t No. 7SST,
o-
2**?3
Swi
GKASlTii CITJ STF.SL ?TV IS IDS
B Ail OH AT. STEET. CORPORATION
CRAKTTE CITY. IJ.L'lSniS
'975
5SS
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
-------
EMB Report No. 75SIN4
CD
^
O
SINTER PLANT,
GRANITE CITY STEEL "DIVISION
NATIONAL STEEL CORPORATION
GRANITE CITY, ILLINOIS
NOVEMBER, 1975
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
-------
AIR POLLUTION EMISSION TEST
Sinter Plant
Granite City Steel Division
National Steel Corporation
Granite City, Illinois
EMB Report No. 75SIN4
by
Thomas A. Loch, Ph.D., P.E.
Prepared for:
U.S. Environmental Protection Agency
Contract N'o. 68-02-1408
by
Clayton Environmental Consultants, Inc
25711 Southfield Road
Southfield, Michigan 48075
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TABLE OF CONTENTS
Page
I. INTRODUCTION 1
II. SUMMARY AND DISCUSSION OF RESULTS 3
III. PROCESS DESCRIPTION AND OPERATION 66
IV. LOCATION OF SAMPLING POINTS 83
V. SAMPLING AND ANALYTICAL PROCEDURES 89
FIGURES
1. Gaseous Hydrocarbons - Particulate Train 12
\
2. Schematic Diagram of Visible Emissions Observation 64
Locations
3. Simplified Schematic Diagram of Sintering Process 67
4. Process Flow Diagram 69
5. Schematic of Venturi Scrubber System and Sampling 84
Locations
6. Location of Sampling Points in the Outlet Stack 85
7. Location of Sampling Points in the Inlet Duct 86
TABLES
I. Filterable and Total Particulate Emissions 7-10
II. Scrubber Efficiencies for Filterable and 11
Total Particulate
III. Total Fluoride Emissions 14-15
IV. Scrubber Efficiencies for Total Fluoride 16
V. Filterable, Condensible, and Gaseous Hydro- 22-24
carbon Emissions
VI. Scrubber Efficiencies for Filterable and 25
Condensible Hydrocarbons
VII. Sulfur Oxides Emissions 27
-------
VIII,
IX.
X.
XI.
XII.
XIII,
XIV.
XV.
XVI.
APPENDICES
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
Page
Carbon Monoxide Emissions 30-33
Summary of Orsat Data 34
Summary of Scrubber Water Analyses 37
Summary of Sinter Feed Analyses 42
Summary of Visible Emissions Observations 48-63
Average Outlet Stack Visible Emissions During 65
Particulate Tests
Basicity of the Sinter 73
Process Material Rates Summary 75
Venturi Parameters 78-81
Complete Non-Condensible Hydrocarbon Results
Complete Particulate Organic Extraction Results
Sample Calculations
Sampling and Analytical Procedures
Sampling Summary and Field Data Sheets
Particulate Train Auxiliary Temperature Data
Laboratory Report
Calibrations
Process Field Data
Visible Emissions Field Data
Test Log
Project Participants
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I. INTRODUCTION
In accordance with the Clean Air Act, the Environmental Protec-
tion Agency is charged with the establishment of performance stand-
ards for new or modified stationary sources. To establish a back-
ground data base useful in developing these standards, the Emission
Measurement Branch of the Environmental Protection Agency (Emission
Standards and Engineering Division) under Task 16 of Contract No.
68-02-1408, commissioned Clayton Environmental Consultants,Inc. to
document the emissions from the Granite City Steel sintering facility
at Granite City, Illinois.
The sintering process utilizes waste materials from other steel-
making processes. Materials including coke breeze, blast furnace
dust, and ore fines are fused into a stable mass called sinter for
use in subsequent blast furnace charging. The flue gases produced
upon heating of the sinter mixture carry particulate, sulfur oxides,
hydrocarbons, carbon monoxide, and fluorides. At Granite City Steel,
the contaminants contained in the flue gases are abated using a two-
stage control system comprised of a parallel bank of mechanical col-
lectors and a high-energy venturi scrubber connected in series.
In this study, the efficiency of the high-energy venturi in con-
trolling the aforementioned contaminant species was determined by
simultaneous source testing at the outlet and inlet of the venturi
scrubber. Process samples obtained from each of the individual
sinter line feed hoppers and the sinter bed itself document the
total process weight and the process input of sulfur and fluoride.
Scrubber outlet and inlet water samples were collected to deter-
mine total dissolved and suspended solids in the scrubbing liquor
as well as pH and fluoride content.
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-2-
Process data and control system performance data were gathered
during the week of May 19-23, 1975. Representatives from PEDCo
Environmental Specialists, Cincinnati, Ohio, monitored the perti-
nent process parameters and documented process operation during
the tests in the "Process Description and Operation" section of
this report. Clayton Environmental Consultants was responsible
for gathering process bulk samples and scrubber liquor samples.
Additionally, Clayton Environmental Consultants, Southfield,
Michigan, provided services and personnel necessary to conduct
the source testing program and assemble this report. Representa-
tives from York Research Corporation, Stamford, Connecticut, con-
ducted particle size distribution tests at the scrubber outlet
and inlet. The results of the particle size study are presented
in a separate report. Environmental Protection Agency personnel
supervised the source testing procedures and the acquisition of
bulk samples. Project participants are delineated in Appendix L.
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-3-
II. SUMMARY AND DISCUSSION OF RESULTS
Process Operation During Testing
The sinter plant operated two shifts per day from 7:00 A.M. to
11:00 P.M. during the week of testing. Since the strand (see
Section III, Process Description and Operation, for terminology)
was started cold each morning, the tests were not started until the
process had reached normal conditions (about 1-1/2 hours).
Iron ore fines, iron-bearing wastes, dolomite,and coke breeze
were blended with rerun sinter fines and water to form the sinter
burden. Both coke oven gas and natural gas were burned at times to
ignite the sinter. About 102 tons of sinter with a base-acid ratio
of 1.44 were produced per hour of operation during the period of
process monitoring. The average total strand burden was 261 tons/hour
During the first particulate test, conducted on May 20, the
venturi scrubber throat was in a fully-open configuration. Sub-
sequently, on May 21, 22, and 23, the scrubber operated with approxi-
mately 26 inches of throat length blocked off by means of a movable
plate installed during the evening of May 20. Further, during the
first particulate test, a portion of the influent scrubbing water
wasblast furnace cooling water, while plant service water was
supplied to the venturi during the second, third, and fourth par-
ticulate tests and the two fluoride tests. Because of these
differences, the results obtained during the first particulate
test are not included in any averages presented in this section.
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-4-
Particulate Sampling Results
Tables 1-1 through 1-4 present the results of the particulate
emission measurements made at the venturi scrubber outlet stack
and inlet duct.
