TEST NUMBER 73-ROC-2
INTERNATIONAL MINERALS AND
CHEMICAL CORP.
NORALYN, FLORIDA
PEDCo ENVIRONMENTAL
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TEST NUMBER 73-ROC-2
INTERNATIONAL MINERALS AND
CHEMICAL CORP.
NORALYN, FLORIDA
Prepared by
Normal Kulujian, P.E.
Richard W. Gerstle, P.E,
Contract No. 68-02-0237
Task No. 19
PEDCo-Environmental Specialists, Inc.
Cincinnati, Ohio
June 1973
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I.. TABLE OF CONTENTS
Page
II. INTRODUCTION 1
III. SUMMARY OF RESULTS 3
IV. PROCESS DESCRIPTION 7
V. PROCESS OPERATION 10
VI. LOCATION OF SAMPLING POINTS 11
VII. SAMPLING AND ANALYTICAL PROCEDURES 14
Set Up Procedure 14
Preliminary Traverse and Moisture 14
Gas Velocity and Temperature 15
Molecular Weight and Gas Analysis 15
Particulate Sampling 15
Sample Storage 17
VIII. APPENDIX
A. COMPLETE PARTICULATE RESULTS WITH EXAMPLE
CALCULATIONS
B. PROCESS .OPERATIONAL LOG
C. FIELD DATA
D. SAMPLING PROCEDURES
E. LABORATORY REPORT
F. SAMPLE NUMBER LOG
G. TEST LOG
H. SAMPLE HANDLING LOG
I. PROJECT PARTICIPANTS AND TITLES
J. PRESURVEY REPORT
11
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II, INTRODUCTION
Under the Clean Air Act of 1970, as amended, the Environ-
mental Protection Agency is charged with the establishment
of performance standards for stationary sources which may
contribute significantly to air pollution. A performance
standard is based on the best emission reduction systems
which have been shown to be technically and economically
feasible. . '
In order to set realistic performance standards, accurate
data on pollutant emissions must be gathered from the stationary
source category under consideration.
Atmospheric emissions of particulate and fluorides from
the International Minerals and Chemical Corporation (IMC) rock
grinding operation in Noralyn, Florida were sampled to establish
a guide for New Source Performance Standards as authorized by
the Clean Air Act of 1970. Triplicate tests were made to
determine particulate concentrations at the inlet and outlet of
the rock grinder.. The three tests Were made February, 1973.
Stored rock is transferred to a mill by a conveyor belt.
Different ducts are used for the ground product and exhaust gases
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from the mill. The exhaust gases are cleaned in a baghouse.
The cleaned exhaust is pulled up through the stack by an induced
draft fan. The material caught in the baghouse is recycled
back to the milling operation.
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III. SUMMARY OF RESULTS
Table 3.1 presents the overall test summary of the three
particulate tests in U.S. and metric units. Results from the
three tests were averaged to obtain values in Table 3.1.
Results from each individual test are summarized in Table 3.2.
The rock grinding operation is enclosed in a building, so
both inlet and outlet sampling sites were under cover. A clean
up area was not available, so the samples from the test trains
were transferred to containers in a mobile van.
The reagent in the Orsat apparatus produced questionable
exhaust gas analyses, so values of ambient air were assumed for
calculations. Since the air entering the milling operation
experiences no change (i.e. combustion), the assumption of
atmospheric properties is valid.
The inlet site consistently had a higher flow rate than
the outlet site; values for the three tests ranged between 16 and
18 percent greater. A leak through the ducting, control device,
or dampers may have accounted for the loss.
The high isokinetic value for the Run No. 8 inlet test
resulted because the improper nozzle size was used. A comparison
of the inlet and outlet catch reveals that while the maximum
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dust from the three tests was caught at the outlet site
(Table 3.2), the inlet sample was the smallest of the three
catches. Therefore the data from the second test (Run No. 8)
was not averaged in Table 3.1 values.
A minor process upset also occurred during Run No. 8,
when a large wooden object jammed the mill. The wood was
removed and the mill was back in operation within ten minutes.
The various types of feed are discussed in Section V.
Raw materials and product samples were taken during the tests.
It was impossible to get a baghouse catch sample because there
was no access opening.
