lUIalden, SOURCE SAMPLING CONTRACT NO. 68-02-0238 TASK NO. 8 JOHN DEERE TRACTOR WORKS EAST MOLINE, ILLINOIS GREY IRON ELECTRIC ARC FURNACE Prepared for Emissions Measurement Branch Environmental Protection Agency EPA Project No. 74-GFE-2 Prepared by Walden Research Division of Abcor Inc. 201 Vassar Street Cambridge, Massachusetts 02139 (C-337-8) 201 Vassar Street D Cambridge Massachusetts C 02139 WALDEN RESEARCH DIVISION OF nuvui inc. Abcor, ------- I TABLE OF CONTENTS i I . Section Title Page I ' INTRODUCTION 1-1 i II SUMMARY AND DISCUSSION OF RESULTS 2-1 III ; PROCESS DESCRIPTION AND OPERATION 3-1 IV LOCATION OF SAMPLING POINTS 4-1 V SAMPLING AND ANALYTICAL PROCEDURES.... 5-1 A. PARTICULATE SAMPLING (EPA METHOD 5) 5-1 B.- SULFUR DIOXIDE (METHOD 6) 5-1 C. NITROGEN OXIDES (METHOD 7) 5-2 D. VISIBLE EMISSIONS (METHOD 9) 5-2 E. EPA COMPARISON PARTICULATE TESTS 5-2 F. CARBON MONOXIDE (METHOD 10) 5-3 G. HYDROCARBONS 5-3 APPENDIX I PARTICULATE TEST RESULTS AND SAMPLE CALCULATION 1-1 APPENDIX II SULFUR DIOXIDE TEST RESULTS AND SAMPLE CALCULATION...... II-l APPENDIX III NITROGEN OXIDES TEST RESULTS AND SAMPLE CALCULATION..... III-l APPENDIX IV CARBON MONOXIDE + HYDROCARBON TEST RESULTS IV-1 APPENDIX V COMPARISON PARTICULATE TEST RESULTS V-l APPENDIX VI FIELD DATA VI-1 APPENDIX VII STANDARD SAMPLING PROCEDURES VII-1 APPENDIX VIII LABORATORY RESULTS VIII-1 APPENDIX IX TEST LOG IX-1 APPENDIX X PROCESS DATA FOR STACK TESTING X-l n lUtAkni ------- I. INTRODUCTION Under the Clean Air Act, as amended, the Environmental 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 pollutants 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 within the various source categories. In the grey iron foundry industry, the No. 2 baghouse at John Deere Company located in East Moline, Illinois was designated by EPA as representative of a well-con- trolled operation, and was thereby selected for the emission testing program. This report presents the results of the testing which was performed at the East Moline facilities of John Deere during the period of July 8 through July 11, 1974. The tests performed were particulate, sulfur dioxide, nitrogen oxides, hydrocarbons, carbon monoxide, visible emissions, and EPA comparison parti- culate sampling tests taken after the No. 2 baghouse serving Mo.2 and No. 3 swinging roof electric arc furnaces at the John Deere Tractor Works, East Moline, Illinois. The tests were conducted by Wai den Research Division of Abcor, Inc. under the technical direction of EPA Project Officer, Joseph F. Peoples, Jr., and with the assistance of Environmental Science and Engineering, Inc. The process monitoring engineer for EPA was Naum T. Georgieff. The Walden test crew consisted of Lawrence Katzman, Program Manager, Richard Furman, Roland Hebert, Gary Pulliam, David Jessich, Roderic Taft, and Dennis Weder and Van Madden from STW Testing, Inc. John Bond and two other personnel from Environmental Science and Engineering, Inc. conducted the continuous testing for hydrocarbons and carbon monoxide. The tests included three three-hour runs designed to measure average emis- sion rates over the tap-to-tap cycle for both furnaces. The comparison parti- culate tests v/ere performed following completion of all other tests. Visible emissions observers v/ere not required under the original task order, however, the EPA Project Officer requested that opacity readings be added to the list of tasks. 