SOURCE TESTING REPORT
ELECTRIC ARC FURNACE
BABC
WILCOX COMPANY
BEAVER FALLS, PENNS
ROY F. WESTOPd, INC.
ENVIRONMENTAL SCIENTISTS AND ENGINEERS
WEST CHESTER • PENNSYLVANIA
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January, 1973
Source Testing Report
The Babcock and Wilcox Company
Electric Arc Furnace
Beaver Falls, Pennsylvania
FTS No. 73-ELC-1
J. rterks
Project Manager
James W. Davison
Sampling Supervisor
Contract No. 68-02-0240
Task Order No. 2
Prepared by:
Roy F. Weston, Inc.
Envi ronmental
Scientists and Engineers
West Chester, Pennsylvania
W.O. 300-39
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Preface
The emission source sampling program detailed in this report
was conducted by Roy F. Weston, Inc. pursuant to a task order
issued by the Environmental Protection Agency (EPA), under the
terms of EPA Contract No. 68-02-0240. Mr. James W. Davison,
Air Sampling Supervisor, directed the Weston field team con-
sisting of :
Charles Cahill
Mark Cosgrove
William Longaker
Charles Mattocks
Noshir Mistry
Peter Radzai
Kenneth Seace
Daniel Welch
Joseph Wilson
Leonard Zmich
Approved For Roy F. Weston, Inc.
Peter J. Marks
Project Manager
Date:
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TABLE OF CONTENTS
Section Page
LIST OF TABLES
LIST OF FIGURES
I INTRODUCTION 1
I I SUMMARY OF RESULTS 3
Preliminary Velocity Traverse 3
Particulates 3
Inlet 3
Outlets 3
Gaseous Sampling 12
Carbon Monoxide 12
Carrier Gas Composition 12
Particle Size 13
I I I PROCESS DESCRIPTION 15
Electric Arc Furnace 15
Air Pollution Control System 16
IV PROCESS OPERATION 17
Electric Arc Furnace 17
Air Pollution Control System 17
V LOCATION OF SAMPLING POINTS 19
Inlet 19
Outlets 19
VI TEST PROCEDURES 2k
Preliminary Velocity Traverse 2k
Sampling 2k
Particulates 2k
Inlet 2k
Outlets 25
Gaseous 27
Particle Size 27
Inlet 27
Outlet 30
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TABLE OF CONTENTS
(continued)
Section page
Analytical 31
Particulates 31
Gaseous 31
VII APPENDIX
A - Particulate Sampling Data and Sample Calculations
B - Gaseous Sampling Data
C - Particle Size Measurements
D - Field Data
E - Standard Test Procedures
F - Sample Identification Log
G - Laboratory Reports
H - Sample Hani ding Log
I - Test Log
J - Process Operation Log
K - Related Reports
L - Summary of Testing Costs
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Table No.
1
2
3
k
5
6
7
10
11
A-1
A-2
A-3
A-4
A-5
A-6
A-7
A-8
B-1
B-2
1-1
Title
Preliminary Velocity Traverse
Summary of Participate Emissions
Summary of Results: Inlet Particulates
Summary of Results: Outlet 1 Particulates
Summary of Results: Outlet 2 Particulates
Summary of Results: Outlet k Particulates
Summary of Results: Outlet 6 EPA
Particulates
Summary of Results: Outlet 6 ASME
Particulates
Summary of Results: Outlet Stack No. 1
Carbon Monoxide
Summary of Results: Carrier Gases
Summary of Particle Size Test Results
Preliminary Velocity Traverse - Inlet
Preliminary Velocity Traverse - Outlets
Particulate Emission Data - Inlet
Particulate Emission Data - Outlet 1
Particulate Emission Data - Outlet 3
Particulate Emission Data - Outlet k
Particulate Emission Data - Outlet 6 EPA
Particulate Emission Data - Outlet 6 ASME
Carbon.Monoxide Concentrations
Summary of Carrier Gas Composition (Orsat
Analysis, Outlet Stack 2)
LIST OF TABLES
Page
k
5
6
7
8
9
10
11
12
13
14
Appendix A
Appendix A
Appendix A
Appendix A
Appendix A
Appendix A
Appendix A
Appendix A
Appendix B
Appendix B
Location of Traverse Points in Circular Stacks Appendix E
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LIST OF FIGURES
Figure No.
1
2
3
k
5
6
7
C-1
C-2
C-3
c-k
C-5
C-6
1-1
1-2
1-3
Title Page
Exhaust Dust System - Inlet Sampling Port 20
Locations
Inlet Duct - Sampling Point Locations 21
Outlets Sampling Port Locations 22
Outlets Sampling Point Locations 23
EPA-OAP Particulate Train 26
ASME (Modified) Particulate Train 28
EPA-OAP Particulate Train - Trace Metals 29
Sample
Pilat Impactor Sampling Train Appendix C
Schematic of Source Test Cascade Impactor Appendix C
(Pilat)
Brinks Impactor Sampling Train Appendix C
Particle Size Distributions - Pilat Appendix C
Impactor
Inlet Particle Size Distribution - Brinks Appendix C
Impactor
Impactor Cut Points for Dry Air at Standard Appendix C
Condi ti ons
Minimum Number of Traverse Points Appendix E
Cross Section of a Circular Stack Divided Appendix E
into 12 Equal Areas Showing Location of
Traverse Points at the Centroid of Each
Area
Cross Section of Rectangular Stack Divided Appendix E
into 12 Equal Areas with Traverse Points
Located at the Centroid of Each Area
2-1
Pitot Tube (Manometer Assembly)
Appendix E
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Figure No.
2-2
3-1
3-2
5-1
5-2
Preliminary Velocity Traverse
Grab Sampling Train
Integrated Gas Sampling Train
Participate Sampling Train
Field Data
5-3 Analytical Data
LIST OF FIGURES
(conti nued)
Page
Appendix E
Appendix E
Appendix E
Appendix E
Appendix E
Appendix E
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SECTION I
INTRODUCTION
In accordance with Section I I I of the Clean Air Act of 1970, the Environ-
mental Protection Agency is charged with the establishment of performance
standards for new installations or modifications of existing installations
in stationary source categories which may contribute significantly to air
pollution. A performance standard is a standard for emissions of air pol-
lutants which reflects the best emission reduction systems that have been
adequately demonstrated, taking into account economic considerations.
The development of realistic performance standards requires accurate data
on pollutant emissions applicable to the various source categories. In
the iron and steel industry, the emissions control system (baghouse) of
the Babcock and Wilcox Company, Beaver Falls, Pennsylvania, Shop Number
Two, was designated by EPA as representative of a wel1-control led operation
of an electric arc steelmaking process, and was thereby selected for the
emission testing program. This report presents the results of the testing
which was performed at the Babcock and Wilcox installation.
Shop No. 2 houses two electric arc furnaces, one with a capacity of
50 Tons per day and the other 75 Tons per day. The steelmaking operation
consists of batch meltdowns followed by oxidizing, slagging, and refining
steps. Each heat lasts for 6-8 hours, with intervals between heats for
equipment maintenance. The furnaces operate 2k hours a day, 5 days a
week.
Two 900-HP fans remove the fumes through two adjoining duct openings in
the shop roof to a single exhaust duct. A 12-compartment baghouse, rated
at 1*80,000 actual cubic feet per minute, cleans the exhaust fumes and dis-
charges them to the atmosphere through six 9'-diameter metal stacks.
The Weston field team arrived at the plant October 11, 1972 to prepare
for the testing program. On October 13, a series of velocity traverses
were performed across the emission control system to obtain a gas flow
balance. Preliminary testing and measurements were completed by October 17,
1972, and formal test runs were conducted October 18, 19, and 20.
Three 4-hour test runs were performed (one each day), at the inlet duct
ahead of the fans and at three of the six baghouse outlets, to determine
the concentration of particulate matter in the gas stream before and after
the baghouse cleansing operation; EPA-OAP sampling trains were used in these
test runs. A modified ASME sampling train was utilized simultaneously
with the EPA-OAP trains to sample emissions at one of the outlets. Another
outlet was selected for collection of three separate samples for trace metals
analysis, and continuous carbon monoxide monitoring was performed on the
same outlet during all testing. An Orsat analysis of the gas was performed
on an integrated sample collected simultaneously with the particulate
sampling. Particle size measurements were performed on the inlet and outlet
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ducts, using two different types of impactors, during selected periods
of the particulate testing.
All particulate samples were returned to the Weston Laboratories in West
Chester, Pennsylvania for analysis. Particle size analyses were performed
by EPA at Research Triangle Park.
The following sections of this report cover the summary of results, pro-
cess description and operation, sampling point location, and sampling and
analytical procedures. EPA prepared the sections describing the process
and the operating data.
-2-
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SECTION I I
SUMMARY OF RESULTS
Preliminary Velocity Traverse
Table 1 is a summary of the velocities and volumetric flow rates of the
gas streams at the one inlet and the six outlet sampling locations. The
average flow rate of the inlet gas stream for the six test runs was ap-
proximately 1*26,000 dry standard cubic feet per minute (47^,000 actual
cubic feet per minute at stack conditions). The overall volumetric gas
flow from the six outlet stacks, as determined by adding the individual
stack flow rates for one test run, was ^5^,000 dry standard cubic feet
per minute (or ^99,000 actual cubic feet per minute at stack conditions).
The inlet flow measurement is considered the more reliable because of
the time interval between the individual outlet measurements, and because
the inlet value represents an average of 6 runs, whereas the outlet value
is derived from a single run. More details of the velocity traverse data
are presented in Tables A-1 and A-2.
Particulates
Table 2 is a summary of the inlet gas flow and of the inlet and outlet
particulate results.
Inlet
The results of the particulate measurements on the samples collected at
the inlet during each of the three test runs are presented in Table 3,
along with pertinent data on sample volume and test conditions. Averaging
the results of the three runs indicates a concentration of particulate
matter in the gas stream of 0.0537 grains per dry standard cubic foot
and an emission rate of 210 pounds per hour (based on total catch). The
averages of the three runs based on particulate matter caught by the
probe and filter only were 0.0518 grains per dry standard cubic foot and
202 pounds per hour. Particle size samples were collected at a point of
average velocity for up to five minute periods. During the meltdown
process, the average particulate concentration was 0.0379 grains per dry
standard cubic feet with an emission rate of 1^0 pounds per hour as was
determined by a Pilat in-stack cascade impactor. Specific details may be
found in Section VI.
Outlets
Tables k through 8 summarize the results of the particulate sampling at
the baghouse outlet stacks. The average particulate concentration for
the three test runs, based on the total catch of the samples at Stacks 3,
k, and 6 (Tables 5, 6, and 7), is 0.0027 grains per day standard cubic
foot, and the average emission rate is 10.3 pounds per hours; corresponding
-3-
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Table 1
Preliminary Velocity Traverse
Inlet Outlets
Run
No.
1
2
3
4
5
6
Gas
Velocity
f pm1
4,183
4,058
^, 220
4,220
4,19^
4,235
Gas
Vol ume
SCFMZ
432,384
411,972
428,419
428,419
425,779
426,137
Stack No,
6
5
4
3
2
1
Gas
Veloci ty
f pml
1,104
1,183
1,240
1,124
1,124
1,135
Gas
Vo 1 ume
SCFMZ
71,309
77,789
81,537
73,909
73,249
76,002
?Feet per minute, stack conditions.
Standard Cubic Feet per Minute, Dry, 70°F, 29»92 Hg.
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Summary of Participate Emissions
Run Number
Date
GAS FLOW
Inlet, SCFM dry
Inlet, ACFM wet
PARTICULATES (Probe and Filter)
Inlet
Grains/SCF, dry
Grains/ACF, Stack Conditions
Pounds/hour
Outlet
Grains/SCF, dry
Grains/ACF, Stack Conditions
Pounds/hour
PARTICULATES (Total Catch)
Inlet
Grains/SCF, dry
Grains/ACF, Stack Conditions
Pounds/hour
10-18-72
431,236
471,699
0.0386
0.0353
143
0.0021
0.0020
7.76
Outlet
1
Grains/SCF, dry
Grains/ACF, Stack Conditions
Pounds/hour^
REMOVAL
Grains/SCF, dry
Grains/ACF, Stack Conditions
Pounds/hour
0.0397
0.0364
147
0.0035
0.0033
12.9
91.2%
90.9%
91.2%
10-19-72
454,932
497,016
0.0564
0.0516
220
0.0010
0.0010
3.90
0.0597
0.0547
233
0.0019
0.0018
7.41
96.8%
96.7%
96.8%
10-20-72
^70,300
504,697
0.0605
0.0564
244
0.0010
0.0010
4.03
0.0618
0.0576
24g
0.0026
0.0024
10.5
95.6%
96.0%
95.6%
Average
452,156
491,137
0.0518
0.0478
202
0.0014
0.0013
5.23
0.0537
0.0496
210
0.0027
0.0025
10.3
94.5%
94.6%
94.5%
Emission particulate concentration average of Stacks 3, 4, and 6.
Calculations based on inlet flow. Values represent total emissions from outlet stacks.
-5-
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Table 3
Summary of Results
INLET
Particulates
Run Number 1 2 3
Date 10-18-72 10-19-72 10-20-72
Volume of Dry Gas Sampled, SCF1 174.56 181,87 186.35
Stack Flow Rate, SCFM2, Dry 431,236 454,932 470,300
Stack Flow Rate, ACFM3, Wet 471,699 497,016 504,697
Percent Moisture by Volume 0.7 0.6 0.6
Stack Gas Temperature, °F 98.6 100,4 94.8
Isokinetic, % 99.5 ' 98.2 97.4
Particulates Results
Probe and Filter Catch, mg 437.9 666.1 732.5
Grains/SCF, Dry 0<0386 0.0564 0,0605
Grains/ACF, Stack Conditions 0.0353 0,0516 0.0564
Pounds/Hour 143 220 244
Total Catch, mg 450.8 705.9 748.1
Grains/SCF, Dry 0.0397 0.0597 0.0618
Grains/ACF, Stack Conditions 0.0364 0,0547 0.0576
Pounds/Hour 147 233 249
Impinger Catch, % 2.86 5'.64 2.09
^Standard Cubic Feet at 70°F, 29.92 in. Hg.
-Standard Cubic Feet per Minute.
Actual Cubic Feet per Minute.
-6-
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Table 4
Summary of Results
OUTLET 1
Particulates
Run Number 1 2 3
Date 10-13-72 10-19-72 10-20-72
Volume of Dry Gas Sampled, SCF 179.25 181.98 190.35
Stack Flow Rate, SCFM2, Dry 67,468 69,141 72,835
Stack Flow Rate, ACFM3, Wet 74,007 75,537 78,632
Percent Moisture by Volume 0.5 0.7 0.4
Stack Gas Temperature, °F 104.1 102.8 101.5
Isokinetic, % 104.3 103.3 102.6
Parti culates
Probe and Filter Catch, mg 17.5 2.1 69.2
Grains/SCF, Dry 0.0015 0.0001 0.0055
Grains/ACF, Stack Conditions 0.0014 0.0002 0.0052
Pounds/Hour 0.869 0.105 3.50
Total Catch, mg 25.7 13.3 81.7
Grains/SCF, Dry 0.0022 0.0011 0.0066
Grains/ACF, Stack Conditions 0.0020 0.0010 000061
Pounds/Hour 1.2766 0.6669 4.1259
Impinger Catch, % 31.9 84.2 15.3
^Standard Cubic Feet at 70°F, 29.92 in. Hg.
,Standard Cubic Feet per Minute.
Actual Cubic Feet per Minute.
-7-
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Table 5
Summary of Results
OUTLET 3
Particulates
Run Number
Date
10-18-72
10-19-72
10-20-72
Volume of Dry Gas Sampled, SCF
Stack Flow Rate, SCFM2, Dry
Stack Flow Rate, ACFM3, Wet
Percent Moisture by Volume
Stack Gas Temperature, °F
Isokinetic, %
170.37
69,135
75,740
0.6
103.0
96.7
176.89
71,209
77,511
0.5
101.7
97.5
179.78
72,127
77,535
0.4
99.1
97.8
Particulates
Probe and Filter Catch, mg 8.4
Grains/SCF, Dry 0.0007
Grains/ACF, Stack Conditions 0.0007
Pounds/Hour 0.450
Total Catch, mg 24.5
Grains/SCF, Dry 0.0022
Grains/ACF, Stack Conditions 0.0020
Pounds/Hour 1.3121
Impinger Catch, % 65.7
12.3
0.0010
0.0010
0.654
22.3
0.0019
0.0018
1.1848
44.8
20.8
0.0017
0.0017
1.101
55.2
0.0047
0.0044
2.9227
62.3
1
Standard Cubic Feet at 70°F, 29.92 in. Hg.
,Standard Cubic Feet per Minute,
Actual Cubic Feet per Minute.
-8-
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Table 6
Summary of Results
OUTLET 4
Particulates
Run Number 1 2 3
Date 10-18-72 10-19-72 10-20-72
Volume of Dry Gas Sampled, SCF1 177.73 185.00 185.09
Stack Flow Rate, SCFM2, Dry 67,479 69,574 70,241
Stack Flow Rate, ACFM3, Wet 73,938 75,653 77,521
Percent Moisture by Volume 0.6 0.5 0.4
Stack Gas Temperature, °F 103.1 101.7 99.2
Isokinetic, % 103.4 104.4 103.4
Particulates
Probe and Filter Catch, mg 37.6 8.7 6.7
Grains/SCF, Dry 0.0032 0.0007 0.0005
Grains/ACF, Stack Conditions 0.0030 0.0007 0.0005
Pounds/Hour 1.88 0.432 0.336
Total Catch, mg 53.8 17.5 18.3
Grains/SCF, Dry 0.0046 0.0014 0.0015
Grains/ACF, Stack Conditions 0.0043 0.0013 0.0014
Pounds/Hour 2.6958 0.8686 0.9166
Impinger Catch, % 30.1 50.3 63.4
^Standard Cubic Feet at 70°F, 29.92 in. Hg.
-Standard Cubic Feet per Minute.
Actual Cubic Feet per Minute.
-9-
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Table 7
Summary of Results
OUTLET 6 EPA
Particulates
Run Number 1 2 3
Date 10-18-72 10-19-72 10-20-72
Volume of Dry Gas Sampled, SCF1 185.50 173.27 178.51
Stack Flow Rate, SCFM2, Dry 72,729 65,648 69,915
Stack Flow Rate, ACFM3, Wet 79,295 71,315 75,536
Percent Moisture by Volume 0.6 0.6 0.7
Stack Gas Temperature, °F 100.3 100.0 100.2
Isokinetic, % 100.1 103.6 96.9
Particulates
Probe and Filter Catch, mg 28.6 1^.3 8.8
Grains/SCF, Dry 0.0023 0.0012 0.0008
Grains/ACF, Stack Conditions 0.0022 0.0012 0.0007
Pounds/Hour 1.48 0.715 0.479
Total Catch, mg 46.3 27.1 18.9
Grains/SCF, Dry 0.0038 0.0024 0.0016
Grains/ACF, Stack Conditions 0.0035 0.0022 0.0015
Pounds/Hour 2.40 1.36 0.959
Impinger Catch, % 38.2 47.2 53.4
2Standard Cubic Feet at 70°F, 29.92 in. Hg.
,Standard Cubic Feet per Minute.
Actual Cubic Feet per Minute.
-10-
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Table 8
Summary of Results
OUTLET 6 ASME
Particulates
Run Number 1 2 3
Date 10-18-72 10-19-72 10-20-72
Volume of Dry Gas Sampled, SCF1 174.95 179.22 176.66
Stack Flow Rate, SCFM2, Dry 71,390 70,912 71,527
Stack Flow Rate, ACFM3, Wet 77,753 76,875 76,468
Percent Moisture by Volume 0.5 0.4 0.3
Stack Gas Temperature, °F 100.1 100.0 96.6
Isokinetic, % 96.2 99.2 96.9
Part icula tes
Nozzle and Thimble Catch, mg 10.7 9.5 2.9
Grains/SCF, Dry 0.0009 0.0008 0.0003.
Grains/ACF, Stack Conditions 0.0009 0.0008 0.0002
Pounds/Hour 0.576 0.496 0.155
Probe and Filter Catch, mg 21.8 16.8 10.2
Grains/SCF, Dry 0.0019 0.0014 0.0008
Grains/ACF, Stack Conditions 0.0018 0.0013 0.0008
Pounds/Hour 1.1740 0.8773 0.5450
Total Catch, mq 40.4 2k.2 20.7
Grains/SCF, Dry 0.0035 O.:0020 0.0018
Grains/ACF, Stack Conditions 0.0033 0.0019 0.0017
Pounds/Hour 2.1757 1.2637 1.1061
Impinger Catch, % 46.0 30.6 50.7
^Standard Cubic Feet at 70°F, 29.92 in. Hg,
,Standard Cubic Feet per Minute.
Actual Cubic Feet per Minute.
-11-
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concentration and emission rates based on probe and filter catch only, are
0.001*1 grains per dry SCF and 5.23 pounds per hour. (It should be noted
that the emission rate calculations in pounds per hour were based on the
inlet gas volume.) The Stack 6 ASME sampling train results (Table 8) are
for method comparison purposes and were not included in the calculation
of the foregoing averages. The results of the particulate sampling at
Stack 1 (where the EPA sampling train was equipped with a quartz tissue
filter rather than the usual glass filter), presented in Table 4, were
also excluded in the calculation of average outlet particulate conditions.
Further detailed results of inlet and outlet particulate testing are pre-
sented in Tables A-3 through A-8.
Gaseous Sampling
Sampling for determination of carbon monoxide content and carrier-gas
composition was conducted at the Stack 1 outlet.
Carbon Monoxide Monitoring
The maximum, average, and ambient air carbon monoxide concentrations re-
corded during the test periods are outlined in Table 9- Complete data
can be found in Appendix B.
Table 9
Summary of Results
Outlet
Stack No. 1
Carbon Monoxide
Run Number 1 2 3
Date 10-18-72 10-19-72 10-20-72
Carbon Monoxide, ppm
Maximum 285 325 275
Average 66 52 48
Ambient k k 5
Carrier Gas Composition
Table 10 provides a summary of the results of the analysis of three 4-hour
integrated samples collected simultaneously with the particulate testing.
This summary indicates that the carrier gas is essentially air.
-12-
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Table 10
Summary of Results
Carrier Gases^
Run Number 1 2 3
Date 10-18-72 10-19-72 10-20-72
Carbon Dioxide, % 0.1 0.1 0.0
/"
Oxygen, % 20.6 20.2 20.7
Carbon Monoxide, % <0.1 <0.1 <0.1
Nitrogen, %2 79-3 79-7 79-3
Orsat Analysis, Volume %, Dry
By difference, Includes other gases
Particle Size
The distribution of particle size of the particulates collected by the two
types of impactors during selected portions of the test runs is presented
in Table 11. The Pilot Impactor data indicate significant differences in
median particle diameter and in particle size distribution between the
inlet and outlet streams and differences in the inlet samples taken during
the meltdown and deslagging periods of the steelmaking process. The median
particle size was much lower (<0.5 microns) in the outlet than in the inlet
samples (5.5 microns during meltdown and 1.25 microns during deslagging).
The particle size distribution in the inlet and outlet samples was markedly
different, with the outlet samples having significantly higher percentages
of particles in the <0.5-micron range (50 to 62 vs. 2.8 to 10) and in the
>20-micron range (20 to 30 vs. 1.8 to 5). There were also significant
differences in particle size distribution of the inlet samples for different
periods of the run; during meltdown 48 percent of the aerosol mass was 5
microns or smaller, while 87 percent was 5 microns or smaller during the
rest of the operation.
The Brinks Impactor data indicate considerable differences in particle
size from run to run, with median diameters of 0.4, 1.0 and 1.2 microns
for Runs 1, 2, and 3 respectively.
-13-
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Table 11
Summary of Particle Size Test Results
Inlet
Mel tdown
Adj ustment ,
Deslaggi ng
Outlet
Mel tdown
Adj ustment ,
Deslaggi ng
Inlet
Run No. 1
Run No. 2
Run No. 3
Percent of Pa
Equal
0.5 u 1 u
2.8 7
10 32
50 50
62 62
0.3 M 0.6^
32 68
12 32
8 26
rticle Mass
to Stated
_5_iL-
48
87
50
65
1.2 n
89
53
45
Less
Si ze
10 If
91.5
92
61
73
1.8 M
89
77
72
than or
Concentration
20 M grains/SCF
Pilat impactor
95 0.0379 ,
(87,000 jzg/nr)
98.2 0.00656
(15,000 Mg/m3)
70 0.0000715
(116 Mg/m3)
80 0.0000401
(92 yag/m3)
Brinks Impcictor
0.00550
0.0294
0.124
Mass Median Emission
Diameter Rate*
M Ibs/hr
5.5 1*K)
1.25 2k
<0.5 0-.27
<0.5 0.16
0.4 21
1.0 111
1.2 463
•-'-Calculations based on inlet flow on day of sample.
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SECTION III
PROCESS DESCRIPTION
Electric Arc Furnaces
Two electric arc furnaces (50- and 75~ton capacity) at Babcock and Wilcox's
No. 2 shop produce new steel from steel scrap and various additives. The
process varies somewhat, depending on the scrap used and the steel being
produced. The furnaces are operated independently of each other. Each
heat normally requires from six to eight hours.
At the beginning of a heat, the furnace roof is swung aside, and scrap is
charged from a large bucket carried by an overhead crane. The bottom of
this bucket is opened to dump the scrap. Lime and/or limestone is added
to act as a slag. Crushed electrode and small quantities of other materials
may also be added at this time.
When charging is completed, the roof is replaced and the electrodes are
lowered. Full power (approximately 10 megawatts on the 50-ton furnace
and 14 megawatts on the 75~ton furnace) is applied to melt the scrap as
quickly as possible. About two hours later, the first charge has melted
down, and a second charge of scrap is added. Usually two charges are suf-
ficient to provide the needed weight of metal, but if the scrap has a low
bulk density, a third and possibly a fourth charge may be required. Full
power is again applied to melt the second charge. Additional limestone
and other materials (such as alloying agents and crushed electrode) may
be added after the second charge has been partially melted.
About 1 1/2 hours after the second charge, a sample of the metal is col-
lected and analyzed. Additional samples are collected and analyzed, and
the metal temperature is determined as needed. After analysis of the
first sample, power is reduced, and adjustment of the composition of the
molten metal to meet the required specifications is begun. Oxygen may
be lanced into the metal to oxidize and remove excess carbon. Carbon
content can also be reduced by adding oxides of alloying agents to supply
oxygen. Other materials may also be added at this time to adjust the
composition of the metal.