Table 1-1 shows that the filterable particulate emissions at
the outlet stack ranged from 29.3 to 42.5 pounds per hour with an
average of 32.1 pounds per hour. Emission factors at the outlet
ranged from 0.11 to 0.16 pounds of filterable particulate per ton
of total strand burden with an average of 0.13 pound of filterable
particulate per ton of total strand burden. Concentrations of fil-
terable particulate at the outlet ranged from 0.017 to 0.025 grain
per dry SCF with an average of 0.019 grain per dry SCF.
Table 1-2 shows that the total particulate emission rate at the
scrubber outlet stack ranged from 66.9 to 89.2 pounds per hour with
an average of 72.3 pounds per hour. Emission factors at the outlet
ranged from 0.27 to 0.34 pound of total particulate per ton of
total strand burden with an average of 0.28 pound of total particu-
late per ton of total strand burden. Concentrations of total par-
ticulate at the outlet ranged from 0.039 to 0.053 grain per dry SCF
with an average of 0.042 grain per dry SCF.
Table 1-3 shows that the filterable particulate emissions at
the scrubber inlet duct ranged from 501 pounds per hour to 546
pounds per hour with an average of 520 pounds per hour. Emission
factors at the inlet ranged from 1.9 to 2.2 pounds of filterable
particulate per ton of total strand burden with an average of 2.0
pounds of filterable particulate per ton of total strand burden.
Corresponding concentrations of filterable particulate at the inlet
ranged from 0.323 to 0.362 grain per dry SCF with an average of
0.338 grain per dry SCF.
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-5-
Table 1-4 shows that the total particulate emissions at the
inlet duct ranged from 604 to 622 pounds per hour with an average
of 619 pounds per hour. Emission factors at the inlet duct ranged
from 2.3 to 2.5 pounds of total particulate per ton of total strand
burden with an average of 2.4 pounds of total particulate per ton of
total strand burden. Corresponding concentrations of total particu-
late at the inlet duct ranged from 0.392 to 0.409 grain per dry SCF
with an average of 0.403 grain per dry SCF.
Scrubber efficiencies were calculated based upon filterable and total
particulate emissions. As shown in Table II, the efficiency of the
scrubber in removing filterable particulate emissions ranged from
91.8 to 94.3 percent with an average of 93.8 percent. The scrubber
efficiencies in removing total particulate emissions ranged from
85.2 to 89.2 percent with an average of 88.3 percent.
The gas flowrate in the scrubber outlet stack ranged from
196,000 to 201,000 dry SCFM with an average of 199,000 dry SCFM.
The average outlet stack gas temperature ranged from 145°F to 149°F
with an average of 149°F. P rcent moisture in the stack gas, by
volume, ranged from 10.6 to 14.7 percent with an average of 10.9
percent.
The gas flowrate measured at the scrubber inlet duct ranged
from 174,000 to 185,000 dry SCFM with an average of 179,000 dry
SCFM. The average temperature of the inlet exhaust gas ranged
from 262°F to 289°F with an average of 272°F. Percent moisture
in the inlet exhaust gas, by volume, ranged from 10.1 to 12.7
percent with an average of 11.5 percent. x
The aforementioned averages exclude the first particulate
test, P-l, due to abnormal scrubber feed water conditions.
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-6-
All tests for particulate emissions were conducted within the
required range of 90 percent and 110 percent of isokinetic.
The summary of chloroform-ether soluble particulate emissions
is presented in the hydrocarbon sampling summary for filterable
and condensible hydrocarbons. Appendix B contains the complete
particulate, organic extraction results. Appendix C displays
o
sample calculations used in developing the particulate emissions
results. Appendix F contains auxiliary temperature data that
document those temperatures existing in the sampling train used
for particulate emissions measurements as shown in Figure 1.
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-7-
TABLE 1-1
SUMMARY OF FILTERABLE PARTICIPATE EMISSIONS
Granite City Steel
Granite City, Illinois
May'20-23, 1975
Source: Sinter Plant Scrubber Outlet
Dimensions
Test Number
Da te
Sampling
Period
Sampled
Volume
Start
Stop
Am3 (1)
DNm3 (2)
ACF (3)
DSCF (4)
Percent Moisture by Volume
Average Stack
Temperature
Stack Gas
Flourate
°C
°F
Am^/min (5)
DNm3/min (6)
ACFMxlO"3 (7)
DSCFMxlCT3 (8)
Percent Isokinetic
Strand
Burden
M tons/hr (9)
tons/hr
P-l*
5/20
09:31
12:23
3.08
2.25
108.7
79.3
| 14.7
63
145
7620
5550
269
196
106.1
239
264
Sample Weight (mg) I! 130.0
Particulate
Concentration
Particulate
Emiss ion
Rate
ing /Am 3
rag /DNm3
gr/ACF
p.r/DSCF
kg/hr
kg/M ton of SB
Ib/hr
Ib/ton of SB
42.2
57.8
0.018
0.025
19.2
0.08
42.5
0.16
P-2
5/21
09:50
13:07
2.91
2.23
102.8
78.6
10.6
64
148
7360
5640
260
199
104.0
233
257
107.1
36.8
48.0
0.016
0.021
16.3
0.07
35.9
0.14
P-3
5/22
09: 15
11:57
2.74
2.09
96.7
73.8
11.0
65
149
7480
5690
264
201
96.3
242
267
81.3
29.7
38.9
0.013
0.017
13.3
0.05
29.3
0.11
P-4
5/23
09:02
11:52
2.71
2.06
95.8
72.8
11.2
65
149
7360
5610
260
198
96.8
225
248
86.4
31.9
41.9
0.014
0.018
14.1
0.06
31.1
0.13
Average
10.9
65
149
7400
5650
261
199
_
233
257
32.8
42.9
0.014
0.019
14.6
0.06
32.1
0.13
(1) Actual cubic meters - stack conditions
(2) Dry normal cubic meters - 20°C, 760 mm Hg
(3) Actual cubic feet - stack conditions
(4) Dry standard cubic feet - 20°C, 760 mm Hg
(5) Actual cubic, meters perminute - stack conditions
(6) Dry normal cubic meters perminute - 20°C> 760 mm Hg
(7) Actual cubic feet per minute - stack conditions
(8) Dry standard cubic feet per minute - 20°C, 760 mm Hg
(9) Metric tone per hour (1 metric ton » 1000 kg)
*Not included in averages Clayton Environmental Consultants
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-8-
TABLE 1-2
SUMMARY OF TOTAL PARTICIPATE EMISSIONS
Granite City Steel
Granite City, Illinois
May20-23, 1975
Source: Sinter Plant Scrubber Outlet
Dimens ions
Test Number
Date
Sampling
Period
Sampled
Volume
Start
. Stop
Am3 (1)
DNm3 (2)
ACF (3)
DSCF (4)
Percent Moisture by Volume
Average Stack
Tempera ture
Stack Gas
Flowrate
°C
OF
Am^/min (5)
DNm3/min (6)
ACFMxlO"3 (7)
DSCFMxlQ-3 (8)
P-l*
5/20
09:31
12:23
3.08
2.25
108.7
79.3
14.7
63
145
7620
5550
269
196
Percent Isokinetic || 106.1
i
Strand !
