EMB REPORT NUMBER 75-CBK-3
POLLUTIO
O
.•>£ ^^_
Canada
CABOT CORPORATION, LTD.
Sarnia, Ontario
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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SOURCE TESTING OF A WASTE HEAT BOILER
EPA Report No. 75-CBK-3
Cabot Carbon of Canada, Ltd.
Sarnia, Ontario
January 14-16, 1975
Prepared for
U.S. Environmental Protection Agency
Emission Measurement Branch
Research Triangle Park, North Carolina 27711
Prepared by
George D. Clayton ft Associates
25711 Southfield Road
Southfield, Michigan 48075
Contract No. 68-02-1408; Task No. 7
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TABLE OF CONTENTS
Page
1
2
4
9
10
I. INTRODUCTION
II. SUMMARY AND DISCUSSION OF RESULTS
III. PROCESS DESCRIPTION AND OPERATION
IV. LOCATION OF SAMPLING PORTS
V. SAMPLING AND ANALYTICAL PROCEDURES
FIGURES
1. Process Gas Flow Diagram
2. Location of Inlet and Outlet Sampling Ports
3. Location of Sampling Points - Boiler Inlet Location
4. Location of Sampling Points - No. 2 Boiler Outlet
5o Schematic Diagram of Sample Gas Conditioning System for
Carbon Monoxide Determination
TABLES
I.
II.
Ill,
IV.
V,
VI.
Summary of Particulate Emissions (English Units)
Summary of Particulate Emissions (Metric Units)
Summary of Hydrogen Sulfide Emissions (English Units)
Inlet to Waste Heat Boilers
Summary of Hydrogen Sulfide Emissions (Metric Units)
Inlet to Waste Heat Boilers
Summary of Hydrogen Sulfide Emissions (English Units)
No. 2 Boiler Outlet
Summary of Hydrogen Sulfide Emissions (Metric Units)
No. 2 Boiler Outlet
VII. Exhaust Gas Composition - Orsat Analyses
VIII. Composition of Flue Gas at Inlet to Boilers
IX, Carbon Monoxide Emissions
X. Reactor Feed Readings and Baghouse Conditions
XI. Summary of No. 2 Boiler Data
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TABLE OF CONTENTS (Continued)
APPENDICES
1. Sample Recording of Carbon Monoxide Emissions
2. Carbon Black Feedstock Composition
3. Natural Gas Composition
4. Velocity Traverse and Moisture Test
5. Particulate Data
6. Sampling Summary Sheet
7. Particulate Weight Data
8. Calculation of Particulate Concentrations and Emissions
9. Hydrogen Sulfide Data
10. Calculation of Hydrogen Sulfide Concentrations and
Emissions
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EMISSION STUDY
Waste Heat Boiler
Cabot Carbon of Canada, Ltd.
Sarnia, Ontario, Canada
January 14-16, 1975
I. INTRODUCTION
The U.S. Environmental Protection Agency retained George D.
Clayton & Associates to conduct an emission study of the No. 2
waste heat boiler at the Cabot Carbon of Canada, Ltd. facility in
Sarnia, Ontario. The purpose of this study was to provide data
for the establishment of performance standards for newly installed
or modified carbon black manufacturing facilities.
The test program included measurement of particulate emis-
sions at the boiler outlet and simultaneous measurement of hydro-
gen sulfide emissions at both the boiler inlet and outlet.
Associated data, including exhaust gas composition, stack gas
temperatures and flowrates, and moisture content, were also
collected. A continuous instrumental measurement of carbon mono-
xide at the waste heat boiler outlet was conducted by a field
team from Battelle Columbus Laboratories, and results are reported
herein.
This study was conducted during January 14, 15, and 16, 1975
by Messrs. Fred Cooper, Richard Griffin, Richard Keller, Richard
Marcus, George Santorilla, Kent Shoemaker, and Jon Schoch of
Clayton & Associates. Mr. Sylas Miller of Battelle Columbus
Laboratories conducted the carbon monoxide monitoring. Monitoring
of production data was conducted by Mr. William DeWeiss of PEDCo-
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- 2 -
Environmental Company. Mr. Robert Martin, Field Testing Section,
Emission Measurement Branch, Office of Air Quality Planning and
Standards directed the field test effort.