About one hour after the first sample is analyzed, the first slag is re-
moved. The furnace is tilted back slightly, and the slag is poured and
skimmed from the surface of the metal. The second (white) slag is then
added, and reduced power is again applied. Shortly after this, a sample
is collected and analyzed to determine what final additions are necessary
to bring the heat to specifications. Various grades and quantities of
ferrochrome, ferrosi1 icon, ferromanganese, aluminum, molybdenum trioxide,
calcium-silicon, etc. are added as needed. A final analysis is taken, and
if this indicates that the steel meets specifications, the temperature is
checked and brought up to the necessary value. Then the heat is tapped.
-15-
-------
When tapping, the furnace is tilted forward and the molten steel pours
out into a ladle. Aluminum or calcium-silicon may be added to the ladle
as tapping occurs. Once tapping is complete, the molten steel is poured
from the ladle into ingot molds.
Air Pollution Control System
Emissions from the furnaces are collected by evacuation of the furnace
shop building. A duct leads from two openings in the building roof to
two 900-horsepower fans, which draw about ^50,000 dry standard cubic feet
per minute of air from the shop. The temperature of this gas ranges from
about 100°F to 160°F, depending on ambient temperature. If a set tem-
perature if exceeded, the control system is protected by exhausting the
gases to the atmosphere.
The fans discharge into 12 baghouse compartments containing 168 Dacron
bags each. Each bag is 11 3/^ inches in diameter and 30 feet long, with
an air-to-cloth ratio of about 2.3 to 1. Pressure drops across the com-
partments are 3-5 to *t.1 inches water gauge.
The bags are cleaned with reverse air from a 150-horsepower fan. The
cleaning cycle consists of two 30-second reverse air periods each fol-
lowed by a 30-second null period. Cleaning of a new compartment is ini-
tiated every five minutes. Reverse air is put back into the baghouse
inlet, and cleaned air is exhausted through six short stacks, each above
a pair of compartments. Dust falls into hoppers at the bottom of each
compartment, and screw conveyors transfer the dust from the hoppers to an
enclosed tank truck trailer which is loaded through a cloth tube. Air
displaced by the dust as it is loaded into the trailer is also recycled
to the baghouse inlet. The dust is later pelletized before it is land-
filled.
The baghouse is guaranteed by the manufacturer to achieve an outlet
particulate loading of 0.00** grains/SDCF.
-16-
-------
SECTION IV
PROCESS OPERATION
Electric Arc Furnaces
During the tests, several alloy steels containing less than 0.15 percent
carbon, 0.30 to 0.60 percent manganese, 0.50 to 2.60 percent chromium,
and Q.bk to 1.13 percent molybdenum were produced. The scrap varied
somewhat for each heat, but consisted generally of purchased light alloy
stampings, revert crop ends, scrap ingots, revert pipe scrap, etc. The
scrap did not appear to be particularly dirty or greasy.
In general, each test run covered one or more periods of meltdown, re-
fining and tapping. The test periods were selected to coincide with
furnace operations expected to produce above-average emissions. Brief
delays in the process caused by restrictions on available power, un-
availability of the overhead crane, sample analyses, etc., occurred in
the operation of this shop. Periods of little or no fume generation also
occurred during normal furnace operations. Testing was conducted through
these periods since they occurred unpredictably, were often of very short
duration, and often affected only one furnace.
During part of Run One, the shop operated below normal power consumption
due to a high power demand in another of the company's electric arc furnace
shops. During Run Three, one heat was atypical. It had been previously
tapped and could not be teemed due to a frozen stopper in the ladle. The
hot metal then had to be put back into the furnace, reheated, and brought
back into specification. Run Three was initiated after the hot metal had
been returned to the furnace and the white slag had been replaced. In
both of these instances, the heats were prolonged, but there seemed to
be little effect on the evolution of emissions.
Oxygen lancing was generally less frequent and of shorter duration at
this shop than at some others. Oxygen lancing was performed twice during
the three test periods, for about three minutes during Run One and about
eight minutes during Run Two.
Logs of the furnace operations are presented in Appendix J.
Air Pollution Control System
The control system appeared to operate well throughout the tests. There
was no visible emissions form the baghouse. Small quantities of dust
could be seen seeping through seams and holes in the shop building roof
if viewed at close proximity, but no visible emissions could be detected
from a distance. During periods in which both furnaces were generating
copious amounts of dust, dust accumulated in the upper part of the building,
-17-
-------
This condition never extended to floor level and did not seem to affect
operations. As dust generation decreased, the control system eventually
cleared the air in the building.
During the tests, each of the two main fans operated between 590 and
KW. Temperatures at the baghouse inlet varied from 8AOF to 115°F, and
pressure drops across the baghouse compartments ranged from 3-5 to k.3
inches water gauge. No bags were replaced, and no malfunctions in the
baghouse operation occurred. One of the limit switches operating the
damper position indicator lights for the cleaning cycle was broken, but
the damper appeared to be operating normally.
-18-
-------
SECTION V
LOCATION OF SAMPLING POINTS
Inlet
The two inlet sample ports were located 35 feet downstream from a bend in
the 12'-diameter metal inlet duct, and 11 1/2 feet from an upstream bend.
Two V-I.D. sample ports were welded to the duct at right angles to each
other. The port position on the top of the duct required a vertical
sampling traverse. A V-I.D. port used for particle size measurements
was located seven feet upstream from the particulate sampling ports.
The port locations did not meet the "eight diameters" criterion as out-
lined in Method 1^; consequently, 2k sampling points were designated for
each axis, for a total of kB sample points. Figure 1 illustrates the
dimensions of the inlet duct and the sample port location. Figure 2
indicates the exact distances of the sample points along each traverse.
Outlets
Two sample ports were installed at right angles to each other in each
of the six outlet stacks (9' -d iameter). The V-I.D. ports were located
k 1/2 feet downstream and k 1/2 feet upstream in the short metal stacks.
A rain cap fitted with sides covered each stack. Figure 3 shows the bag-
house outlet stacks with pertinent dimensions and port identification.
The port locations did not meet the "eight diameters" criterion and again
*»8 sampling points were required. The sampling point distances are shown
in Figure 4. The carbon monoxide sampling probe was positioned in the
No. 1 stack, and the Orsat integrated samples were collected from the
No. 2 stack. Particle-size measurements were conducted on the No. 5
stack at a single traverse point on the X axis.
EPA Standards of Performance for New Stationary Sources, Federal Register,
Volume 36, No. 2kJ, December 23, 1971.
-19-
-------
I
to
o
75 TON FURNACE
W.O.30039
BABCOCK AND WILCOX
BEAVER FALLS, PENNSYLVANIA
SHOP NUMBER 2
EXHAUST DUCT SYSTEM
INLET SAMPLING PORT LOCATIONS
INLET AT
BAGHOUSE
EXHAUST
HOOD
}
/
x'k
/ \i \
\
-*
*-*
PARTICULATE
SAMPLE PORT
PORT LOCATION
PARTICLE
SIZE SAMPLE
LOCATIONS
FIGURE 1
50 TON FURNACE
ROY F. WESTOIM, IMC.
ENVIRDMIV1ENTAL SCIENTISTS AfsJD ENGllNJEERS
LEWIS LAME • WEST CHESTER • PEM(\JSYLVANiA • 1S3SO
-------
BABCOCK AND WILCOX
BEAVER FALLS, PENNSYLVANIA
INLET DUCT
SAMPLING POINT LOCATIONS
PORT X
PORT Y
LOCATION OF SAMPLING POINTS ACROSS A RADIUS
TRAVERSE POINT
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
DISTANCE
INCHES
1.6
4.6
7.9
11.4
15.1
19.0
23.2
27.9
33.1
39.2
46.5
57.3
TOTAL NUMBER OF SAMPLING POINTS - 48
TRAVERSE POINT
NUMBER
13
14
15
16
17
18
19
20
21
22
23
24
DISTANCE
INCHES
86.7
97.5
104.8
110.9
116.1
120.8
125.0
128.9
132.6
136.4
139.4
142.4
FIGURE 2
W.0.30039
— 21 —
ROY F. WESTOIM, INC.
ENVIRONM ENTAL SCIENTISTS AND ENGINEERS
LEWIS LANE • WEST CHESTER • PENNSYLVANIA • 1938O
-------
BABCOCK AND WILCOX
BEAVER FALLS, PENNSYLVANIA
NUMBER 2 BAGHOUSE
OUTLETS SAMPLING PORT LOCATIONS
I
KJ
10
W.0.30039
REVERSE AIR
MANIFOLD
NLET AIR
MANIFOLD
ELECTRICAL
CONTROL BLDG.
ROY F. WESTOIM. INC.
nor«j(viErjiAi_ SCIENTISTS AND K M rj IMF-: ens
FIGURE 3
-------
BABCOCK AND WILCOX
BEAVER FALLS, PENNSYLVANIA
BAGHOUSE 2 OUTLETS
SAMPLING POINT LOCATIONS
117.25'
LOCATION OF SAMPLING POINTS ACROSS A RADIUS
TRAVERSE POINT
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
DISTANCE
INCHES
1.3
3.8
6.5
9.3
12.3
15.5
18.9
22.8
27.0
31.9
37.9
46.7
TRAVERSE POINT
NUMBER
13
14
15
16
17
18
19
20
21
22
23
24
DISTANCE
INCHES
70.6
79.4
85.4
90.3
94.5
98.4
101.8
104.9
108.0
110.8
113.5
116.0
W.O.30039
TOTAL NUMBER OF SAMPLING POINTS - 48
— 23 —
FIGURE 4
ROY F. WESTOIM, INC.
ENVIRONMENTAL SCIENTISTS AND ENGINEERS
LEWIS LANE • WEST CHESTER • PENNSYLVANIA • 1938Q
-------
SECTION VI
PROCEDURES
Preliminary Velocity Traverse
A series of velocity traverses were conducted on October 13, 1972, in
accordance with procedures detailed in EPA Method 1^. Two testing teams,
provided with "S" type pitot tubes and inclined manometers, performed
simultaneous velocity measurements at the inlet sampling location and
at each of the six baghouse outlet sampling locations. The measurements
were repeated six times at the inlet position, with one complete traverse
determination at each of the six outlets. The pitot tube was positioned
in each stack at each of the 48 traverse points for 30 seconds, to obtain
a constant pressure differential reading at the manometer. A single
traverse at both the inlet and outlet was also conducted to determine
any variability of the static pressure in the stack.
The summary results of these measurements is reported in Section II of
this report, with complete data presented in Tables A-1 and A-2 of Ap-
pendix A.
Sampling
Particulates
Inlet
The sampling train designed to perform the particulate sampling at the
inlet sampling location was a modified EPA-OAP train. The modifications
included the substitution of an inconel metal probe for the prescribed
pyrex glass probe and the elimination of heating the probe and filter
holder compartment. The difficulties imposed by the necessity for a
vertical sampling traverse across the 12'-diameter duct required that
the probe be fitted with a right-angle connection at the sample box in
order to maintain the box in an upright position; several lines were at-
tached to the probe to maintain the proper nozzle direction.
An 0.1875"-I.D. stainless steel nozzle was attached to the 5/8" diameter
inconel probe. The probe was connected directly to the filter holder
containing a 9 cm.-diameter Reeve Angel glass fiber filter. The glass
cyclone was not used, and a glass connection provided the link between
the filter holder and the impinger. Impingers One and Two contained
100 ml of distilled water each, the third impinger was dry, and the final
impinger contained 200 grams of pre-weighed dry silica gel. To complete
the train, a Research Applicance Meter Control Box provided a leakless
vacuum pump, a dry test meter, and a calibrated orifice connected to an
Standards of Performance for New Stationary Sources, Federal Register,
Volume 36, No. 2^7, December 23, 1971.
-2k-
-------
inclined manometer. Stack gas velocity measurements were accomplished
by means of a calibrated "S" type pi tot tube attached to the sampling
probe and positioned so that the measurements were made at the nozzle
tip. The sampling train is illustrated in Figure 5.
Before the start of each test, leak checks were made on the entire train;
all checks indicated 0.02 CFM or less at a vacuum of 15" Hg before the
train was used.
Samples were collected for five minutes at each of the 48 sampling ports,
for a total run time of four hours. The velocity was observed immediately
after positioning the probe at each sampling point, and sampling rates were
adjusted to maintain isokinetic sampling conditions. Temperature measure-
ments were made of the stack gas and at the inlet and outlet of the dry
test meter. Test data were recorded every five minutes throughout the
sampling.
A consistent procedure was employed for sample recovery. The glass fiber
filter was placed in a container and sealed. The nozzle, probe, and front
half of the filter holder were brushed and washed twice with acetone into
a glass sample bottle. The contents of each of the first two impingers
were measured and placed in separate sample bottles. The impingers and
connectors were first washed with distilled water into the impinger water
sample, and then washed with acetone into a final sample container. The
silica gel was weighed to the nearest 0.1 gram.
The detailed procedures for sampling particulates conform to Method 5 of
the EPA Standards of Performance for New Stationary Sources^ (See Appendix
E).
Outlet
Three sampling trains identical to the train used at the inlet (except
that the I.D. of the nozzle was .375 inches) were assembled and utilized
to sample simultaneously at baghouse outlets 3, 4, and 6. These stacks
were chosen for sampling by EPA and appeared to represent the average
performance of the baghouse. Since all compartments seemed equal by
visual inspection, eas'e of sampling became the principal consideration
for selection of sampling points.
The sampling procedures were similar to those described for inlet sampling
(Method 5). Twenty-four traverse points per axis were sampled for five
minutes, for a total test time of four hours. All three outlet stacks
were sampled simultaneously with the inlet sampling.
Vederal Register, Volume 36, No. 2kl, December 23, 1971
-25-
-------
BABCOCK AND WILCOX
BEAVER FALLS, PENNSYLVANIA
EPA-OAP PARTICULATE TRAIN
10
MODIFIED TYPE IMPINGER
GREENBURG-SMITH TYPE IMPINGER
MODIFIED TYPE IMPINGERS
VACUUM GAUGE
THERMOMETERS
W.0.30039
PITOT TUBE
AND
MANOMETER
IMPINGERS IN ICE BATH
ORIFICE
AND
MANOMETER
FIGURE 5
ROY F. WESTOIM, INC.
ENVIRONMENTAL SCIENTISTS ANO ENGINEERS
LEWIS LANE • WEST CHESTER • PENNSYLVANIA • 193BD
-------
In addition to the EPA sampling performed on Stack 6, another type of
sampling train was used to sample simultaneously along the opposing
axis. This train, a combination ASME-EPA train (see Figure 6), was used
for method-comparison purposes. Three 4-hour tests were performed with
this train, which was assembled and operated in the following manner.
A 0.375"-I.D. nozzle was attached directly to a stainless steel thimble
holder which contained a medium-porosity alundum thimble. An inconel
probe (not heated) conveyed the gases to a glass filter holder con-
taining a fiber glass filter and then through EPA-type impingers ar-
ranged as described earlier in this section. The sampling procedures
and test times were identical to those of the EPA procedures used for
the EPA-OAP train at Stack 6. Some difficulty was experienced during
Run 2 (Stack 6, EPA), because of a control box failure. The box was
replaced immediately, and adjustments were made to maintain isokinetic
sampling.
Another EPA sampling train was used to obtain a particulate sample for
trace metal analysis. The sampling was accomplished utilizing an EPA
train similar to those used for sampling Stacks 3, 4, and 6, except
that the probe was constructed of pyrex glass and the filter was of
tissue quartz material (See Figure 7). Sampling was performed at
isokinetic conditions at a single traverse point, Number 5 on the Y
axis. Three 4-hour samples were collected simultaneously with the
other particulate samples.
Gaseous
Three 4-hour integrated gas samples were collected for Orsat analysis,
to determine the composition of the gas stream and to calculate the
molecular weight of the carrier gas. Each sample consisted of two
cubic feet of gas collected in a Tedlar Bag according to the technique
described in EPA Method 3. The stainless steel probe was positioned
to sample through a port in baghouse outlet Stack Number 2. Three
Orsat analyses were performed on each sample.
Continuous monitoring of the gas stream for concentration of carbon
monoxide was maintained throughout each 4-hour particulate test period.
A teflon line was extended from Stack Number 1 to a Non-Dispersive
Infar-Red instrument located at ground level. A separate teflon line
was used to sample the ambient air entering the shop through louvers
at ground level. A detailed explanation of the apparatus and the
procedures can be found in Appendix E.
Particle Size
Inlet
Particle size measurements were conducted at the inlet by using a
Pilat cascade impactor. A second series of tests were conducted with
a Brinks cascade impactor. Both units were placed inside the stack
-27-
-------
BABCOCK AND WILCOX
BEAVER FALLS, PENNSYLVANIA
ASME (MODIFIED) PARTICULATE TRAIN
to
CD
MODIFIED TYPE IHPINGER
GRENBURG-SMITH TYPE IMPINGER
MODIFIED TYPE IMPINGERS
VACUUM RAUGE
PI TOT TUBE
AND
MANOMETER
INCONEL PROBE
ALUNDUM THIMBLE
IMPINGERS IN ICE BATH
f THERMOMETERS
r-Cskl—i
L
ICA GEL
DRY TEST METER
ORIFICE
AND
MANOMETER
DISTILLED WATER
FIGURE 6
W.0.30039
ROY F. WEBTOINI, INC.
NVIHl INMKN I A I !_U : 11- M T I JJ T 51 A N I > [• ISJI 11 M I {, 11
t Wlfi I ATSJI. • \A/( !il lIHH-Slfcf'l • Mi:iSJW!*;vt.VAMlA • HCJtil
-------
KJ
W.O.30039
BABCOCK AND WILCOX
BEAVER FALLS, PENNSYLVANIA
EPA-OAP PARTICULATE TRAIN
TRACE METALS SAMPLE
PITOT TUBE
AND
MANOMETER
THERMOMETER
MODIFIED TYPE IMPINGER
GREENBURG-SMITH TYPE IMPINGER
MODIFIED TYPE IMPINGERS
THERMOMETERS
DRY TEST METER
IMPINGERS IN ICE BATH
DISTILLED WATER
ORIFICE
AND
MANOMETER
FIGURE 7
ROY F. WESTOIM, INC.
E NVIHONIV1 ENTAL SCIENTISTS AND ENGINEERS
LEWIS LANE • WEST CHESTER • PENNSYLVANIA . 1938O
-------
separately, and sampling rates were adjusted to maintain isokinetic
sampling conditions at a point of average velocity. Samples were
collected on aluminum foil surfaces and weighed to the nearest micro-
gram, using experimental methods developed by the Source Sample and
Fuels Analysis Branch of EPA. During the meltdown process, the particulate
concentration with the Pilat impactor was 87,000 pg/m? at standard con-
ditions; after the meltdown period, the concentration ranged from 8,000
/Kj/m3 to 2^,000 Aig/nK. During meltdown, a higher proportion of larger
particles was found than during other process intervals. Neither type
of distribution was well described by a log normal curve but exhibited
a slanting course of direction. The results show that 48 percent of the
aerosol mass during meltdown was <5 microns, compared to 87 percent during
the oxidizing, slagging, and refining periods. The mass median diameter
(roughly equivalent to the "average particle size") was fairly large during
meltdown (5-5 microns) compared to the other process intervals (1.25 microns)
The Brinks cascade impactor was employed for the same type of measure-
ments as the Pilat unit and presented data for determining mass median
diameters. Several problems were encountered with both units in attempt-
ing to obtain representative samples over any length of time. The con-
centration of fumes was so great that sampling had to be kept very short
in order to avoid overloading the various stages. Because of operating
limitations with the Brinks impactor, it was impossible to achieve 100
percent isokinetic sampling rates. The relatively high average stack
velocity (approximately 70-75 fps) and the limitation of flow rate through
the impactor made it necessary to accept mid-range operating conditions.
As a result, sampling rates were approximately 40 percent isokinetic.
Outlet
Particle size measurements were conducted on outlet Stack Number 5
using a Pilat in-stack cascade impactor. Sampling procedures were the
same as those used at the inlet sampling point. The outlet concentrations
were fairly constant, regardless of the process intervals, with results
ranging from 92 ju§/m to 116 Mg/m^. The size distributions on the out-
let aerosol indicated many large and small particles with practically
no intermediate-size particles. For example, the results show that
during meltdown, 50 percent of the aerosol mass was <0.5 micron, while
^9 percent of the mass was >10 microns. Similar!ly, during the oxidizing,
slagging, and refining periods, 62 percent of the mass was <0.5 micron
and 27 percent was >10 microns. The mass median diameter was too low to
be determined with the sampler involved.
An estimate of the efficiency of the baghouse can be determined from
these data even though samples were not collected simultaneously. During
meltdown, 6,090 /ug/m' of the particles were <1 micron and entered the
baghouse (87,000 x 0.007); 58 jug/m3 (<1 micron) exited the baghouse
(116 x 0.50). The removal efficiency, therefore, was 99-0 percent of the
submicrometer aerosol. For the adjustment and deslagging process, the
removal efficiency was 98.8 percent for particles 1 micron or smaller.
-30-
-------
Of the particles larger than 10 microns, 99.^ percent were removed during
meltdown and 97-9 percent removed during oxidizing, slagging, and refining
periods. Additional particle size information may be found in Appendix C.
Analyti cal
Particulates
The acetone probe washings samples were transferred to tared beakers and
evaporated to dryness at ambient temperature; the beakers were desiccated
and dried to a constant weight. Results are reported to the nearest 0.5
mg. The filters were desiccated for 2k hours and weighed to a constant
weight. The distilled water samples from the first two impingers were
evaporated to dryness after extraction for organics with chloroform and
ether. The final acetone wash samples were evaporated to dryness as
described for the probe washings sample. Some of the acetone probe wash
sample from Run 1, Stack 3 was spilled on site, but total sample volume
was recorded and considered in the analysis.
The weight of the material collected on the filter plus the probe wash-
ings sample residue weight represents the particulates collected by the
front half of the train. The total weight of particulates collected in-
cludes the remaining residue weights of the impinger water sample, chloro-
form extract, and acetone wash sample. All weights are adjusted by the
corresponding values of appropriate blanks. Detailed analytical procedures
and calculations are included in EPA Method 5 (Appendix E).
Several difficulties became apparent during analysis of the quartz filter
samples from Stack 1. This type of filter is extremely fragile and con-
sequently is vulnerable to loss of bits of the filter either by breaking
or by adhering to the 0-ring in the filter holder. (Static electricity
build-up during sampling made it especially difficult to remove the filter
at Stack 1 during Run Number 2, which accounts for the unusually high
weight loss reported for that run. It is possible to reduce this static
electricity by making sure that the probe is grounded throughout the run.)
The filters tend to accumulate moisture rapidly, which requires extra
care in the weighing. All the filters supplied by EPA experienced a loss
from the original weight, regardless of whether they were used in the test
or remained in the envelopes. This loss was considered in the calculation
of the results, by subtracting the average weight loss of blank filters.
Gaseous
The composition of the carrier gas sample was determined by standard Orsat
analysis according to procedures and calculations outlined in EPA Method 3
(Appendix E). This analysis was completed off site, because the low
ambient temperatures on site made it impossible to conduct accurate
Orsat analysis there.
-31-
-------
The gas stream analysis associated with the carbon monoxide monitoring
was accomplished by passing the sample through a Beckman Non-Dispersive
Infra-Red analyzer. The instrumentation provided a continuous print-out,
Carbon monoxide sampling procedures are included in Appendix E.
-32-
-------
APPENDIX A
-------
APPENDIX A
PARTICULATE SAMPLING DATA
-------
Table A-1
Preliminary Velocity Traverse
INLET
Date
Barometric Pressure in.Hg
Moisture, % By Volume (Assumed)
Molecular Weight, Dry Stack Gas
Mole Fraction Dry Gas
Molecular Weight Wet Stack Gas
2
Stack Area, In.
Static Pressure in.Hg
Stack Pressure Absolute in.Hg
Run
No.
1
2
3
4
5
6
Average ACFM
Velocity
Head
in. H70
1.395
1.290
1.394
1.394
1.377
1.392
iCFM 425
FM 473
Stack
Temp.
°F
90
100
100
100
100
105
,518
,964
Average
Velocity X Temp. R
27.70
26.87
27.94
27.94
27.77
28.04
10-13-72
29.10
2.0
29.00
.980
28.78
16286.
28.96
Stack Gas
Veloci ty
FPM1
4183
4058
4220
4220
4194
4235
Stack Gas
Volume
SCFM
432,384
411,972
428,419
428,419
425,779
426,137
^Stack condi tions.
A-1
-------
Table A-2
Preliminary Velocity Traverse
OUTLETS
Date 10-13-72
Barometric Pressure in. Hg 29.10
Moisture, % By Volume (Assumed) 2.0
Molecular Weight Dry Stack Gas 29.00
Mole Fraction Dry Gas .980
Molecular Weight Wet Stack Gas 28.78
Stack Area, In.2 10404.
Static Pressure, In. Hg .008
Stack Pressure, Absolute in. Hg 29.10
Stack
No.
1
2
3
4
5
6
Veloci ty
Head
in. H?0
.104
.099
.101
.122
.111
.095
Stack
Temp.
85
100
95
95
95
105
Average
J Velocity X Temp.uR
7.53
7.46
7.46
8.23
7.85
7.33
Stack Gas
Velocity
FPM1
1135
1124
1124
1240
1183
1104
Stack Gas
Vo 1 ume
SCFM
76,002
73,249
73,909
81,537
77,789
71,309
Total DSCFM 453,798
Total ACFM 499,439
Stack condi tions.
A-2
-------
Table A-3
INLET
Particulate Emission Data
Run No.
Date
Time
°n
Tt
pb
Pm
Vm
Tm
-v..td
Vwgas
% M
Md
% C0£
%02
% CO
%M
2
*
24 hour clock
Sampling Nozzle Diameter, in.
Net Time of Test, min.
Barometric Pressure, in. Hg
absolute
Average Orifice Pressure
Drop, in. H20
Volume of Dry Gas Sampled,
cu.ft. at meter conditions
Average Gas Meter Temperature,
Volume of Dry Gas Sampled, A
cu.ft. at standard conditions
Total H20 Collected, ml,
impingers and silica gel
Volume of Water Vapor Collected,
Percent Moisture in the Stack
Gas by Volume
Mole Fraction of Dry Gas
.
