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