The study was designed to include measurement of particulate
emissions, moisture content, and exhaust gas flowrates at the
common inlet duct to the Nos. 1 and 2 waste heat boilers. Diffi-
culties with sampling equipment at this location prevented the
sample collection simultaneously with particulate samples col-
lected at the outlet.
II. SUMMARY AND DISCUSSION OF RESULTS
Process Operation
During tests 1 and 3, tail gas from production of carbon
black was supplemented by natural gas to fire the No. 2 waste
heat boiler. During test 2, production units 2, 3, and 5 were
operating; therefore, no natural gas was needed as auxiliary
fuel. Because only two or three of six production units were
operating during the study, no tail gas was vented through the
thermal oxidizer.
Particulate
Tables I and II present the results of particulate emission
measurements at the boiler outlet location in both English and
metric units, respectively. Total particulate emissions varied
from 6.0 to 8.4 and averaged 6.9 pounds per hour. Emission rates
during use of gas-boosted fuel (tests 1 and 3) were not signifi-
cantly different from that resulting from flue gas alone (test 2),
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~ 3 -
An average of 34 percent of the total weight was captured in the
impinger portion of the train. All tests were conducted well
within a range of 90 and 110 percent of isokinetic.
Attempts to collect particulate samples at the inlet to the
boilers were unsuccessful. Highly positive static pressure and
high moisture and carbon monoxide concentrations in the exhaust
gas led to two problems. Short circuits in the heated stainless
steel probe prevented sample collection. Finally the sampling
nozzle and pitot tube head were crushed in the gate valve (part
of the leak-tight sampling port assembly) from slippage within
the two-inch conduit probe sheath.
The exhaust gas flowrate and temperature at the inlet loca-
tion were measured on January 15, 1975. Exhaust gas flowrates
were 14,800 SCFM or 45,100 ACFM at a temperature of 393°F. Stack
gas moisture content at this location was 47 percent by volume
as measured by a moisture determination on January 15, 1975.
Hydrogen Sulfide
Hydrogen sulfide concentrations at the boiler inlet location
varied from 592 to 1011 parts per million (Tables III and IV).
Measurements of hydrogen sulfide emissions from the boiler (Tables
V and VI) were greater during the first three tests than during
test 5. Due to suspected contamination from the large volume of
accumulated moisture in the first impinger, a dry midget impinger
was added after the impinger containing hydrogen peroxide during
test 5, which resulted in lower measured concentrations.
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- 4 -
Exhaust Gas Composition
Table VII presents the composition of the exhaust gas at the
boiler outlet location. The oxygen concentration at this loca-
tion averaged 3.5 percent for the three tests.
Table VIII shows the composition of flue gas at the boiler
inlet. Reported results are the average of several grab samples.
Carbon Monoxide
Results of carbon monoxide monitoring (Table IX) indicate an
overall average of 56 parts per million of carbon monoxide as
analyzed at the field site. Because ascarite in an impinger pre-
ceding the analyzer removed the interfering carbon dioxide from
the sampled gas stream, the concentration of carbon monoxide after
correcting for the carbon dioxide concentration in the stack was
slightly lower than that measured on a C0o-free basis. Appendix 1
shows the strip chart output of continuous carbon monoxide analy-
sis.
III. PROCESS DESCRIPTION AND OPERATION
Process Description
The Sarnia plant of the Cabot Carbon of Canada, Ltd. has six
carbon black production units. A simplified flow diagram of the
off-gas flow is shown in Figure 1„ The plant was built in 1953.
The No. 1 boiler was built with the original plant at a design
capacity of 30,000 Ib/hr of 250 psig steam. The No. 2 boiler was
installed about 1960 with a design capacity of 60,000 Ib/hr of
steam. Finally a thermal oxidizer was installed in 1972 and has
no heat recovery capacity. The plant design capacity was reported
as 175 MM Ib/yr.
