AIR
             EM IS
                         EPA PROJECT REPORT NUMBER
                   GREAT NORTHERN PAPER COMPANY

                     Cedar Springs,  Georgia
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
          Office of Air and Waste Management
      Office of Air Quality Planning and Standards
           Emission Measurement Branch
        Research Triangle Park, North Carolina

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                     TABLE OF CONTENTS
      APPENDIX A:  COMPLETE PARTICULATE  RESULTS  AND  EXAMPLE
                   CALCULATIONS

      APPENDIX B:  FIELD DATA

      APPENDIX C:  PRELIMINARY TRAVERSES

      APPENDIX D:  PROCESS DATA

      APPENDIX E:  TEST METHODS

      APPENDIX F:  TEST LOG AND SAMPLE  IDENTIFICATION

      APPENDIX G:  PROJECT PARTICIPANTS
                                                               PAGE
I      INTRODUCTION                    "                          1

II     SUMMARY AND DISCUSSION OF RESULTS                 .        3

III    PROCESS DESCRIPTION AND OPERATION                         6

IV     LOCATION OF SAMPLING PORTS                               10

V      SAMPLING AND ANALYTICAL PROCEDURES                       12


      LIST OF FIGURES
      FIGURE I:    STACK LAYOUT AND TEST  PORT  LOCATION          2

      FIGURE II:   THE KRAFT PULPING PROCESS AT  THE  GREAT       7*
                   NORTHERN MILL  IN CEDAR SPRINGS,  GEORGIA

      FIGURE III:  FLOW DIAGRAM OF THE NO.  2 LIME  KILN  AT       8^
                   THE GREAT NORTHERN MILL IN  CEDAR  SPRINGS,
                   GEORGIA

      FIGURE IV:   LOCATION OF SAMPLING PORTS                  11


      LIST OF TABLES

      TABLE I:   PARTICULATE SUMMARY - ENGLISH  UNITS             *»

      TABLE I:   PARTICULATE SUMMARY - METRIC UNITS              5


      APPENDICES

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                            -1-

                       INTRODUCTION
A Cottrell Environmental Sciences, Inc., test team performed
stack sampling tests at a kraft pulp mill lime kiln owned
and operated by the Great Northern Paper Company, Cedar
Springs, Georgia, during the period of September 16 through
September 20, 197^.

Lime kiln #2 at Great Northern Paper Company's Cedar Springs
mill (now Great Southern Paper Company at same location) was
manufactured by Traylor Engineering and  installed in 19&3-
The kiln is 265 feet long with an inside diameter of 11 feet
and it can be fired on either #6 fuel oil or natural gas.
Great Northern operates this system at or near its design
capacity of 210 tons of lime produced per day.  The kiln's
particulate emissions are controlled by  a high energy ven-
turi scrubber/demisting tower manufactured by Air Pollution
Industries and a 50.5 foot high smokestack with an inside
diameter of six (6) feet.  (See Figure  I)

The purpose of the  test program is to obtain emission data      '
as part of the background data needed to establish new  source  4
performance standards as authorized by  the Clean Air Act.  The
U.S. Environmental  Protection Agency's  Emission Standards and
Engineering Division of the Office of Air Quality Planning and
Standards selected  this particular lime  kiln control system
because it is thought to represent best  available control tech-
nology.  Several other kraft pulp mill  lime kilns are also be-
ing tested by the EPA to obtain additional emission data.  Part-
iculate samples were extracted from the  smokestack approximately
57 feet above ground level (downstream  of the cyclonic  demister)
and 29 feet beneath the stack outlet.   Six EPA Method 5 part-
iculate tests and six EPA Method 3 Orsat analyses were  per-
formed during each  of the two operating  conditions:  Oil  fired
and gas fired.  The EPA will subsequently analyze the part-
iculate samples for trace elements.  Oil samples were col-
lected for analysis by the EPA.

