EMISSION TESTING REPORT
EPA REPORT NO. 74-CRN-9
QUAKER OATS COMPANY
ST. JOSEPH, MISSOURI
PEDCo ENVIRONMENTAL
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PEDCo-EN VI RON MENTAL
SUITE 13 • ATKINSON SQUARE
CINCINNATI. OHIO 45246
51 3 1-7-7 1-4330
EMISSION TESTING REPORT
EPA REPORT NO. 74-CRN-9
QUAKER OATS COMPANY
ST. JOSEPH, MISSOURI
Submitted by:
PEDCo-Environmental Specialists, Inc.
Suite 13, Atkinson Square
Cincinnati, Ohio 45246
Contract No. 68-02-0237
Task 29
Prepared by: William DeWees .
Richard Gerstle, P.E.
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1. TABLE OF CONTENTS
Page
II. INTRODUCTION 1
III. SUMMARY OF RESULTS 2
IV. PROCESS DESCRIPTION . 5
V. LOCATION OF SAMPLING POINTS ' 7
VI. PROCESS OPERATION 12
VII. SAMPLING AND ANALYTICAL PROCEDURES . 13
VIII. APPENDIX ' •
A. PARTICULATE RESULTS AND EXAMPLE CALCULATIONS
B. SAMPLING METHODS
C.. LABORATORY REPORT
. D. TEST LOG
E. FIELD DATA .
F. PROJECT PARTICIPANTS AND TITLES
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LIST OF FIGURES
Figure Page
1 Grain dryer vent initial sampling point
location 9
2 Exhaust section with louvers 10
3 Grain dryer vent final sampling point
location 11
4 EPA Method 5 particulate sampling train 14
5 High Volume particulate train 16
i
6 Scaffolding and sample setup on grain
dryer " 17
7 Sample trains setup for simultaneous
sampling 18
11
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LIST OF TABLES
Table Page
1 Summary of Particulate Results with EPA 3
Method 5 Train
2 Summary of Particulate Results with Hi 4
Vol Train
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II. INTRODUCTION
Under the Clean Air Act of 1970, as amended, the Environmental
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.
The grain dryer at the Quaker Oats Co. in St. Joseph, Missouri
was designated as a well-controlled stationary source in the grain
industry and was thereby selected by OAP for an emission testing
program. The tests were conducted during the period of November
14 to November 16, 1973 while corn was being dried.
Emissions from the grain dryer are controlled by a 58 mesh
screen and a moving vacuum cleaning head. The dryer is a column
type with crossflow drying and recirculating exhaust air.
Two tests were conducted at the grain dryer screen outlet to
determine the filterable and total particulate emissions. Two
sampling trains were used simultaneously to measure particulate
during each test. These trains were the EPA Method 5 train and
a high volume sampling train.
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III. SUMMARY OF RESULTS
A summary of particulate emission data from the grain dryer
is presented in Table 1 for the EPA Method 5 train and in Table
2 for the high volume train. The filterable particulate as
measured by the probe and filter catch in the Method 5 train
averaged 6.0 pounds per hour at a concentration of 0.014 grains
per DSCF. The total particulate catch, including the impinger
catch, averaged 8.5 pounds per hour at a concentration of 0.02
grains per DSCF. The impingers collected an average of 29.85
percent of the total particulate.
The first test with the high volume train was terminated
halfway through the test because the velocity measuring device
was not working correctly. The particulate concentration during
the second run was 0.0093 grains per DSCF, and agreed well with
the 0.0087 value obtained during the partially completed first
test.
When comparing the filterable particulate values obtained
with the Method 5 sampling train to those obtained with the. high
volume sampling train, a variation of approximately 55% occurred
with the EPA train yielding higher values.
Visual determination of the opacity of emissions was
recorded every 15 seconds during both tests in accordance with
Method 9 of the December 23, 1971, Federal Register, Vol. 36,
No. 247, by Ken Woodard, Project Engineer for EPA. An opacity
reading of zero was recorded for every reading.
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. Table 1. SUMMARY OF PARTICULATE RESULTS
, . WITH EPA METHOD 5 TRAIN
Run. Number
Date
Volume .of Gas Sampled - DSCFa
Percent Moisture by Volume
Average Stack Temperature - °F
Stack Volumetric Flow Rate - DSCFM
Stack Volumetric Flow Rate - ACFMC
Percent Isokinetic
i
Percent,Excess Air
/
Percent Opacity
Feed Rate - ton/hr
Particulates - probe,
and filter catch
mg
gr/DSCF
gr/ACF
Ib/hr
Ib/ton feed
Particulates - total catch
rag
gr/DSCF
gr/ACF
Ib/hr
Ib/ton feed
Percent impinger catch
11/15/73
127.349
3.5
103
59833
66063
110
0
42.45
90.5
0.011
0.010
5.62
0.133
134.3
0.016
0.015
8.35 •
0.197
11/16/73
•90.006
3.2
115
43196
48735
107.7
0
30.26
100.0
0.017
0.015
6.35
0.209
137.0
0.024
0.021
8.70
0.287
32.6
27.1
Dry standard cubic feet at 70°F, 29.92 in. licj.
