SN 16544.009
Test Number FA-6
Chromium Mining and Smelting
Corporation
Memphis, Tennessee
by
C.C. Gonzalez/R.N. Allen
June, 1972
RESOURCES RESEARCH, INC.
A SUBSIDIARY OF TRW INC.
WESTGATE PARK • 7600 COLSH/HC DRIVE • McLEAN, VIRGINIA 22101
Contract Numbtr CPA 70-11
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SN 16544.009
Test Number
Chromium Mining and Smelting Corporation
Memphis, Tennessee
by
C. C. Gonzalez/R. N. Allen
June, 1972
Resources Research, Inc.
A Subsidiary of TRW Inc.
7600 Colshire Drive
McLean, Virginia 22101
Contract Number CPA 70-81
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I. TABLE OF CONTENTS
Page
II. INTRODUCTION 3
III. SUMMARY OF RESULTS 6
IV. PROCESS DESCRIPTION 12
V. LOCATION OF SAMPLING POINTS 15
VI. PROCESS OPERATION 18
VII. SAMPLING PROCEDURES 20
VIII. APPENDIX 21
A. Complete Particulate Results with
Example Calculations
B. Complete Gaseous Results with
Example Calculations
C. Complete Operation Results
D. Field Data
E-1. Sampling Procedures
E-2. Cleanup and Analytical Procedures
F. Laboratory Report
G. Test Logs
H. Related Reports
I. Project Participants and Titles
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LIST OF TABLES
Table No.
1
2
3
4
Title
Overall Summary of Results and Particulate Removal
Efficiency
Inlet Total Catch vs. Percent Solids in Scrubber Water
Summary of Results - Scrubber Exhaust
Summary of Results - Inlet Duct to Scrubber
Page
6
8
9
10
LIST OF FIGURES
Figure No.
1
2
3
4
Title
Block Diagram - Sample Locations
Process Flow Diagram - Furnace 21
Sample Locations, Furnace 21
Sampling Point Locations
Page
4
13
16
17
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II. INTRODUCTION
Source emission tests are being performed on a series of electric
furnace installations used for processing of reactive metals (ferroalloys),
for the Office of Air Programs, Environmental Protection Agency. This survey
includes the determination of filterable and total particulate matter, Orsat
analyses, plus particle size analyses under a separate contract (EPA Order
#2PO-68-02-3680). The series of tests contained in this report were performed
at the Chromium Mining and Smelting operation (CHROMASCO), Fite Road, P. 0. Box
28538, Memphis, Tennessee, 38128, during the week of February 1, 1972.
Emissions from this particular plant were determined for Furnace No. 21,
producing silico-manganese. This furnace is rated at a nominal 7 megawatts.
This unit was completely hooded, and exhaust gases were directed to a newly
designed wet scrubber. The scrubber was manufactured by Aronetics, Inc.;
and basically employs the waste heat from the exhaust gases to power the
ejector-venturi type scrubber section. A hood was located over the tapping
exhaust, and this led to the furnace cover, such that some tapping fumes
were collected by the overall system.
All sample locations are shown in Figure 1 on the following page.
Further detailed diagrams and descriptions are included in Sections IV and
V of this report (Process Description and Location of Sampling Points).
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(ATMOSPHERE )
ORES
ELECTRICAL
POWER
CARBON
REDUCING
AGENTS
FLUXES, ETC.
ELECTRODES
\
HOOD
0
z
77777/7
ELECTRIC ARC
FURNACE
0
DUST
COLLECTION
SYSTEM
TA P
HOOD
LADLE
77777/7
SAMPLE
LOCATIONS
PRODUCT
MOLDS
SLAG
DISPOSAL
FIGURE 1. BLOCK DIAGRAM-SAM PL E LOCATIONS
-------
Three participate collection efficiency tests were conducted using the
EPA train as described in Appendix E-1. Integrated combustion gases were
sampled in a Tedlar* bag and analyzed by standard Orsat. Particle size was
measured in situ with a Brink Model B* sampler. The overall survey included
six particulate emission runs, six Orsat measurements, and particle size
analyses as made under the separate contract.
*Mention of a specific company or product does not constitute endorsement
by EPA.
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III. SUMMARY OF RESULTS
Shown below 1n Table 1 are the results and averages of the Inlet
and Outlet tests performed on the Aronetics scrubber system, along with
the corresponding particulate removal efficiencies.
TABLE 1
Overall Summary of Results and Particulate Removal Efficiency
Scrubber Scrubber
Outlet (Exhaust) Inlet Duct
Total Particulate Total Particulate
Date Test No. Grains/SCF Ib/hr Grains/SCF Ib/hr % Efficiency
2/1/72 One 0.0489 7.08 2.19 301.6 97.6
2/2/72 Two 0.101 13.42 1.40 197.6 93.2
2/2/72 Three 0.107 14.21 1.35 190.9 92.6
Average 0.0856 11.57 1.65 230.0 94.5
The best particul ate removal efficiency occurred during Test No. One,
1n which both the highest inlet, and lowest outlet, particulate emission
rates were observed. Correlation of the data in Table 1 and Table 2 as
follows substantiates the variation in particulate grain loading. Note that
in Test No. One low grain loading at the outlet, high grain loading at the
inlet and high percent solids in the scrubber water going to the clarifier
are all consistent with the overall result.
-------
Reasons for the unusual results during the first test are hypothetical,
however, there were several differences in test data and conditions for
this run. The condensible portion of inlet sample, as well as that in the
exhaust sample, were greater during this period. There was appreciably
lower moisture content measured from the exhaust stack, although it is
possible this was either coincidental or due to an early problem with the
box heater, allowing condensate to form in the cyclone/filter area. At the
inlet duct location water filled impingers collected enough material to
affect the color and clarity of the solution. The filter being used with
the particle size sampler caused extreme difficulty due to clogging with
a wax like material. Dust that was collected on the filters was a slightly
different color (more brown or pink) on the second day of testing. The
filters in the particulate train also had a wax like material on them.
Upon questioning, the operators stated that occasionally there is a
very heavy coating of oil associated with the iron and steel turnings,
that are part of the standard furnace feed mix. There was no possible way
to ascertain that this actually occurred on the previous day, however the
above factors indicate that such an occurrence may have been the cause of
the inconsistent results for Run No. 1.
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TABLE 2
Inlet Total Catch versus Percent Solids
In Scrubber Water Going to the Clariflers
Inlet Total Catch % Solids in Scrubber
Run No. (gralns/CF, dry STD) Water Going to the Clarifiers
CSD-1
CSD-2
CSD-3
2.19
1.40
1.35
20
10
7
Scrubber and furnace operation was stable throughout the entire survey.
Particulate and gaseous emission summaries for the scrubber inlet duct
and exhaust are shown in Table 3 and 4 on the following pages. Flue gas
conditions are included, and percent particulate matter in the impinger
train has been calculated. The condensible portion was less than 2 percent
prior to the collection system. At the outlet the condensible fraction
ranged from 5 to 18 percent, and averaged slightly less than 10 percent.
Gas temperatures and velocities remained rather stable at the outlet
location, but underwent fairly wide variations from point to point, as well
as with time, at the inlet location. Considering the normal variation in
operating conditions, and the configuration of the inlet sample port loca-
tion, inlet and outlet flue gas volumes agreed rather well.
Carbon dioxide values appeared to be approximately eight times greater
at the exhaust than at the inlet duct. There was no reason for this ab-
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TABLE 3
Scrubber Exhaust
SUMMARY OF RESULTS
Run Number
Date
Stack Flow Rate - SCFM * dry
% Water Vapor - % Vol.
7. CO 2 - Vol % dry
7o 02 - Vol % dry
% Excess air & sampling point
S0« Emissions - ppm dry
NO Emissions - ppm dry
X
Particulates
Probe, Cyclone, & Filter Catch
gr/SCF* dry
gr/CF @ Stack Conditions
Ibs./hr.
Particulate from impinger train
(% of total)
Total Catch
gr /SCF * dry
gr /CF @ Stack Conditions
Ibs./hr.
Percent Efficiency
r.SF-1
2/1/72
16,890
10.3
4.3
16.9
416
N/M
N/M
0.0403
0.0340
5.83
17.6
0.0489
0.0386
7.08
97.6
CSE-2
2/2/72
15,500
**
15.5
4.0
17.2
457
N/M
N/M
0.0932
0.0701
12.38
7.7
0.101
6.0759
13.42
93.2
CSE-3
2/2/72
15,500
**
15.5
4.0
17.2
457
N/M
N/M
0.102
0.0767
13.55
4.6
0.107
0.0804
14.21
92.6
••
-
N/M = not measured
* 70°F, 29.92" Hg
*» at Saturation Point
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TABLE 4
Inlet Duct to Scrubber
SUMMARY OF RESULTS
Run Number
Date
Stack Flow Rate - SCFM * dry
% Water Vapor - % Vol.
% C02 - Vol 7. dry
% 02 - Vol % dry
7» Excess air & sampling point
S0~ Emissions - ppm dry
NO Emissions - ppm dry
X
Particulates
Probe, Cyclone, & Filter Catch
gr/SCF* dry
gr/CF @ Stack Conditions
Ibs./hr.
Particulate from impinger train
(% of total)
Total Catch
gr /SCF * dry
gr /CF @ Stack Conditions
Ibs./hr.
Percent Efficiency
CSD-1
2/1/72
16,070
4.19
0.6***
20.4
3322***
N/M
N/M
2.15
0.675
296.1
1.8
2.19
0.688
301.6
CSD-2
2/2/72
16,470
4.23
0.5***
20.5
3988***
N/M
N/M
1.38
0.444
194.8
1.4
1.40
0.450
197.6
CSD-3
2/2/72
16,500
4.24
0.5***
20.5
3988***
N/M
N/M
1.33
0.426
188.1
1.5
1.35
0,433
190.9
N/M = not measured
* 70°F, 29.92" Hg
*** See results; believed to be 1n error
10
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normality. All hypothetical explanations had a major flaw, and it was
impossible to satisfactorily explain these results at a later time. It
might be possible that there was insufficient mixing, and air stratifi-
cation at the inlet duct caused the low readings, but this was not expected
due to the visual appearance of the system. The same individual ran all
analyses, and would hardly be able to produce such close duplication of
results and yet allow such flagrant errors. Since a scrubber of this type
is not likely to generate CC^ gas, the better mixed, outlet gas is believed
to offer more realistic results. The CO infrared analyzer was set up at
the inlet location, but an electrical malfunction caused it to be set aside.
No CO analyses were then performed, except for the zero reading by the Orsat
analyzer during each particulate run.
Fume capture by the hood over Furnace 21 was 95 to 100 percent during
normal operation. During the short periods in which the side doors were
opened to charge feed materials and stoke the furnace, the air flow patterns
were disrupted, and large volumes of the fumes would escape. Fume capture
by the tapping exhaust hood was estimated to be in the order of 20 percent,
with the remainder escaping to the atmosphere from various openings in the
building.
11
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IV. PROCESS DESCRIPTION
Reactive metals are generally ferroalloys which are produced In sub-
merged arc electric furnaces. The facility under consideration in this
report is an open furnace, with hooding and a wet scrubber system to reduce
the emission of fumes and dust following collection by the hooding. The
operation of this special scrubber system is detailed in Appendix C.
Figure 2 is a cross-sectional process flow diagram indicating the furnace
under test-in this survey.
The electric arc is employed as a concentrated source of heat. Ap-
propriate ores are added to the surface of the furnace through mechanized
equipment and chutes. Additional carbon in the form of coke, wood chips,
etc., is an integral part of the furnace mix, along with specialized fluxes,
etc. The mix is added to the surface of the furnace and spread over the
surface with stoking machines.
The very high temperatures produced initiate a reaction in the bottom
of the furnaces and form a layer of metal which is tapped at appropriate
times. As the ores and carbonaceous materials gradually settle to the
bottom of the furnace, the heat, in absence of oxygen, causes the carbon
to react with the oxide ores removing oxygen and thus produces elemental
metal. Escaping gases, composed largely of carbon monoxide, are burned
at the surface of the furnace in open units.
12
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t*>
TAP
EMERGENCY
VENT
SCRUBBER
INLET DUCT
SAMPLE PORTS
C S D
\
IT'
I Rl
DOOR!
