EPA PROJECT REPORT NUMBER 74-CKQ-l
CD
O
U. S. STEEL CLAIRTON COKE WORKS
Clairton., Pennsy 1 vania
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Waste Management
Office of Air Quality Planning and Standards
Emission Measurement Branch
/ Research Triangle Park. North Carolina
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U. S. STEEL CLAIRTON COKE WORKS
CLAIRTON, PENNSYLVANIA
74-CKO-1
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TABLE OF CONTENTS
Section Page
I Introduction . . 1
II Results " 1
III Process Description and Operation 2
IV Procedure 2
V Appendices H
1. Field Data: Charging Emissions
2. Field Data: Topside Inspection
3. Process Description:
Stage Charging-Clairton Works
4. Test Procedure
5. Participants
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I. Introduction
During the period of May 6-9, 1974, emission tests were con-
ducted at the U. S. Steel Clairton Coke Works, Clairton, Pennsylvania.
Under the direction of Reid Iversen of the U. S. Environmental Pro-
tection Agency (EPA), three inspectors similtaneously observed the
coke oven charging operations. The purpose of the tests was to deter-
mine the total time during which visible emissions were emitted from
the charging ports and/or hoppers during the actual oven charging opera-
tion; the emissions were not quantified in terms of percent opacity.
In addition to observing the charging emissions, the observers performed
numerous "Topside Inspections" which involved walking the length of the
coke battery and noting which ovens had visible emissions leaking from
oven lids and/or standpipes. The oven numbers and points of emissions
were recorded.
Various plant personnel and other observers were present during
the test period; a complete list of those persons is presented in
Appendix V.
II. Results
The inspectors observed the charging on batteries 1-3 upon the
recommendation of U. S. Steel personnel; they indicated that these
batteries would have the least emissions during charging. Table 1 is
a test log indicating on which oven batteries the inspectors were ob-
serving, as well as the number of charges observed each day.
Table 2 is a tabulation of the total time each inspector observed
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visible emissions for each charge. The field data sheets are found
in Appendix I. Appendix II contains the data sheets for the topside
inspections.
III.Process Description and Operation
Table 3 lists the design parameters of Coke Batteries 1-3.
Appendix III contains an article, prepared by U. S. Steel personnel,
which explains the stage charging process at the Clairton Works.
During the testing, coke batteries 1, 2, and 3 were operating in
a normal manner. Table 4 lists the operating conditions during the
test period. Table 5 lists the coal mixes and analyses for the testing
period.
IV.Procedure
The observers situated themselves on top of the coke battery such
that they had a clear view of all four charging hoppers and ports of
the oven being charged. One stopwatch was used to time the period of
visible emissions; a second stopwatch was used to time the charge period.
On the first day of observations, the inspectors simply recorded the
total time of visible emissions for each charge. On the' second, third,
and fourth days of observations, in addition to recording the total time
of visible emissions, the observers indicated what portion of these
emissions were observed prior to leveling of the charge. The moment the
leveling began was determined by listening for a buzzer blown by the
larry car operator or by watching the leveling bar.
The test method used is presented in Appendix IV.
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TABLE 1
Test Log
Date
5/6/74
5/7/74
5/8/74
5/9/74
Time
1230-1600
850-1120
1250-1530
850-1125
1245-1550
840-1115
1300-1505
Battery Number
1,2,3
2,3
1,2
2,3
2,3
1,2
3,2
Number of
Charges
Observed
21
14
17
14
18
14
16
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TABLE 2
Summary of Visible Emissions
Date
Oven/Battery
Total Period of Visible Emissions
(Seconds)
5/6/74 A30/1
B30/1
A3 0/2
B30/2
A30/3
B30/3
Cl/2
AT/3
Bl/3
Cl/3
B3/2
A3/3
B3/3
B5/2
A5/3
B5/3
B7/2
A7/3
B7/3
B9/2
°A9/3
5/7/74 . B9/2
A9/3
B9/3
BIT/2
All/3
Iversen
n
22
4.5
3
8
15
16
5
11
5
14
13
3
20
3
8
8
17
12
4
13
26
25
3
20
11
Neulicht
31
25
2
4
14.5
15.5
18.5
23.5
48
16.5
35
22
16
27
19
14
11
28.5
21
16
27
32
14
2.5
25
15.5
Smith
13.5
18
10.5
11.5
11
6
16
4
10
5
8
3
14
10
6
3.5
8.5
20
11
11
16
17.5
67
7
9.5
6
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-Date
TABLE 2
(Continued)
-Summary of Visible Emissions
•Oven/Battery
-Total Period of Visible Emissions
(Seconds)
5/7/74 Bll/3
B13/2
A13/3
B13/3
B15/2
A15/3
B15/3
B17/2
Al 7/3
A21/1
B21/1
A21/2
A23/1
B23/1
A23/2
A25/1
B25/1
A25/2
A27/1
B27/1
A27/2
A29/1
B29/1
A29/2
A31/1
. B31/1
5/8/74 A31/3
B31/3
Iversen
- 16.5
17
13.5
8
10.5
16
19.5
10.5
14
14
42
15
18
105
12
15
12
14
18
27
14
15.5
14
18
13
10
2
19
Neulicht
14
23
18 .
