mg
 Silica  Gel
   Walght  after  test:
   Uaight  before test:         2£31_-
   Moisture weight collected:   ij-J__
   Container  number:         1.      2.
 Sample number:.
 Method  determination
                                           3.
                                                   4.
                                              Analyze for:
                                                                Moisture  total  --
                                                                     "tr
                                           36

-------
PLANT
«if
SAMPLING SUMMARY SHEETS



            LOCATION
SAMPLED SOURCE
Train Data
'Run
. No..
';"
t~j
3'

Date
lr-;/7/
,51/S-T/
5V8-7/

Nozzle
dia.
i n .
J90
,/?3
, / £3

Net
time
min.
A3Z
A3Z
;3i

Bar.
pres.
"Hg.
2221-
Uzii.
tf.fo

Orifice
.diff.AH
"H20
£, */
2,tf£
2.IS

Volufiie sampled
meter cond.
cu. ft.
/07,
jfij,?^
/ 03, ?$S

Meter
temp.
oF
JDV
US'
M3

Volume sampled
standard cond.
cu. ft.
/£/,<* 7
3v./S
9t,Cb

Moisture and Gas Data
Run
No.
/
lr
J>

Total
mo'isture
nil.
J?,S
^,D
31/. Z>

Moisture
std. cond.
cu. ft.
J.t>
j ,J3
/, (*£'

Mole
fraction
dry gas
.9*
. 1>

Molecular
wt. of moist.
stack gas
2&.J3
Z$,?2
2?,J$

 tack Data

Run
No.
;
1
3

Stack
area
in2
t/o>l
l/o 71
L/v?L,

Velocity
head
"H20
/<l
,o 2-


Stack
pi-ess.
"Hg. Abs.
Z9.$,'li/
•^D.H

Stack
velocity fpm
stack cond.
££.-0
U*i 71*
L/^ */•£

Stack ....
gas volume
scfm
A3, 4*5"
99.%$
//)/ >/9
'<••£/: • •' 	
Percent
i so kinetic
/OJ, 7
^£^ . .
7 /;-, a


-------
                                PRELIMINARY FIELD DATA
                                   Stack Geometry


                                            Plant  oL/Lo^.i ffrnj.^   %

                                        r   Test No.

                                            Location

                                            Date
                                    A.  Dist. from inside of far  wall  to outside of
                                        near wall, in., = 	£/ ?"	

                                    B.  Wall thickness, in., =     4/
                                        Inside diameter of stack  = A-B
                              3
                                        Stack Area =

                                    Comments:
  Sketch of stack cross-section
  showing sampling holes

  Calculations:
•  Calculator
  NCAJ'-28 (12/67)
                                        Point
                                         t

                                          7
                                          71
                                         /I
    % Dia. for
   circular stack
   6.7
                                                11.1
   9 '7-  f
38,
Dist. from outside
of samnle port,  in.
                                                                 7.6

-------
                                VELOCITY TRAVERSE  FIELD  DATA
L
Plant
Test  .
Location __
Date 	O V f- X
                                                                       . \>o,-» A
                                                                                   o. (o _  30.
                                                                                   "
                                                                                 Me
          Operator
.;
i
i
f

j
i
t
1
i
-
•

i





Clock |

\Ai
L _U_
i -3
i
i
5
6
" ~ ~ 	 '
s^
*
1 f

I
\/l-
!
1 _
(D
Ap *7; u o

O-62.
0.0,5
0.-77'
0--74
O.T5
0.-72
o.e^
0.6&
O.b6
.
0.«,5
D.5S
r . ~ "
(i) •
J~ ~\ \' •>' p TT 7T
f -£\ I . i !i j n,jU

- •









,


AP-,
&/
1
3
V

/:-
./.. .
o
?
/"
)'
/i-

121
In. H.,0
0.40
O.G0
. 0.74
. o.11
0.79
0.^4
0.-I3
0. fc'1
O.7I
O.bl
O.G-L
O.SG

' 151
/AP, -In. H00
" ' C " " " '











%.f
Stac!: Tynipt,0F j
0~/_Zl \2) i
/^\Z3& J
i
1 ^y ^^ ^^
y ^^\ 7*\ 1 ^r ^ ^y j
\^i >< j
^^5^) \i \
V2>* " i
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/^ i' !
i
	 	 .
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/ , / • i
^a ''r 1
! ' 1
                                                        /v
Cor.;n:.)iv:s:

-------
 Plant         ty^       >^        Date
 Sampling  location /ttL& V
 STACK  DATA  FOR NOMOGRAPH:


 1.   Meter AH      -rrtffi  £.&/   jn H20


                        f% ""^                 •a**"
 2.   Avg. meter tempt  (ambient + 20°    / 6S    °F
 3.   Moisture  (volume) _ -^ _     %
 4.   Avg.  static press. G   , ^ _ in. HOX.073 ^   .. Q & _ ^in. Hg.
 5,   Bar.  press  sampling point- ^&  VJjj	injig •*•   .. O ^f  (static press in.He;) =

            3^}. fit/   in. Hg.
 6.   Bar  press  of meter  .-5 V, 0 ^-    in. Hg.


 7.   vpn°  ?'              1n" Hg -
      s   m    g:    __ in. Hg •
                                 .  ^". X '

 8.   Avg.  stack  temperature      ._L_/__
 9.   Avg.  stack  velocity  (AP)     * w> ___ in H^O.


" ---      C  factor  (1)    |.2'3 _   (2)      A X 7)
                                      40

-------
       ;'• '•  f> /   :   J-
/'lant /!^Aizf (£'tWrd
                                             FARTICULATE FTfL.D DATA





                                       VERY IMPORTANT - I ILL IK ALL  BLANKS
?:ead and record  ?.•;  cho stavt of



      eoc v\


  THOL05ZW«.  I;-:1:.!-£?,ATOU5-
                                                                                 Bc-.r. Press. "
.o ^.-.jn
'" a r •' to '•   Mae r K. e. r?
                                          aater  Box Setting,  '^_
                                        rc-3u en   vecor  -2- -s.'-    fnnutj
                                                                                Prcb;; Tio Dia.,  in.
                                                                                Prooa Haaxt-r Setting
                                                              ry uaf: TOTP .  ! V
                                                             In'upl  ' Uutlet ! Cc;
                                                                                     2*0  _.

                                                                                        . I    fr
                                                                           Ll^ZIZ^lLlIIIZIL
                                                              lu      («32-
                                                                .   i     _  (
                  .<^:4c       c.ej  _j__..^ 4,^ 4--~;^--j


                                       !     4.Z-
                                                                                8i-  !

-------
 r^^'j i.
jCo.Tir-srtts
  A-i-
  73-/-I
vo
i


It

(0

6
7
G
S
• 4
1
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-f
•2-
4
6
1
6
9
10
[1
9
CTcc:< '*-
Time
Dry Gas
.Meter, CF
•V~> I n

3t-

_ .
•soz.ir.-2.
—
... ' } -
Jy-f)

AT-

4fi
48
Cjj

S4
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71.

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75

76
g|
54-
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3$
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lot

to*?
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£_i j ^^4-
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c.e^»
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4-, 2-5
4.1
4,2.
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2.45


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4.1*5
4.2*5
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4,O
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— ' 	
5.^6
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3.6

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3,

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4. 1 ' S
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4,2
4,2 -j
4.^5
4.2
4. 2<:?
•4.7-
•4.C-
3.7'i
^ ^c,
^v-i
;^5.*3
r5.6
'^.6'
5.%
4,2
4.2^
.... ,.*.*-.„.».,»
Dry Gas Te:r,p.
°F
Inlet
Mfe

Ufa

—
11 (^
•"— ..
1(7

f 17
, jg,
lift

H^
U«3
JJ-55
il€) .'.-'
H2L '
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1 1-7

—
US
f(g
ua
us
Us
U9
u^
—
, (C)
1155
—
f/9
/jg
i i $
1 1 eS\
t ( */
Outlet
!
, —
\&3
' /f<5
HO
liO
IK

id
—
IM
(10

/|O
/I/
i/d
no
/(O
Vacuum
In. Hg
Gauge
7, "5
-7
7
7
7
£>
*&
&
S
^
e
*=-.•=>

B.1^
^5 c^
6
7.S
£,<=,
6-.S
fr.S
*T 2.45^

5
6?
c-
7
7
7<5
7-S
S
s

7.5
~7/=>
7,^
7.6
7
-7
7
7. -5
_6
. ,4?- - - .£. ..
Box
Temp.
op
2^,5
~_
25^,
—
_
Z'-Z.C1
—
ZZ.5
—
"Z~3O
25S
ZZS
—
260
Z4S
2iO
• 2.3(-\
2'2/j
^_-
2iO


2.iO
2 SO
—
zzc?
23P
210
z?o
24O
250
Z10
—
245
24Oj
-
240
240
23O
2 jo
^.^
-
Impir.ger
Temp
7o
_^_
71
. —
, —
"7 »
. 	
'7O
— .
T |
70
72-

V4
73
73
1"=}
7^
^—
72.