."".
1
10-18-72
0945-1432
• 0.1875
240
29.20
1.72
.176.21
63.9
174.56
26.5
1.26
0.7
0.992
0.1
20.6
0.0
79.3
2
10-19-72
1002-1502
0.1875
240
29.30
1 .88
184.23
67.8
181.87
24.0
1.14
0,6
0.993
0.1
20.2
0.0
79.7
3
10-20-72
1000-1501
0.1875
240
29.50
1.98
190.44
76.2
186.35
23.6
1.12
0.6
0.994
0.0
20.7
0.0
79.3
*70°F, 29.92 in. Hg, dry basis
A-3
-------
Run Mo.
'•'Wd
KW
cp
AP
Ts
NP
Pst
PS
VS
As
0-s
Qa
% 1 -
mf
mt
Ic
Can
Cao
T.blc A- 3
(cor, I' i nued
Molecular Weight of Dry Stack
Gas
Molecular W e i 9 h i o f We t S I; a c k
Gas
Pi tot Tube Coefficient
Average Velocity Hac-ici of
Stack Gas, i n. H20
Ave rage S t a c. k Teirpe r a t u i 'c; , F
Net Ssmpl i ivg Poi r.ts
Static Pressure of Stack, in.Hg
Stack Pressure, in. Hg absolute
Stock Velocity at Stack Condi -
t ions , f PITS
Stack Area, sqv in.
Dry Stack Gas Volume, at
Standard Conditions"", SCFM
Stack Gas Volume at Stack
Condition, ACFM
Percent Isokinetic
Particulate - Probe, and
Filter, mg
Particulate - Total, mg
% Impinger Catch
Particulate - Probe, and
Filter, gr/SCF"
Particulate - Total, gr/SCF"'
1
28.83
28.70
0.851
1.38
98.6
48.
-0.14
29.06
4168
16286
431236
471699
99.5
437.9
450.8
2.86
0.0386
0.0397
2
28.82
28.70
0.851
1.51
100.4
.48.
-0.14
29.16
4391.
16286
454932
497016
98.2
666.1
705.9
5.64
0.0564
0.0597
3
28.82
28.70
0.851
1.59
94.8
48.
-0.14
29.36
4463.
16286
470300
504697
97.4
732.5
748, i
2.09
0.0605
0.0618
"70°F, 29.92 in. Hg, dry basis
A-4
-------
Run No,
Table A-3
(cont i ivjecl)
-at
a LI
Part i cs-il 5t:e - Prob.-.-,, and
Pi Iter, gr/ACf-
Parti culate - Iota!,qr/ACF
0.0353
0.0516
0.05^7
0.0576
"ax
Pa r t i c.u 1 a ;•.e ~ Probe > a nd
Filter, Ib/hr.
Particulate - Total, Ib/hr,
142.77
146.98
219.90
233.04
243.98
249.18
A-5
-------
Table A-4
OUTLET 1
Particulate Emission Data
Run No.
Date
Time
Dn
Tt
pb
Pm
Vm
Tm
Vmstd
Vw ...
Sas
% M
Md
% C02
% 02
% CO
% N2
.•
2k hour clock
Sampling Nozzle Diameter, in. •
Net Time of Test, min.
Barometric Pressure, in. Hg
absolute
Average Orifice Pressure
Drop, in. H20
Volume of Dry Gas Sampled,
cu.ft. at meter conditions
Average Gas Meter Temperature,
Volume of Dry Gas Sampled, ,,,
cu.ft. at. standard conditions
Total H20 Collected, ml,
impingers and silica gel
Volume of Water Vapor Collected,
scf*~ -%- --
Percent Moisture in the Stack
Gas by Volume
Mole Fraction of Dry Gas
.-
1
10-18-72
0946-1432
0.375
240
29.20
1.92
194.04
102.1
179.25
22.0
1.04
0.5
o.ssk
0.1
20.6
0.0
79.3
2
10-19-72
1000-1502
0.375
240
29.30
. 2.06
19^.33
96.6
181.98
27.1
1.29
0.7
0.992
0.1
20.2
0.0
79.7
3
10-20-72
1000-1505
0.375
2*fO
29.50
2.25
204.38
103.7
190.35
19.5
0.92
0.4
0.995
0.0
20.7
0.0
79.3
"70°F, 29.92 in. Hg, dry basis
A-b
-------
Run No.
MWd
MW"
CP
AP
TS
Np
Pst
Ps
vs
As
as
Qa
% 1
mf
mt
Ic
Can
cao
Table A-4
(cont i nued j
Molecular Weight of Dry Stack
Gas
Molecular Weight of Wet Stack
Gas
Pitot Tube Coefficient
Average Velocity Head of
Stack Gas, in. H20
Average Stack Temperature, °F
Net Sampl i ng Poi nts
Static Pressure of Stack, in.Hg
Stack Pressure, in. Hg absolute
Stack Velocity at Stack Condi-
tions, fpm
Stack Area , sq. in.
Dry Stack Gas Volume at
Standard Conditions", SCFM
Stack Gas Volume at Stack
Condition, ACFM
Percent Isokinetic
Particulate - Probe, and
Filter, mg
Particulate - Total, mg
% Impinger Catch
Particulate - Probe, and
Filter, gr/SCF*
Particulate - Total, gr/SCF*
1
28.83
28.70
0.834
0.08
104.1
48
+ .01
29.21
1024
10404
67468
74007
104.3
17.5
25.7
31.9
0.0015
0.0022
2
28.82
28.70
0.834
0.09
102.8
48
+ .01
29.31
1045
10404
69141
75537
103.3
2.1
13.3
84.2
0.0001
0.0011
3
28.82
28.70
0.834
0.09
101.5
48
+ .01
29.51
1088
10404
72835
78632
102.6
69.2
81.7
15.3
0.0055
0.0066
""70°F, 29.92 in. Hg, dry basis
A-7
-------
Run No.
au
Table A-4
(cont inued)
Cat Particulate - Probe, and 0.0014 0.002 0.0052
Filter, gr/ACF
C Particulate - Total,gr/ACF 0.0020 0.0010 0.0061
A-8
Caw Particulate - Probe, and 0.8693 0.1053
Filter, Ib/hr.
Cax Particulate - Total, Ib/hr. 1.2766 0.6669 4.1259
-------
Table A-5
OUTLET 3
Particulate Emission Data
Run No.
Date
Time
D
n
Tt
Pb
Pm
Vm
Tm
Vmstd
vw ..
Sas
% M
Md
% C02
% 02
% CO
% N2
.*
24 hour clock
Sampling Nozzle Diameter, in.
Net Time of Test, min.
Barometric Pressure, in. Hg
absolute
Average Orifice Pressure
Drop, in. H20
Volume of Dry Gas Sampled,
cu.ft. at meter conditions
Average Gas Meter Temperature,
Volume of Dry Gas Sampled, ^
cu.ft. at standard conditions"
Total H20 Collected, ml ,
impingers and silica gel
Volume of Water Vapor Collected,
scf*
Percent Moisture in the Stack
Gas by Volume
Mole Fraction of Dry Gas
.-
1
10-18-72
0947-1434
0.375
240
29.20
2.02
187.48
111.6
170.37
22.0
1 .Ok
0.6
0.993
0,1 .
20.6
0.0
79.3
2
10-19-72
1003-1502
0.375 '
240
29.30
. 2.20
193.17
109.1*
176.89
20.0
0.95
0.5
0.994
0.1
20.2
0.0
79.7
3
10-20-72
1002-1502
0.375
240
29.50
2.25
195.99
112.4
179.78
18.7
0.89
O.k
0.995
0.0
20.7
0.0
79.3
"70°F, 29.92 in. Hg, dry basis
A-9
-------
Run No.
MWd
MW
CP
AP
Ts
Np
Pst
-Ps
Vs
As
as
Qa
% 1 '
mf
mt
Ic
Can
cao
Table A-5
(continued)
Molecular Weight of Dry Stack
Gas
Molecular Weight of Wet Stack
Gas
Pitot Tube Coefficient
Average Velocity Head of
Stack Gas, in. H20
Average Stack Temperature, F
Net Sampling Points
Static Pressure of Stack, in.Hg
Stack Pressure, in. Hg absolute
Stack Velocity at Stack Condi-
tions, fpm
Stack Area, sq. in.
Dry Stack Gas Volume at
Standard Conditions", SCFM
Stack Gas Volume at Stack
Condition, ACFM
Percent Isokinetic
Partfculate - Probe, and
Filter, mg
Particulate - Total, mg
% Impinger Catch
Particulate - Probe, and
Filter, gr/SCF*
Particulate - Total, gr/SCF*
1
28.83
28.70
0.834
0.09
103.0
48
+ .01
29.21
1048
10404
69135
75740
96.7
8.4
24.5
65.7
0.0007
0.0022
2
28.82
28.70
0.834
0.09
101.7
48
+ .01
29.31
1072
10404
71209
77511
97.5
12.3
22.3
44.8
0.0010
0.0019
3'
28.82
28.70
0.834
0.09
99.1
48
+ .01
29.51
1073
10404
72127
77535
97.8
20.8
55.2
62.3
0.0017
0.0047
X70°F, 29.92 in. Hg, dry basis
-------
Run No.
au
Table A-5
(cont i nued)
Cat Particulate - Probe, and 0.0007 0.0010 0.0017
Filter, gr/ACF
C , Particulate-Total.gr/ACF 0.0020 0.0018
A-11
Caw Particulate -• Probe, and 0.4^99 0.6535 1.1013
Filter, Ib/hr.
Cax Particulate - Total, Ib/hr. 1.3121 1.1848 2.9227
-------
Table A-6
OUTLET 4
Particulate Emission Data
Run No.
Date
T ime
D
n
Tt
Pb
Pm
Vm
Tm
Vn>std
vw
Sas '
% M
"d
% C02
% 02
% CO
%M
N2
.•
24 hour clock
Sampling 1,'ozzle Diameter, in.
Net Time of Test, min.
Barometric Pressure, in. Hg
absol ute
Average Orifice Pressure
Drop, in. H20
Volume of Dry Gas Sampled,
cu.ft. at meter conditions
Average Gas Meter Temperature,
Volume of Dry Gas Sampled,
cu.ft. at standard conditions"
Total H20 Collected, ml,
impingers and silica gel
Volume of Water Vapor Collected,
scf*
Percent Moisture in the Stack
Gas by Volume
Mole Fraction of Dry Gas
,
1
10-18-72
0945-1432
0.375
240
29.20
1.92
194.37
107.9
177.73
25.0
1.19
0.6
0.993
0.1
20.6
0.0
79.3
2
10-19-72
1001-1500
0.375
240
29.30
2.04
200.50
104.9
185.00
19.5
0.92
0.5
0.995
0.1
20.2
0.0
79.7
3
10-20-72
1000-1500
0.375
240
29.50
2.08
200.39
108.2
185.09
18.5
0.88
0.4
0.995
0.0
20.7
0.0
79.3
~70°F, 29.92 in. Hg, dry basis
A-12
-------
Run No.
MWd
MW
CP
AP
Ts
Np
Pst
.PS
V'
As
0-s
Qa
% 1 '
mf
mt
Ic
Can
Cao
Table_A-6
(cont i nued)
Molecular Weight of Dry Stack
Gas
Molecular Weight of Wet Stack
Gas
Pitot Tube Coefficient
Average Velocity Head of
Stack Gas, in. H£0
Average Stack Temperature, F
Net Sampling Points
Static Pressure of Stack, in.Hg
Stack Pressure, in. Hg absolute
Stack Velocity at Stack Condi-
tions, fpm
Stack Area, sq. in.
Dry Stack Gas Volume at
Standard Conditions", SCFM
Stack Gas Volume at Stack
Condition, ACFM
Percent Isokinetic
Particulate - Probe, and
Fi 1 ter, mg
Particulate - Total, mg
% Impinger Catch
Particulate - Probe, and
Filter, gr/SCF*
Particulate - Total, gr/SCF*
1
28.83
2,8.70
0.850
0.08
103.1
48
+ .01
29.21
1023
10404
67479
73938
103.4
37.6
53.8
30.1
0.0032
0.0046
2
28.82
28.70
0.850
0.08
101.7
48
+ .01
29.31
1047
10404
69574
75653
104.4
8.7
17.5
50.3
0.0007
0.0014
3
28.82
28.70
0.850
0.08
99.2
48
+ .01
29.51
1045
10404
70241
77521
103.4
6.7
18.3
63.4
0.0005
0.0015
V70°F, 29.92 in. Hg, dry basis
A-13
-------
Run No.
au
Table A-6
(cont inuecl)
C Particulate - Probe, and 0.0030 0.0007 0.0005
Filter, gr/ACF
•W
C_M Particulate-Total.gr/ACF 0.00^3 0.0013 0.0014
Caw Particulate - Probe, and 1.88^1 0.^318 0.3356
Filter, Ib/hr.
Cax Particulate - Total, Ib/hr. 2.6958 0.8686 0.9166
-------
Table A-7
OUTLET 6 EPA
Particulate Emission Data
Run No.
Date
Time
D
n
Tt
Pb
Pm
Vm
Tm
V<%td
vw ...
Sas '
% M
Md
% C02
% 02
% CO
% N2
.*
2k hour clock
Sampling Nozzle Diameter, in.
Net Time of Test, min.
Barometric Pressure, in. Hg
absolute
Average Orifice Pressure
Drop, in. H20
Volume of Dry Gas Sampled,
cu.ft. at meter conditions
Average Gas Meter Temperature,
Volume of Dry Gas Sampled, ^
cu.ft. at standard conditions"
Total H20 Collected, ml ,
impingers and silica. gel
Volume of Water Vapor Collected,
scf * .-;••.•-
Percent Moisture in the Stack
Gas by Volume
Mole Fraction of Dry Gas
.-
1
10-18-72
0945-1432
0.375
240
29.20
•2.31
201.12
103.6
185.50
24.0
1.14
0.6
0.993
0-.1
20.6
0.0
79.3
2
10-19-72
1002-1502
0.375
240
29.30
. 1.89
183.49
91.7
173.27
22.9
1.09
0.6
0.993
0.1
20.2
0.0
79.7
3
10-20-72
1000-1500
0.375
240
29.50
2.11
190.91
101.3
178.51
30.0
1 .42
0.7
0.992
0.0
20.7
0.0
79.3
*70°F, 29.92 in. Hg, dry basis
A-15
-------
Run No.
MWd
MW
CP
A P
Ts
Np
Pst
.PS
vs
As
0-s
Qa
% 1 '
mf
mt
Ic
Can
. cao
Table A-7
(cont i nued)
Molecular Weight of Dry Stack
Gas
Molecular Weight of Wet Stack
Gas
Pitot Tube Coefficient
Average Velocity Head of
Stack Gas, in. H20
Average Stack Temperature, F
Net Sampl i ng Poi nts
Static Pressure of Stack, in.Hg
Stack Pressure, in. Hg absolute
Stack Velocity at Stack Condi-
tions, fpm
Stack Area , sq. i n.
Dry Stack Gas Volume at
Standard Conditions'', SCFM
Stack Gas Volume at Stack
Condition, ACFM
Percent Isokinetic
Particulate - Probe, and
Filter, mg
Particulate - Total, mg
% Impinger Catch
Particulate - Probe, and
Filter, gr/SCF*
Particulate - Total, gr/SCF"
1
28.83
28.70
0.851
0.09
100.3
48
+ .01
29.21
1097
10404
72729
79295
100.1
28.6
46.3
38.2
0.0023
0.0038
2
28.82
28.70
0.851
0.07
100.0
48
+ .01
29.31
986
10404
65648
71315
103.6
14.3
27.1
47.2
0.0012
0.0024
3
28.82
28.70
0.851
0.08
100.2
48
+ .01
29.51
1039
10404
69915
75536
96.9
8.8
18.9
' 53.4
0.0008
0.0016
'70°F, 29.92 in. Hg, dry basis
A-16
-------
Run Mo.
table A-7
(cont inuecl)
Cat Particulate - Probe, and 0.0022 0.0012 0.0007
Fi Her, gr/ACF ; . ..
Cau Particulate -Total,gp/ACF 0.0035 0.0022 0.0015
Caw Particulate- Probe, and 1.^799 0.7150 O.if79
Fi Iter, Ib/hr.
Cax Particulate - Total, Ib/hr. 2.3958 1.3551 0.959
A-17
-------
Table A-8
OUTLET 6 ASME
Participate Emission Data
Run No.
Date
Time
D
n
Tt
Pb
pm
Vm
Tm
V-.td
Sas '
% M
"d
7o C02
% 02
% CO
% N2
2k hour clock
Sampling Nozzle Diameter, in.
Net Time of Test, min.
Barometric Pressure, in, Hcj
absol ute
Average Orifice Pressure
Drop, in. h^O
Volume of Dry Gas Sampled,
cu.ft. at meter conditions
Average Gas Meter Temperature,
Volume of Dry Gas Sampled,
cu.ft. at standard conditions"
Total H20 Col lected, ml ,
impingers and silica gel
Volume of Water Vapor Col lected,
scf*
Percent Moisture in the Stack
Gas by Volume
Mole Fraction of Dry Gas
1
10-18-72
0945-1432
0.375
240
29.20
3.87
190.26
107.5
174.95
20.3
0.96
0.5
0.994
OJ
20.6
0.0
79.3
2
10-19-72
1002-1502
0.375
240
29.30
2.15
192.94
101.3
179.22
16.6
0.79
0.4
0.995
0.1
20.2
0.0
79.7
3
10-20-72
1000-1500
0.375
240
29.50
2.16
190.14
105.0
176.66
13.5
0.64
0.3
0.996
0.0
20.7
0.0
79.3
"70°F, 29.92 in. Hg, dry basis
-------
Table A-8
(continued)
Run No.
MWd
MW
C .
P
P
Ts
NP
Pst
PS
vs
As
"•
^
% 1
mf
mt
Ic
c_
Molecular Weight of Dry Stack
Gas
Molecular Weight of Wet Stack
Gas
Pi tot Tube Coefficient
Average Velocity Head of
Stack Gas, in. H20
Average Stack Temperature, F
Net Sampling Points
Static Pressure of Stack,
in. Hg
Stack Pressure, in. Hg absolute
Stack Velocity at Stack Condi-
tions, fpm
Stack Area, sq. in.
Dry Stack Gas Volume at
Standard Conditions", SCFM
Stack Gas Volume at Stack
Condition, ACFM
Percent Isokinetic
Particulate-Nozzle and Thimble, mg
Particulate - Probe, and EPA
Fi Iter, mg
Particulate - Front Half, mg
Particulate - Total, mg
% Impinger Catch
Particulate-Nozzle and Thimble,
Particulate - Probe, and Filter,
1
28.80
28.70
0.834
0.09
100.1
48
+.01
29.21
1076
10404
71390
77753
96.2
10.7
11.1
21.8
40.4
46.0
0.0009
0.0010
2
28.82
28.70
0.834
0.09
100.0
48
+.01
29.31
1063
10404
70912
76875
99.2
9.5
7.3
16.8
24.2
30.6
0.0008
0.0006
3
28.82
28.70
0.834
0.08
96.6
48
+.01
29.51
1058
10404
71527
76468
96.9
2.9
7.3
10.2
20.7
50.7
0.0003
0.0006
an
gr/SCF*
*70°F, 29.92 in. Hg, dry basis.
A-19
-------
Table A-8
(continued)
Run No. 1 2 3
Particulate - Front Half, gr/SCF* 0.0019 0.0014 0.0008
Cao Particulate - Total, gr/SCF* 0.0035 0.0020 0.0018
Particulate-Nozzle and Thimble, 0.0009 0.0008 0.0002
gr/ACF
C . Particulate - Probe, and EPA 0.0009 0.0006 0.0006
Filter, gr/ACF
Particulate - Front Half, gr/SCF* 0.0018 0.0013 0.0008
Cau Particulate - Total, gr/ACF 0.0033 0.0019 0.0017
Particulate-Nozzle and Thimble, 0.576 0.496 0.155
Ib/hr.
C=u, Particulate - Probe, and Filter, 0.5975 0.3808 0.3898
3 Ib/hr.
Particulate - Front Half, Ib/hr. 1.1736 0.8765 0.5443
C Particulate - Total, Ib/hr. 2.1757 1.2637 1.1061
dx
A-20
-------
Sample Calculations
Inlet Run No. 1
1
uinG of dry gas sampled at stf>;rJAr<:i conditions'5, DSCF
Y! .7 X 176.21 (29.20-+ 1.72 )
nistd
--174.58 DSCF
?.. Voluinc of v/itor vapor r:l st^nd^rd co:idit'ior;i;b4 SCF
\as " 0.0474 x Vw = 0
0/;7^ x 26.5 = 1.26 $CF
3. Percent moisture in stack gas
100 x V
v.(.
TOO x 1.26
stci
4. Kole fraction of dry gas
M,
ion - fj_ f-y
100'
TJ-O « . 72
"loo
= 0.993
5. Molecular weight of dry stack gas
9P
i /
(0.1 X -) +. (20,6 x -) + (79.3 X ->- ) = 28.84
1Sample results may not correspond to computer calculated figures in every
case because of intermediate computer roundoff.
A-21
-------
6. [k'lc.-cular weioht of wet stack nos
Ml.1 « I-;V/ x M •)- 1C (i -- !-!) - 28.84 x .993 + 18 (1 - -993 ) ^ 28.76
7. Stock gas velocity at stack conditions , fpi-.i
Vs = 5128.8 x Cp xAP x (Ts
/
/
1/2
r 1 "1
5128.8 x 0.851 x 27.61 [29.06 x 28.76j
1/2
fpm
3. Stnck gas volumetric flow r\vte at standard conditions . DSCFM
0.123 x V x Ac x I', x Pp ' 0.123 x 4168 x 16286>: .993 X29.06
_ ___ ____ ,5 _____ i..___,,-^__.^L... - '' _______ _ ..... j ____ __^ __.^ _ n/ioi oio
(T, + 460) .; ' . (98.6+460) "431,312
9. Stack gas voluiretric flow rate at stack conditions, ACFM
.056-^5 x Qs (Ts . 460)
_ >05645 x431 .312 (98.6 .JG
29.06 x .993
ACH-1
10. Percent isokinetic
1,032 x (T + *GO) x
_
r/T -
A>I -
.6^- 460)x 174.58
T v
i x
X29.06 x .993 x (.18757
2 = 99.2
A-22
-------
.11. Pcrtkulat.r-: - probe, cyclone, and fllttr, or/DSCF
437.9 .. 0.0386 qr/DSCF
V*,.
.12. Psrficulate - total, ur/DSCF
Cao * 0.0154 x - * 0.0154 x ^fg- a °'°398 ^/DSC
'sui
Particulate - probe, cyclone, and filter at stsck conditions, nr/^-C
17.7 x C x P x !•', 17.7 x.0386 >;29.06 x .993
„ ___ ,....,.„ ,.5'1L«.™ •'_. ____ '' - ._* _ „ __ . _______ • ___
(T> /;60) ~ ( 98.6 * ^GO)
Particulate - total at slack conditions, gr/ACF
'17.7' x C x PS x M,, 17.7 x.0398 X29.06 x .993
:aw= —"TT'^coi—'"= r~s8T~+~m) •= °-0364
o
..15. Participate - probe, cyclone, arid filter, Ib/hr
Caw = 0.00857 x Cpn.x Qs = O.COC57 x.0386 x ^31,312= 142.68 Ib/hr
A-2 3
-------
16. Particulate, total; Ib/hr
Cax = 0.00857 x Cao x 0_s = 0.00857 x .0398 x 431,312 = 1^7.11 Ib/hr
aDry standard cubic feet at 70°F, 29.92 in. Hg.
Standard Conditions at 70°F, 29.92 in. Hg.
x (Ts + 460) is determined by averaging the square root of the
product of the velocity head (&P ) and the absolute
stack temperature from each sampling point.
Dry standard cubic feet per minute at 70°F, 29.92 in. Hg
A-24
-------
Name of Company
Address
Name of Contacts
Plant Telephone Number_
Description of Process_
PRELIMINARY SURVEY
City_
Title,
Title,
Title
Date of Survey_
State
Operating Schedule of Process_
Batch or Continuous Process
Feed Composition and Rates
Type of Fuel
Production Rate
Description of Air Pollution Control Equipment and Operation_
Safety Hazards_
A-25
-------
PRELIMINARY SURVEY
Issumed Constituents of Stack Gas for Each Sampling Site
Possible Testing Sites (1)
2)
3)__
I
an Samples be Collected of:
a. Raw Materials
b. Control Equipment Effluent
c. Ash
d. Scrubber Water
•Signature Required on Passes
Are the Following Available at the Plant?
a. Parking Facilities
/-•
b. Electrician
c. Electric Extensions
d. Safety Equipment
e. Ice
f. Distilled Water •
e.
f.
9-
Product
Fuel
Other
g. Clean-up Area
h . Lab . Faci lit! es_
i. Sampli ng Ports
j . Scaffold i ng
k. Rope
1. Equ i pment
Elevator
A-26
-------
PRELIMINARY SURVEY
1. Electricity Source
a. Amperage per circuit
b. Location of fuse box
c. Extension cord lengths
d. Adapters needed?
2. Safety Equipment Needed
a. Hard hats
b. Safety glasses
c. Goggles
3. Ice
a. Vendor
b. Location
. Sampli ng Ports
a. Who will provide
b. Size opening
Quant i ):y
d. Safety shoes
e. Alarms
f. Other
Welder:
5. Scaffolding
a. Height
b. Length
6. Motels
a.
Phone
A-27
Rate
-------
PRELIMINARY SURVEY
7. Restaurants
a. Near Plant
b. Near Motel
8. Airport Convenient to Plant_
Comments:
Di stance
SURVEY BY:
A-28
-------
Sketch of Stack to be Sampled Showing Locations of Port Openings, Water
Sprayers, Flow Interferences, Dilution Air Inlets, and Scaffolding or
Platform Erection Dimensions
A-29
-------
APPENDIX B
-------
APPENDIX B
GASEOUS SAMPLING DATA
-------
Table B-1
CARBON MONOXIDE CONCENTRATIONS
at Babcock and Wilcox Co., Beaver Falls, Pa. (ppm)
5 Minute Avg. CO Max. CO
Period Ending ppm ppm
October 18. 1972
0905 105 165
0910 111 170
0915 5*
0920 125 175
0925 , 164 185
0930 164 180
0935 60 100
0940 165 185
0945 120 175
0950 25 125
0955 109 150
0955 5*
1000 66 140
1005 83 135
1010 138 155
1015 85 128
1020 56 100
1030 64 110
1035 26 40
1040 40 45
1045 60 70
1050 85 115
1055 125 • 165
1100 125 285
1105 128 150
1110 217 275
1115 200 255
1120 75 100
1125 83 125
1130 83 95
1135 85 100
1140 74 90
1145 80 140
1150 70 165
1155 48 60
1200 45 85
* Ambient Sample
S-1
SCOTT RESEARCH LABORATORIES. INC.
