72-MM-I6
(REPORT NUMBER)
AIR POLLUTION EMISSION TEST
DELTA AND PINE LAND COMPANY
SCOTT, MISSISSIPPI
(PLANT ADDRESS)
U. S. ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Water Programs
Office of Air Quality Planning and Standards
Emission Standards and Engineering Division
Emission Measurement Branch
Research Triangle Park, N. C. 27711
-------
PARTICIPATE EMISSION MEASUREMENTS
FROM COTTON GINS
Plant Tested
Delta and Pine Land Company
Scott, Mississippi
November 1974
EMB Project Report No. 72-MM-16
Prepared for
Environmental Protection Agency
Office of Air Quality Planning and Standards
Emission Measurement Branch
Research Triangle Park
North Carolina 27711
by •
W. R. Feairheller
D. L. Harris
M. T, Thalman
MONSANTO RESEARCH CORPORATION
DAYTON LABORATORY
1515 Nicholas Road
Dayton, Ohio 45407
Report Reviewed by John W. Snyder
Contract No. 68-02-0226, Task No. 6
-------
TABLE OF CONTENTS •;
PAGE
I. INTRODUCTION 1
II. SUMMARY AND DISCUSSION OP RESULTS 6
III. PROCESS DESCRIPTION AND OPERATION 23
IV. SAMPLING AND ANALYTICAL PROCEDURES, 30
A. LOCATION OF SAMPLING POINTS 30
B. SAMPLING PROCEDURES 37
C. ANALYTICAL PROCEDURES 38
-------
LIST OF TABLES
No.. . Page
1, Summary of Sample Point Numbers, Control
Devices, and Emission Source 4
2. Summary of Emission Measurements Made at the
Delta and Pine Land Company, Scott, Mississ-ippi 11
3. Summary of Velocity and Estimated Emissions of
Un'gampled Stacks at Delta and Pine Land Company,
•Scott, Mississippi 12
4. Total Calculated Emissions for Sampled
Operational Systems 14
5. Analysis of Seed Cotton and Trash 16
6. Summary of Results - Outlet of the Heater
No. 1, Tower Dryer, Inclined Cleaner -
Point No. 1C 17
7. Summary of Results - Outlet of the Unloading
Separator - Point No. 8 18
8. Summary of Results - Outlet of the Lint
Cleaner, Lint Cleaner Condenser, Gin Stand
No. 3 - Point No. 12 19
9. Summary of Results - Outlet of the Lint
Cleaner, Lint Cleaner Condenser, Gin Stand
No. 2 - Point No. 12 20
10. Summary of Results - Outlet of the Lint
Cleaner, Lint Cleaner Condenser, Gin Stand
No. 1 - Point No. 13 21
11. Summary of Results - Outlet of the Battery
Condenser - Point No. 14 22
12. Dimensions at Cyclone Sites 34
ii
-------
LIST OF FIGURE
No. Page
1. Schematic Diagram of Cotton Gin Control
Devices 3
2. Plant Plow Diagram . 24
3. Location of Emission Control Devices 25
4. Schematic Diagram of the In-line Filters and
Sampling Ducts for Sites 11, 12, and 13 32
5. Schematic Deagram of the Battery Condenser,
In-line Filter, and Sampling Ducts - Site 14 33
6. Schematic Diagram of the Cyclone Units and
Sampling Ducts 35
7. Diagram of Straightening Vane . 36
iii
-------
SECTION I
INTRODUCTION
The test is part of the Cotton Ginning Industry Study, a
project of the Industrial Survey Section, Industrial Studies
Branch, Emission Standards and Engineering Division, Office
of Air Quality Planning and Standards, Environmental Pro-
tection Agency. The field test work was directed by Joseph
Bazes and John Snyder of the Field Testing Section, Emis-
sion Measurement Branch. The sampling was performed by
Monsanto Research Corporation (MRC). The Cotton Ginning
Industry Study is being conducted by William 0. Herring,
Industrial Survey Section.
Under the Clean Air Act of 1970, the Environmental Protec-
tion Agency is given the responsibility of establishing
performance standards for new installations or modifications
to existing installations in stationary source categories.
As a contractor, Monsanto Research Corporation, under the
Environmental Protection Agency's "Field Sampling of Atmos-
pheric Emissions" Program, was asked to provide emission
data from the Delta and Pine Land Company, Scott, Mississippi,
The cotton gin selected and studied was equipped with the
best types of pollution control equipment currently available.
This report tabulates the data collected at the Delta and
Pine Land Company during the periods from October 25 to
October 27, 1972, and from November 6 to November 17, 1972.
In this cotton gin, vacuum is used to remove the field picked
cotton from the cotton wagons and then the material inside
-------
the gin is moved from one operation to the next by a moving
air system. Air moves the material to the ginning machines
for removal of dirt, plant material, the cotton seeds, and
fine lint, and finally to the battery condenser and the
press or baling machine. The air from the unloader, feeder,
dryer, and lint cleaners is exhausted from the building into
a group of twenty-six cyclones, while the air from the lint
cleaner condenser and battery condenser is exhausted through
rotary screen in-line filters. The trash, including plant
debris and dirt, is .directed to two cyclones mounted on a
tepee burner. A schematic diagram of the control devices
with respect to the building and indicating which of the
devices were sampled is shown in Figure 1. The description
of the device and the designation of the sample point num-
bers and source of emissions are given in Table 1.
The major emphasis of the study was to obtain accurate data
on the particulate emissions. Outlets to the atmosphere
were measured for particulate concentrations using Method 5,
"Determination of Particulate Emissions from Stationary
Sources." Other procedures that were required during the
study included Method 1, "Sample and Velocity Traverses for
Stationary Sources;" Method 2, "Determination of Stack Gas
Velocity and Volumetric Flow Rate (Type S Pitot Tube);"
Method 3, "Gas Analysis for Carbon Dioxide, Excess Air and
Dry Molecular Weight;" and Method 4, "Determination of Mois-
ture in Stack Gases."
Samples of unprocessed seed cotton and trash were obtained
from three different locations within the cotton process-
ing system. The samples were analyzed at the EPA Pesticides
Monitoring Laboratory in Bay St. Louis, Mississippi, for
pesticide content. High concentrations of both p,p''-rDDT
(up to 59 ppm) and Toxaphene (up to 135 ppm) were found.
-------
1 1
Tepee Burner
A A 13 A 7
r- -1 A| 1_ A.—
I I n n n
L J 14 M LJ
42" IB
In-line
Filter Size 11,12
14
Cyclone Size 1,
5,6,7
2,3
2 * 11
-, A. ,
n n n
U U LJ
^4'uJI
,13 30"
42"
32"
,8,9,10 34"
36"
IT
9l(S/
19" 8B©©8C
8A©©8 ^*
15"
7A©@ 7
19" 6B(S)(o)6C
19" 5B©@5C
5A©@ 5
24" 4B©@4C
4A@© 4
13" 3A(5)©3
15" 2A(o)(S)2
19" 1B© © 1C
1A<£) © 1 ~~*
Figure 1. SCHEMATIC DIAGRAM OP COTTON GIN CONTROL DEVICES
ARROW HEADS INDICATE SAMPLED DEVICES
-------
Table 1. SUMMARY OF SAMPLE POINT NUMBERS,
CONTROL DEVICES, AND EMISSION SOURCE
Sample
Point
No.
1
2
3
4
5
6
1
8
9, 10
s
Control Device
Cyclone (4)
Cyclone (2)
Cyclone (2)
Cyclone (4.)
Cyclone (4)
Cyclone (4)
Cyclones (2)
Cyclones (4)
Cyclone (1 ea)
Size of
Device
(in.)
32
36
36
32
34
. 34
34
34
34
Source of Emissions
t
Heater No. 1, Tower
Dryer, Inclined Cleaner
Overflow Separator
Extractor Feeder
Inclined Cleaner
Condenser, Unit-Saw,
Lint Cleaner
Condenser, Unit-Saw,
Lint Cleaner
Trash Line from Filters
Unloading Separator
Trash Lines from All
11 Filter (1)
12 Filter (1)
13 Filter (1)
30
30
30
Cyclones, Dryer Cleaner
Gin Stand No. 3, Lint
Cleaner, Lint Cleaner
Condenser
Gin Stand No. 2, Lint
Cleaner, Lint Cleaner
Condenser
Gin Stand No. 1, Lint
Cleaner, Lint Cleaner
Condenser
14
Filter (1)
30
Battery Condenser
-------
Extensive modifications were required o'n the control devices
at the cotton gin prior to sampling. All twenty-six cyclones
were prepared for sampling by replacing the rain cap with a
duct of the same diameter as the cyclone outlets. The duct,
resembling a candy cane, consisted of a large radius 180°
bend, a straightening vane, and a long length of straight
pipe. With this device, the flow was directed downward to-
ward the ground. The straightening vane reduced or elimi-
nated the cyclonic flow pattern, and the long length of
duct provided relatively stable flow at the sampling points.