ID'
_E±
U
FURUACE 21
GROUND LEVEL"
'SCRUBBER
EXHAUST
SAMPLE P 0 RTS
C S E ^
RECYCLE D
W AT ER
HEAT
EXCHAMG-ER
SCRUBBER
SYSTEM
DEMISTER
FIGURE 2. PROCESS FLOW DIAGRAM, FURNACE 21
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Furnace 21 Is a nominal 7 to 9 megawatt unit, producing s1T1co-
manganese metal, using prebaked electrodes. Gases and fumes from the
normal furnace operation are passed through a unique wet scrubber, using
the high-temperature gases as a source of energy for the gas flow. A
separate fan and exhaust system 1s employed to collect fumes from around
the tapping operation. This duct leads into the furnace hooding system.
The furnace 1s tapped at intervals of approximately 90 minutes. After
molten metal and slag pour into ladles, the slag is removed and disposed
of by various means. Molten product is poured into molds, after which
it 1s broken Into usable sizes.
14
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V. LOCATION OF SAMPLING POINTS
The locations of sample ports were selected and approved by the EPA
Project Officer during a presurvey inspection trip, as shown in Figure 3.
The inlet duct was provided with two three-inch flanged ports set at 90°
to one another on the same plane. These ports were located approximately
two to three pipe diameters following a slight bend. The duct was lined
with high temperature fire brick so that an inside diameter of three
feet was available. Sampling was performed through only one of these
ports, due to the lack of suitable access to the other opening. As shown
in Figure 4, the cross-section of this duct was divided into six equal
areas. Particulate tests were conducted for four minutes at the centroid
of each area as shown. A sturdy table provided support for the sampling
train, allowing the nozzle to be turned such that it was directed directly
into the gas stream at all times. Two sample points from the inaccessible
traverse direction were reached from this single port.
The top of the scrubber demister supported a 16-foot high, four-foot
diameter stack equipped with two three-inch couplings at the 12-foot
level, set at 90° to one another. Plywood platforms were mounted below
each port so that the sample train could make sample traverses of two
diameters at right angles. The two traverses allowed equal area sampling
as shown in Figure 4. A complete sample run v/as conducted by providing
four minutes at the centroid of 24 equal areas, during a period of 96
minutes, which covered a tap cycle of the furnace.
15
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4'ID
O
r
EXHAU ST STAC K
NLET DUCT
GRO UN D LEVEL
FIGURE 3. SAMPLE LOCATIONS, FURNACE 21
16
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SCRUBBER EXHAUST (OUTLET)
4' I. D.
Platforms
3' I. D.
INLET DUCT
N.E. Port
(In acces sable)
Platform
FIGURE 4-SAMPLING POINT LOCATIONS
17
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VI. PROCESS OPERATION
All sampling was carried out while the process was running normally.
Furnace 21 used a system of pre-baked electrodes. Its operation appeared
quite uniform considering the inherent load variations. During Test No.
One there was a short period of load drop but it was not believed to be
significant. The furnace load averaged 7200 killowatts during the testing
period. Any periods of furnace "blows" or minor process load variations
are considered normal operation. Routine operation is as follows: Fifteen
minutes after tapping, there will be stoking; 30 minutes after tap, there
will be charging; 45 minutes will have another stoking; 60 minutes will be
for charging; and 75 minutes after tapping, there will be another tapping
cycle. During the charging or stoking operation, the area may become
rather dusty because at least one, or both, doors are open. Tapping
ordinarily takes 10 to 15 minutes. Appendix C tabulates the available
operating data.
Operation of the scrubber was uniform during the course of each test.
Data concerning scrubber operation, the scrubber water entering the clari-
fiers, and their percent solids content, are also included in Appendix C.
There is a direct relationship between the inlet duct total particulate
emission data and the percent solids as measured in the recycled scrubber
water.
As far as it can be determined, there were no problems with the opera-
tion of the scrubber system. Data in Appendix C indicates quite stable
18
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conditions throughout the operation of the scrubber during the test. Note
that when the percent solids in the scrubber water going to the clarifiers
was the highest (20%), the inlet particulate emissions were also the
highest.
19
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VII. SAMPLING PROCEDURES
Test methods were In accordance with standard methods as published
in the Federal Register. Volume 36, Number 159, Part II, August 17,
1971. See Appendix E for pertinent sections of this publication.
Deviations from the above methods were as follows:
1. At the outlet 24 points were sampled (criteria call for 36)
(Reason: Deemed to be suitable and appropriate for this location.)
2. At the inlet 14 points were sampled (criteria call for 24)
(Reason: Only 2 points could be reached due to the inaccessibility
of one of the sample ports.)
3. Test timeswere96 minutes each (instead of 2 hours).
(Reason: This period covered one complete cycle of the operation.)
20
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VIII. APPENDIX
21
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APPENDIX A
COMPLETE PARTICULATE RESULTS WITH EXAMPLE CALCULATIONS
-------
Considering the Inherent variability of furnace operations, the
changes in inlet duct particulate concentrations were considered to be
quite reasonable.
During the initial exhaust run, CSE-1, a very high vacuum developed
in the particulate sample control box. It was found that the stack moisture
had wet the filter and caused this obstruction. The probe and filter
assembly had not been sufficiently preheated. The isokinetic rate was
successfully managed for the first half of the run, and the entire filter
assembly was heated thoroughly, prior to beginning the second part traverse.
The ratio of particulate trapped by the water impinger, versus the
total catch was very low and consistent for the inlet runs, and higher and
less consistent for the outlet runs.
Moisture content of exhaust gases during Test One (CSE-1) was actually
calculated at 10 percent, but it 1s suspected that a mistake was made when
measuring the condensate. The calculated percent moisture in Runs CSE-2
and CSE-3 was 24 percent water vapor. Based upon standard humidity data,
the actual moisture vapor in the saturated exhaust gas would have been
approximately 15 percent. The additional condensate was due to the collec-
tion of water droplet carryover. If the water droplets contained particulate
matter, this additional material was considered as part of the total emission.
Calculations were based on the actual moisture content for the saturated gas
in the stack, not total moisture.
A-l
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REPORT NO.
PAGE
OF
PAGES
Test No.
Name of Firm
Location of Plant
Type of Plant
Control Equipment
Sampling Point Local
Pollutants Sampled
Time of Particulate
CSE-1
Run No. CSE-2
CSE-3
Run No. CSD-1
CSD-2
'Run No. CSD-3
Run No.
SOURCE TESTING CALCULATION FORMS
Chroma sco
Woodstock, Tennessee
Ferroalloys
Scrubber
;ions Scrubber Inlet and Exhaust
Particulate
Test : /
2/1/72 14:30
Date 2/2/72 Begin 8:50
2/2/72 12:55
Date 2/1/72 Begin 14:30
2/2/72 8:49
Date 2/2/72 Begin T2:54
Date Begin
No. Runs 6
16:48
End 10:38
14:38
End 16!31
10:33
End 14:40
End
PARTICULATE EMISSION DATA
Run No.
P, barometric pressure, "Hg Absolute
P orifice pressure drop, "H20
V volume of dry gas sampled @ meter
conditions, ft. 3
T Average Gas Meter Temperature, °F
V Volume of Dry Gas Sampled @
mstd. Standard Conditions, ft. 3
V Total HpO collected, ml., Impingers
& Silica Gel.
V Volume of Water Vapor Collected
Wgas ft.3 @ Standard Conditions*
CSE-1
29.7
0.83
47.48
79
46.4
T|?
5.31
CSE-2
29.7
0.758
44.6
73
44.1
297 3
14T1«
CSE-3
29.7
0.755
46.5
78
45.5
309 1
14.7®
CSD-1
29.7
2.24
68.775
68
68.9
63.4
3.01
CSD-2
29.7
2.20
72.894
85
70.7
65.9
3.12
CSD-3
29.7
2.43
76.89
87
74.3
69.5
3.29
* 70°F, 29.92" Hg.
0 including water droplets.
A-2
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PARTICULATE EMISSION DATA (CONT'D)
Run No.
7M -7, Moisture in the stack gas by
volume
Md - Mole fraction of dry gas
% C02
% 02
7, N2
M W
-------
PARTICIPATE EMISSION DATA (cont'd)
Run No.
C - Particulate, total, gr/cf
§ stack cond.
C - Particulate, probe, cyclone,
aw and filter, Ib/hr.
C - Particulate - total, Ib/hr.
ax * .
% EA- % Excess
sampling
air §
point
Percent of Total Catch
Trapped by
Water Implngers
CSE-1
0.0386
5.83
7.08
416
17.6
CSE-2
0.0759
12.38
13.42
457
7.7
CSE-3
0.0804
13.55
14.21
457
4.6
CSD-1
0.688
296.1
301.6
3322
1.8
CSD-2
0.450
194.8
197.6
3988
1.4
CSD-3
0.433
188.1
190.9
3988
1.5
*70°F. 29.92" Hg.
A-4
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SAMPLE PARTICULATE CALCULATIONS
(CSE-1)
1. Volume of dry gas sampled at standard conditions - 70°F, 29.92"
Hg, ft3.
17'7 X Vm (Pb + Pm
\ 137(
'mstd ' (Tm + 46°)
V_ = ^ .1 . ITT/ = Ft3 •
(17.7M47.48) (29.7 +M3)
\ 13.6/
(79 + 460)
2. Volume of water vapor at 70°F and 29.92" Hg, ft3
Vwgas = 0.0474 X Vw= ft3
= (0.0474)(112)
= 5.31
3. % moisture in stack gas
100 X Vw
= 46.40
mstd wgas
(100)(5.31)
46.4 + 5.31
10.3
A-5
-------
4. Mole fraction of dry gas
100 - %M
MH = -
d 100
100 - 10.3
100
= 0.897
5. Average molecular weight of dry stack gas
= (4.3K.44) + (16.9)(.32) + (78.8)(.28)
= 29.36
6. Molecular weight of stack gas
M W = M W d X Md + 18 (1 - Md)
= (29.36)(0.897) + 18(1 - 0.897)
= 28.19
7. Stack velocity @ stack conditions, fpm
Average r i
V. = 4350 X WAP. X (T + 460)
5 V d o
= (4350)01.3) ]
(29.7)(28.
u
= (4350)01.3) X (0.0346)
* 1700
A-6
-------
8. Stack gas volume @ standard conditions, SCFM
0.123 X V X Ac X M. X Pc
Q = _ ! _ ! _ S _ 1 = SCFM
S (Ts + 460)
(0.123) (1700) (1810) (0.897) (29. 7)
597
= 16,390
9. Percent isokinetic
1032 X (Ts+ 460) X V
VsXTtXPsXMdX (Dp)2
_ (1032)(597)(46.40)
(1700)(96)(29.7)(0.897)(0.25)(0.25)
= 105.2
10. Particulate - probe, cyclone, and filter, gr/SCF
Mf
Can = 0.0154 X = gr/scf
mstd
- (0-0154)021.4)
46.4
= 0.0403
11. Particulate total, gr/SCF
M*
C = 0.0154 X ^_ _ ^/opc
ao = gr/SCF
mstd
A-7
-------
- (0-0154)047.2)
46.4
= 0.0489
12. Particulate - probe, cyclone and filter,
gr/CF at stack conditions
17.7 X Can X Ps X Md
C . = = gr/CF
at (Ts +460)
- 17.7 X 0.0403X 29.7 X .897
597
= 0.0318
13. Participate - total, gr/CF @ stack conditions
17.7 X C X P X NL
(Ts + 460)
= gr/CF
- 17.7 X 0.0489 X 29.7 X .897
597
= 0.0386
14. Participate - probe, cyclone filter, Ib/hr
C311 = 0.00857 X Can X Q = Ib/hr
ctw otn s
= 0.00857 X 0.0403 X 16,890
= 5.83
A-8
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15. Particulate - total, Ib/hr
C = 0.00857 X C X Q = Ib/hr
ax ao s
=0.00857 X 0.0489 X 16, 890
= 7.08
16. % excess air at sampling point
100 X % 02
%EA
(0.266 X % N2)-% 02
100 X 16.9
(.266 X 78.8) - 16.9
416
A-9
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APPENDIX B
COMPLETE GASEOUS RESULTS WITH EXAMPLE CALCULATIONS
-------
ORSAT RESULTS
Date Run No. % C02 % 02 % CO
2/1/72 CSE-1 4.3 16.9 Nil
CSD-1 0.6 20.4 Nil
2/2/72 CSE-2 4.0 17.2 Nil
CSD-2 0.5 20.5 Nil
2/2/72 CSE-3 4.0 17.2 Nil
CSD-3 0.5 20.5 Nil
The low, unexpected COp readings for Runs CSD-1, CSD-2
and CSD-3 are believed to be erratic. Averages for inlet
and outlet were 0.53% and 4.1% respectively.
