74-KPM-13
                             (REPORT NUMBER)
AIR POLLUTION EMISSION  TEST
                     ALTON BOX BOARD COMPANY
                           (PLANT NAME)
                      JACKSONVILLE. FLORIDA
                         (PLANT ADDRESS)
          U. S. ENVIRONMENTAL PROTECTION AGENCY
                Office of Air and Water Programs
            Office of Air Quality Planning and Standards
            Emission Standards and Engineering Division
                 Emission Measurement Branch
              Research Triangle Park, N. C.  27711

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  EPA REPORT NUMBER 74-KPM-13

    ALTON BOX BOARD COMPANY

    JACKSONVILLE, FLORIDA
          FINAL REPORT

          Submitted to
Environmental Protection Agency
    Office of Air Programs

    Contract No.  68-02-0225

          Task No. 24
         Submitted by
  Engineering-Science, Inc.
     7903 Westpark Drive
   McLean, Virginia  22101
       December, 1974

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TABLE OF CONTENTS
Section                  Title

    I        INTRODUCTION

   II        SUMMARY AND DISCUSSION OF RESULTS

  III        PROCESS DESCRIPTION AND OPERATION
                A.  Process Description
                B.  Process Operation

   IV        SAMPLING AND ANALYTICAL PROCEDURES
                A.  Location of Sampling Points
                B.  Sampling Procedures
                C.  Analytical Procedures
 7
11

15
15
15
18
Appendix     The Appendices are omitted from this  copy

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Table

  II-l

  II-2

 III-l
              LIST OF TABLES

       Title

Particulate Emission Summary

Particulate Emission Summary (Metric System)
Page

  3

  4
Summary of Calculations of Equivalent Pulp Production
Rate                                                    14
Number

 III-l

 III-2


  IV-1


  IV-2
              LIST OF FIGURES

        Title

The Kraft Pulping Process

Recovery Furnace and Precipitator at the Alton
Box Board Mill in Jacksonville, Florida

General Layout, Alton Box Board, Jacksonville,
Florida

Alton Box Board, Jacksonville, Florida, Stack
Test Ports
Page

  8


 10


 16


 17
                                  ii

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I    INTRODUCTION








     Under Section 111 of the Clean Air Act of 1970, as amended, the




Environmental Protection Agency is charged with the establishment of




performance standards for new 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 is normally gathered from the




stationary source category under consideration.




     The No. 9 black liquor recovery boiler at Alton Box Board Company in Jack-




sonville, Florida, was designated as a possible well-controlled stationary




source in the Kraft pulp industry and was thereby selected by the Office




of Air Quality Planning and Standards for an emission testing program.




Tests were conducted by Engineering Science, Inc. personnel during




December 10-13, 1973.




     This plant processes about 650 tons/day of Kraft pulp.  The No. 9




recovery furnace is designed to burn approximately 93,750 pounds/hour of




black liquor solids.  Air pollution control for this furnace consists of



an electrostatic precipitator.




     Samples were collected after the control device to determine




filterable and total particulate emissions.  Sampling was scheduled during




the boiler soot blowing in order to obtain maximum emission levels.




     The test team and EPA are indebted to Mr. John Jones of the Alton




Box Board Company for his cooperation in the sampling program.

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II   SUMMARY AND DISCUSSION OF RESULTS








     The three particulate sampling runs, which comprised the test pro-




gram, were successfully completed during periods of estimated peak




emissions.  The tests were conducted in the outlet stack of the electro-




static precipitator which controls the emissions from the black liquor




recovery boiler.  It was assumed that maximum emission levels are reached




during boiler tube soot blowing.  This condition is part of normal




boiler operation and occurs at intervals of approximately eight hours.




Each soot-blowing cycle takes approximately three hours.  Continuous




communication with plant-operating personnel ensured that all testing




was conducted during periods of soot blowing.




     A summary of the test results is offered in Tables II-l and II-2.




The average total particulate emission rate established by the test




results was approximately 117 Ib/hr at an average total particulate




concentration of 0.124 gr/scf.  The process emission rate for the No. 9




recovery boiler (i.e., the ratio of emission rate to production rate)




at the average emission rate of 117 Ib/hr and the average production




rate of unbleached air-dried pulp of 19.0 tons/hr was 6.16 Ibs/ton.