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Table 3.1 OVERALL SUMMARY OF RESULTS FROM PHOSPHATE ROCK GRINDER
Pollutant
Measurement
System
Volume of Gas Sampled
Percent Moisture by Volume
Average Stack Temperature
Dry Stack Volumetric Flow Rate
Actual Stack Volumetric Flow Rate
Percent Isokinetic
Feed Rate
., Partial Catcha
Weight
Concentration/Dry Volume
Concentration/Actual Volume
Concentration/Time
Lb/ton, Feed Concentration/
Input Feed Rate
Total Catch
Weight
Concentration/Dry Volume
Concentration/Actual Volume
Concentration/Time
Lb/ton, Feed Concentration/
Input Feed Rate
Percent Impinger Catch
Units
U. S.
DSCF
%
oF
DSCFM0"
ACFMd
%
Ton/hr
mg
gr/DSCF
gr/ACF
Ib/hr
Ib/ton
mg
gr/DSCF
gr/ACF
Ib/hr
Ib/ton
%
Metric
DNm3e
%
°C
DNm /sec
M3/secq
%
Mton/hr
mg
mg/DNm3
mg/m3
kg/hr
kg/Mton
mg
mg/DNm3
mg/m^
kg/hr
kg/Mton
%
Particulate
. U. S.
' Inlet"
61.564
5.98
202
2996
3931
104.2
34.5
12915
3.246
2.473
83.03
2.399
12949
3.255
2.480
83.25
2.405
0.25
Outlet
114.743
5.97
161
2708
3312
98.4
35.0
48.0
0.00647
0.00529
0.150
0.0042
100.6
0.01358
0.01110
0.314
0.0089
50.6
u Metric
Inlet"
1.7433
5.98
94.2
1.414
1.855
104 . 2
31.3
12915
7427
5658
37.66
1.199
12949
7446
5673
37.76
1.203
0.25
Outlet
3.2492
5.97
71.5
1.278
1.563
98.4
31.7
48.0
14.8 '
12.1
0.0679
0.0021
100.6
31.08
25.40
0.142
0.0044
50.6
a) Partial catch includes probe, cyclone and filter.
b) Dry standard cubic feet at 70°F, 29.92 in. Hg.
c) Dry standard cubic feet per minute at 70°F, 29.92 in. Hg.
d) Actual cubic feet per minute.
e) Dry normal cubic meters at 21.1°C, 760 mm Hg.
f) Dry normal cubic meters per second at 21.1°C,
760 mm Hg.
g) Actual cubic meters per second.
h) Second inlet test (Run No. 8) not included in
averages.
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Table 3.2 PARTICULATE EMISSION DATA SUMMARY
IMC Corp., Noralyn, Florida - Rock Grinder Operation
Run
Date
Volume of Gas Sampled-DSCFa
Percent Moisture by Volume
Average Stack Tempera ture-°F
Stack Volumetric Flow Rate-
DSCFMb
Stack Volumetric Flow Rate-
ACFMC
Percent Isokinetic
Feed Rate-ton/hr
Particulates-probe, cyclone,
and filter catch
mg
gr/DSCF
gr/ACF
Ib/hr
Ib/ton feed
Particulates , total catch
mg
gr/DSCF
gr/ACF
Ib/hr
Ib/ton feed
Percent impinger catch
Inlet
7
2-16-73
60.401
6.07
203
2916
3835
105.0
36.0
14513
3.708
2.820
92.686
2.574
14556
3.719
2.828
92.961
2.582
0.3
8
2-16-73
59.022
5.91
205
2903
3822
213.8
36.0
10303
2.694
2.048
67.027
1.861
10332
2.702
2.052
67.216
1.867
0.3
9
2-16-73
62.728
5.89
200
3075
4026
103.4
33.0
11316
. 2.784
2.126
73.373
2.223
11342
2.790
2.131
73.542
2.228
0.2
Outlet
7
2-16-73
114.965
5.32
161
2720
3295
98.2
36.0
63.3
0.00849
0.00698
0.198
0,0055
111.0
0.01490
0.01224
0.347
0.0096
43.0
8
2-16-73
112.393
6.05
161
2654
3256
98.3
36.0
47.8
0.00656
0.00535
0.149
0.0041
130.0
0.01784
0.01455
0.406
0.0113
63.2
9
2-16-73
. 116.870
6.53
160
2751
3386
98.7
33.0
33.0
0.00435
0.00354
0.102
0.0031
60.7
0.00801
0.00651
0.188
0.0057
45.6
a) Dry standard cubic feet at 70°F, 29.92 in. Hg.
b) Dry standard cubic feet per minute at 70°F, 29.92 in. Hg.
c) Actual cubic feet per minute.