Dry standard cubic feet -per minute at 70°F, 29.92 in. llg.
Actual cubic feet per minute.
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Table 2. SUMMARY OF PARTICULATE RESULTS
WITH HI VOL TRAIN
Run Number
Date 11/15/73
Volume of Gas Sampled - DSCFa 937
Average Stack Temperature - °F .. 103
Stack Volumetric Flow Rate - DSCFMb 34502d
Stack Volumetric Flow Rate - ACFMC 37'905d
Percent Isokinetic . 115
Percent Excess Air
Percent Opacity 0
Feed Rate - ton/hr 42.45
11/16/73
2794
103
57770
64114
110
0
30.26
Particulates - probe,
and filter catch
mg
gr/DSCF
gr/ACF
Ib/hr
Ib/ton feed
527.2
0.0087
0..008
2.57d
O.'061d
1683.4
0.0093
0.0084
4.6
0.152
NOTE: Moisture measured with Method 5 (Table 1) was used
to determine dry gas volumes.
d .
Dry standard cubic feet at 70°F, 29.92 in-Hg.
Dry standard cubic feet per minute at 70°F, 29.92 in. Jig.
Actual cubic feet per minute.
These values are not correct since velocity measuring device was
not operating properly.
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IV. PROCESS DESCRIPTION
Quaker Oats uses the new Hart Carter HC dryer for drying
corn, exclusively. The HC dryer is a column type dryer in
which two-thirds of the air handled is recirculated to con-
serve heat and reduce fuel usage.
The corn is not cleaned before it is dried. It enters
the top of'the dryer and is split into two columns. The two
columns of corn continuously flow through the dryer to the bot-
tom from which it is conveyed to storage bins. Sheet metal
with 5/64" diameter perforations forms the sides of the columns.
The sheets have 45 percent open area. Hot gases from the com-
bustion of natural gas are blown into the area between the
grain columns in the top portion of the dryer. The air at 200°F
passes through the columns of grain removing the excess moisture
In the bottom-one-third'of the dryer, ambient air is drawn
through the columns to cool the corn. Only one-third of the
heated air (about 48,000 cfm) is discharged and replaced by the
cooling air, and two-thirds of the heated air is recirculated.
The corn received has a maximum moisture content of 20 per-
cent. It is dried to about 15 percent moisture for proper
storage. If the desired moisture level is not achieved
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on the first pass., the corn is passed through the dryer a
second time. The rated capacity of the dryer is 2000/bu/hr
to remove.five percent moisture. It is actually operated at
1000 to 1800 bu/hr. There is however, no direct way to
measure the grain flow through the dryer and the depth of
grain in the storage bin is measured every two hours to
estimate throughput.
Emissions from the dryer are controlled with a Day Vac
dust filter with 58 mesh screens. The filter screens are
cleaned by a vacuum head that continuously traverses the
media. The material retained by the filter is transferred
to storage tanks and subsequently sold as cattle feed
ingredient.
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V. LOCATION OF SAMPLING POINTS
Since the exhaust gases from this process do not flow
through a conventional system of circular or rectangular
ductwork^ Federal Register Method 1 was not used to deter-
mine the number and location of the sampling points. Figure
1 shows the initial sampling point configuration; it was
selected arbitrarily after a presurvey of the grain dryer.
The dryer (see Figure 2) was shut down during the week
of the presurvey. Consequently, it was not possible to
study the effluent flow patterns or take velocity readings
in advance of the test. This was not, at the time, thought
to be a serious consideration, because EPA had done one
previous test on a Day-Vac controlled dryer (Quaker Oats
Co., Chattanooga, Tennessee). At Chattanooga, the flow
exited (after exhaust louvers were removed) approximately
perpendicular to the bird screen, at velocities of between
100 and 500 feet per minute. Since the Day-Vac unit on the
St. Joseph dryer was comparable in size to the unit at
Chattanooga, it was assumed that flow patterns and velocities
similar to those encountered at Chattanooga would be observed
1
Federal Register, Vol. 36, No. 247, Part II, Thursday,
December 23, 1971.