     In an effort to eliminate the possible need for a filter change




during the testing, a cyclone separator was installed upstream of the




filter holder in the heated sample box.  During each test run, condensation




collected in the cyclone.  This occurred even though the probe heater and




sample heater were apparently operating normally.  The volumes of liquid




collected in the cyclone were as follows:  run 1 - 118 ml, run 2 - 31 ml and




run 3 - 136 ml.  At the 145-foot sampling elevation, the wind was strong and




at the first few traverse points, the sample box was suspended about 13 feet

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                               TABLE II-l
                      PARTICULATE EMISSION SUMMARY
                                   Run Number & Date
                                           2

Volume of Dry
Gas Sampled (SCF)
Moisture by Volume (%)
Orsat Analysis
(% by Volume)
CO
£
Average Stack Temperature
Stack Flow Rate (SCFM)
Percent Isokinetic
12/11/73
53.66
32.16

10.0
9.1
0
(°F) 249.0
109,190
108.7
12/12/73
53.42
33.70

11.9
7.1
0
239.7
106,826
110.6
12/13/74
55.43
34.39

13.8
4.6
0
241.0
113,807
107.7
Average
54.17
33.42

11.9
6.9
0
243.2
109,941
109.0
Production Rate (tons/hr of
unbleached air-dried pulp)      19.5        18.3        19.2        19.0

Particulates
(Front-Half Catch)
gr/SCF
Ib/hr
Ib/ton
Particulates (Total Catch)
gr/SCF
Ib/hr
Ib/ton
.118
110.86
5.66

.131
122.48
6.28
.094
85.77
4.69

.107
98.25
5.37
.120
116.91
6.09

.134
131.14
6.84
.111
104.51
5.48

.124
117.29
6.16
     NOTE:  Standard Conditions - 70° F,  29.92  in. Hg

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                          TABLE II-2
PARTICULATE EMISSION SUMMARY
(Metric System)
Run Number & Date
123
12/11/73
Volume of Dry Gas
Sampled (Mm )
Moisture by Volume (%)
Or sat Analysis
(% by Volume)
C00
9
°9
cS
Average Stack Temperature
(°C)
Stack Volumetric Flow Rate
(Nm /min)
Percent Isokinetic
Production Rate (M tons/hr
of unbleached air-dried pulp)
Particulates
(Front-Half Catch)
mg/Nm
kg/hr
kg/M ton
Particulates
(Total Catch)
mg/Nm
kg/hr
kg/M ton

1.52
32.16


10.0

9.1
0

120.6

3,092
108.7

17.7


271.09
50.28
2.84


299.53
55.56
3.14
12/12/73

1.51
33.70


11.9

7.1
0

115.4

3,025
110.6

16.6


214.39
38.90
2.34


245.59
44.57
2.68
12/13/74

1.57
34.39


13.8

4.6
0

116.1

3,223
107.7

17.4


274.31
53.03
3.05


307.68
59.48
3.42
Average

1.53
33.42


11.9

6.9
0

117.4

3,113
109.0

17.2


253.26
47.41
2.74


284.27
53.20
3.08
NOTE:  Standard Conditions - 21.1°C,  760 mm Hg

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out from the stack.  The wind cooled both the exposed length of probe and the



heated cyclone/filter compartment of the sample box.  This cooling was apparently



sufficient to cause the condensation.  The wind was moderate and relatively



constant during the first two runs, but the ambient temperature increased



about 20°F from run 1 to run 2.  It is believed that the higher ambient temper-



ature caused the reduction in cyclone condensate catch collected during the



second run.  The ambient temperature dropped only about 6°F between run 2 and



run 3, but the wind velocity greatly increased thus accounting for the additional



amount of liquid collected in the cyclone during run 3.



     The liquid collected in the cyclone was transferred to an individual



sample container so that it could be analyzed separately.  After removal of



this catch from the train, the normal clean-up procedures were followed.



