Project No. 75-SIN-3
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AIR POLLUTIO
EMISSION TEST
PARTICLE SIZE ANALYSIS
KAISER STEEL CORP.
FONTANA, CALIFORNIA
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
-------
REPORT NO. PAGE.
PARTICLE SIZE ANALYSIS
KAISER STEEL
FONTANA, CALIFORNIA
for
Emission Measurement Branch
of the
Environmental Protection Agency
Task #22
Contract #68-02-1401
Project No. 75-SIN-3
Prepared by
York Research Corporation
One Research Drive
Stamford, Connecticut 06906
Y-8479-22
August 26, 1975
YORK RESEARCH CORPORATION
-------
REPORT NO. Y-8479-22 PAGE.
TABLE OF CONTENTS
PAGE
ACKNOWLEDGEMENTS ' 1
I. INTRODUCTION 2
II. SUMMARY OF RESULTS . 2
III. SAMPLING METHODS 9
A. Sample Locations and Traverse Points 9
B. Sampling Procedures 10
1. Equipment Preparation 10
2. Sampling 10
3. Sample Recovery 10
C. Calculations 11
APPENDIX A 16
Impactor Operating Techniques
APPENDIX B 31
Computer Printout
APPENDIX C 36
Calculation Equations
APPENDIX D
Raw Field Data
YORK RESEARCH CORPORATION j$m STAMFORD, CONNECTICUT
-------
REPORT NO. Y-84 79-2 2 PAGE
LIST OF FIGURES
PAGE
Figure 1 - Andersen Test 1 4
Figure 2 - Andersen Test 2 5
Figure 3 - Andersen Test 3 6
Figure 4 - Andersen Test 4 7
Figure 5 - Combined Andersen Tests 8
Figure 6 - Sampling Location 12
Figure 7 - Field Data Sheet 13
YORK RESEARCH CORPORATION ftjm STAMFORD, CONNECTICUT
-------
REPORT NO. Y-8479-22 PACE
ACKNOWLEDGEMENTS
York Research Corporation would like to express its appreciation
to Lance Granger of EPA and the crew from Pacific Environmental
Services for their assistance during the testing program.
YORK RESEARCH CORPORATION Jm STAMFORD, CONNECTICUT
-------
REPORT NO. Y-8479-22 PAGE 2
I. INTRODUCTION
York Research Corporation was retained by the Emission
Measurement Branch of the Environmental Portection Agency to
perform four particle size tests at the outlet of the bag-
house at the Kaiser Steel Sinter Plant located in Fontana,
California. This series of tests was designed to assist
EPA in developing criteria for standards of performance for
new Sintering Plants by the measurement of particulate
emissions in various micron size ranges. Testing took place
concurrently with particulate mass measurement by Pacific
Environmental Services between June 3 and June 5, 1975.
The sintering operation at Kaiser Steel, Fontana, is a normal
sintering operation which takes fine (small particles) ore
dust, mill turnings, coke and other steel mill renderings
and makes it into a granular mix which can be charged into a
blast furnace. Sinter strands operate on a continuous feed
basis and the particle size testing took place during normal
operation.
The baghouse controls only emissions from the windbox portion
of the process. This is the portion of the strand where
combustion takes place. Outlet samples were taken in the duct
work just prior to the ID fan. No samples were taken at the
inlet to the baghouse.
This report was prepared by York Research under Task #22 of
Contract #68-02-1401 with the Emission Measurement Branch
of the Environmental Portection Agency.
II. SUMMARY OF RESULTS
The following graphs are from testing performed by York
Research personnel on June 3 and 5, 1975.
The results presented are the aerodynamic particle size
distributions based on a 1 gm/cc particle density.
Because of the similarity of the four outlet Andersen tests
(figures 1 through 4), the particle size and distribution
per stage were grouped together yielding the following:
YORK RESEARCH CORPORATION fmJW STAMFORD, CONNECTICUT
-------
REPORT NO.
Y-8479-22
PAGE
AVERAGE SIZE RANGE (microns)
>9.71
9.71-6.06
6.06-4.10
4.10-2.79
2.79-1.78
1.78- .88
.88- .54
.54- .35
AVERAGE % PER STAGE
20.42
22.96
16.87
. 14.45
11.70
5.90
2.16
.99
4.55
The above results are presented graphically in Figjure 5. The
high percentage (43%) of particles over 6 microns in size
is not what would be expected at the outlet of a baghouse.
However, the particle size sampling at the sintering plant
in Bethlehem, Pennsylvania (Task #18, Contract #68-02-1401)
was also performed at the outlet of a baghouse and a similar
distribution was found. Since no testing was performed at
the inlet it was not possible to calculate fractional
efficiencies. Also, without the knowledge of the inlet
distribution of particles it is not possible to judge whether
or not the outlet distribution is reasonable. Broken, loosely
fit or poorly sealed bags would permit the emission of particles
in the size ranges experienced at this location.
YORK RESEARCH CORPORATION
STAMFORD, CONNECTICUT
-------
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REPORT NO. Y-8>479-22 PAGE. 9
DISCUSSION
All tests for particle size determination were performed at
the outlet of the baghouse air pollution control device.
These tests were all performed during normal operations of
the sintering process. There was an interruption in the
process during test three and during this interruption
sampling was stopped.
Since there was no testing performed at the inlet to the
baghouse the collection efficiency and fractional collection
efficiencies cannot be calculated.
III. SAMPLING METHODS
Samples were taken at the outlet of the baghouse utilizing
an Andersen inertial cascade impactor. A complete des-
cription of the selection and operation of the impactor
appears on Appendix A.