3
-
19
20
19
15
-
49
15
24
108
16
17
9
13
22
33
14
17
16
24
13
13
4
-
Smith
6
8
8
5
11
7
9
5
6
-
-
12
30
8.5
7
10
7
6.5
12
10
12
24
20
34
21
19
4
16
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Date
TABLE 2
(Continued)
Summary of Visible Emissions
Oven/Battery
Total Period of Visible Emissions
(Seconds)
5/8/74. B2/2
C2/2
A2/3
B2/3
C2/3
B4/2
A4/3
B4/3
B6/2
A6/3
B6/3
B8/2
BIO/3
B12/2
A12/3
B12/3
B14/2
A14/3
B14/3
B16/2
A16/3
B16/3
B18/2
AT 8/3
Bl 8/3
B20/2
A20/3
B20/3
Iversen
74
76
23
17
79
15
19
16
16
36
18
15
-
-
18
20
12
15
14
16
20
11
12
13
14
-
-
-
Neulicht
-
-
-
15
82
16
27
15
13
27
20
8
5
9
17
-
7
24
14
15
10
8
13
15
21
-
17
14
Smith
17
64
21
16
60
-
22
18
6
25
13
- '•
-
9.5
5
11
5
10
9.5
.
12
7.5
37
-
-
28
14
16
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TABLE 2
(Continued)
Summary of Visible Emissions
Date
Oven/Battery
Total Period of Visible Emissions
(Seconds)
5/8/74 B22/2
A22/3
5/9/74 A22/1 .
B22/1
A22/2
B24/1
A24/2
A26/1
B26/1
A26/2
A28/1
B28/1
A28/2
A30/1
B30/1
A30/2
Al/1
Bl/1
Cl/1
Al/2
Bl/2
A3/1
B9/1
A9/2
B9/2
All/1
Bll/1
All/2
A13/1
B13/1
A13/2
B13/2
Iversen
-
-
13
12.5
23
28.5
14
5
9
13
6.5
12.5
12
20
7
14
20
12
9.5
12
17
21
74.5
-
12
10
85
13
13
2
-
20
Neulicht
18
13
10 '
15
32
29
4
4
8
11
13
11
12
15
1
22
-
-
' -
-
-
-
18
-
7
95
-
12
6
• 27.
. • '-
Smi th
16.5
19
16
13
12
25
9
5
9
20
6
11
15
18
12
10.5
.
-
-
-
-
-
-
-
-
-
-
-
-
'
-
-
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TABLE 3
COKE: OVEN1 DESCRIPTION.
PLANT
TYPE OF OVEN
NUMJLR in' ii.-I
BATTERY NO. 0
NUM^-R OF OVE.
DATE OF TNITI.
DATE OF LAST
DATE OF LAST 1
HOT DIMENSIONS
•
&,
c
H
U
3
cs.
OVEN
WIDTH
OVEN
LENGTH
OVEN
HEIGHT
CAI.CULAT
•
SUPPiJER
HEATING SYSTEM DESIGN
FUEL 'GAS US.: D
1'ERl Eo OF EACH TYPE
I OTH!--; DESIGNATION
:S .EACH BATTERY
\L OPERATION
FLOOR UP RE CHILD
\\D UP REiJUELD
COKE SIDE
PUSHER SIDE
AVERAGE
TAPER
BETWEEN DOORS
FACE TO FACE BRICKWORK
FLOOR TO ROOF
FLOOR TO COAL LINE
FREE SPACE ABOVE COAL
FLOOR-TOP OF HORIZONTAL FLUE
ZD CAPACITY CU. FT. OF COAL
TOP OF OVEH TO BATTERY TOP
PAD TO OVEN FLOOR
CENTER TO CENTER HEATING WALL
A"C . 1 "'"' '
LINER BR
Claircon
Wilnutte
Sir/'lo -Divided
Coke Oven Gir.
3
1,2,3
64
1918(1-2-3)
-
1955(1-2-3)
20-1/4"
17-1/8"
18-11/16"
3"
37' - 4-1/2"
. 40' - 0-1/2"
11' - 10-1/4".