Burden
M tons/hr (9)
tons/hr
239
264
Sample Weight (mg) || 272.9
Particulate
Concentration
Particulate
Emission
Rate
ing /Am ^
mg/DNm3
gr/ACF
gr/DSCP
kg/hr
kg/M ton of SB
Ib/hr
Ib/ton of SB
88.6
121
.0.039
0.053
40.4
0.17
89.2
0.34
P-2
5/21
09:50
13:07
2.91
2.23
102.8
78.6
10.6
64
148
7360
5640
260
199
104.0
233
257
226.3
77.8
101
0.034
0.044
34.3
0.15
75.8
0.29
P-3
5/22
09: 15
11:57
2.74
2.09
96.7
73.8
11.0
65
149
7480
5690
264
'201
96.3
242
267
205.7
75.1
98.4
0.033
0.043
33.6
0.14
74.1
0.28
P-4
5/23
09:02
11:52
2.71
2.06
95.8
72.8
11.2
65
149
7360
5610
260
198
96.8
225
248
186.1
68.7
90.3
0.030
0.039
30.4
0.14
66.9
0.27
Average
_
_
10.9
65
149
7400
5650
261
199
_
233
257
73.9
96.6
0.032
0.042
32.8
0.14
72.3
0.28
(1) Actual cubic meters - stack conditions
(2) Dry normal cubic meters - 20"C> 760 mm Hg
(3) Actual cubic feet - stack conditions
(4) Dry standard cubic feet - 20°C, 760 mm Hg
(5) Actual cubic meters per minute - stack conditions
(6) Dry normal cubic meters per minute - 20°C, 760 mm Hg
(7) Actual cubic feet per minute - stack conditions
(8) Dry standard cubic feet per minute - 20°C, 760 mm Hg
(9) Metric tons per hour (1 metric ton «= 1000 kg)
*Not included in averages Clayton Environmental Consultants
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-9-
TABLE 1-3
SUMMARY OF FILTERABLE PARTICIPATE EMISSIONS
Gsranite City Steel
Graraite City, Illinois
May 20-23, 1975
Source: Sinter Plant Scrubber Inlet
Dimensions; iQ6"xll6"
Test Number
Date
Sampling
Period
Sampled
Volume
Start
-Stop
Am 3 (!)
DNm3 C2)
ACF C3)
DSCF £4)
Percent Moisture by Volume
Average Stack
Tempera ture
Stack Gas
Flov;ratc
°C
°F
Am3 /win C5)
DNm3/min C6)
ACFMx 10~J
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-10-
TABLE 1-4
SUMMARY OF TOTAL PARTICIPATE EMISSIONS
Granite City Steel
Granite City, Illinois
May 20-23, 1975
fjource: Sinter Plant Scrubber Inlet
Dimensions: 106" x 116"
Test Number
Date
Sampling
Period
Sampled
Volume
Start
. Stop
Am3 (1)
DNm3 (2)
ACF (3)
DSCF (4)
Percent Moisture by Volume
Average Stack
Temperature
Stack Gas
Flowrate
°C
°F
Am-' /rain (5)
DNm3/rain (6)
ACFMx 10~J (7)
DSCFMX 1Q-3 (8)
Percent Isokinetic |
Strand
Burden
M-tons/hr (9)
tons/hr
Sample Weight (ing)
Particula te
Concentration
Particula te
Emission
Rate
mg/Am^
mg/DNm3
gr/ACF
gr/DSCF
kg/hr
kg/M ton of SB
Ib/hr
Ib/ton of SB
P-l*
5/20
09:15
12:25
5.41
3.07
191.1
108.3
12.4
143
289
8700
4930
307
174
_10&*$_
239
264
2842.6
525
926
. 0.230
0.405
274
1.1
604
2.3
P-2
5/21
09:50
13:08
4.96
2.90
175.1
102.5
11.7
133
272
8550
5000
302
177
OP . 5
Vf - f* "" » t ~~ i*> IllfJ] fff
233
257
2707.2
546
934
0.239
0.408
280
1.2
618
2.4
P-3
5/22
09:15
11:58
5.17
3.06
182.5
108.2
12.7
128
262
8840
5240
312
185
_100^?_
242
267
2749.5
532
899
0.232
0.392
282
1.2
622
2.3
P-4
5/23
09:02
11:50
4.87
2.90
172.0
102.3
10.1
138
281
8390
4990
296
176
99 .5
225
248
2710.3
557
935
0.243
0.409
280
1.2
617
2.5
Average
_
11.5
133
272
8590
5080
303
179
-
233
257
__
545
923
0.23.8
0.403
281
1.2
619
2.4
(1) Actual cubic meters - stack conditions
(2) Dry normal cubic meters - 20°C, 760 mm Hg
(3) Actual cubic feet - stack conditions
(4) Dry standard cubic feet - 20°C, 760 mm Hg
(5) Actual cubic meters per minute - stack conditions
(6) Dry normal cubic meters per minute - 20°C, 760 mm Hg
(7) Actual cubic feet per minute - stack conditions
(8) Dry standard cubic feet per minute - 20°C, 760 mm Hg
(9) Metric tons per hour (1 metric ton = 1000 kg)
*Not included in averages
Clayton Environmental Consultants
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-11-
TABLE II
SUMMARY OF SINTER PLANT SCRUBBER EFFICIENCIES
FOR PARTICULATE MATTER
Granite City Steel
Granite City, Illinois
May 20-23, 1975
Contaminant
Filterable
Particulate
Tot: 1
Particulate
Test
Number
1*
2
3
4
.Average
1*
2
3
4
Average
Emission Rate, Ib/hr
Scrubber
Inlet
520
501
512
546
520
604
618
622
617
619
S crubber
Outlet
42.5
35.9
29.3
31.1
32.1
89.2
75.8
74.1
66.9
72.3
Percent
Efficiency
91.8
92.8
94.3
94.3
93.8
85.2
87.7
88.1
89.2
88.3
*Not included in averages
Clayton Environmental Consultants, Inc
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HYDROCARBON TRAIN
PARTICULATE
TRAIN
Water-filled \ Silica
Impingers \ Gel
Condensate
Trap
FIGURE 1
Gaseous Hydrocarbons - Particulate Train
Granite City Steel
Granite City, Illinois
May 20-23, 1975
Ni
I
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-13-
Fluoride Sampling Results
Tables III-l and III-2 present the results of the fluoride emis-
sions measurements at the scrubber outlet stack and inlet duct, re-
spectively. Total fluoride emissions measured at the outlet stack
ranged from 0.98 to 2.7 pounds per hour with an average of 1.8
pounds per hour. Emission factors ranged from 0.004 to 0.01 pound
of fluoride per ton of total strand burden with an average of 0.007
pound of fluoride per ton of total strand burden. Corresponding
total fluoride concentrations in the outlet stack gas ranged from
0.0006 to 0.002 grain per dry SCF with an average of 0.001 grain
per dry SCF.