A. Sample Locations and Traverse Points
Samples were taken from the duct situated between the bag-
house outlet and ID fan as shown in Figure 6.
Traverse points were selected by the use of. the EPA Method 1
and consisted of M- points on a diameter. One run was
performed at each of these points on one diameter only.. Each
run is considered a separate test. A sampling traverse was.
not possible at this location because of the variation in
velocity across the duct and the need to have a constant
isokinetic flow rate during sampling.
B. Sampling Procedures
1. Equipment Preparation
Prior to sampling the collecting surfaces were greased with
a benzene-vacuum grease mixture. The surfaces were then
baked for 6 to 8 hours at 400ฐF, dessicated and weighed on
an analytical balance (sensitivity ฑ .01 mg). The Andersen
collecting surfaces are the jet stage plates of the impactor
as no suitable substrate can be used with the Mark II
sampler. The impactor was assembled in a clean area.
YORK RESEARCH CORPORATION WJm STAMFORD, CONNECTICUT
-------
REPORT NO. Y-8479-22 PAGE 10
2. Sampling
Prior to each sample, stack velocity, pressure, temperature
and flue gas composition was determined. From equations
on the field data sheets (Figure 7) an isokinetic sampling
rate was calculated. Sampling durations were selected such
that, hypotehtically, the sample taken would be of signi-
ficant mass but not so large as to permit re-entrainment
from the collecting surface.
Due to the high negative duct pressure at the inlet to the
fan, the Andersen sampling rate was established and then
the impactor was inserted and positioned in the duct.
During the pre-sampling heating of the impactor, a plug
was inserted in place of the nozzle to avoid backflow through
the impactor.
3. Sample Recovery
Upon completion of sampling, the impactor was carefully with-
drawn from the port and placed in a special carrying case
for transportation to the clean area. In the clean area,
the impactors were disassembled and the collection surfaces
were placed in an oven for 1 hour at 120ฐC for drying. The
samples were then dessicated for 4-6 hours and weighed on
the analytical balance.
C. Calculations
The calculations were performed utilizing specially designed
computer programs. A list of the equations used by the
computer appears in Appendix C.
YORK RESEARCH CORPORATION STAMFORD, CONNECTICUT
-------
REPORT NO. Y-84 7 9-2 2
PAGE. 11
25'
H5
FLOW
91
SAMPLE
PORT
FAN
TRAVERSE POINTS
1-6.1"
2-22,8'
3-68.3'
4-84,9'
SAMPLING LOCATION
FIGURF 6
YORK RESEARCH CORPORATION
STAMFORD, CONNECTICUT
-------
REPORT NO. Y-8479-22 PAGE 12.
PAKTICLE SIZE FIELD DATA
Job No. Date
Client Clock Time
Plant Location Impactor ID_
Unit Tested Operator
Test No. Test Conditions
Stack Location Duct Dimensions
Barometric Press. Ambient Temp.
Duct Static Press. (inH00)(P ,) Pitot Factor (FJ_
ฃ Q '~ ~""~""" "--'"-- 5
Nozzle Size (dn)(in) Sample Time (min)_
Impactor Temp.
Md = Mole Fraction Dry = (1- ) = P (ฑ ) =_
MW ,=Molecular weight dry flue gas=(. 44 x %C00)+(. 32 x %0_)+(. 28 x %CO)+(. 28 x %N0)=
Q eL ฃi ฃi
MW = Molecular weight flue gas=(MWd)(Md)+ 18 (l-Md)=_
Vs=Stackgasvelocity=5121.(Fs)
f
2
R = Sampling rate , stack conditions=V . 00545 dn.= _ cfm
s s
R =Sampling rate, meter conditions=R s x |^m ' x Md=
XII ป S *
Traverse Data
Pt . AP(inH20) T (ฐF)
1
2
3
4
5
6
Avg.
FIGURE 7
YORK RESEARCH CORPORATION fecio STAMFORD, CONNECTICUT
-------
REPORT NO. Y-8479-22 PAGE 13
BIBLIOGRAPHY
1) "Fundamentals of Air Pollution," Stern, Wohlers, Boubel,
Lowry, Copyright 1973, Academic Press.
2) "Feasibility of Emission Standards Based on Particle Size,"
Midwest Research Institute, March 1974.
YORK RESEARCH CORPORATION fetp STAMFORD, CONNECTICUT
-------
REPORT NO. Y-8479-22
PAGE. 14
PREPARED BY:
APPROVED BY:
Alan Ferguson
Project Director
vironmeVital Sciences
YORK RESEARCH CORPORATION
STAMFORD, CONNECTICUT
-------
REPORT NO. Y-8479-22
PAGE 15
APPENDIX A
IMPACTOR OPERATING TECHNIQUES
YORK RESEARCH CORPORATION
STAMFORD, CONNECTICUT
-------
REPORT NO. Y~8479 22 PAGE
APPENDIX
IMPACTOR OPERATING TECHNIQUES
A. Impactor Selection
In deciding \vhich cascade impactor is the appropriate device
for a sampling program, the main criteria is the mass loading
and its effect on sampling time. In high grain loading
situations such as the inlet to control devices, a low flow
rate impactor (less than 0.1 acfm) is preferable because it.
permits reasonably long process averaging times, although in
some cases, even with low flow rates the sampling time may be
limited to only a few minutes. The use of a high flow rate
impactor in these cases, would be unwise because impractically
short sampling times would be required in order to avoid inipac-
tor overloading. On the other hand, low dust concentrations
would result in excessively long sampling times with the low
flow units. Impactors operating at flow rates near 0.5 acfm
are normally used under these conditions to keep sampling
times reasonably short. Even high flow rate impactors fre-
quently require sampling times in excess of two hours to collect
weighable stage loadings, especially at the outlet of high
efficiency collectors.