1-1 ------- II. SUMMARY AND DISCUSSION OF RESULTS Tables 2-1 through 2-13 summarize the results of parti oil ate, hydro- carbon, carbon monoxide, sulfur dioxide, nitrogen oxides, opacity readings and EPA comparison tests performed on the No. 2 baghouse stack at the John Deere Tractor Works, East Moline, Illinois. Tables 2-1, 2-3, 2-5, 2-7, 2-9, and 2-11 give the tests results in English units, while Tables 2-2, 2-4, 2-6, 2-8, 2-10, and 2-12 give the tests results in Metric units. The particulate concentrations in Tables 2-1,2-2, 2-11, and 2-12 are given for the front half (particulate matter collected on the filter and all sample exposed surfaces prior to the filter) and the total particulate con- centration including the condensible portion of the sample catch. The nit- rogen oxide test results are given as twelve samples which consist of six runs taken on each of two days. The average visible emissions are given for the first three runs for both the baghouse stack and roof monitor vent above the furnaces. Hydrocarbons and carbon monoxide are reported every 6 minutes. 2-1 lUhUen, ------- TABLE 2-1 PARTICULATE SUMMARY ENGLISH UNITS ro i ro Run Number Date Volume of Gas Sampled-DSCF Percent Moisture by Volume Average Stack Temperature-°F Stack Volumetric Flow Rate-DSCFM Stack Volumetric Flow Rate-ACFM Percent Isokinetic Percent Stack Opacity Percent Roof Monitor Opacity Particulates - Probe & Filter Catch mg. gr/DSCF gr/ACF Ib/hr Particulates - Total Catch mg. gr/DSCF gr/ACF 'lb/hr Percent Impinger Catch 1 July 8, 1974 90.22 3.0 197 65,973 85,212 100.8 1.18 0.11 38.5 0.0066 0.0051 3172 . 63.8 0.0109 0.0084 6.17 39.7 2 July 9, 1974 93.36 2.8 171 69^,611 86,454 98.8 0.87 0.03 23.3 0.0038 0.0031 2". 26 38.6 0,0064 0.0052 3.81 39.6 i ' 3 i July 9, 1974 91.57 3.2 195 65,508 84,818 103.0 2.12 0.09 22.3 0.0038 0.0029 2.11 29.9 0.0050 0.0039 2.83 25.4 Average ~ 91.75 3.0 188 67,031 85,495 100.9 1.41 0.08 28.0 0.0048 0.0037 2.71 44.1 0.0074 0.0058 4.27 34.9 ------- TABLE 2-2 PARTICULATE SUMMARY METRIC UNITS rsj Run Number Date Volume of Gas Sampled-Nm9 Percent Moisture by Volume Average Stack Temperature-°C Stack Volumetric Flow Rate-Nm3/m1n Stack Volumetric Flow Rate-'m3/m1n Percent Isokinetic Percent Stack Opacity Percent Roof Monitor Opacity Partlculates - Probe & Filter Catch m9- , rng/Nnr mg/m3 kg/hr Partlculates - Total Catch mg. mg/Nm3 mg/m3 kg/hr n A. 9 J /% A- l_ Percent Implnger Catch 1 July 8, 1974 2.56 3.0 91.7 1 ,868 2,413 100.8 1.18 0.11 38.5 15.0 11.6 1.69 63.8 24.9 .19.2 2.80 39.7 2 July 9, 1974 2.64 2.8 77.2 1,971 2,448 98.8 0.87 0.03 23.3 8.8 7.2 . 1.04 . 38.6 14.6 11.9 1.72 39.6 3 July 9, 1974 2.59 3.2 90.6 1,855 2,402 103.0 2.12 0/09 22.3 8.6 6.6 0.96 29.9 11.5 9. 0 1.28 25.4 Average 2.60 3.0 86.5 « 1 ,898 * 2,421 100.9 1.41 ' 0.08 ' 28.0 10.8 8.5 1.23 44.1 17.0 . 13.4 1.93 34.9 ------- ro i TABLE 2-3 SULFUR DIOXIDE SUMMARY '.. ENGLISH UNITS Run Number Date Volume of Gas Sampled-DSCF Stack Volumetric Flow Rate-DSCFM Stack Volumetric Flow Rate-ACFM Laboratory Data Normality of Barium Perchlorate-g-eq/1 TUrant Volume Minus Blank Volume-mis Replicate 1 Replicate 2 Replicate 3 Total Solution Volume-mis Volume of Sample Aliquot-mis S0_2 Concentration - (Average of 3 Replicates) Ibs/DSCF ppm (Volume) @ 25°C Ibs/hr 1 July 8, 1974 3.55 65,973 85,212 0.0103 ' 0.37 0.41 0.325 125 20 4.70 x 10"7 2.88 1.86 2 July 9, 1974i \ 3.52 69,611 86,454 . 