Total fluoride emissions measured in the inlet duct ranged from
11.8 to 12.6 pounds per hour with an average of 12.2 pounds per hour.
Emission factors ranged from 0.04 to 0.05 pound of fluoride per ton
of total strand burden with an average of 0.04 pound per ton of total
strand burden. Corresponding total fluoride concentrations in the
inlet exhaust gas were 0.008 grain per dry SCF for each of the two
tests conducted.
As shown in Table IV, the scrubber efficiencies in removing
total fluoride emissions ranged from 77.1 to 92.2 percent with an
average of 84.6 percent.
The exhaust gas flowrates measured in the outlet stack ranged
from 187,000 to 191,000 dry SCFM with an average of 189,000 dry
SCFM. Stack gas temperatures ranged from 148°F to 152°F with an
average of 150°F at the outlet. The gas flowrate measured in the
inlet duct ranged from 176,000 to 177,000 dry SCFM with an average
of 176,000 dry SCFM. The average exhaust gas temperature in the
inlet duct ranged from 268°F to 288°F with an average of 278°F.
All tests were conducted within the range of 90 percent and
110 percent isokinetic.
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-14-
TABLE III-l
SUMMARY OF FLUORIDE EMISSIONS
Granite City Steel
Granite City, Illinois
May 20-23, 1975
Source: Sinter Plant Scrubber Outlet
Dimensions: 116"I.D
Test Number
Date
Sampling
Period
Sampled
Volume
Start
Stop
Am3 (1)
DNm3 (2)
ACF 0)
DSCF (4)
Percent Moisture by Volume
Average Stack
Temperature
Stack Gas
Flowrate
°C
°F
Am3/min (5)
DNm3/min (6)
ACFM (7)
DSCFM (8)
Percent Isokinetic
Strand
Burden
M tons/hr^
tons /hr
Sample Weight (mg)
Total .
Fluoride
Concentration'
Total
Fluoride
Emiss ion
Rate
mg/Am-'
mg/DNm3
gr/ACF
gr/DSCF
kg/hr
kg/M ton of SB
Ib/hr
Ib/ton of SB
F-l
5-21
15:43
18:27
2.85
2.20
100.8
77.6
9.9
64
. 148
7020
5400
248,000
191,000
106.9
239
264
3.0
1.1
1.4
0.0005
0.0006
0.44
0.002
0.98
0.004
F-2
5-22
14: 23
17:02
2.62
2.01
92.6
70.9
10.2
67
152
6920
5300
244,000
187 ^OjOp^^,
99.5
240
265
7.7
2.9
3.8
0.001
0.002
1.2
0.005
2.7
0.01
Average
-
_
-
.
-
-
-
10.0
66
150
6970
5350
246,000
189,000
-
240
264
-
2.0
2.6
0.0008
0.001
0.82
0.004
1.8
0.007
(1) Actual cubic meters - stack conditions
(2) Dry normal cubic meters - 20°C, 760 mm Hg
(3) Actual cubic feet - stack conditions
(4) Dry standard cubic feet - 20°C, 760 mm Hg
(5) Actual cubic meters per minute - stack conditions
(6) Dry normal cubic meters per minute - 20°C, 760 mm Hg
(7) Actual cubic feet per minute - stack conditions
(8) Dry standard cubic feet per minute - 20°C, 760 mm Hg
(9) Metric tons per hour (1 metric ton = 1000 kg)
Clayton Environmental Consultants
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-15-
TABLE III-2
SUMMARY OF FLUORIDE EMISSIONS
Granite City Steel
Granite City, Illinois
May 20-23, 1975
Source: Sinter Plant Scrubber Inlet
Dimensions: 106"xll6"
Test Number
Date
Sampling
Period
Sampled
Volume
Start
Stop
Am3 (1)
DNm3 (2)
ACF 0)
DSCF (4)
Percent Moisture by Volume
Average Stack
Temperature
Stack Gas
Flowrate
°C
oF
Am^/min (5)
DNm3/min (&)
ACFM (7)
DSCFM (8)
Percent Ir.okine t ic
Strand
Burden
M tons/hr^^
tons/hr
Sample Weight (mg)
Total
Fluoride
Concentration
Total
Fluoride
Emission
Rate
mg/Am3
mg/DNm^
gr/ACF
gr/DSCF
kg/hr
kg/M ton of SB
Ib/hr
Ib/ton of SB
F-l
5-21
15:44
18:28
2.81
1.66
99.1
58.7
11.1
131
268
8450
5010
299,000 '
177,000
102.5
239
264
31.7
11.3
19.1
0.005
0.008
5.7
0.02
12.6
0.05
F-2
5-22
14:25
17:04
2.88
1.68
101.6
59.4
10.8
142
288
8540
4990
301,000
176^000
104.1
240
265
30.2
10.5
18.0
0.005
0.008
5.4
0.02
11.8
0.04
Average
-
_
-
-
-
-
11.0
136
278
8500
5000
300,000
176^000
-
240
264
-
10.9
18.6
0.005
0.008
5.6
0.02
12.2
0.04
(1) Actual cubic meters - stack conditions
(2) Dry normal cubic meters - 20°C, 760 mm Hg
(3) Actual cubic feet - stack conditions
(4) Dry standard cubic feet - 20°C, 760 mm Hg
(5) Actual cubic meters perminute - stack conditions
(6) Dry normal cubic meters perminute - 20°C, 760 mm Hg
(7) Actual cubic feet per minute - stack conditions
(8) Dry standard cubic feet per minute - 20°C, 760 mm Hg
(9) Metric tons per hour (1 metric ton = 1000 kg)
Clayton Environmental Consultants
-------
-16-
TABLE IV
SUMMARY OF SINTER PLANT SCRUBBER EFFICIENCIES
FOR TOTAL FLUORIDE
Granite City Steel
Granite City, Illinois
May 20-23, 1975
Test
Number
1
2
Average
Emission Rate, Ib/hr
Scrubber
Inlet
12.6
11.8
12.2
S crubber
Outlet
0.98
2.7
1.8
Percent
Efficiency
92.2
77 .1
84.6
Clayton Environmental Consultants, Inc.
