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 ------- 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 ------- 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. ------- 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. ------- -2- 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. ------- -3- 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. ------- -4- 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. ------- -5- 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. ------- -6- SET 2510 02 0874 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. ------- -7- 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. ------- -8- 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. ------- -9- SET 2510 02 0874 1 1 \ X --^ t 6' — -~. •M^ 0— . * ~>A-~ s • 4 •*-*, X \ 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. ------- -10- 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. ------- -11- 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. ------- THERMOMETER- PHOBE CM 00 o p o LO C«J X X PITOT MAKCMETER & (OPTIONAL); I CYCLONE l ICE WATEa BKtH JTHSRHO?4ŁtSB.Sj VACUUM DRY TE^T METER MR T\OHT PUMP iJL ATE c. AM PI-J ------- |