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- 5 -
Carbon black is produced at the Sarnia plant by controlled
pyrolysis of residuum tar. The reaction zone in the furnace is
maintained at approximately 2700°F by combustion of natural gas
with controlled quantities of air. Carbon black oil, which has
been heated to approximately 350°F by natural gas-fired heaters,
is injected into the reaction zone where partial combustion and
thermal decomposition of the liquid hydrocarbon takes place. The
resulting gases and carbon black are cooled by means of a water
quench to stop further reaction,,
Quality of the carbon black is controlled mainly by varying
air, oil, and natural gas ratios and water quench. At the Sarnia
plant, several grades of carbon black are produced, and in some
cases different grades are produced on the same unit.
The type of carbon black produced is important to the opera-
tion of the boilers, dryers, and oxidizer. No problems are expe-
rienced when the off-gas has a heating value of 50 BTU/scf
(including water vapor). The typical flue gas heat values reported
were 42 to 44 BTU/scf for fine particle black, about 53 BTU/scf
for medium black and up to 65 BTU/scf for large particle blacko
Separation of carbon black from furnace gases is accomplished
by fiberglass and Nomex bag filters. Each of the six plant units
has its own baghouse. Units 2, 3, and 4 use Wheelabrator bag
filters with fiberglass bags while units 1, 5, and 6 use Micro-
pulsair bag filters with Nomex bags. The Micropulsair bag fil-
ters can run with a very high air-to-cloth ratio of four to one,
but they have experienced a typical bag life of only 22 to 24
weeks. In addition to the short bag life, the gases have to be
cooled to at least 375°F before entering the filter.
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The Wheelabrator bag filters use fiberglass fabric which can
withstand inlet temperatures of 450 to 500°F and typically run an
air-to-cloth ratio of one and one-half to one. The fiberglass
filters are cleaned on a three and one-half minute cycle with a
back-flow of off-gas,, The bag life was reported to be one to two
years.
On units 1, 2, 3, and 4, the carbon black from the main pro-
cess bag filter is conveyed by air to the process filter, through
a hammermill, and into an agitator tank. On units 5 and 6, the
carbon black flows by gravity through a hammermill, and into an
agitator tank. From the agitator tanks, the carbon black is
pelletized by means of a wet process, using water and a binder
additive on units 1, 2, 5, and 6, and a dry process on units 3
and 4. Approximately equal weights of carbon black and water are
used in the wet process to form the pellets. Drying the pellets
to less than one-percent moisture content is accomplished in
rotary drum dryers. Off-gas and natural gas are burned in these
dryer furnaces and the resulting combustion gases are cooled to
approximately 1400°F by dilution air to prevent hot spots and
burning of the carbon black. The hot gases heat the carbon black
indirectly from the outside of the dryer drum shell. Approxi-
mately 50 percent of the exhaust gases from this first pass are
exhausted directly to the atmosphere at about 800-900°F. The
remaining gases pass through the inside of the dryer drum and
heat the carbon black by direct contact. These gases also serve
to purge the water vapor from the dryer and exit through a fiber-
glass purge gas filter.
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Normally, with six units in operation, approximately 56 per-
cent of the off-gas produced is consumed in the dryers and the
boilers. The remainder of the off-gas is burned in a thermal
oxidizer. The boilers, dryers, and oxidizer are fed typical gas
rates as shown in Figure !„ The gas from each unit enters a com-
mon flue gas line. However, the gas is not necessarily uniformly
mixed before entering each combustion unit. The duct configura-
tion is arranged so the oxidizer tends to receive a lower BTU gas
stream than the boilers and dryers. The off-gas is capable of
self-sustaining combustion in both the dryers and boilers. Due
to the plant's need for steam, natural gas is normally used as
a supplemental fuel in both boilers.
Process Operation
Due to the slowdown in the rubber industry, units 1 and 4
were shut down. Also, the off-gas from unit 6 was vented to the
atmosphere because of its low BTU value. The only units intro-
ducing off-gas into the header were units 2, 3, and 5. This gas
was consumed as fuel by boilers 1 and 2 and units 1, 5, and 6
dryers.
The plant operations were in good working order. All units
maintained steady-state conditions while feeding off-gas to the
header. When any operational problem occurred, the unit's off-
gas was removed from the header and vented. For this reason no
tests were performed during upset conditions.