Preliminary traverses were performed in  each of the exist-
ing three ports at  the stack test site  on September 16,  197^
to determine  if straightening vanes  installed by the Great
Northern Paper Company prior to the test program were suc-
cessfully eliminating a vortex flow pattern  in the stack  due
to the cyclonic mist eliminator.  The results of these  trav-
erses may be  found  in Appendix C.  From  this data  it is ap-
parent that the four foot high steel cross straightening  vanes
only partially eliminated the cyclonic  flow and  it  is not un-
reasonable to conclude that no greater  than a 50% vorticity
reduction was achieved.  Moreover, the  double steam plume
"characteristic of  the cyclonic demister  remained after  the  in-
stallation of the  straightening vanes.   The accuracy of the
test results  as reported should be considered somewhat  ques-
tionable  in view of the continued presence of cyclonic  flow.

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                                   -2-
                                    T£<>T
                                        _
                                    foKT3 GO
                                             s/
                                             ai
                                             A
    Section A-A
A' High Steel Cross
Straighteniag Vanes
                                             35V
7  7  7  7  7
                                                  f r
                      FIGURE  I   - STACK LAYOUT  AND

                           TEST PORT LOCATION

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             SUMMARY AND DISCUSSION OF RESULTS
A summary of test results is presented in Table I.   Appendix
A of this report contains a computer printout, sample calcul-
ations, a handwritten calculation form,  a sample weight "Mas-
ter Sheet" and laboratory analysis forms.  All raw data sheets
may be found in Appendix B.

A 0.25" stainless steel  sampling nozzle  was utilized during
the test program with the exception of the first five (5)
points of port A during  Test #1.  An actual nozzle diameter
of 0.375 inches had been selected but was abandoned after
five (5) traverse points because the vacuum pump could not
generate enough suction  to produce the sampling rates.  A
weighed average "Equivalent Nozzle Diameter" was computed
for the isokinetic rate  calculation for  Test #1.

The probe wash catch of  Test #1 contained a large quantity
of black partlculate matter.  Due to equipment shipping prob-
lems, a stainless steel  probe had to be  utilized instead of
the glass lined probe specified.  The probe used for this
test program was borrowed from the Great Northern Paper Com-
pany and was previously  used to test the recovery boilers'
electrostatic precipitator.  Prior to usage, the sampling
probe was water and acid washed with 8M  nitric acid and
acetone rinsed by Mr. J.W. Brown, EPA, inside Great Northern
Paper Company's Test Laboratory, sealed  with duct tape and,
transported to the test  site.   It was the opinionoof the
author  (at that time) that further probe cleaning was un-
necessary prior to testing.

During Test #3 the EPA sampling train filter had to be
changed after sampling 28 of **0 test points.  This was most
likely due to an unscheduled shut off of the scrubber  spray
shower by plant personnel.

An unscheduled shut down of the lime kiln due to a defective
drag chain forced a delay during Test #5.  The sampling
train was shut off after sampling 20 points and the nozzle
was taped shut to prevent sample contamination.  The test
resumed after repair was completed.

The average grain loading for Tests #2 and #3 (Natural gas-
fired) was 0.0412 grains/SCFD.  The average grain loading
for Tests #5 and #6  (Oil-fired) was 0.0932 grains/SCFD.
The grain loading for Test ffk will not be used by EPA for
New Source Performance Standards data as it is so much smal-
ler than the other two tests.

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                                      TABLE  I
                                PARTICULATE  SUMMARY
                                   ENGLISH  UNITS
RUN NUMBER
~" te
1
Gas
9-17
2
Gas
9-18
3
Gas
9-18
1*
Oil
9-19
5
Oi 1
9-19
6
Oi I
9-20
Volume of Gas Sampled - DSCFa

Percent Moisture by Volume

Average Stack Temperature -°F
A0.18   3**.3/t  37.66  30.81   38.^   48.36

 *M.'17  *t0.99  38.98  36.52   32.60   36.32

 155.1  151.1  1 5 ^. *>  1A8.1   152.2   U8.9
Stack Volumetric Flow  Rate  -  DSCFMb    24.054  22.342  2A,96*t 21,159 25,575  33,^75