-------
-17-
llydrocarbon Sampling Results
For the purposes of this study, three classes of hydrocarbon
emissions were defined and measured including (1) filterable,
(2) condensible, and (3) non-condensible or gaseous. Filterable
hydrocarbons are defined here as those hydrocarbons which are
deposited prior to and on a filter maintained at 250°F + 50°F*.
Because these filterable hydrocarbons are inherently included as
part of the total filterable particulate, a chloroform-ether
extraction is performed to determine that portion of the filter-
able particulate matter which is soluble in chloroform-ether and
therefore defined as hydrocarbons. Condensible hydrocarbons are
defined here as those which pass through the heated filter and are
collected in a chilled impinger train with an initial temperature
of 250°F and a final temperature of 88°F. 'Particulate matter which
is dissolved by chloroform-ether extractions performed-on the resi-
due resultant from analysis of the condensible (impinger) fraction
is defined as condensible hydrocarbons. Non-condensible (gaseous)
hydrocarbons are here defined as those which pass through the
impinger train and are subsequently sampled from a portion of the
particulate train impinger exhaust (see Figure 1).
An emissions summary for each of these three hydrocarbon sample
fractions is presented in Tables V-l through V-3. Complete results
for non-condensible hydrocarbons and particulate organic extrac-
tions are presented in Appendices A and B, respectively.
Table V-l summarizes the chloroform-ether soluble portion of
the filterable particulate (CEFP) emissions measured in the outlet
* Although, on several occasions, filter temperatures exceed
250 J; 50°F range, such temperatures are atypical since
nearly 95% of all filter temperatures are within this range.
-------
-18-
stack and inlet duct of the scrubber. The measurements were made
by analysis of filterable particulate collected in Tests P-l through
P-4. The table shows that emission rate of CEFP at the outlet
ranged from 3.4 to 9.1 pounds per hour with an average of 5.3 pounds
per hour. The concentrations of CEFP in the outlet stack ranged
from 0.002 to 0.005 grain per dry SCF with an average of 0.003 grain
per dry SCF. At the inlet, the emission rate of CEFP ranged from
22.3 to 56.0 pounds per hour with an average of 40.5 pounds per
hour. The concentration of CEFP ranged from 0.014 to 0.037 grain
per dry SCF with an average of 0.027 grain per dry SCF in the inlet
exhaust gas. Based upon mass emission rates, the scrubber effi-
ciencies for CEFP ranged from 79.0 percent to 93.8 percent with an
average of 85.9 percent as shown in Table VI.
Table V-2 summarizes the chloroform-ether soluble portion of
the condensible particulate (CECP) emissions measured in the outlet
stack and inlet duct of the scrubber. The measurements were made
by analysis of the condensible particulate collected in tests P-l
through P-4. The table shows that the emission rate of CECP at the
outlet ranged from 10.6 to 17.7 pounds per hour with an average of
14.4 pounds per hour. Correspondingly, concentrations of CECP
ranged from 0.006 to 0.010 grain per dry SCF in the outlet stack
gas. At the inlet, the emission rate of CECP ranged from 28.5 to
68.2 pounds per hour with an average of 47.6 pounds per hour.
The concentration of CECP ranged from 0.019 to 0.043 grain per dry
SCF with an average of 0.031 grain per dry SCF in the inlet exhaust
gas. Based upon mass emission rates, the scrubber efficiencies
for CECP ranged from 37.9 percent to 84.5 percent with an average
of 63.4 percent as shown in Table VI.
-------
-19-
Because the CEFP and the CECP are necessarily obtained from
a
particulate test catch material, the results of CEFP and CECP as
obtained from P-l are not included in any of the above averages
of emission rates or concentrations (since scrubber conditions
were atypical).
Table V-3 summarizes the concentrations of non-condensible
(gaseous) hydrocarbon emissions measured in the outlet stack and
the inlet duct. Integrated gas samples collected from a portion
of the particulate train (impinger) exhaust, were analyzed in the
field by two methods: (1) by flame ionization detection (FID), and
(2) by gas chromatography. The results are expressed in Table V-3
in parts per million (ppm) , by volume, as methane. (Duplicate
analyses were conducted in the laboratory on the same integrated
samples to determine the magnitude of any losses and verify the
resultsj complete field and laboratory measurement data for gaseous
hydrocarbons are presented in Appendix A).
At the scrubber outlet stack, total non-condensible hydrocarbons
(TNCH) as measured by FID, ranged from 300 to 3800 ppm with an average
of 1480 ppm as methane. The TNCH, measured by gas chromatography,
ranged from 362 ppm to 10,380 ppm with an average of 3550 ppm as
methane at the outlet. Individual hydrocarbon species detected at
the outlet included: methane, ranging from 150 ppm to 2170 ppm
with an average of 950 ppm; ethane, ranging from 12 ppm to 65 ppm
with an average of 39 ppm; ethylene, ranging from 17 ppm to 90 ppm
with an average of 46 ppm; and acetone, ranging from 39 ppm to
9740 ppm with an average of 2310 ppm -- all expressed as methane.
-------
-20-
At the scrubber inlet duct, TNCH, as measured by FID, ranged
from 260 ppm to 2100 ppm with an average of 1120 ppm as methane.
The TNCH, measured by gas chromatography, ranged from 1660 ppm to
1700 ppm with an average of 1680 ppm as methane at the inlet.
Individual hydrocarbon species detected at the inlet included:
methane, ranging from 140 ppm to 2460 ppm with an average of 880
ppm; ethane, ranging from 16 ppm to 57 ppm with an average of
38 ppm; ethylene, ranging from 17 ppm to 75 ppm with an average of
43 ppm; and acetone, ranging from 140 ppm to 3000 ppm with an average
of 1210 ppm -- all expressed as methane.
Analysis for TNCH and the constituent species revealed that wide
variation in measured concentrations, by either FID or gas chromato-
graphy, preclude scrubber efficiency determinations. Despite nearly
simultaneous sampling, measured outlet concentrations are greater
than measured inlet concentrations. As such, it is concluded
that these measurements are useful in establishing the species of
TNCH emissions and order of magnitude estimates of their concen-
trations. Consequently, mass emission rates are not calculated
from these data.
Table V-3 indicates that methane and acetone are emitted in
significant concentrations with traces of ethane and ethylene.
Further, it appears from the data that the scrubber does not
measurably abate these "gaseous"hydrocarbons.
The concentrations of acetone found in both the. outlet and
inlet exhaust gases may be attributable to contamination by ace-
tone as it is used in standard clean-up procedures. The signi-
ficantly greater outlet concentrations compared to inlet concen-
trations also tend to indicate that contamination is likely.