B-l
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APPENDIX C
COMPLETE OPERATION RESULTS WITH EXAMPLE CALCULATIONS
-------
OPERATION OF CHROMASCO'S #21 FURNACE ON
FEBRUARY 1 AND 2, 1972
PRODUCT: SilicoManganese
GRADE: 18.5% Si; 1.57. C, 66.07. Mn
AVERAGE LOAD: 7200 KW
AVERAGE DAILY RAW MATERIALS USED:
OPERATING TIME: 94.5%
TAP TIMES: START
Feb. 1 12:00
Feb. 1 1:45
Feb. 1 3:30
Feb. 1 ' 5:00
Feb. 2 9:00
Feb. 2 10:35
Feb. 2 12:10
Feb. 2 1:30
Feb. 2 3:11
Ore & Slag -
Reducers
Other
TOTAL
- 163,000$
41,500$
30.500S
235,000*
END
12:15a.m.
2:00p.ra.
3:45p.m.
5:15p.m.
9:15a.m.
10:50a.m.
12:25p.m.
l:45p.ra.
3:30p.m.
C-l
-------
.jr£r:^.rr£..^r--Vrrzr-ferj=-.
r~'~^'3'-i:"-^L- \ ..J^'VfzuiX—
^'E—ri^r—Ef il^ •'^~=^~~^E^^{:^=^^:^=^&~
llYlzr~ ~F-v -t_~~ —"T '—
\ ~>.»\ ~ ^^^^ i" ^^'
iv.Vr.-j.^.1: _ ,.J*:T---..-\TL ^i—
.W,~i^l -Tr=r:
;'™vtr:rrr:r ™.«.ft
"/"i """""/"~irrrz" /"~ r~ /* /"~**-±"^"r*"~~a ~ ,~~~~'-^t' I—-•• '~/~"r^. *"' /~" ~j"~~T~"~^r~r~~L"~^rm~*z.T'i^'^*~i~"/•—-•"••— -/——--— / — -..^.-—/..——.,.....j...... —-—/-"• """"*/"• *T'*"i*^i
~- / — r ~r../.. zrrtt!U' /. ."i_rc^-"— / ..TT"-"—~j.»~i'.™ii..'".-Z.I fl /~~n.~^/"~ ^^7 ^.^ T^ V~ " ~ / r *^^_ / r. / T^ ? .^.. /^^^^ rr/ .". T^rr/r^iT.'.. . /_ . .1^7^ ^r_ ^ ^ T .t«zi
' :; r"1 "*/ _—.";•""/~"t*r~~"7j**—— —-f--- ——-_-_•/,•-_-;-^ jjfc^^--^— -/--^.--.-^{-1^—•- -a=—^EV- —^--- /— •—^—— -/ .—..-—.-./-•.-——.. / x i"-/"—*^"^ ', '"*•**""'*i""mtT /""rr*: /** "*"~irt'_/**T.I."_"iI^LZ
r z^:l.^rr/^L. ..
-------
^:.7 V-H- _/^;^v^ft-c I ^.^.L e-WT- -rVM
^TC^SJLjj^LilSLiht^^
C-3
-------
ARONETICS
FORUERlt MOa»«t DIVISION OF *RO. me
PO BOX BIS
TULLAHOMA. TENNESSEE 37388
FUME CLEANING SYSTEM FOR CHROMASCO
Installation of a process emission cleaning system has been
completed for one of the ferro-alloy furnaces at the Memphis plant of
Chromasco. The new equipment was developed by Aronetics, Inc. of Tullahoma,
Tennessee with the assistance of Chromasco and the Shelby County Health
Department. Initial check-out operations have begun and it is expected
that the system will be operating full time within eight (8) weeks.
The Aronetics equipment utilizes the heat energy in the process
discharge gases to power the wet scrubbing system. Water droplets capture
the very small particles produced by the furnace and prevent the particles
from being discharged into the air. The water is cleaned and reused.
The various elements of the system are shown in the attached
drawing. A furnace enclosure has been installed to minimize the inflow of
air and to conserve the heat energy discharged. The enclosure also protects
the Chromasco employees and provides improved working conditions. Eojar
large dop.rs are provided so that the furnace can be charged and stoked.
The emergency discharge stack is normally closed when the gas
cleaning system is operating. The stack is opened or closed with a remotely
controlled damper valve. The ADTEC offtake duct is located on the opposite
side of the furnace enclosure. Furnace gases are drawn through this duct
to the heat exchanger. Here the gases are cooled and the water is heated.
The hot water is delivered to the nozzle which converts part of the water
to steam. This steam is used to break up the remaining water and accelerate
the water droplets to a high velocity. Gas and water droplets flow down
the mixing duct producing the draft- i-oqi.Hr.oH t-n nporgt-o i-h* system. Capture
of the solid particles by water droplets also occurs in the mixing duct.
The separator is used to remove the dirty water droplets from the
clean gases. This dirty water is pumped from the bottom of the separator
and the gases flow out the clean gas discharge located at the top of the
separator. The wattr is piped to the clarifier where it is treated to remove
the solid particle*. Clean water from the top of the clarifier is piped to
the primary pumps. These pumps return the water to the heat exchanger for
reuse.
Pilot tests of this system monitored by the Shelby County Health
Department showed that cleaning ability of the equipment more than meets the
Code requirements. It should be noted that Chromasco has installed this
equipment over fifteen (15) months before it is required by the Air Pollution
Control Regulations.
Every effort has been made to design and provide a simple system
with rugged components. It is expected that a high degree of reliability
will be achieved with low maintenance requirements.
C-4
-------
OPERATION OF ADTEC SCRUBBER ON 21 FURNACE
February 1 a^d 2, 1972
• • . . .
Time
Feb 1
1253
1357 .
1508
Feb 2
0803
t0903 '
:i0377
1207
1323
1420
1545
Temp
Gas to
HE
of
1100
1050
1095
1025
1120
1065
1090
1105
1035
1085
Temp •
Gas From
HE
.of
326
320
342
343
344
334
358
356
319
344
Temp
Water .
To Nozzle
of .
373.
370
365
378
381
383
378
377
377
384
Flow
Water
To Nozzle
• cm
82
82
82
86
. 81
82
86
8t
80
82
. Flow
Gas
in HE
= */M .
774
855
824
920
830
897
920
843
874
881
Water /Gas
Ratio
0.81
0.79
0.82
0.77
0.80
0.75
0.77
0.79
0.76
0.77
x - H.E. = Heat'Exchanger
C-5
-------
PER CENT SOLIDS (BY VOLUME)
IN THE SCRUBBER WATER GOING TO THE CLARIFIERS
DATE
Feb.
Feb.
Feb.
Feb.
Feb.
Feb.
Feb.
Feb.
Feb.
Feb.
*
1
1
2
2
2
3
3
3
3
•
3
•TIME
1500 *
1700
1000 **
1330 ***
1430
900
1030
1130
1300
1400
PERCENTAGE
20%
n
10Z
71
91
n
10*
107.
4%
20%
*
CS'D-2.
February 15, 1972
GF/jj
C-6
-------
-------
'
::::-r-:---'/'-— — ::>
' "
^^r^^:^>-^
^^-^
-.••/.: . .: .::"--"-"--vj '
f-:. ^yv; ~;:-L^i:^^^ r-^^^rrvn . ^?.7T
- "•'*-* -
: CM
M .
Nozzle
Temperature
O) Heat Exchanger
Outlet Temp-
erature
Furnace Cas Off
Take Tempera-
ture
(Special Scale)
_ _
-.-.". •'•-—•.r.-rv. :"•:•'•• r.-TTj^-'r :".-:-::r-~ -.-.':. :^.'v-'-— .-:: r:.;"r:-i: :.-_-. r '• .-•'—-—"-- ;:-; '.'•'• .'•:.• . -JiV' '•• Cv^ .«-'--•'« ;'^
"^-^^'^^-^^;^.^/-^-^':-^
'?V-r--i. -.: •.:-- V -IV^ff" ^N : - .-:.- :' ":^^w j"^'^ : .^^ ;. :: ;'.r:u
'
Heat Exchanger
Inlet Tetnpera-
.
~0-
(Special Scale)
o
m
C-8
-------
. -. ..,, . .
r^-rl .:;--...vv. ^>— --•.-"--- -t-V^- ::.-':.-: .-.:..:~..:.-V:.'i'..:.:' -^-
-.v
- - •• - -—- - •
T ~. - *•• Q_
-^.^- o
,_ | r_^ _ -t-J^'_
• •;: CM
O
-fcr
"-. • . _'.
SSrr-^^
(6) Nozzlii Water
Temperature
(3) Heat Exchanger
. Outlet Temp-
. erature
(1) Furnace Gas Off
Take Tempera-
ture
(Special Scale)
(2) Heat Exchanger
Inlet Tempera-
ture
(Special Scale)
C-9
-------
APPENDIX D
FIELD DATA
-------
Part 10, p. 4 of 8
Plant
Run No.
Location
Date •
Operator
f JHc.&M**&&
PARTICIPATE FiaO DATA
VERY IMPORTANT - FILJ.J^.ALL^ BLANKS
Read and record at the start of each
test point or, if single point
sampling, read and.record every 5
minutes.
Sample Box Ho.
Meter Box »No.
Probe Length
Ambient Temp °F_
Bar. Press. "Hg
Assumed Moisture £__
Hecter Box Setting,
13
°F
4*C&A
>u*
Point
i : — A
Clock
T1a:e
' t
r t^
if
a*
14
i
j
i
1
i
1
I
!
Dry Gas
Meter, CF
r—
Pit
in.
C A
,u
,93
ft"
9' 19
•7*'
ot
H20
P M
•7f
i.-ic
/.0o
1.10
,15
Orifice AH
in H^O ;
Desired "
.
Actual
:
Dry Gas Temp.
OF
Inlet I Outlet
1
1
1
Pump
Vacuum
In. Hg
Gouge
.
Box
Tor:p.
°F
t
t -
1
i
t
1
I-
I
i
1
!
1
II
1
Ircpir.ger
T£TP
°F
.
S-- .-!,
CUv-^
Press
in. I-ic;
Stack
Ternp
op
/ZZ»
!
• i
»
1
:
i
\
1
t
1
•
. I 1
i
!
i
-------
Par
PARTICULATE FIELD
ERY IMPORTANT - FILL IN.ALL
Plant L
Run No.
Read and record at the start of each
test point or, if single point
sampling, read and record every 5
minutes.
Sample Box No.
Ambient Temp °F
Bar. Press. "Hg
Locatien QjL
Date 3-/y A 2
Assumed Moisture 2
Probe Length
Heater Box Setting, °F
Operator
e'
Probe Heater Setting £ 0
Probe Tip Dia.,
X -I
Clock
Point
Dry Gas
Meter, CF
Pi tot
in.
AP
Orifice AH
in HoO
Desired
Dry Gas Temp.
Actual Inlet I Outlet
Pu^ip
Vacuum
In. Hg
Gouge
Box
Temp.
°F
Impinger
Tsxp
°F
Stack
Press
Stsck
Temp
op
-------
Comments:
NCAP-37-(12/67)
-------
Pjirt TO, p.-.-.4 of 8
Plant
PARTICIPATE FIELD DATA
VERY IMPORTANT"- FILL IN.ALL BLANKS
Reap and record at the start of each
test point or, if single point
sampling, read anti record every 5
minutes. i' . ;:
Run No. •
Location
Date
Sesple Box No.
Meter "Box No.
Probe Length
Ambient Temp °F_
Bar. Press. "Hg_
6 0 .
2,9.7
Assumed Moisture %
"3
Oparator
Probe Heater Setting
'&-
Heater Box Setting, °F_
Probe Tip Dia., In.
3±
Point
Clock
Dry Gas
Meter, CF
Pi tot
in. ^20
AP
Orifice
/in H^O
Desired " Actual
Dry Gas Temp.
Inlet Outlet
Pump
Vacuum
In. Kg
Gauge
Box
Ter^p.
°F
Inpinger
°F
$*• -/-I,.
I_U^K
Press
in. n
Stack
Temp
°F
-------
Comments:
NCAP-37'(12/67)
-------
,Part 10, p. 4 of 8
PARTICULATE FIELD DATA
VERY IMPORTANT - FLR.ALL BLANKS
Read and record at the start of each
test point or, if single point
i sampling, read and record every 5
UfrlH) rillfrmlnutes. . .
Sample Box No.
Meter Box No.
Probe Length
Ambient Temp °F p
Bar. Press. "Hg 2$. 1
Assumed Moisture
^j
, -
L,
Prcbs Heater Setting
Heater Box Setting, CF ?-£t)
Probe Tip Dia., In.