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at St. Joseph. Had this assumption proved to.be valid, the
40 point layout shown in Figure 1 would have been adequate.
However, for reasons outlined in Section VII of this report,
the top and bottom fourths of the screen had to be blocked
off with plastic sheeting, and the number of sampling points
had to be reduced from 40 to 16. Figure 3 shows the final
sampling point configuration.
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14.. 5"
4
O
5
o
12
O
13
0
20
O
21
0
28
O
29
O
36
O
37
O
3
o
6
o
11
0
14
O
19
O
22
O
27
O
30
O
35
O
38
0
.
T-t T^ X*"l
FRONT
h28 "
'""
2 1
O O
7 8
0 0
10 9
0 0
15 16
0 0
18 17
0 O
23 24
0 0
26 25
0 0
31 32
0 0
34 33
0 0
3o 48
*-6"
10' -^
r 14.5"
,—-"12v
_[ /
-i
2 4 "
i
V
\
20.' ^
\
'
,
\
\
V
1 ^
\
\.
\
V
\
v.
Ik
v_
x^
— EXIT GAS
FILTER
58 MES
—BIRD SCRE
— EXIT GAS
< — ."18"
— EXIT GAS
SIDE
Figure 1. Grain dryer vent initial sampling point location,
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Figure 2. Exhaust section with louvers
10
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20
9'6"
4
o
5
o
12
o
13
O
3
o
6
o
11
o
14
o
14.5"
2
O
7
o
10
O
15
o
6"
10'
1
o
8
o
9
O
16
O
PLASTIC
VENT
COVER
x-14"
28"
\
\
PLASTIC
:VENT
COVER
•EXIT GAS
FILTER PANEL
EXIT GAS
-BIRD SCREEN
EXIT GAS
\
FRONT
SIDE
Figure. 3. Grain dryer vent final sampling point location,
11
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VI. PROCESS OPERATION
The following is process data taken by EPA during the
testing on November 15 and 16, 1973.
PROCESS DATA
Test
Run
1
2
Time
2:00 p.m.
4:00 p.m.
6:00 p.m.
8:00 p.m.
8:00 a.m.
10:00 a.m.
1.2:00 noon
2:00 p.m.
4:00 p.m.
Drying
Rate
bu/hr
1250
1500
1000
1125
% Moisture
in
17
16.5
16.8
17.7
18.0
18.9
17.5
17.6
.17.7
out
15
.13.4
14.3
14.7
14.7
16.5
15.8
. 15.0
15.8
Grain Temp.
in
72°
79°
76°
71°
64°
62°
72°
68°
68°
out
83°
87°
86°
84°
77°
75°
82°
91°
86°
Dryer
Temp.
°F
200°
202°
202°
200°
200°
200°
204°
204°
202°
Grain: white corn, 57 Ib/bu test weight, 1.0 percent to. 1.5 percent
foreign material
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VII. SAMPLING AND ANALYTICAL PROCEDURES
All sampling, procedures were selected by EPA prior to field
sampling. All analyses of collected samples 'were performed by
PEDCo. Appendix C contains detailed sampling and analytical
procedures.
Velocity and Gas Temperature
Gas velocities for the Method 5 train were measured with
the Hastings-Raydist Velocity Probe (Model SVS-1.5K SER 11),
calibrated for use with a type S pitot tube. Gas velocities
for the high volume train were measured with a standard type
pitot tube and an electronic manometer supplied by EPA. In all
cases velocities were measured at each sampling point across
the exit vent to determine an average value according to procedures
described in Federal Register , Method 2. Temperatures were
measured with long stem dial thermometers.
Particulates
Method 5 as described in the Federal Register , was used
to measure particulate matter. A rigid train consisting of a
heated glass lined probe, a 3" glass fiber filter, and a series
of Greenburg-Smith impingers was employed in the simultaneous
particulate test as shown in Figure 4.
1 Ibid.
13
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GLASS
'ED
S
E
r
M
FILTER —j
S 1
. 1 "in
STACK WALL 1 f~ £ 3=
' i? 1
1 .
i
1
THERMOMETER
PITOT TUBE
HEATED 1
SECTION H
Y
HASTINGS VELOCITY
METER
CALIBRATED ORIFICE
L.
I • . ' SILICA
|j_qO_mT_._ OF WATER ._
THERMOMETERS •
CONTROL
VALVES
UHCILICAL
CORD
VACUUM
GAUGE
Hh
MANOMETER'I
Figure 4. EPA Methods particulate sampling train.