-------
-21-
The measurements of average INCH by FID and gas chromatography
compare well when the concentrations of acetone (as methane) are
deleted from the TNCH sum. At the outlet, the average TNCH as
methane is 1480 ppm by FID and 1035 ppm by gas chromatography.
excluding acetone*(3550 ppm with acetone included). At the inlet,
the average TNCH as methane is 1120 ppm by FID and 961 ppm by gas
chromatography excluding acetone*(1680 with acetone included).
Therefore, it is concluded that the two independent measures of
TNCH are in very good agreement if acetone is treated as a con-
taminant. If acetone is included, the two measures of TNCH are
in, at least, order of magnitude agreement.
In all of the aforementioned hydrocarbon sampling results,
outlet and inlet stack gas flowrates, temperatures, and moisture
content are those measured during corresponding particulate tests.
Since the gaseous hydrocarbon analyses were conducted on an inte-
grated sample of gas which was saturated with respect to moisture
content (at the particulatetrain impinger, average exit tempera-
ture of 88 °F), the concentrations are obtained on an "as analyzed"
basis. Analyses conducted at about 75°F include inherently about
3-percent moisture by volume. Because the results of the analysis
are expressed on a dry basis, a maximum possible error would be
approximately negative 3 percent.
Complete sampling train temperature 'data are included in
Appendix F.
* TNCH excluding acetone, by gas chromatography, were computed by
summing the averages of methane, ethane, and ethylene (all expressed
as methane). The result is not numerically equal to the average
sum of TNCH computed by summing all four species less the average
acetone concentration. This occurs because sums of averages are
not equal to averages of sums when the number of elements in each
sum is different.
-------
TABLE V-l
SUMMARY OF CHLOROFORM-ETHER SOLUBLE
FILTERABLE PARTICULATE EMISSIONS
Granite City Steel
Granite City, Illinois
May 20-23, 1975
Test
Number
!*
2
3
4
1975
Date
5/20
5/21
5/22
5/23
Sampling
Period
09:15-12:25
09:50-13:08
09:15-11:58
09:02-11:52
Average
Scrubber Outlet | Scrubber Inlet
Concentration
gr/DSCF
0.005
0.005
0.002
0.002
0.003
«3
mg/DNmJ
11.7
12.2
4.5
4.7
7.1
Emission
Rate
(Ibs/hr)
8.6
9.1
3.4
3.5
5.3
Concentration
gr/DSCF
0.029
0.029
0.014
0,037
0.027
mg/DNm^
66.6
65.3
32.2
84.8
60.8
Emis s ion
Rate
(Ibs/hr)
43.5
43.3
22.3
56.0
40.5
NJ
I
*Not included in averages
Clayton Environmental Consultants, Inc.
-------
TABLE V-2
SUMMARY OF CHLOROFORM-ETHER SOLUBLE
CONDENSIBLE PARTICULATE EMISSIONS
Granite City Steel
Granite City, Illinois
May 20-23, 1975
Test
Number
1 *
2
3
4
1975
Date
5/20
5/21
5/22
5/23
Sampling
Period ;
09: 15-12:25
09:50-13:08
09:15-11:58
09:02-11:52
Average
Scrubber Outlet | Scrubber Inlet
Concentration
gr/DSCF
0.008
0.010
0.006
0.009
0.008
mg/DNm3
17.7
23.7
14.1
20.0
19.3
Emission
Rate
(Ibs/hr)
13.0
17.7
10.6
14.8
14.4
Concentration
gr/DSCF
0.026
0.019
0.043
0.030
0.031
mg/DNm3
58.3
43.1
98.6
69.7
70.5
Emission
Rate
(Ibs/hr)
38.0
28.5
68.2
46.0
47.6
I
tsi
*Not included in averages
Clayton Environmental Consultants, Inc.
-------
TABLE V-3
SUMMARY OF GASEOUS HYDROCARBON EMISSIONS
DETERMINED BY FIELD ANALYSIS
Granite City Steel
Granite City, Illinois
May 20-23, 1975
Sampling
Station
Sinter
Plant
Scrubber
Outlet
Test
No.
1
2
3
4
5
6
7
8
Date
1975
5/20
5/20
5/21
5/21
5/22
5/22
5/23
5/23
Sampling
Period
11:00-11:06
11:48-11:54
12:14-12:20
12:55-13:01
11:03-11:09
11:46-11:52
10: 17-10:23
11:38-11:44
Average
Sinter
Plant
S crubber
Inlet
1
2
3
4
5
6
7
8
5/20
5/20
5/21
5/21
5/22
5/22
5/23
5/23
10:41-10:47
12: 15-12:22
11:56-12:03
12:36-12:44
09:55-10:02
11:24-11:31
09:21-09:32
10:57-11:20
Average
Tota 1
Non-condensible
Hydrocarbons
By FID
(ppm as CH^)
400
370
1750
1600
3800
3000
300
640
1480
380
470
1800
1600
2100
1100
1220
260
1120
Gas Chromatographic Results (ppm as CH4)
Methane
264
256
1610
2170
590
1990
150
580
950
319
320
2460
2010
280
1330
208
140
880
Ethane
23
27
60
65
24
64
12
39
36
26
54
57
38
16
"
38
Ethylene
31
40
60
72
27
90
17
28
46
46
34
75
66
29
52
22
17
43
Acetone
58
39
9740
3780
160
70
2310
3000
280
1410
140
1210
Total
Non-condensible
Hydrocarbons
376
362
10380
5920
690
3550
_
1700
1660
^
1680
I
ro
Clayton Environmental Consultants, Inc
-------
-25-
TABLE VI
SUMMARY OF SINTER PLANT SCRUBBER EFFICIENCIES
FOR CHLOROFORM-ETHER SOLUBLE PARTICULATE MATTER
Granite City Steel
Granite City, Illinois
May 20-23, 1975
Contaminant
Chloroform-
Ether Soluble
Filterable
Par ticulate
Chloroform-
Ether Soluble
Condensible
Particulate
Test
Number
1*
2
3
4
Average
1*
2
*
3
4
Average
Emission Rate, Ib/hr
Scrubber
Inlet
43.5
43.3
22.3
56.0
40.5
38.0
28.5
68.2
46.0
47.6
Scrubber
Outlet
8.6
9.1
3.4
3.5
5.3
13.0
17.7
10.6
14.8
14.4
Percent
Efficiency
80.2
79.0
84.8
93.8
85.9
65.8
1 37.9
84.5
67.8
63.4
*Not included in averages
Clayton Environmental Consultants, Inc
-------
-26-
Sulfur Oxides Sampling Results
Table VII presents the emission rates and concentrations of
sulfur oxides measured at the scrubber outlet. Sulfur oxides
emissions at the scrubber outlet stack ranged from 136 to 213 pounds
per hour with an^average of 186 pounds per hour. These emission
rates correspond to outlet stack gas concentrations ranging from
70.3 to 109 parts per million with the average of 95.4 parts per
million by volume. Exhaust gas flowrates ranged from 194,000 to
195,000 dry SCFM at the outlet stack with an average of 195,000
dry SCFM. Outlet temperatures ranged from 148°F to 150°F with
an average of 149°F.