0.0103 0.11 0.06 0.08 125 20 1.07 x 10"7 0.66 O.W 3 July 9, 1974 , 4.56 65,508 84,818 0.0103 0.16 0.26 0-.26 125 20 , 2.23 x 10"7 1.37 0.88 Average 3.88 67,031 85,495 "0.0103 125 20 ' 2.67 x:lO 1.64 ' 1.06 -7 ------- TABLE 2-4 SULFUR DIOXIDE SUMMARY METRIC UNITS ro i in Run Number Date Volume of Gas Sampled-N_m3 Percent Moisture by Volume Average Stack Temperature-°C Stack Volumetric Flow Rate-Nm3/m1n Stack Volumetric Flow Rate-m3/m1n Laboratory Data Normality of Barium Perchlorate-g-eq/1 Titrant Volume Minus Blank Volume-mis Replicate 1 Replicate 2 Replicate 3 Total Solution Volume-mis Volume of Sample Aliquot-mis SO? Concentration - (Average of 3 Replicates) gms/Nm3 kg/hr ppm 1 July 8, 1974 0.10 3.0 91.7 ""1,868 2,413 0.0103 0.37 0.41 0.325 125 20 7.54 x 10"3 0.84 2.88 2 July 9, 1974 0.10 2.8 77.2 1,971 2,448 . 0.0103 0.11 0.06 0.08 125 20 1.72 x 10"3 0.20 0.66 3 July 9, 1974 0.13 3.2 90.6 1,855 2,402 0.0103 0.16 0.26 0.26 125 20 , 3.58 x 10"3 0.40 1.37 1 .Average : 0.11 3.0 86.5 1,898 2,421 i 0.0103 1 125 20 4.28 x 10"3 . 0.48 1.64 ------- TABLE 2-5 NITROGEN OXIDES SUMMARY ENGLISH UNITS Run Number Date Percent Moisture by Volume Stack Volumetric Flow Rate-DSCFM Stack Volumetric Flow Rate-ACFM Analysis FVosk Volume-nils Ab;sorbant Volume-mis .Initial Pressure-In. Hg. Fl'hnl Pressure-In. Hg. Initial Teniperature-°F Final Tempera ture-°F Total NOX Collected-ug NOx Concentration ' Ibs/DSCF x 10-7 (as NOg) DDII) '* * Mr"1 lbs/hr. 1 2,038 24.5 4.80 30.43 104 105 6.8' 2.61 2.22 1.03 2 2,030 24.0 4.90 30.73 97 109 7.6 2.93 2.50 1.16 3 July 1 ,961 25.0 4.80 29.33 100 102 12.1 5.02 4.28 1.99 4 8, 1974 3.0 65,973 85,212 1,992 24.5 5.00 30.03 100 104 7.6 3.05 2.60 1.21 5 2,040 23.5 4.80 29.73 100 105 11.3 4.45 3.79 1.76 6 1,994 . 24.0 4.65 30.08 100 106 12.1 4.80 4.09 1.90 7 1,964 24.5 4.83 30.29 83 96 22.7 8.99 7.66 3.75 8 9 July - 2,046 .2,024 24.0 25.0 4.53 4.63 30.34 30.09 88 92 94 93 42.3 34.0 . 15.8 12.9 13.5 11. 0 6.60 5.39 10 9, 1974 2.8 69,611 86,454 2,009 26.0 4.63 29.44 97 92 287.2 113.0 96.3 47.2 11 12 - 2,020 2,005 25.0 24.0 4.93 4.73 29.14' 30.09 102 105 92 92 34.0 510.1 13.6 195.0 11.6 166.2 5.68 81.4 Average. 2.9 67,792 85.833 31.8 27.1 13.3 ro i en ------- TABLE 2-6 NITROGEN OXIDES SUMMARY METRIC UNITS Run Number Date Percent Moisture by Volume ' Stock Volumetric Flow Rate-NjnVmln 5tcck Volumetric Flow Rate-m'/mln Analysis Flask Volume-mis Absorbant Volume-mis Initial Pressure-mm Hg. Final Prcssure-nm Hg. Initial Temperature-°C Final Tcmporature-°C Total NOX collected-ug NOx Concentration mg/Nm1 x 10'4 (as N02) ppm kg/hr 1 2 2,038 2,030 24.5 24.0 121.9 124.5 772.9 780.5 40.0 36.1 40.6 42.8 6.8' 7.6 4.18 4.69 2.22 2.50 0.47 0.53 3 July 3.0 1.868 2,413 1,961 25.0 121.9 745.0 37.8 38.9 12.1 8.04 4.28 0.90 4 8, 1974 1,992 24.5 127.0 762.8 37.8 40.0 7.6 4.89 2.60 0.55 5 2,040 23.5 121.9 755.1 37.8 40.6 11.3 7.13 3.79 0.80 6 1,994 24.0 118.1 764.0 37.8 41.1 12.1 7.69 4.09 0.86 7 1,964 24.5 122.7 769.4 28.3 35.6 22.7 14.4 7.66 1.70 $ 2,046 . 24.0 115.1 770.6 31.1 34.4 42.3 25.3 .13.5 2.99 9 July 2,024 25.0 117.6 764.3 33.3 33.9 34.0 20.7 11.0 2.44 ' 10 11 9, 1974 2.8 1,971 2.448 2;009 2,020 26.0 25.0 117.6 125.2 747.8 740.2 36.1 38.9 33.3 33.3 207.2 34.0 181.0 21.8 96.3 11.6 21.4 2.58 12 ' 2.005 24.0 120.1 764.3' 40.6 33.3 510.1 312.4 166.2 36.9 Average 2,9 1,920 2,430 - 51.0 27.1 6.0 ro ------- TABLE 2-7 CARBON MONOXIDE SUMMARY "ENGLISH UNITS ro i oo Run Number Date Time of Sampling, m1n. Number of Readings Stack Vblumtrlc Flow Rate, ACFM Average Stack Temperature °F Carbon Monoxide Concentration PPM High Low Mean Lbs/hr High Low Mean 1 July 8, 1974 228 37 85,212 197 130 28 75 38.8 