The resulting residue weights were included in the front-half particulate cal-



culations.  The volume of the cyclone condensate    was added to the condensate



volume collected in the impingers to determine the total moisture content of



the sampled gas .



     During the testing there was deflection of the probe when it was



extended to the furthest traverse points within the stack.  This was



caused by the weight of approximately 10 feet of unsupported probe



assembly.  Prior to field testing, it was observed that when 10 feet of



probe was cantilevered, the end sag was about 13 inches.  The angle of



deflection, 0, of  the probe tip from a position normal or square to the



direction of gas flow can be calculated from the following equation:
                             -
                     radians   GEI
 (1)  In  the laboratory report contained in Appendix D, the cyclone  condensate

     is  referred to as "Front Half Water Catch."

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where        W = 0.061 Ib/in. = weight/unit length


             L = 120 in. = length of probe


             E = 2.75 x 107 Ibs/in. = Young's Modulus

                           A
             I = 0.0044 in.  = Moment of Inertia


This angle was computed to be 8.5°.  The effective nozzle area, then, is


the area of an ellipse with major and minor axes of r and r times the cosine


of 0, respectively, where r is the radius of the nozzle opening.  As the


effective nozzle area was reduced by only 1.1%, it is felt that this effect


is negligible.


     Testing proceeded smoothly and normally on three consecutive days


with no equipment, personnel or process problems encountered.

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Ill  PROCESS DESCRIPTION AND OPERATION








     The Alton Box Board mill at Jacksonville, Florida, produces 650




tons of kraft pulp per day.  The pulp is made into linerboard in the




adjoining paper mill.



     The EPA test program at this mill consisted of three particulate




tests on the outlet of the Number 9 recovery furnace precipitator.






A.  Process Description




    1.  General




     Kraft pulp is produced from wood as shown in Figure III-l.  In the




process, wood is chipped into small pieces, then cooked in six batch




digesters at elevated temperature and pressure.  The cooking chemicals,




called white liquor, are sodium hydroxide and sodium sulfide in water




solution.  The white liquor chemically dissolves lignin, leaving wood




cellulose  (pulp)  which is filtered from the  spent liquor and washed.




The pulp is then made into linerboard.



     The balance of  the process is designed to recover  the cooking




chemicals.  Spent cooking  liquor and  the pulp wash water are combined




for treatment.  The  combined  stream,  called weak black liquor,  is con-




centrated  in multiple-effect  evaporators and  stored.   As needed,  the




black liquor is drawn from storage and  oxidized in an  air sparging  tank.




The oxidized liquor  receives  its final  concentration in direct contact




evaporators and is then  fired to a recovery  furnace.




     Combustion of the organics  in the  black liquor provides most of the




heat needed to generate  process  steam.   Inorganic chemicals  from the black




liquor  are recovered as  a  molten  smelt  at  the bottom of the  furnace.  The




smelt,  consisting of sodium carbonate and  sodium  sulfide,  is dissolved

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                                                                  FIGURE  III-l
                      THE KRAFT PULPING  PROCESS
o
          Wood
Z3
CL.
   White Liquor
   (NaOH + Na2S)
DIGESTER
SYSTEM

Piiln fe


	 W
^ ^
PULP
WASHERS
eak Black Liquc
                                                                 Pulp

                                                                 Water
                     RECOVERY
                      FURNACE
                       SYSTEM
                                 Heavy
                                 Black
                                 Liquor
                (Na
                    Smelt
                               Air
                                I
BLACK
LIQUOR
OXIDATION
TANK



MULTIPLE
EFFECT
EVAPORATOR
SYSTEM
2C03
                         Na2S)
                                              Air
                                               1
           Water
                       SMELT
                     DISSOLVING
                       TANK
    t
                         T
                    Green Liquor
                        \	
      White Liquor
      (recycle to
      digester)
                    CAUSTICIZING
                        TANK
                                       Calcium
                                      Carbonate
                                         Mud
                                                    ENGINEERING-SCIENCE, INC.

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in water and transferred to a causticizing tank.  Lime added to this tank




converts sodium carbonate to sodium hydroxide, completing the regeneration




of white liquor, which is then recycled to the digesters.  The calcium




carbonate mud that precipitates from the causticizing tank, is recycled



to a kiln to regenerate lime.