Units 2 and 3 have Wheelabrator bag filters with new fiber-
glass bags installed on July 10, 1974 and August 12, 1974
respectively. The installation dates are well within the one to
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two year bag life. Unit 5 has a Micropulsair bag filter with new
Nomex bags installed on November 27, 1974. The average Nomex bag
life has been 22 to 24 weeks. All units should have been repre-
sentative of a well-controlled carbon black process.
The reactor's feed readout and baghouse temperatures and
pressures are presented in Table X. All reactor feed readouts
are expressed as percent of nozzle or orifice meter flow control.
Therefore, the numbers recorded are of little direct value except
to show that the units remained constant throughout the test
periods. The average production of carbon black was calculated
by plant personnel from these data. The carbon black production
during testing was about 5,500 Ib/hr from units 2, 2,100 Ib/hr
from unit 3, and 3,400 Ib/hr from unit 5.
Boiler No. 2 was operated at 50,000 pounds of steam per hour
at a pressure of 260 psig during all tests* The second test on
boiler No. 2 was performed during the combustion of off-gas only.
The first and third tests were performed with the addition of
natural gas to the boiler. Boiler operating data are presented
in Table XI. The off-gas flows could not be determined directly
from panel board data, and only comparative orifice pressure
drops are presented. Boiler combustion air flows were not
measured directly either. Total heat input, based on steam
production and a boiler efficiency of 75 percent was calculated
for tests 1, 2, and 3, respectively, to be 81.3, 84.7, and 84.7
MM BTU/hr (1270 BTU/lb x steam rate/0.75). Natural gas provided
20 to 25 percent of the heat input in tests 1 and 3.
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IV. LOCATION OF SAMPLING PORTS
The inlet sampling was conducted in the common duct from the
six carbon black production units to the No. 1 and No. 2 waste
heat boilers. This circular duct is four feet in diameter and
runs horizontally along the edge of the building which houses the
boilers (Figure 2). Two ports were utilized at this location,
one on the side and one on the top of the duct. Although a bot-
tom port would have been preferable, plant personnel suspected
that the bottom of the duct was weak from corrosion due to mois-
ture accumulation. The inlet sampling cross section was located
more than eight duct diameters of straight, horizontal airflow
downstream and more than two duct diameters upstream from duct
elbows or transitions. Therefore, the stack was divided into 12
equal annular areas, six points on each diameter, as shown in
Figure 3.
Due to the high positive pressure, high moisture content,
toxicity, and flammability of the reactor tail gases at the inlet
sampling location, a special port arrangement had to be constructed
for the sampling probes. Each of the two ports consisted of a
four-inch nipple welded to the stack to which a gate valve was
attached. A three and one-half inch hole was drilled through
the stack wall. The "pitobe" nozzle and Pitot tube head were
located in a four-inch nipple and the probe was encased in two-
inch conduit which could slide through a packing gland into the
stack in order that the gases in the duct did not leak from the
sampling port during testing.
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Exhaust gases passing the inlet sampling location are drawn
by either of two fans to the No. 1 and No. 2 waste heat boilers.
After passing through the waste heat boiler, exhaust gases
are vented through each of two separate horizontal ducts. Exhaust
gases from the two boilers are then combined in the breeching and
are exhausted through a tall circular stack. Sampling was con-
ducted at the outlet of the No. 2 boiler in the 80-inch high by
48-inch wide cross section as indicated in Figure 4. Eight ports
located on the side of the duct were used for the collection of
the samples. No. 2 boiler outlet samples were collected at each
of 40 sampling ports at this location in spite of its proximity
to a bend and dampers which were both within two diameters of the
sampling cross section.
V. SAMPLING AND ANALYTICAL PROCEDURES
Particulate Sampling
Particulate sampling at the boiler outlet location was con-
ducted according to the principles outlined in Method 5, 40CFR60.
Deviations from this method are noted below:
1. The outlet duct was divided into 40 equal areas and
sampling and velocity traverse measurements were made
at the midpoints of these areas. Method 1, 40CFR60,
would have required a larger number of sampling points
due to the proximity of the bend upstream and dampers
downstream. However, turning vanes in the bend upstream
and the open dampers downstream both acted to produce a
more uniform velocity traverse than would usually be
expected.