While sampling was also conducted at the scrubber inlet duct,
laboratory analyses and subsequent data processing indicate that
results of sulfur oxides measurements at the inlet location must
be invalidated. These results are not ^consistent with the outlet .
location sampling results, the expected emissions of sulfur oxides
from this type of process, or the pH measurements made on the
scrubber water. Investigation into the analytical procedure has
not revealed any interference effects due to other contaminants
present in the inlet gas stream capable of producing errors of
sufficient order of magnitude with reference to the analytical
procedure for sulfur oxides. Further, the triplicate mea'surements
for sulfur oxides made on the inlet are in relatively good agreement
among themselves. As such, it must be concluded that the inlet
sampling results are invalid due to an experimental anomaly.
-------
-27-
TABLE VII
SUMMARY OF SULFUR OXIDES EMISSIONS
Granite City Steel
Granite City, Illinois
May 20-23, 1975
Source:
Sinter Plant Scrubber Outlet
Dimensions: 116" I.D.
Test Number
Date
Sampling
Period
Sampled
Volume
Average Stack
Temperature
Stack Gas
Flowra te
Cone en tra tion
Emis sion
Rate
Start
Stop
DNm3 (D
DSCF (2)
°C
°F
Am3/nin <3>
» (A \
DNm /m in v '
ACFM ^
(6)
DSCFM v '
ppm
0
mg/DNm
gr/DSCF
kg/hr
Ibs/hr
SOV-1
A
5-21 '
14:23
14:53
0.0283
0.999
64
148
7190
5520
254,000
195^000
107
94.6
209
SOx-2
5-21
17:55
18:25
0.0285
1.01
64
' 148
7190
5520
254,000
195,000
109
96.5
213
SOx-3
5-22
14:55
15:25
0.0282
0.996
66
150
7200
5500
254,000
194^000
70.3
61.8
136
(1) Dry normal cubic r.eters - 20°C, 760 mm Hg
(2) Dry standard cubic feet - 20°C, 760 mm Hg
(3) Actual cubic meters per minute - stack conditions
(4) Dry normal cubic meters per minute 20°C, 760 mm Hg
(5) Actual cubic feet per minute - stack condition
(6) Dry standard cubic feet per minute - 20°C, 760
mm Hg
-------
-28-
Carbon Monoxide Sampling Results
Tables VIII-1 through VIII-4 and Table IX present the results
of carbon monoxide emissions measurements at the outlet and inlet
of the scrubber. These tables list the results of gas chromato-
graphic analyses of integrated gas samples acquired from the out-
let and inlet streams directly as well as samples acquired from
the particulate sampling train exhaust (see Hydrocarbon Sampling
Results and Figure 1).
Table VIII-1 shows that, at the scrubber outlet, emission
rates of carbon monoxide ranged from 5470 pounds per hour to 7810
pounds per hour with an average of 6610 pounds per hour using the
gas chromatographic analysis of the samples acquired for subse-
quent Orsat analyses. Similarly, Table VIII-3 shows that analysis
for carbon monoxide at the outlet, using integrated samples ac-
quired from the particulate train impinger exhaust,yielded mass
emission rates of carbon monoxide ranging from 4730 pounds per
hour to 9160 pounds per hour with an average of 6410 pounds per
hour. These data are in good agreement and indicate that the
particulate sampling train does not remove measurable amounts of
carbon monoxide.
Table VIII-2 shows that the total mass emission rate of carbon
monoxide at the inlet ranges from 5080 pounds per hour to 7250
pounds per hour with an average of 5840 pounds per hour using the
gas chromatographic analysis of the samples acquired for subsequent
Orsat analyses. Similarly, Table VIII-4 shows that analysis for
carbon monoxide at the scrubber inlet, using integrated samples
acquired from the particulate train impinger exhaust, yielded
mass emission rates ranging from 3180 pounds per hour to 8130
pounds per hour with an average of 5230 pounds per hour. These
-------
-29-
data are in good agreement and also illustrate that the particulate
sampling train does not remove significant amounts of carbon monoxide
In general, the outlet and inlet mass emission rates, as measured
by gas chromatographic analysis of samples acquired by two different
methods, are equal within the limits of experimental accuracy.
As such, it is concluded that the scrubber does not remove measurable
amounts of carbon monoxide.
As an independent check of these measurements, an Orsat measure-
ment of carbon dioxide, oxygen, carbon monoxide, and nitrogen was
obtained for each of the four particulate tests (predominantly for
the purpose of establishing molecular weight of the gas for the
particulate tests) . These data are tabulated in Table IX). The
measurements indicate that percent carbon monoxide at the scrubber
outlet ranges from 0.4 percent to 0.7 percent by volume with an
average of 0.5>percent (5000 ppm). At the scrubber inlet the mea-
surements also indicate that the carbon monoxide level ranges from
0.4 percent to 0.7 percent by volume with an average of 0.6 percent
(6000 ppm). These results are in good agreement with results
obtained from gas chromatographic analyses within the limits of
experimental accuracy. These data also indicate that the scrubber
does not remove significant amounts of carbon monoxide. As such,
efficiency tabulations .are not presented.
-------
-30-
TABLE VIII-1
SUMMARY OF CARBON MONOXIDE EMISSIONS
MEASURED FROM ORSAT GAS SAMPLES BY GAS CHROMATOGRAPHY
Granite City Steel
Granite City, Illinois
May 20-23, 1975
Source: Sinter Plant Scrubber Outlet
Dimens ions
116" I.D
Test Number
Date
Sampling
Period
Sampled
Volume
Average Stack
Temperature
Stack Gas
Flowrate
Concentration
Emiss ion
Rate
Start
Stop
DNm3 <1>
DSCF (2)
°C
°F
Am3/min (3>
o ( £.}
DNm /mi n v '
ACFM ^
DSCFM ^
ppm
mg/DNm
gr/DSCF
kg/hr
Ibs/hr
Orsat-1
5-20
09:31
12: 23
_
,__-_,.
