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
------- |