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2. A glass cyclone was placed in the heated filter box to
remove some particulate materials prior to filtration.
3. Calculation of the average stack gas velocity included
an averaging of the square roots of the products of
velocity pressure and absolute stack temperature at each
of the traverse points.
4. Rather than using Orsat analysis for the measurement of
exhaust gas composition at the waste heat boiler inlet
location, grab samples of the flue gas were collected
in glass sample bombs with stopcocks on either end.
These samples were analyzed by Cabot personnel using
the gas chromatograph at the Sarnia plant. This method
was used because of the unusual composition of this
exhaust gas stream.. (The Orsat apparatus cannot detect
the large amounts of low molecular weight hydrogen gas
present in thjLs source . )
Moisture content and particulate sampling field data sheets
are presented in Appendices 4 and 5, respectively. Appendix 6
contains the sample volume and percent isokinetic calculations
for particulate samples collected at the boiler outlet, and
Appendix 7 contains the laboratory weights of materials captured
during these tests. Appendix 8 presents the nomenclature and
sample calculations used in calculating particulate emission
results.
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Hydrogen Sulfide
\
Sampling and analysis for hydrogen sulfide at both the boiler
inlet and outlet sampling locations was conducted according to
the principles outlined in Method 11, 40CFR60, with the following
exceptions:
1. Due to the high concentrations of hydrogen sulfide at
the waste heat boiler inlet location, sampling periods
were very brief. The yellow color of cadmium sulfide
was visible in the third impinger soon after sampling
commenced.
2. The high moisture content in the stack exhaust gas at
the outlet location resulted in a large amount of moisi-
ture condensate in the first impinger. The increased
liquid volume in this impinger resulted in carry-over
of the solution from the first impinger into the second
impinger which contains the cadmium hydroxide. This was
suspected after completion of the first four tests;
therefore, during the fifth test an additional impinger
was added after the impinger containing hydrogen perox-
ide to collect the entrained solution. This arrange-
ment resulted in no poisoning of the cadmium hydroxide
containing impingers; therefore, contamination was
avoided.
3. A heated glass probe was used at the boiler outlet to
withdraw the sample from the stack. A probe was con-
nected directly to the first impinger without the use of
Teflon tubing.
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Appendix 9 presents the field data sheets for hydrogen sul-
fide sampling and Appendix 10 presents the sample calculations
used to calculate these data.
Carbon Monoxide
Carbon monoxide was measured by Method 10, 40CFR60, with
the following exceptions:
1. As shown in Figure 5, moisture from the stack gas was
removed by passing the exhaust gas through modified
Greenburg-Smith impingers rather than using an air-
cooled condenser.
2. The carbon monoxide was continuously monitored by non-
dispersive infrared techniques using a Beckman model
305B analyzer. The 0 to 1,250 ppm range was used. The
sensitivity is rated at 0.5 percent of full scale with
an accuracy of + 1 percent. The analyzer was calibrated
before and after each run with zero nitrogen and a certi-
fied standard carbon monoxide span gas of 1050 ppm.
This report prepared by: S±3^iJ} \J). (, /Lux..
Fred I. Cooper (J iQ
Group Leader, Source Sampling Studies
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200 ft STACK
VENT STACK
(NORMALLY
CLOSED)
THERMALOXIDIZER
CONTROL VALVE PUTS
ALL EXCESS TAIL GAS
THROUGH OXIDIZER
TOTAL TAIL GAS PROD
BOILER USE
DRIERS USE
REMAINDER TO
THERMAL
OXIDIZER
3,850,000 'Scfh
2,000,000 scfft
530.000 scfh
1,320,000 scfh
FIGURE 1
PROCESS GAS FLOW DIAGRAM
Cabot Carbon of Canada, Ltd.
Sarnia, Ontario
January 14-16, 1975
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FIGURE 2
LOCATION OF INLET AND OUTLET SAMPLING PORTS
Waste Heat Boilers
Cabot Carbon of Canada, Ltd.
Sarnia, Ontario
January 14-16, 1975
To
Stack
#2 Boiler
Exhaust
#1 Boiler
Exhaust
Inlet
Sampling Location
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0.0"
4" Coupling
!" Packing gland
4" Valve
3 1/2" hole
48" I.D.