-72-
7 X
—
~7I
'H
10
71
70
70

—
6-e3!
/^^>
—
6V>
6^
6?6
c t
6&
—
Stack
Press
in. Hg




\
/
f
V


























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)
/







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\
j
/
I



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1
\

Stack
Temp
r
' 238
240
230
230
~Z So
2 30
2 ^O
^•^^
2 -^2
2 3 i
Z ^%
-2£~?
2^7
22S
z^s ;
Z^L
<2^£
2^
"Z'Z*?.
2iO


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22-$.
? 24
8.1(0
22C-
ZZB
2i)
2i;
23^
2'i)
1SJ
214

Z3IS
Z5-i
z3'3
Z'li
Z^.3
•2 ^ "> ;
233

-------
j >V.Y\ I'
'
j ^
i Comments
~$>-\-&
Clock
i i rr.s
I2e
'"' "7 0X3
' fo
Itfr
' 12*?
Dry Gas
Meter, CF
i 2/3L 3X
'E.'tM-.C-j
£^7. S3
5oj. T_I
j'$2.| 3 -?#
K4I 38«,/b«


/"~~"\
(jL/fy)
^—^^





/ L/f.^5 }
Pi tot
in. H20
AP
^ • t^w*
/^) ft "^
ev^i
<3>.^C-
<9.3^
i?. "7 5
0 70
0 S4
^^^
(^'


>, ^/55"

j

1


'









'
























Orifice AH
in f-UO
Desired
4.J<==>
<4.2^
4.36
^ ,e;
4.0
3 G-
3. IS
'2.C-

(












Actual
•4.\fs
-4, ZS
-4.3.'^
4 i^
4.C
•*> <,,
5. i ^
2.<-

. — L, .. _ „ _ .,^.... .»-
Dry Gas Temp.
Inlet
U©
i ii*^
us
i,?5
uft
118
ifft
U#l

^ !
/

~3 $fy









j







1












1




•
'






































//•^>,-5~
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~}-rh
s=*#



















1
1



-••






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HO
MO
no
(JO

103
IO9
loV



jOCo, X
"p&^-f-

^ x^\
f- (/ / /)
-~^_"











f'urijp
Vacuum
In. Hg
Gauge
!.<=>
£5
^>
-j.c,
7, S
C-, 5
^.^
F5




















i
























i
Box
Temp .
°F
Z20
Z2S
Zfy
Z~LC*
ZzS
2-'io
Z'iS
24«3






























*



Impinger
Temp
CF
<2?fr
fe>6
C.-7
C-'7
6^>
G9.
tr"23
72.




















Stack
Press
i n . Hg




























I














































\










i
Stack i
Tcrr.p
r
23S
?3C,
2135
2"«
zy±
2-a,cr
23^
^35^




^ ^*7
1


























i
i
1

-------
rtwtJEaSfL
F:'J."i i>rO,. •
e*r - A/^y^C
                                PARTICULATf
ihELJ^IO^il -  F:LL IN ALL  BLANKS
Read  ar.d record £•;  the ste.rt  of
 e- r- ;•»  A *z.r \  rv^i S *^i '*"
 <«/ •- •'  U •-.- -1 C w \J • i * ' • •
                                                                       Afibisnt Ts^p  °F
                         PATHCLCG!:.AL  INC.if:L'.R:\TORS-
                         redd iif.i record s\-;.,-y  5  niinutes.
                                                                                          Gar.  Prt-:ss.
                                                                                          Asrunied Moisture 2	Z_
                                                                                          Hsfetc-r Sox Setting, °F
                                                                                             •;b.» Tip Dla.»  I^-J^
                                                                                           •'robe Ltii'.oth
                                                                                          Probe He;:1:&v-  Settiriq