The in-line filters controlling emissions from the three
gin stands and the battery condenser were modified by re-
placing the rain shields with a 90° bend and a sufficient
length of pipe to meet required sampling criteria. As the
air flow from the filters is directed out of both sides of
the unit, both outlets were provided with ducting. Details
of the modifications are given in Section IV.
The following sections of this report include the summaries
of data, conclusions, and process description. The appen-
dicies provide complete data summaries, field and analytical
data sheets, production data, and sampling logs.
-------
SECTION II
SUMMARY AND DISCUSSION OP RESULTS
The emission control devices at the "Green Gin" of the
Delta and Pine Land Company consist of twenty-eight small
diameter cyclones and four in-line filters. Twenty-six of
the cyclones are arranged in two rows and are grouped in
two to four units for each of the eight ducts from the
plant. Two cyclones are located on the trash incinerator
(a tepee burner) to separate the bulk trash from fine par-
ticulate. Each in-line filter has two inlet ducts. The
filter, consisting of a rotating screen, removes large par-
ticulate from the air stream which is then emitted from
both sides of the unit into the atmosphere.
A summary of the emission sources and the control devices
by site designation is given in Table 1. A diagram show-
ing the physical layout of the devices in relation to the
gin building was shown in Figure 1.
The sampling program at this gin was planned to include all
of the listed control devices. The large number of emission
points, wet weather, the fact that the subcontractor hired
to install ducts did not finish on time, and the necessity
of sampling at another gin during this year's ginning sea-
son required that a number of points be deleted from the
plan. The wet weather contributed delays in several ways.
When the fields were very wet, cotton could not be picked
-------
by the mechanical pickers. During this time, only the dry
areas were picked. In general, if cotton was available for
ginning during the rain periods, the emissions were sampled.
Referring to Figure 1 and Table 1, emission data were col-
lected at points 1, 8, 11, 12, 13, and 14. These points
represent all of the low pressure system and the first two
stages of the high pressure system of the plant. These
systems and the operational scheme of the plant will be ex-
plained in more detail in Section III of this report.
The "Green Gin" is representative of modern cotton ginning
plants and is quite well controlled by the present concepts.
The plant was constructed in 1966 and employs established
ginning and control equipment. At the normal production
rate of 20 bales per hour, there is considerable evidence
of emission from all outlets. In addition, during ginning,
the tepee burner operates to burn trash, including material
from the bottom of all cyclones and plant debris. The
smoke from the tepee burner has a yellowish white color and
has a quite acrid, very characteristic odor.
Considerable additional duct work was required at the gin
before sampling could begin. Delta Sheet Metal of Green-
ville, Mississippi, was hired as a subcontractor to provide
the needed modifications.
The in-line filters have two outlets venting directly from
the sides of the filter into the outside air. Each outlet
is covered with a rain cap. These rain shields were re-
moved and replaced with a 90° bend and a long straight run
of duct work. Identical units were installed on each side
of the filter. The ducts were of 30 inch I.D. on the small
filters at sites 11, 12, and 13 and 42 inch I.D. on the
battery condenser filter, site 14., In general, a minimum
7
-------
duct length of three diameters upstream and one diameter
downstream from the sampling points were available on all
of these units. In each case, one side of the unit was sam-
pled for particulate loading, and the other side was tra-
versed for velocity and temperature data.
The exhaust from the other systems (unloading separator,
inclined cleaner, extractor feeders, gin stands, and trash
lines) were directed to cyclones, which were grouped in
banks of 2 or 4 from each inlet line. The cyclones were
capped with a rain shield, adjusted by the gin builder to
yield a back pressure that would provide good separation
efficiency. Such a system, however, is not suitable for
testing from two points of view. First, no suitable loca-
tion is available in the exhaust from the cyclone, due to
the short length of outlet pipe, and second, the flow from
these devices is cyclonic and thus, would require a device
to eliminate the spiral flow pattern. The sampling modifi-
cations for these devices were required to provide a sam-
pling location consistent with good sampling practice and
also include straightening varies.
The approach considered and finally adopted was to remove
the rain cap and replace it with a large radius 180° bend,
a straightening vane, and a long straight length of pipe.
The duct additions resembled a large "candy cane." Each
cyclone in a bank was provided with the same type of device
so that changes in back pressure would not change the pro-
portion of air to each cyclone in the bank.
Some preliminary tests were conducted at the gin to deter-
mine the effect of the duct modification on cyclone opera-
tion. A sample port for static pressure measurements
was cut in the inlet of cyclone site number 8. The test
data given below indicates that while there is a different
8
-------
pressure with the bend and straightening vane than in nor-
mal operation, the pressure difference is less than the
normal variation in static pressure.
Condition Date Inlet Pressure In.
Normal
Duct Work in Place
Simulated Vane
Normal
Duct/Straightening Vane
9/27/72
9/27/72
9/27/72
9/28/72
9/28/72
1.55
1.45
1.20
1.55
0.0,
.75, 1.40, 1.20
The readings taken with the duct in place on September 28,
1972, over a 1.5 hour period, showed considerable variation.
These variations typically exceeded 0.2 inches of water and,
at the extreme, ranged from 0.0 to 1.6 inches of water.
As the tests were not conclusive, calculations were made of
the expected pressure drop due to the added duct work. Con-
sidering a 17 inch duct, the 180° bend would be equal to 43
feet of straight duct. (Industrial Ventilation Manual,
Section 6, Figures 6-10, 1955) Based on data from the Air
Conditioning Handbook, 100 feet of 17 inch duct causes a
pressure equal to about 0.25 inches of water. Thus, the
elbow and length of duct is equivalent to 43 feet (180°
elbow) plus 12 feet (straight duct). The total length of
55 feet should show a back pressure of 0.14 inches of water.
The value is very close to the 0.15 inches of water differ-
ence in pressure obtained at another cotton gin with and
without the complete "candy cane" (Test Report 72-MM-23).
As a result of these tests, we believe that while there is
a difference in pressure caused by the additional duct work,
it is not sufficient to cause a serious deviation in the
test results.
-------
A summary of the emission data on all sampled outlets is
given in Table 2. Three isokinetic (90-1105?). sampling runs
were conducted at each site. Each run was verified in the
field for isokinetic conditions before acceptance. Samples
were collected from sites 1, 8, 11, 12, 13, and 14A, for a
total of eighteen runs.
At each site, any unsampled outlets were traversed for ve-
locity and temperature data during the sampling of the out-
lets given in Table 2. The summary of the data on unsam-
pled ducts is given in Table 3- During sampling run 1 on
site 1, outlets 1A, IB, and 1C were traversed. Thus, the
data in Table 3 labeled 1A-1, 1B-1,. 1C-1 were collected
during sampling of duct 1-1, 1A-2, IB-2, 1C-2 during 1-2,
etc. After completion of the analytical results, the emis-
sion rate in grains per DSCF was calculated for each sam-
pled run. This value was then assumed to be the emission
rate in all ducts of the same bank. The Ib/hour data was
then calculated from the grains/DSCP and the calculated
air flow rate at each individual outlet. The pounds of
emission per ton of cotton produced was calculated from
the pounds/hour figure.
Table 4 summarizes the data for each group of outlet con-
trol devices with a single outlet. This data, based on
front-half loading (from the probe tip to filter, and not
the contents of the impinger section), provides the com-
bined total emission rate in Ibs/hr (Kg/M ton) and the
emission factors in Ib/ton (Kg/M ton) for all outlets in
a bank.
In general, the emission rate and emission factors for the
cyclones are about half of the corresponding figures for
the in-line filters. However, point 11, the filter con-
trolling emissions from the third gin stand and associated
10
-------
Table 2.. SUMMARY OF EMISSION MEASUREMENTS MADE AT DELTA AND PINE LAND COMPANY, SCOTT, MISSISSIPPI
Date
1972
10/25
10/25
11/6
11/6
11/7
11/8
11/8
11/10
11/10
h-1
I—1 11/10
11/10
'11/10
11/10
11/10
11/17
11/17
11/17
11/17
11/17
Test
No.