-------
Table B-1
(continued)
5 Minute Avg. CO Max. CO
Period Ending ppm
B-2
1205 45 95
1210 20 40
1215 70 150
1220 74 150
1225 50 55
1230 4*
1235 35 60
1240 51 75
1245 30 40
1250 26 40
1255 26 35
1300 21 30
1305 88 130
1310 55 110
1315 4*
1320 35 65
1325 20 20
1330 20 20
1335 20 20
1340 20 20
1345 25 30
1350 75 95
1400 3* -
1405 10 15
1410 25 45
1410 3*
1415 10 10
1420 10 10
1425 10 10
1430 10 10
1435 10 10
1440 4*
1445 10 10
1450 55 110
1455 20 40
1500 25 35
* Ambient Sample
SCOTT RESEARCH LABORATORIES. INC
-------
Table B-1
(conti riued)
5 Minute
Period Ending
October 19. 1972
0905
0910
0915
0920
0925
0930
0935
0940
0945
0950
0955
1010
1015
1020
1025
1030
1035
1040
1045
1050
1100
1105
1110
1115
1120
1125
1130
1135
1140
1145
1150
1155
1200
1205
1210
1215
1220
1225
1230
1240
1245
1250
Avg. CO
ppm
60
151
'51
40
140
165
155
175
25
290
5*
125
125
75
15
30
35
80
50
60
40
60
65
90
75
5*
75
40
25
35
30
15
90
30
15
15
35
55
5*
60
40
60
Max. CO
ppm
100
190
175
90
175
195
165
210
100
325
135
140
80
25
35
70
150
140
110
55
75
90
105
100
90
80
30
55
35
15
160
35
15
15
35
75
110
75
75
* Ambient Sample
3-3
SCOTT RESEARCH LABORATORIES, INC.
-------
Table B-1
(conti nued)
5 Minute Avg. CO Max. CO
Period Ending ppm ppm
1300 10 10
1305 10 10
1310 10 10
1315 5*
1320 10 10
1325 10 10
1330 10 10
1335 60 110
1340 25 50
1345 15 15
1350 10 10
1355 10 10
1405 3* -
1410 15 15
1415 20 20
1420 20 20
1425 20 20
1430 20 20
1435 20 20
J.440 3* ' -
1450 25 25
1455 25 25
1500 20 20
1505 25 30
1510 25 25
1525 25 25
October 20. 1972
0910 30**
0915 15 15
0920 10 10
0925 10 10
0930 10 10
0935 4*
0940 10 10
0945 10 10
0950 10 10
0955 10 15
1000 15 15
1005 40 70
1010 75 115
1015 60 95
1020 25 25
* Ambient Sample
** Thursday Bag Sample
SCOTT RESEARCH LABORATORIES, INC.
-------
Table B-1
(continued)
5 Minute Avg. CO Max. CO
Period Ending ppm ppm
1030 -4*
1035 25 40
1040 25 30
1045 "25 25
1050 21 25
1055 3*
1100 10 10
1105 10 10
1115 24 38
1120 48 75
1125 31 75
1130 35 50
1135 30 50
1140 25 45
1145 25 45
1150 25 50
1155 25 40
1200 25 55
1205 10 10
1210 10 10
1215 10 10
1220 10 10
1225 10 10
1230 2*
1240 56 74
1245 40 70
1250 18 22
1255 20 24
1300 16 20
1305 10 14
1310 70 144
1315 160 176
1320 146 176
1325 106 132
1330 60 96
1335 40 70
1340 86 98
1345 66 106
1350 56 106
1355 140 176
* Ambient Sample
B-5
SCOTT RESEARCH LABORATORIES. INC.
-------
Table B-1
(continued)
5 Minute Avg. CO Max. CO
Period Ending ppm ppm
1400 100 140
1405 90 108
1410 120 186
1415 "58 96
1420 110 172
1425 180 275
1430 100 240
1435 140 185
1440 100 190
1445 32 40
1450 60 105
1455 56 70
1500 30 40
1505 3*
* Ambient Sample
3-6
SCOTT RESEARCH LABORATORIES, INC.
-------
Table B-2
Summary
Carrier Gas Composition
Orsat Analysis
Outlet Stack 2
Run No. 1 2 3
Date
C02, % 0.1 0.0 0.0
0.1 0.1 0.0
0.1 0.0 0.0
02, % 20.6 20.2 20.7
20.6 20.3 20.8
20.5 20.2 20.7
CO, %
I
-------
APPENDIX C
-------
APPENDIX C
PARTICLE SIZE MEASUREMENTS
-------
APPENDIX C
PARTICLE SIZE MEASUREMENTS
Introduction
Determinations of particle size distribution of fume emissions at the
Electric Arc Iron and Steel furnace of the Babcock-Wi1 cox Company,
Beaver Falls, Pennsylvania were conducted from October 18, 1972 to
October 20, 1972. Sampling was conducted on the controlled and
uncontrolled furnace fume emission emitted during the time emission
tests. Samples for the evaluation of particle size distribution
were gathered at the inlet using both the Pilat in-stack sampler
(Figures C-l and C-2) and the Brinks Cascade Impactor (Figure C-3);
only the Pilat unit was operated at the outlet location.
Prior to collecting samples in the field, each impactor was calibrated
to determine air flow rates at various operating conditions. A
calibration curve was constructed by plotting the pressure drop
across the sampling train versus the air flow rate. The impactor
was inserted into the stack for sample collection. The sampling
durations ranged from two minutes to 120 minutes. Sampling
rates were predetermined and were adjusted to maintain isokinetic
sampling conditions at a point of average velocity.
These particle size impactors are of multi-jet construction and
are inserted directly into the stack gases to collect the sample.
The impactor separates particulates according to their aerodynamic
properties. The data are obtained by simply determining the weight
of the material collected on each stage of the impactor. An
appropriate nozzle size is used to attain isokinetic sampling
condi tions.
Each cascade impactor was mounted on a probe and connected to a
vaccum pump by flexible tubing. Metering valves were used on
the inlet side of the pump to adjust the air flows through the
samplers. Volumetric flow rates through the samplers were
measured by using a dry gas meter. Samples were collected on
preweighed aluminum foil surfaces weighed to the nearest
microgram using methods developed by EPA. A final filter of
tissue quartz followed the impactors.
C-l
-------
223
FILTER
RUBBER TUBING
DRY GAS METER
t ttf
GAS FLOW
DIRECTION
VACUUM PUMP
FIGURE C-l PILAT IMPACTQR SAMPLING TRAIN
-------
o
I
IM FACTOR STAGE
\ \\\\\\\\\
' 1 \ i \ V \ V \ \ \ vv
\\ \\x\\\\\\\
IMPACTOR PLATE
O-RINGS
SPACING STUDS
LOCATED AT EQUAL
INTERVALS ABOUT
CIRCUMFERENCE
Figure C-2 Schematic of Source Test Cascade impactor (Pilat)
-------
IM FACTOR
FILTERx
223
lf*^-NOZZLE
MM
GAS FLOW
DIRECTION
VACUUM PUMP
"SILICA GEL
IMPINGER
DRY GAS METER
Figure C-3 Brinks Impactor Sampling Train
-------
Graphical presentations of the data showing log-probability plots
of cumulative percent less than stated micron size versus the
impactor stage particle size cut (D'pc) for each-stage in microns
are given in Figures C-k and C-5. The characteristic diameter of
an aerosol particle for each Brinks impactor stage (o'pc) has
been calculated for an air flow rate of 0-lU cfm through the
imnactor, assuming particles of unit density (1 gram per cubic
centimeter), using the equation described by J.A. Brink, Jr.
(Reference: Industrial Engineering and Chemistry, Vol. 50,
pp. 6^5-6^8 April 1958)The characteristic diameters are as
follows:
Inlet location
Brink Run 1
Brink Run 2
Brink Run 3
Stage
1
2
3
k
5
1
2
3
4
5
1
2
3
4
5
No. Weight Gain,ug
11
0
21
35
31
Total 9H
118
126
111
102
65
Total 522
605
566
39^
386
164
Total 2,115
Cumulative
Mass i >
D'pc
11.3
11.3
32.7
68. k
100.0
22.6
^6.7
68.0
87.5
100.0
D'pc microns
3.0
1.8
1.2
. 0.6
0.3
3.0
1.8
1.2
0.6
0.3
28
56
75
93
.6
.k
,0
.3
100.0
.0
,8
,2
0.6
0.3
The low total sample weight of Run 1 with the Brinks impactor suggests
that the sample time should probably have been extended. It is
uncertain whether the zero sample weight on Stage No. 2 actually
represents a size range void of particles. It is entirely possible
that a longer sample time would have resulted in a weight gain on
the second stage. Choice of a conclusion would be based on mere
speculation.
In addition to the Pilat and Brink particle measurements, three
representative dust samples were collected from the captured baghouse
dust. A centrifugal classifier was used to determine the terminal
velocity distribution of the samples by EPA laboratory personnel.
The tabular and graphical presentation of data showing the percent
by weight of those particles in the dust samples having terminal
velocities less than various indicated values follows.
C-5
-------
,0
7JQ.
0-.i-
0.01 0.05 0.1 0.2 0.5 1 2 . 5 10 20 . 30 40 40 60 70 80 90 95 93 99
Figure C-4 Particje Size Distributions-Pilat Impactor
C-6
99.6 99.1 99.M
-------
5,0
4.0
3.0
2.0
FIGURE C-5
INLET PARTICLE SIZE DISTRIBUTION - BRINKS IMPACTOR
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
-• RUN NO.l
RUN NO.2
RUN NO.3
0.
0.5
10 20 30 40 50 60 70 80 90 95
CUMULATIVE * MASS± PARTI CLE DIAMETER
98 99
99.8 99.9
99.99
-------
i&iE.piiriHLfenH;:!^^
p:.-
-.-fip^BJtil'i^S^^
7is^iii^M&MSiS]iSij^K9jijii^l^
i:-::-::-;::^:-!::™:-:-!:::::!:::':
—:j:::}:rrEH:,ipii4
^.: :.i::r: n+i - ^ — r - ^ - :ir -;: r.r: r,;.---, ~. :i; :.-n:
.-r.; :.:zn-:r: .gtm-ir. ..r:::::.:r-:f:.: :a — t^ir^rrg..
-••j-.ru.-4rr
^4'""'4"t~ T r'~-"T'-'"* -' ""*rrTT'• *"jl'u*z* *~t"" "i*i ~*"'*"*'*r~' "d"";*'*" •'*t•—*t'p~" •••'f'--*-'t --*-t'
'^71'- ,t. iTrTTi.' -| ^T-i-t £—»-i Vr — .TT^'-^-'--'! r-r—'»-t~--'"T T1'' -t ' ~* 1*'T'ITTT"'! r'^'Tt'i r'. \', *", i * "t' rrt"t r>'t'
^^::^
. ..i _; ;-^. ,.,-^..... .._ -,..;» i i. timT • ^_,_ . •,. i.ti.
* ••.,._•!. _u. u. • i „;- , * * - —• _.... — , . ....... . . - : ... ..,..,„.,...«...
--*. t - --•- ^ - -r—•— •» —* * * , ' • .1 ,„ I T' —~.™.... j .-••...,.._.).»..,....., _ ... _ t-.....« •••••••
...ifrrfft.*.....
:.i::tii-!:tiii:te!i
JHiili
^^
11:',.
I
ilTiniii-iiiJiii-iiiiiiii,
^^•fifi'litnliMfthi'l
ss
*! f«t:! h t HIP t T t u "I •. |-t I; rjj «v •
u *r jo s*
BEEM/M
C-8
-------
Data Sheet-1
Date 12-11-72
Sample No. 72-004-333
Weight of Beaker 35.8819 Grams
and Sample
Weight of Beaker 25.8707 Grams
Weight of Sample 10.0112 Grams
Throttle 18
Weight Before
Wt. After
Wt. Removed
Throttle 17
Wt. Before
Wt. After
Wt. Removed
Throttle 16
Wt. Before
Wt. After
Wt. Removed
Throttle 14
Wt. Before
Wt. After
Wt. Removed
35.8819 G
34.6548 G
1.2271 G
34.6548 G
32.2591 G
2.3957 G
32.2591 G
29.0038 G
3.2553 G
29.0038 G
27.6253 G
1.3785 G
Throttle 12
Wt. Before
Wt. After
Wt. Removed
Throttle 8
Wt. Before
Wt. After
Wt. Removed
Throttle 4
Wt. Before
Wt. After
Wt. Removed
Throttle 0
Wt. Before
Wt. After
Wt. Removed
27.6253 G
27.2067 G
0.4186 G
27.2067 G
26.8255 G
0.3812 G
26.8255 G
26.6711 G
0.1544 G
26.6711 G
26.5840 G
0.0871 G
C-9
-------
Data Sheet - 2
Throttle
18
IT
16
14
12
8
4
0
We i gh t
Removed
1.2271
2.3957
3.2553
1 .3785
0.4186
0.3812
0.1544
0.0871
Cumul at ive
Weight
1.2271
3.6228 •
6.8781
8.2566
8.6752
9.0564
9.2108
9.2979
Cumulative
% Removed
12.26
36.19
68.70
82.47
86.65
90.46
92.01
92.88
Sample Weight 10.0112
Grams
C-10
-------
j
I
" "J
1
"I
__"j
."j
. .
46 tf 30 -3*
C-ll
-------
Data Sheet-]
Sample No. 72-004-366
Weight of Beaker 37.7959
And Sample
Date 12-11-72
Grams
Weight of Beaker
Weight of Sample
Throttle 18
Wt. Before
Wt. After
Wt . Removed
Throttle 17
Wt. Before
Wt. After
Wt . Removed
Throttle 16
Wt. Before
Wt. After
Wt. Removed
Throttle 14
Wt.
Wt.
Wt.
Before
After
Removed
37-
36.
1.
36.
33.
2.
33-
30.
3.
30.
29.
1.
27.7827 Grams
10.0132 Grams
7959 G
4735 G
3224
4735
9190
5545
9190
7701
1489
7701
^55?
3148
G
G
G
G
G
G
G
G
G
G
Throttle 12
Wt. Before
Wt. After
Wt. Removed
Throttle 8
Wt. Before
Wt. After
Wt. Removed
Throttle 4
Wt. Before
Wt. After
Wt . Removed
Throttle 0
Wt.
Wt.
Wt.
Before
After
Removed
29
29
0
29
28
0
28
28
0
28
28
0
• 4553
.0855
.3698
.0855
.7283
.3572
.7283
.5846
.1^37
.5846
.5057
.0789
G
G
G
G
G
G
G
G
G
G
G
G
C-12
-------
Data Sheet-2
Throttle
18
IT
16
14
12
8
k
0
Weight
Removed
1.3224
2.5545
3.1489
1.3148
0.3698
0.3572
0.1437
0.0789
Cumulative
Weight
1 .3224
3.8769
7.0258
8.3406
8.7104
9.0676
9.2113
9.2902
Cumulative
% Removed
13.21
38.72
70.17
83.30
86.99
90.56
91.99
92.78
Sample Weight 10.0132 Grams
C-13
-------
rrrr
Utt M/M
-------
Data Sheet-1
Date 12-12-72
Sample No.
Weight of Beaker
And Sample
Weight of Beaker
Weight of Sample
72-004-399
36.5225 Grams
26.501(4 Grams
10.0181 Grams
Throttle 18
Wt. Before 36.5225 G.
Wt. After 34.9015 G.
Wt. Removed 1.6210 G.
Throttle 1?
Wt. Before
Wt. After
Wt. Removed
Throttle 16
34.9015 G.
32.^378 G.
2.4637 G.
Wt. Before 32.4378 G.
Wt. After 29.4440 G.
Wt. Removed 2.9930 G.
Throttle 14
Wt. Before 29-4440 G.
Wt. After 28.2302 G.
Wt. Removed 1.2130 G.
Throttle 12
Wt. Before 28.2302 G.
Wt. After 27.9787 G.
Wt. Removed 0.2515 G.
Throttle 8
Wt. Before 27-9787 G.
Wt. After 27.6079 G.
Wt. Removed 0.3700 G.
Throttle 4
Wt. Before 27.6079 G.
Wt. After 27.4284 G.
Wt. Removed 0.1795 G.
Throttle 0
Wt. Before 27-4284 G.
Wt. After 27.4001 G.
Wt. Removed 0.0283 G.
C-15
-------
Data Sheet-2
Throttle
18
17
16
14
12
8
4
0
Weight
Removed
1.6210
2.4637
2.9938
1.2138
0.2515
0.3708
0.1795
0.0283
Cumulative
Weight
1.6210
4.0847
7.0785
8.2923 ,
8.5^38
8.9146
9.0941
9.1224
Cumulative
% Removed
16.18
40.77
70.66
82.77
85.28
88.98
90.78
91.06
Sample Weight 10.0181 Grams
C-16
-------
Conclusions
These data show the value of performing particle size measurements to
supplement EPA's stack testing program. The techniques used are not
at the stage that can be referred to as routine since more field
evaluation is required; however, in conjunction with EMB, it is hoped
that continued improvement of the sampling methods and techniques
will tend to fill the information gap area pertaining to the size
distribution of aerosols emitted from stationary sources.
C-17
-------
Particle Size Sampling Log (inlet Location)
Unit Date Time Duration (min.)
Pilat Impactor 10-18-72 10:45-10:50 5
12:45-12:48 2.2
13:15-13:20 5
Brinks Impactor 10-20-72 11:15-11:16
11:30-11:31 2
14:10-14:11
14:20-14:21 2
15:40-15:42 2
Particle Size Sampling Log (Outlet Location)
Unit Date Time Duration (min.)
Pilat Impactor 10-19-72 9:^5-10:15 30
11:00-12:00 60
13:00-15:00 120
15:35-16:35 60
C-18
-------
PARTICLE SIZE CALCULATIONS
C-19
-------
Data Analysis
The reduction of field data obtained with a cascade impactor can
sometimes be troublesome and extremely time-consuming because of the
computations involved. The basic equation that defines the cut points
of the cascade impactor is
JL
Dpc = 1 A3 x "~ ' "~-1- "- ' 2
4 /J4 D3c Ps \
\PP F Po C )
(1)
where
C = 1 + 2L
Dpc
1.23 x OAld -O.MJ. Dpc x \0~f
'4 |
J
(2)
While these equations can be solved rigorously when necessary, it is
usually easier to solve them by trial and error. In many sampling
situations it is possible to make certain simplifying assumptions
and then combine these two equations to give
/
2.05 X 108
gc fl PS ^p F PO
(3)
This equation can then be solved directly to give the cut point at
each stage.
One approach that can be used to further simplify the computations
is to develop curves for the impactor stage cut points at one set of
conditions, say air at standard conditions and a particle density of
1.0. A suitable correction factor can then be applied to these curves
for the actual sampling conditions. Unfortunately, further simplifications
are involved in making the correction factor simple enough to be of
value. Therefore, the use of this type of approach suffers from
some restrictions.
Figure C-6 shows a calibration for dry air standard conditions with
unit particle density. The type of correction factor developed is also
shown. However, this curve is restricted to situations where the gas
being sampled is air with a water vapor content less than about 50 percent.
C-20
-------
Figure C-6
IMPACTOR CUT POINTS FOR DRY AIR
AT STANDARD CONDITIONS
1.0
PARTICLE DENSITY
2.0 3.0 4.0 5.0
IMPACTOR PRESSURE DROP ("Hg)
CORRECTION FACTOR TO OTHER CONDITIONS:
Dpc = Dpc<7'73K * ° 309>
K =.!*-+• /_«r7
vy >•
C-2l
-------
All of the restrictions involved in going from equations (l) and (2)
to the calibration curve can sometimes be quite awkward, particularly
in cases where a wide variety of different types of sources are being
sampled.
In summary, there are basically two ways that the computational
difficulties associated with using the cascade impactor can be overcome.
Where basically the same types of sources are being sampled, the
calibration curve approach will work very well; however, in the general
case where a wide variety of different types of sources are being
sampled, the simplest approach is to use a computer program based
on a rigorous solution of the cascade impactor equations.
C-22
-------
Nomenclature
DC = impactor stage jet diameter, cm
Dpc = impactor stage particle cut point, microns
D' = impactor stage particle cut points at standard
conditions, microns
F = gas flow rate at impactor inlet, (cc) / (sec)
9C = 1 (gm) ' (atm) / (cm) / (sec)2
K = imperical correction factor
L = gas mean free path, cm
P0 = absolute pressure at impactor inlet, atm.
PS = absolute pressure at impactor stage outlet, atm
Q = gas density at impactor inlet, (gm) / (cc)
P = gas density at impactor stage outlet (gm) /(cc)
/*p = density of aerosol particle, (gm) / (cc)
u = gas viscosity at impactor stage outlet,
(gm) / (cm) / (sec)
C-23
-------
PARTICLE SIZE FIELD
AND
LABORATORY DATA
C-24
-------
FIELD DATA
PROBE LENGTH AND TYPE
DATE /S-'Ze -' ''?%...
SAMPLING LOCATION /Stf'ife-tfS*.- -"!/**£
o
ro .
TRAVERSE
POINT
NUMBER
3 ' //«'-V.
fH/S,f(t
f/<2,ftt'~
tufTplkl
C&X
SAMPLE'TYP
RUN NUMBEF
OPERATOR .
AMBIENT TE
BAROMETRIC
STATIC PRE!
FILTER NUM
A!G./^
~~~ -— ___
#;*e\i ';/&*;.
i ; # -c
, / ', C~£ \ '/'jiV.///.
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GAS METER READING
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METER BOX
METER AHg
C FACTOR
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PROBE HEATER SETTING
HEATER BOX SETTING
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' ^_ SCHEMATIC OF TRAVERSE P(
^EAD AND RECORD ALL DATA EVERY
VELOCITY
HEAD
(ip,), in. H70
5 f.
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ORIFICE PRESSURE
DIFFERENTIAL
(AH), in. H20)
DESIRED
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TEMPERATURE
INLET
(Tmin).°F
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TEMPERATURE,
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TEMPERATURE,
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COMMENTS: \./_ / t-~&& ~~C~£si& £s^( C*; /•*''$¥' f / •
c7"
EPA (Dm) m
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-------
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= 0.
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-------
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P^
f/ayy^ fity'.c )
US.
^i._...
4-
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C-27
-------
72 \IQ \X0\
c»r.r.ial].ng Date sr.| '••o.}'-'ay I
HKQUHST & REPORT
(Must be filled out for each test run)
first loent.
ITo. Used 7*
No. Used 72.-OOI 731
Test No. f*.
Run No. •
INDUSTIV/
COHPAIJY
\. <7>,.f<:l S7c^-/
JUso Table A
- UNIT .PROCESS/OPERATION
AIR POLLUTION CONTROL
FUEL USED
"INLET j2 .
•QUTLFTI- G;:S VOUJ;-E sn~-~t-
OUTLETU (MRTER VOL. IN FT3)
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VcyiU. l-'o.
7z--t°l—22&
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Description of
Sairiple or Snraple
Fraction
sA<7
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/ , d
•
• ••' '• • '
/
v/
V-- . l'k- ' . '
SAMPLING A//J ' - /? /:•' *^"/ REQUEST /^"C ^
(i£ apolicable)
TS
ANALYSIS REQUESTED
-------
PA i 10 \2l
Sarcoling Date ICr.| i-io-lua
UKQUI3ST & REPORT
(Must be filled out for each test run)
Tirstncifint.
MO. used
iciont. ~
.'• No. Used 7Z~COf 7.37
.O
Run No.
HO. 75-et.c- (
I'.IDUSTP.Y
CCMPAJIY
y-y.-'.-.OD
.'J~
£?• /
Sami:
wt .
(Solid)
^^{hZ^
At
12 6
///
1C2U
fn£
JtAr^rO
• f:.'v ,
1*5 ., i
Vol .
(Liquid)
ml
•///A
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F
Analysis Ilcoucsted - General Comments
(aoprox. concentrationn-ponnibio interferences
etc.) (Indicate specific analysis oa backside) -
"Exz/scs/e -wtq/u-Jt t/rwxM'f fiir/sc£
-------
REQUEST & REPORT
I
. (
"
.
0
1
•Vj,
. O
i
Samcling DC
[NDUSTRY
:OMPANY
•\DD:IESS ' .
STAPLING
tc!ent. Ho.
ZZ /£>
ite »r. '-io.
-A/7^
X^l
first J-oenr.
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Last iaenc.
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1 PROCESS/OPERP.TION
POLLUTION. CONTROL
~//~ /P FUEL USED
/ j "INLET
•>^ ., \ OUTLET
Description of
Sr.mole or Sample
Fraction
tz-001 75^1 S&cre.
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f)3 •*$$/ f/iO
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72-Otf/ '/*•/£•
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7J>.-ot>i 7'/3 \ 7/^W^i
COMMENTS:-
Ytf/fc
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If ^ 1
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_.. GAS 'VOLUME SAr
O (METER .VOL. IK
Samr
M 'C >
('Solid)
£(f?
S66
39#
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• f\ ,"y ,
10 Vol.
(Liquid)
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/
V
'
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Run No. ^
_, .. • SiJWs/
"% (J • nvvTwwpn nv LsJL £~-
"ATR ANALYST*? PFQl^KTHn ...,_
-------
FIELD OPERATING INSTRUCTIONS FOR BRINKS IMPACTOR
D. Bruce Harris
R. M. Statnick
Process Measurements Section
Research Lab orator'-' Branch
Control Systems Division
C-51
-------
1. Clean all surfaces by washing in Alknox solution in an ultrasonic
cleaner for 1 minute.