Stack Vo I umetric Flow  Rate  -  ACFMC     40,847  36,200 *t1,2*tO 33,179 40,9^0  52,351
Percent Isokinetic
102.98  107.35 105.36  101.70  10*5.98 100.91
Percen t Excess A i r
 27.37   53.88  36.42    54.55   52.96   28.74
Percent Moisture  (Psychrometric)
Feed Rate - ton/hr
  31.5  28.75  29.75    27.0    28.0  26.75
  N/A    	    	      	     	   r--
Part i cul ates - probe, cyclone,
and filter catch
mg
qr/DSCF
cr'r/ACF
Ib/hr
Ib/ton feed
Participates - total catch
mg
qr/DSCF
qr/ACF
Ib/hr
1 b/ ton feed
Percent inpinger catch
278.5
0. 107
0.0629
22.06
N/A
^406. 7
0. 1562
0.0919
32.20
N/A
31 . 5
76.5
0.03^
0.021 1
6.58
» _ _
250.3
0.1125
0.0689
21 .5^
...
69. *»
117.0
0.0^+79
0.0290
10. 26
_. _ _
209. 1
0.0857
0.0519
18. 33

i»A.O
61 . 2
0.0307
0. 0195
5.56
•.*,«.
120. 3
0.0603
0.0385
10.93

^9. 1
228. 8
0.0919
0.057*»
20. 13
_ _ _
267-0
0. 1072
0.0669
23.50
...
M.3
296. 2
0.09^5
0. 0604
27.12
„ *. M
393-5
o. 1256
0.0802
36.02
...
2*4.7
•
aDry  standard  cubic  feet  at  70°F,  29.92 in. Hg.

Hry  standard  cubic  feet  per minute at 70°F, 29.92  in. Hg.

-Actual  cubic  feet  per  minute

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                                     TABLE
PAK
RUN NUMBER
Hate
Volume of Gas Sampled - Nm3 (a)
Percent Moisture by Volume
Average Stack Temperature - °C
Stack Volumetric Flow Rate -
Nrr>3/mi n . (b)
Stack Volumetric Flow Rate -
m3/m in. (c )
Percent Isokinetic
Percent Excess Air
Percent Moisture (Psych romet ri c)
Feed Rate - Mton/hr
Particulates - probe, cyclone,
and filter catch
••ng
mg/N.m3
mg/m3
kg/hr
kg/Mton Feed
Barticulates - total catch
mq
mq/N.m3
mq /rr>3
kq/hr
kg/Mton Feed
Percent impinger catch
-t 	 	 .- -^
1 I UULA 1 t
METRIC UN
1
Gas
9-17
1 . 138
41 . 17
68.4
681.2
1157.2
102.98
27.37
31.5
N/A

278-;5
244.7
143.9
10.00
N/A

406.7
357.4
210. 3
14.61
N/A
31 .5

:> o n ri H t\ i
ITS
2
Gas
9-18
0.973
40.99
66.2
632.7
1025.2
107-35
53.88
28.75
-. m, m.

76.5
.78.6
48.3
2.98
M « m*

250.3
257.2
157.7
9-77
*• m* •»
69.4

3
Gas
9-18
1 .067
38.98
68.0
707-0
1167.9
105.36
36.42
29.75
mm _ _

117-0
109-7
109-6
4.65
mm mm mm

209. 1
196.0
118.8
8.31
mm mm. mm
44.0

4
Oi 1
9-19
0.873
36.52
64.5
599.2
939 -6
101 .70
54.55
27.0
mm mm _

61 .2
70. 1
44.6
2.52
•» — «

120. 3
137.8
88.1
4.96
mm mm. _.
49- 1

5
Oi 1
9-19
1 .089
32.60
66.8
724.3
1159.4
104.98
52.96
28.0
......

228.8
210.1
131.4
9-13
*. — M

267.0
245- 2
153.1
10.66
r i_i 	
14.3

6
01 1
9-20
1 .370
36.32
64.9
948.0
1482.6
100. 91
28.74
26.75
— — —

295. 2
216.2.
138.2
12. 30
— .. M

393-5
287.2
183.5
16. 3 *
mm mm ^r
24.7

JDry  normal  cubic meters per minute at 21.1°C, 760mm Hg




 Actual  cubic  meters per minute

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                            -6-