8.4 22.4 2 July 9, 1974 216 35 86,454 171 142 32 84 44.8 10.1 26.5 i . - \ 3 \ July 9, 1974 222 38 84,818 -t 195 104 19 59 31.0 5.7 17.6 Average 222 37 85 ,495 188 125 26 73 38.2 8.1 22.2 ------- TABLE 2-8 CARBON MONOXIDE SUMMARY METRIC UNITS fSJ I vo Run Number Date Time of Sampling, m1n. Number of Readings Stack Volumetric Flow Rate, m^/mln. Average Stack Temperature °(J Carbon Monoxide Concentration PPM High Low Mean Kg/hr High Low Mean 1 July 8, 1974 228 37 - 2,413 91.7 130 28 75 17.6 3.8 10.2 2 July 9, 1974 216 35 2,448 77.2 142 32 84 20.3 4.6 12.0 3 July 9, 1974 222 38 2,402 90.6 104 19 59 14.1 2.6 8.0 Average 222 37 2,421 86.5 125 . 26 73 17.3 3.7 10.1 ------- TABLE 2-9 HYDROCARBON SUMMARY ENGLISH UNITS ro i Run Number Date Time of Sampling, m1n. Number of Readings Stack Volumetric Flow Rate, ACFM Average Stack Temperature °F Hydrocarbon Concentration PPM High Low ' Mean Lbs/hr High Low Mean 1 July 8, 1974 228 37 85,212 197 12.7 6.4 8.6 2.17 1.09 1.47 2 July 9, 1974 216 35 -86,454 1.71 14.6 6.6 9.6 2.63 1.19 1.73 3 July 9, 1974 222 38 84,818 195 15. 3 5.4 11.5 2.61 0.92 1.96 Average 222 37 85,495 188 14.2 6.1 9.9 2.76 1.21 1.91 ------- TABLE 2-10 HYDROCARBON SUMMARY METRIC UNITS ro i tl ^ ^ Run Number 1 Date July 8, 1974 Time of Sampling, m1n. 228 Number of Readings 37 3 Stack Volumetric Flow Rate, Irr/m1n. 2,413 Average Stack Temperature -°C 91.7 Hydrocarbon Concentration PPM High 12.7 Low 6.4 Mean 8.6 Kg/hr High 1.07 Low 0.54 Mean 0.73 i 2 July 9, 1974 216 35 2,448 77.2 14.6 6.6 9.6 1.30 0.59 0.85 3 July 9, 1974 222 38 2,402 90.6 15.3 5.4 11.5 1 .29 0.45 0.97 Average 222 37 i 2,421 ; 86.5 14.2 6.1 9.9 1.36 0.60 0.94 ; i .*" - ------- TABLE 2-11 COMPARISON PARTICIPATE SUMMARY ENGLISH UNITS Run Number 4A 4B 5A 58 6A 6B ro i ro Run Method Date Volume of Gas Sampled-DSCFM Percent Moisture by Volume Average Stack Temperature-°F Stack Volumetric Flow Rate-DSCFM Stack Volumetric Flow Rate-ACFM Percent Isok1net1c Partlculates - Probe & Filter mg. gr/DSCF gr/ACF Ib/hr. Parti cul ate - Total Catch nig. gr/DSCF gr/ACF Ib/hr. Percent Implnger Catch Comp. July 10, 144.31 2.1 182 61,855 77,588 96.7 40.5 0.0043 0.0034 2.30 50.1 0.0054 0.0043 2.84 19.2 EPA-5 1974 143.42 2.2 183 61,783 77,589 96.2 33.8 0.0036 0.0029 1.93 58.9 0.0063 0.0050 3.36 42.6 Comp. July 10, 148.41 1.8 180 63,957 79,776 96.2 35.2 0.0037 0.0030 2.03 42.6 0.0044 0.0035 2.43 17.4 EPA-5 1974 148.85 2.0 . 180 63,905 79,765 96.6 24.9 0.0026 0.0021 1.41 35.4 0.0037 0.0030 2.01 29.7 1 Comp. July 11, 143.53 2.5 163 62,032 75,767 95.9 . 31.0 0.0033 0.0027 1.77 38.9 0.0042 0.0034 2.22 20.3 EPA-5 1974 143.76 2.6 163 61,972 75,781 96.2 30.1 0.0032 0.0027 1.72 33.7 0.0036 0.0029 1.92 10.7 Averages Comp. EPA 145.42 2.1 176 62,615 77,710 96.3 35.6 0.0038 0.0030 2.03 43.9 0.0047 0.0037 2'r50 18.9 145.34 2.3 176 62,553 77,711 96.4 29.6 0.0031 0.0026 1 .69 42.7 0.0045 0.0036 2.43 | 30.7 ------- TABLE 2-12 COMPARISON PARTICIPATE SUMMARY METRIC UNITS Run Number 4A 4B 5B 6A 6B ro i (A) Run Method Date Volume of Gas Sampled-Nni3 Percent Moisture by Volume Average Stack Tempera ture-°C Stack Volumetric Flow Rate-N_m3/ro1n Stack Volumetric Flow Rate-m3/m1n Percent Isoklnetlc Partlculates - Probe & Filter my . mg/Njn3 mcj/m3 kg/hr Partlculates - Total Catch mg. mg/N_m3 mg/ni3 kg/hr Percent Implnger Catch ! Comp. July 10. 4.09 2.1 83.3 1,752 2,197 96.7 40.5 9.90 7.83 1.04 50.1 12.25 9.75 1.29 19.2 EPA-5 1974 4.06 2.2 83.3 1,750 2,197 96.2 33.8 8.33 6.71 0.88 58.9 14.51 11.52 1.52 42.6 Comp. July 10, 4.20 1.8 82.2 - 1,811 2,259 96.2 35.2 8.38 6.79 0.92 . 