1C1
1C2
1C 4
8-1
14A2
8-4
14A4
8-5
14A5
13-1
12-1
13-2
12-2
11-1
12-3
13-3
11-2
11-3
Teat Site
Cyclone - Heate No. 1,
Inclined Cleane
Cyclone - Heate No. 1,
Inclined Cleane
Cyclone - Heate No. 1,
Inclined Cleane
Cyclone - Unloading
Separator
Filter - Battery
Condenser
Cyclone - Unloading
Separator
Filter - Battery
Condenser
Cyclone - Unloading
Separator
Filter - Battery
Condenser
Filter - Gin Stand 1,
Lint Cleaner
Filter - Gin Stand 2,
Lint Cleaner
Filter - Gin Stand 1,
Lint Cleaner
Filter - Gin Stand 2,
Lint Cleaner
Filter - Gin Stand 3,
Lint Cleaner
Filter - Gin Stand 2,
Lint Cleaner
Filter - Oln Stand : ,
Lint Cleaner
Filter - Gin Stand 3,
Lint Cleaner
Filter - Gin Stand 3,
Average
Ft/Sec
1560
1680
1550
1670
1520
1800
1470
1800
1450
1580
1470
1560
1370
1570
1410
1220
1570
1550
Velocity
(m/Sec)
(475)
(512)
(472)
(509)
(463)
(549)
(448)
(549)
(442)
(482)
(448)
(475)
(418)
(479)
(130)
(372)
(479)
(172)
Average Stack
Temperature
0 F
130
134
119
77
83
76
76
66
79
74
68
70
59
69
•63
61
67
61
0
(51
(56
(48
(25
(28
(24
(21
(18
(26
(23
(20
(21
(15
(20
(17
(17
(19
(17
C
.1)
.7)
.3)
.0)
.3)
.1)
.1)
.9)
.1)
.3)
.0)
.1)
.0)
.6)
.2)
.8)
.4)
.8)
Emission Rate
(Front )
Lba/Hr
0.682
0.340
0.666
0:459
2.30
0.481
2.05
0.694
2.67
3.24
2.77
5.56
4.37
1.30
1.59
2.03
1.74
1.58
(Kg/Hr)
(0.309)
(0.154)
(0.302)
(0.208)
(1.04)
(0.218)
(0.930)
(0.315)
(1.21)
(1.47)
(1.26)
(2.52)
(1.98)
(0.590)
(0.721)
(0.921)
(0.789)
(0.717)
Emission Rate
(Total)
Lbs/Hr
2.32
0.616
0.920
1.55
3.19
0.556
. 2.53
0.852
3.01
1.10
3.15
6.22
5.09
1.56 •
2.21
- 2.50
2.05
2.20
(1.05)
(0.279)
(0.117)
(0.703)
(1.58)
(0.252)
(1.15)
(0.386)
(1.37)
(1.86)
(1.13)
(2.82)
(2.31)
(0.708)
(1.00)
(1.13)
(0.930)
(0.998)
Emission Factor
(Front)
Lb/Ton
0.115
0.0685
0.127
0.109
0.701
0.186
0.487
0.158
0.562
0.684
0.546
1.05
0.812
0.304
0.371
. 0.474
0^363
0.363
(Kg/M Ton)
(0.0725)
(0.0342)
(0.0547)
(0.0546)
(0.349)
(0.0932)
(0.243)
(0.0793)
(0.281)
(0.342)
(0.274)
(0.522)
(0.406)
(0.152)
(0.186)
(0.325)
(0.181)
(0.181)
Emission Factor^
(Total)
Lb/Ton
0.494
0.124
0.176
0.369
1.06
0.216
0.601
0.195
0.634
0.865
0.621
1.17
0.946
0.364
0.516
0.581
0.127
0.506
(Kfly
(0
(0
(0
(0
(0
(0
(0
(0
(0
(0
(0
(0
(0.
(0.
(0.
(0.
(0.
(0.
'M Ton)
246)
0620)
0755)
185)
530)
108)
301)
0972)
318)
433)
311)
584)
473)
182)
258)
399)
214)
253)
t H20
1.76
1.80
5.37
2.58
1.25
1.32
1.20
1.30
1.23
3.21
0.02
3.31
0.00
0.55
1.11
1.03
1.42
0.00
Lint Cleaner
-------
Table 3. SUMMARY OP VELOCITY AND ESTIMATED EMISSIONS OP UNSAMPLED STACKS AT DELTA AND PINE LAND COMPANY, SCOTT, MISSISSIPPI
Site
Test
No*
1-1
1A-1
1B-1
1-2
1A-2
1B-2
1-1
1A-4
IB- 4
8A-1
8B-1
8C-1
SA-4
8B-4
80-1
8A-5
8B--5
8C-5
Sampled
Site No*
1C-1
1C-1
10-1
1C-2
1C-2
1C- 2
1C-4
1C-4
1C-4
8-1
8-1
8-1
8-4
8-4
8-4
8-5
8-5
8-5-
Test Sits
Cyclone - Heater No. 1,
Inclined Cleaner
Cyclone - Heater No, 1,
Inclined Cleaner
Cyclone - Heater No. 1,
Inclined Cleaner
Cyclone - Heater No. 1,
Inclined Cleaner
Cyclone - Heater No. 1,
Inclined Cleaner
Cyclone - Heater No. 1,
Inclined Cleaner
Cyclone - Heater No. 1,
Inclined Cleaner
Cyclone - Heater No. 1,
Inclined Cleaner
Cyclone - Heater No. 1,
Inclined Cleaner
Cyclone - Unloading
Separator
Cyclone - Unloading
Separator
Cyclone - Unloading
Separator
Cyclone - Unloading
Separator
Cyclone - Unloading
Separator
Cyclone - Unloading
Separator
Cyclone - Unloading
Separator
Cyclone - Unloading
Separator
Cyclone - Unloading
Separator
Average Stack
Temperature
129
123
127
129
126
126
142
139
141
82.0
81.0
78.0
83.0
83.0
81.0
85.0
81.0
73-0
(53-9)
(50. 6}
(52.8)
(53-9)
(52.2)
(52.2)
(61.1)
(59.4)
(60.6)
(27.8)
(27.2)
(25-6)
(28.3)
(28.3)
(27.2)
(29.4)
(27-2)
(22.8)
Average Stack
Gas Velocity
Pt/Min i"™ /IUM i-^
1470
1370
1350
1570
1380
1380
1420
1280
1230
1230
1540
1400
1380
966
1750
1220
1260
1470
(448)
(418)
(.411)
(479)
(421)
(421)
(433)
(390)
(375)
(375)
(469)
(427)
.(121)
(294)
(533)
(372)
(384)
(448)
Stack Plow Rate
1850
1740
1700
1970
1740
1740
1670
1520
1450
1870
2310
2146
2140
1500
2720
i860
1940
• 2300
(0.873)
(0.821)
(0.802)
(0.930)
(0.821)
(0.821)
(0.788)
(0.717)
(0.684)
(0.883)
(1.10)
(1.01)
{•1.01)
(0.708)
(1.28)
(0.878)
(0.916)
(1.09)
Particulate Emission
(Sampled Site)
GR/DSCP '" '" T
0.0406
0.0406
0.0406
0.0190
0.0190
0.0190
0.0409
0.0409
0.0409
0.0209
0.0209
0.0209
0.0199
0.0199
0.0199
0.0287
0.0287
0.0287
{FiK/Nm* )
(92.9)
(92.9)
(92.9)
(43.5)
(43.5)
(43.5)
(93.6)
(93.6)
(93.6)
(47.8)
(47.8)
(47.8)
(45.5)
(45-5)
(45.5)
(65.7)
(65.7)
(65.7)
Estimated
Emission Rate
Lb/Hr
0.644
0.605
0.592
0.321
0.283
0.283
0.585
0.533
0.508
0.335
0.419
0 . 383
0.365
0.256
0.464
0.457
0.477
0.566
(0.292)
(0.274)
(0.269)
(0.146)
(0.128)
(0.128)
(0.265)
(0.242)
(0.230)
(0.152)
(0.190)
(0.1Y4)
(0.166)
(0.116)
(0.210)
(0.207)
(0.216)
(0.257)
Emission Factor
Lb/Ton
0.137
0.129
0.126
0.0647
0.0571
0.0571
0.112
0.102
0.0969
0.0798
0.0998
0.0912
0.141
0.0992
0.180
0.104
0.109
0.129
(Kg/ n Ton)
(0.0685)
(0.0643)
(0.0631)
(0.0324)
(0.0284)
(0.0284)
(0.0480)
(0.0438)
(0.0417)
(0.0399)
(0.0499)
(0.0457)
(0.0709)
(0.0496)
(0.0897)
(0.0521)
(0.0544)
(0.0647)
-------
Table 3. (.Continued)
Site
Test
No.
