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