2. Rinse all parts, after cleaning, with acetone. Do not touch impactor
stages with bare fingers•- use non-contaminating tongs or tweezers.
i
3. Dry stages in vacuum oven (or desicator) at 140 F (60 C) for 15 minutes.
4. Allow stages to come to thermal equilibria in a desicator.
5. Weigh stages and back up filter (W).
6. Assemble Brinks Impactor. Wrap with heating tape1;, and/or insulate
the outsides as needed. . •
7. Attach -Brinks Impactor to vacuum .system capable of achieving 20" Hg @ 3 cfm.
8. Set the temperature at above the dew point (apx 250 F; ^110 C). Do not
overheat filter! When temperature is reached (1) place sample probe
into position, (2) slowly close pump bypass valve, (3) set pressure
. drop at 5.-10" of Hg. ..:.-,
9. Sample time depends on stack loading.
Note: (1). Difficulty in maintaining pressure drop requiring almost
continuous adjustment, indicates filter build-up. Dis-
continue sampling and check for leaded or wet filter.
(Wet filter invalidates sample)
• (2) If stages are wet, invalidate sample provided one
is after a dry particulate, e.g., fly .ash.
(3) Prior to control equipment a 5y DSQ scalping cyclone
may be required. • •• .
10. Carefully disassemble the Brinks Impactor in a sheltered area. Place
stages in individual covered petri dishes. . Millipore 47 mm Plastic
Petri Dish is excellent. ^ ,
11. Remove cover from petri dishes and place the- bottom half, plus stage,
into a vacuum oven.(110°F, 45-50°C) for 15 minutes drying.
12. Remove from oven and place in desicator to achieve thermal equilibria.
13. Weigh each stage (W ) , . ,
, i«i • ' . - - ;
14. Repeat from step 1.
Weights:. W13 - Ws = Wparticulate W^ - W£ = W- particulate
NOTE: In some cases, especially lightly loaded stages, the weight difference
.may be negative. This is a common feature of impactors. Be certain
to use the same balance for each weighing.
-------
Kl:QU!3ST & K
(Must be filled out for each test run)
T,-^;;':T.;V/
y ' Z, \/ 0 1 / i 1
, ^
, (fS
:• ir.'">'i; .icjRnt .
KO. upC:d -?2-{>e<+- 3JS3
/) J. 1
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2 T.nble 'v.)
•* WiUcv A™
.No. Used 7^-£dV ^733
1 PROCSSS/OPS^TION'
POLLUTION CONTROL
Tnsf. K'o, . . /
Run No. /
£:,/*'C f.yfc Arc -Sl^ee / /~ilKJL&<:<
& X *\ si t L: f. G-
FUEL USED
-. -r-.v •<.-- rt,-;r/>rj- fr,-r/l< T* , Nt>*)-<.
.s--:"Mr-:a
.....;cn
TC'-nL. KO.
fS- rs ^ ^
/' 'INLET
»a./*i^/-«.
' QYjrr.T pr
Dencri^tion of
Snninle or Somple
!7^-ec>v ~*\%i £>us4A cMLccJif-
\
i
: i
Si
uii
i
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i
•
, ' ' GA'S VOLUME SAM
IS (METi'JR VOL. IN
(Solid!)
J Pi~* i-yLjU>^^ \
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fi£ acolicable)
A///4
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-
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P. o. _ _
FJ!.!-.:> 1
— - -•
Analysis Ucfucrtod - General Com:aonts
(aoprox. concentrations-iiossible interferor.cis
etc.) (Indicate specific analysis en backside)
/^ /Ljr ir &L< '
^P ^/
.
r OFFICER
/) Jl f> £> '1} REQUEST , c ,
6e*v/t> £•- £•***&*] PK"IEWEP BY i.
-------
£ REPORT
o,
Sampling Da
INDUSTRY
COMPANY
•\DDRESS
3.Y-PLING
METHOD
Idsnt. No.
Jt-ccv -ML-
COMXSh'TS:
SAMPL.I
.CONTRA
7i
te'Xr.
/e L/<5> 1
IWUST: DO iiiieci o
first itienti.
Ko. Used '72-cctf _-J^6
tv _&L{1>) TTNiy
" ' (Use Tnbla. A) •
/* // „ __ /I . <"* * f u f , 7\ T T?
Hi
j.or encn tcct run; .
•N T»«t K"- /
bast ±oent.
No. Used 1/?2^'<5^!<' 3 <^- ^ Run Ko. ^
1 PROCESS/OPERATION
POLLUTION CONTROL
•-\ -DO /" FUEL VSE°- '
^
y^l' A-
/ ' ; INLET
V . OUTLE1
Description of
Sample or Snmnle
Frnction
bwt f*ih.r&J ih*-*^ l^;^A{^^^
" • rf^
•
•
Kl . '
QA.U VOLUME SAV
I2SI (Hvrj :R VOL. IN
(Solid)
~° Vol.
(Liquid)
Fll
i
.
.
' ^^^ ^ >^^^4/^3^^
' -• fc^,^.^ ^
-------
~J
REQUEST & .REPORT
(Must be filled out for ench test run)
DnteTTFT
y 1
inEl'oTP.Y
co!',? M;Y
A:./; >;;::?; 3
i'ircr leant.
No.. Used ~?2
i*nst J-cieivc.
Wo- Used 7
/
Test No. _
Run No. .3
J) 2-S- /)
o.^
-------
APPENDIX D
-------
APPENDIX D
FIELD DATA
-------
TRAVERSE POINT LOCATION FOR CIRCULAR DUCTS
PLANT bHR 16-VCG
DATE In - n . - -7 V— , ^
SAMPLING LOCATION Of 7T-i_^.T- ( ^ 1
INSIDE OF FAR V/ALL TO
OUTSIDE OF NIPPLE, (DISTANCE A)
INSIDE OF NEAR WALL TO
OUTSIDE OF NIPPLE, (DISTANCE B)
STACK I.D., (DISTANCE A - DISTANCE E
NEAREST UPSTREAM DISTURBANCE
NEAREST DOWNSTREAM DISTURBANCE
CALCULATOR I) ^V
I2_|u
S3^"
) h7 »/c."
^4-'1 ^
S A # J
TRAVERSE
POINT
NUMBER.
1
1.
3
4- •
5"
/
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l2>
ILI-
!7.
> V*
/9
,? -0
2-i
j "ju
X3y
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FRACTION
OF STACK I.D.
\A
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1 0 . 4"
\ "> 1
1 o • 1-"
1 &> ,
l^.lf
x3>. o-
a 7. >- __,
^ 2-. 2>
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L'1,1
l^.z*
77,0
?'$,L
?*? 5
9-^,^
?9,^ •
9z,f
fv- c
%,^
*?£?
STACK I.D.
in. is-"
"v--
PRODUCT OF
COLUMNS 2 AND 3
(TO NEAREST 1/8 INCH)
M
1 , iq
fa . Lf 5"
• ^ . 5 L
1.31
• - 1 ^ %y
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• ^ 7,?" 7
4-6* .'«7
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\ L=. . o L> i (0
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6 'o^-i*- £0 3/P
^Lf, 1 1/- "9^- Vp^
P"3.l 3 ^3 'A?-
^9.11 S^j •
Qt/.ijD3 ^^
9 j>t ^ c 9 £ ^
lol, iv /oi V^-
lo<. ^3 lo^(/>-
\ O (} * ij£5 / / L/ t y
ULr, £T M^Vj-
in.^r 1/7 '/?-
M9.7V Uc( %>'
-------
TRAVERSE POINT LOCATION FOR CIRCULAR DUCTS
PLANT t^A fcS4-UJ
DATE m -n, -71-
SAMPLING LOCATION ) M LTI T~
INSIDE OF FAR
OUTSIDE OF
INSIDE OF NEAF
OUTSIDE OF
STACK I.D., (DIS
NEAREST UPST
WALL TO
NIPPLE, (DISTANCE A)
\ WALL TO
NIPPLE, (DISTANCE B)
TANCE A - DISTANCE E
*EAM DISTURBANCE
NEAREST DOWNSTREAM plST-URBANCE
CALCULATOR \ )£WM
, >i
5" A M
) /^/-^f- n
^ 3
. // ' i u
^o d
TRAVERSE
POINT
NUMBER
I
Z
o
O
A
(->
I
. £•
*?
/o
//
/3
/r
• JL
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2.2-
'! «'
-^4-
FRACTION
OF STACK I.D.
I.I
3.)^.
10,5"
1 r~\
1 {j£> i 1
' •Yc?,vt
2-2.0
2J7.-X,
• o2-.3
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£7,7
li.^?"
0")-0
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f~*~\f* f^
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Ot/. < .
9/,,)>
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STACK I.D.
(M-M-11
---
PRODUCT OF
COLUMNS 2 AND 3
(TO NEAREST 1/8 INCH)
hsV
4 17
4-6> - S"i
^7,3)
O "7 U.Q
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2_O , 9- v-
i.r, OD
| Xp4 r>(^
^ 0 * )
3J-, , 3 7
ricl . 3S
1 a •) , u- }u-
t t "^ * • '
SCHEMATIC OF SAMPLING LOCATION
DISTANCE B
5-^"
TRAVERSE POINT LOCATION
FROM OUTSIDE OF NIPPLE
(SUM OF COLUMNS 4 & 5)
7,o?" i"
•(0,'il 10 '•./?•
3> , 4- V I ^ 3/P-
k.5?£- /^"7>
1.0 , CsV* 2.0 V^>
2,<4. i"| 2.M- Vv
5.^,t,Jr'- ^-C2' S/V
^3-4-4- 33'L-
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/ « . .^3 \ I o V?.
/i/.- I'-fvyi-
-------
I-2--
PRELIMINARY VELOCITY TRAVERSE
PLANT.
DATE_
! <4 I C
LOCATION miPT-
STACK I.D tVr"
BAROMETRIC PRESSURE, in. Hg_
STACK GAUGE PRESSURE, in. H?0.
.. ». *•
OPFRATORS Mt?*j.v<^
K -
TRAVERSE
-POINT
NUMBER
1
i-
3
q.
r
6,
-7
?r
c;
•/o
//
/>-
/ a,
/^/
/r
/4
/ 7
/?r
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ao
a»
7 2-'
*» -^
-• •- ?
AVERAGE
. VELOCITY
-HEAD
(Aps), in.H20
•1b
1,1.0
[ .^6
|>M-6
l-V-o
. .1,^-0
li^fo
/.4-o
/.«/r
I . H-o
l.'M-o
1,4-0
1^4-0
I.H-^
/-Co
/,/a
A ^b
/, oro
;. s"o
/,ro
. /. ro
A^o
'A^
AfD.
/^o
STACK
TEMPERATURE
(Ts), °F
^-£>
- ••
3o >
•117
V
1./
SCHEMATIC OF TRAVERSE POINT LAYOUT
TRAVERSE
POINT .
NUMBER
\
2_
O '
- V- '
C
6
?
?•
9
/o
n
- 1 y-
ib
m.
,'
i i
!U
n
\r£-
,^
: 2O
'2-1
^^-'-
i^
X4-
AVERAGE
VELOCITY
HEAD
(Aps), in.H20
'fto
;,i_o
/xlO
/,if
|.4o •
I- 4-o
|.4o.-'
l.^o
1.4-0
K4-o
l,3iT
i , 3 r
l-4-o
l.f i"
i.ro
/,ro
/. -vO
A 4'o
/,«To
/.4o
/./o
'/*To
A yf
/•/o
/v3?'
STACK
TEMPERATURE
(Ts), °F
^?(0
— •
>WL
-------
PRELIMINARY VELOCITY TRAVERSE
DATE L f
LOCATION D-fctt-l
STACK I.D. //'7.Z5
BAROMETRIC PRESSURE, in. Hg__
STACK GAUGE PRESSURE, in. H20.
OPERATORS.
3
J
TRAVERSE
POINT
NUMBER
v:/
i
3
<•/
j>
^
7
•g
7
/D
//.
/t
/5
/v
^
A
/7
/a"
n
i'O
I/
it
23
ZH
AVERAGE
VELOCITY
HEAD
(Aps), in.H20
.QV
,0^
-67
.O'S'S"
JO
JO
.//
•Ji-
//Z
,/^"
Jlf
.11
-07
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,//
,//*"
,//^"
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./J5^
,^5-
,/^
.O^'*^*
,0^&"
, o^^-
STACK
TEMPERATURE
(Ts), 'F
e-s-
-.
/^
SCHEMATIC OF TRAVERSE POINT LAYOUT
TRAVERSE
POINT
NUMBER
V /
z
3
V
c
£
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DATE
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PLANT
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SAMPLED SOUKCE_
Train Data
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PLANT
SAMPLING SUMMARY SHEETS
LOCATION ^
SAMPLED SQURCE_
Train Data
Run
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NOMOGRAPH DATA
PLANT JL±LtL_
DATE.
SAi.iPLING LOCATION .
CALIBRATED PRESSURE DIFFERENTIAL ACROSS
ORIFICE, in. H20
4-0
AVERAGE METER TEMPERATURE (AMBIENT + 20°F),°F
PERCENT MOISTURE IN GAS STREAM BY VOLUME
BAROMETRIC PRESSURE AT METER, in. Hg
STATIC PRESSURE IN STACK, in. Hg - , 1 4-
(Pm±0.073 x STACK GAUGE PRESSURE in in. H20)
RATIO OF STATIC PRESSURE TO METER PRESSURE
AVERAGE STACK TEMPERATURE, °F
AVERAGE VELOCITY HEAD, in. H20
MAXIMUM VELOCITY HEAD, in. H20
C FACTOR ,
CALCULATED NOZZLE DIAMETER, in. -
ACTUAL NOZZLE DIAMETER, in.
REFERENCE Ap, in. H20
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Tmavg.
Bwo
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NOMOGRAPH DATA
PLANT
DATE
0 -
SAMPLING LOCATION
OTK
C l< -
LL"/
CALIBRATED PRESSURE DIFFERENTIAL ACROSS
ORIFICE, in. H20
-*f&
AVERAGE METER TEMPERATURE (AMBIENT + 20°F),°F
%
PERCENT MOISTURE IN GAS STREAM BY VOLUME
BAROMETRIC PRESSURE AT METER, in. Hg
STATIC PRESSURE IN STACK, in. Hg 4- , OO £*
(Pm±0.073 x STACK GAUGE PRESSURE in in. H20)
RATIO OF STATIC PRESSURE TO METER PRESSURE
AVERAGE STACK TEMPERATURE, °F
AVERAGE VELOCITY HEAD, in. H20
MAXIMUM VELOCITY HEAD, in. H20
C FACTOR
CALCULATED NOZZLE DIAMETER, in.
ACTUAL NOZZLE DIAMETER, in.
REFERENCE Ap, in. H20 .; .
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Tmavg.
Bwo
pm
ps
PVP
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APavg.
APmax.
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90
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NOMOGRAPH DATA
PLANT.
DATE_
SAMPLING LOCATION
r*~\
OUT: v- \ -
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CALIBRATED PRESSURE DIFFERENTIAL ACROSS
ORIFICE, in. H20
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c\o
PERCENT MOISTURE IN GAS STREAM BY VOLUME
BAROMETRIC PRESSURE AT METER, in. Hg
STATIC PRESSURE IN STACK, in. Hg ^ ,OO^'
(Pm±0.073 x STACK GAUGE PRESSURE in in. H20)
RATIO OF STATIC PRESSURE TO METER PRESSURE
AVERAGE STACK TEMPERATURE, °F
AVERAGE VELOCITY HEAD, in. H20
MAXIMUM VELOCITY HEAD, in. H20
C FACTOR
CALCULATED NOZZLE DIAMETER, in. .
ACTUAL NOZZLE DIAMETER, in.
REFERENCE Ap, in. H20
AH@
T|navg.
Bwo
pn,
ps
Ps/Pm
savg.
APavg.
APmax.
l.su
Lo
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-------
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NOMOGRAPH DATA
PLANT.
DATE _
10 -\<:-n
SAMPLING LOCATION
A
CALIBRATED PRESSURE DIFFERENTIAL ACROSS
ORIFICE, in. H20
fftr
AVERAGE METER TEMPERATURE (AMBIENT + 20 °F),°F
°IC
PERCENT MOISTURE IN GAS STREAM BY VOLUME
BAROMETRIC PRESSURE AT METER, in. Hg
STATIC PRESSURE IN STACK, in. Hg . 4- - OO $"
(Pm±0.073 x STACK GAUGE PRESSURE in in. H20)
RATIO OF STATIC PRESSURE TO METER PRESSURE
AVERAGE STACK TEMPERATURE, °F
AVERAGE VELOCITY HEAD, in. H20
MAXIMUM VELOCITY' HEAD, in. H20 • "
C FACTOR
CALCULATED NOZZLE DIAMETER, in. '
ACTUAL NOZZLE DIAMETER, in.
REFERENCE Ap, in. H20
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T|nav|.
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NOMOGRAPH DATA
PLANT.
DATE _
r i-
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ORIFICE, in. H20
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•?o
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BAROMETRIC PRESSURE AT METER, in. Hg
STATIC PRESSURE IN STACK, in. Hg '4 , O6 &"
(Pm±0.073 x STACK GAUGE PRESSURE in in. H20)
RATIO OF STATIC PRESSURE TO METER PRESSURE
AVERAGE STACK TEMPERATURE, °F
AVERAGE VELOCITY HEAD, in. H20
MAXIMUM VELOCITY HEAD, in. H20
C FACTOR
CALCULATED NOZZLE DIAMETER, in. '
ACTUAL NOZZLE DIAMETER, in.
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NOMOGRAPH DATA
PLANT '•- "
DATE
SAMPLING LOCATION
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6
CALIBRATED PRESSURE DIFFERENTIAL ACROSS
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^A
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io
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RATIO OF STATIC PRESSURE TO METER PRESSURE
AVERAGE STACK TEMPERATURE, °F
AVERAGE VELOCITY HEAD, in. H20
MAXIMUM VELOCITY HEAD, in. H20
C FACTOR .
CALCULATED NOZZLE DIAMETER, in.
ACTUAL NOZZLE DIAMETER, in. .
REFERENCE Ap, in. H20
AH@
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NOMOGRAPH DATA
PLANT.
DATE _.
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CALIBRATED PRESSURE DIFFERENTIAL ACROSS
ORIFICE, in. H20
AVERAGE METER TEMPERATURE (AMBIENT + 20 *F),0F
PERCENT MOISTURE IN GAS STREAM BY VOLUME
BAROMETRIC PRESSURE AT METER, in. Hg
STATIC PRESSURE IN STACK, in. Hg
(Pm±0.073 x STACK GAUGE PRESSURE in in. H20)
RATIO OF STATIC PRESSURE TO METER PRESSURE
AVERAGE STACK TEMPERATURE, °F
AVERAGE VELOCITY HEAD, in. H20
. MAXIMUM VELOCITY HEAD, in. H20
C FACTOR .
CALCULATED NOZZLE DIAMETER, in. ..
ACTUAL NOZZLE DIAMETER, in.
REFERENCE Ap, in. H20 .
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FIELD DATA
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DATE_
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SCHEMATIC OF TRAVERSE POINT LAYOUT
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SCHEMATIC OF TRAVERSE POINT LAYOUT
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PLANT EPA
DATE
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SAMPLE TYPE
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OPERATOR _
AMBIENT TEMPERATURE
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SCHEMATIC OF TRAVERSE POINT LAYOUT
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POINT
NUMBER
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T,..r .
TIME, mm
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EPA (Dur) 235
472
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EPA (Our) 235
472
-------
TRAVERSE
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PLANT.
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73
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FIELD DATA
PLANT.
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SAMPLING LOCATIQ
SAMPLE TYPE
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L
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STATIC PRESSURE, (P$)
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REFERENCEAp
SCHEMATIC OF TRAVERSE POINT LAYOUT
READ AND RECORD ALL DATA EVERY_A_ MINUTES
TRAVERSE
POINT
NUWTSR
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SAMPLE TYPE (BAG, INTEGRATED, CONTINUOUS) f
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AMBIENT TEMPERATURE
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13 1 W o
A ^11) 230
-------
'LANT
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DRY MOLECULAR WEIGHJ4?ETERMINATION
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10-
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iAMPLING TIME (24-hr CLOCK)
iAMPLING LOCATION
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iAMPLE TYPE (BAG, INTEGRATED, CONTINUOUS) .J_
ANALYTICAL METHOD '
\MBIENT TEMPERATURE
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DRY MOLECULAR WEIGHT DETERMINATION
PLANT.
DATE_
COMMENTS:
in -
SAMPLING TIME (24-hr CLOCK)
SAMPLING LOCATION
//CTD
SAMPLE TYPE (BAG, INTEGRATED, CONTINUOUS)
ANALYTICAL METHOD
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PA (Our) 230
4/72
-------
APPENDIX E
-------
APPENDIX E
STANDARD TEST PROCEDURES
-------
APPENDIX E
STANDARD TEST PROCEDURES
Method 1 - Sample and Velocity Traverses
for 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 procedures for determining compliance with the New
Source Performance Standards. Unless otherwise specified, this
method is not Intended to apply to gas streams other than those
emitted directly to the atmosphere without further processing.
2. Procedure.
2.1 Selection of a sampling site and minimum number of traverse points.
2.1.1 Select a sampling site that is at least eight stack or duct
diameters downstream and two diameters upstream from any flow
disturbance such as a bend, expansion, contraction, or visible
flame. For rectangular cross section, determine an equivalent
diameter from the following equation:
, , Jt n (length)(width) , , ,
equivalent diameter = 2 ]ength+wtdth— equation 1-1
2.1.2 When the above sampling site criteria can be met, the minimum
number of traverse points Is twelve (12).
2.1.3 Some sampling situations render the above sampling site criteria
Impractical. When this is the case, choose a convenient sampling
location and use Figure 1-1 to determine the minimum number of
traverse points. Under no conditions should a sampling point be
selected within 1 Inch of the stack wall. To obtain the number
of traverse points for stacks or ducts with a diameter less than
2 feet, multiply the number of points obtained from Figure 1-1
by 0.67.
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 4, and for rectangular stacks
the number follows the criteria of Section 2.2.2.
2.2 Cross-sectional layout and location of traverse points.
E-1
-------
FIGURE 1-1
MINIMUM NUMBER OF TRAVERSE POINTS
NUMBER OF DUCT DIAMETERS UPSTREAM
(DISTANCE A)
0.5 1.0 1.5 2.0
50
40
30
20
10
0
2.5
I
T
T
T
A
t
B
Z
I
X
DISTUR-
BANCE
u SAMPLING
" SITE
DISTUR-
BANCE
rib
5
6
7
NUMBER OF DUCT DIAMETERS DOWNSTREAM
(DISTANCE B)
10
E-2
-------
2.2.1 For circular stacks locate the traverse points on at least two
diameters according to Figure 1-2 and Table 1-1. The traverse
axes shall divide the stack cross section into equal parts.
2.2.2 For rectangular stacks divide the cross section into as many
equal rectangular areas as traverse points, such that the ratio
of the length to the width of the elemental areas is between
one and two. Locate the traverse points at the centroid of each
equal area according to Figure 1-3.
3. References
Determining Dust Concentration in a Gas Stream, ASME Performance
Test Code No. 27, New York, N.Y., 1957.
Devorkin, Howard, et at., Air Pollution Source Testing Manual, Air
Pollution Control District, Los Angeles, California, November, 1963.
Methods for Determination of Velocity, Volume, Dust and Mist Content
of Gases, Western Precipitation Division of Joy Manufacturing Co.,
Los Angeles, Calif. Bulletin WP-50, 1968.
Standard Method for Sampling Stacks for Particulate Matter, In:
1971 Book of ASTM Standards, Part 23, Philadelphia, Pa. 1971,
ASTM Designation D-2928-71.
E-3
-------
FIGURE 1-2
CROSS SECTION OF A CIRCULAR STACK D I \i I D E D INTO i ": EQUAL
AREAS SHOWING LOCATION OF T R A u [ P ' f :- fj I N T $ AT THE
CFNTRO I 0 OF EACH AREA
FIGURE 1-3
CROSS SECTION OF RECTANGULAR STACK OIVIOED INTO '2 EQUAL
AREAS. WITH TRAVERSE POINTS LOCATED AT THE CENTROIO OF
EACH AREA.
-------
Location of traverse points in circular stacks
(Percent of stack diameter from Inside'wall to traverse point)
Traverse
point
number
on a
diameter
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23'
24
Number of traverse points on a diameter
2
14.6
85.4
4
6.7
25.0
75.0
93.3
6
4.4
14.7
29.5
70.5
85.3
95.6
8
3.3
10.5.
19.4
32.3
67.7
80.6
89.5
96.7
10
2.5
8.2
14.6
22.6
54.2
65.8
77.4
85.4
91.8
97.5
12
2.1
6.7
11.8
17.7
25.0
35.5
64.5
65.0
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
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
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
98.6
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
E-5
-------
Method 2 - Determination of Stack Gas Velocity and
Volumetric Flow Rate (Type "S" Pltot Tube)
1. Principle and ApplIcabllity.
1.1 Principle. Stack gas velocity Is determined from the gas density and
from measurement of the velocity head using a Type "S" (Stauschelbe
or reverse type) pltot tube.
1.2 Applicability. This method should be applied only when specified by
the test procedures for determining compliance with the New Source
Performance Standards.
2. Apparatus.
2.1 Pltot tube - Type "S" (Figure 2-1), or equivalent, with a coefficient
within ± 5% over the working range.
2.2 Differential pressure gauge - Inclined manometer, or equivalent, to
measure velocity head to within 10% of the minimum value.
2.3 Temperature gauge - Thermocouple or equivalent attached to the pitot
tube to measure stack temperature to within 1.5% of the minimum
absolute stack temperature.
2.k 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.
2.6 Gas analyzer - To analyze gas composition for determining molecular
weight.
2.7 Pltot tube - Standard type, to calibrate Type "S" pitot tube.
3. Procedure.
3.1 Set up the apparatus as shown In Figure 2-1. Make sure all connections
are tight and leak free. Measure the velocity head and temperature at
the traverse points specified by Method 1.
3.2 Measure the static pressure In the stack.
3.3 Determine the stack gas molecular weight by gas analysis and appropriate
calculations as Indicated in Method 3.
E-6
-------
FIGURE 2-1
PITOT TUBE (MANOMETER ASSEMBLY)
PIPE COUPLING
TYPE S PITOT TUBE
TUBING ADAPTER
MANOMETER
E-7
-------
A. Calibration.
k.\ To calibrate the pitot tube, measure the velocity head at some point
In a flowing gas stream with both a Type "S" pltot tube and a standard
type pitot tube with known coefficient. Calibration should be done In
the laboratory and the velocity of the flowing gas stream should be
varied over the normal working range. It Is recommended that the
calibration be repeated after use at each field site.
k.2 Calculate the pitot tube coefficient using equation 2-1.