11A-1
11A-2
11A-3
12A-1
12A-2
12A-3
13A-1
13A-2
13A-3
11-2
11-1
11-5
Note:
Sampled
Site No.
11-1
11-2
11-3
12-1
12-2
12-3
13-1
13-2
13-3
11A-2
11A-1
11A-5
Test Site
Filter - Gin Stand 3,
Lint Cleaner
Filter - Oin Stnad 3,
Lint Cleaner
Filter - Gin Stand 3,
Lint Cleaner
Filter - Gin Stand 2,
Lint Cleaner
Filter - Gin Stand 2,
Lint Cleaner
Filter - Gin Stand 2,
Lint Cleaner
Filter - Gin Stand 1,
Lint Cleaner
Filter - Gin Stand 1,
Lint Cleaner
Filter - Gin Stand 1,
Lint Cleaner
Filter - Battery
Condenser
Filter - Battery
Condenser
Filter - Battery
Condenser
The particulate emissions, particulE
Average Stack
Temperature
0 F (° C)
68.0 (20.0)
65.0 (18.3)
65.0 (18.3)
77.0 (25.0)
75.0 (23.9)
65.0 (18.3)
71.0 (23.3)
70.0 (21.1)
65.0 (18.3)
79.0 (26.1)
78.0 (25.6)
80.0 (26.7)
ite emissions rate,
Average stack
Gas Velocity
Ft/Mln (m/Mln)
1130 (136)
1530
1190
1310
1100
1310
1290
1210
1100
1130
1110
1390
and emiss
(166)
(151)
(399)
(335)
(399)
(393)
(369)
(335)
(136)
(139)
(121)
lion factors
Stack Flow Rate
DSCFM (
7130
7590
7510
6130
5130
6510
6150
5810
5190
13600
13600
13100
are based
NmVSec)
(3.37)
(3.58)
(3.5D
(3.03X
(2,56)
(3.09)
(2.90)
(2.7D
(2.59)
(6.12)
(6.12)
(6.18)
Particulate Emission Estimated
(Sampled Site) Emission Rate
QR/DSCF
0.0195
0.0262
0.0235
0.0111
0.0731
0.0263
0.0502
0.0865
0.0389
0.0186
0.0171
0.0227
(11.6)
(60.0)
(53.8)
(101)
(167)
(60.2).
(115)
(198)
(89.0)
(12.6)
(39.1)
(51.9)
Lb/Hl
1.19
1.70
1.51
2.13
3.10
1.17
2.65
1.31
1.83
2.17
1.99
2.55
• (Kg/Hr)
(0.510)
(0.771)
(0.685)
(1.10)
(1.51).
(0.667)
(1.20)
(1.95)
(0.830)
(0.981)
(0.903)
(1.16)
Emission Factor
Lb/Ton
0.278
0.351
0.317
0.179
0.632
0.313
0.559
0.810
0.128
0.662
0.607
0.777
(Kg/ M Ton)
(0.139)
(0.177)
(0.173)
(0.239)
(0.316V
(0.172)
(0.279)
.(0.101)
(0.211)
(0.330)
(0.303)
(0.389)
on "front-half" loading only .
-------
Table 4. TOTAL CALCULATED EMISSIONS FOR SAMPLED OPERATIONAL SYSTEMS
(Based on "Front-half" Particulate Loading)
Total Particulate
System
Heater No. 1, Tower
Dryer, Inclined Cleaner
Unloading Separator
Gin Stand No. 3, Lint
Cleaner, Lint Cleaner
Condenser
Gin Stand No. 2, Lint
Cleaner, Lint Cleaner
Condenser
Gin Stand No. 1, Lint
Cleaner, Lint Cleaner
Condenser
Battery . Condenser
Site
No.
1
1
1
8
8
8
11
11
11
12
12
12
13
13
13
14
14
14
Run
No.
1
2
4
1
4
5
1
2
3
1
2
3
1 '
2
3
2
4
5
Emissions
GR/DSCF
0.0406
0.0190
0.0409
0.0209
0.0199
0.0287
0.0195
0.0262
0.0235
0.0441
0.0731.
0.0263
0.0502
0.0865
0.038.9
0.0186
0.0171
0.0227
(Mg/Nir^)
(92.9)
(43.5)
(93.6)
(47.8)
(45.5)
(65.7)
(44.6)
(60.0)
(53.8)
(101)
(167)
(60.2)
(115)
(198)
(89.0)
(42.6)
(39.1)
(51.9)
Emission Rate
Lb/Hr
2.52
1.23
2.29
1.60
1,57
2.19
2.49
3.44
3.09
5.20
7.77
3.06
5.89
9.87
3-86
4.47
4.04
5.22
(Kg/Hr)
(1.14)
(0.558)
(1.04)
(0.726)
(0.712)
(0.993)
(1.13)
(1.56)
(1.40)
(2.36)
(3.52)
(1.39)
(2.67)
(4.48)
(1.75)
(2.03)
(1.83)
(2.37)
Emission Factors
Lb/Ton
0.537
0.247
0.438
0.380
0.606
0.500
0.582
0.717
0.710
1.03
1.44
0.714
1.24
1.86
0.902
1.36
1.09
1.34
(Kg/M Ton)
(0.269)
(0.124)
(0.219)
(0.190)
(0.303)
(0.250)
(0.291)
(0.359)
(0.355)
(0.515)
(0.720)
(0.357)
(0.620)
(0.930)
(0.451)
(0.680)
(0.545)
(0.670)
-------
lint cleaner and lint cleaning condenser has lower emissions
than the other filters on similar systems. It is possible
that this gin stand was not in use as much as the other two
gin stands, but we cannot be certain of this with the avail-
able information.
Based on average results of the six systems that were tested
at this plant, the emissions are estimated to be about 5.2
pounds of particulate per ton of cotton produced. If all
possible emission points except the smoke from the tepee
burner were considered, the value could be easily double
this figure or about 10 pounds of particulate per ton of
cotton produced.
Samples of seed cotton and trash from the cotton gin were
submitted for analysis to Dr. Han Tai at the EPA Pesticides
Monitoring Laboratory in Bay St. Louis, Mississippi. The
results of these analyses are shown in Table 5-
Complete data for the tests conducted at each site is given
in Tables 6 through 11.
15
-------
Table 5- ANALYSIS OF SEED COTTON AND TRASH
Test No. 72-MM-16
Seed Cotton (Unprocessed)
Trash
Source
Sample No.*
p,p'-DDT(ppm)
o,p-DDT(ppm)
p,p'-TDE(ppm)
p,p'-DDE(ppm)
Toxaphene (ppm)
DEF(ppm)
Methyl
Raw
Material
653
3.97
0.47
0.27
0.56
9.10
0.05
N.D.
Raw
Material
654
2.40
0.37
N.D.**
0.28
6.8
N.D.
N.D.
Raw
Material
655
7.82
0.70
N.D.
0.16
4.12
0.17
N.D.
Greenleaf and
Stock Extractor
656
10.1
1.0
0.21
0.45
25.9
0.17
0.17
Gin Stand
Mote Chamber
657
17.2
2.0
0.78
r.o
27-9
0.17
0.06
Gravity
Cleaner
658
53.0
5.94
2.60
3-91
136.0
0.07
0.10
*A11 sample numbers contained the prefix 72-004. The complete numbers were 72-004-653 to
72-004-658.
**N.D. - not detected. Minimum detection limit: p,p'-DDT; o,p-DDT; p,p'-TDE; and p,p'-DDE is
0.01 ppm., Toxaphene 0.1 ppm, DEF and Methyl Parathion 0.05 ppm.