    2.  Recovery Furnace




     The Number 9 recovery furnace was designed by Combustion Engineering




to burn 93,750 pounds of black liquor solids per hour; this corresponds




to a pulp production rate of about 600 tons per day.   Fuel oil is also




burned in the furnace at a design rate of about 10 gallons per minute.




The furnace has a conventional design, with two parallel cascade direct




contact evaporators.  Strong black liquor is oxidized in a single stage,




air-sparged tank.  The furnace was installed in 1969.




     Soot is blown from the furnace boiler tubes with steam.  Each soot




blowing cycle takes about three hours and is performed once a shift,




or less often,





    3.  Electrostatic Precipitator




     Exhaust gases from the Number 9 recovery furnace are cleaned in an




electrostatic precipitator.  The precipitator was installed in 1970 by




the Koppers Company.  The unit was designed to treat 325 F combustion




gases at a rate of 243,300 ACFW.   As shown in Figure III-2, the pre-




cipitator has two separate chambers in parallel; each chamber has three




electrical fields.  The precipitator is situated near ground level and




exhausts through a tall stack.




     Dust collecting on the precipitator electrodes is shaken loose by




a system of rappers.  The rappers operate in a continuous cycle, with

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                                     RECOVERY FURNACE AND PRECIPITATOR AT THE

                                             ALTON  BOX BOARD MILL IN

                                              JACKSONVILLE, FLORIDA
                  RECOVERY

                  FURNACE
m

O

z
m
m
3D
9
CO
o

m
Z
O
m
                                                                                 Sampling
                                                                                  Ports
                                  Furnace
                                 Combustion
                                   Gases
^-
x._




/\
nTRFPT
CONTACT
EVAPORATOR
(EAST)

^^^ ^**\.
| DIRECT
CONTACT
EVAPORATOR
(WEST)

*1
1
1
k .
*-?
i
ELECTROSTATIC
PRECIPITATOR
(EAST CHAMBER)


ELECTROSTATIC
PRECIPITATOR
(WEST CHAMBER)




^
£
INDU
Air
                                              t_
Black Liquor
DRAFT

 FAN
                                                   c:
                                                   70
Z
O

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each cycle lasting 2 1/2 minutes.  The dust falls into hoppers and is




flushed out with black liquor, and recycled to the process.






B.  Process Operation




    1.  General




     The purpose of the tests was to measure particulate emission levels




during normal plant operation.  The information was to help  demonstrate




actual control levels for recovery furnace operations.




     As mentioned above, soot is blown from the tubes just once a shift.




This practice makes it difficult to select a sampling period representa-




tive of recovery furnaces in general, since most mills blow  soot continually.




It was decided to sample entirely during periods of soot blowing, the most




severe condition for the precipitator.  The -measurements, therefore,  repre-




sent the maximum emissions from this precipitator during normal plant




operation.





    2.  Recovery Furnace




     During the particulate tests, significant furnace parameters were




monitored.  Readings were made every half hour and recorded  on the process




data sheets contained in Appendix C.




     As far as known from the process data and conversations with the




operators, the equipment operated normally during the tests.  The black




liquor charge rate varied between 141 and 155 gallons per minute, as




normal.  Auxiliary fuel oil was fired at an average rate of  about




12 gallons per minute during the first two tests.  During the third,




the rate was increased to 20 gallons per minute.  (One of the bark boilers




had broken down the previous evening, and additional steam was needed




from the recovery furnace.)
                                    11

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      3.   Electrostatic  Precipitator

      The operation of  the precipitator was monitored during the tests.

 Readings of the primary voltage, primary current, and secondary current

 were recorded every half hour.  The secondary current was read at two

 locations; at the precipitator control panel and in the furnace control

 room.  Readings from the control panel were nearly twice as high, and

 are  considered more accurate by the plant.  The readings were recorded

 on the bottom of the furnace process data sheets, included in Appendix C.

      As  far as known from the process data and conversations with the

 operators, the precipitators operated normally during the tests.  Three

 of the discharge electrodes were inoperative, but they are just a small

 fraction of the several hundred electrodes installed and are not thought

 to affect performance  significantly.