The Brink Impactor (Figure A-l) is the low flow rate impactor
which will be used under-heavy dust loading conditions, while
the Anderson (Figure A-2) impactor is the high flow rate unit
which will be used most often at control device outlets.
In many instances, the percentage (by weight) of material with
sizes larger than the first impaction stage cut point can be
quite high. In such cases, precollector cyclones are necessary
to prevent the upper impactor stages from overloading. The
Brink cyclones which are used were fabricated by York Research
Corporation personnel.
To insure a valid size distribution from impactor measurements,
it is imperative that isokinetic sampling be used, if at all
possible. Figure A-3 depicts the relationship between flue
gas velocity and impactor flow rate for various nozzle sizss.
This graph is used as a convenient means of selecting nozzle
sizes to insure isokinetic sampling when the gas velocity is
YORK RESEARCH CORPORATION (iSsnl STAMFORD,
-------
REPORT NO.
Y-8479-22
PAGE
NOZZLE.
F.ILTER
A
PRECOLLECTION
CYCLONE
-
~
ฃ JET STAGE
(5 TOTAL)
COLLECTION
""PLATE
-SPRING
B
BRINK CASCADE IMPACTOR
FIGURE A-l
YORK RESEARCH CORPORATION tefeci STAMFORD, CONNECTICUT
\v....... r.
v--
-------
REPORT NO.
Y-8479- 22
r
PAGE
o \ JET ,
ฐo ฐ \STAGE
o co ฐQ \ 'AND
0 o - 'COLLECTION
0 /SURFACE
(9 TOTAL)
f* r*"\ / f* **"
SPA Cu
NOZZLE
CORE
PLATE
HOLDER
ANDERSEN IMPACTOR
YORK RESEARCH CORPORATION (SlEi3 STAMFORD, CONNECTICUT
*ฃฃ&'
-------
REPORT NO.
Y-8479-22
PAGE
NOTE
HEAVY HORIZONTAL LIMES INDICATE MAXIMUM FLOW
RATES WITHOUT REENTRAWMENT FOR VARIOUS IMPACTORS.
'
EIE:EiE:E:^7:.^^
5 Eiiฑ:&Eฃฑi^gz^^
I- n . ^"^^ii^li-^^slilzsj-i "2ifiii/ui? ~7/j'^'t'^^~iTf2i^'yr:~r^'L^'
t^ vซ .' ^~_,~~~j? _^^*^^__^*^i"u^-^_^"^J^_71r'^^,,^-____] "7"l^l *.C-"--'lซ- _ t __ i^* ~^ - * i-"." '"^-- T-- , .. T*""^ -i .X- _ . _. ,_ * ': " ''r ,"^*l'7-'^ ^ \!1 '^"'^'"C'T''' "iTj
" '
GAS VELOCITY (FT/SEC.)
Figure A3. Nomograph For Selecting Nozzles For Isokinetic
Sampling. .
YORK RESEARCH CORPORATION
STAMFORD, CONNECTICUT
-------
REPORT NO. Y-8479 ~ 22 PAGE
known and the appropriate impactor flow rate has been chosen.
Also indicated on the graph are heavy horizontal lines giving
the upper flow rate limits for various irrtpactors to insure that
severe reentrainment does not occur.
B. Sampling Time
The length of the sampling time is dictated by mass loading
and size distribution. An estimate for initial tests can be
made from Figure A-4, Tests subsequent to the first should
have sampling times adjusted such that no single stage, ex-
cluding a cyclone, if one is used, contains more than 10 mg
of mass.
c Collection Substrates and Adhesives
The Brink is generally used with aluminum foil or glass fiber
substrates, the Anderson Mark II sampling head cannot be vised
with any type of substrate and the jet stages themselves must
be weighed. Depending on the temperature in the sampling duct,
silicone vacuum grease-or other high viscosity grease may be
vised on the collection surface to aid in the retention of the
impacting particles. It has been found that a thick (20%)
solution or suspension of benzene and grease serves this
purpose well and is fairly easy to apply.- If duct temperatures
are 400ฐF or lower, this grease-benzene mixture will hold
up satisfactorily under most sampling conditions. Horizontal
operation of the irapactors with greased substrates is not
recommended due to possible flow of the grease. The Brink foil
substrates are fitted to the shape of the collection plates.
After being shaped, a paint brush is used to place the benzene
and high vacuum grease solution on the foils.- Four to five
drops are placed on the upper stage Brink foils leaving a
residue of about 20 mg after evaporation of the benzene, and
a' single drop is placed in the center of the last two Brink
stage foils. This same solution is applied to the Anderson
plates with a brush and covering the area between the jet holes
on each plate. These greased collection surfaces are then
baked at 400OF for 6-8 hours. If stage loadings are low,
smaller amounts of grease can be used. When a new batch
of grease is used, checks should be made for weight loss by the
grease subsequent to the initial bakeout. After removal from
the oven, the substrates are conditioned in a desiccator for
6 to 12 hours prior to weighing.
YORK RESEARCH CORPORATION >^m\ STAMFORD, CONNECTICUT
-------
GP.AiN LOAO'NG (GRAINS/ACF)
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ฑi:l!ii:;:.brnฑLj.ui.!!Jj JJLli:i! liidatidiilLiiiik'bl'iiJJ'JJ^;
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1.0 O.3 0.4 O.3 0,3
SELtlCTEO FLCvV RATES (acfm)
O.I 0.03 0.0-J 0.01 0.00.