-------
Table 6. SUMMARY OP RESULTS
OUTLET OP THE HEATER NO. 1 TOWER DRYER, INCLINED CLEANER - POINT NO,
1C
Run Number:
Date:
Method Type:
Volume of gas sampled-DSCFl-(Nm3)'*
Percent Moisture by Volume
Average Stack Temperature-°F-(°C)
Stack Volumetric Plow Rate-DSCPM2-(Nm3/sec)
Stack Volumetric Flow Rate-ACFM3-(m3/sec)
Percent Isokinetlc
Product Rate-ton lint cotton/hr-(M ton/hr)5
Duration of run - minutes
Partleulates - probe, cyclone
and filter catch
mg
grains/DSCF6-(mg/Nm3)
lb/hr-(Kg/hr)
Ib/ton of lint cotton produced
(kg/M ton of lint cotton produced)
Partleulates - total catch
mg
grains/DSCF6-(mg/Nm3)
lb/hr-(Kg/hr)
Ib/ton of lint cotton produced
(Kg/M ton of lint cotton produced)
percent implnger catch
1C1
.102
101
Average
10/25/72
71.8
0.0106 (92.9)
0.682 (0.309)
0.115 (0.0725)
225
0.138 (316)
2.32 (1.05)
0.491 (0.246)
10/25/72
11/6/72
28.1
130
I960
2180
1.70
EPA-5
(0.801)
1.76
(51.4)
(0.925)
(1.03)
101
(1.26)
60.0
30.0
131
2090
2310
1.96
EPA-5
(0.850)
1.80
(56.7)
(0.986)
(1.10)
102
(4.50)
60.0
28.2
119
1900
2160
5.24
EPA-5
(0.799)
5.37
(18.3)
(0.897)
(1.02)
107
(5.52)
60.0
28.9
128
1980
2230
1.97
(0.818)
2.98
(53.1)
(0.936)
(1.05)
104
(1.76)
60.0
37.1
0.0190 (43.5)
0.310 (0.151)
0.0685 (0.0342)
67.0
0.0344 (78.7)
0.616 (0.279)
0.124 (0.0620)
44.6
74.9
0.0409 (93.6)
0.666 (0.302)
0.127 (0.0547)
104
0.0565 (129)
0.920 (0.417)
0.176 (0.0755)
28.0
62.3
0.0335 (76.7)
0.563 (0.255)
0.114 (0.0538)
132
0.0763 (175)
1.29 (0.582)
0.265 (0.128)
46.5
TDrY~Standard Cubic Feet § 70°F, 29.92 in Hg
2Dry Standard Cubic Feet per Minute % 70°F, 29-92 in Hg
3Actual Cubic Feed per Minute - Stack Conditions
'•Normal Cubic Meters at 21.1°C, 760 mm Hg
5Metrlc Tons per Hour (1 metric ton = 1000 Kg)
6Grains per Dry Standard Cubic Feet
-------
Table 7. SUMMARY OP RESULTS
OUTLET OP THE UNLOADING SEPARATOR - POINT NO. 8
Run Number:
Date:
Method Type:
Volume of gas sampled-DSCF'-CNm3)1*
Percent Moisture by Volume
Average Stack Temperature-°F-(°C)
Stack Volumetric Flow Rate-DSCFM2-(Nm3/sec)
Stack Volumetric Flow Rate-ACFM3-(mVsec)
Percent Isoklnetic
Product Rate-ton lint cotton/hr-(M ton/hr)5
Duration of run - minutes
Particulates - probe, cyclone
and filter catch
mg
gralns/DSCF6-(mg/Nm3)
lb/hr-(Kg/hr)
Ib/tbn of lint cotton produced
(kg/M ton of lint cotton produced)
Partlculates - total catch
mg
grains/DSCF6-(mg/Nm3)
lb/hr-(Kg/hr)
Ib/ton of lint cotton produced
(Kg/M ton of lint cotton produced)
percent implnger catch
801
11/6-7/72
EPA-5
32
77
.1
.0
2560
2630
1.
0.
0.
0.
0.
1.
0.
20
0209
459
109
0707
55
369
(0.
2.58
(25
(1.
(1.
101
(3.
60,. 0
13.6
(17
(0.
(0.
147
909)
.0)
21)
21)
81)
.8)
208)
0546)
(162)
(0.
(0.
703)
185)
36
76
804
11/8/72
EPA-5
.4
.0
2820
2830
2.
0.
0.
0.
0.
0.
0.
58
0199
481
186
0230
556
216
(1.
1.32
(24
(1.
(1.
104
(2.
60.0
47.1
(45
(0.
(0.
54.3
(52
(0.
(0.
03)
.4)
33)
34)
34)
.5)
218)
0932)
.6)
252)
108)
37.5
66.0
2850
2840
4.38
805
11/10/72
EPA-5
(1.06)
1.30
(18.9)
(1.35)
(1.34)
106
(3.97)
60.0
Average
70.3
13.3
69.2
0.0284 (65.0)
0.694 (0.315)
0.158 (0.0793)
85.1
0.0349 (79.9)
0.852 (0.386)
0.195 (0.0972)
18.7
35.3
73.0
2740
2770
3.72
(1.00)
1.73
(22.8)
(1.30)
(1.3D
104
(3.37)
60.0
- 53.3
0.0231 (52.8-)
0.545 (0.247)
0.151 (0.0757)
95.5
0.0429 (98.2)
0.986 (0.447)
0.260 (0.130)
34.1
'Dry Standard Cubic Feet @ 70°F, 29-92 In Hg
2Dry Standard Cubic Feet per Minute % 70°F, 29.9? in Hg
3Actual Cubic Feed per Minute - Stack Conditions
••Normal Cubic Meters at 21.1°C, 760 mm Hg
5Metric Tons per Hour (1 metric ton = 1000 Kg)
6Grains per Dry Standard Cubic Feet
-------
Table 8. SUMMARY OP RESULTS
OUTLET OP'THE LINT CLEANER, LINT CLEANER CONDENSER, GIN STAND NO. 3 - POINT NO. 11
Run Number:
Date:
Method Type:
Volume of gas sampled-DSCF^CNm3)11
Percent Moisture by Volume
Average Stack Temperature-°F-(°C)
Stack Volumetric Plow Rate-DSCFM2-(Nm3/sec)
Stack Volumetric Flow Rate-ACFM3-(m3/sec)
Percent Isokinetlc
Product Rate-ton lint cotton/hr-(M ton/hr)5
Duration of run - minutes
Particulates - probe, cyclone
and filter catch
mg
grains/DSCF6-(mg/Nm3)
lb/hr-(Kg/hr)
Ib/tbn of lint cotton produced
(kg/M ton of lint cotton produced)
Partleulates - total catch
mg
gralns/DSCF6-(mg/Nm3)
lb/hr-(Kg/hr)
Ib/ton of lint cotton produced
(Kg/M ton of lint cotton produced)
percent impinger catch
1101
11/17/72
EPA-5
29. 8 (0.
0.55
69.0 (20
7800 (3.
7700 (3.
95.4
4.28 (3.
60.0
37.
0.0195
1.30
0.304
45.
0.0234
1.56
0.364
7
(44
(0.
(0.
844)
.6)
68)
63)
88)
.6)
590)
152)
3
(53.5)
(0.708)
(0.182)
1102
11/17/72
EPA-5
29.7
1.
67.0
7760
7700
96
4.80
60
0.
1.
0.
0.
2.
0.
50
0262
74
363
59
0309
05
427
(0.
42
(19
(3.
(3.
.4
(4.
.0
.5
(60
(0.
(0.
841)
.4)
66)
63)
35)
.0)
789)
181)
.6
(70.7)
(0.930)
(0.214)
1103
Average
11/17/72
EPA-5
32.9 (0.932)
0.00
64.0 (17.8)
7840 (3-70)
7610 (3.59)
106
4.35 (3.95)
60.0
50.
0.0235
1.58
0.363
69.
0.0327
2.20
0.506
(53.8)
(0.717)
(0.181)
8
(71.8)
(0.998)
(0.253)
30.8 (0.872)
0.657
66.7 (19.3)
7800 (3.68)
7670 (3.62)
99.3
4.48 (4.06)
60.0
0.
1.
0.
0.
1.
0.
- 46,
0231
54
343
58.