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IV. PROCESS DESCRIPTION
A phosphate rock plant flow diagram, shown in Figure 4.1,
illustrates the steps of the process in relation to the grinding
operation. After the phosphate rock is mined and dried, it is
ready to be ground.
The Noralyn, Florida IMC plant uses the swept air principle
of grinding the phosphate rock. A picture of the grinding
operation is shown in Figure 4.2. Each of three mills can
process approximately 35 tons of rock per hour. The velocity
of the air through the Raymond Mills governs the particle size
of the ground rock. The ground product is fed to a rail car
where it is shipped to fertilizer or elemental phosphorus
plants. Exhaust gases pass through a baghouse and an induced
draft fan before being emitted to the atmosphere. The baghouse
collection hopper is ducted back to mills, recycling the caught
particles.
Two different milling configurations were present at the
Noralyn plant. These are discussed extensively in Appendix C.
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cc
HIGH PRESSURE
WATER
DRAGLIf!E
RECOVERY PLANT
OVERBURDEN .:-
•; BEDROCK :.-.>XN'-'* <\V-^ '
I I
DRY ROCK STORAGE
J
DRY
ROCK
SHIPPING
GROUND ROCK
SHIPPING
WET ROCK STORAGE
AND RECOVERY
'igure 4.1 Phosphf.te rock flow sheet.
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PRODUCT
RAYMOND
MILL
CONTROL
DAMPER
BAGHOUSE
C) CONVEYOR
STACK HAD COVER
NO VISIBLE EMISSIONS
G. RILEY SAW SOME BEFORE TEST STARTED
ROOF
Fiaure 4.2 Diagram of phosphate rock grinder at IMC plant, Noralyn, Florida
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V. PROCESS OPERATION*
During the testing, process operations of the Noralyn
rock grinding mill No. 4 were monitored by Mr. J. Peoples of
EPA. Mr. Peoples collected process data and communicated
to the testing crew any upsets or abnormalities during the
testing periods.
Feed and grinding rates are based on estimates obtained
from IMC plant personnel and observed loading rates of railroad
cars (Appendix C contains detailed comments recorded during
the testing periods).
Particulate tests were conducted on February 16, 1973 at
the No. 4 rock grinder unit. The sampling began at 11:25 A.M.
The material processed during the first and second run was a
65-200 grind (65% through a 200 mesh screen). A 90-100 grind
was produced during the third run. The testing was completed
at 7:45 P.M. Raw materials and product samples were obtained
during all of these tests. No process upsets occurred during
Runs 1 and 3. However during Run 2 testing had to be delayed
twice due to operational difficulties. The opacity of the
grinder stack was less than 10% opacity during the testing
periods.
*Written and supplied by EPA.
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VI. LOCATION OF SAMPLING POINTS
A section 24 inches upstream from the entrance to the
baghouse was the best inlet sampling site. The 11.75 inch
diameter duct had a 45 degree bend approximately 42 inches up-
stream of the sampling site. A diagram of the rock grinding
inlet and sampling points is shown in Figure 6.1.
Since the inlet sampling location was only about 3.6
diameters downstream of the duct bend, 28 traverse points were
chosen. The project officer approved the number of sampling
points and a test duration of 84 minutes (3 minutes per point).
Two sample ports were installed on the west side and
bottom of the horizontal duct. The sample box was placed
on a variable set of jacks when sampling the vertical traverse
points.
Two possible outlet sampling sites were considered,
one inside the building and one on the roof. The inside
site was chosen so both inlet and outlet sampling team
could coordinate the tests. The chosen sampling site was
less than one foot from the roof and approximately four feet
below the top of the stack as shown in Figure 6.2. Sampling
ports were cut from the narrow side of the 12 in. x 14 in.
rectangular stack. Six sample points were chosen on four
traverse locations; the 24 points were sampled for five
minutes each, or 120 minutes per test. The draft fan was the
nearest upstream obstruction, 64 inches from the sampling site,
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11 .75" ID
ii
f\
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•<—
\
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LA
4? " >
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ALL DIMENSIONS
IN FEET ARE .