      4.   Equivalent Pulp Production Rate

      The operation of  the recovery furnace is quantitatively related

 to the pulp production rate in the digesters.  As a result, pollutant

 emission rates can be  expressed on the basis of equivalent pulp

 production, as shown below:
              (\         /             \     /  /Equivalent Pulp\
 Emission Rate\   _     (Emission Rate]   /   I Production Rate I .
 (Ib/ton  pulp)y   "     y   (Ib/hr)   I  /    \   (ton/hr)    /        Eq.

       To use Equation III-l,  the  equivalent pulp  production was  calculated

 from the black liquor  charged during the tests, as shown below:


/Equivalent\        /Black  \   /Pulp  to Liquor\   / % Solids  \
I    Pulp    \   =    I Liquor  I  /    Ratio       \   I (Test Avg.) I    Eq.(III-2)
I Production I        I Charged I  I at avg. % Solidsl   I  % Solids   I '
\  (tons)  /        \(gallons)/  \ (tons/gallon)  /   \(base Avg.)/

      The pulp-to-liquor ratio in Equation III-2 was estimated to  be 0.0022

 tons of  unbleached air-dried pulp per  gallon of  black liquor  fired.   The

 ratio was determined by dividing total pulp production for a  30-day period


                                       12

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 at  a southern Kraft mill,  by the total black liquor fired in a same period.

 The  average percentage  of  solids of  the black liquor was  63.2.

      The last term in Equation III-2 corrects for the  actual percentage  of

 solids  in the black liquor  charged during  the  tests, to  that  on which the

 pulp-to-liquor ratio is based (63.2).

      Substitution of the  appropriate constants into Equation III-2 gives:


fEquivalent\    / Black  \    /          \                 \
    Pulp   \  _ /  Liquor \   /   0.0022  \     /  % Solids \         E  ,
[Production/  ~l  Charged  I   l( ton/gallon))     ( (test  avg.) )          q'U
x  (tons)  /    Vgallons)/   \          /     \     63.2    /


      Equation III-2 was used to calculate the equivalent  pulp production

 during each test  on the recovery furnace.   Dividing by the time  elapsed

 while charging the black   gave the equivalent pulp production rate.

 The calculations  are summarized in Table III-l.   As shown, the average

 rate was found to be 19.0 tons per hour.   Substituting into  Equation III-l

 gives the following equation, which was used to calculate mass emission

 rates:


     /Emission Rate)        /Emission Rate)   //  19.0 \            _,  ,TTT ..
     ( (Ib/ton)    /    =    \  (Ib/hr)    }/  \(ton/hr))'           Eq. (III-4)
                                    13

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                                                    TABLE IIT-1




                             SUMMARY OF CALCULATIONS OP EQUIVALENT PULP PRODUCTION RATE
Black Liquor Readings
flours (1) Integrator (2) Avg. Z
Date - 1973 Start Finish Start Finish Solids
Dec. 11 1226 1600 22,624,905 22,627,954 65.5
Dec. 12 1104 1432 22,645,655 22,648,536 63.2
Dec. 13 0933 1201 22,663,017 22,665,086 65.8
Black
Liquor
Charged
(Ibs)
30,490
28,810
20,690
Equivalent
Pulp Elapsed
Production (3) Time
(tons) (hrs)
69.5
63.4
47.4
3.57
3.47
2.47
Equivalent
Pulp
Production
Rate(4)
(tons/hr)
19.5
18.3
19.2
19.0 (Avg.)
(1)  Item 12 on the process data sheets.




(2)  Item 11 on the process data sheets.




(3)  Calculated from Equation 2.



(4)  Calculated by dividing Equivalent Pulp Production by Elapsed Time.