42.6 10.14 8.07 1.10 17.4 EPA-5 v 1974 4.21 2.0 B2.2 1,810 2,259 96.6 24.9 5.91 4.77 0.64 35.4 8.41 6.82 0.91 29.7 Comp. July 11, 4.06 2.5 72.8 1,757 2,145 95.9 31.0 7.64 6.25 0.80 38.9 9.58 7.76 1.01 20.3 EPA-5 . 1974 4.07 2.6 72.8 1,755 2,146 96.2 30.1 7.40 6.24 0.78 33.7 8.28 6.67 0.87 10.7 Comp. 4.12 2.1 80.0 1,773 2,200 96.3 35.6 8.64 6.96 0.92 43.9 10.66 8.53 1.13 18.9 EPA 4.12 2.3 80.0 1,771 2,201 : 96.4 i 29.6 7.21 5.91 0.77 42.7 10.40 8.34 1.10 j 30.7 ------- TABLE 2-13 SUMMARY OF OPACITY READINGS ro i Run Number Date Duration of Observations (m1n) Total No. of Readings No. Readings Unobserved No. Readings 0% Opacity 5 10 15 20 25 30 - 100 Percent Readings Unobserved Percent Readings 0% Opacity 5 10 15 20 25 30 - 100 1 July 8, Obs. 1* 230 920 0 729 166 24 1 0 0 0 0 79.24 18.04 2.61 0.11 0 0 0 100 1974 Obs. 2* 230 896 24 880 13 3 0 0 0 0 2.68 98.21 1.46 0.33 0 0 0 0 100. 2 July 9. Obs. 1 222.5 890 . 0 754 120 14 1 1 0 0 0 84.72 13.48 1.58 0.11 0.11 0 0 100 1974 Obs. 2 220 880 876 3 1 0 0' 0 0 0 99.55 0.34 0.11 0 0 0 0 100 3 July 9. Obs. 1 219 876 601 192 70 12 1 0 .0 0 68.61 21.92 7.99 1.37 0.11 0 0 100 1974 Obs. 2 215 860 854 1 1 3 1 0 . 0 0 99.29 0.12 0.12 0.35 0.12 0 0 100 Average Opacity ° Sum of Nos. No. Readings Observable 1.18 0.11 0.87 0.03 2.12 0.09 Obs. 1 » Observer of Stack Emissions-. .Obs. 2 - Observer of Roof Monitor Emissions. Obs. 1 - R. Furman Obs. 2 - R. Hebert - Both observers were certified at RTP 1n January 1974. ------- III. PROCESS OPERATION AND DESCRIPTION A. PROCESS OPERATION 1. Electric Arc Furnaces : Process operation was normal during all tests. Gray iron with a carbon level of 3.33 to 3.80 percent was produced from the foundry's usual charge materials. The scrap charged did not appear to be particularly dirty or greasy. Each test was begun when operations were started on one of the two furnaces. The tests continued for three hours covering two full heats on each furnace during each test. Brief delays, which are considered normal, occurred in the melting process. Unavailability of the overhead crane, temporary unavailability of power, need for metallurgical sampling, lack of storage space for molten metal, electrode repl.acemen.ts, stuck roof, etc., are all normal causes of delays. These conditions are reported in the log of process operations in Appendix X of this report. 2. Air Pollution Control System The dust control system operated normally throughout the tests. The pressure drop across the compartments ranged between 2 and 7 inches of water gauge. No stratifications or layering of particulate emissions (that sometimes occur) were observed in the furnace or scrap bay areas, although there is rather heavy traffic of ladles to transfer metal. The atmosphere in the melting bay area'was clear at all times. During charging, dark colored emissions were visible above the furnaces (probably soot from burned oil) for a couple of minutes when the charge is compressed with the bucket. The charge is small, bulky pieces of scrap that have to be smashed down in order to close the roof. The emissions were carried up by the heat inpetus and, upon reaching the velocity contours of the roof fans, they dissipated and were no longer visible. 