Point
Dry Gas
Mater, CF
Pi tot
in. H20
AP
Orifice AH
in HoO
Dry Gas Temp.
Op
Inlet Outlet
Pump
Vacuum
In. Kg
Gouge
Box
Te.^p.
°F
Impinger
Stack
Press
in. Hg
Stack
Ter^p
o
-------
Comments:
NCAP-37-(12/67)
-------
.Part10, p. 4 of 8
PARTICULATE FIELD DATA
VERY I-ffffORTANT - FILL IN.ALL BLANKS
- _
! Plant
Run No.
Location
D£te
Read ,fii|d/record at the start of each
test'point or, if single point
sampling, read and record every 5
minutes.
Sample Box No.
Meter Box No.
Probe Length
Ambient Temp °F_
Bar. Press. "Hg
i
Operator
Point
Clock
Dry Gas
Meter, CF
Probe Hsater Setting
Assumed Moisture 2__
Heater Box Setting,
Probe Tip Dia., In.
Pi tot
in. K20
AP
Orifice AH
in HnO .
Desired " Actual
Dry Gas Temp.
Inlet i Outlet
Pump
Vacuum
In. Hg
Gouge
Box
Temp.
Impinger
Tcxp
°r
Press
in. no,
Stsck
Terr.p
°F
• a 7
,97
3
. 3 -
(, 7,
t, 7
, r
.77
- 3 >T
,77
77
\ K t> v I V9y .
.51
.77
to
n-\t<;
^7.
19
7*
_^ I.
±
dJL
tO.
\ Seo,
/ 37"
' C «/
70
J_L
f \/L: /
,69
it*
"T
? /*•'«/
3±
' i-'
^
"'L
; 3Ju
96
79
-^
7*
-+
!«..{
-------
1
1
f
o
vo
i
1
•,#c
Point
e&£'\ I
^ J*-
f\\)6~*
}Jt^
Clock
TiJBS
iLmt
/ 6 .* u y
//i rti»i
IX^*
Dry Gas
Keter, CF
h" A o , 3 7
^aa.^"o
^7. -V??
4^^^r
Pi tot
in. H20
Ap
« ^
1 •/«
/ «/ 0
•
• *? 3s
0
Actual
/.to
1,10
.
t
• £ "S
Dry Gas
°F
Inlet
/of
J O(e
g*^. 3
Temp.
Outlet
ft)
8 *
"?y . /
Pump
Vacuum
In. Hg
Gouge
^
^
,
.' 0 7
.
Box
Temp.
°F
3oo
\^
^^ti
Ircpinger
°F
to°
\*Jo*
•
v *
y ^ 7
!
i
1
Coir.ir.snts:
NCAP-37'(.12/67)
-------
-lO, p. 4 of 8
PARTI CULATE FIELD DATA
VERY IMPORTANT - FIL.N .ALL BLANKS
• Plant C&A.
Run No.
Locatien
Date
+jr
Read and record at the start of each
test point or, if single point
sampling, read and record every 5
minutes.
Sample Box No.
Meter Box No.
Probe Length
Ambient Temp °F
Bar. Press. "Hg st9, 7
Assumed Moisture %
Oparator
V$»tr»v»,Prcbe Heater Setting
Heater Box Setting, °F
Probe Tip Oia., In.
Point
Clock
Tissa
Dry Gas
Keter, CF
1 Pi tot
in.
AP
Orifice AH
in H^O
Desired
Actual
Dry Gas Temp.
°F
Inlet Outlet
Pump
Vacuum
In. Hg
Gouge
Box
To.-rp.
Impinger
. Tc^p
i
S* ~~k
Press
in. Kg
Stack
Ten:?
&$:**
Sr*
. 3 o
_££_
—a.L.
6.0
/£>
. 0
. I o
P 9 ,
Jo
13* .
It,
10
/£>
-21.
1 0
I.IO
LC.
Ji3-
92
JM.
•«».•
./a
3 i it '* I
••~i~:
If
,5-5-'
10
II
jtAL
/5> I
J^L
J1L
±L
72.
jL£.
JL
/ff ?^
JL^.
1 V
IT
& / /
°
71
n
ft
I3.
-------
• • - ".: "
Point
C-Sd^ii
* It
•
i
1
. 1
i
i
\ AVG-.
Clock *
Tircs
/e; >Y
• t>.- 3 tf
.
94
l^gJW1 ,-\ «.
CWA ^
•/CV^"^^
-5 Dry Gas
Meter, CF
5"6 . » /
•
.166
AH
0
Actual
• «^
.'« 9 £
'
«^^T
Dry Gas
°F
inlet
?^r
'Xf
'
~)o
^
1-1 f
Impinger
Tcr^p
°F
(,0
^,-
6 o
Stcck
Press
in. Ho
.
J!^^3
-0. « /
Stack
Tcn-.p
op
) 3""
/3»*
•
'
; 17
Coirments:
NCAP-37'(12/67)
-------
Part. 10, p. 4 of 8
PARTICIPATE FIELD DATA
Plant
VERY IMPORTANT' - FILL JN.. ALL. BLANKS
Read and record at the start of each
test point or, if single point
sampling, read and record every 5
minutes.
Run No.
Location
Date
^ 3
SdMAjJJU
Box No.
Meter Box No. •_
Probe Length
Ambient Temp °F_
Bar. Press. "Hg
Assumed Moisture %
/3
Oparator
£o«w», Probe Heater Setting
Heater Box Setting, °F
Probe Tip Oia., In.
"
Point
Clock
Ttoe
Dry Gas
Meter, CF
Pi tot
in. H.20
AP
Orifice AH
in HoO
Desired
Actual
Dry Gas Temp.
°F
Inlet I Outlet
Pump
Vacuum
In. Hg
Gouge
Box
Tcr.p.
°F
Impinger
Texp
°F
Stack
Press
i P. . Hq
Stack
Ten:?
. 3 o
; 03
(,0
f.
I
•T73
13
70
'I • 61
70
/3
S3*'
iSftivj
i 5"?a.
t/O
i|
•^r 8*
i
I ^9^ . ft
^
.6,0 I /£*
/o
i
I3IS
: /
32,
7V
13*'
^»./A<
_25L
a*
7 yi/.' /
9/1
At,
7?
ii. i
7?
03
J32
4o 6 •
am
133 '
,? 7
Jot,
-------
1
1
CO
1
* d:
Po-int
CSfc" II
,2,
AOL.
>4S';
Tisss
y if ; 5 iy
j ij ; •}<(
.
i
*?6
Dry Gas
Meter, CF
£/o, as
6» SU fcM
^/A - *T
*
Pi tot
in. H20
AP
• a v
» n«
.^03
Ori f i ce
in Ho
Desired
.?^
k ?W
•
-.
% 7 5"^~
AH
Actual
, S-z.
i 7W
.
(
'
. 7 ^",5"
t
Dry Gas
°F
Inlet
1 o%
II o
J? 7
Temp.
Outlet
7?
g'tf
•
•
~? 7- "J^"
Pump
Vacuum
In. Kg
Gouge
SL-f
•Ji"
.
M.2>
Box
Temp.
°F
J?C»
/
Son
Impinger
°F
^o
I
S 0
SuuCiC
Press
in. Hg
-.e»
"^MBftfc?
'^^^/J
^ d * O f
Stack
Tcnsp
op
»3o*
/3c"
'
1
131
Comments:
NCAP-37-(12/67)
-------
PARTICULATE CLEANUP SHEET
Date:
Run number:
Operator:
Plant:
Sample box number:
Location of sample port:
Barometric pressure:
Ambient temperature:
JL '
Impinger
Volume after sampling
Impinger prefilled with
Volume collected
lOOi
ml Container No.._
ml Extra No.
1007.
Ether-chloroform extraction
"•of impinger water £.$*0 mg
Impinger water residue
mg
Impingers and back half of
filter, acetone v/ash:
Container
Extra No.
Weight results_
mg
Dry probe and cyclone catch:
Container
Extra No.
Weight results
mg
Probe, cyclone, flask, and
front half of filter,
acetone wash:
No. /GO/
Extra Mo. Weight results
"N>
QOO
£>O 0
7*2.. 7^
'TotaT^arti
particulate weight
tug
Filter Papers.and Dry Filter Particulate
AL)^y*ih*4~ jP**^ oVT"
Filter number Cuircaimi no. Filter number Container no.
jz.^39,6,
- Filter particulate
weight 73'£f. 6 mg
mg
Silica Gel
Weight after test:
Weight before test:
Moisture weight collected:
Container number: 1 •/00(j 2.
Moisture total £&• 4 gm
3.
4.
Sample number:_
Method determination:
Comments;
Analyze for:
D-14
-------
PARTICULATE CLEANUP SHEET
Date:
Run number:
Operator:
punt:
Sample box number:
Location of sample port:
Barometric pressure: _
Ambient temperature: _ __
Implnger
Volume after sampling #5? ml
Implnger prefllled w1thV°0ml
Volume collected 3^ ml
ContaTner No.
Extra No.
Ether-chloroform extraction
~ of 1l"P1n9er water £.4 ma
Implnger water residue
'Jo/./ mg
Impincjers and back half of
; filter, acetone wash:
Container No
Extra No.
Weight results
'Dry probe and cyclone catch:
Container No._
Extra No.
Weight results
jng
Probe, cyclone, flask, and
| front half ?f filter,
' acetone wash:
Container
Extra No.
Weight results
mg
Filter Papers and Dry Filter Particulate
Filter number Container no. Filter «fewwr Container no.
O, Ztf*? |
I
] g^^afe^y „—p-r r* itf-=* ,
lt>20ooa
Total particulate weight
• Filter particulate
we i ght +1t3.r mg
- mg
Silica Gel
Weight after test:
Height before test: , , /^*'
Mols-ture'weight collected: A7> 9
Container number: .
Moisture
gro
Sample number;
Method determination:
Comments;
Analyze for:
D-15
-------
Date: ^
Run number: C—S
Operator: /
PARTICULATE CLEANUP SHEET
"7"L Plant:
Sample box number:
Location of sample port:
Barometric pressure:
Ambient temperature:
Impinger H20
I ml
Volume after sampling
Impinger prefilled
Volume collected ^/ ml
Container No
Extra No>
1037
Ether-chloroform extraction
~ of Impinger water /» ^ ag
Impinger water residue •£ ??.f mg
Impingers and back half of
filter, acetone wash:
Container No
Extra No.
Weight results_
//• /
Dry probe and cyclone catch:
Container No.
«
Extra No.
Weight results^
jng
Probe, cyclone, flask, and
front half of filter,
acetone wash:
Container No
Extra flo.
Weight results JLGO4-.1L
»ng
Filter Papers and Dry Fi Heir Parti cul ate
Filter number Container no.
•41 tor number Container no.
. g
Totan^par'ticulate weight
Filter parti cul ate
we ight 4-4-f/*o nig
&5~J.7.
mg
Silica Gel
Weight after test:
Weight before test:
Moisture weight collected:
Container number: . \.fQ3cf 2.
3.
4.
Moisture total
Sample number;
Method determination:
Comments;
Analyze for:
rtfrtO C&**»4*
D-16
-------
Date: «
Run number: d
Operator:
PARTICULATE CLEANUP SHEET
Plant:
& ~
Sample box number:
'Ju.
*
J +»
Location of sample port:
Barometric pressure:
Ambient tenperature:
Implnger
Volume after sampling
Implnger prefllled
Volume collected
ml Container
Extra No.
ml
Ether-chloroform extraction
~ of Implnger water
Implnger water residue
Impincjers and back half of
filter, acetone wash:
Container Ho./6/b
Extra No. Weight results
mg
Dry probe and cyclone catch:
Container No..
Extra No.
Weight results
jng
Probe, cyclone, flask, and
front half of filter,
acetone wash:
Container No. ID l£L
Extra No. Weight results
mg
Filter Papers and Dry Filter Parti cul ate
f&# . u>-*-.
Filter number Container no. riltei nuiiiuyi'1 Container no.
Total particulate weight
Filter particulate
we 1 ght /o9.<£* mg
S+7. Z mg
Silica Gel
Weight after test:
Weight before test:
Moisture weight collected:
Container number: 1./Ol J 2.
Moisture total
gm
4.
