74-L1M-5	
                               (REPORT NUMBER)
AIR  POLLUTION  EMISSION  TEST
                     U. S. Lime Division
                             (PLANT NAME)

                     Flintkote Company
                     City of Industry
                           (PLANT ADDRESS)

                     California
           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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               SET 2510 02 0874
     U.S. Lime Division of Flintkote Company
          City of Industry, California

         EMB Project Report No. 74-L1M-5
                 Final Report
                 Prepared for:

        Environmental Protection Agency
 Office of Air Quality Planning and Standards
Research Triangle Park, North Carolina  27711

     EPA Contract 68-02-0233, Task No. 19
                 October 1974
                      by
     SCOTT ENVIRONMENTAL TECHNOLOGY, INC.
             2600 Cajon Boulevard
       San Bernardino, California  92411

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SET 2510 02 0874
                            TABLE OF CONTENTS

1.0  INTRODUCTION
2.0  SUMMARY & DISCUSSION OF RESULTS
3.0  PROCESS DESCRIPTION & OPERATION
4.0  LOCATION OF SAMPLING POINTS
5.0  SAMPLING AND ANALYTICAL PROCEDURES
Page
 1
 3
 6
 8
11
Appendix A:  Complete Particulate Results with Example
             Calculation
Appendix B:  Field Data
Appendix C:  Laboratory Report
Appendix D:  Test Log
Appendix E:  Process Operation Data
Appendix F:  Project Participants
A-l
B-l
C-l
D-l
E-l
F-l
     SCOTT ENVIRONMENTAL TECHNOLOGY, INC.

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 SET 2510 02 0874
                             1.0  INTRODUCTION
           In accordance with Section III of the Clean Air Act of 1970, the
 Environmental Protection Agency is charged with the establishment of
 performance standards for new installations or modifications of existing
 installations in stationary source categories which may contribute
 significantly to air pollution.  A performance standard is a standard for
 emissions of air pollutants which reflects the best emission reduction
 systems that have been adequately demonstrated taking into account economic
 considerations.
           The development of realistic performance standards requires accurate
 data on pollutant emissions applications to various source categories.  Thus
 Scott Environmental Technology performed source sampling tests at the
 U.S. Lime Division of the FlintkoteCompany in the City of Industry,  California
 during the week of April 15, 1974.   The purpose of the test was to obtain
 background data for development of National New Source Performance Standards
 in the lime industry.  The plant under consideration is involved primarily
 in lime hydration.  Wet exhaust gases from a seasoning chamber are passed
 through a Ducon scrubber where the heavy residue is collected-in a slurry
 tank.  The wet gaseous stream is then vented to the atmosphere via a tall
 stack, about 100  feet above ground  and 26.75 inches in diameter.
           The original task order specified six two-hour runs on the outlet
 of the scrubber only.  The EPA Project Officer,  however, modified this plan
 to three four-hour runs becuase of low outlet emission rates.  Due to a
 lack of silo storage space at the plant during run three, the sampling time
 for this run was  reduced to two hours.  Also, during the second test run, a
 screw auger to the storage bin plugged up and caused a temporary plant upset.
 The delay was only for about twenty minutes and did not significantly affect
 the test run.
           The samples were analyzed for the determination of total particulate
 loading.   The test method used was  Method 5, "Determination of Particulate
.Emissions from Stationary Sources" as published in the December 23,  1971
"Federal Register^.   However, two important modifications were incorporated
     SCOTT ENVIRONMENTAL TECHNOLOGY, INC.

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SET 2510 02 0874

in the sampling scheme:  (i) the impinger catches were retained  and
analyzed, and (ii) a "front-half" water wash was found necessary for
complete sample recovery.
          The test team comprised of three EPA representatives and two
Scott employees.  Three complete tests were performed traversing the
stack in two perpendicular directions.  The test equipment was set up
on April 15, 1974, and the tests performed on April 16, 17, and  18, 1974.
    SCOTT ENVIRONMENTAl TECHNOLOGY, INC.

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 SET 2510 02 0874

                   2.0   SUMMARY  & DISCUSSION  OF  RESULTS
          A summary of  the  test results  is presented  in  Table 1 (British
 Units) and Table  2 (Metric  Units).  As can be seen, all  three runs  showed
 a very high stack gas moisture  content (40-50%).  Moreover,  the sampling
 nomograph had  to  be often reset during runs  because of fluctuations in
 stack temperature that  caused large changes  in  the moisture  content of
 the saturated  gas stream.   Also, a nozzle size  at the low end of the
 acceptable range  (0.210 ins.) was  used in the first two  runs  in order  to
 reduce the volume of water  collected in  the  impingers.   This  results in
 over isokinetic  (>110%) average sampling rate because the operating orifice
 pressure drop  (AH) was  forced below the  straight-line calibration range.
 Therefore a larger nozzle size  (0.302 ins.)  was used in  the  last run to
 bring the isokinetic sampling rate to within acceptable  limits.
          It should be  pointed  out here  that the isokinetic values  reported
 in Tables 1 and 2 are average values, averaged  over the  isokinetic  rates
 determined at  each sampling point.  The  percent isokinetic rate  at  each
 traverse point was based on the volume sampled  at each point,  the velocity
 (pressure drop and stack temperature) measured  at each point,  and the
 sampling time  at  each point.
          A visible emission check was also  conducted during  this test
program on 4/18/74.  Due to the high moisture content, the stack  plume
was essentially all water vapor.  An overcast background, however,  rendered
detection of any other possible visible emissions virtually impossible.
     SCOTT ENVIRONMENTAL TECHNOLOGY, INC.