0290
94
432
(52.8)
(0.699)
(0.171)
(66.3)
(0.879)
(0.216)
16.8
15.3
28.2
20.1
'Dry Standard Cubic Feet @ 70°F, 29.92 in Hg
2Dry Standard Cubic Feet per Minute @ 70°F, 29.92 in Hg
3Actual Cubic Feed per Minute - Stack Conditions
"Normal Cubic Meters at 21.1°C, 760 mm Hg
5Metrlc Tons per Hour (1 metric ton = 1000 Kg)
6Grains per Dry Standard Cubic Feet
-------
Table 9. SUMMARY OP RESULTS
OUTLET OP THE LINT CLEANER, LINT CLEANER CONDENSER, GIN STAND NO. 2 - POINT NO. 12
IV)
o
Run Number:
Date:
Method Type:
Volume of gas sampled-DSCFMNm3)"
Percent Moisture by Volume
Average Stack Temperature-°F-(°C)
Stack Volumetric Plow Rate-DSCFM2-(Nm3/sec)
Stack Volumetric Flow Rate-ACFM3-(m3/sec)
Percent Isokinetlo
Product Rate-ton lint cotton/hr-(M ton/hr)5
Duration of run - minutes
Partlculates - probe, cyclone
and filter catch
mg
grains/DSCF6-(mg/Nm3)
lb/hr-(Kg/hr)
Ib/tbn of lint cotton produced
(kg/M ton of lint cotton produced)
Partlculates - total catch
mg
grains/DSCF6-(mg/Nm3)
lb/hr-(Kg/hr)
Ib/ton of lint cotton produced
(Kg/M ton of lint cotton produced)
percent implnger catch
1201
11/10/72
EPA-5
30.6 (0.867)
0.02
68.0 (20.0)
7310 (3.46)
7220 (3.11)
105
5.07 (1.60)
60.0
87.6
0.0441 (101
2.77 (1.26)
0.546 (0.274)'
99.5
0.0501 (115)
3.15 (1.43)
0.621 (0.311)
1202
11/10/72
EPA-5
27.7 (0.784)
0.00
59.0 (15.0)
' 6970 (3.29)
6720 (3-17)
100
5.38 (4.88)
60.0
131
.0.0731. (167) .
4.37 (1.98)
0.812 (0.406)
153
0.0852 (195)
5.09 (2.3D
0.946 (0.473)
1203
11/17/72
EPA-5
29.7 (0.841)
1.11
63.0 (17.2)
7060 (3.33)
6920 (3.27)
106
4.28 (3.88)
60.0
50.8
0.0263 (60.2)
1.59 (0.721)
0.371 (0.186)
70.3
0.0365 (83.5)
2.21 (1.00)
0.516 (0.258)
Average
29.3
63.3
7120
6950
4.91
(0.531)
0.377
(17.4)
(3-36)
(3.28)
104
(4.45)
60.0
12.0
14.4
27-7
89.8
0.0478 (109)
2.91 (1.32)
0.576 (0.289)
108
0.0573 (13D
3.48 (1.58)
0.694 (0.347)
18.0
'Dry Standard Cubic Feet @ 70°F, 29-92 in Hg
2Dry Standard Cubic Feet per Minute § 7"0°F, 29-92 in Hg
3Actual Cubic Feed per Minute - Stack Conditions
^Normal Cubic Meters at 21.1°C, 760 mm Hg
5Metric Tons per Hour (1 metric ton = 1000 Kg)
6Grains per Dry Standard Cubic Feet
-------
Table 10. SUMMARY OF RESULTS
OUTLET OP THE LINT CLEANER, LINT CLEANER CONDENSER, GIN STAND NO. 1 - POINT NO. 13
ro
Run Number:
Date:
Method Type:
Volume of gas sampled-DSCP^CNm3)"
Percent Moisture by Volume
Average Stack Temperature-°F-(°C)
Stack Volumetric Flow Rate-DSCFM2-(Nm3/sec)
Stack Volumetric Flow Rate-ACFM3-(m3/sec)
Percent Isokinetic
Product Rate-ton lint cotton/hr-(M ton/hr)5
Duration of run - minutes
Partlculates - probe, cyclone
and filter catch
mg
grains/DSCF6-(mg/Nm3)
lb/hr-(Kg/hr)
Ib/ton of lint cotton produced
(kg/M ton of lint cotton produced)
Partlculates. - total catch
mg
grains/DSCF6-(mg/Nm3)
lb/hr-(Kg/hr)
Ib/ton of lint cotton produced
(Kg/M ton of lint cotton produced)
percent implnger catch
1301
11/10/72
EPA-5
30.8 (0.872)
3.21
74.0 (23.3)
7540 (3.56)
7750 (3.66)
102
4.74 (4.30)
60.0
100
0.0502 (115)
3.24 (1.47)
0.684 (0.342)
127
0.0634 (145)
4.10 (1.86)
0.865 (0.433)
. 1302
11/10/72
EPA-5
29.8 (0.844)
3.31
70.0 (21.1)
7500 (3-54)
7660 (3.62)
100
5.32 (4.83)
60.0
167
0.0865 (198)
5.56 (2.52)
1.05 (0.522)
187
0.0968 (222)
6.22 (2.82)
1.17 (0.584)
1303
11/17/72
EPA-5
27.0 (0.765)
1.03
64.0 (17.8)
6100 (2.88)
5990 (2.83)
111
4.28 (3.88)
60.0
68.2
0.0389 (89.0)
2.03 (0.921)
0.474 (0.325)
83-9
0.0479 (HO)
2.50 (1.13)
0.584 (0.399)
Average
29.2 (0.827)
2.52
69.3 (20.7)
7050 (3.33)
7130 (3.37)
104
4.78 (4.34)
60.0
112
0.0585 (134)
3.61 (1.64)
0.736 (0.396)
133
0.0694 (159)
4.27 (1.94)
0.873 (0.472)
21.3
10.7
18.7
16.9
'Dry Standard Cubic Feet @ 70°F, 29.92 in Hg
2Dry Standard Cubic Feet per Minute @ 70°F, 29-92 in Hg
3Actual Cubic Feed per Minute - Stack Conditions
••Normal Cubic Meters at 21.1°C, 760 mm Hg
5Metric Tons per Hour (1 metric ton = 1000 Kg)
6Grains per Dry Standard Cubic Feet
-------
Table 11. SUMMARY OF RESULTS
OUTLET OF THE BATTERY CONDENSER - POINT NO. l4A
ro
Run Number:
Date: -
Method Type:
Volume of gas sampled-DSCF^Nm3)1*
Percent Moisture by Volume —•-
Average Stack Temperature-0F-(° C)
Stack Volumetric Flow Rate-DSCFM2-(Nm3/sec)
Stack Volumetric Flow Rate-ACFM3-(m3/sec)
Percent Isoklnetic
Product Rate-ton lint cotton/hr-(M ton/hr)5
Duration of run - minutes
Partlculates - probe, cyclone
and filter catch
mg
gralns/DSCF6-(mg/Nm3)
lb/hr-(Kg/hr)
Ib/ton of lint cotton produced
(kg/M ton of lint cotton produced)
Partlculates - total catch
mg
grains/DSCF6-(mg/Nm3)
lb/hr-(Kg/hr)
Ib/ton of lint cotton produced
(Kg/M ton of lint cotton produced)
percent Implnger catch
14A2
11/8/72
EPA- 5
31.1 (0.881)
1.25
83.0 (28.3)
14400 (6.80)
14600 (6.89)
107
3.28 (2.98)
60.0 .
37.5
0.0186 (42.6)
2.30 (1.04)
0.701 (0.349)
57.2
0.0283 (61.8).
3.49 '(1.58)
1.06 (0.530)
.14A4
11/10/72
EPA-5
30.5 (0.864)
1.20
76.0 (24.4)
14000 (6.61)
14200 (6.70)
108
4.21 (3.82)
60.0
33.9
0.0171 (39.1)
2.05 (0.930)
0.487 (0.243)
41.8
0.0211 (48.3)
2.53 (1.15)
0.601 (0.301)
14A5
11/10/72
EPA-5
30.0 (0.850)
1.23
79.0 (26.1)
13700 (6.47)
14000 (6.61)
108
4.75 (4.31)
60.0
44.3
0.0227 (51.9)
2.67 (1.21)
0.562 .(0.281)
49.8
0.0256 (58.6)
3-01 (1.37)
0.634 (0.318)
Average
30.5 (0.865)
1.23
79.3 (26.3)
14000 (6.63)
14300 (6.73)
108
4.08 (3.70)
60.0
38.6
0.0195 (44.5)
2.34 (1.06)
0.583 (0.291)
49,
0.0250
3.01
0.765
6
(57.2)
(1.37)
(0.383)
34.4
11.0
21.4
'Dry Standard Cubic Feet @ 70°F, 29-92 In Hg
2Dry Standard Cubic Feet per Minute @ 70°F, 29.92 In Hg
3Actual Cubic Feed per Minute - Stack Conditions
^Normal Cubic Meters at 21.1°C, 760 mm Hg
5Metrlc Tons per Hour (1.metric ton = 1000 Kg)
6Grains per Dry Standard Cubic Feet
-------
SECTION III
PROCESS DESCRIPTION AND OPERATION
INTRODUCTION
This process description shows the process equipment and
materials from which all emissions are derived and identi-
fies each of those sources with the specific device being
used to control emissions therefrom.
