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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