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SET 2510 02 0874
                        Table  1   SUMMARY OF RESULTS
                              (British Units)
Run Number
Date:
                            ,(a)
Volume of Gas Sampled - DSCF
Percent Moisture by Volume **
Average Stack Temperature - °F
Stack Volumetric Flow Rate -DSCFM
Stack Volumetric Flow Rate -ACFM
Percent Isokinetic

Percent Opacity
Feed Rate - ton/hr

Particulate - probe, cyclone, &
       filter catch

mg
gr/DSCF
gr/ACF
Ib/hr
Ib/ton feed

Particulate - total catch

mg
gr/DSCF
gr/ACF
Ib/hr
Ib/ton feed

Percent Impinger Catch
1
4/16/74
74.2
44.5
CM174
(^4901
C) 10701
101.3
0
14
104.2
0.02164
0.00991
0.91
0.065
129.6
0.02691
0.01233
1.13
0.081
2
4/17/74
80.6
48.0
178
4775
11154
115.7
0
14
140.8
0.02690
0.01151
1.10
0.079
181.3
0.03463
0.01483
1.42
0.101
3
4/18/74
80.5
47.5
177
4797
11084
106.7
0
14
191.3
0.03658
0.01583
1.50
0.107
211.0
0.04034
0.01746
1.66
0.119
Average
78.4
46.7
176
4824
10980
107.9
0
14
145.4
0.02855*
0.01248*
1.17
0.084
174.0
0.03415*
0.01494*
1.40
0.100
                                     19.6
                                         22.3
9.34
17.1
(a)
(b)
(c)
*
**
Dry standard  cubic  feet  at  70°F,  29.92 in.Hg.
Dry standard  cubic  feet  per minute at 70°F,  29.92 in.Hg.
Actual cubic  feet per  minute.
Weighted Averages
Based on saturated psychrometric values  at stack  temperature.
     SCOTT ENVIRONMENTAL TECHNOLOGY, INC.

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SET  2510  02  0874
                        Table 2  SUMMARY OF RESULTS
                               (Metric Units)
Run Number

Date:                       f  v
                           3^a;
Volume of Gas  Sampled -  Nm
Percent Moisture by  Volume **
Average Stack  Temperature  - °C
Stack Volumetric Flow Rate-Nm
Stack Volumetric Flow Rate-m  ,
Percent Isokinetic

Percent Opacity
Feed Rate - M^to.n/hr

Particulate -  probe,  cyclone,
    and filter catch
mg/Nm
mg/m
kg/hr
kg/M ton

Particulates -  total  catch
mg/Nra
mg/m
kg/hr
kg/M ton

Percent Impinger Catch
4/16/74
2.100
44.5
,78.9
138.8
303.0
101.3
0
12.7
104.2
49.6
22.7
0.40
0.031
129.6
61.7
28.2
0.49
0.039
4/17/74
2.281
48.0
81.1
135.2
315.8
115.7
0
12.7
140.8
61.7
26.3
0.48
0.038
181.3
79.5
33.9
0.61
0.048
4/18/74
2.278
47.5
80.6
135.8
313.9
106.7
0
12.7
191.3
84.0
36.2
0.66
0.052
211.0
92.6
39.9
0.73
0.057
                                     19.6
22.3
9.34
                   Average
                   2.220
                   46.7
                   80.2
                   136.6
                   310.9
                   107.9

                   0
                   12.7
                   145.4
                   65.5*
                   28.6*
                   0.51
                   0.040
174.0
78.4
34.2
0.61
0.048

17.1
 (a)  Dry normal cubic meter at 21.1°C and  760 mm Hg.
 (b)  Dry normal cubic meters per minute at  21.1°C,  760  mm Hg.
 (c)  Actual cubic meters per minute.
 *    Weighted average.
**   Based on saturated psychrometric values at  stack temperature.
     SCOTT ENVIRONMENTAL TECHNOLOGY, INC.