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The high volume sampling train shown in Figure 5 was
also employed in the simultaneous sampling in order to
compare data from the .two trains.
The original test procedure, designed by EPA, called
for 40 points to be sampled by both particulate trains, with
the exhaust louvers removed from the vent. The flow at each
sample point was to be channeled and streamlined by "false
ducts," one foot in diameter and three feet in length, made
of rolled sheet metal. These "ducts" were to be pressed up
against the discharge screen; each sampling nozzle was to be
inserted, facing the screen, through a port cut in the side
of one of these cylinders. For easy access to the vent, a
scaffold had been constructed during the week of November 5,
1973, 30" from and directly in front of the dryer face, as
shown in Figure 6. The sampling trains, sheet metal "ducts",
etc., were to be mounted on a sturdy wooden plank. This
plank would rest on a caster board (see Figure 7), which
would allow the trains to be moved quickly and easily from
side to side. The sampling rig was to be hoisted to the top
of the vent at the outset of each run; there it would rest
on a pair of swing-away support braces attached to the
scaffolding. The four topmost points (left to right) would
be sampled; then the trains would be shut, and the rig
lowered (two feet) to the next pair of support braces, where
four more points would be tested, and so on.
15
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ELECTRIC
MANOMETER
VACUUM
BLOWER
INSULATED HEATING JACKET
. VACUUM LINE
.STAINLESS STEEL
FILTER HOLDER
ROOTS
DRY GAS
METER
CONDENSER
VACUUM
-GAGE
THERMOMETER
~
/ 1
ORIFICE METER
ORIFICE
MANOMETER
Figure 5. High Volume particulate train.
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Figure 6. Scaffolding and sample setup on grain dryer.
17
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1' DlftMETER STACKS PLACED
OIRECTIY ON VENT
HI VOL TRAIN
jg?gg5g55»'K^(7i^>^^
.Figure 7. Sample trains setup for simultaneous sampling
18
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On Wedne.sday, November 14, 1973, a preliminary velocity
traverse of the discharge screen of the St. Joseph dryer was
attempted. Surprisingly, it was found that there was almost
no measurable flow outward from the lower two-thirds of the
I
screen. Almost the entire flow was being emitted from the
top third of the vent, in a somewhat random, non-directional
fashion. It is believed that this effect was the result of
thermal gradients existing between the.bottom of the vent
and the top. The discharge air at the bottom of the vent,
being warmer than the air near the top/ had a tendency to
rise sharply upward before it reached the screen. This heat
rise.effect was apparently great enough to overcome the
outward (90° to screen) velocity component of the discharge
air.
Since the proposed test method was based on the assump-
tion that there would be a measurable outward flow.from the
vent, it became clear that either the test method needed to
be revised, or the source itself would have to be modified
in such a way as to produce the desired outward flow, with-
out disturbing the drying process. It was finally agreed
that the latter was the more viable of the two alternatives;
as a result, 'the top fourth and bottom fourth of the screen
were blocked off, forcing the flow to discharge outward
through the middle. Due to reduced discharge area, the
observed effluent velocities were relatively high for this
type of source, averaging about 600 feet per minute. The
number of sampling points was reduced from 40 to 16, and the
19
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time at each point was increased from 3 minutes to.8.
Two particulate runs were performed with the high
volume and'EPA Method 5 trains side-by-side. Sampling was
conducted under isokinetic conditions by monitoring the
velocity and adjusting the sampling rate accordingly.
Sample recovery for both trains consisted of triple
rinsing the nozzle, probe, cyclone by-pass, and front half
of filter holder with acetone into a glass container.
In addition, for the Method 5 train, the back half of
the filter holder, impingers, and connecting tubes were
first rinsed with distilled water and placed into a glass
container along with the impinger contents. These compo-
nents were then rinsed with acetone and these washings
placed into another glass container. Blank samples .of water
and acetone were also taken in the field and analyzed along
with the sample containers.
Analysis
The analytical procedures used for the EPA train followed
the methods described in the Federal Register of August 17,
1971. The procedures included evaporating all acetone at
room temperature and pressure, evaporating organic water
extracts at room temperature and pressure, boiling off
impinger water after extraction, and then desiccating all
remaining residues and filter (s) to a constant weight.
After desiccating to a constant weight the residues and
1
Federal Register, August 17, 1971, Vol. 36, No. 159, Part II,
20
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filters were weighed to the nearest 0.1 mg. All liquid
fractions were corrected for acetone arid distilled water
i
blank values.
The analyses for the high volume train were only performed
on the acetone wash of the probe and front half of the
filter holder and on the .filter itself *
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