3-1 IllUbi, ------- B. PROCESS DESCRIPTION 1. Electric Arc Furnaces The John Deere foundry in Moline, Illinois, produces a gray iron for castings in the two furnaces tested. Each has a capacity of IT to 13 tons of iron per heat (about 10.3 tons per hour). The furnaces are located in a bay together with two other arc furnaces (identical to the other two) and two holding furnaces. The scrap bay is located to the left and parallel to the furnace's bay, under the same roof. To the right are located the holding furnaces and the nodular iron inoculation ladles. The furnaces are manufactured by the Whitting Corporation. They each have a diameter of 11'-0" and a roof that swivels open for buc- ket charging. Power is supplied by a 13,800 KVA high voltage transformer with six taps on the secondary coil. Normally, only taps numbers 1 and 3 and used. The composition of a typical charge is as follows: Shreds (steel scrap) and borings 11,000 Ibs Returns 12,900 Ibs Ferro-Silicon 300 Ibs Carbon Riser 500 Ibs i Shreads are steel pieces no larger than two feet in any flat direction (mostly sheet metal). A premium price is paid for this scrap. The returns are defective castings from the foundry. The returns also in- clude sprues, end gates, and risers from castings. Borings are excess metal from drilling and machining operations. The latter are centrifuged to remove excessive oil. They use carbon (carbon riser) from several different suppliers. The amount of carbon, FeMn or silicon additives added to the charge does not vary much, if at all. At the beginning of a heat, the furnace roof is swung aside and the bucket of scrap discharges its contents into the furnace. After the charge, the roof is closed and the electrodes are lowered. Power is 3-2 lUlalden, ------- supplied from tap number 1 to melt the scrap as /quickly as possible. Tap number 1 has 280 volts and 27,000 amperes (7.56 mw). As soon as a large pool of molten metal is formed and the bath becomes flat, power is re- duced by changing to tap number 3 (240 volts). It takes about 30 minutes to achieve a flat bath. The furnace remains on tap number 3 for 25 to 30 minutes of refining. During this time, the furnace is slagged and the chemistry is checked and adjusted. These operations last about 10 minutes. The slag is removed with the power off and the electrodes lifted slightly. The furnace is tilted about 5° .and the slag is skimmed from the surface of the metal bath. If the proper chemistry of the gray iron has been achieved, the furnace is then ready for tapping. Prior to tapping, power is supplied from tap number 3 (240 volts) to superheat the metal to 2750°F for gray iron and 2800°F for no- dular iron. During tapping, the furnace is tilted 45° to pour the metal in the transfer ladle. Power is off and the connection between the furnace hood and the exhaust duct is broken during this operation. The molten metal is transferred to one of the induction holding furnaces. The high transformer rating (Ultra High Power), rapid analy- ses and temperature checks and precise control of metallurgy by a well- trained team result in a very short melting time of 70 minutes or slightly i ' ' more per heat. 2. Air Pollution Control System Emissions are evacuated from the furnaces via a side draft hood, a spout pouring hood and a slag door hood. They are collected in a baghouse upstream of an induced draft fan. Most emissions during charging, tapping, and slagging are exhausted from the building by a roof fan located above each furnace. During slagging, the hood on the furnaces remains in operation, and angle of tilt being only 10°. Several other fans located in the roofs of both bay areas evacuate fumes not evacuated by