0.0!
Figure A4. Sampling Tiiv.e Uetermirxation For Total Mass Collection
of. 25 Mil 3 iyrams .
-------
REPORT NO. Y-8479- 22
The use of grease with Brink and Anderson Impactors is nocessary
because of problems with reentrainment and particle bounce,
which is especially severe at jet velocities over 35 to 40 rn/sec
and occurs'-in some instances at even lower velocities. Hich
I -*
impactor flow rates result in high jet velocities in the lower
stages. The use of grease allows higher flow rates than could
be attained without grearje by improving the particle retention
of the impaction surface,, but care must also be taken to
insure that grease is not blown off the substrates. Grease
blowoff can occur at jet velocities greater than 65 m/sec.
Therefore, for each impactor there is a maximum permissible
flow rate, the value of which depends on the type of impaction
substrate that is being used.
Back-up filters are used on all impactors to collect, the material
that passes the last impaction stage. Binderless glass
fiber filter materials such as Gelman Type A Glass Fiber Filter
Web is used for this purpose. For the Brink, 47 mm diameter
circular discs are placed in the filter holder at the outlet
of the last stage of the impactor. The filter is protected
by a teflon washer and a second filter disc placed behind the !
actual filter, which acts as a support. The Anderson used
2%" diameter filter discs placed above the final "F" stage.
D. Mu11ipqint S amp1inq
Although it is desirable'to sample at several points across a
duct to insure that the sample collected is representative of
the flue gas, the impactors should be operated isokinetically
at a constant flow rate for each point sample. To .accomplish
a traverse, the .impactor is operated at several discrete
points across the duct, with properly selected nozzles and. flow
rates for isokinetic sampling, and the results a\Teraged to give
an "average" dust loading.
E. Impactor Orientation
Whenever possible, the impactors are oriented vertically to
minimize gravitational effects such as flow of grease or falloff
of collected particles. Horizontal placement is necessary at
times and extra care must be taken on such to not bump the
impactor against, the port during removal operations.
RCH CORPORATION f^izcr'' STAMFORD, CONNECTICUT
JLvvxi. A. *i*s -' *vA. ** A%.X A. JL A. %^-_ ^ ..,*7vrr:,.;
-------
REPORT NO. Y-8479- 22 PAGE.
F. Heating Impactor
All condensable vapors must be in a gaseous state until they
exit from the impactor unless a condensate is the prime aerosol
being measured. In streams above 350ฐF, auxiliary heating is
not usually required. Below 350ฐF, the exit temperature of
the impactor is maintained at least 20 F above the process
temperature. A thermocouple is normally used to monitor the
temperature of the exit gas from the impactor.
Whether the impactor is being heated in the duct or externally,
with heater tape, etc., an allowance of 15 minutes- warm-up
time is allowed, as a minimum to insure that the impactor has
been heated to duct or operating temperature.
G. Probes
Sampling probes to an impactor outside the duct are used only
if there is no other way. Probes are kept to a minimum length
and contain the fewest possible bends. A precollector cyclone
is mounted at the end of the probe to remove the large particles
and thus reduce line losses.
H. Balance Requirements '
For accurate weighing of collected material, a balance with a
sensitivity of at least 0.01 milligrams is required. Th-is
is especially true for the lower stages of the Brink Impactor
where collection of 0.3 mg or less is not uncommon. The balance
must also be insensitive to vibration if it is to be used in the
field. A Mettler H51 Balance is used by York Research Corpora-
tion and has been found to be satisfactory under all field
test conditions which have been .encountered.
I. Sampling Configurations .
Several sampling train arrangements are available depending on
the impactor used, flow, sampling time/ etc. The low flow rates
for Brinks sampling made a dry gas meter useless. In per-
forming our tests, we have used an in-stack system which
incorporates a calibrated rotameter as shown in Figure A-5.
The higher flow rate Anderson Impactor can be used in conjunctio
with a gas meter as shown in Figure A-6.
To insure proper measurement by the orifices and dry gas meter
and to protect the vacuum pumps from damage resulting from
YORK RESEARCH CORPORATION STAMFORD. CONNECTIC
-------
0
tn
b .
q
j
O
0
O
H
i i
O
: :|*-1: x\
?J:lซ ]."!
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g"
>ri
O
O
O
O
o
c.
I--1
BRINK. SAMPLING TRAIN
'
STACK '" .. ' - .ROTAMETER
1 .. . ' ' '
L i i -J D "" N
Y BRINK
J
' r\
r -\
ff Y
~rfi
* v
4 \_
. 11
'-rr' /(7 /v^i
/ !\ J \^ V> u;
rH i^^T
- ..-.-.. M | I
DRYING 4|; ' | J!
. . COLUMN |H 1 I
fWiVW ' H .?,
v\^|
^
f i
PUMP
MANOMETER
. k^ .
. FIGURE A- 5 . NTS
-------
x
x
'l
ANDERSEN
X
x
'. 'X
x
X?-
U ';'-. II
hrc; '-in:'
,[ฃ1; i-'v L4L
IMPINGERS
PUMP GAS ORIFICE
METER
ANDERSEN
SAMPLING. TRAIN
FinijRF. A-6__
NTS 1
-------
REPORT NO. Y-8479- 22 PAGE
condensable vapors, it is necessary to cool and dry the sampled
gases immediately after they leave the impactor. For long
sampling times or in cases where there is high water content,
a series of condensers in.an ice bath is useful in removing
the water. A drying column is normally used .after the
condensers for further protection of the gas meter.