C - C /A Pstd equation 2-1
test pstd V APtest
where:
C- = Pltot tube coefficient of Type "S" pltot tube
test
C = Pltot tube coefficient of standard type pltot tube
Pstd (If unknown, use 0.99)
A pstd = Velocity head measured by standard type pitot tube
APtest = Velocity head measured by Type "S" pltot tube
*4.3 Compare the coefficients of the Type "S" pltot tube determined first
with one leg and then the other pointed downstream. Use the pitot
tube only if the two coefficients differ by no more than 0.01.
5. Caculations.
Use equation 2-2 to calculate the stack gas velocity.
equatlon 2"2
where:
(Vs)a « Stack gas velocity, feet per second (f.p.s.)
K - 85.^8 pi- (.. lb: Up } 1/2 when these units are used.
p sec. \ID. mole- K /
C = Pltot tube coefficient, dlmenslonless.
(Ts)gv = Average absolute stack gas temperature, °R
B Average velocity head of stack gas, Inches H-0 (see
Figure 2-2).
PS = Absolute stack gas pressure, Inches Hg.
E-8
-------
MS = Molecular weight of stack gas (wet basts),
Ib./lb.-mole
Md (1-BWQ) + l8Bwo
Mj => Dry molecular weight of stack gas (from Method 3)
B^ = Proportion by volume of water vapor In the gas
stream (from Method k)
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 determine the
average stack gas velocity from Equation 2-2.
Use Equation 2-3 to calculate the stack gas volumetric flow rate.
Qs - 3600 (1-BWo) V A LlpL-) (plL-) equation 2-3
\us;avg./ V std /
where:
Qs = Volumetric flow rate, dry basis, standard conditions,
cu.ft./hr.
A » Cross-sectional area of stack, sq.ft.
Tst(j = Absolute temperature at standard conditions, 530°R.
Pstd <= Absolute pressure at standard conditions, 29.92 Inches Hg.
6. References.
Mark, L.S., Mechanical Engineers' Handbook, McGraw-Hill Book Co., Inc.,
New York, N.Y., 1951.
Perry, J.H., Chemical Engineers' Handbook, McGraw-Hill Book Co., Inc.,
New York, N.Y., I960.
Shlgehara, R.T., W.F. Todd, and W.S. Smith, Significance of Errors In
Stack Sampling Measurements. Paper presented at the Annual Meeting of
the Air Pollution Control Association, St. Louis, Mo., June 1^-19, 1970.
Standard Method for Sampling Stacks for Particuiate Matter, In: 1971 Book
of ASTM Standards, Part 23, Philadelphia, Pa., 1971, ASTM Designation
D-2928-71.
Vennard, J.K., Elementary Fluid Mechanics, John Wiley 6 Sons, Inc., New
York, N.Y., 1947.
E-9
-------
Figure 2-2
PRELIMINARY VELOCITY TRAVERSE
PLANT
DATE
LOCATION
STACK I.D.
BAROMETRIC PRESSURE, in. Hg_
STACK GAUGE PRESSURE, in. H20.
OPERATORS
SCHEMATIC OF TRAVERSE POINT LAYOUT
TRAVERSE
POINT
NUMBER
AVERAGE
VELOCITY
HEAD
(Aps),in.H20
STACK
TEMPERATURE
(Ts), °F
EPA (Dur) 233
4/72
TRAVERSE
POINT
NUMBER
AVERAGE
VELOCITY
HEAD
(Aps), in.H20
STACK
TEMPERATURE
(Ts), °F
E-10
-------
Method 3 - Gas Analysis for Carbon Dioxide, Excess Air,
and Dry Molecular 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 procedures for determining compliance with the New Source
Performance Standards. The test procedure will Indicate whether a
grab sample or an integrated sample is to be used.
2. Apparatus.
2.1 Grab sample (Figure 3~1).
2.1.1 Probe - Stainless steel or Pyrex1 glass, equipped with a filter
to remove particulate matter.
2.1.2 Pump - One-way squeeze bulb, or equivalent, to transport gas
sample to analyzer.
2.2 Integrated sample (Figure 3-2).
2.2.1 Probe - Stainless steel or Pyrex1 glass, equipped with a filter
to remove particulate matter.
2.2.2 Air-cooled condenser or equivalent - To remove any excess moisture.
2.2.3 Needle valve - To adjust flow rate.
2.2.k 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 cfm.
2.2.6 Flexible bag - Tedlar , 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 is varying with time or a
sample traverse is conducted,.
2.3 Analysis.
2.3.1 Orsat analyzer, or equivalent.
Trade name.
E-11
-------
FIGURE 3-1
GRAB-SAMPLING TRAIN
PROBE
FLEXIBLE TUBING
TO ANALYZER
-FILTER (STEEL WOOL)
SQUEEZE BULB
E-12
-------
FIGURE 3-2
INTERATED GAS SAMPLING TRAIN
RATE METER
AIR-COOLED CONDENSER
PROBE-
QUICK DISCONNECT
E-13
-------
3. Procedure.
3.1 Grab sampl Ing.
3.1.1 Set up the equipment as shown in Figure 3-1, making sure all
connections are leak-free. Place the probe in the stack at a
sampling point and purge the sampling line.
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 velocity.
3-3 Analysis.
3.3.1 Determine the C02» ^2' anc' ^0 concentration as soon as possible.
Make as many passes as are necessary to give constant readings.
If more than ten passes are necessary, replace the absorbing
solution.
3.3.2 For grab sampling, repeat the sampling and analysis until three
consecutive samples vary no more than 0.5 percent by volume for
each component being analyzed.
3.3.3 For integrated sampling, repeat the analysis of the sample until
three consecutive analyses vary no more than 0.2 percent by
volume for each component being analyzed.
4. Calculations.
k.] Carbon dioxide. Average the three consecutive runs and report the
result to the nearest 0.1%
. 2 Excess air. Use Equation 3~1 to calculate excess air, and average
the runs. Report the result to the nearest 0.1% excess air.
-------
* EA • 0.2*1, (-'u'obs tt co) " "» .q»tio«3-i
where:
% EA = Percent excess air
% Q^ ~ Percent oxygen by volume, dry basis
% N£ = Percent nitrogen by volume, dry basis
% CO = Percent carbon monoxide by volume, dry basis
0.26*4 = Ratio of oxygen to nitrogen in air by volume
Dry molecular weight. Use Equation 3-2 to calculate dry molecular
weight and average the runs. Report the result to the nearest tenth.
Md = Q.kk (% C02) + 0.32 (* C02) + 0.28 (% N2 + % CO) equation 3-2
where:
molecular weight, Ib./lb-mole
% C02 = Percent carbon dioxide by volume, dry basis
% 02 = Percent oxygen by volume, dry basis
% N2 = Percent nitrogen by volume, dry basis
O.A5 = Molecular weight of carbon dioxide divided by 100
0.32 = Molecular weight of oxygen divided by 100
0.28 = Molecular weight of nitrogen and CO divided by 100
5. References.
Altshuller, A. P., et al., Storage of Gases and Vapors in Plastic Bags,
Int. J. Air & Water Pollution, 6:75-81, 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 196^.
Devorkin, Howard, et al., Air Pollution Source Testing Manual, Air
Pollution Control District, Los Angeles, California, November 1963.
E-15
-------
Method 5 - Determination of Particulate Emissions from
Stationary Sources
1. Principle and ApplIcability.
^,
1.1 Principle. Particulate matter is withdrawn isokinetically from the
source and its weight is determined gravimetrically after removal of
uncombined water.
1.2 Applicability. This method is applicable for the determination of
particular emissions from stationary sources only when specified by
the test procedures for determining compliance with New Source
Performance Standards.
2. Apparatus.
2.1 Sampling train. The design specifications of the particulate sampling
train used by EPA (Figure 5-1) are described in APTD-0581. Commercial
models of this train are available.
2.1.1 Nozzle - Stainless steel (316) with sharp, tapered leading edge.
2.1.2 Probe - Pyrex' glass with a heating system capable of maintaining
a minimum gas temperature of 250°F at the exit and during sampling
to prevent condensation from occurring. When length limitations
(greater than about 8 ft.) are encountered at temperatures less
than 600°F, Incoloy 825^, or equivalent, may be used. Probes for
sampling gas streams at temperatures in excess of 600°F must have
been approved by the Administrator.
2.1.3 Pitot tube - Type "S", or equivalent, attached to probe to
monitor stack gas velocity.
2.1.*» Filter Holder - Pyrex' glass with heating system capable of
maintaining minimum temperature of 225°F.
2.1.5 Impingers/Condenser - Four impingers connected in series with
glass ball joint fittings. The first, third, and fourth Impingers
are of the Greenburg-Smlth design, modified by replacing the tip
with a 1/2-inch ID glass tube extending to one-half inch from the
bottom of the flask. The second impinger Is of the Greenburg-Smith
design with the standard tip. A condenser may be used In place
of the Impingers provided that the moisture content of the stack
gas can still be determined.
1 Trade name.
E-16
-------
REVERSE-TYPE
PITOT TUBE
FIGURE 5-1
PARTICULATE SAMPLING TRAIN
THERMOMETER-
CHECK
VALVE
IMPINGERS
"Z. ICE BATH
PITOT MANOMETER
VACUUM
LINE
-------
2.1.6 Metering system - Vacuum gauge, leak-free pump, thermometers capable
of measuring temperature to within 5°F, dry gas meter with 2%
accuracy, and related equipment, or equivalent, as required to
maintain an isokfnetic sampling rate and to determine sample
vo1ume.
2.1.7 Barometer - To measure atmospheric pressure to ±0.1 inches Hg.
2.2 Sample recovery.
2.2.1 Probe brush - At least as long as probe.
2.2.2 Glass wash bottles - Two.
2.2.3 Glass sample storage containers.
2.2.A Graduated cylinder - 250 ml.
2.3 Analysis.
2.3.1 Glass weighing dishes.
2.3.2 Desiccator.
2.3.3 Analytical balance - To measure to ±0.1 mg.
2.3.*» Trip balance - 300 g. capacity, to measure to ±0.05 g.
3. Reagents.
3.1 Samp]ing.
3.1.1 Filters - Glass fiber, MSA 1106 BH1, or equivalent, numbered for
identification and preweighed.
3.1.2 Silica gel - Indicating type, 6-16 mesh, dried at 175°C (350°F)
for 2 hours.
3.1.3 Water.
3.1.*» Crushed Ice.
3.2 Sample recovery.
3.2.1 Acetone Reagent grade.
Trade name.
E-18
-------
3.3 Analysts.
3.3.1 Water.
3.3.2 Deslccant - Drlerlte1, Indicating.
4. Procedure.
4.1 Sampling.
4.1.1 After selecting the sampling site and the minimum number of
sampling points, determine the stack pressure, temperature,
moisture, and range of velocity head.
4.1.2 Preparation of collection train. Weigh to the nearest gram
approximately 200 g. of silica gel. Label a filter of proper
diameter, desiccate2 for at least 24 hours and weigh to the
nearest 0.5 mg in a room where the relative humidity Is less
than 50%. Place 100 ml of water In each of the first two impingers,
leave the third impinger empty, and place approximately 200 g
of prewelghed silica gel in the fourth impinger. Set up the train
without the probe as In Figure 5-1• Leak check the sampling train
at the sampling site by plugging up the inlet to the filter holder
and pulling a 15 In. Hg vacuum. A leakage rate not in excess of
0.02 cfm at a vacuum of 15 in. Hg Is acceptable. Attach the
probe and adjust the heater to provide a gas temperature of about
250°F at the probe outlet. Turn on the filter heating system.
Place crushed Ice around the impingers. Add more ice during the
run to keep the temperature of the gases leaving the last impinger
as low as possible and preferably at 70°F or less. Temperatures
above 70°F may result in damage to the dry gas meter from either
moisture condensation or excessive heat.
4.1.3 Partlculate train operation. For each run, record the data required
on the example sheet shown in Figure 5~2. Take readings at each
sampling point, at least every 5 minutes, and when significant
changes in stack conditions necessitate additional adjustments
in flow rate. To begin sampling, position the nozzle at the first
traverse point with the tip pointing directly into the gas stream.
Immediately start the pump and adjust the flow to isokinetic conditions.
Sample for at least 5 minutes at each traverse point; sampling
time must be the same for each point. Maintain isokinetic sampling
throughout the sampling period. Nomographs are available which aid
in the rapid adjustment of the sampling rate without other
computations. APTD-0576 details the procedures for using these
nomographs. Turn off the pump at the conclusion of each run and
record the final readings. Remove the probe and nozzle from the
stack and handle In accordance with the sample recovery process
described in Section 4.2.
Trade name.
2Dry using Drlerlte1 at 70°F ±10°F.
E-19
-------
Figure 5~2
FIEIDOATA
PLANT.
OATE_
SAMPLING LOCATION.
SAMPLE TYPE
RUN NUMBER
OPERATOR
AMBIENT TEMPERATURE .
BAROMETRIC PRESSURI .
STAIICI'HtSSURE, (Ps)_
FILTER NUMBfR(s)
PROBE LENGTH AND TYPE.
NOZZLE I.D.
ASSUMED MOISTURE, % _
SAMPLE BOX NUMBER
METER BOX NUMBER
METER aHt,_
C FACTOH_ . .
I'KOW HI ATI R SI FI ING _
HIAll.H IIUX SLUING
RLfLKLNCt Ap
SCHEMATIC OF 1WVERSE POINT LAYOUT
READ AND RECORD ALL [ATA EVERY.
MINUTES
i
ro
o
TRAVERSE
POINT
NUMBER
^v CLOCK TIME
sTTIMG\^cw
TIME, mm x^
~7r- -___
GAS METER READING
(Vro), II3
VELOCITY
HEAD
(APS), in. H20
•
ORIFICE PRESSURE
DIFFERENTIAL
(AH), n. H20)
DESIRED
ACTUAL
STACK
TEMPERATURE
(T ),"F
DRYGAS METER
TEMPERATURE
INLET
lT.inl."F
OUTLET
lTmoul>."F'
PUMP
VACUUM,
in. Hg
SAMPLE BOX
TEMPERATURE,
°F
IMPINGER
TEMPERATURE.
°F
COMMENTS:
EPA ,0uil 235
-------
k.2 Sample recovery. Exercise care In moving the collection train from
the test site to the sample recovery area to minimize the loss of
collected sample or the gain of extraneous particulate matter. Set
aside a portion of the acetone used In the sample recovery as a blank
for analysis. Measure the volume of water from the first three
implngers, then discard. 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 sample-exposed surfaces prior to the filter in this container
and seal. Use a razor blade, brush, or rubber policeman to lose
adhering particles.
Container No. 3- Transfer the silica 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.
^.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,
desiccate, 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 pressure.
Desiccate and dry to a constant weight. Report results to the
nearest 0.5 mg.
Container No. 3- Weigh the spent silica gel and report to the
nearest gram.
5. Calibration.
Use methods and equipment which have been approved by the Administrator
to calibrate the orifice meter, pltot tube, dry gas meter, and probe
heater. Recalibrate after each test series.
6. Calculations.
6.1 Average dry gas meter temperature and average orifice pressure drop.
See data sheet (Figure 5~2).
6.2 Dry gas volume. Correct the sample volume measured by the dry gas
meter to standard conditions (70°F, 29.92 Inches Hg) by using
Equation 5~1•
E-21
-------
Figure 5~3
ANALYTICAL DATA
PLANT.
DATE_
SAMPLING LOCATION.
SAMPLE TYPE
RUN NUMBER
SAMPLE BOX NUMBER.
CLEAN-UP MAN
COMMENTS:
FRONT HALF
ACETONE WASH OF NOZZLE, PROBE, CYCLONE (BYPASS), CONTAINER.
FLASK, FRONT HALF OF FILTER HOLDER
FILTER NUMBER CONTAINER
LABORATORY RESULTS
FRONT HALF SUBTOTAL
BACK HALF
IMPINGER CONTENTS AND WATER WASH OF
IMPINGERS, CONNECTORS, AND BACK
HALF OF FILTER HOLDER
ACETONE WASH OF IMPINGERS, CONNECTORS,
AND BACK HALF OF FILTER HOLDER
CONTAINER
ETHER-CHLOROFORM
EXTRACTION
CONTAINER.
BACK HALF SUBTOTAL
_mg
.nig
.mg
_mg
TOTAL WEIGHT
_mg
MOISTURE
IMPINGERS
FINAL VOLUME
INITIAI VOLUME
NFTVm IIMF
SILICA GEL
FINAI WFIRHT
INITIAI WFIRHT
NFTWFIRHT
EPA (Dur) 231
4 72
ml
ml
ml
g
g
g
g
g
_ g
F-
TOTAL MOISTURE
E-22
-------
"r^- )' ('"' TCrW)v.( b\^
equation 5~1
where:
V = Volume of gas sample through the dry gas meter (standard
mstd conditions), cu.ft.
Vm = Volume of gas sample through the dry gas meter (meter
conditions), cu.ft.
Tstc| = Absolute temperature at standard conditions, 530°R
Tm = Average dry gas meter temperature, °R
P^ » Barometric pressure at the orifice meter, Inches Hg
AH = Average pressure drop across the orifice meter, inches H-O
13.6 = Specific gravity of mercury
Pstcj = Absolute pressure at standard conditions, 29.92 Inches Hg
6.3 Volume of water vapor.
V . y, (CSi ) (SSI) . (0.OW SLf*.) V, equation 5-2
wstd c\Vo / VPstd / \ ml / 'c
where:
V = Volume of water vapor In the gas sample (standard
std conditions), cu.ft.
V] » Total volume of liquid collected In Implngers and
c silica gel (see Figure 5~3)» ml
H20 = Density of water, 1 g/ml
M.. « ™ Molecular weight of water, 18 Ib/lb-mole
R = Ideal gas constant, 21.83 inches Hg-cu.ft./lb.-mole-°R
H20
T = Absolute temperature at standard conditions, 530°R
std
P . = Absolute pressure at standard conditions, 29.92 Inches Hg
E-23
-------
6.4 Moisture content.
Vw
Bwo = V n? equation 5-3
mstd wstd
where:
Bwo = Proportion by volume of water vapor in the gas stream,
dimension less
V = Volume of water In the gas sample (standard conditions),
std cu.ft.
Vm = Volume of gas sample through the dry gas meter (standard
std conditions), cu.ft.
6.5 Total particulate weight. Determine the total particular catch from
the sum of the weights on the analysis data sheet (Figure 5-3).
6.6 Concentration.
6.6.1 Concentration in gr/scf
c' = (0.0154 3L J f __IL_ J equation 5-4
\ m9 / \ mstd /
where:
c's = Concentraction of particulate matter in stack gas,
gr/scf, dry basis
MS = Total amount of particulate matter collected, mg
m
Volume of gas sample through dry gas meter (standard
std conditions), cu.ft.
6.6.2 Concentration in Ib/cu.ft.
m _, m J
std std
-------
where:
c = Concentration of particulate matter in stack gas,
Ib/scf, dry basis
1*53,600 - Mg/lb.
Mn = Total amount of particulate matter collected, mg
Vm = Volume of gas sample through dry gas meter (standard
std conditions), cu.ft.
6.7 Isokinetic variation.
T
i = — ——^t> D': ' —— x 100
0V P A
v s s n
equation 5~6
where:
I = Percent of isokinetic sampling.
V]c = Total volume of liquid collected in implngers and silica
gel (see Figure 5~3), ml
/>H20 = Density of water, 1 g/ml
MU o = Molecular weight of water, 18 Ib/lb-mole
2
Vm - Volume of gas sample through the dry gas meter (meter
conditions), cu.ft.
Tm = Absolute average dry gas meter temperature (see Figure
5-2), OR
''bar = Barometric pressure at sampling site, inches Hg
AH = Average pressure drop across the orifice (see Figure 5-2),
inches H20
TS =» Absolute average stack gas temperature (see Figure 5~2), °R
0 = Total sampling time, minutes
R = Ideal gas constant, 21.83 inches Hg-cu.ft./lb. mole-°F
E-25
-------
Vs = Stack gas velocity calculated by Method 2, Equation 2-2,
ft/sec
PS = Absolute stack gas pressure, inches Hg
An = Cross-sectional area of nozzle, sq.ft.
6.8 Acceptable results. The following range sets the limit on acceptable
isoktnetic sampling results:
If 90% 4 14110%, the results are acceptable; otherwise, reject
the results and repeat the test.
7. References.
Addendum to Specifications for Incinerator Testing at Federal Facilities,
PHS, NCAPC, Dec. 6, 196?.
Martin, Robert M., Construction Details of Isokinetic Source Sampling
Equipment, Environmental Protection Agency, APTD-0581.
Rom, Jerome J., Maintenance, Calibration, and Operation of Isokinetic
Source Sampling Equipment, Environmental Protection Agency, APTD-0576.
Smith, W. S., R. T. Shigehara, and W. F. Todd, A Method of Interpreting
Stack Sampling Data, Paper presented at the 63rd Annual Meeting of the
Air Pollution Control Association, St. Louis, Mo., June Tf-19, 1970.
Smith, W. S., et al., Stack Gas Sampling Improved and Simplified with
New Equipment, APCA paper No. 67-119, 1967.
Specifications for Incinerator Testing at Federal Facilities, PHS,
NCAPC, 1967.
E-26
-------
Baghouse Outlet Stack
Calculation of Stack Area (from Geometry of cross section)
Stack Transition is from 9' square at bottom to 9' diameter circle at
top in a height of 5'.
Port
14"
5'
_L
-9'
A1
\
Side Top
X = i».5' sec (45°) - 4.5'
= k.5' [sec (kS°) - l]
= 4.5' [ /I -l] • 4.5' [ 0.414]
X = 1.86'
Port (^ is located at 14" from top of transition, measured on the diagonal
of the corner formed by the transition of the square (Section A'-A')
1 "Port
AC AE
i • ,m B -—__
BC DE
AC = /(5)2 + (1.82)2
Section A'-A1
= / 25 + 3.46
» / 28-46
- 5.33'
E-27
-------
AC_= AE_
BC DE
DE
(AE)_ (BC)
AC
DE
12
(1.86)
0.407'
Cross section B'-B1, which is cross section on plane of port(£, Is shown
be 1 ow:
F I G
Section B'-B'
Area of Cross Section
FGH
A (Area of FGH) +
4 (Area of Sector FHJ)
(F"H)2 - (l"H
= 3.83
fG v/3.83
AFGH = d-95') (4.5')
AFGH =
- 20.25
1.95
E-28
-------
TT
LFHJ = 2 (Arc tan
36o - 4 C-FHG)
2 (Arc tan 0.433)
2 (23.4°)
(AFHJ>
= ^.08,
= 37.152 sq.ft
'SECTION B'-B'
^SECTION B'-B1
* (8.775) + 37.152
35.100 + 37.152
sq.in.
72.252 sq.ft. x —^-ft-.—
10404.288 sq.ln.
10400 sq.in.
E-29
-------
Calculation of Outlet Stack Area Assuming Circular Cross-Section
Measured outside circumference CQ = 30'1/2"
Wall Thickness 1/4"
C =TTd = 2lT r
30-1/24 ft.
,1-1/4"
Co 30 (12) + 0.5
-rf ~ TT
360.5
-TT— = 114.75
do - 2t » 114.75 - .50
114.25"
V di2 Tf(n4.25)2
10251.873 sq.in.
Difference
10404 - 10252
x 100
152
1.46S
x 100
E-30
-------
APPENDIX F
-------
APPENDIX F
SAMPLE IDENTIFICATION LOG
-------
APPENDIX F
SAMPLE IDENTIFICATION LOG
Run No. 1; Date October 18. 1972
Sample No.
Stack No.
72-OOl)--301
(EPA-1 )-302
-303
-304
-305
72-004-306 '
-307
-308
-309
-310
72-004-311
-312
-313
-314
-315
72-004-316
-317
-318
-319
-320
72-004-321*
(Ml) -322*
-323*
(EPA-5)-324*
-325*
-326*
-327*
72-004-328**
-329**
-330**
-331**
-332**
Inlet
Inlet
Inlet
Inlet
Inlet
Outlet No. 3
Outlet No. 3
Outlet No. 3
Outlet No. 3
Outlet No. 3
Outlet No. 4
Outlet No. 4
Outlet No. 4
Outlet No. 4
Outlet No. 4
Outlet No. 6
Outlet No. 6
Outlet No. 6
Outlet No. 6
Outlet No. 6
Outlet No. 6
Outlet No. 6
Outlet No. 6
Outlet No. 6
Outlet No. 6
Outlet No. 6
Outlet No. 6
Outlet No.l
Outlet No. 1
Outlet No.l
Outlet No.l
Outlet No. 1
72-004-333
Recovered from
truck
Fraction
Probe acetone wash
FiIter
Impinger water and wash
Ether-chloroform extraction
Impinger acetone wash
Probe acetone wash
Filter
Impinger water and wash
Ether-chloroform extraction
Impinger acetone wash
Probe acetone wash
Filter
Impinger water and wash
Ether-chloroform extraction
Impinger acetone wash
Probe acetone wash
Filter
Impinger water and wash
Ether-chloroform extraction
Impinger acetone wash
Nozzle and thimble acetone wash
Alundum fi1ter
Probe and front half of filter acetone
Glass fiber fiIter
Impinger water and wash
Ether-chloroform extraction
Impinger acetone wash
Probe acetone wash
FiIter
Impinger water and wash
Ether-chloroform extraction
Impinger acetone wash
baghouse dust
wash
•X-
*••*
ASME
Glass probe
F-l
-------
Run No. 2; Date October 19, 1972
Sample No.
72-004-334
(EPA-6)-335
(EPA-l6)-336
-337
-338
72-004-339
(EPA-7)-340
-341
-342
-343
72-004-344
(EPA-8)-345
-346
-347
-348
72-004-349
(EPA-9)-350
-351
-352
-353
72-004-354*
(M2) -355*
-356*
-357*
-358*
-359*
-360*
72-004-361**
-362**
-363**
-364**
-365**
72-004-366
Stack No.
Inlet
Inlet
Inlet
Inlet
Inlet
Outlet
Outlet
Outlet
Outlet
Outlet
Outlet
Outlet
Outlet
Outlet
Outlet
Outlet
Outlet
Outlet
Outlet
Outlet
Outlet
Outlet
Outlet
Outlet
Outlet
Outlet
Outlet
Outlet
Outlet
Outlet
Outlet
Outlet
No.
No.
No.
No.
No.
No.
No.
No.
No.
No.