-------
            Clock
                 Dry  Gas
               Meter,  C-
              PI tot
              in. H20
                            Orifice  AH
                               in H00
        Dry Gas Temp.
             °F
                                             Desired  'J Actua.  I
                                                                   Inl
                                                      Outlet
                                                                                Pur.ip
                                                                               Vacuum
                                                                               In. Hg
                                                                               Gauge
Box
Temp.
 CF
                                                                                                    •:* s-j
                                                                                                 Impinger
                                                                                                   Te^ip
                                                                                 °F
Stack
Press
in.
                                                      Hg
Stack
Temp
 o.-
-i-6  i
                                                -3.4-
                                                                                      G
                                                                                Tl
  .A
               40
               o.6<)
                           •54
                                                no
                  lo4
                                                                                fo
                                 230
                                                                                                   72.
-7 i
                                                -34
                                                                    110
                                                        106
                                                                                75
                                                          2A
               117
                                      3. V
                                                                     /u
                                                        J07
                                                           J..S"
                                                                                  73
                                                                                    L*
                                                                                           in
                                                 . A5"
                                      , /S
                                                                                     . D
                                                                                 £ f
                                               IV5
                                     j.f/y
                                                                                G't
                                               1,0 X
                                     2. GO
                                                                      / f 5
                     45^.5     ,
                                             ~nq:
                                                  o:
73f.^7V"

-------
                                  " I": O~" 1 -'"I'' ST"  ~\l.'i fl ~\-'~f *
                                  !.",.". ! i 1^ :_'_.-( , L.  . 1 CLL> L.V. I f.
                                                                        r^blent Temp  °F  76
 Rend .;,,c'  record cv  the  stSf-t of
• each t>:ct po'Jr.t.

 PATfiOLC'~ICAl !MCi.*/£RATORS-
1 r«rid and  record t-\2^w 5 minutes.
                                                                         Bar. f;ra3s.  "Hg_*k>
                                                                                 Moisture %  71
Heater  Box Setting,  "F___g

?-rob2 lip D-;a.,  lX'.OJ&5_
 !  u*.
J ~ apr&coT-.
                                                                        Proifr Haste:*  Settin
                                          V£cui.::n  i3cx
                                                  I  ry  ;:s   en-p
                                                                   I In. H--;  iT&nj.    Tcnp    i Tress
                                         	p __ ,__.|	; 	___-
                                3^4=	3.4.
                                                                   ;	s.S_ J  ^
-------
                   I
            Clock  i   Dry Gas
CScrcersts"   If me   J  Meter,  CF" '
                                  Pi tot
                                 in. H2C
                                                Orifice
                                                   in H00
                                             Dosi red   " Actual
                                                                                  rpuwp
Dry Gas Temp.    Vacuum
     °f;          In.  Hcj
                                                                   Inlet   Outlet
                                                                             Gauge
                                                                             Box
                                                                             Temp
                                                                              °F
                                        .Impi'nger
                                          Temp
                                           °F
                                                                                                       Stack
                                                                                                       Press
                                                                                                       in. rig
                                                                                                                Stack
                                   0.65
                                               3,05
   ;v "7
Ql    554.42.
                                                           S.2.
                                                                                       2.10
              54   5Q7.ZS
      4
               57 J  5jQ. I
                                               3.2.
                                                5.1-5
                                                     ••3.15
                                   0.60
                                                                                             240
                     SI8.S4
                                                                                             2-.3G
              12
                                                                                      4-
      2
                     SZS.flY
                                                                     96,
                                                                                              ZiO
                                                5.0
                                                            3.0
                                                               97
                                                                         5
                                                                                      -2KL
                                                           ^£0
               tH
                                                 3 IS
                                                                       SI
                                                                               2-.C
                                           70
                                   0. #
                                                 3. IS
_3_i:
                                                                                      LiL.
                                                                                        220
                                                                                        •70
                                                                             93
                                                                                       b.S
                                                                                     I . gsO
                                                3.J5
                                                                              94
                                                                                5.5
^i
  r~
f'>"L
f ^ l
l *j
                                                                    lot
                                                            3.0
                                                      iOt
S-i-^
                                 ^&.
                                                            2.r>
"
                                                                    _L£L
                                                                                       5
                                                                                       B
                                                                                                                      2S
                                                 2.A
      id
               114
              !, 1 1
^L.
7i
              V2-3
                                    C. BP
                                                      3 l«5
                                                                96-
                             s
                                                            3. ?S
                                    0.
                                                             3.'.
                                                 To »
                                                             '5.5
                                                                     ICO
                                                                     loj
                                                                                              za?
                                    0.15
                                                                      tot
                       •S6. 50
                                                                      101
                                              2 ,
                                                                       ~R\