FIGURE 3
LOCATION OF SAMPLING POINTS - BOILER INLET LOCATION
Cabot Carbon of Canada, Ltd.
Sarnia, Ontario
January 14-16, 1975
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FIGURE 4
LOCATION OF SAMPLING POINTS - NO. 2 BOILER OUTLET
Cabot Carbon of Canada, Ltd.
Sarnia, Ontario
January 14-16, 1975
6
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-------
Stainless Steel Probe
1/2" O.D. x 41
To I
Glass Wool
uct
500 ml Standard Impingers
To
NDIR
via
SS
Bellows
Pump
&
Flowmeter
FIGURE 5
SCHEMATIC DIAGRAM OF SAMPLE GAS CONDITIONING SYSTEM
FOR CARBON MONOXIDE DETERMINATION
No. 2 Boiler Outlet
Cabot Carbon of Canada, Ltd.
Sarnia, Ontario
January 14-16, 1975
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TABLE I
SUMMARY OF PARTICULATE EMISSIONS (ENGLISH UNITS)
No. 2 Boiler Outlet
Cabot Carbon of Canada, Ltd.
Sarnia, Ontario
January 14-16, 1975
Test
Number
1
2
3
1975
Date
1/14
1/15
1/16
Sampling
Period
16:30 - 18:30
13:20 - 15:20
09:52 - 11:12
AVERAGE
Stack Gas
Conditions
Temp
(°F)
460
415
385
420
Flowrate
(Dry SCFM)
15,800
20,600
17,200
17,900
Filterable
Particulate
gr/DSCF
0.029
0.028
0.032
0.030
Ibs/hr
4.0
5.0
4.6
4.5
Total
Particulate
gr/DSCF
0.045
0.048
0.042
0.045
Ibs/hr
6.0
8.4
6.2
6.9
George D. Clayton & Associates
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TABLE II
SUMMARY OF PARTICULATE EMISSIONS (METRIC UNITS)
No. 2 Boiler Outlet
Cabot Carbon of Canada, Ltd.
Sarnia, Ontario
January 14-16, 1975
Test
Number
1
2
3
1975
Date
1/14
1/15
1/16
Sampling
Period
16:30 - 18:30
13:20 - 15 :20
09:52 - 11:12
AVERAGE
Stack Gas
Conditions
Temp
(°C)
238
213
196
216
Flowrate
(DNm3/min)
447
582
486
505
Filterable
Particulate
mg/DNm3
67.4
64.6
72.1
68.0
kg/hr
1.8
2.3
2.1
2.1
Total
Particulate
mg/DNm3
101.9
108.7
96.2
102.3
kg/hr
2.7
3.8
2.8
3.1
George D. Clayton & Associates
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TABLE III
SUMMARY OF HYDROGEN SULFIDE EMISSIONS (ENGLISH UNITS)
INLET TO WASTE HEAT BOILERS
Cabot Carbon of Canada, Ltd.
Sarnia, Ontario
January 14-16, 1975
Test
Number
1
2
3
4
5
6
1975
Date
1-14
1-14
1-15
1-15
1-16
1-16
Sampling
Period
15:31-15:41
16:45-16:55
13:25-13:35
14:00-14:10
10:01-10: 11
10:41-10:51
Stack Gas
Cond itions
Temp .
(°F)
_
-
393
393
-
-
Flowrate
(DSCFM)
_
-
14,800
14,800
-
-
Hydrogen Sulfide
Concentration
gr/DSCF
0.444
0.389
0.366
0.413
0.494
0.625
ppm
719
629
592
668
799
1011
Hydrogen Sulfide
Emission Rate
(Ibs/hr)
-
-
46.4
52.4
-
-
George D. Clayton & Associates
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TABLE IV
SUMMARY OF HYDROGEN SULFIDE EMISSIONS (METRIC UNITS)
INLET TO WASTE HEAT BOILERS
Cabot Carbon of Canada, Ltd.
