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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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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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
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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.
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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.
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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.
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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.
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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.
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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
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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.
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1
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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
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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
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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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