-------
     Date: 	
     Run number:
     Opentor:
                                   PARTICIPATE CLEANUP SHEET
                                            Plant:

               &
    Sample box number:   /	/
Location of sample port:
Barometric pressure:     j£>.  d
Ambient temperature:	
                                                                           dik. ***•&>,
• .. I
i:mpi.iger
Volume after sampling /Off ml
Implnger prefilled withW ml
Volur.e collected      ^ I  ml
                                     Container No. 7ft-    Ether-ch"oroform extractior
                                     Extra No.            -' of 1mP':n9,er water	^	m9
                                                          Impinger water residue   /&,
               Filter Papers and Dry Filter Particulate
      Filter number   Container no.    Filter number  Container nc.
                                    I
                                     Total particulate weight
                                                                            3.2,'?
                                                                            ,*-"* **> / /
                                           _mg
Impi
fi
Dry
Prob
fr
ac
nqers and back half of Container No. i/J3
Uer, acetone wash: ' , c^^,.^.. a. . "... Weight results

probe and cyclone catch: •• Cofliaiaer ~SD«.
Extra 'No. rV?evght results

•e, cyclone, flask, and Container No. £/£.
•ont half of filter, ,- H ,, . ,. ,. ) c, 1
t ,,^h. ' txura Ho. . Weight results / 7, ^
t. LUf -C \ ( Go it • '
mg

mg

mg

                                                                     Filter particylate
                                                                       wei ght	x.%_	mg
                                            mg
    SiV:ca Gel
      Wuight after test:.
      Weight before test:
      Moisture weight collected:
                                                                            6 -

                                                                 Moisture total  *?&
Container number:
Sample number: . L~i
I
Method determination:
1. 2. 3. 4.
---'-- . |
f Analyze for: • .

Coirnitnts: • • •
                                                  48

-------
                               PARTICULATE CLEANUP SHEET
Date: 	
Run number:
Operator: _
                                            Plant:  dHjb*f
S-ample box number: 	j_
                                            Location of sample pert:
                                            Barometric pressure:	
                                            Ambient temperature:	
                                                                             Hu\
Jtnpinger H20
Volume after sampling   2.52 ml
impinger prefilled with.^6^ ml
Volume collected         4$ ml
                                 Container Mo.«,;$/4-     Ether-chloroform extraction
                                                      •  of impinger water	O
                                 Extra No.•
                                  25-= T 2-
                                                      Impinger water residue   /A
                                   jng
                                    mg
Itnpingers and back half of
  filter, acetone wash:
                                 Container Mo.5a
                                 Extra  No.       .      Weight  results
                                                                                       jmg
Dry probe and cyclone catch:      Container No._
                                 Extra  No.
                                                      Weight results
                                                                                        mg
Probe, cyclone, flask, and
  front half of filter,
                                 Container NoJS_C_
                                 Extra  Mo.
                                                      Vleight results
                                                                                        mg
           Filter Papers and Dry Filter Particulate
  Filter number   Container no.    Filter number  Container no.
                                                                 Filter particulate
                                                                   weight     ^ , 7
                                 Total particulate weight
                                                                                        nig
                                                                                        mg
Silica Gel
  Weight after test:
  Weight before test:
  Moisture weight collected:
  Container number:          1
                                    2.
                                            3.
4.
                                                                              . 3,
                                                                 Moisture total
                                                                                        gm
-Sample number:	
Method determination:"'
Comments:
                                             . Analyze for:
                                               49

-------
 Date:
                               PARTICIPATE CLEANUP SHEET
                                           Plant:
Run  number:
Operator: _
Semple box number:
           Location of sample  p
           Barometric  pressure:
           Ambient temperature:
                                                                    3£> .
•Imping er
Volume after  sampling   2-4-7- ml
Impinger  prefilled with £fa ml
Volume collected         "38ml
                                 Container No.6 n   Ether-chloroform extraction
                                                      • of impinger water	Q
Extra No.
                                                     Impinger water residue   /£>, 0
            Filter Papers and Dry Filter Particulate
  Filter number   Container no.    Filter number  Container no.
                                 Total particulate weight
                                                                             17,9
                                                      mg
Impingers and back half of
filter, acetone v/ash:
Dry probe and cyclone catch:
Probe, cyclone, flask, and
front half of filter,
ucetone wash:
Container Mo. [j$
Extra No. Weight results