Sample number:
Method determination:,
Comments;
Analyze for:
D-17
-------
PARTICULATE CLEANUP SHEET
Plant:
Bun number:
Operator:
Sample box number:
Location of sample port:
Barometric pressure:
Ambient temperature:
Implnger H20
Volume after sampling r;V> ml
Implnger prefllled w1th4-t?t ml
Volume collected _zisjnl
Container No. /0.3R Ether-chloroform extraction
Extra No. ~ of 1mP1n9er water %5.9 ma
Implnger water res1due_
ma
Implngers and back half of
filter, acetone wash:
Container No. /O3c>
Extra No. Weight results
rog
Dry probe and cyclone catch:
Container No._
Extra No.
Weight results
jng
Probe, cyclone, flask, and
front half of filter,
acetone wash:
Container No.
Extra Mo.
Weight results
mg
Filter Papers and Dry Filter Particulate
.
Fllter number Container no. FUtor number Container no.
/»?. 7 i
l
i ^777 Total participate weight
Filter participate
weight -2 >/"£.? mg
l±L_m9
Silica Gel
Weight after test: A14.1
Weight before test: llltL.
Holsture weight collected: .3.2,3
Container number: \i)V3l 2.
3.
Moisture total
-------
Date: f
Run number:
Operator: _
5 ^"
Sample box number:
PARTICULATE CLEANUP SHEET
"•.' : "•'.' Plant: /^n>
Location of sample port:
Barometric pressure; 3
-------
APPENDIX E
STANDARD SAMPLING PROCEDURES
-------
15708
PROPOSED RULE MAKING
Subporl E—Standards of Perform-
ance for Nitric Acid Plant*
S 466.50 Applicability and designation
of affected facility.
(a) The provisions of this subpart are
applicable to nitric acid plants.
"Weak nitric acid" means acid
which is SO to 70 percent In strength.
§ 466.52 Standard for nitrogen oxides.
No person subject to the provisions of
this subpart shall cause or allow the dis-
charge Into the atmosphere of nitrogen
oxides in the effluent which are:
(a) In excess of 3 Ibs. per ton of acid
produced (1.5 Kgm. per metric ton),
maximum 2-hour average, expressed as
NO.
(b) A visible .emission within the
meaning of this part.
§466.53 Emission monitoring.
(a) There shall be Installed, cali-
brated, maintained, and operated, in any
nitric acid plant subject to the provisions
of this subpart, an instrument for con-
tinuously monitoring and recording
emissions of nitrogen oxides.
(b) The Instrument installed and used,
pursuant to this section shall have a
confidence level of at least 95 percent and
be accurate within ±20 percent and shall
be calibrated Jn accordance with the
method(s) prescribed by the manufac-
turer^) of such instrument; the instru-
ment shall be calibrated at least once
per year unless the manufacturer(s)
specifies or recommends calibration at
shorter Intervals, in which case such
specifications or recommendations shall
be followed.
(c) The owner or operator of any
nitric acid plant subject to the provisions
of this subpart shall maintain a file of all
measurements required by this subpart
and shall retain the record of any such
measurement for at least 1 year follow-
ing the date of such measurement.
§ 466.54 Test methods and procedures.
(a) The provisions of this section are
applicable to performance tests for deter-
mining emissions of nitrogen oxides from
nitric acid plants.
(b) All performance tests shall be con-
ducted while the affected facility is
operating at or above the acid product
rate for which such facility was designed.
(c) Test methods set forth In the ap-
pendix to this part shall be used as
follows:
(1) For each repetition the NO. con-
centration shall be determined by using
Method 7. The sampling location shall be
selected according to Method 1 and the
sampling point shall be the centroid of
the stack or duct. The sampling time
shall be 2 hours and four samples shall
be taken during each 2-hour period.
(2) The volumetric flow rate of the
total effluent shall be determined by us-
ing Method 2 and traversing according
to Method 1. Gas analysis shall be per-
formed by Method 3, and moisture con-
tent shall be determined by Method 4.
(d) Acid produced, expressed In tons
per hour of 100 percent weak nitric acid,
'shall be determined during each 2-hour
testing period by suitable flow meters and
shall be confirmed by a material balance
over the production system.
(e) For each repetition, nitrogen ox-
Ides emissions, expressed in Ib./ton of
weak nitric acid, shall be determined by
dividing the emission rate in Ib./hr. by
the acid produced. The emission rate
shall be determined by the equation, lb./
hr.=QxC, where Q=volumetric flow
rate of the effluent in ft.'/hr. at standard
conditions, dry basis, as determined In
accordance with J 466.54(d) (2), and
C=NO, concentration In Ib./f t.', as deter-
mined in accordance with i 466.54(d) (1),
corrected to standard conditions, dry
basis. • •'
Subpart F—Standards of Perform-
ance for Sulfuric Acid Plants
g 466.60 Applicability and designation
of affected facility.
(a) The provisions of this subpart are
applicable to sulfur acid plants.
(b) For purposes of ! 466.11(e) the en-
tire plant Is the affected facility.
§ 466.61 Definitions.
As used In this part, all terms not
denned herein shall have the meaning
given them in the Act:
(a) "Sulfuric acid plant" means any
facility producing sulfuric acid by the
contact process by burning elemental sul-
fur, alkylatlon acid, hydrogen sulfide,
organic sulfldes and mercaptans, or acid
sludge.
(b) "Acid mist" means sulfur acid mist,
as measured by test methods set forth
in this part.
§ 466.62 Standard for sulfur dioxide.
No person subject to the provisions of
this subpart shall cause or allow the dis-
charge into the atmosphere of sulfur di-
oxide in the effluent in excess of 4 Ibs.
per ton of acid produced (2 kgm. per
metric ton), maximum 2-hour average.
§ 466.63 Standard for acid mist.
No person subject to the provisions of
this subpart shall cause or allow the dis-
charge into the atmosphere of acid mist
in the effluent which is:
(a) In excess of 0.15 lb. per ton of acid
produced (0.075 Kgm. per metric ton),
maximum 2-hour average, expressed as
H.SO,.
(b) A visible emission within the
meaning of this part.
§ 466.64 Emission monitoring.
(a) There shall be installed, calibrated,
maintained, and operated, in any *^fv.ric
acid plant subject to the provisions of
this subpart, an Instrument for continu-
ously monitoring and recording emis-
sions of sulfur dioxide.
(b) The instrument Installed and used
pursuant to this section shall have a con-
fidence level of at least 95 percent and be
accurate within ±20 percent end shall
be calibrated in accordance with the
method (s) prescribed by the manufac-
turer^) of such instrument, the instru-
ment shall be calibrated at least once per
year unless the manufacturer (s) speci-
fies or recommends calibration at shorter
intervals, in which case such specifica-
tions or recommendations shall be fol-
lowed.
(c) The owner or operator of any sul-
furic acid plant subject to the provisions
of this subpart shall maintain a file of
all measurements required by this sub-
part and shall retain the record of any
such measurement for at least 1 year
following the date of such measurement.
§ 466.65 Test methods and procedures.
(a) The provisions of this section are
applicable to performance tests for de-
termining emissions of acid mist and sul-
fur dioxide from sulfuric acid plants.
(b) All performance tests shall be con-
ducted while the affected facility is op-
erating at or above the acid production
rate for which such facility was designed.
(c) Test methods set forth in the
appendix to this part shall be used as
follows:
(1) For each repetition the acid mist
and SO, concentrations shall be deter-
mined by using Method 8 and traversing
according to Method 1. The sampling
time shall be 2 hours, and sampling vol-
ume shall be 40 ft.3 corrected to standard
conditions.
(2) The volumetric flow rate of the
total effluent shall be determined by us-
ing Method 2 and traversing according
to Method 1. Gas analysis shall be per-
formed by Method 3. Moisture content
can be considered to be zero.
(d) Acid produced, expressed in tons
per hour of 100 percent sulfuric acid
shall be determined during each 2-hour
testing period by suitable flow meters
and shall be confirmed by a material
balance over the production system.
(e) For each repetition, acid mist and
sulfur dioxide emissions, expressed in
Ib./ton of sulfuric acid shall be deter-
mined by dividing the emission rate in
Ib./hr. by the acid produced. The emis-
sion rate shall be determined by the
equation, lb./hr.=QxC, where Q=volu-
metric flow rate of the effluent in ft.'/hr.
at standard conditions, dry basis, as de-
termined in accordance with § 466.65 (d)
(2), and C=acid mist and SO, concen-
trations in lb./ft.' as determined in ac-
cordance with 5 466.65(d) (1), corrected
to standard conditions, dry basis.
APPENDIX—TEST METHODS
METHOD 1—SAMPLE AND VELOCITY TRAVERSES
FOB STATIONARY SOURCES
1. Principle and applicability.
1.1 Principle. A sampling site and the
number of traverse points are selected to
aid In the extraction of a representative
sample.
1.2 Applicability. This method should be
applied only when specified by the test pro-
cedures for determining compliance with
FEOHAl REGISTER, VOL. 36, NO. IS*—TUESDAY, AUGUST 17, 1971
E-l
-------
I
ro
New Source Performance Standards. This
method Is not Intended to apply to gas
streams other than those emitted directly to
the atmosphere without further processing.
2. Procedure.
3.1 Selection of a sampling site and mini-
mum number of traverse points.
2.1.1 Select a sampling site that. Is at
least eight stack or duct diameters down-
stream and two diameters upstream from
any flow disturbance such as a bend, expan-
sion, contraction, or visible flame. For a
rectangular cross section, determine an
equivalent diameter from the following
equation:
equivalent diamcter=2
,[• (length) (width) "I
L length+width J
equation 1-1
2.1.3 When the above sampling site cri-
teria can be met, the minimum number of
traverse points Is twelve (12).
2.1.8 Some sampling situations reader the
above sampling site criteria Impractical.
When this Is the case, choose a convenient
sampling location and use Figure l-l to
determine the minimum number of traverse
points.
2.1.4 To use Figure 1-1 first measure the
distance from the chosen sampling location
to the nearest upstream and downstream
disturbances. Determine the corresponding
number of traverse points for each distance
from Figure 1-1. Select the higher of the two
numbers of traverse points, or a greater value.
such that for circular stacks the number is
a multiple of four, and for rectangular staples
the number follows the criteria of section
2.2.2.
2.2 Cross sectional layout and location of
traverse points.
2.2.1 For circular stacks locate the traverse
points on two perpendicular diameters ac-
cording to Figure 1-2 and Table 1-1.
NUMBER OF DUCT DIAMETERS UPSTREAM'
(DISTANCE A)
•FROM POINT Of ANY TYPE OF
DISTURBANCE (BEND. EXPANSION, CONTRACTION, ETC.)
Figure 1-2. Cross section of circular stack showing location of
traverse points on perpendicular diameters.
b
. 0
______
0
1
1
•° i °
**• — t — "
i
O 1 O
1
1
r r -1
1
01 0
1
!
o •
c
i
i
I
Figure 1-3. Cross section of rectangular stack divided Into 12 equal
areas, with traverse points at centroid of each area.
10
NUMBER OF OUaOIAMETm DOWNSTREAM*
(DISTANCE •)
Figure 1*1. Minimum mimbar of Invent polnti.
FEDERAL RECISTER, VOl. 36, NO. 159—TUESDAY, AUGUST 17, W1
-------
Table 1-1. Location of traverse points in circular stacks
(Percent of stack diameter from inside wall to traverse point)
i
CO
Traverse
point
number
on a
diameter
1
2
3
4
6
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
' 21
22
23
24
Number of traverse
6 8 10
4.4 3.3 2.5
14.7 10.5 8.2
29.5 19.4 14.6
70.5 32.3 22.6
85.3 67.7 34.2
95.6 80.6 65.8
89.5 77.4
96.7 85.4
91.8
97.5
12
2.%
6.7
11.8
17.7
25.0
35.5
64.5
75.0
82.3
88.2
93.3
97.9
14
1.8
5.7
9.9
14.6
20.1
26.9
36.6
63.4
73.1
79.9
85.4
90.1
94.3
98.2
points
16
1.6
4.9
8.5
12.5
16.9
22.0
28.3
37.5
62.5
71.7
78.0
83.1
87.5
91.5
95.1
98.4
on a diameter
18
1.4
4.4
7.5
10.9
14.6
18.8
23.6
29.6
38.2
61.8
70.4
76.4
81.2
85.4
89.1
92.5
95.6
93.6
20
1.3
3.9
6.7
9.7
12.9
16.5
20.4
25.0
30.6
38.8
61.2
69.4
75.0
79.6
83.5
87.1
90.3
93.3
96.1
98.7
22
1.1
3.5
6.0
8.7
11.6
14.6
18.0
21.8
26.1
31.5
39.3
60.7
68.5
73.9
78.2
82.0
85.4
88.4
91.3
94.0
96.5
98.9
24
1.1
3.2
5.5
7.9
10.5
13.2
16.1
19.4
23.0
27.2
32.3
39.8
60.2
67.7
72.8
77.0
80.6
83.9 :
86.8
89.5
92.1
94.5
96.8
98.9
S.2.2. Tor rectangular stack! divide the
erou section Into as many equal rectangular
areas aa traverse points, such that the ratio
of the length to the width of the elemental
area* Is between one and two. locate the tra-
verse points at the centrold of each equal
area according to Figure 1-3.