Reference is made to the attached drawings showing the
plant flow diagram (Figure 2) and location of each emission
control device (Figure 3). Details on the individual items
of process equipment, mentioned in this process description,
may be found in the Handbook for Cotton Ginners, Agricul-
ture Handbook No. 260 (USDA), 1964.
SEED COTTON UNLOADING
Seed cotton is unloaded from trailers by means of telescop-
ing suction tubes. The resulting air stream, containing
seed cotton, passes through ductwork to a rock trap, where
heavy impurities such as rocks and green bolls are removed,
then to the unloading separator, where air and seed cotton
are separated. The air from the unloading separator (con-
taining impurities such as dust derived from the seed
23
-------
ro
Cyclone
Set8
Cyclone
SeUFan
Unloading at Trailers
(Telescope Suction Tube)
Incinerator / incinerator
Nx^Y^X Cyclone Set
DRIER-CLEANER COMBINATION
From Cyclone Sets
1 thru 8
c£-5crew Conveyor
Screen
Box"
(M
o'r>
t ^
Dis
Screw J
tributor\
.
r*
Extra
Feec
J<
8 Cyclone
Set?
Cyclone
Set?
QD
3 SYSTEMS INPARALLa
•Ducts from Ijnt
cleaners behind:
Gin Stand No.3
Gin Stand No 2
-O»-
ABREVIATIONS:
A - Air
SC - Seed Cotton
LC- Lint Cotton
S - Seed
T - Trash
NG - Natural Gas
Screw Conveyor
with Dropper & Blower
Gin Stand
_U nit-Air
Lint Cleaner
A.LC
Condenser-U nit-Saw-
Lint Cleaners (2)
' Gin Stand No 1
Batteryjtondenser
A/U 1 i.
Fan
Screw Conveyor
Pan Screw Conveyor
do
Cyclone
Set 3
Dropper
Inline
Filters
A.f Nos.
Al
Fan
>Fan
do
Cyclone Cyclone
Set 5 . Set 6
LC Bales
(500Ib)
Figure 2. PLANT FLOW DIAGRAM - COTTON GINNING PLANT, TEST No..72-MM-16
-------
ro
ui
1
Q.
O
|8
To
Ol
Inline Filters (A)
(numbered as shown)
Door
13
f< < 11 w< <
11
Cotton Ginning
Plant Bldg.
• i
TTT*
Fans (2 shown)
Incinerator
Cyclones (2)
Unloading of SC Raw Material f rom Trailers
Pigure 3. LOCATION OF EMISSION CONTROL DEVICES
_ Cycl one Sets
(numbered as shown)
Screw Conveyor
(receivingtrash from
cyclone sets 1 thru 8)
- COTTON GINNING PLANT, TEST No. 72-MM-16
-------
cotton) is drawn through the unloading fan to cyclone bank
8 while the seed cotton flows into the feed control unit.
SEED COTTON DRYING AND CLEANING
A stream of hot gases is formed as a fan draws ambient air
from inside the plant and forces it through heater No. 1
where natural gas is burned and the resulting combustion
products mix with the air stream. The hot gas mixture thus
formed flows through a duct to the seed cotton outlet of
the feed control unit, where the seed cotton is entrained
and carried through a tower dryer to an inclined cleaner.
Gases, containing trash, are separated from the seed cotton
in the inclined cleaner and are drawn through a fan to
cyclone bank 1.
A stream of hot gases formed in heater No. 2, similar to
that formed in heater No. 1, flows through a duct to the
seed cotton outlet of the inclined cleaner where the seed
cotton is entrained and carried through the cleaner-dryer
combination (a dryer with two green-leaf-and-stick removers
attached). Trash from the two green-leaf-and-stick remov-
ers, of the dryer-cleaner combination, flows through vacuum
droppers to a duct having a vacuum, induced by a fan,
wherein it is carried in an air stream to the incinerator
cyclones. The same vacuum line receives trash from other
sources which are shown in Figure 3, and which will be
noted in the following paragraphs.
The seed cotton from the dryer-cleaner combination is
drawn through ducts to two inclined cleaners, in parallel.
Air and trash from the two parallel inclined cleaners is
drawn through a fan to cyclone bank 4. The seed cotton
from those two cleaners flows (by gravity) into one gravity
26
-------
cleaner each. Trash from these two gravity cleaners flows
into a screw conveyor (which also receives trash from the
unit-air lint cleaner, discussed in a following paragraph),
thence through a dropper into the vacuum line leading to
the incinerator cyclones. The seed cotton from the gravity
cleaners flows (again by gravity) into the screw distribu-
tor, which carries it into the ginning system.
GINNING AND LINT CLEANING
The screw distributor distributes seed cotton to three ex-
tractor feeders which, in turn, feed it to one gin stand
each, at rates controlled to the gin stand capacity. When
the flow of seed cotton from the screw distributor exceeds
the total of the intake rates of the extractor feeders, the
excess seed cotton flows into the overflow hopper, from
which it is again picked up, at a suitable time, by suction
applied within the hopper and routed through the overflow
separator back to the screw distributor. Air from the
overflow separator (containing trash) is exhausted through
a fan to cyclone bank 2.
Trash from the three extractor feeders and gin stands is
carried by a screw conveyor, then a dropper, into the vac-
uum line leading to the incinerator cyclones.
Within the gin stands, lint cotton is separated from seed.
The seed is removed to an elevated seed house by means of
a screw conveyor with dropper and blower. The lint cotton
is carried in air streams through the unit-air cleaners
(one for each gin stand), then through the condenser-unit-
saw lint cleaners (two in parallel for each gin stand),
then to the battery condenser.
27
-------
Trash from the three unit-air lint cleaners is carried by
screw conveyor (with trash from the gravity cleaners)
through a dropper into the vacuum line to the incinerator
cyclones. Air from the upper (condenser) sections of the
six condenser-unit-saw lint cleaners (containing trash)
flows through one fan each, to in-line filters 11, 12, and
13. (The air-and-trash streams from the condensers of
lint cleaners behind gin stands 1, 2, and 3 flow to in-line
filters 13, 12, and 11 respectively.)
Air streams (containing trash and motes) from the saw units
of the three condenser-and-unit-saw lint cleaners nearer
to the gin stands flow through fans to cyclone bank 5. The
corresponding air streams from the saw units of the three
condenser-and-unit-saw lint cleaners further from the gin
stands flow through fans to cyclone bank 6.
Air from the battery condenser flows into the baling press
where the products, bales of lint cotton, are formed.
The air-and-trash streams exhausted from in-line filters
Nos. 11 through 14 flow through a fan to cyclone bank 7.
Trash from cyclone banks 1 through 8 flows into a screw
conveyor under those cyclones. It is then moved through
a dropper and duct, under positive pressure from a blower,
into the air-and-trash line to the incinerator cyclone set.
Thus, the total trash from the emission control system is
carried into the tepee burner incinerator where it is
burned, the smoke from that incinerator forming an addi-
tional emission point.
28
-------
Typical process operation at the "Green Gin" can be sum-
marized as follows:
Normal plant operating schedule:
20 hrs/day (2 shifts)
6 days/week
6 weeks/year, plus spasmodic periods to process remnants.
Prom October to January (ginning season).