the furnace roof fan. They are also used for general ventilation of fumes and heat from the melt shop. The height from the top of the hoods to the roof of the building is about 40 feet. Ulalden, ------- the baghouse, manufactured by Pangborn, automatically shakes the bags. Each of the six compartments is consecutively off-line for five minutes to allow cleaning the bags. The pressure drop is 2 - 3 inches water gauge. There are 420 bags. The bags are made of Dacron and can withstand a maximum temperature of 275°F. The cloth area of, the bags is 44,940 square feet and the fan throughput is about 86,000 actual cubic feet per minute. The baghouse has six hoppers which all empty into a common screw conveyor. The dust is conveyed via two additional screw conveyors and a small bucket elevator into a:pelletizer. ------- I IV. LOCATION OF SAMPLING POINTS i A schematic layout of the test site is shown in Figure 4-1. The five test ports were six-inch welded half couplings located five equivalent stack dianeters downstream and 1.3 equivalent diameters upstream of the nearest flow disturbances. A layout of the particulate traverse points is shown in Figure 4-2. According to Method 1, samples were taken at each of the thirty points at six minutes per point for a total of 180 minutes for each sample run. The traverse points were located at the centroid of-each equal area. 4-1 ------- Top View equivalent diameter = 4.99 feet Side View STACK EXTENSION 6 _^ < J * 3' i 2l'- ^ \ 5" t ^ ^ * 7" 1 i 3' r FAN HOUSING Figure 4-1. Schematic Layout of Test Site. 4-2 ------- -I/" 1*3 / 13/6 -. 14'' 14' 14" f 131 1 -" 486 e sV e 39^3 *-' - ₯ iUs o ^ - 2ll e f 9 , «r 138 ' ETI Dl .c» 81 v Al f s, | 1 DIST/s 'CRT PORT D PORT C PORT B DISTANCE FROM STACK WALL PORT A Figure 4-2. Participate Sampling Points, No. 2 Baghouse Stack John Deere Tractor Works, East Moline, Illinois. 4-3 Illbkk ------- V. SAMPLING AND ANALYTICAL PROCEDURES All sampling and analytical raw data is provided in Appendices VI and VIII, respectively. Computer summaries of each test sample is provided in Appendices I, II, III, IV, and V. A. PARTICULATE SAMPLING (EPA METHOD 5) The particulate sampling was performed in accordance with EPA Method 5, Federal Register. December 23, 1971. The location of the sampling site, determination,of stack gas velocity and volumetric flow rate, gas analysis for carbon dioxide and dry molecular weight, and determination of moisture in the stack gases were performed in accordance with Methods 1, 2, 3 and 4, respectively, of the aforementioned document. The only variation from Method 5 as described; in the Federal Register was the addition of one hundred milliliters of water to the third im- pinger. Normally, the third impinger is left empty, however, the addition of water did not alter the sampling methods or results as the water was eventually evaporated in a beaker for the determination of particulate matter in the residual water fraction. The particulate samples were stored in acid-washed Wheaton bottles and analyzed at the Walden labora- tories. Sample recovery and analysis procedures were in accordance with Method 5, Federal Register, August 17, 1971. All labeled particulate samples will be held by the EPA for their use. B. SULFUR DIOXIDE (METHOD 6) The sulfur dioxide tests were performed in accordance with EPA Method 6, Federal Register, December 23, 1971. The location of.the stationary sam- pling point was approximately the average velocity point for that port