3. References. Determining Dust Concen-
tration In a Gas Stream. ASME Performance
Test Code #27. New York. 1957.
Devorkln, Howard, et al. Air Pollution
Source Testing Manual. Air Pollution Con-
trol District. Los Angeles. November 1983.
Methods for Determination of Velocity,
Volume, Dust and Mist Content of Gases.
Western Precipitation Division of Joy *tanu-
facturlng Co. Los Angeles. Bulletin V'P-50.
1908.
not be used In the case of nbndlrectlonal
flow.
2. Apparatus.
2.1 Pltot tube—Type S (Figure 3-1),.or
, equivalent.
2.2 Differential pressure gauge—Inclined
manometer, or equivalent, to measure ve-
locity head to within 10 percent of .the mini-
mum valve.
2.3. Temperature gauge—Thermocouples.
bimetallic thermometers, liquid filled sys-
tems, or equivalent, to measure stack tem-
perature to within 1.5 percent of the mini-
mum absolute stack temperature.
2.4 Pressure gauge—Mercury-filled U-tube
manometer, or equivalent, to measure stack
pressure to within 0.1 in. Hg.
2.5 Barometer—To measure atmospheric
pressure to within 0.1 In. Hg.
' standard Method for Sampling Stacks for
Partlculate Matter. In: 1971 Book of ASTM
Standards, Part 23. Philadelphia, 1971. ASTM
Designation D-2928-71.
METHOD 2—DETERMINATION Or STACK CAS
VELOCITY (TYPE 8 PITOT TUBE)
1. Principle and applicability.
1.1 Principle. Stack gas velocity Is de-
termined from the gas density and from
measurement of the velocity head using a/
Type S (Stauschelbe or reverse type) pitot
tube.
1.2 Applicability. This method should be
applied only when specified by the test pro-
cedures for determining compliance with
New Source Performance Standards. Being a
directional Instrument, a pltot tube should
3.0 Gas analyzer—To analyze gas compo-
sition for determining molecular weight.
3.7 Pltot tube—Standard type, to cali-
brate Type S pltot tube.
3.-Procedure.
3.1 Set up the apparatus as shown In Fig-
ure 2-1. Make sure all connections are tight
and leak free. Measure the velocity head at
the traverse points specified by Method 1.
'3.2 Measure the temperature of the stack
/as. If the total temperature variation with
time Is less than 60* P., a point measurement
will suffice. -Otherwise, conduct a tempera-
ture traverse.
• 3.3 Measure the static pressure in the
•stack.
3.4 Determine the stack gas molecular
weight by gas analysis and appropriate cal-
culation as Indicated In Method 3.
PIPE COUPLING
TUBING ADAPTER
O
8
I
I
Figure 2-1. Pitot tube - manometer assembly.
4. Calibration.
4.1 To calibrate the pltot tube, measure
the velocity head at some point in a flowing
gas stream with both a Type S pltot tube and
a standard type pltot tube with known co-
efficient. The velocity of the flowing gas
stream should be within the normal working
range.
FEDERAL REGISTER,-VOL. 36, NO. 159—TUESDAY, AUGUST 17, 1971
-------
PROPOSED RULE MAKING
15711
4.3 Calculate the pltot tube coefficient
using Equation 9-1.
where:
c»i..«=Plto* tube coefficient of Type 8
pltot tube.
C».u=Pltot tube coefficient of standard
type pltot tube (If unknown, use
0.99).
AP.,4=Veloclty bead measured by stand-
ard type pltot tube.
AP, ,=Velocity head measured by Type S
pltot tube.
C3 Compare the coefficients of the Type S
pltot tube determined first with one leg and
then the other pointed downstream. Use the
pilot tube only If the two coefficients differ
by no more than 0.01.
« Oaioulations.
equation 2-1 Uae Equation 2-2 to calculate the stack gas
velocity.
V.-K.CV1
equation 2-2
»here:
V.=Stack gas velocity, feet per second (f.p.s.).
Ks=86.48
ft. / lb. \V>
eeo. Mb-mote-'B/
when these units
•ranged.
fc
p.-
M,=
Pltot tube coefficient, dlmensiocless.
'Absolute stack gas temperature, °K.
•Velocity head o! stack gas, In HiO (see fig. 2-2).
Absolute stack gas pressure, In Hg.
Molecular weight of stack gas, Ib./lb.-mole.
PLANT_
DATE i
RUN NO.
STACK DIAMETER. In.
BAROMETRIC PRESSURE, In.
STATIC PRESSURE IN STACK (Pg), In. Hg._
OPERATORS .
SCHEMATIC OF STACK
CROSS SECTION
Traverse point
Velocity head,
in. H20
AVERAGE:
Stack Temperature
Figure 2-2 shows a sample recording sheet
for velocity traverse data. Use the averages in
the last two columns of Figure 2-2 to deter-
mine the average stack gas velocity from
Equation 2-2.
C. References.
Mark, L. 8. Mechanical Engineers' Hand-
book. McGraw-Hill Book Co., Inc., New York,
1951.
Perry, J. H. Chemical Engineers' Handbook.
McGraw-Hill Book Co., Inc., New York, 1960.
Shlgehara, R. T., W. F. Todd, and W. S.
Smith. Significance of Errors In Stack Sam-
pling Measurements. Paper presented at the
Annual Meeting of the Air Pollution Control
Association, St. Louis, Mo., June 14-19, 1970.
Standard Method for Sampling Stacks for
Partlculate Matter. In: 1971 Book of ASTM
standards, Part 23. Philadelphia, 1971. ASTM
Designation D-2928-71.
Vennard, J. K. Elementary Fluid Mechanics.
John Wiley and Sons, Inc., New York, 1947.
METHOD 3—CAS ANALYSIS FOB CARBON DIOXIDE.
' KJCCESS ADI, AND DRT MOLECU1AE WEIGHT •
1. Principle and applicability.
1.1 Principle. An integrated or grab gas
sample is extracted from a sampling point
and analyzed for its components using an
Orsat analyzer.
1.2 Applicability. This method should be
applied only when specified by the test pro-
cedures for determining compliance with New
Source Performance Standards.
2. Apparatus.
2.1 Grab sample (Figure 3-1).
2.1.1 Probe—Stainless steel or Pyrex1
glass, equipped with a filter to remove par-
ticulate matter.
2.1.2 Pump—One-way squeeze bulb, or
equivalent, to transport gas sample to ana-
lyzer..
2.2 Integrated sample (Figure 3-2).
2.2.1 Probe—Stainless steel or Pyrex1
glass equipped with a filter to remove par-
ticulate matter.
2.2.2 Air-cooled condenser—To remove
any excess moisture.
2.2.3 Needle valve—To adjust flow rate.
2.2.4 Pump—Leak-free, diaphragm type.
or equivalent, to pull gas.
2.2.5 Rate meter—To measure a flow range
from 0 to 0.035 c.f m. •
2.2.6 Flexible bag—Tedlar,1 or equivalent,
with a capacity of 2 to 3 cu. ft. Leak test the
bag in the laboratory before using.
2.2.7 Pitot tube—Type S, or equivalent,
attached to the probe so that the sampling
flow rate can be regulated proportional to the
stack gas velocity when velocity la varying
with time or a sample traverse is conducted.
2.3 Analysis.
2.3.1 Orsat analyzer, or equivalent.
3. Procedure.
3.1 Grab sampling.
3.1.1 Set up the equipment as shown In
Figure 3-1. Place the probe In the stack at a
campling point and purge the sampling line.
Figure 2-2. Velocity traverse data.
1 Trade name.
FEDERAL REGISTER, VOL. 36, NO. 159—TUESDAY, AUGUST 17, 1971
No. 150—Pt n-
E-4
-------
15712
PROPOSED RULE MAKING
PROBE
FLEXIBLE TUBING
T£R(G
FILTER (GLASS WOOL!
SQUEEZE BULB
Figure 3-1. Grab-sampling train.
RATE METER
VALVE
AIR-COOLED CONDENSER / PUMP
PROBE
QUICK DISCONNECT
FILTER (GLASS WOOL)
RIGID CONTAINER'
Figure 3-2. Integrated gas - sampling train.
3.1.2 Draw sample into the analyzer.
3.2 Integrated sampling.
3.2.1 Evacuate the flexible bag. Set up the
equipment as shown In Figure 3-2 with the
bag disconnected. Place the probe In the
stack and purge the sampling line. Connect
the bag, making sure that all connections
are tight and that there are no leaks.
3.2.2 Sample at a rate proportional to the
stack gas velocity.
3.3 Analysis.
3.3.1 Determine the CO2. CK, and CO con-
centrations as soon as possible. Make as many
passes as are necessary to give constant read-
Ings. If more than 10 passes are necessary,
replace the absorbing solution.
3.3.2 For Integrated sampling, repeat the
analysis until three consecutive run* vary
no more than 0.2 percent by volume for e&h
component being analyzed.
4. Calculations.
4.1 Carbon dioxide. Average the three
consecutive runs and report result to the
nearest 0.1 percent CO*.
4.2 Excess air. Use Equation 3-1 to cal-
culate excess air, and average the runs. Re-
port the result to the nearest 0.1 ; rcent
excess air.
%KA =
(%0.)-0.5(%CO) '
0.264(% N,)-(% 0,)+0.5(
equation 3-1
where:
%EA= Percent excess air.
%O,= Percent oxygen by volume, dry
basis.
%N,= Percent nitrogen by volume, dry
basis.
%CO=Percent carbon monoxide by vol-
ume, dry basis.
0.264 = Ratio of oxygen to nitrogen In air
by volume.
4.3 Dry molecular weight. Use Equation
3-2 to calculate dry molecular weight and
average the runs. Report the result to the
nearest tenth.
CO,) +0.32(% O,)
+0.28(% N,+ %CO)
Equation 3-1
where:
Md=Dry molecular weight, lb./lb.-
mole.
% CO, = Percent carbon dioxide by volume,
dry basis.
%O,= Percent oxygen by volume, dry
. basis.
%N,= Percent nitrogen by volume, dry
basis.
0.44= Molecular weight of carbon dioxide
divided by 100.
0.32= Molecular weight of oxygen
divided by 100.
0.28= Molecular weight of nitrogen
divided by 100.
6. References
TO ANALYZER AltshuUer, A. P., et al. Storage of Oases
and Vapors In Plastic Bags. Int. J. Air &
Water Pollution. 6.76-81.1963.
Conner, William D., and J. S. Nader Air
Sampling with Plastic Bags. Journal of the
American Industrial Hygiene Association.
25:291-297. May-June 1964. ,
Devorkln, Howard, et al. Air Pollution
Source Testing Manual. Air Pollution Con-
trol District. Los Angeles. November 1963.
METHOD 4 DETERMINATION OF MOISTUBE IK
STACK CASES
1. Principle and applicability.
1.1 Principle. Moisture Is removed from
the gas stream, condensed, and determined
gravlmetrlcally.
1.2 Applicability. This method Is appli-
cable for the determination of moisture in
stack gas only when specified by test proce-
dures for determining compliance with New
Source Performance Standards. This method
does not apply when liquid droplets are pres-
ent In the gas stream.'
Other methods such as drying tubes, wet
bulb-dry bulb techniques, and volumetric
condensation techniques may be used sub-
ject to the approval of the Administrator.
2. Apparatus.
2.1 Probe—Stainless steel or Pyrex> glass
sufficiently heated to prevent condensation
and equipped with a filter to remove par-
ticulate matter.
2.2 Implngers—Two midget Implngers,
each with 30 ml. capacity, or equivalent.
2.3 Ice bath container—To condense
moisture In Implngers.
2.4 Silica gel tube—To protect pump and
dry gas meter.
2.6 Needle valve—To regulate gas flow
rate.
2.6 Pump—Leak-free, <«••»»"•»•"» type, or '
equivalent, to pull pas through train.
2.7 Dry gas meter—To measure to within
» percent of the total sample volume.
2.8 Rotameter—To measure a flow range
from 0 to 0.1 c.f.m.