Average plant operating capacity:
525,000 Ibs of seed cotton/day (processed)
175,000 Ibs of lint cotton/day (produced)
280,000 Ibs of seed/day (produced)
Peak plant operating capacity:
600,000 Ibs of seed cotton/day (processed)
200,000 Ibs of lint cotton/day (produced)
320,000 Ibs of seed/day (produced)
29
-------
SECTION IV
SAMPLING AND ANALYTICAL PROCEDURES
LOCATION OP SAMPLING POINTS
There are two types of emission control devices at the
Delta and Pine Land Company cotton gin; in-line filters
controlling emissions from the battery condenser and the
lint cleaner condensers and cyclones controlling emissions
from the overflow separators, lint cleaners, unloading
separator, dryer cleaners, extractor feeders, and trash
hopper.
The in-line filters from the gin stands, lint cleaners,
and lint cleaner condensers had 30 inch outlets; the bat-
tery condenser, 42 inch outlets. The rain shields were
removed and replaced with a short adaptor, a 90° elbow and
a straight length of pipe, each the same diameter as the
outlet. To simplify sampling, the ducts were directed
downward. As a result the ducts were sampled with two hor-
izontal traverses rather than one horizontal and one ver-
tical traverse.
The sample ports on the lint cleaner condensers were lo-
cated 125 inches (4.2 Dia.) from the 90° elbows, and 25
inches (0.83 Dia.) from the outside air. The bottom of
the ducts was approximately 42 inches above the ground. A
diagram of the duct design and sample port location is
30
-------
shown in Figure 4. Only one section of scaffolding was
required to reach the sample ports on these three units.
The battery condenser sampling ports were 156 inches (3.7
Dia.) below the elbow and 36 inches (0.86 Dia.) above the
outside air. The bottom of the duct was about 48 inches
above the ground. The battery condenser ducts and sample
ports are shown in Figure 5. The ports were reached with
scaffolding two sections high.
Each of the cyclones at the gin was equipped with a sam-
pling duct in place of the rain cap. The duct was fitted
to the short exhaust duct on the top of the cyclone and
consisted of a large radius 180° bend, a straightening
vane, and a long length of straight pipe. The "candy
cane" sampling ducts were built in three inside diameters;
16, 17, and 18 inches as required; to fit the cyclone ex-
haust duct. A schematic diagram of the sampling ducts in
place on a cyclone set: is shown in Figure 6. Table 12. lists
the cyclone sites and the important dimensions at each
location. Figure 7 shows the construction of the straight-
ening vanes.
Each cyclone duct was provided with an inspection port in
the l80° bend directly above the straightening vane. This
port, which was closed with a sheet metal band during sam-
pling, provided access to the straightening vane. The
vane was cleaned prior to each test so that the flow would
not be restricted, and thus, divert the air stream to an-
other outlet.
Continuous rows of scaffolding were set up on both sides
of the sampling ducts to provide access. All samples were
collected on ducts farthest from the building. All sampling
31
-------
IX)
Sample
Site
11, 12,
13
Rain Shield (removed)
Traverse
Site
1.1 A, 12A,
13A
125"
(4.2 D)
25"
(0.83 D)
42"
Figure 4. SCHEMATIC DIAGRAM OF THE IN-LINE FILTERS AND SAMPLING DUCTS
FOR SITES 11, 12, AND 13
-------
Rain Shield (removed)
OJ
uo
36"
(0.86 D)
Figure 5. SCHEMATIC DIAGRAM OP THE BATTERY CONDENSER IN-LINE FILTER
AND SAMPLING DUCTS - SITE 14
-------
Table 12. DIMENSIONS AT CYCLONE SITES
Sampling Port Location
U)
Cyclone
Site Diameter
No. Inches
1 32
2 36
3 36
4 32
5 34
6 ' 34
7 34
8 34
Cyclone
Outlet
Inches
16
18
18
16
17
17
17
17
Duct
I. D.
Inches
16
18
18
16
17
17
17
17
Total Duct
Length In.
(Dia.)
192
192
192
'192
192
192
192
192
(12.0)
(10.7)
(10.7)
(12.0)
(11.3)
(11.3)
(11.3)
(11.3)
Upstream
Distance
In. (Dia.)
120
119
119
120
120
120
120
120
(7.5)
(6.6)
(6.5)
(7.5)
(7.0)
(7.0)
(7.0)
(7.0)
Downstream
Distance
In. (Dia.)
72
73
73
72
72
72
72
72
(4.5)
(4.1)
(4.1)
(4.5)
(4.2)
(4.2)
(4.2)
(4.2)
No. of
Traverse
Points
12
16
16
12
12
12
12
12
Radius of
180° Bend
(inches)
40
45
45
40
42.
42.
42.
42.
5
5
5
5
Note: Port locations apply to both sampled and unsampled sites.
All straightening vanes were honeycombed with 2.5 inch squares, 7-5 inches long, and with
a diameter of 16, 17, or 18 inches.
-------
180 DEGREE BENDS
STRAIGHTENING
VANES
UJ
BUILDING
Figure 6. SCHEMATIC DIAGRAM OF THE CYCLONE .UNITS AND SAMPLING DUCTS
(Table 12 lists the dimensions for the
ducts and sample port locations)
-------
«•*-
-+6-18
~r
7.5
Figure 7. DIAGRAM OP STRAIGHTENING VANE CONSTRUCTION
-------
ports were readily accessible, and-equipment could be easily
moved from one location to another.
No other modifications were required at this gin. Ample
electrical capacity was available for all testing in the
fan room adjacent to the cyclone banks.
SAMPLING PROCEDURES
The outlets from all of the control devices at the cotton
gin were sampled generally in accordance with the methods
given in the August 17, 19713 Federal Register. One excep-
tion was the use of the wet bulb-dry bulb technique to ob-
tain initial moisture levels, rather than Method 4, "Deter-
mination of Moisture in Stack Gases." The low moisture
levels (0-5.4$) and low stack temperatures (below 212°F)
permitted the use of this deviation.
Method 5 of the Federal Register Methods was used to obtain
the emission rate of all sampled outlets. During these
sample runs, any unsampled outlets in the same cyclone bank
or connected to the same control device were traversed to
obtain the velocity profile and stack temperature follow-
ing Method 2. If it is assumed that the loading in grains/
standard cubic foot is the same at all outlets of the con-
trol devices in one unit, the emission rate in Ib/hr would
be a function of the differences in velocity at the out-
lets. The loading in grains/cubic foot were obtained from
the Method 5 data, and from the velocity traverse of the
unsampled ducts, the emission rate in Ib/hr can be calcu-
lated for each individual outlet.
No conditions were encountered during this sampling program
that were beyond the normal operating parameters of the
37
-------
Method 5 sampling apparatus. The sampling runs were stopped,
however, when portions of the gin ceased operation or if
unusual conditions occurred in the gin. The runs were re-
started when normal operation resumed.
While sampling was in process, production data was recorded
by Mr. William Herring of EPA. The information obtained
included the number and weight of finished cotton bales
produced during the entire length of each run. The data
was used to calculate the emission rate in terms of cotton
produced.
ANALYTICAL PROCEDURES
Samples from the Method 5 sampling trains were recovered
as outlined in the August 17, 1-971, Federal Register.
After removal of the filter, all sample exposed surfaces
were washed with reagent grade acetone or distilled water
as specified. All sample bottles for liquid samples were
obtained from Wheaton Scientific, Catalogue No. 219630.
Each of these bottles and the petri dishes for sample fil-
ters were acid soaked with a 1:1 HNOs for one day, rinsed
with distilled water and soaked with distilled water for
one day.
Sample recovered from the High Volume sampler included re-
moval of the filter and placing it in a large mouth bottle,
removal of the cyclone bottle and sealing it, and washing
of all exposed surfaces of the train with acetone. Ace-
tone washings were placed in acid washed Wheaton bottles.
Analytical procedures for the Method 5 samples follow the
Federal Register guidelines, with one exception. Container
No. 3 as indicated in the method contains water from the
38.
-------
impingers and washing of the glassware of the train. The
-solution was extracted with chloroform and ether, and then
the extracted portion was dried to constant weight, as
specified. In addition, the remaining water after extrac-
tion was evaporated to dryness at 212°P to constant weight.
Both weights were included in the total mass of particulate,
Sample weight from the Method 5 samplers were reported as
"front half" (probe washings and filter collection weights)
and "total" (front half plus water, chloroform-ether ex-
tract, and impinger acetone washing weights).
All particulate mass analyses with the exception of that
of the impinger acetone washings were preformed at Monsanto
Research Corporation, Dayton Laboratory. The sample for
each run was analyzed at the EPA laboratories, and the data
was supplied to MRC for inclusion in this report.
39
------- |