being tested. Each sample run was located in various test ports so there would be no interference with the traversing particulate sampling train. The tests were not run for the complete 3-hour period due to carry-over of the sulfuric acid fraction in the isopropanol impinger. Each test was conducted 5-1 ------- until bubbles from the first isopropanol impinger began carrying over into the second impinger containing the sulfur dioxide fraction. The duration of the sample runs were from one hour and thirty minutes to two hours and twenty minutes. Three replicate analyses were performed by the barium- thorin titration method on each sample and recorded as the average of the three replicates. C. NITROGEN OXIDES (METHOD 7) The nitrogen oxide tests were performed in accordance with^EPA Method 7, Federal Register, December 23, 1971, and a modified draft sup- plied by the EPA. Six samples were obtained on each of the first two test runs as requested by the EPA Project Officer. A probe heater was re- quired as the probe did not remain dry during the purging period. The samples were analyzed colorimetrically using the phenoldisulfonic acid procedure at the Wai den laboratories. D. VISIBLE EMISSIONS (METHOD 9) The determination of the opacity of emissions was performed in accordance with Method 9, Federal Register, December 23, 1971. Observa- tions were made during the three three-hour particulate runs on both the baghouse stack and roof monitor vent above the furnaces by certified opacity observers. Both were.certified at Research Triangle Park in January 1974. E. EPA COMPARISON PARTICULATE TESTS The EPA comparison tests were performed separately from the pri- mary test functions. Three repetitions of the prescribed test method were performed following the completion of the other task order requests. The test procedures and equipment were provided by the EPA Project Officer and performed with his guidance and assistance. The first two repetitions were conducted with one hundred milliliters of water in the third impinger while the third impinger was left empty during the third repetition. 5-2 llUatbii ------- F. CARBON MONOXIDE (METHOD 10) Carbon monoxide concentrations were measured with a Beckman Model 315B non-dispersive infrared spectophotometer (MDIR). The instrument was operated as outlined in the manual provided by the manufacturer. Method 10 as outlined in the Federal Register of 8 March 1974 was used as a guide in the sampling and analysis of carbon monoxide concentrations. G. HYDROCARBONS The hydrocarbon concentration (as methane) was determined with a Beck- man Model 400 Hydrocarbon Analyzer. The instrument was operated as prescribed by the manual provided by the manufacturer. lU/alden, 5-3 ------- WALDEN SOURCE TEST REPORT MPAN= HN R TRACTOR WORKS C370B LOCflTION= EAST PROr.FSSa F » IINOIS ABC FUtfNACFS qONTRQI FOUIPMFNT= HAGHOUSE TEST SCHEDULE RUN NO. DATE POLLUTANTS SAMPLED 1 ? 3 4A 48 5 A 5B 6A 6B 8 9 9 1 1 ] 1 1 1 JULY74 JULY74 JULY74 OJULY74 OJULY74 OJULY74 OJULY74 1JULY74 1JULY74 PART PART PART PART P.AR.T PART PAw.T PART PART 502 S02 S02 * CO .and Science NOX NOX CO* CO CO HC* HC HC HC tests: were conducted by and Engineering, Inc. OPACITY OPACITY OPACITY Environmental ' <;PFCTAI INFORMATION FPA METHOD S FOR PARTICULATES, EPA METHOD 6 FOR 502, EPA METHOD 7 FOR NOX, EPA METHOD 9 FOR VISIBLE. EMISSIONS, EPA METHOD 3 FOR GAS ANA LY_SJLS COMPARISON PARTICULATE TESTS RUN IN ACCORDANCE WITH DIRECTION OF EPA PROJECT OFFICER ------- |