No.
No.
No.
No.
No.
No.
No.
No.
No.
No.
No.
No.
No.
No.
No.
No.
No.
Recovered
truck
3
3
3
3
3
4
4
4
4
4
6
6
6
6
6
6
6
6
6
6
6
6
1
1
1
1
1
from
Fraction
Probe acetone wash
Fi Iter
Impinger water and wash
Ether-chloroform extraction
Impinger acetone wash
Probe acetone wash
FiIter
Impinger water and wash
Ether-chloroform extraction
Impinger acetone wash
Probe acetone wash
Filter
Impinger water and wash
Ether-chloroform extraction
Impinger acetone wash
Probe acetone wash
Filter
Impinger water and wash
Ether-chloroform extraction
Impinger acetone wash
Nozzle and thimble acetone wash
Alundum fi1ter
Probe and front half of filter acetone wash
Glass fiber filter
Impinger water and wash
Ether-chloroform extraction
Impinger acetone wash
Probe acetone wash
Filter
Impinger water and wash
Ether-chloroform extraction
Impinger acetone wash
Baghouse dust
* ASME
** Glass probe
F-2
-------
Run No. 3; Date October 20, 1972
Sample No.
(EPA-1 0-368
-369
-370
-371
72-004-372
(EPA-1 2) -373
-37V
-375
-376
72-00^-377
(EPA-1 3) -378
-379
-380
-381
72-004-382
( EPA-1 4) -383
-384
-385
-386
72-00^-387*
(M5) -388*
-389*
(EPA-1 5) -390*
-591*
-392*
-393*
72-004-394**
-395**
-396**
-397**
-398**
72-004-399
72-004-400
-401
-402
-403
-404
-405
Stack No.
Inlet
Inlet
Inlet
Inlet
Inlet
Outlet No. 3
Outlet No. 3
Outlet No. 3
Outlet No. 3
Outlet No. 3
Outlet No. 4
Outlet No. 4
Outlet No. 4
Outlet No. 4
Outlet No. 4
Outlet No.
Outlet No.
Outlet No.
Outlet No.
Outlet No.
Outlet No.
6
6
6
6
Outlet No. 6
Outlet No. 6
Outlet No. 6
Outlet No.
Outlet No.
6
6
6
6
Outlet No. 6
Outlet No. 1
Outlet No. 1
Outlet No. 1
Outlet No. 1
Outlet No. 1
Recovered from
truck
Fraction
Probe acetone wash
FiIter
Impinger water and wash
Ether-chloroform extraction
Impinger acetone wash
Probe acetone wash
Filter
Impinger water and wash
Ether-chloroform extraction
Impinger acetone wash
Probe acetone wash
FiIter
Impinger water and wash
Ether-chloroform extraction
Impinger acetone wash
Probe acetone wash
Filter
Impinger water and wash
Ether-chloroform extraction
Impinger acetone wash
Nozzle and thimble acetone wash
Alundum fi1ter
Probe and front half of filter acetone wash
Glass fiber filter
Impinger water and wash
Ether-chloroform extraction
Impinger acetone wash
Probe acetone wash
Filter
Impinger water and wash
Ether-chloroform extraction
Impinger acetone wash
Baghouse dust
Acetone blank
Water blank
Ether-chloroform blank
Trace metals blank filters
Glass fiber blank filters
Alumdum thimble
* ASME
** Glass probe
F-3
-------
APPENDIX G
-------
APPENDIX G
LABORATORY REPORTS
-------
ANALYTICAL DATA
PLANT.
DATE_
SAMPLING LOCATION.
SAMPLE TYPE
RUN NUMBER
SAMPLE BOX NUMBER.
CLEAN-UP MAN
COMMENTS:
FRONT HALF
ACETONE WASH OF NOZZLE, PROBE, CYCLONE (BYPASS),
FLASK, FRONT HALF OF FILTER HOLDER
FILTER NUMBER
- I?
CONTAINER 3 O \
LABORATORY RESULTS
f* t me
CONTAINER
/5"3. 0
-Nig
FRONT HALF SUBTOTAL
BACK HALF
IMPINGER CONTENTS AND WATER WASH OF
IMPINGERS, CONNECTORS, AND BACK
HALF OF FILTER HOLDER
ACETONE WASH OF IMPINGERS, CONNECTORS,
AND BACK HALF OF FILTER HOLDER
CONTAINER.
ETHER-CHLOROFORM
EXTRACTION
CONTAINER.
BACK HALF SUBTOTAL
TOTAL WEIGHT
-
/»
.?
_mg
.mg
.mg
.mg
mt
MOISTURE
IMPINGERS
FINAL VOLUME
INITIAL VOLUME
NET VOLUME
SILICA GEL
FINAL WEIGHT
INITIAL WEIGHT
NET WEIGHT
EPA (Dur) 231
4/72
*Lcn> ml
3LCTO ml
O ml
»-feX
>6,sT|f
i *
8 *
g B:
G-1
TOTAL MOISTURE
2-fe./
-------
ANALYTICAL DATA
PLANT
DATE.
SAMPLING LOCATI0JL
SAMPLE TYPE
RUN NUMBER
SAMPLE BOX NUMBER
CLEAN-UP MAN
O
C\J
COMMENTS:
\
FRONT HALF
ACETONE WASH OF NOZZLE, PROBE, CYCLONE (BYPASS),
FLASK, FRONT HALF OF FILTER HOLDER
£±
FILTER NUMBER
CONTAINER.
CONTAINER
LABORATORY RESULTS
.nig
FRONT HALF SUBTOTAL
A*
/ ?.
.mg
.mg
BACK HALF
IMPINGER CONTENTS AND WATER WASH OF
IMPINGERS, CONNECTORS, AND BACK
HALF OF FILTER HOLDER
ACETONE WASH OF IMPINGERS, CONNECTORS,
AND BACK HALF OF FILTER HOLDER
MOISTURE
IMPINGERS
FINAL VOLUME
INITIAL VOLUME
NET VOLUME
.ml
.ml
.ml
SILICA GEL
FINAL WEIGHT ^v o g
INITIAL WEIGHT 2^TP g
NET WEIGHT I* g
EPA (Dur) 231
4/72
. -8
lem g
-g
ETHER-CHLOROFOJM
EXTRACTION
BACK HALF SUBTOTAL
TOTAL MOISTURE
.mg
» I
me
TOTAI WEIGHT
iL&tTr nut
-------
ANALYTICAL DATA
PLANT.
DATE.
EPA
^ia
COMMENTS:
SAMPLING LOCATIpU
SAMPLE TYPE
RUN NUMBER.
SAMPLE BOX NUMBER
CLEAN-UP MAN
O
S'^acic 3
FRONT HALF
ACETONE WASH OF NOZZLE, PROBE, CYCLONE (BYPASS),
FLASK, FRONT HALF OF FILTER HOLDER
CONTAINER.
FILTER NUMBER
- V-
CONTAINER
'*
LABORATORY RESULTS
e~
-$T O
3 0 7
FRONT HALF SUBTOTAL
mg
.mg
?» V
.mg
BACK HALF
IMPINGER CONTENTS AND WATER WASH OF
IMPINGERS, CONNECTORS, AND BACK
HALF OF FILTER HOLDER
ACETONE WASH OF IMPINGERS, CONNECTORS,
AND BACK HALF OF FILTER HOLDER
MOISTURE
ETHER-CHLOROFORM
CONTAINER.
3 \ O
BACK HALF SUBTOTAL
IMPINGERS . Q -,
FINAI vmilMF l^ ^
INITIA' vmilMF ^rt>.
NET V^Li'MF " ^
SILICA GEL
FINAL WEIRHT "ISI^S
INITIAL WEIGHT T^O~D
NET WE^HT ^LD
EPA (Dur) 231
4/72 '• S)n* S
_ml
fcml
_ml
g ^
B ~L
e '
*i«fUL I
\& g e
fTD i e
19 I B!
G-3
^i%j ^^cr «n -«i
TOTAL MOISTURE
-
* »
r» •
. /
mK
TOTAI WFIGHT
£ r • O mtt
-------
ANALYTICAL DATA
PLANT.
DATE.
SAMPLING LOCATION
SAMPLE TYPE .
RUN NUMBER
SAMPLE BOX NUMBER.
CLEAN-UP MAN
0 -
4-
FRONT HALF
ACETONE WASH OF NOZZLE, PROBE, CYCLONE (BYPASS),
FLASK, FRONT HALF OF FILTER HOLDER
CONTAINER
FILTER NUMBER
CONTAINER 5
LABORATORY RESULTS
* me
.mg
FRONT HALF SUBTOTAL
.mg
BACK HALF
IMPINGER CONTENTS AND WATER WASH OF
IMPINGERS, CONNECTORS, AND BACK
HALF OF FILTER HOLDER
ACETONE WASH OF IMPINGERS, CONNECTORS,
AND BACK HALF OF FILTER HOLDER
rntiTAiNFR :> \ O
ETHER-CHLOROFORM
EXTRACTION 31 +
2oT
BACK HALF SUBTOTAL
11.3
.mg
.mg
.mg
TOTAL WEIGHT
ra
« O mg
MOISTURE
IMPINGERS f
FINAL VOLUME _2£>A
INITIAL VOLUME
NET VOLUME
ml
ml
ml
SILICA GEL
FINAL WEIGHT ^> 7 B
INITIAL WEIGHT Z^T> g
NET WEIGHT _ ^_ g
EPA (Dur) 231
4/72
TOTAL MOISTURE
-------
ANALYTICAL DATA
PLANT EPA
DATE
In -\-~7
SAMPLING LOCATION
SAMPLE TYPE _
RUN NUMBER _
( I)
SAMPLE BOX NUMBER
CLEAN-UP MAN
COMMENTS:
FRONT HALF
ACETONE WASH OF NOZZLE, PROBE, CYCLONE (BYPASS),
FLASK, FRONT HALF OF FILTER HOLDER
FILTER NUMBER
ft) -
- S
CONTAINER 3^.
CONTAINER _3
LABORATORY RESULTS
?. 3
FRONT HALF SUBTOTAL
mg
'• /
_mg
mo-
.mg
BACK HALF
IMPINGER CONTENTS AND WATER WASH OF
IMPINGERS, CONNECTORS, AND BACK
HALF OF FILTER HOLDER
ACETONE WASH OF IMPINGERS, CONNECTORS,
AND BACK HALF OF FILTER HOLDER
MOISTURE
3^-0
CONTAINER.
ETHER-CHLOROFORM
EXTRACTION
IMPINGERS ^r
FINAI vm IIMF »» J ml
INITIAL VniUMF SLOCJ ml
NET VOI IIMF — ' S "1
S'LICAGEL . '
FINAL WFIRHT *** ' ^ g ^~ '-Jg
INITIAL WFIGHT AOY ) g 2-£> o g
NET WFIGHT ' b> R '^' ^ B
EPA (Our) 231
4/72
B
B
B;
G-5
TOTAL MOISTURE
y —
20 , 3
.mg
BACK HALF SUBTOTAL
TOTAL WEIGHT
/£.!
VOs
> HIE
I mg
.mg
-------
ANALYTICAL DATA
PLANT.
DATE_
SAMPLING LOCATION _
SAMPLE TYPE B
RUN NUMBER.
QgJTl-g_
SAMPLE BOX NUMBER
CLEAN-UP MAN
COMMENTS:
6,
FRONT HALF
ACETONE WASH OF NOZZLE, PROBE, CYCLONE (BYPASS),
FLASK, FRONT HALF OF FILTER HOLDER
FILTER NUMBER
^t
CONTAINER.
CONTAINER
LABORATORY RESULTS
.m8
7
.m8
FRONT HALF SUBTOTAL
.mg
BACK HALF
IMPINGER CONTENTS AND WATER WASH OF
IMPINGERS, CONNECTORS, AND BACK
HALF OF FILTER HOLDER
ACETONE WASH OF IMPINGERS, CONNECTORS,
AND BACK HALF OF FILTER HOLDER
MOISTURE
IMPINGERS
FINAL VOLUME .
INITIAL VOLUME
NET VOLUME .
SILICA GEL
FINAL WEIGHT
INITIAL WEIGHT
NET WEIGHT
EPA (Dur) 231
4/72
1*3
3sO<>
-/7
>M
~LQCl
?-\
ml
ml
ml
f T^T-o
8 2=
ETHER-CHLOROFORM
EXTRACTION 3 \Q
CONTAINER ^ ^— O
BACK HALF SUBTOTAL
TrtTAI UICIPUT
TOTAL Wtmn 1
2tO mg
^ 8 mp
/?.* m*
V 6 -3 me
8
8
,81
G-6
TOTAL MOISTURE
-------
ANALYTICAL DATA
PLANT.
DATE_
KPft l^m
\C> -
SAMPLING LOCATION.
SAMPLE TYPE
RUN NUMBER
SAMPLE BOX NUMBER.
CLEAN-UP MAN
COMMENTS:
FRONT HALF
ACETONE WASH OF NOZZLE, PROBE, CYCLONE (BYPASS),
FLASK, FRONT HALF OF FILTER HOLDER
FILTER NUMBER
LABORATORY RESULTS
CONTAINER.
CONTAINER
.mg
FRONT HALF SUBTOTAL
.mg
BACK HALF
IMPINGER CONTENTS AND WATER WASH OF
IMPINGERS, CONNECTORS, AND BACK
HALF OF FILTER HOLDER
ACETONE WASH OF IMPINGERS, CONNECTORS,
AND BACK HALF OF FILTER HOLDER
CONTAINER.
ETHER-CHLOROFORM
EXTRACTION 3-37
CONTAINER i3Jf"
BACK HALF SUBTOTAL
TOTAL WEIGHT
30.1
< •
Tt /
.mg
.mg
.mg
3?.g m.
MOISTURE
IMPINGERS
FINAL VOLUME .
INITIAL VOLUME.
NET VOLUME .
.ml
.ml
.ml
SILICA GEL
FINAL WEIGHT «^X"- I g
INITIAL WEIGHT 7^Th g
NET WEIGHT I*?.7 8
EPA (Dur) 231
4/72
TOTAL MOISTURE
G-7
-------
ANALYTICAL DATA
PLANT
HPft
'VUlO
DATF \O - V^ -~11~~
SAMPLING LOCATION ^ (DCT^n_».V~ ^SVSO
SAMPLE TYPE -y-^^JTkr.itJVt^
RUN NIIMRFR C^-J
SAMPLE BOX NIIMRFR I '
CLEAN-UPMAN C^OXvO^ .
FRONT HALF
ACETONE WASH OF NOZZLE, PROBE, CYCLONE (BYPASS),
FLASK, FRONT HALF OF FILTER HOLDER
FILTER NUMBER V 2-)
BACK HALF
IMPINGER CONTENTS AND WATER WASH OF
IMPINGERS, CONNECTORS, AND BACK
HAI F OF Fll TFR HOI HER
ATFTCINF UIACH OF IMPINftFRS CONNECTORS
AND BACK HALF OF FILTER HOLDER
MOISTURE
IMPINGERS . ) (
FINAI vm 'IMF ' ' ' ml
INITIAl Vm UMF 1&& ml
NETVOLIIWF ~^JT ml
SILICA GEL - ,
FINAL WP'RHT A>1 » Y g i-*- 1 » ^ g
INITIAL WE'GHT 7j01^ g 7^0T> g
NET WEIGHT ,, VJ.%V« MiJg
C 1
LABORATORY RESULTS
CONTAINER 1&>\ O* p me
i tt
CONTAINER ^L,t^ /• " me
FRONT HAI F SUBTOTAL 2* / mg
mNTAINFR ^>U3 O • / mg
ETHER-CHLOROFORM . Q
EXTRACTION ''/if » • 7 mg
^jfe i
U. *i
CONTAINEB 3(c»J T • <+ mg
BACK HALF SUBTOTAL // * 2. m*
TOTAL WEIGHT / 3 . 3 me
g
g .^ ,
e TOTAL MOISTURE J-),\ g
EPA(Dur)231
4/72
G-8
-------
ANALYTICAL DATA
PLANT E.V>f\
DATE
SAMPLING LOCATION
SAMPLE TYPE
RUN NUMBER.
SAMPLE BOX NUMBER
CLEAN-UP MAN
FRONT HALF
ACETONE WASH OF NOZZLE, PROBE, CYCLONE (BYPASS),
FLASK, FRONT HALF OF FILTER HOLDER
FILTER NUMBER
CONTAINER.
CONTAINER
LABORATORY RESULTS
10.0 m,
. 3
.mg
BACK HALF
IMPINGER CONTENTS AND WATER WASH OF
IMPINGERS, CONNECTORS, AND BACK
HALF OF FILTER HOLDER
ACETONE WASH OF IMPINGERS, CONNECTORS,
AND BACK HALF OF FILTER HOLDER
FRONT HALF SUBTOTAL
. 3
CONTAINER -^ ^
ETHER-CHLOROFORM
EXTRACTION 3^3
BACK HALF SUBTOTAL
TOTAL WEIGHT
«• «3 ing
/» O mg
* z _
to .0 m
22.3 nut
MOISTURE
IMPINGERS
FINAL VOLUME .
INITIAL VOLUME.
NET VOLUME .
.ml
ml
.ml
SILICA GEL
FINAL WEIGHT ^Vf. \ g
INITIAL WEIGHT 7tflt , g
NET WEIGHT .
EPA (Dur) 231
4/72
.g
>g
g
g
g.
TOTAL MOISTURE
G-9
-------
ANALYTICAL DATA
PLANT-
DATE.
10 -
SAMPLING LOCATION,
SAMPLE TYPE
RUN NUMBER
SAMPLE BOX NUMBER.
CLEAN-UP MAN
(?-}
COMMENTS:
FRONT HALF
ACETONE WASH OF NOZZLE, PROBE, CYCLONE (BYPASS),
FLASK, FRONT HALF OF FILTER HOLDER
FILTER NUMBER
BACK HALF
IMPINGER CONTENTS AND WATER WASH OF
IMPINGERS, CONNECTORS, AND BACK
HALF OF FILTER HOLDER
ACETONE WASH OF IMPINGERS, CONNECTORS,
AND BACK HALF OF FILTER HOLDER
CONTAINER.
CONTAINER
LABORATORY RESULTS
_mg
FRONT HALF SUBTOTAL
• 0
&•
.mg
CONTAINER B^U
ETHER-CHLOROFORM
CONTAINER 3*40
BACK HALF SUBTOTAL
TOTAI WFIRHT
O« / mg
2«O mg
1 • Tr mg
9» S mg.
ir»S m
MOISTURE
IMPINGERS
FINAL VOLUME
INITIAL VOLUME
NET VOLUME
SILICA GEL
INITIAL
NET WEIGHT
EPA (Dur) 231
4/72
' 5 Q
.ml
.ml
.ml
JZ^LLg
TOTAL MOISTURE
• *
5-10
-------
ANALYTICAL DATA
PLANT C V K ^>fe LJL }
DATE IO -\^ -TV
SAMPI ING \ nrATinf| <^,7VLLT~ S^>&r ie
SAMPI F TYPF \~Sfrl? Ocjn U±X*
RUN NI1MRFR C 2- )
SAMPL F RnX NUMBER (a A^™ ^
CLEAN-UP MAN
FRONT HALF
ACETONE WASH OF NOZZLE, PROBE, CYCLONE (BYPASS),
FLASK, FRONT HALF OF FILTER HOLDER
FILTER NUMBER l^»v\<^UL. ^ ~ ]
^-ILSTtf? "^OA - \O
BACK HALF
IMPINGER CONTENTS AND WATER WASH OF
IMPINGERS, CONNECTORS, AND BACK
HAI F OF FILTER HOLDER
APFTONF WASH OF IMPINGERS CONNECTORS
AND BACK HALF OF FILTER HOLDER
MOISTURE
IMPINGERS r
FINA1 VOl (IMF 1 ' V, ml
INITIAI VOl (IMF "2^1? ml
NETVOIIIMF -J'j" ml
SILICA GEL
FINAL WF'RHT V^W. L, g l^l^t' g
INITIAL WF'GHT ~Z0T> g l£m g
NFTWFIGHT /^«L R ^ l^' g
EPA (Dur) 231
4/72 G'11
COMMENTS:
A
i
/
•
LABORATORY RESULTS
CONTAINER 3&+ ?»6 me
CONTAINER 5 .Cf 0» 7 me
3H~ ^", V
3^7 /.f
FRONT HALF SUBTOTAL /6» ^ me
P.nNTAINFR ?> Srt 3»0 me
ETHER-CHLOROFORM ^ -»
EXTRACTION ~ fj. O**r mg
*J w I -^
CONTAINER ^ryO **T mg
BACK HALF SUBTOTAL ?* V me
TOTAI WFIRHT ^%2 me
g
g ii (
g, TOTAL MOISTURE /»• u ' g
-------
ANALYTICAL DATA
PLANT.
DATE_
1 O -
SAMPLING LOCATION.
SAMPLE TYPE
RUN NUMBER
SAMPLE BOX NUMBER.
CLEAN-UP MAN
-B- "T^ >>
COMMENTS:
L
FRONT HALF
ACETONE WASH OF NOZZLE, PROBE, CYCLONE (BYPASS),
FLASK, FRONT HALF OF FILTER HOLDER
FILTER NUMBER
EP A
BACK HALF
IMPINGER CONTENTS AND WATER WASH OF
IMPINGERS, CONNECTORS, AND BACK
HALF OF FILTER HOLDER
ACETONE WASH OF IMPINGERS, CONNECTORS,
AND BACK HALF OF FILTER HOLDER
MOISTURE
IMPINGERS
FINAL VOLUME
ml
INITIAL VOLUME 7^n-» ml
NET VOLUME - I j> ml
SILICA GEL
FINAL
INITIAL WEIGHT
NET WEIGHT
EPA (Dur) 231
4/72
3-»tt7i
-g
-g
CONTAINER 1 S-*j
CONTAINER ^
LABORATORY RESULTS
//.
FRONT HALF SUBTOTAL
TOTAL MOISTURE
G-12
mg
< • *
mg
/V.3
r.flNTAINFR 3vi 1
ETHER-CHLOROFORM
EXTRACTION^C-V,
CONTAINER ^ \^>
BACK HALF SUBTOTAL
TOTAL WEIGHT
&,r
1,0
y.3
/Z. 9
m./
me.
_mg
_mg
mg
mg
-------
ANALYTICAL DATA
PLANT.
DATE_
SAMPLING LOCATION
SAMPLE TYPE
RUN NUMBER
SAMPLE BOX NUMBER
CLEAN-UP MAN
Lix
COMMENTS:
FRONT HALF
ACETONE WASH OF NOZZLE, PROBE, CYCLONE (BYPASS),
FLASK, FRONT HALF OF FILTER HOLDER
FILTER NUMBER
- ( \
CONTAINER 34? 7
CONTAINER
LABORATORY RESULTS
y*STA m.
. /
FRONT HALF SUBTOTAL
.mg
BACK HALF
IMPINGER CONTENTS AND WATER WASH OF
IMPINGERS, CONNECTORS, AND BACK
HALF OF FILTER HOLDER
ACETONE WASH OF IMPINGERS, CONNECTORS,
AND BACK HALF OF FILTER HOLDER
CONTAINER.
ETHER-CHLOROFOF
EXTRACTION 3 ~)Q
CONTAINER.
3") 1
BACK HALF SUBTOTAL
TOTAL
» r
«
' '
O» 2.
/«*"•
mg
mg
MOISTURE
IMPINGERS
FINAL VOLUME
0
'" 1
ml
INITIAL VOLUME 7ITU ml
NET VOLUME — */— ml
SILICA GEL
FINAL '
INITIAL WEIGHT
NET WEIGHT
EPA (Dur) 231
4/72
> ,V
+1^1
TOTAL MOISTURE
G-13
-------
ANALYTICAL DATA
PLANT.
DATE.
SAMPLING LOCATION
SAMPLE TYPE
RUN NUMBER
SAMPLE BOX NUMBER.
CLEAN-UP MAN
COMMENTS:
g^- OPffreJg. \
FRONT HALF
ACETONE WASH OF NOZZLE, PROBE, CYCLONE (BYPASS),
FLASK, FRONT HALF OF FILTER HOLDER
FILTER NUMBER
CONTAINER 3>9*-/-
CONTAINER
LABORATORY RESULTS
fag. 2.
mg
.mg
FRONT HALF SUBTOTAL
.mg
BACK HALF
IMPINGER CONTENTS AND WATER WASH OF
IMPINGERS, CONNECTORS, AND BACK
HALF OF FILTER HOLDER
ACETONE WASH OF IMPINGERS, CONNECTORS,
AND BACK HALF OF FILTER HOLDER
MOISTURE
IMPINGERS
FINAL VOLUME .
INITIAL VOLUME.
NET VOLUME —
SILICA GEL
FINAL WEIGHT
INITIAL WEIGHT
NET WEIGHT
EPA (Dur) 231
4/72
.ml
.ml
ml
Ol
fi <3
ETHER-CHLOROFORM
EXTRACTION 3^7
CONTAINER-3SLS1
BACK HALF SUBTOTAL
.mg
3« 0
.mg
t *
TOTAL
TOTAL MOISTURE
G-1U
-------
ANALYTICAL DATA
PLANT.
DATE_
SAMPLING LOCATION
SAMPLE TYPE ^"ft
RUN NUMBER
C*
SAMPLE BOX NUMBER.
CLEAN-UP MAN
COMMENTS:
FRONT HALF
ACETONE WASH OF NOZZLE, PROBE, CYCLONE (BYPASS),
FLASK, FRONT HALF OF FILTER HOLDER
CONTAINER.
LABORATORY RESULTS
B mg
FILTER NUMBER
CONTAINER 3")
t Z
mg
FRONT HALF SUBTOTAL
2 O . ?
mg
BACK HALF
IMPINGER CONTENTS AND WATER WASH OF
IMPINGERS, CONNECTORS, AND BACK
HALF OF FILTER HOLDER
ACETONE WASH OF IMPINGERS, CONNECTORS,
AND BACK HALF OF FILTER HOLDER
ETHER-CHLOROFORM
CONTAINER.
BACK HALF SUBTOTAL
TOTAL
.mg
.mg
*• V mg
3V. V m.
mg
MOISTURE
IMPINGERS
FINAL VOLUME .
INITIAL VOLUME.
NET VOLUME .
SILICA GEL
FINAL
.ml
.ml
.ml
-
»/
INITIAL WEIGHT ?AU g
NET WEIGHT |fr/ g
EPA (Dur) 231
4/72
7-*rti
43
g
g
•g;
TOTAL MOISTURE
I?".?