2.9 Balance—Capable of measuring to the
nearest 0.1 g.
2.10 Barometer—Sufficient to read to
within 0.1 in. Hg.
2.11 Pilot tube—Type S, or equivalent, at-
tached to probe so that the sampling flow
rate can be regulated proportional to the
stack gas velocity when velocity is varying
with time or a sample traverse is conducted.
3. Procedure.
3.1 Place about 5 ml. distilled water In
each Implnger and weigh the Implnger and
contents to the nearest 0.1 g. Assemble the
apparatus without the probe as shown in Flg-
•ure 4-1. Leak check by plugging the inlet to
the first impinger and drawing a vacuum. In-
sure that flow through the dry gas meter is
Mess than 1 percent of the sampling rate.
3.2 Connect the probe, and sample at a
constant rate of 0.075 c.f.m. or at a rate pro-
portional to the stack gas velocity not to ex-
ceed 0.075 c.f.m. Continue sampling until the
dry gas meter registers 1 cu. ft. or until visible
liquid droplets are carried over from the first
impinger to the second. Record temperature,
pressure, and dry gas meter reading as re-
quired by Figure 4-2.
3.3 After collecting the sample, weigh the
impingers and their contents again to the
nearest 0.1 g.
i Trade name.
: If liquid droplets are present in the gas
stream, assume the stream to be saturated,
determine the average stack gas temperature
(Method 1), and use a psychrometrle chart
to obtain an approximation of the moisture
percentage.
FEDERAL REGISTER, VOL. 36, NO. 159—TUESDAY, AUGUST 17, 1971
E-5
-------
4. Calculation!.
4.1 Volume of water collected.
, (W,-W.)HT.M.
equation 4-1
where:
V»«=Volume of water vapor collected
(standard conditions), cu. ft.
PROPOSED RULE MAKING
Wt=nnal weight of Impingen and
contents, g.
Wi=Inltial weight of Implngers and
contents, g.
B=Ideal gas constant, 21.83-ln. Hg—
cu. ft./lb. mole-' B.
T.u=Absolute temperature at standard
conditions, 630* B.
P.I4=Pressure at standard conditions,
39.92 In. Hg.
M,=Molecular weight of water, 18
Ib./lb. mole.
SILICA GEL TUBE
HEATED
FILTER '(GLASS WOOL)
ICE BATH
LOCATION.
TEST
DATE
OPERATOR.
POMP
Figure 4-1. Moisture-sampling train.
COMMENTS
DRY GAS METER
BAROMETRIC PRESSURE.
CLOCK TIME
GAS VOLUME THROUGH
METER, (Vm).
ft*
ROTAMETER SETTING,
ftVmin
-
-
METER TEMPERATURE,
•F
43 Gas volume.
15713
l-
' in. Hg/ T. equation 4-2
where:
V.«=Dry gas volume through meter at
standard conditions, cu. ft.
V»=Dry gas volume measured by meter.
cu. ft.
Pm = Barometric pressure at the dry gas
meter, In. Hg.
P.u=Pressure at standard conditions.
29.92-ln. Hg.
T.,j= Absolute temperature at standard
conditions, 530° R.
T»= Absolute temperature at meter
(•P.+460). 'R.
4.3 Moisture content.
Y..
'V..
"V..+V..
-f (0.025)
Figure 4-2. Field ir.clslure determination.
equation 4-3
where:
Bw.=Proportion by volume of water
vapor In the gas stream, dlmen-
slonless.
Vw«=Volume of water vapor collected
(standard conditions), cu. ft.
V»«=Dry gas volume through meter
(standard conditions), cu. ft.
BwB=Approxlmate volumetric proportion
of water vapor In the gas stream
leaving the Impingers, 0.025.
5. References.
Air Pollution Engineering Manual,
Danlelson, J. A.
-------
15714
PROPOSED RULE MAKING
3.1.3 Pltot tube—Typ« 8. or equivalent,
attached to probe to monitor (tack gas
Telocity.
3.1.4 Filter holder—Pyrex1 glass with
beating system capable ol maintaining any
temperature to a maximum of 225* F.
2.1.5 Implngers—Four Implngers con-
nected in series with glass ball Joint fittings.
The first, third, and fourth Implngers are of
the Greenhurg-Smlth design, modified by re-
HEATED AREA
PROBE
REVERSE-TYPE
PITOT TUBE
placing the tip with a Vi-lnch ID glass tube
extending to '/i-lnch from the bottom of the
flask. The second Implnger Is of the Qreen-
burg-Smlth design with the standard tip.
2.1.8 Metering system—Vacuum -gauge,
leak-free pump, thermometers capable of
measuring temperature to within 5' F., dry
gas meter with 2 percent accuracy, and re-
lated equipment, or equivalent, as required
to maintain an isoklnetic sampling rate and
to determine sample volume.
FJLTER HOLDER THERMOMETER CHECK
VALVE
VACUUM
LINE
IMPIMGERS ICE BATH
PASS.VALVE
VACUUM
\ GAUGE
MAIN VALVE
DRY TEST METER
AIR-TIGHT
PUMP
Figure 5-1. Paniculate-sampling train.
3.1.T Barometer—To measure atmospheric
pressure to ±0.1 In. Hg.
13 Sample recovery.
3.3.1 Probe brush—At least as long as
probe.
2.2.2 Qlaw ~ash bottles—Two.
2.2.3 Glass sample storage containers.
3.2.4 ursduated cylinder—260 mU
2.3 Analysis.
2.3.1 Qlw« -relghlng dishes.
2.3.2 'Desiccator.
2.3.3 Analytical balance—To measure to
±0.1 mg.
2.3.4 Beakers—250 ml.
1 Trade name..
2.3.5 Separator? funnels—600 ml. and
1,000 ml.
2.3.8 Trip balance—300 g. capacity, to
measure to ±0.05 g.
2.3.7 Graduated cylinder—25 ml.
3. Reagents.
3.1 Sampling
3.1.1 Filters—Glass fiber, MSA 1106 BH,
or equivalent, numbered for identification
and prewelghed.
3.13 Silica gel—Indicating type, « to 18
mesh, dried at 175* O. (350' F.) for 2 hours.
•3.1.3 Water—Dainnlzed, distilled.
3.1.4 Cninhe
-------
PROPOSED RULE MAKING
15715
PLANT
LOCATION.
OPERATOR.
DATE
RUN NO.
SAMPLE BOX N0j_
METER BOX N0._
METER AHg
C FACTOR
AMBIENT TEMPERATURE.
BAROMETRIC PRESSURED
ASSUMED MOISTURE, «_
HEATER BOX SETTING
PROBE LENGTH, in.
NOZZLE DIAMETER, in. _
PROBE HEATER SETTING.
SCHEMATIC OF STACK CROSS SECTION
TRAVERSE POINT
NUMBER
TOTAL
SAMPLING
TIME
(«), min.
AVERAGE
STATIC
PRESSURE
(Ps). in. Hg.
STACK
TEMPERATURE
). h3
GAS SAMPLE TEMPERATURE
AT DRV GAS METER
INLET
ITm ,„.).- F
Avg.
OUTLET
(Tmoul).eF
Avg.
Avg.
SAMPLE BOX
TEMPERATURE,
»F
IMPINGER
TEMPERATURE,
"F
4.2 Sample recovery. Exercise care in mov-
ing the collection train from the test site to
the sample recovery area to minimize the loss
of collected sample or the gain of extraneous
participate matter. Set aside portions of the
water and acetone used in the sample recov-
ery as blanks for analysis. Place the samples
In containers as follows:
Container No. 1. Remove the filter from Its
holder, place In this container, and seal.
Container No. 2. Place loose particulate
matter and acetone washings from all sam-
ple-exposed surfaces prior to the filter In this
container and seal. Use a razor blade, brush.
or rubber policeman to loosen adhering par-
ticles.
Container No. 3. Measure the volume of
water from the first three Impingers and
place the water in this container. Place water
Figure 5-2. Particulate field data.
rinsings of all sample-exposed surfaces be-
tween the filter and fourth Impinger In this
container prior to sealing.
Container No. 4. Transfer the slllcft gel
from the fourth impinger to the original
container and seal. Use a rubber policeman
as an aid in removing silica gel from the
Impinger.
Container No. 5. Thoroughly rinse all sam-
ple-exposed surfaces between the filter and
fourth Impinger with acetone, place the
washings In this container, and seal.
4.3 Analysis. Record the data required on
the example sheet shown In Figure 5-3.
Handle each sample container as follows:
Container No. 1. Transfer the filter and any
loose particulate matter from the sample
container to a tared glass weighing dish, des-
sicate, and dry to a constant weight. Report
results to the nearest 0.5 mg.
Container No. 2. Transfer the acetone
washings to a tared beaker and evaporate to
dryness at ambient temperature and pres-
sure. Dessicate and dry to a constant weight.
Report results to the nearest 0.5 mg.
Container No. 3. Extract organic particulate
from the Impinger solution with three 26 ml.
portions of chloroform. Complete the ex-
traction with three 25 ml. portions of ethyl
ether. Combine the ether and chloroform ex-
tracts, transfer to a tared beaker and evapo-
rate at 70° P. until no solvent remains. Des-
sicate, dry to a constant weight, and report
the results to the nearest 0.5 mg.
Container No. 4. Weigh the spent silica
gel and report to the nearest gram.
FEDERAL REGISTER, VOl. 36, NO. 159—TUESDAY, AUGUST 17, 1971
E-8
-------
15716
PROPOSED RULE MAKING
PIANT_
OATE__
RUN NO,
CONTAINER
NUMBER
1
2
3a«
3b«»
S
TOTAL
WEIGHT OF PARTICIPATE COLLECTED.
mg
FINAL WEIGHT
X,
TARE WEIGHT
;x^
WEIGHT GAIN
•
where:
V-.,«=Volum« of gas sample through the
dry gas meter (standard condi-
tions) , cu. ft.
V»=Volume of gas sample through the
dry gas meter (meter conditions),
eu. ft.
T,a=Absolute temperature at standard
conditions, 630 °B.
T.=Aver age dry gits meter temperature,
•B.
P,,,=Barometric pressure at the orifice
meter, In. Hg.
AH=Pressure drop across the orifice
meter, in HO.
13.6=Specific gravity of mercury.
PM1=Absolute pressure at standard con-
ditions, 29.92 In. Hg.
6.14 Volume of Water vapor.
cu. ft.
1.0474
*3a • ORGANIC EXTRACT FRACTION.
"3b • RESIDUAL WATER FRACTION.
FINAL
INITIAL
LIQUID COLLECTED
TOTAL VOLUME COLLECTED
VOLUME OF LIQUID
WATER COLLECTED
IMPINGER
VOLUME.
ml
-
SILICA GEL
WEIGHT.
9
9* ml
ml.
equation 5-2
where:
Vw.t4=Volume of water vapor In the gas
sample (standard conditions) , cu.
' ft.
Vi.rrToUl Tolume of liquid collected in
Unpingers and silica gel (see Fig-
ure 5-3), ml.
»H,o=Denslty of water, l g./mL
Mn,o= Molecular weight of water, 18 Ib./lb.
mole.
B= Ideal gas constant, 21.83 in Hg-cu.
ft./lb. mole-°B.
Tita=Ab6olute temperature at standard
conditions, 530° R.
P td=Absolute pressure at standard con-
ditions. 29.92 In. Hg.
6.1.4 Total gas volume.
"tottl= * m»td~t" V wltd
•CONVERT WEIGHT Of WATER TO VOLUME BY DIVIDING TOTAL WEIGHT"
INCREASE BY DENSITY OF WATER. (1 g/ml):
INCREASE, g
(1 g/ml)
VOLUME WATER, ml
equation 5-3
where:
V,,,ll=Total volume of gas sample (stand-
ard conditions) , cu. ft.
V»i,ia= Volume of gas through dry gas
meter (standard conditions), cu.
ft.
• V.mlJ= Volume of water vapor in the gas
sample (standard conditions) , cu.
ft.
6.1.6 Total particulate weight. Determine
tli« total particulate catch from the sum of
the weights on the analysis data sheet (Fig-
ure 5-3).
6.1.6 Concentration.
Figure 5-3. Analytical data.
IL.\(™±\
Container No. 5. Transfer the acetone
washings to a tared beaker and evaporate to
dryuess at ambient temperature and pres-
sure. Desiccate, dry to a constant weight, and
report the results to the nearest 0.5 mg.
5. Calibration.
Use standard methods and equipment ap-
proved by the Administrator to calibrate
the orince meter, pilot tube, dry gas meter,
and probe heater.