Container No. 	
Extra No. 'Wei
-------
                                 SAMPLING  SUM.1 WRY SHEETS
PLANT
                                     LO CAT I ON
SAMPLED SOURCE_
 •
Train Data
"Run-
No.-
V:
£
o

L Date
5y?-7/
3-I1-7/
5-?b~ii

Nozzle
dia.
in.
,/JTo
,2v5~D
,/JTp

Net"
time
win.
Z^/l
;^v -
^-
Bar.
pres.
"Ho.
3 *, ££
30,0 p
3i>,^^

Orifice
diff.AH
"H?0
jJV
3,tf
l,1tl\

Volume sampled
meter cond.
CO. ft.
r /.s
X/.T)
72,1)

Moisture
std. cond.
cu. ft.
tj.ZI
1,3 

Molecular
wt. of moist.
stack gas
28.1?
2t.t>?
21, n

 itack Data
Run
No.
(
I
3
Stack
area
iV
/V
, *Lf
. oQ

Stack
press.
"Hg. Abs.
ja, ofy
_30rt>t/
3 0,Dtf

Stack
temp .
oF
ZZ 1
£ t/3
2 Vf

  ilocitv and Calculation-Data
  !un
 _Avera g e	
v/  Velocity x  temperature °R"
   Stack
velocity fpm
 .stack cond.
  Stack . ..-,.
gas volume
  scfm
 Percent
isokinetic
                                         34-23
             JL£^l3.
                                         3S */'
-------
                                 APPENDIX C
                             LABORATORY RESULTS

     Tables C - 1 and C - 2 present a summary of the particulate cleanup
and analysis data.  Table C - 3 presents the results of a metals analysis
conducted on the samples from runs no. 3 of the clinker cooler and finish
mill stacks.
                               TABLE C - 1
                   PARTICULATE RESULTS. CLINKER COOLER ^

impinger water
probe, cyclone
filter
Total particulates, mg

sample no.
wt. , mg
sample no.
wt., mg
sample no.
wt. , mg
run 1
(1 A)
14.5
(1 B)
11.8
0.0 x
26.3
run 2
(2 Aj
17.6
(2B)
19.4
1.1
38.1
run 3
(3 A)
9.1
(3 B)
13.4
0.8
23.3
Note:  v/ater blank: 1.4 mg/500 ml
       acetone blank: 1.1 mg/500 ml
                              TABLE C - 2
             PARTICULATE RESULTS, FINISH MILL GRINDING SYSTEH ^] ^
                                                run 1          run 2       run 3
impinger water            sample no.             (4 AJ          (5 A^)       (6A,)
                          wt., mg          .     10.9          10.9        10.8
probe, cyclone            sample no,             (4 B)          (5 B)       (6BJ .
                          wt., mg               19.2          20.2        14.1
filter                    sample no.             (4 C)          (5 c)       (,6C)
                          wt., mg	2.8	6.7	3.0
Total Particulates, mg                          32.9          37.8         27.9

* Several particles of silica gel found in impinger water; removed before analysis
Note:  water blank: 1.4"mg7500ml
       acetone blank: 1.1 mg/500 ml

(1)  Blank values have been substracted from sample results.
                                       52

-------
                                   TABLE C - 3

                           RESULTS OF METALS ANALYSIS
(a)
Sample: run number
3, clinker cooler
Types of Analyses - S

Analysis
wS?.m{5le No.
wt . , mg
Element
Hg
Be
Cd
As
V
Mn
N1
Sb
Cr
Zn
Cu
Pb
Se

SSMS
3A+3B
22.5
0.01
<0.005
2.
0.3
0.3
5.
100.
0.1
40.
20.
15.
20.
2.

OES
3A-8-3B
22.5
<0.03
<0.02
<2.
<2.
1.
10.
2*00.
<1.
80.
 (c)
3.
<0.1
7.
<500.
30.
(c)
(c)
(c)
(c)
(c)


OES
3C
0.8
(c)
(b)
<15
< 2
10
<600
<60
(c)
(c)
(c)
(c)
(c)

(a)   All results given in total micrograms per sample.

(b)   Not detectable by OES.

(c)   Useful determination is  precluded by high contribution from blank.

 *   Glass filters - values  given are impurity levels above glass background.

 Comments - (1)   Estimates of precision are ±25% and ±100% for  SSMS.