Sarnia, Ontario
January 14-16, 1975
Test
Number
1
2
3
4
5
6
1975
Date
1-14
1-14
1-15
1-15
1-16
1-16
Sampling
Period
15:31-15:41
16:45-16: 55
13:25-13:35
14:00-14: 10
10:01-10: 11
10:41-10: 51
Stack Gas
Conditions
Temp .
<°C)
-
-
201
201
-
-
Flowra te
(DNm3/min)
-
-
418
418
-
-
Hydrogen Sulfide
Concentra tion
mg/DNm3
1017
889
837
945
1131
1430
ppm
719
629
592
668
799
1011
Hydrogen Sulfide
Emission Rate
(kg/hr)
-
-
21.1
23.8
-
-
George D. Clayton & Associates
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TABLE V
SUMMARY OF HYDROGEN SULFIDE EMISSIONS (ENGLISH UNITS)
NO. 2 BOILER OUTLET
Cabot Carbon of Canada, Ltd.
Sarnia, Ontario
January 14-16, 1975
Test
Number
1
2
3
5*
1975
Date
1/14
1/14
1/15
1/16
Sampling
Period
15:33 - 16:33
16:52 - 17:53
13:27 - 14:28
09:59 - 10:59
Stack Gas
Conditions
Temp
<°F)
460
460
415
385
Flowrate
(Dry SCFM)
15,800
15,800
20,600
17,200
Hydrogen Sulfide
Concentration
gr/DSCF
0.008
0.005
0.001
0.00003
ppm
13.5
8.7
1.6
0.04
Hydrogen
Sulfide
Emission
Rate
(Ibs/hr)
1.1
0.73
0.17
0.004
* Test number 4 is void
George D. Clayton & Associates
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TABLE VI
SUMMARY OF HYDROGEN SULFIDE EMISSIONS (METRIC UNITS)
NO. 2 BOILER OUTLET
Cabot Carbon of Canada, Ltd.
Sarnia, Ontario
January 14-16, 1975
Test
Number
1
2
3
5*
1975
Date
1-14
1-14
1-15
1-16
Sampling
Period
15:33-16:33
16:52-17:53
13:27-14:28
09:59-10:59
Stack Gas
Cond it ions
Temp.
(°C)
238
238
213
196
Flowra te
(DNm3/min)
447
447
582
486
Hydrogen Sulfide
Concentration
mg/DNm3
19.2
12.3
2.3
0.06
ppm
13.5
8.7
1.6
0.04
Hydrogen Sulfide
Emission Rate
(kg/hr)
0.51
0.33
0.08
0.002
*Test number 4 is void.
George D. Clayton & Associates
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TABLE VII
EXHAUST GAS COMPOSITION - ORSAT ANALYSES
No. 2 Boiler Outlet
Cabot Carbon of Canada, Ltd.
Sarnia, Ontario
January 14-16, 1975
Particulate
Test
Number
1
2
3
AVERAGE
Exhaust Gas Composition,
Percent (Dry Basis)
Carbon
Dioxide
9.2
8.4
9.1
8.9
Oxygen
3.2
4.0
3.4
3.5
Carbon
Monoxide
<0.2
<0.2
<0.2
<0.2
Nitrogen
87.6
87.6
87.5
87.6
Moisture
Content
(Percent)
32.9
36.7
31.5
33.7
George D. Clayton & Associates
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TABLE VIII
COMPOSITION OF FLUE GAS AT INLET TO BOILERS
Cabot Carbon of Canada, Ltd.
Sarnia, Ontario
January 14-16, 1975
1975
Date
1-14
1-15
Flue Gas Composition
(percent by volume, dry basis)
C02
3.9
4.1
C2H2
0.5
0.5
H2
17.9
17.2
Ar
0.9
0.9
N2
63.7
64.4
CH4
0.7
0.6
CO
12.4
12.3
George D. Clayton & Associates
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TABLE IX
CARBON MONOXIDE EMISSIONS
No. 2 Boiler Outlet
Cabot Carbon of Canada, Ltd
Sarnia, Ontario
January 14-16, 1975
Run
Number
1
2
3
4
Sample
Port
8
8
5
2
1975
Date
1-14
1-15
1-16
1-16
Sampling
Time
ta r t
15:45
10:55
09:45
13:05
top
16:35
14: 00
10:40
13:45
Carbon Monoxide Concentration
(ppm by volume)
dry basis, C02 free
Max.