The use of a calibrated orifice to monitor the impactor flow
rate involves the following equation giving the pressure drop
across the orifice meter manometer.
where ,
MM = Mean Molecular Weight of Flue Gas
MA = Mean Molecular Weight of Air
-------
REPORT NO. Y-8479-22 PAGE
P = Ambient stack pressure "Hg
FH Q = Volume fraction of water in flue gas
In-stack sampling is recommended in all cases where practical;
however, in certain cases, out-of-stack sampling is the only
solution.
A sufficiently long" piece of pipe is attached to the impactor
to insure proper positioning and traverse capabilities in the
duct and to insure that the impactor is not cooled by heat
transfer along the probe if external heating of the impactor
is not used.
Negative duct pressures can cause problems resulting from
backflow through the impactor causing material to be blown off
the collection substrates onto the underside of the jet plate
after conclusion of sampling. Thus, care must be taken to insure
that no gas flow through the impactor takes place except when
sampling. In these cases}the sampler is started and stopped
outside the duct and carefully inserted while running. The
test time is started and stopped when.the impactor enters and
leaves the duct.
-J. Preparing- the Impactors .
The impactor is carefully loaded with the preweighed collecting
surfaces. The Andersen requires that extra attention be paid
. to the alignment of one stage-to the next stage insuring that
the jets of one stage are above the collection surface of the
next stage.. After all stages are loaded, the entrance cap is
placed on the Brink and the shell is placed on the Andersen..
The Brink is tightened with wrenches to make certain the
asbestos gaskets are seated. Handtightening is sufficient for
the Andersen Impactor. Overtightening will cause the stainless
steel seals to cut into the Andersen collective surfaces. After
assembly., the appropriate nozzle is added.
If supplemental heating is required, the heating tapes, insula-
tion and temperature monitors need to be added. A thermocouple
mounted in the gas flow immediately after the impactor is best
for controlling heating. This also yields the temperature
needed- for calculating impactor cut points. A heating tape of
sufficient heating capacity is wrapped around .the impactor.
Fiber .glass tape is again added to hold, the asbestos in place
as insulation. An easily removed wrapping of aluminum foil
YORK RESEARCH CORPORATION feis] STAFFORD, CONNECTICUT
-------
REPORT NO. Y-8479- 22 . PAGE
is sometimes used to keep the impactor clean while in the duct.
The impactor is then mounted on the appropriate probe, taken
to the sampling position- and installed in the sampling system.
K- Taking the Sample
The impactor should be preheated for at least 15 minutes before
sampling. If supplemental heat is being used, the impactor
should be brought up to temperature outside the duct and then
allowed some time to equilibrate after insertion. The nozzle
should not point upstream into the gas flow.during this
phase.
The flow rate must be maintained at the predetermined level .
during testing to assure stable cut points. Any attempt to
modulate flow to provide isokinetic sampling could destroy the
validity of the data. The correct flow rate should be esta-
blished quickly, especially for the short sampling times
typically found at inlets.
L- Disassembling the I rap actor ' '
The post test procedure is very important in obtaining useful
results. The crucial part is to make sure the collected
material stays where it originally impacted. After the test,
the -impactor should be qarefully removed from the duct without
jarring, removed from the probe, and allowed to cool.
Disassembly is quite tricky in some cases, it is helpful to have
a pair of fine, tweezers and a balance brush. Careful disassem-
bly of a Brink is a necessity for obtaining good stage weights.
If a precollector cyclone has been used, all material from
nozzle to the outlet of the cyclone is included with the
cyclone catch. All of this material is brushed onto a small
tared 1" x 1" aluminum foil square to be saved for weighing.
Cleaning the nozzle well is also important, especially if it
is a small bore nozzle. All material between the cyclone
outlet and second stage nozzle is generally included with
material collected on the first collection substrate. All
appropriate walls are brushed off as well as around the under-
side of the nozzle where a halo frequently occurs on the upper
Brink stages. All material between the second stage nozzle
and third stage' nozzle is generally included with that on the
second collection substrate. This process should be continued
down to the last collection substrate. Care is necessary in
taking .out the filter. A good pair of sharp fine tweezers ?.s
YORK RESEARCH CORPORATION SS1 STAMFORD,
-------
REPORT NO. Y-8479- 22 ' PAGE
essential in removing the foil substrates from the plates
without losing grease and collected material.
Cleaning an Anclerser.. is a demanding chore. A foil to hold the
Stage 1 collecting surface is laid out. Next, the nozzle
and entrance cone ara brushed out and onto the foil. Then
the materials on Sta-r/2 0 is brushed off. Next, any material
on the top 0-ring and bottom of Stage 0 is brushed onto the
foil. Finally, the ฃta'je 1 collecting surface is placed on the
foil and last, the tc.p of the Stage 1 plate 0-ring and cross
piece is brushed off. This process is continued through the
lower stages. Finally, the filter is carefully removed. Again,
all material is desiccated 6 to 8 hours before final weighing.
,. 7
-------
REPORT NO. Y-8479-22 PAGE. 31
APPENDIX B
COMPUTER PRINTOUT
YORK RESEARCH CORPORATION (yjprcj STAMFORD, CONNECTICUT
-------
Page 32
YORK RESEARCH CORPORATION
ONE RESEARCH DRIVE, STAMFORD, CONNECTICUT 06906
JOB NUMBER: Y8479-22
CLIENT* EPA - KAISER STEEL
PLANT LOCATION: FONTANA, CALIFORNIA
UNIT TESTED: BAGHOUSE
STACK NUMBER: 2
STACK LOCATION: OUTLET - 84 IN.