            (2)   Where discrepancies in results occur between OES and  SSMS,  take
                 the average  as being most correct.  If greater accuracy is
                 demanded, the concentrations can be determined by AA9  other
                 classical chemical  techniques and/or bettez standardization of
                 the OES and  SSMS.

            (3)   High in the  SSMS column is given where concentrations  ere
                 found generally greater than 500 ppm.   The latitude of the
                 photographic emulsion prevents obtaining detections to 0,1  pptn
                 and up to 500 ppm.   This would not  be  a proiblerr. with  electrical
                 detection,
                                         •33

-------
                                 TABLE C - 4

                              RESULTS OF METALS ANALYSIS^
Sample; run number
3, finish mill air separator
Types of Analyses - Spark Source Mass Spectrograph (SSMS)
Optical Emission Spectrography (QES)
'Analysis
Sample No.
wt. ,mg
Element
Hg
Be
Cd
As
V
Mn
Ni
Sb
Ir
Zn
Cu
Pb
Se
SSMS
6A+6B
24.9
0.02
<0.02
2.
1.
1.
4.
300o
0.3
20*
10.
10.
4.
1.
OES
6A-5-6B
24.9
<0.02
<0.02
<2.
<2.
2,
6.
400.
<1.
40.
<10.
10.
6.
(b)
SSMS
6C
3.0
0,04
<0.005
<0.4
<0.4
<5.
<5.
<15.
0.03
10.
<4.
<0.5
28
<0.3
OES
6C
3.0
<0.6
<60.
<30.
<30.
<6.
<6.
<15,
<30.
<30.
<3,
<15.
(b)
Analysis
Sample Mo.
wt.smg
Element
B
F
Li
Ag
Sn
Fe
Sr
Na
K
Ca
Si
Mg

SSMS
24.9'
40.
0.1
2.
60.
200.
10.
High
High
High
High
High

OES
. 6A*6B
3.0
40.
(b)
<3.
2.
40.
400.
16.
10,000.
10,000.
50,000.
1,500.
100.

SSMS
6C
3.0
(c)
(c)
3.
<0.4
20.
<500.
50,
(c)
(c)
(c)
(c)
(0

OES
6C
3.0
(c)
(b)
<15.
<2.
<20
<600.
< 60.
(c)
(c)
(c)
(c)
(c)

     All results given In total microgratns per sample.
(b)   Not detectable by OES.

(c)   Useful determination is precluded by high contribution from blank.
 &   Glass filters - values  given are impurity levels above glass background.

 Comments - (1)   Estimates of precision are ±25% ano ir-1007, for SSMS.
            (2)   Where discrepancies in results occur betwean OES and SSMS, take
                 the average as being most correct.   If grettcr accuracy is
                 demanded, the concentrations can be determined by kA,  other
           ..      classical chemical techniques and/or better standardization of
                 the OES and SSMS.

          -  (3)   High in the" SSMS column, is given where concentrations  are
                 found generally greater than f>00 ppr.-..  The latitude  of the
                 photographic emulsion prevents obtaining dite'ctions  to 0.1 ppm
                 and up to 500 ppm.  This  would not  be a problem with electrical
                 'detection.

-------
                                  APPENDIX  D
                                   Test  Log
Table D • 1 presents the actual time during which  sampling was  conducted.

                                 Table D - 1

                                Sampling Log
(Clinker Cooler)
Ru£
1

2

3


Run
1

2

3

Date
5-18-71

5-18-71

5-18=71


Date
5-19-71

5-19-71

5-20-71

Sampling Port
A
B
A
B
A
B
(Finish Mill
Sampling Port
A
B
A
B
A
B
Began
•08-. 25
09:34
11:10
12:18
14:24
15:35
Grinding System)
Began
10:41
11:54
14:58
16:13
09:17
10:30
Ended
09:31
10:40
12:16
13:24
15:30
16:41

Ended
11:53
13:06
16:10
17:25
10:29
11:42
Elapsed Time (mi n )
66
66
66
66
66
66

Elapsed Time(min)
72
72
72
72
72
72
                                  APPENDIX  E
                       PROJECT PARTICIPANTS AND  TITLES
 Name
 Joe Bazes
 Howard Crist
 Frederick Maerker
 Clyde Riley
 Gene Smith
 Philip York
     Title.
Chemical Engineer, ETB
Analytical Chemist, ETB
Chemical Engir.':^ , F.T3
Technicians ETB
Chemical r.;:gineir, Evu
Chemical u ^•k^y-, j.';2

-------