APPROXIMATE
WALKWAY —
LOOKING NORTH
LOOKING WEST
-0.10"
SECTION AA
POINT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
TRAVERSE
DISTANCE,
INCHES
1 .0
1 .0
1 .0
1 .7
2.4
3.2
4.3
7.5
8.6
9.4
10.0
10.7
10.7
10.7
Figure 6.1 Diagram of rock grinder inlet and sampling points
12
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ITLET
IMPLING
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SECTION AA
PLATFORM
/-AND BUILDUP
/ FOR SAMPLE BOX
TRAVERSE
DISTANCE,
POINT INCHES
1 1.0
2 3.0
3 5.0
4 7.0
5 9.0
6 11.0
\
EXISTING STRUCTURE
ALL DIMENSIONS
IN FEET ARE
APPROXIMATE
Figure 6.2 Diagram of rock grinder outlet and sampling points.
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VI. SAMPLING AND ANALYTICAL PROCEDURES
All particulate sampling procedures were similar to
Method 5 as defined in the Federal Register. The contractor
performed all testing and sample recovery operations; collected
samples were analyzed by EPA personnel. The inlet and outlet
sampling crew consisted of two man teams which included a
probe and meter technician.
Set Up Procedure
The inlet and outlet trains were set up in a routine
fashion. In both cases the sample box and meter box were
within 15 feet of each other.
Preliminary Traverse and Moisture
A preliminary velocity traverse at the inlet and outlet
location determined approximate nozzle sizes and isokinetic
sampling conditions. A 0.180-inch I.D. nozzle was used for
inlet testing while the outlet was sampled with a 0.277 inch
I.D. nozzle. The wrong nozzle (0.125 I.D.) was inadvertently
placed on the probe for the second inlet test (Run 8). This
resulted in a high isokinetic sampling rate.
The inlet stack gas moisture was determined by a train
similar to Figure 4.2, Federal Register/ Volume 36, No. 247,
page 24887. A wet and dry bulb thermometer was used to calculate
outlet flue gas moisture.
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Gas Velocity and Temperature
Velocities were measured at each sampling point across
the stack diameter to determine an average value according to
procedures described in the Federal Register. Gas flow
temperatures were measured by long stem dial thermometers.
Molecular Weight and Gas Analysis
The flue gas was assumed to have a composition and molecular
weight similar to atmospheric air. The values were used to
determine isokinetic sampling rates.
Particulate Sampling
Particulate matter was isokinetically sampled from the
drying operation with a train shown in Figure 7.1. The train
consisted of a stainless steel nozzle, a heated glass probe,
a heated glass fiber filter, and four impingers connected in
series with glass ball joint fittings. The first two impingers
contained 100 ml of water each, the third impinger was left
empty and approximately 200 grams of preweighed silica gel were
placed in the fourth impinger.
In all cases sampling was conducted under isokinetic
conditions by continually monitoring the velocity with a pitot
tube and adjusting the sampling rate accordingly.
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FILIER HOLDER
STACK V/ALl
THERMC.V.E fER
REVERSE-TYPE
PHOT IU3E
DRY TEST METER VACUUM PUMP
Figure 7.1. Particulate sampling train.
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Inlet concentrations were so heavy that several filter
changes were needed during each test to pull the proper amount
of air through the train. During the last inlet test (Run 9),
an impinger connector was broken while transferring the train
between sampling ports. Contents from the broken inipinger were
included in the acetone wash.
The train cleanup procedure consisted of measuring the
water collected and weighing the silica gel to determine
moisture content. The water was then poured into a glass
jar. The filter was removed and placed in a marked container.
The probe and front half of the filter holder were then rinsed
with analytical reagent grade acetone and the washings placed in
a glass container. The rear half of the train consisting of
filter holder, impingers, and connectors was rinsed with
distilled water and this water added to the impinger contents.
The rear half of the train was then rinsed with acetone and
placed in a third sample jar. A portion of the acetone and
distilled water used in the sample recovery were set aside and
used as blanks for analysis.
Sample Storage
All samples were placed in 1000 ml glass and polyethylene
containers and marked with EPA identification tags (see Appendix
F). The bottles were then put in wooden boxes with styrofoam
separators and hand delivered to EPA, North Carolina, after all
tests were completed.
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