TEST NUMBER: 1
DATE: 060375
CONDITIONS: NORMAL
. AMBIENT TEMP-DEG Fป 70
BAR. PRESS-IN HG:28.86
DIAMETER
STAGE (MICRONS)
I > 9.80
2 9.80-6.11
3 6.11-4.13
4 4.13-2.81
5 2.81-1.79
6 1.79-0.89
7 0.89-0.54
8 0.54-0.35
FILTER < 0.35
ANDERSEN PARTICLE SIZING
WEIGHT % PER CUM% GR/SCFD MG/NCMD
(MILLIGRAMS) STAGE
-------
Page 33
YORK RESEARCH CORPORATION
ONE RESEARCH DRIVE, STAMFORD, CONNECTICUT 06906
JOB NUMBER: Y8479-22
CLIENTi EPA - KAISER STEEL
PLANT LOCATION: FONTANA, CALIFRONIA
UNIT TESTED: BAGHOUSE
STACK NUMBER: 2
STACK LOCATION: OUTLET - 68.25
TEST NUMBER: 2
DATE: 060375
CONDITIONS: NORMAL
AMBIENT TEMP-DEG F* 70
BAR. PRESS-IN HG:28.86
DIAMETER
STAGE (MICRONS)
1 > 9.80
2 9.80-6.11
3 6.11-4.13
4 4.13-2.81
5 2.81-1.79
6 1.79-O.89
7 0.89-0.54
8 0.54-0.35
FILTER < 0.35
ANDERSEN PARTICLE SIZING
WEIGHT % PER CUM% GR/SCFD MG/NCMD
(MILLIGRAMS) STAGE
-------
Page 34
YORK RESEARCH CORPORATION
ONE RESEARCH DRIVE, STAMFORD, CONNECTICUT 06906
JOB NUMBER: Y8479-22
CLIENT: EPA - KAISER STEEL
PLANT LOCATION: FONTAMA, CALIFORNIA
UNIT TESTED: BAGHOUSE
STACK NUMBER: 2
STACK LOCATION: OUTLET - 22.75 IN.
TEST NUMBER: 3
DATE: 060575
CONDITIONS: NORMAL
AMBIENT TEMP-DEG F: 70
BAR. PRESS-IN HG:28.9I
DIAMETER
STAGE (MICRONS)
I > 9.80
2 9.80-6.11
3 6.11-4.13
4 4.13-2.81
5 2.81-1.80
6 1.80-0.89
7 0.89-0.54
8 0.54-0.35
FILTER < 0.35
ANDERSEN PARTICLE SIZING
WEIGHT % PER CUM% GR/SCFD MG/NCMD
(MILLIGRAMS) STAGE
-------
Page 35
YORK RESEARCH CORPORATION
ONE RESEARCH DRIVE, STAMFORD, CONNECTICUT 06906
JOB NUMBER: Y8479-22
CLIENT: EPA - KAISER STEEL
PLANT LOCATION: FONTANA, CALIFORNIA
UNIT TESTED: BAGHOUSE
STACK NUMBER: 2
STACK LOCATION: OUTLET - 7 IN.
TEST NUMBER: 4
DATE: 060575
CONDITIONS: NORMAL
AMBIENT TEMP-DEC F* 70
BAR. PRESS-IN HG:2R.91
DIAMETER
STAGE (MICRONS)
I > 9.47
2 9.47-5.90
3 5.90-3.99
4 3.99-2.71
5 2.71-1.73
6 1.73-0.86
7 0.86-0.52
8 0.52-0.33
FILTER < 0.33
ANDERSEN PARTICLE SIZING
WEIGHT % PER CUM% GR/SCFD MG/NCMD
(MILLIGRAMS) STAGE
-------
REPORT NO. Y-84 7 9-2 2 PAGE 36
APPENDIX C
CALCULATION EQUATIONS
YORK RESEARCH CORPORATION frjjra STAMFORD, CONNECTICUT
-------
REPORT NO. PAGE.
BRINK PARTICLE SIZING CALCULATIONS
CO = Percent carbon monoxide in gas (dry)
CO2 = Percent carbon dioxide in gas (dry)
H2O = Percent water in gas (volumetric basis)
N2 = Percent nitrogen in gas (dry)
Gฃ = Percent oxygen in gas (dry)
Pb = Barometric pressure (in. Hg)
PBt = Static pressure in stack (in. ^O)
t = Total test time (min)
Tst = Stack temperature (ฐF)
T2 = Temperature of gas at sampling conditions (ฐK)
VA = Sampling rate (ACFM)
W = Total weight of particulate sampled (mg)
w(i) = Weight of particulate each stage (mg)
/Op = Density of particle (gm/cc)
/\ = Viscosity (micro-poise)
1. Static pressure at inlet to impactor (atm)
pst .
29.92
2. Molecular weight of stack gases (gm/gm mole)
r I
MW = [(C02 x . 44)+(02 x . 32)+(N2 x . 28)+(CO x . 28)1 x
Hฐ
~
1-
Hฐ
18 x 2
3. Inlet flow to impactor (cc/sec)
F = 472 V.
4. Effective pressure drop across impactor (in. Hg)
2.3055
Ap = / I v
*-* E V 24.5818 ;
5. Pressure drop across impactor (in. Hg)
MW
6. Density of gas at inlet sampling conditions (gm/cc)
MW x PT
82.06xT
ฃi
YORK RESEARCH CORPORATION ptgi' STAMFORD, CONNECTICUT
-------
REPORT NO.