60
100
60
90
Min.
20
60
45
50
Avg.
31
68
50
75
dry basis
Max .
54
92
55
82
Min.
18
55
41
45
Avg .
28
62
45
68
George D. Clayton & Associates
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TABLE X
REACTOR FEED READINGS AND BAGHOUSE CONDITIONS
Cabot Carbon of Canada, Ltd.
Sarnia, Ontario
January 14-16, 1975
Test No.
Date 1975
Time
Unit 2
Reactors
Baghouse
Type of
Unit 3
Reactors
Baghouse
Type of
Unit 5
Reactors
Baghouse
Type of
Oil
Gas
Air
In 8F
Out °F
AP IWC
Inlet IWC
Carbon Black
Oil
Gas
Air
In 8F
Out °F
AP IWC
Inlet IWC
Carbon Black
Oil
Gas
Air
In °F
Out °F
AP IWC
Inlet IWC
Carbon Black
1
1/14
3:30
69
8.7
64
470
410
4.8
11.0
*
Shut
84
74
60
375
350
11
14.5
***
1
1/14
4:30
69
8.7
64
470
410
4.2
11.0
Down
84
74
60
375
350
• 10.2
14.5
1
1/14
5:30
69
8.7
64
470
410
4.5
11.0
84
74
60
375
350
12
17
2
1/15
1:30
69
8.6
62
470
410
4.5
12
*
67
62
60
480
435
4.7
11
**
83
73
60
375
350
9.5
15.5
***
2
1/15
2:30
69
8.6
62
470
410
4.6
12
67
62
60
480
435
4.8
12
83
73
60
375
350
12.3
14.8
2
1/15
3:30
69
8.6
62
470
410
4.5
12
67
62
60
480
435
4.8
11
83
73
61
375
350
10
15.5
2
1/15
4:30
69
8.6
62
470
410
4.2
12
67
62
60
480
435
5.0
.12
83
73
61
375
350
12.4
15.2
3
1/16
10:00
-
Unit
67
60
63
475
435
4.0
10
**
83
74
62
375
350
10
14.2
***
3
1/16
11:00
Down
67
60
63
475
435
4.5
11
83
74
62
375
350
10
14.4
* Non-reinforcing (Particle size 75 millimicrons)
** Reinforcing (Particle size 23 millimicrons)
*** Reinforcing (Particle size 27 millimicrons)
NOTE: Particle diameters are in terms of electron microscope measurement.
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TABLE XI
SUMMARY OF NO. 2 BOILER DATA
Cabot Carbon of Canada, Ltd.
Sarnia, Ontario
January 14-16, 1975
Test No.
Date 1975
Time
Off-Gas Flowa
Temp. , °F .
Press., IWC
Boiler Press., IWC
Air Flowa
Nat. Gas Flow, scfh X 103d
Outlet Gas Temp., °F
Steam Flow, Ib/hr x 103
Temp., °F
Header Press., psig
Boiler Press., psig
1
1/14
3:30
48
375
4.0
1.5
50
17
415
2.8
48
517
250
260
1
1/14
4:30
34
375
4.0
1.5
50
21
415
2.8
48
520
250
260
1
1/14
5:30
34
375
4.0
1.5
50
21
415
2.8
48
520
250
260
2
1/15
1:30
82
395
6
3
50
0
445
2.8
50
520
250
260
2
1/15
2:30
84
395
7
3.2
50
0
445
2.8
50
515
250
260
2
1/15
3:30
84
400
7
3.2
50
0
445
2.8
50
520
250
260
2
1/15
4:30
84
400
7
3.2
50
0
445
2.8
50
515
250
260
3
1/16
10:00
57
395
2.7
1.8
50
16
415
2.9
50
515
250
260
3
1/16
11:00
57
395
2.8
1.8
50
16
415
2.9
50
520
250
260
Percent of scale reading, orifice coefficient unknown.
IWC = inch of water column.
Q
Percent of scale reading to maintain two percent oxygen
at boiler outlet.
Standard cubic feet per hour at 60°F.
Note: Data obtained or'calculated from panel board.
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