6. Calculations.
6.1 Sample concentration method.
6.1.1 Average dry gas meter temperature.
See data sheet (Figure 5-2).
6.1.2 Dry gas volume. Correct the sample
volume measured by the dry gas meter to
standard conditions (70° P., 29.92 in. Hg) by
using Equation 5-1.
v
equation 5-1
c.'
equation 5-4
where;
c'.=Concentration of particulate matter
In stack gas (Sample Concentra-
tion Method), gr./s.c.f.
M.=Total amount of particulate mat-
ter collected, mg.
V,.1.,=Total volume of gas sample (stand-
ard conditions), cu. ft.
6.3 Ratio of area method.
6 J.I Stock gas velocity. Collect the neces-
sary data as detailed in Method 2. Correct the
FIOKAL K6ISTEI. VOL 34, NO. 159—TUESDAY, AUGUST 17, If71
E-9
-------
stack gas velocity to standard conditions
(29.92 in. Hg, 530° R.) as follows:
S
i
a
mi '
1' in. Hg/ \ T. / equation 5-5
where:
V.iM=Stack gas velocity at standard con-
ditions, ft. /sec.
V.=Stack gas velocity calculated by
Method 2, Equation 2-3, ft./sec.
P.=Absolute stack gas pressure. In. Hg.
P,tt=Absolute pressure at standard oon-
tlons, 39.92 In. Hg.
Tlt<=Absolute temperature at standard
conditions, 530* R.
T.= Absolute stack gas temperature
(average), *R.
t
6.2.2 Concentration.
'•=0:'
Mj A.
e A_
where:
Ci=Concentration of partlculate matter
In the stack gas (Ratio of Area
Method), gr./s.c.f.
M.=Partlculate mass now rate through
the stack (standard conditions),
mass/time.
Qi= Volumetric flow rate of gas stream
through the stack (standard con-
ditions) , volume/time.
Mr. = Total amount of partlculate matter
collected by train, mg.
. I=Total sampling time, mln.
A.=Cross-sectional area of stack, sq. ft.
A.=Cross-sectlonal area of nozzle, sq. ft.
V.,ta=Stack gaa velocity at standard con-
ditions, ft./sec.
6.3 Isokinetlc variation.
c.
^XlOO--
9V.P.A.
X100 =
min.
AH
c'.=Concentration of paniculate matter
In the stack gaa (Sample Concentra-
tion Method). gr./s.c.f.
7. References.
Addendum to Specifications for Incinerator
Testing at Federal Facilities PBS, KCAPC.
Dec. 6,1867.
Martin, Robert M. Construction Details of
Isoklnetlo Source Sampling Equipment. En-
vironmental Protection Agency, APTD-0581.
Bom, Jerome J. Maintenance, Calibration,
and Operation of Isoklnetlo Source Sampling
Equipment. Environmental Protection
Agency, APTD-0676.
Smith, W. S.; R. T. Bhlgehara, and W. F.
Todd. A Method of Interpreting Stack Sam-
pling Data. Paper presented at the 63d
Annual Meeting of the Air Pollution Control
Association, St. Louis. June 14-19, 1970.
Smith, W. S., et al. Stack Gas Sampling Im-
proved and Simplified with New Equipment.
APCA Paper No. 67-119.1967.
Specifications for Incinerator Testing at
Federal Facilities. PHS, NCAPC. 1967.
METHOD S—DETERMINATION OF STOTOB DIOXIDE
EMISSIONS FROM 8TATIONABT SOUftCES
1. Principle and applicability.
1.1 Principle. A gas sample Is extracted
from the sampling point In the stack, and
the acid mist Including sulfur trloxlde Is
separated from the sulfur dioxide. The sulfur
dioxide fraction Is measured by the barium*
thorln tltratlon method.
1.3 Applicability. This method Is appllca-
9V.P.A.
where: '
I=Percent of isoklnetlc sampling.
Ci=Concentratlon of participate matter
in the stack gas (Ratio of Area
Method), gr./s.c.f.
C 4 = Concentration of partlculate matter .
In the stack gaa (Sample Concen-
tration Method), gr./s.c.f.
Vi.sTotal volume of liquid collected In
Implngers and silica gel (see Fig-
ure 5-3), ml.
»H.o=Density of water, 1 g./ml.
R=r Ideal gas constant, 31.83 In. Hg-cu.
ft./lb. mole-'R.
Mnao=Molecular weight of water, 18 Ib./lb.
mole.
Vm— Volume of gas sample through the
dry gas meter (meter conditions),
cu. ft.
T»=Absolute average dry gas meter tem-
perature (see Figure 5-2), *R.
Pblr=Barometrlc pressure at sampling
site. In Hg.
AH=Aver age pressure drop across the ori-
fice (see Figure 5-2), in H3O.
Ti=Absolute average stack gas tempera-
ture (see Figure 6-2), 'R.
equation 5-7
*=Total sampling time, mln.
V.=Stack gaa velocity calculated by
Method 2, Equation 2-2, rt./sec.
P.=Absolute stack gas pressure. In. Hg.
A.=Cross-sectional area of nozzle, sq. ft.
6.4 Acceptable results. The following
range sets the limit on acceptable Isoklnetlc
sampling results:
If 83 percent .c.f.h. flow rang*.
2.1.8 Dry gas meter—Sufficiently accurate
to measure the sample volume within 1
percent.
2.1.9 Pltot tube—Type S, or equivalent,
necessary only If a sample traverse Is re-
quired or if stack gas velocity varies with
time.
2.2 Sample recovery.
2.2.1 Glass wash bottles—Two.
2.2.2 Polyethylene storage bottles—To
store Implnger samples.
2.3 Analysis.
1 Trade name.
PROBE (END PACKED
WITH QUARTZ OR
PYREX WOOL)
TYPE S PITOT TUBE
HCKWALL
ri
MIDGET BUBBLER MIDGET IMPINGERS
GLASS WOOL
SILICA GEL DRYING TUB!
PITOT MANOMETER
• <• +c ' Equation 8-8
where :
c.= Average partlculate concentration la
the stack gas, gr./s.c.f.
c«= Concentration of partlculate matter
In the stack gas (Ratio of Area
Method) , gr./s.c.f.
'PUMP
DRY GAS METER ROT,
Figure 6*1. SOa sampling train.
O
S
m
O
JO
O
FEDERAL REGISTER, VOL. 36, NO. 159— TUESDAY, AUGUST 17, 1971
-------
APPENDIX F
LABORATORY REPORT
-------
All laboratory analyses were supervised and performed by EPA personnel
Complete sample boxes were shipped by air freight, directly to the EPA
facilities in Durham, M. C. Results are presented in this section.
F-1
-------
ENVIRONMENTAL PROTECTION AGENCY
Office of A1r Programs
Research Triangle Park, North Carolina 27711
Reply to
Attnof: ATD Date April 10, 1972
Subject-. Mass Analysis of Participate Samples from Chromium Mining and Smelting-
Woodstock, Tenn.
To: Hlnton Kelly, Chemical Engineer, Petroleum & Chemical Section, ETB, ATD
Particulate samples from six tests at the Chromium Mining and Smelting
Company, Woodstock, Tenn. were analyzed for mass as specified 1n the
Federal Register. Listed below 1n Table I are the results of the analysis,
listed according to EPA code number and Source test numbers.
TABLE I
MASS ANALYSIS OF SOURCE SAMPLES FROM
CHROMIUM MINING & SMELTING-WOODSTOCK, TENN.
EPA Code f
1013
1012
1016
1015
1014
Total
1017
Test I
CSE-1
CSE-1
CSE-1
CSE-1
CSE-1
CSE-1
CSE-1
Sample
Fraction
F
C
B
C-E
H20
S-G
Mass (mg)
109.5
11.9
8.6
5.1
12.1
147.2
14.0 gm.
1027 CSE-2 F 256.9
1026 CSE-2 C 9.9
1030 CSE-2 B 4.3
1029 CSE-2 C-E 3.9
1028 CSE-2 H20 13.5
Total CSE-2 288.5
1031 CSE-2 S-G 22.3 gm.
F-2
-------
TABLE I (Continued)
EPA Code 1
1041
1040
1044
1043
1042
Total
1045
1004
1002
1003
1005
1001
1008
1007
1006
Total
1009
1019
1020
1021
1018
1024
1023
1022
Total
1025
Test 1
CSE-3
CSE-3
CSE-3
CSE-3
CSE-3
CSE-3
CSE-3
CSD-1
CSD-1
CSD-1
CSD-1
CSD-1
CSD-1
CSD-1
CSD-1
CSD-i
CSD-1
CSD«2
CSD-2
CSD-2
CSD-2
CSD-2
CSD-2
CSD-2
CSD-2
CSD-2
Sample
Fraction
F
C
B
C-E
H20
S-G
F
F
F
F
C
B
C-E
H20
S-G
F
F
F
C
B
C-E
H20
S-G
Mass (mg)
286.6
15.4
10.6
1.9
2.9
317.4
29.1
-------
TABLE I (Continued)
EPA Code 1
1033
1035
1034
1032
1038
1037
1036
Total
1039
1010
1011
Test 1
CSD-3
CSD-3
CSD-3
CSD-3
CSD-3
CSD-3
CSD-3
CSD-3
CSD-3
H20 Blank
Acetone Blank
Sample
Fraction
F
F
F
C
B
C-E
H20
S-G
120 ml.
95 ml .
Mass (mq)
2122.8
1808.0
480.2
2004.2
11.1
1.6
99.1
6527.0
28.5 gm.
0.0
0.3
where: F - filter fraction; c - front half (acetone);
B - back half (acetone); C-E - organic extraction;
HpO - Implnger water residue. Each value has been adjusted to
correct for the appropriate blank weight.
These samples have been sealed to prevent contamination and are
being held for any further desired analyses at the IRL Building.
Frank W11shire
Chemist
Petroleum & Chemical Section
Emission Testing Branch, ATD
F-4
-------
APPENDIX G
TEST LOG
-------
APPENDIX G - TEST LOG
Date (1972)
2/1/72
2/2/72
2/2/72
Time
1430-1648
1430-1631
0850-1038
0849-1033
1255-1438
1254-1440
Location
Exhaust
Inlet
Exhaust
Inlet
Exhaust
Inlet
Sample No.
CSE-1
CSD-1
CSE-2
CSD-2
CSE-3
CSD-3
Particulate
X
X
X
X
X
X
Orsat
X
X
X
X
X
X
Notes: On Monday (1/31) all RRI field personnel arrived at the test
site, unpacked and checked equipment. On Tuesday (2/1) equipment
was set up and preliminary measurements made. The first efficiency
test was carried out by mid-afternoon that day after a delay caused
by Chromasco having to build a test platform at the exhaust stack.
On Tuesday (2/1) two particulate efficiency tests were carried
out without any difficulty. Gas sample bags were collected along
with each particulate to be analyzed for 02, C02 and CO at the
site. Late in the afternoon a group of RRI personnel returned home.
On Wednesday (2/2) the remainder of RRI personnel returned
home after completing packing and shipping of the test equipment.
6-1
-------
APPENDIX H
RELATED REPORTS
-------
Related reports covering emissions from reactive metals furnaces,
under this same contract for the Environmental Protection Agency, are
as follows:
Test Number
FA-1
FA-2
FA-3
FA-4
FA-5
FA-6
Survey Location
Foote Mineral Company,
Steubenville, Ohio
Union Carbide Corporation
Marietta, Ohio
Airco Alloys and Carbide
Niagara Falls, New York
Ai rco
Charleston, S. C.
Union Carbide Corporation
Alloy, West Virginia
Chromium Mining & Smelting
Corporation
Memphis, Tennessee
Control Device
None
Venturi Scrubber
Baghouse
Electrostatic
Precipitator
Baghouse
ADTEC
Scrubber System
Status
Issued
Aug., 1971
Issued
Oct., 1971
Issued Oct., 1971
(Rev. Dec., 1971)
Issued Nov., 1971
Draft Issued
Mar., 1972
This Report
H-l
-------
APPENDIX I
PROJECT PARTICIPANTS AND TITLES
-------
PROJECT PARTICIPANTS AND TITLES
R. N. Allen, P.E., Project Manager
C. C. Gonzalez, Chemist, Crew Leader
T. E. Eggleston, Industrial Hygienist
G. B. Patchell, Senior Technician
J. R. Avery, Technician
L. W. Baxley, Technician
B. M. Brown, Technician
0. R. McReynolds, Technician
1-1
------- |