G-15
-------
ANALYTICAL DATA
PLANT.
DATE.
SAMPLING LOCATION.
SAMPLE TYPE
RUN NUMBER.
SAMPLE BOX NUMBER
CLEAN-UP MAN
COMENTS:
FRONT HALF
ACETONE WASH OF NOZZLE, PROBE, CYCLONE (BYPASS),
FLASK, FRONT HALF OF FILTER HOLDER
FILTER NUMBER EPA
CONTAINER ?>") 3
CONTAINER
LABORATORY RESULTS
0. 6
mg
.mg
BACK HALF
IMPINGER CONTENTS AND WATER WASH OF
IMPINGERS, CONNECTORS, AND BACK
HALF OF FILTER HOLDER
ACETONE WASH OF IMPINGERS, CONNECTORS,
AND BACK HALF OF FILTER HOLDER
MOISTURE
IMPINGERS
FINAL VOLUME .
INITIAL VOLUME.
NET VOLUME " I*
^
1*9
.ml
.ml
.ml
SILICA GEL
FINAL
INITIAL WEIGHT 7 g
G-16
-------
PLANT
DATE
SAMPLING LOCATION
SAMPLE TYPE
RUN NUMBER
SAMPLE BOX NUMBER
CLEAN-UP MAN
ANALYTICAL DATA
COMMENTS:
FRONT HALF
ACETONE WASH OF NOZZLE, PROBE, CYCLONE (BYPASS),
FLASK, FRONT HALF OF FILTER HOLDER
FILTER NUMBER
I/Id -
CONTAINER.
LABORATORY RESULTS
*•<£ me
CONTAINER
FRONT HALF SUBTOTAL
mg
Afe
.mg
BACK HALF
IMPINGER CONTENTS AND WATER WASH OF
IMPINGERS, CONNECTORS, AND BACK
HALF OF FILTER HOLDER
ACETONE WASH OF IMPINGERS, CONNECTORS,
AND BACK HALF OF FILTER HOLDER
MOISTURE
IMPINGERS s
FINAL VOLUME ' ' 4
ml
^ ' '
CONTAINER
ETHER-CHLOROFORM
EXTRACTION
CONTAINER.
^
BACK HALF SUBTOTAL
INITIAL VOLUME
NET VOLUME
SILICA GEL
FINAL WEIGHT
INITIAL WEIGHT
NET WEIGHT
EPA (Dur) 231
4/72
~7^rt> ml
- If/ .,. ml
~Lf\\ g ~)^*~i\ (
Jlr.f ( 7^ |
8
I
•?!
6-17
. T
O*
/ 0 .
.mg
.mg
.mg
.mg
mg
TOTAL MOISTURE
-------
ANALYTICAL DATA
PLANT.
DATE_
I O ~ 2-0 '
SAMPLING LOCATION
SAMPLE TYPE
RUN NUMBER.
SAMPLE BOX NUMBER
CLEAN-UP MAN
I~JS&.
COMMENTS:
L
FRONT HALF
ACETONE WASH OF NOZZLE, PROBE, CYCLONE (BYPASS),
FLASK, FRONT HALF OF FILTER HOLDER
FILTER NUMBER
- 1
CONTAINER.
CONTAINER
LABORATORY RESULTS
.nig
.mg
FRONT HALF SUBTOTAL
* ?
.mg
BACK HALF
IMPINGER CONTENTS AND WATER WASH OF
IMPINGERS, CONNECTORS, AND BACK
HALF OF FILTER HOLDER
ACETONE WASH OF IMPINGERS, CONNECTORS,
AND BACK HALF OF FILTER HOLDER
T» 7
ETHER-CHLOROFORM
EXTRACTION-Tcw*
CONTAINER 3^k?
BACK HALF SUBTOTAL
TOTAL WEIGHT
1.9
3.9
so./
l*.9
mg
mg
mg
mg
MOISTURE
IMPINGERS
FINAL VOLUME .
INITIAL VOLUME.
NET VOLUME ~ I 5
.ml
.ml
.ml
SILICA GEL
FINAL'
INITIAL WEIGHT
NET WEIGHT
EPA (Dur) 231
4/72
g
g
g
g
g.
TOTAL MOISTURE
-------
APPENDIX H
-------
APPENDIX H
SAMPLE HANDLING LOG
-------
SAMPLE HANDLING LOG
Plant:
.•;-'
7
Recorded By: /-r-
Run
No.
Sample
No.
Act i vi ty
Date
Time
Personnel
Remarks
( v
L ;• 1_. 0 , -t"^ ••. •- v,.
ce
, Ckt-; 5tvv_ . ^ ,'; i«
. //", .'Jr-
//•?•-! 2
-, /
S -W • v\'t> '• 6. 1 tr.
tr.A-v
?
(0 ' i.. \
V 0
M
t }
-^ cl - u^ T i^kj t>t^ck.
CM <-
13-30.
t> (
v'c. S
2—
-------
SAMPLE HANDLING LOG
Plant:
Recorded By
Run
No.
Sample
No.
Activity
Date
T i me
Personnel
Remarks
/C)0 CJ
^A .^,,0
-------
APPENDIX I
-------
APPENDIX I
TEST LOG
-------
APPENDIX I
Test Log
Test No.
1 Date: 10-18-72
Time Interval
Port X
Port Y
Duration, Minutes
Inlet
0945-1145
1232-1432
240
Outlet 1
1
0946-1146
1232-1432
240
Outlet 3
0947-1147
1232-1434
240
Outlet 4
0945-1145
1232-1432
240
Outlet 6
0945-1145
1232-1432
240
2 Date: 10-19-72
Time Interval
Port X2
Port Y
Duration, Minutes
1002-1222
1302-1502
240
1000-1220
1302-1502
240
1003-1223
1302-1502
240
1001-1221
1300-1500
240
1002-1222
1302-1502
240
Date: 10-20-72
Time Interval
Port X
Port Y
Duration, Minutes
1
1000-1200
1301-1501
240
1000-1200
1305-1505
240
Outlet Probe remained at Port X for duration of test.
Test interrupted for 20 minutes to replace faulty equipment.
1002-1202
1302-1502
240
1000-1200
1300-1500
240
1000-1200
1300-1500
240
-------
APPENDIX J
-------
APPENDIX J
PROCESS OPERATION
-------
APPENDIX J
PROCESS OPERATION
Log of Process Operation - October 18, 1972
Time
9:45 a.m.
9:56
10:01
10:30
10:40.
10:42
10:52
11:00
11:06
11:22
11:25
11:30
11:34
11:35
11:36
11:49
12:00 p.m.
50-Ton Furnace
Power just turned back on
after power shortage.
Furnace melting down first
charge. Megawatts - 9 to 11
Recharge initiated.
Recharge terminated.
Power back on.
Megawatts - 9 to 11.
Reduce power due to
power requirements.
Megawatts - 5 to J.
75-Ton Furnace
Power just turned back on
after power shortage.
Furnace melting down first
charge.
Recharge initiated.
Recharge complete, power on.
Add crushed electrode.
Megawatts - 8 to 9.
First sample taken.
Megawatts - 8.5 to 9.
£>2 lancing initiated.
C>2 lancing terminated.
Power back on.
Sample taken.
Add 960 pounds molybdenum
oxide.
Add 1,000 pounds
1imestone.
J-l
-------
Time
12:15
12:16
12:20
12:22
12:24
12:28
12:31
12:39
12:49
12:50
12:51
12:54
12:58
1:07
1:12
50-Ton Furnace
1:15
1:20
1 :22
1:33
Fi rst sample taken.
Additions to furnace.
Sample taken.
Addition of 500 pounds
molybdenum oxide.
Sample taken.
Addition of 400 pounds
Spiegal.
Deslagging initiated.
Deslagging complete.
Addition of 25 pounds of
crushed electrode.
75-Ton Furnace
Og lancing initiated.
05 lancing terminated.
Addition of 500 pounds Spiegal
Reduction, add lime and
s i1i ca.
Megawatts - 10.
'Deslagging initiated.
Deslagging finished.
Add 500 pounds 50 percent
ferrosi1 icon.
Megawatts - 3 to 6
Whi te slag added.
Sample taken.
Addition of 38 pounds of
aluminum.
Sample taken, addition of
3,500 pounds 06 ferrochrome.
J-2
-------
Time
50-Ton Furnace
75-Ton Furnace
1:40
1:50
1:58
2:0?
2:09
2:14
2:16
2:19
2:25
2:28
Addition of 205 pounds
of calcium-si 1 icon.
Addition of crushed
electrode.
White slag added.
Megawatts - 1.5 to 3-
Sample taken.
Addition of 2,000 Ibs.
06 ferrochrome.
This heat resulted in:
2 - 33,300 lb. ingots
1 - 37,000 lb. ingot
Total 103,600 Ibs.
Total charge consisted of:
10,000 Ibs. revert butts
10,000 Ibs. revert TE pipe
40,000 Ibs. revert billets
44,000 Ibs. purchased basic
scrap
400 Ibs. molybdenum ore
sinter
300 Ibs. broken electrode
104,700 Ibs. Total
J-3
Additions -
800 pounds 06 ferrochrome
370 pounds 80-7 ferrochrome
Addition of 40 pounds
molybdenum oxide.
Addition of 500 pounds
50 percent ferrosilicon
Megawatts - 1.5 to 2.
Power off, addition of
slag material to furnace.
Tap furnace. 75 pounds
aluminum added to ladle.
Tap complete.
Pou red.
15 - 10,500 lb. ingots
1 2,000 lb. butt
Total 159,500 Ibs.
Total charge consisted of:
90,000 Ibs. revert butts, pipes
and bi1 lets
61,000 Ibs. light stampings and
mi seellaneous
400 Ibs. molybdenum ore sinter
400 Ibs. broken electrode
151,800 Ibs. Total
-------
Log of Process Operation - October 19, '972
Time
10:00 a.m.
10:05
10:0?
10:18
10:37
10:46
10:55
11:13
11:15
11:23
11 :27
11:32
11:36
11:50
11:56
11:58
50-Ton Furnace
Furnace melting down second
charge. Megawatts - 9 to
9.5.
Megawatts - 5.5 to 6.
Addition of 1,000 pounds
1imestone.
Fi rst sample taken,
Sample taken.
Addition of 300 pounds
of molybdenum oxide.
Sample taken; addition of
UOO pounds Spiegal.
Reduction.
Deslagging initiated.
75-Ton Furnace
Furnace being recharged.
Recharge complete.
Megawatts - 9 to 13.
Megawatts - 8.5
Addition of 1,500 pounds
1imestone.
First sample taken.
Op lancing initiated.
Og lancing terminated.
Sample taken.
°2 lancing initiated.
09 lancing terminated.
Addition of 360 pounds
molybdenum oxide.
Very short 02 ]ance.
Oeslagging terminated.
J-k
-------
Time
50-Ton Furnace
75-Ton Furnace
12:01 p.m.
12:02
12:05
12:11*
12:17
12:25
12:30
12:38
12:52
1:05
1:15
1:21
1:25
1:29
1:42
1:43
1:4?
Addition of 200 pounds
calcium-si 1 icon.
White slag added.
Sample taken.
Addition of 2,000 pounds
06 ferrochromium.
Megawatts - 3 to 5-
Addition of 300 pounds
of 06 ferrochromium.
Addition of 260 pounds
of 70-5 ferrochromium.
Additions - 300 pounds
80-7 ferromanganese;
50 pounds 50 percent
ferrosi1 icon.
Addition of 1 1/2
pounds Skamex.
Furnace tap, 255 pounds
calcium-silicon in ladle.
Tap complete, poured
1 - 32,900 Ib. ingot
2 - 32,300 Ib. ingots
1 - 4,000 Ib. butt
Total 101,500 Ibs.
Sample taken.
Addition of 500 pounds Spiegal
Deslagging initiated.
Deslagging terminated.
Addition of 600 pounds 50
percent ferrosilicon.
White slag added.
Megawatts - 1.5 to 2.
Sample taken.
J-5
-------
Time
50-Ton Furnace
75-Ton Furnace
2:04
2:20
2:25
2:40
2:45
3:02
Total charge for this heat
was:
6,000 Ibs.
10,000 Ibs.
20,000 Ibs.
24,000 Ibs.
42,000 Ibs.
400 Ibs.
300 Ibs.
102,700 Ibs.
revert scrap ends
revert TE pipe
revert skulls and billets
B and W Burner basic
and Barberton rings
purchased basic
scrap
molybdenum ore
sinter
broken electrode
Total
Repair furnace lining.
First charge of new heat.
Power turned on.
End test run.
Addition of 600 pounds 70-5
ferrochromium.
Addition of 430 pounds 80-7
ferromanganese.
Furnace tapped, 250 pounds
calcium-silicon in ladle.
Poured
12 - 10,500 Ib. ingots
1 - 10,700 Ib. ingot
1 - 4,000 Ib. butt
Total 140,700
Total charge for this heat was:
30,000 Ibs.
122,000 Ibs.
revert scrap ends
purchased alloy,
1i ght stamping and
mi seellaneous
broken electrode
300 Ibs
152,300 Ibs. Total
Repair furnace lining.
J-6
-------
Log of Process Operation - October 20, 1972
Time
10:00 a.m.
50-Ton Furnace
Furnace had just been
deslagged.
10:02
10:05
10:15
10:20
10:23
10:45
10:55
10:59
11:15
11:20
Addition of 215 pounds
calcium-si 1 icon.
White slag added.
Megawatts - 1.6.
Sample taken.
Addition of 2,000 pounds
of 06 ferrochromium.
75-Ton Furnace
Furnace had been tapped at
7:15 a.m., but the ladle
stopper became frozen shut
and the ladle had to be
poured back into the furnace.
This was done at 8:10 a.m.
At 10:00 a.m. the white slag
had just been put back onto
the heat.
Megawatts - 3.
Sample taken.
Megawatts - 2.
Additions: 200 pounds 06
ferrochromium; 200 pounds
medium carbon ferromanganese.
Additions of 1,000 pounds 50
percent ferrosi1 icon.
Furnace tapped.
Furnace tap complete.
Poured
7 - 10,200 Ib. ingots
5 - 10,400 Ib. ingots
1 - 10,000 Ib. butt
133,400 Ibs. Total
J-7
-------
Time
11:20
50-Ton Furnace
11:27
11:29
11:50
11 :32
11:45
11:57
11:58
12:04 p.m.
12:24
12:40
12:49
Addition of 460 pounds
06 ferrochromium.
Addition of 350 pounds
70-5 ferrochromium.
Addition of 400 pounds
80-7 ferromanganese.
75-Ton Furnace
Total charge for this heat was:
126,000 Ibs. revert light
stampings
18,000 Ibs. B and W Billet scraps
11,000 Ibs. scrap ingots
400 Ibs. broken electrode
155,400 Ibs. Total
Repair furnace lining.
Addition of 175 pounds
50 percent ferrosi1 icon.
Addition of 1 1/2 pounds
Skamex.
Furnace tap.
Furnace tap complete.
Poured
3 _ 34,600 Ib. ingots
1 - 5,000 Ib. butt
Total 108,800 Ibs.
Total charge for this heat was:
28,000 Ibs. revert crop ends
79,000 Ibs. purchased basic scrap
400 Ibs. molybdenum oxide
400 Ibs. broken electrode
107,800 Ibs. Total
Repair furnace lining.
First charge of new heat.
First charge of new heat,
Power on.
Repai r ai r hose.
J-8
-------
Time
1:04
1:05
1:07
1:17
1:21
2:00
2:40
2:50
2:54
2:55
2:59
3:02
50-Ton Furnace
Hang new electrode.
Dust blown from top of
furnace.
Power back on. Megawatts
7 to 11.
Megawatts - 11 to 12.
Recharge.
Recharge complete.
Power back on.
Test complete.
75-Ton Furnace
Air hose repair complete.
Power back on.
Megawatts - 13 to 14.5.
Furnace roof opened.
Recharge.
J-9
-------
APPENDIX K
-------
APPENDIX K
RELATED REPORTS
-------
~O I «v\ >O
t—J
.U.
.:h^ ROY F. JsA/ESTDN, JNC. ;
"
<;-;:/" ENVIRONMENTAL SCIENTISTS AND ENGINEERS
',-'-•' \ LEWIS LANE » WEST CHESTER u PENNSYLVANIA
\ .
27 September 1972
-..-... • . ' . i
. • . i
Environmental Protection Agency . • |
Office of Air Programs . 1
Applied Technology Division • I
Research Triangle Park, North Carol ina '27711 • I
Attention: Mr. Clyde E. Riley, W.O. 300-39
Project Officer
Subject: Presurvey Report Concerning the Preliminary Visit
to the Babcock and Wi Icox Company, Beaver Falls,
Pennsy Ivan ia •
'Dear Mr.; R'i ley: ; •
An on-site presurvey of the air pollution control facilities serving three
shops of the Babcock and Wilcox Company, Beaver Falls, Pennsylvania, was
conducted, by Mr. C. E. Riley of the Environmental Protection Agency and
Mr. J. W. Davison of Roy F. Weston, Inc. on-21 September 1972. The pre-
survey visit included a tour of shops one, two, and 'three and an examina-
tion of the five recently constructed baghouses located at these shops.
•Mr. L. T. Kaercher, Assistant Plant Engineer of Babcock and V/.i Icox,
represented the company during this presurvey visit.
The Babcock and V/i Icox Company's electric arc steel production facilities
consist of three separate shops in the Beaver Falls area. Shop number one
contains two twenty-five tons per day furnaces. The furnace fumes are
evacuated from the upper area of the building through an eight f oof square. . jj
duct by a 900 HP fen. The air flow is distributed through ten compartments
of the baghouse which is designed for 230,000 actual cubic feet per minute
of air flow. No ports have been installed before the inlet to the baghouse.
Sampling ports can be located in the duct at a point midway between the
building and the fan inlet. Scaffolding will be necessary to allow sampling
at this point which is approximately forty feet from the roof of an adjacent
bui Id ing. .-•
K-1
-------
ROY F. WESTON. INC.
e-NVtrJTnL SCilSMTlSTIT. AND ElMGrrJCCRS
Environmental Protection Agency
Mr. ' Clyde E. .Ri ley -2- 27 September 1972
The ouLlet of the baghouse is provided with ten short metal stacks. The :
ten foot high stacks are five feet in diameter and are circular in the upper 1
four feet. However, the shape expands to five foot square at the roof level. '•
Two three inch ports are located at right angles to each other on the two ;
end stacks and in one other stack (No. 5). The other seven stacks have one \
port installed in each. Port location is poor because of the short stack 1
and additional sampling points will be required. The ports have been in-
stalled at an odd angle which will present probe entry difficulties. These
ports should be removed and rewelded on those stacks selected for sampling. :
A railing exists which will interfere with sample box movement. This ,
railing will have to be cut away at the sampling locations and support i
scaffold! ng wi 1 1 be necessary for the sample boxes. Each stack is equipped ,
with a rain cap. Mr. Kaercher indicated that he would be reluctant to re-
move these rain caps for sampling purposes, '
I
Shop number two houses one fifty tons per day furnace and one seventy-five !
tons per day furnace. Two 900 HP .fans, .remove the fumes from the shop J
through two ducts. A si ng le
from the roof will be necessary to reach the center point of the duct for •
sampling. . i
. s
The six metal stacks are similar in shape to those on baghouse one, j
••(circular to square) and have double ports Insta 1 led .only, on- the end . j
stacks. Some ports will have to be relocated and additional ports will . j
be necessary. Scaffolding wi 1 1 have to be erected to support the sampling j
equipment. . j
Shop number three (Kopper Works) is located several miles distant from I
shops one and two. One fifty ton furnace, one seventy-five ton furnace, j
and three one hundred ton furnaces are operated within the shop. Three 1
baghouses clean the 1,700,000 actual cubic feet of air drawn from this |
shop. Baghouses number three and four are located within the same j
structure, while baghouse five is situated a considerable distance away
at the other side of the shop.
Baghouse three air flow is directed through a twelve feet diameter duct
through two fans into ten compartments. Number four baghouse air flow
is drawn from a separate vent in the shop roof and also distributed to
K-2
-------
•\
-ROY P. WESTON. INC.
Environmenta1 Protection Agency
Mr. Clyde E. Riley .
-3-
27 September 1972
to ten compartments. The duct diameter is fourteen feet. Both ducts have
long runs so that a choice of port installation will only be influenced by
the most practical scaffolding construction location. Perhaps a single
run of scaffolding can be positioned between both ducts to accomplish
slmul taneous . samp 1 i tig.
Simultaneous sampling wi11 be necessary
stacks serve two cornpartrnents; one each
baghouses. . • .
because each of the ten outlet
for number three and number five
The outlet stacks are ten feet high and ten and one half feet in diameter.
The shape is circular to square and the installed ports will not be adequate
in number or position on the stacks; Scaffolding will be necessary for
sampling. Al1 stacks have rain caps. Baghouse number three air flow is
1*60,000 ACFM and baghouse four is 600,000 ACFM. The temperature of the
air is 150°F and the stacks are under positive pressure.
Baghouse number five also receives air flow from shop three through a
separate fourteen feet diameter duct. Ports will have to be installed in
this duct and scaffolding erected before sampling can be accomplished. The
design flow to baghouse is 600,000 ACFM.. Seven ten feet diameter stacks on
baghouse five are also circular to square shape. Ports are not positioned
correctly and additional ports are needed. Rain caps are on all stacks.
Scaffolding will be necessary.
The emission from all stacks of the five baghouses wi.l 1 be essential ly air
at from 110 F to 150 F with approximately two percent moisture content.
"Particulate loading will be very low and v/ill necessitate sampling tests
of long duration (probably four hours). In.all cases at the stack locations,
the sample port location does not meet the eight diameters criteria and
additional sampling points will be necessary. The principle contact at
Babcock and Wi Icox wi 11'. be Mr. Leo T. Kaercher and can be contacted at
^12-8^6-0100. This report, along with the preliminary survey forms and
drawings, includes all of the pertinent observations and data gathered
from the presurvey visit. If you should have any questions or desire more
detailed information, do not hesitate to call us.
. . Very truly yours,
J7-Marks
Group Manager
Laboratory Services
James W. Davison
Satnpl ing Supervisor
JWD: PJM: 1 m
Enclosure
K-3
-------
PRELIMINARY SURVEY
Hame of Company
6/?gCOCK
UJlLCQX CO.
Address
F4UIS
Name of Contacts ^£0 T. k#g
-------
Page 2
PRELIMINARY SURVEY
jssumed Constituents of Stack Gas for Each Sampling Site
possible Testing Sites (1)_
2)
3)
Can Samples be Collected of:
a. Raw Mater ials
b. Control Equipment Effluent
c. Ash
d. Scrubber Water
Signature Required on Passes
*re the Following Available at the Plant?
a. Parking Facilities
b. Electr ician
c. Electric Extensions
d. Safety Equipment
e. I ce
f. Disti1 led Water
yes
e. Product
f. Fuel
g. Other
g.
h.
Clean-up Area C/f\
Lab. Faci1i t i es *"*
SamplIng Ports
Scaffold i ng
Rope
Equ i pment
Elevator
K-5
-------
Electricity Source
a. Amperage per circuit
b. Location.of fuse box
c. Extension cord lengths
.d. Adapters needed?
Safety Equipment Needed
a. Hard hats '
b. Safety glasses •
c. Goggles
Page 3
PRELIMINARY SURVEY
•SO
•Ice
a. Vendor
b. Location
Sampli ng Ports
a. Who will provide
b. Size opening
Quant i ty
yes
d. Safety.shoes
e. Alarms
f. Other
Welder:
AfL
3 '*-.
"
i. Scaffolding
a. 'Height t> \f££tt*ST
b. Length
i. Motels
a.
is chose
-------
Page k
PRELIMINARY SURVEY
Restaurants
a . Near PI ant
b. Near-Motel V6-S
8. Airport Convenient to Plant P ifTS f3C/C6 ^ _^_ Distance_
Comments:
SURVEY BY:
K-7' -
-------
STACK DATA
Properties of
3urpose of stack
Height ft.
Width ft.
Length ft. Port Height
Diameter ft. 1 .D.
Via 1 1 th ickness i n.
Material of construction
Ports: a. Existing
b. Size opening
c. Distance of
1 Platform
Straight distance before
port
Type of restriction
Environment
Work Space
Ambient temp. °F
Avg. pi tot readincLHgO, -i n Hg —
Stack velocity F/M
S-6H4 flZPt^
Moisture % by volume
Stack temperature °F
'articulate loading gr/SCF
'artic le . s ize
3ases present
Stack pressure H?0 in llg
•later sprays
)i lution air
Elevator
GA£h»»>J*
-&to*€4*F NO 1
1 o stVkks
9'
/.o'
— .
f.o'
VM "
M£T»L
a o/j 3
1 0*» 7
*.s"
11,"
*'
efli^ C/JP
Oyroooes
3IAT^O«M
^°
0. II"
1330
*J 6 0,OOO
1 t.
»5Z)°
0.00*
;o-4"» AA.
/>l^
II
A/0
A;O
A;O
SflCAmfi <».^*"
Stock— Ho- —'r
7 Vfrt-C K-S
-?x
/o.ox
—
/ft o'
'A/ "
rj£r/9L
Z 0*> 3
1 OAJ
•3fr"<7i.rtrf0
K-8
-------
T''*
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K-9-
RFW 227- 8—68
-------
DATE.
EOV F. WGSYQN
SVEST CHESTER. PENNSYLVANIA
P R O J E C 7
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W'.G. MO
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WEST CHESTCR. PENNSYLVANIA f..,,(.,;r
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K-11
-------
I ••' i
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' /• •• '..- • \ .•'' •
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' '>- -V-\.v "V"~ ' '• V -V A
-------
APPENDIX
-------
APPENDIX L
SINGLE SOURCE
SUMMARY OF TESTING COSTS
Company tested Babcock and Wilcox Company
(Name)
Beaver Fa 1 1 s
Pennsylvania
Testing Dates
(City)
October 17, 1972
(State)
thru October 20, 1972
Travel
Setup/cleanup
Field testing
Laboratory analysis
Report writing
Planning/administration
TOTAL
Overhead
Fixed Fee
(Month, day, year)
Manhours
125
394
579
;is kj
160
ration kO
1,345
(Month, day, year)
Cost
dollars
$ 594
1,806
3,447
267
815
437
$7,366
$9,355
500
Note: Does not include Direct Expenses,
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