PAGE
7. Pressure at outlet of stage' six (atm)
-
I 29.92
8. Pressure at outlet of stage five (atm)
P = P -
5 I 29.92
9. Pressure at outlet of stage 4, stage 3 and stage 2 (atm)
10. Density of the gas at outlet of each stage (gm/cc)
6
11
P,
A) =
I
i=2
11. Stage Jet Diameter (cm)
Dc(2)
Dc(3)
Dc(4)
Dc(5)
Dc(6)
,249
.1775
.1396
.0946
.0731
12. Characteristic diameter of particle for each stage i (microns)
Follow statements 9-14 to determine how correct value is obtained before
moving to next stage.
Dp(i) = -12.45X1
+ I 155/C +
V/ฐ(i) P(i)
(2.05x 108)CCO Dc(i)3
(F)(PT)
13. Average molecular velocity for each stage (cm/sec)
8 x P(l) x 1.013 x 10l
14. Mean free path of gas molecules for each stage (cm)
2/C
YORK RESEARCH CORPORATION Esmd .STAMFORD, CONNECTICUT
-------
REPORT NO.
PAGE
-4
15. If Dp(i) x 10 / L(i) is greater than or equal to 2. 7 go to statement 8
for next stage. If the ratio is less than 2.7 go to next statement. When
all stages are completed go to statement 19.
\
16. Empirical correction factor for resistance of gas to movement
C = 1.0 +
2L(i)
Dp(i) x 10-4
1.23+.41e(-44Dp(i)Xlฐ
-4
17. New characteristic diameter of particles on stage i (microns)
DpW-lMSxloV/^
..3
18. When the new diameter is within 1% of the previous diameter save that value.
Return to statement 8 until each stage is completed or continue with the next
statement when all stages are completed.
19. Sampling rate (SCFMD)
X
(T + 460.)
st
1-
H2ฐ
100
20. Volume of gas sampled (SCFD)
V = V -x t
S VSDX
21. Sampling rate (NCMMD)
SMD
V
SD
22. Particulate concentration for each stage (grains/SCFD)
, 7
Gr(i) = .01543
23. Particulate concentration for each stage (mg/NCMD)
E(i) = 2288. 56 Gr(i) ?
24. .Total particulate concentration (grain?/ SCFD)
W
TGr = . 01543
V,
YORK RESEARCH CORPORATION
STAMFORD, CONNECTICUT
-------
REPORT NO.
PAGE.
25. Total participate concentration (mg/NCMD)
TC = 2288.56 TGr
26. Percentage of total amount recovered for each stage
, 7
r(i) = 100 ^
27. Cumulative percentage smaller than upper diameter, Dp(i), for each stage
CP(1) = 100 .
= CP(i) - r(i)
YORK RESEARCH CORPORATION fcgga STAMFORD, CONNECTICUT
-------
REPORT NO. PAGE
VISE VISCOSITY CALCULATIONS
Xl = Carbon dioxide in gas (mole fraction)
X2 = Carbon monoxide in gas (mole fraction) ' .
Xs = Nitrogen in gas (mole fraction)
X4 = Oxygen in gas (mole fraction)
Xs = Moisture in gas (mole fraction)
Tic = Temperature of impactor (ฐC)
WTi .= Molecular weight of carbon dioxide (gm/gm mole)
WT2 = Molecular weight of carbon monoxide (gm/gm mole)
WTs = Molecular weight of nitrogen (gm/gm mole)
WT4 = Molecular weight of oxygen (gm/gm mole)
WT5 = Molecular weight of water (gm/gm mole)
1. Pure gas viscosity of CO (micro-poise)
Z
= 138. 51 + (0.499 x T. ) - (0. 267 x 10~3) x T. 2 + (0. 966 x 10~?) x T. 3
2. Pure gas viscosity of CO (micro-poises)
/,(2 = 165.763 + (0.422 x T. ) - (0.213 x 10"3) x T. 2
3. Pure gas viscosity of N (micro-poises) " .
ฃt
u . = 166.48 + (0. 421 x T. ) - (0.139 x 10~3) x T. 2
. ' ^3 ic ic
4. Pure gas viscosity of O (micro-poises)
^4 = 190.187 + (0. 558 x T. ) - (0. 336 x 10~3) x T. 2 + (0.139 x 10~6) x T. 3
5. Pure gas viscosity of HO (micro-poises)
LA
Mt. = 87. 800 + (0. 374 x T. ) + (0. 238 x 10~4) x T. 2
/^V-h x in ir*
v *W J-Vy
6. Final viscosity of the mixture (micro-poises)
n
1=1
X. 0 ..
where 0ij is given by the equation:
,1/2
,vhere Vij is given by
*, _ 11+ (Xi/^j)
(WTj/WTj
1 + (WTi
i / WTj ,]3-/2
YORK RESEARCH CORPORATION fSEgg STAMFORD, CONNECTICUT
)
-------
REPORT NO.