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                   3.0  PROCESS DESCRIPTION & OPERATION
          Limestone consists primarily of calcium carbonate or combinations
of calcium and magnesium carbonate with varying amounts of impurities.  Lime
is a calcined or burned form of limestone, commonly divided into two basic
products—quicklime and hydrated lime.  Calcination expels carbon dioxide
from the raw limestone, leaving calcium oxide (quicklime).  With the addition
of water, calcium hydroxide (hydrated lime) is formed.
          The basic processes in production are (1) quarrying the limestone
raw material, (2) preparing the limestone for kilns by crushing and sizing,
 (3) calcining the limestone, and (4) optionally processing the quicklime
further by additional crushing and sizing and then hydration.
          The Flintkote Company lime plant in Industry,  California, operates
a calcitic quicklime atmospheric hydrator to produce calcium hydroxide
 (hydrated lime).   The quicklime feed of approximately 14 tons per hour is
crushed and pulverized before being fed to a pugmill premixer where it is
wet with a lime slurry from the scrubbing system.   The reaction takes place
in an agitated seasoning chamber.  A rate retardant is added to the seasoning
chamber to control the high temperatures obtainable in this exothermic reaction.
The final moisture content of the hydrated lime was reported to range from
0.5 to 1.0 percent.
          The offgas from the seasoning chamber is scrubbed in a Ducon UW-4
dynamic water scrubber with about 165 pounds per minute of water.  Gas
temperature into the scrubber is 190°F.  Operating variables during the tests
are summarized in the following Table.
          Three particulate samples were taken from the scrubber stack by
Scott Environmental Technology, under contract to the EPA.  Samples 1 and 2
were of four-hour duration.  Sample 3 was of two-hour duration.  Visible
emission data were recorded by an EPA observer for one how: during the third
test.   A large st-eam plume was observed but no other visible emissions were
discernible.   Preliminary calculations indicated about 40 percent moisture
in the gases  out  of the scrubber.
     SCOTT ENVIRONMENTAL TECHNOLOGY, INC.

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SET 2510 02 0874
          Three baghouse collectors controlled emissions from loading, milling,
sacking, screening and separating processes in the lime plant.  No visible
emissions were apparent from these collectors.  No sampling of these emissions
was done.
          According to Flintkote and EPA process data, the plant was operating
normally throughout all three tests.  The process shut down for approximately
five minutes during the second test due to a blocked feed screw and may result
in a slightly lower particulate catch for that test.  All three tests appeared
to be successful.
       TABLE 3 - SUMMARY OF ATMOSPHERIC HYDRATOR AND WATER SCRUBBER
                     OPERATING DATA DURING SAMPLING

Date                                    4/16/74      4/17/74      4/18/74
Test No.                                   123
Lime Feed Rate (tons/hr)                  14           14           14
Water Feed Rate (tons/hr)                  111
Hydrated Lime Production (tons/hr)       17-18        17-18        17-18
Scrubber Water (Ibs/min)                160-166      165-168      165-169
Scrubber Temp, before airbleed (°F)     203-206      202-210      208-215
Scrubber Temp, after airbleed (°F)      184-192      188-192      188-192
     SCOTT ENVIRONMENTAL TECHNOLOGY, INC.

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SET  2510 02 0874

                   4.0   LOCATION OF SAMPLING POINT
          The exhaust from the lime hydration operation passes  through a
Ducon Scrubber before entering the stack.  The sample collection ports
were located sixteen feet above the scrubber/stack interface as de-
tailed in Figure 1.  Two ports whose axes were perpendicular were lo-
cated at this point.  The stack inside diameter is 26.75 inches from the
scrubber to the exit.
          The sampling probe was traversed in and out of each port sampling
at twelve locations in each direction.  The location of each sampling  point
is shown in Figure 2.
      SCOTT ENVIRONMENTAL TECHNOLOGY, INC.

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SET 2510 02 0874


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                                   Slurry
                                    Tank
              Exhaust Gas From
              Seasoning Chamber
                                                  Rain  Cap
                                                  Roof -  91'  Above Ground
                                                  Sample Ports  (2)
                                                  71' Above Ground
                                                  Stack - 26 3/4"  I.D.
                                                    Ducon Scrubber
                       Figure 1   Sample Port Locations
    SCOTT ENVIRONMENTAL TECHNOLOGY, INC.

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      SET 2510 02 0874
Sample Port A-
Sample Probe Location
(24 each)
Sample Port B
                                              26.75  inch
                                                  I.  D.
                                 Cross Section  of Stack
                            Figure 2    Sampling Point Locations
           SCOTT ENVIRONMENTAL TECHNOLOGY, INC.

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SET 2510 02 0874

                 5.0  SAMPLING AND ANALYTICAL PROCEDURES

          Samples for the determination of total particulate loading were
collected using one probe and traversing two perpendicular ports.  The
sampling and analytical procedures used were in accordance with Method 5,
"Determination of Particulate Emissions from Stationary Sources," as
published in the Federal Register, Volume 36, No. 247, Tuesday, December 23,
1971.  However, two important modifications were incorporated in this
procedure:  (i) the impiriger catches were retained and analyzed, and (ii)
a "front-half" water wash was found necessary for complete sample recovery.
All dried particulate samples collected were forwarded to the EPA for
analysis after determination of particulate mass.
          Briefly, the method consisted of withdrawing a sample isokinetically
from the stack through a heated probe into a filter and impinger train as
shown in Figure 3.  The sample volume is measured with a dry gas meter and
isokinetic conditions were maintained by monitoring the stack gas velocity.
After testing was completed, the train was thoroughly washed including the
probe.  A water and acetone wash were used and collected in separate containers,
These washings were evaporated, dried and weighed along with the filter
and summed to obtain the total weight of particulate matter collected.
     SCOTT ENVIRONMENTAL TECHNOLOGY, INC.

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