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!V   SAMPLING AND ANALYTICAL PROCEDURES

A.   Location of Sampling Points
     The testing was conducted in the 185-foot high precipitator outlet
stack.  The work platform was about 142 feet above grade, 3 feet wide,
and extended around one-third of the stack circumference.  Two 4-inch
pipe ports, located 90  apart, extended through the 28-inch double wall
thickness and protruded 8 inches from the stack.  The ports were located
about 109'-6" downstream from the breeching and about 39'-3" upstream
from the stack outlet to the atmosphere.  The inside diameter of the
stack at the test ports was 10'-9".  Figures IV-I and IV-II illustrate
the test site.
     In accordance with EPA Method 1 (Federal Register, Vol. 36, No. 247,
Part II, Dec. 23, 1971), 6 point traverses were conducted because the
test locations were ideally located more than 8 diameters downstream
from the breeching to the stack and more than 2 diameters upstream from
the top of the stack.  Sampling points 1 through 6 were obtained in port
A and points 7 through 12 in port B.
     The traverse point locations, as measured from the inside stack
wall at the sampling port, were as follows;

                    Points 1 & 7        5.75 in.
                           2 & 8       19.00 in.
                           3 & 9       38.00 in.
                           4 & 10      91.00 in.
                           5 & 11     110.00 in.
                           6 & 12     123.25 in.

B.  Sampling Procedures
    Because of the long probe length necessary  to  traverse  the  stack,
an unsheathed, 16 ft. incolloy liner was used for  the  testing.   It was

                                   15

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                    GENERAL LAYOUT
        ALTON  BOX BOARD, JACKSONVILLE,  FLA,
Outlet  Stack
Test Ports
                                        Inlet
                                     Test Ports
                      n    n    n
                      Wet Bottom  Electrostatic  Precip.
                                    (2)
From Recovery
      ler
                                                                    Direct Contact
                                                                     Evaporator

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                                                          FIGURE IV-2
         ALTON BOX BOARD, JACKSONVILLE.  FLA.
                    STACK TEST PORTS
   Concrete Stack
             Ladder
                                               Port B
                                                4" Test Ports
Davit &  Pulley Existing
                          Port A
                 Cross Section at Stack  Ports
                                          Exit ID 10'6"
Stack Ports
^n


vo
IT)
f- 	
) 	




_
**









                           17
ENGINEERING-SCIENCE. INC.

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fitted with a  standard nozzle at one end and a standard ball-joint for




connection to  the sample train at the other end.  The liner was wrapped




with a heating tape, an insulating asbestos tape and then a protective




layer of duct  tape.  A laboratory check of the probe heater prior to the




field work indicated the air inside the tube was heated to 270°F when




plugged directly into a 110-volt AC supply.  This same power source was




used during the testing program.  A Type S pitot tube, approximately 15




feet long, was clamped to the probe completing the assembly.  An overhead




angle rail was  set up from which the sample box/probe assembly was supported




by a trolley.   This allowed for smooth in and out movement of the probe




during the long traverse.




     A standard EPA sampling train including a cyclone separator was




utilized during all testing.  The cyclone was installed upstream of the




filter holder,  inside the heated box.  Two passes were made in each port




so that a total of 10 minutes per traverse point and 2 hours per test




total sampling time were accumulated.




     The sampling was conducted as specified by EPA Methods 1 through 5




with the additional requirement that the cyclone condensate and the




impinger contents were collected and analyzed for particulate content.




These methods were published in the Federal Register, Volume 36, Number 247,




Part II, Thursday, December 23, 1971.  The procedure for recovery and




analysis of the impinger contents are published in the Federal Register,




Volume 36, Number 159, Part II, Tuesday, August 17, 1971.  The cyclone




condensate was recovered in the same manner as the impinger contents.






C,  Analytical Procedures




    The cleanup site  was located in an enclosed truck which was  parked




yery close to  the base of the stack.  All sample train preparation and
                                    18

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clean-up was performed in this clean, well-lighted, enclosed area.  The




particulate trains were charged, capped and hoisted up to the stack work




platform by rope and pulley.  After each test, the train and probe were




capped and lowered to the ground.  They were then carried the short dis-




tance to the truck and cleaning proceeded.  All the integrated gas




samples, taken during particulate sampling, were run through the Orsat




analysis the same day they were collected, soon after the test run was




completed.  The procedures followed for the laboratory analyses and




calculations of results are defined in the previously referenced issues




of the Federal Register.
                                   19

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