             PROCESS DESCRIPTION AND OPERATION
The Great Northern Company mill at Cedar  Springs, Georgia,
produces about 1700  tons of kraft pulp per day.  The mill
also produces 380 tons of neutral sulfite semi-chemica1
(NSSC) pulp per day.  All of the unbleached pulp is convert-
ed  into paper.
                    PROCESS  DESCRIPTION
                       A.  Gene ra1
The process for making kraft pulp  from wood  is  shown  in
Figure  II.  In the process, wood  is chipped  into  small pieces
and then cooked in digesters at elevated  pressure  and  temp-
erature.  The cooking chemicals,  called white  liquor,  are
sodium  hydroxide and sodium sulfide in water solution.   The
white liquor chemically dissolves  lignin,  leaving  wood cel-
lulose  (pulp) which  is filtered from  the  spent  liquor  and
washed.  The pulp  is made  into paper.

The balance of the pulping process  is designed  to  recover  the
cooking chemicals.   Spent  cooking  liquor  and the  pulp  wash
water are combined for treatment  to recover  chemicals.   The
combined stream, called weak black  liquor,  is  concentrated
in multiple-effect evaporators.   The  strong  black  liquor
leaving the evaporators is burned  in  a recovery furnace.

Combustion of the  organic  matter  in the black  liquor  provides
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  car-
bonate  and sodium  sulfide, is dissolved  in water  and  trans-
ferred  to a causticizing tank.  Lime  added  to  this tank  con-
verts sodium carbonate to  sodium  hydroxide,  completing the
regeneration of white liquor.  The  white  liquor is then  re-
cycled  to the digesters.   The calcium carbonate mud  that pre-
cipitates from the causticizing tank  is  recycled  to  the  kilns
to regenerate lime.
                    B.   Lime  KiIn  No.  2
The  number  2  lime  kiln was  installed  in  1963  and  was  designed
by Traylor  Engineering to produce  210  tons  of  lime  per  day.
JThis  is  equivalent  to a  pulp  production  rate  of about  840
tons  per  day.  This  rotary  kiln  is  265  feet  long, with  an  in-
side  diameter  of  11  feet.   It  is fired with  either  natural
gas  or No.  6  oil.

The  feed  to the kiln  is  the calcium carbonate  slurry  that  pre-
cipitates  from the  causticizing  tanks.   The  slurry  is  washed
and  then  dried on  a  rotary  vacuum  drum,  as  shown  in  Figure  III

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                                  -7-
      WOOD
IQUOR___
Na2S)
DIGESTER
SYSTEM

— PULP- 	 *

— IJ F A K
PULP
WASHERS
RI A™ i rniif
                                                        -PULP

                                                        •WATER
                     RECOVERY
                      FURNACE
                      SYSTEM
      STACK
O
O
UJ
                     I
                   SMELT
              (Na2C03 +
                               HEAVY
                             — BLACK-
                              LIQUOR
                           n
                            AIR
                         MULTIPLE
                          EFFECT
                        EVAPORATOR
                          SYSTEM
          WATER-
                   SMELT
                DISSOLVING
                    TANK
  L
WHITE LIQUOR
(RECYCLE TO
 DIGESTER)
               GREEN  LIQUOR
                     I
CAUSTICIZING
    TANK
                                       LIME
                                           CALCIUM.
                                         •CARBONATE
                                             MUD
Figure I I The Kraft Pulping Process  at the Great Northern Mill
                     in Cedar Springs, Georgia

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-i
                 LIME
                   . MUD
                     AIR
                     GAS OR
                     NO. £>  OIL
                               LIME
                             (PRODUCT)
           SAMPLING  PORTS
                                                                EXHAUST
                                                                  GAS
                                                                                         STACK
                                                                        JL
FRESH
WATER'
                                                                     VENTURI
                                       \
                               DEMISTER
                  -RECYCLE-
•^BLEED
                   Figure i |  |  Flow Diagram of the No.  2 Lime Kiln at the Great Northern Mill
                                               in Cedar Sorinqs, Heorqia
                                                                                                           CO