PAGE
CO
C02
H20
N2
02
Pi
Tst
t
VA
w
AP
ANDERSEN PARTICLE SIZING CALCULATIONS
Percent carbon monoxide in gas (dry basis)
Percent carbon dioxide in gas (dry basis)
Percent moisture in gas
Percent introgen in gas (dry basis)
Percent oxygen in gas (dry basis)
Gas pressure at impactor inlet (atm)
Temperature of- the impactor (ฐK)
Stack temperature (ฐF)
Total test time (man)
Sampling rate (ACFM)
Total weight of sample collected (mg)//
Pressure drop across impactor (atm)
Particle density (gm/cc)
Viscosity (micro-poise)
In
jH = Viscosity (micro-poise)
1. Molecular weight of stack gases (gm/gm mole)
/
MW
r n l~ H2ฐl
= (CO x.44H(COx.28)+(N x-.28)+(0.x.32) x 1- ~~-1
L_ ^ ^ ^ U I 100 j
18 x
H2ฐ
-~
2. Local pressure at each stage (atm)
.,
l&
/>\
3. Mean free path for each stage (cm)
i) = . 00104
MW
4. Diameter of collection plate holes for each stage (cm)
DC(1) = 0.1613
DC(2) = 0.1181
DC(3) = 0. 091.4
DC(4) = 0..0711
5. Inlet flow to impactor (cc/sec)
DC(5) = 0.0533
DC(G) = 0. 0343
DC(7) = 0.0254
DC(8) = 0. 0254
F=472V
.
A
YORK RESEARCH CORPORATION
.STAMFORD, CONNECTICUT
-------
REPORT NO. ' ' PAGE
6. Initial approximation of cut point diameter for each stage (microns)
DPC(1) = 9.5 " DPC(5) = 1.75
DPC(2) = 6.0 DPC(6) = 0. 90
DPC(3) = 4.0, DPC(7) = 0.54
DPC(4) = 2.8 DPC(8) = 0.36
7. Cunningham's correction factor for resistance of gas to movement
C " l-
DPC(i) x 10"*
8. Cut point diameter for each stage (microns)
(-.44xDPC(i)xlO~4/L(i)7l
i- ^+-4ie J
- 1.4,
.,3
7
Return to statement 5 for each stage until the difference from the previous value
is less than . 001.
9. Sampling rate (SCFMD)
_, 53.0. x V. x PT , HnO
VSD= A I x 1- 2
(T + 460) 100
10. Volume of gas sampled (SCFD)
11. Sampling rate (NCMMD)
VSMD = ' ฐ283168 VSD
12. Particulate concentration for each stage (grains/SCFD)
9
Gr(i) = . 01543 x
s
13. Particulate concentration for each stage (mg/NCMD)
9
E(i) = 2288.56 Gr(i)
1J.
YORK RESEARCH CORPORATION ggg STAMFORD, CONNECTICUT
-------
REPORT NO.
' PAGE
14. Total particulate concentration (grains/SCFD)
TGr = . 01543 ~- ' '
s
15. Total particulate concentration (mg/NCMD)
TC = 2288.56 TGr
16. Percent of total amount recovered for each stage
r(i) = 100 *G>
17. Cumulative percent smaller than upper diameter, Dp(i), for each stage
CP(1) = 100
1) = CP(i) - r(i)
YORK RESEARCH CORPORATION [TEES STAMFORD, CONNECTICUT
-------
REPORT NO. Y-8479-22 PAGE
APPENDIX D
Raw Field Data Sheets
YORK RESEARCH CORPORATION &งfra STAMFORD, CONNECTICUT
-------
YORK RESEARCH CORPORATION
ANDERSON FIELD DATA SHEETS
: 6 k/
l
TIME
: //#"- .Q ?..
^-to
CLIENT :
PLANT LOCATION;
OPERATOR :
PORT DESIGNATION; 5>7>?CX: /l/fl ft '
Pb: ___2jLAb Test No-; I
Tซ:
Location
: .OoTie
oTi er
Pซ:
Nozzle:
Meter End:
Meter Start:
Net:
Av? vs: -
TI!
Vel. Traverse
Vp-1
2
3
4
5
6
Avg.
c
9*1 '
It, 0
C,-
"L
//,
I
Plate Desig Gross (gm) Tare(gm) Net (gut)
''C, j
,00
r <0 O/ ^ 7
OOI
-------
YORK RESEARCH CORPORATION
DATE;
c hhr
ซ i
CLIENT:
PLANT LOCATION:
OPERATOR:^
PORT DESIGNATION: _-
'0 /** fa
PC:
Nozzle:
Meter End:
Meter Start
Net:
Vel. Traverse
Vp-1
2
3
4
5
6
Avg
ANDERSON FIELD DATA SHEETS
TIME:
/I/*,
Test No.:
Location:
Avg Vs :
Plate Desig Gross(gm) Tare(gm) Net (gm)
D
3/1 . Q037/
//. ^ 7
Dfe
1 1*
, oooi
00 / 8 0
-------
YORK RESEARCH CORPORATION
DATE:
CLIENT
PLANT LOCATION;
OPERATOR:
PORT DESIGNATION:
Pv>:
p
*s-
Nozzle;
Meter End:
Meter Start;
Net:
Vel. Traverse
Vp-1
2
3
4
5
6
Avg
ANDERSON FIELD DATA SHEETS
TIME:
Test No.:
Location:
3-*, ?J
Avg Vs:_
Plate Desig Gross(gm) Tare(gm) Net (gm)
c/-
0,7
C.
//. 5T/3
-------
YORK RESEARCH CORPORATION
DATE:
ANDERSON FIELD DATA SHEETS
TIME: /$ c^"
CLIENT:
PLANT LOCATION:
OPERATOR:^.
PORT DESIGNATION;
jrf#C(<
Test No. :
Location:
7
Nozzle:
Meter End
fS?
Meter Start
: XJ/ป
Net:
Avg Vs:
TT:
Vel. Traverse
Vp-1
2
3
4
Avg
Plate Desig Gross(gm) Tare(gm) Net (gm)
30,
.OQ331/
CD3/0
//,
------- |