10' - 0-3/8"
13"
9' - 11-1/8"
626.29
V - 7-3/4"
10' - 7-1/4" •
3' - 9-1/V
_, . . , ^ r^ ... , T . .. _ , _ v . -,.^ T. p . -ii _ 1 1 ,n
..'.. ^ '-."•- ^ « :. •'.--\iJL> ^ 1.1 .-, x. ^Jiv... w .^ | J J i'
ICK DENSITY
OVEH FLOOR
OVEN JAM
REG EN ERA
(..''. ;-..\ DOi;
• r " IT;? r : ' <
j i- -\ U- ^ I., w
AUX. END FLUE
NUMBER OF GAS
NUMBER OF AIR
CiLARGING
HOLES
NUMBER OF COL
INSIDE D I AM El
NUM3ER OF HAT
TYPE OF OVE;;
NUMBER OF OVE
ui
X
o
K-J
E-
O
TYPE OF
DOOR CLE
J,V-:H CLE
LEVF.i F'R
33
TOR WALLS
K LiNINGS
LO Ii'i 1;!:.AIINC. WALL
HEATING SYSTEM
•'ORTS EACH FLUE
PORTS EACH FLUE
NUMBERS PER OVEN
DIAMETER
LECT1NG J-LMNS - POSITION
ER OF STAN!) PIPE
i'KRY CROSSOVER MAINS
POORS
::S PER OFERAT1NG UNIT
REVERSE MACHINE
ANERS
A::ERS
DOOR ACTIVATORS
LID !. I .--:••:•!: 5
ELK3W CLEAN'-X.S
CHARGING
PUSHING
"iV-'E OF
CAR EMISSION'S COinROL
EMISSIONS CONTROL
LA:1./, L C. '•..'. r E r.'''
Hi:;i! L;;J i;,ir.iLi.i.::f; ^::>\. ' .
112/-7cu.£t.
Clay
Silica
Si lica
Brick
28
.
1
1
4
• 14"
2
13"
2
. Scli-So-nling
192
Mechanical
-
-
-
'
-
Stage Charging
Good Operating Practice
'Cir.vicy j
A i c -^vs t'.-.r
1
Information from letter of 9/6/74 fi"om John G. Munson, Assistant to Vice
President of U. S. Steel, to Reid Iversen, EPA.
-' :' 8 ' :-
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TABLE 4 '
PROCESS INFORMATION
Typical Readings for Underfiring Controls
Batteries
Dates
Gas Volume
Gas Pressure
Waste Heat
Stack Draft
cu.ft./hr.
mm- H?0
PS °Fahr.
PS mm FLO
May
1-2-3
6-9, 1974
286,000-335,000
139-174
320-370
17-18
Typical Flue Temperatures
Date
5-6
5-7
5-8
5-9
Avg.
#1
P.S. C.S.
2629 2699
2616 2699
2610 2698
2610 2689
2616 2696
Batteries
•#2
P.S.
2612
2607
2618
2606
2611
1-2-3
C.S.
2691
2683
2700
2683
2689
P.S.
2595
2605
2595
2601
2599
#3 '
C.S.
2689
2702
2690
2700
2695
Typical Oven Pressure
Average + 4 mm FLO
Production
Date Ovens charged/day
Scheduled production 270
5/6/74 255
5/7/74 258
5/8/74 259
5/9/74 270
Information from letter of 9/6/74 from John G. Munson, Assistant to Vice
President of U. S. Steel, to Reid Iversen, EPA.
•9
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TABLE 5"1
COAL MIXES AND ANALYSES
Batteries 1-2-3
May 6-9, 1974
COAL MIXES
5-6
5-7
5-8
5-9
31% Robena
31% Robena
31% Robena
31% Robena
24% Maple Creek
24% Maple Creek
24% Maple Creek
24% Maple Creek
25% Low Vol
25%,.Low Vol
25% Low Vol
25% Low Vol
20% Special
20% Special
20% Special
20% Special
Date
5-6
5-7
5-8
5-9
Avg.
H2°
7.6
6.6
7.1
7.4
7.17
Ash
00
90
7.
6.
6.75
7.10
6.94
Blend Analyses
Bulk
Sul. Dens.
1.32
1.29
1.26
1.27
1.28
52.6
52.7
52.6
52.6
52.6
+.500"
4.6
4.6
2.2
3.0
Screen Size
+.250"
16.0
14.7
15.1
15.3
(- ) .125"
61.7
62.4
65.8
64.2
3.6
15.3
63.5
Information from letter of 9/6/74 from John G. Mimson, Assistant to Vice
President of U. S. Steel, to Reid Iversen, EPA.
10
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