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                           -9-
The dried cake is removed from the drum on a knife edge and
conveyed to the kiln.  In the kiln, the calcium carbonate
mud is roasted and carbon dioxide  is driven off, leaving
calcium oxide (lime)  as product.
An adjustable throat venturi scrubber
particulate emissions from the kiln.
factured by Air Pollution Industries,
197**.  It is designed to operate at a
inches of water.  Fresh water is used
b i ng sys tern.
                                      is used to control the
                                      The scrubber was manu-
                                      Inc., and installed  in
                                      pressure drop of 2k
                                      as makeup to the scrub'
                     PROCESS OPERATION
                        A.  Genera 1
The purpose of the test program was to measure emission levels
during normal mill operation.  Process conditions were ob-
served, and testing was done only when the test facility ap-
peared to be operating normally.  During the tests,  important
operating conditions were monitored and recorded on  process
data sheets.  The records are in Appendix D.
                   B.  Lime KiIn No. 2
A total of six tests were conducted.  Three on each type of
fuel burned in the kiln.  As far as is known from the process
information and conversations with the operators, the lime
kiln operated normally during the tests.  According to  the
operators, the process control of the kiln  is not as.smooth
when it is fired on oil as compared to natural gas firing.
This is mainly due to the less precise fuel flow adjustment
available for residual oil operation.

As  for the scrubber, the shower water was cut off during run
#3  for about 20 minutes to solve an overflow problem.   Dur-
ing the rest of the testing, the pressure drop across the
venturi scrubber ranged between 13-0 and 20.8 inches of water
This is about 10 to 20 percent below the typical operating
pressure drop of the scrubber system.  No makeup lime was
added  to the kiln feed during testing.

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                           -10-

                LOCATION OF SAMPLING PORTS
Figure IV illustrates the location of kO test points used
during velocity traverses and particulate runs.   Port C
was used during the preliminary traverse of September 16,
\37k.  Ports A & B were used for particulate sampling.

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                   -11-
                      A
                                                 N
     Not used
     for testing
                                            is  it, 17 18 n
"FIGURE  iv  -  LOCATION OF SAMPLING  POINTS

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                           -12-

            SAMPLING AND ANALYTICAL PROCEDURES
Appendix E contains a copy of pertinent section? from the
Federal Register, Volume 36, Number 2kJ,  December 23, 1971,
a schematic of the sampling train utilized, and a laboratory
analysis procedure.

The Federal Register outlines the methods to be used for
sample and velocity traverses for stationary sources (Method
I), the determination of stack gas velocity and volumetric
flow rate  (Method  II), the determination of particulate
emissions  from stationary sources  (Method V), and gas analy-
sis for carbon dioxide, excess air and dry molecular weight
(Method III).   However, the "back half" analysis of Method
V was performed as prescribed by Federal  Register, Volume
36, Number 159, August 17, 1971.

The sample train schematic in Appendix E, illustrates the
remote filter box modification of EPA Method V.  The "op-
tional" cyclone located in the heated area between the probe
and filter was not used.  Prior to testing, 100 ml of dis-
tilled, deionized water was placed in impingers one and two,
and 200 grams of silica gel was placed in impinger four.

The fiberglass filters were prepared using a slightly dif-
ferent method than is outlined in the laboratory analysis
procedure.  Each filter was dessicated for 2A hours, weighed
to +_ 0.0001 grams, and stored in plastic bags prior to and
after use.  A "front half" water wash was also included in
the cleanup procedure, the resulting sample weight being
added to the "front half" acetone wash catch.  The water
wash was necessary because previous lime kiln testing ex-
perience indicated the presence of acetone insolubles in
the front  half of  the sample train.

Fisher brand Orsat apparatus and chemicals were used for
gas analysis in accordance with Method III.  The model util-
ized had a 100 ml  burette immersed in a water jacket.

Calculation of the amount of water vapor possible at the  re-
corded temperatures and stack pressure show that more water
was collected than a saturated gas stream at those temper-
atures could have  as a vapor.  Therefore, the psychrometric
chart was  utilized for moisture determination  in the sat-
urated effluent.
                                ma*imi»iaitBBrTm^'iaMr«t»*aaiEaci>KfB»^

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