63
145
7620
5550
269,000
196,000
9130
___
i
3540
7810
Orsat-2
i-21
09: 50
13:07
H«_
, -
64
148
7360
5640
260,000
199,000
6300
-'
__
2480
5470
Orsat-3
5-22
09: 15
11:57
_
_,
65
149
: 7480
5690
264,000
201,000
7470
^ ^_
n.im.T_
2970
6550
(1) Dry normal cubic meters - 20°C, 760 mm Hg
(2) Dry standard cubic feet - 20°C, 760 mm Hg
(3) Actual cubic meters per minute - stack conditions
(4) Dry normal cubic meters per minute - 20°C, 760 mm Hg
(5) Actual cubic feet per minute - stack conditions
(6) Dry standard cubic feet per minute - 20°C, 760 mm Hg
Clayton Environmental Consultants
-------
-31-
TABLE VIII-2
SUMMARY OF CARBON MONOXIDE EMISSIONS
MEASURED FROM ORSAT SAMPLES BY GAS CHROMATOGRAPHY
Granite City Steel
Granite City, Illinois
May 20-23, 1975
Source: Sinter Plant Scrubber Inlet
Dimensions: 106" x 116"
Test Number
Date
Sampling
Period
Sampled
V o 1 um e
Average Stack
Temperature
Stack Gas
Flowra te
Concentration
Emission
Rate
Start
Stop
DNm3 CD
DSCF <2^
°C
°F
Am3/min <3>
0 (£.\
DNm /m in v '
ACPM <5>
DSCFM * '
ppm
o
mg/DNm
gr/DSCF
kg/hr
Ibs/hr
Orsat-1
5-20
09: 15
12:25
143
289
8700
4930
307,000
174,000
9550
3290
7250
Orsat-2
5-21
09:50
13:08
133
272
8550
5000
302,000
177,000
6580
2310
5080
Orsat-3
5-22
09:15
11:58
128
262
8840
5240
312,000
185,000
6440
2360
5200
(1) Dry normal cubic meters - 20°C, 760 mm Hg
(2) Dry standard cubic feet - 20°C, 760 mm Hg
(3) Actual cubic meters per minute - stack conditions
(4) Dry normal cubic meters per minute - 20°C, 760 mm Hg
(5) Actual cubic feet per minute - stack conditions
(6) Dry standard cubic feet per minute - 20°C, 760 mm Hg
Clayton Environmental Consultants
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-32-
TABLE VIII-3
SUMMARY OF CARBON MONOXIDE EMISSIONS
MEASURED FROM GASEOUS HYDROCARBON SAMPLES
BY GAS CHROMATOGRAPHY
Granite City Steel
Granite City, Illinois
May 20-23, 1975
Source: Sinter Plant Scrubber Outlet
Dimensions: 116" I.D.
Test Number
Date
Sampling
Period
Sampled
Volume
Average Stack
Temperature
Stack Gas
Flowrate
Con centra tion
Emission
Rate
Start
Stop
DNm3
0 ( A)
DNm /m in v '
ACFM x 10~*5)
DSCFMxlO"3 ^6)
ppm
mg/DNm3
gr/DSCF
kg/hr
Ibs/hr
HC-1
5-20
11:00
11:06
63
145
7620
5550
269
196
10700
4150
9160
HC-2
5-20
11:48
11:54
63
145
7620
5550
269
196
9450
3670
8090
HC-3
5-21
12:14
12: 20
64
148
7360
5640
260
199
7730
3050
6720
HC-4
5-21
12:55
13:01
64
148
7360
5640
260
199
5440
2140
4730
HC-5
5-22
11:03
11:09
65
149
7480
5690
264
201
5590
2230
4910
HC-6
5-22
11:46
11:52
65
149
7.480
5690
264
201
5530
2200
4850
HC-7
5-23
10:17
10:23
65
149
7360
5610
260
198
_
HC-8
5-23
11:38
11:44
65
149
7360
5610
260
198
_
(1) Dry normal cubic meters - 20°C, 760 mm Hg
(2) Dry standard cubic feet - 20°C, 760 mm Hg
(3) Actual cubic meters per minute - stack conditions
(4) Dry normal cubic meters per minute - 20°C, 760 mm Hg
(5) Actual cubic feet per minute - t;tack conditions
(6) Dry standard cubic feet per minute - 20°C, 760 mm Hg
Clayton Environmental Consultants
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-33-
TABLE VIII-4
SUMMARY OF CARBON MONOXIDE EMISSIONS
MEASURED FROM GASEOUS HYDROCARBON SAMPLES
BY GAS CHROMATOGRAPHY
Granite City Steel
Granite City, Illinois
May 20-23, 1975
Source: Sinter Plant Scrubber Inlet
Dimensions: 106" x 116"
Test Number
Date
Sampling
Period
Sampled
Volume
Average Stack
Temperature
Stack Gas
Flowrate
Concentra tion
Emis s ion
Rate
Start
Stop
DNm3
q ( t.\
DNm /m in v '
ACFMxlO'3 (5)
DSCFNxlO"3^ '
ppm
mg/DNm3
gr/DSCF
kg/hr
Ibs/hr
HC-1
5-20
10:41
10:47
__
143
289
8700
4930
307
174
7730
2660
5870
HC-2
5-20
12: 15
12: 22
143
289
8700
4930
307
174
10700
3690
8130
HC-3
5-21
11:56
12:03
133
272
8550
5000
302
177
6150
2160
4750
HC-4
5-21
12:36
12:44
133
272
8550
5000
302
177
6080
2130
4700
HC-5
5-22
09:55
10. 02
-
128
262
8840
5240
312
185
5870
2150
4740
HC-6
5-22
11:24
11:31
_ _ '
128
262
8840
5240
312
185
3940
1440
3180
HC-7
5-23
09:21
09:32
_
138
281
8390
4990
296
176
HC-8
5-23
10:57
11: 20
__
_
138
281
8390
4990
296
176
.
(1) Dry normal cubic meters - 20°C, 760 mm Hg
(2) Dry standard cubic feet - 20°C, 760 mm Hg
(3) Actual cubic meters per minute - stack conditions
(4) Dry normal cubic meters per minute - 20°C, 760 mm Hg
(5) Actual cubic feet per minute - stack conditions
(6) Dry standard cubic feet per minute - 20°C, 760 mm Hg
w-vironmontal Consultants
-------
-34-
TABLE IX
SUMMARY OF ORSAT DATA
Granite City Steel
Granite City, Illinois
May 20-23, 1975
Sampling
Location
Scrubber
Inlet
S crubber
Outlet
Particulate
Test
Number
1
2
3
;
4
1
2
3
4
1975
Date
5/20
5/21
5/22
5/23
5/20
5/21
5/22
5/23
Orsat
Run
No.
1
2
3
Avg.
1
2
3
Avg.
1
2
3
Avg.
1
2
3
Avg.
1
2
3
Avg.
1
2
3
Avg.
1
2
3
Avg.
1
2
3
Avg.
Exhaust Gas Compos it ion (percent, dry basis)
Carbon
Dioxide
5.4
5.4
5.4
5.4
4.4
4.8
4.5
4.6
5.5
5.4
5.6
5.5
4.7
4.6
4.8
4.7
5.6
5.5
5.4
5.5
5.0
4.9
4.9
4.9
5.0
4.8
4.6
4.8
4.6
4.8
5.0
4.8
Oxygen
15.6
14.8
15.0
15.1
15.8
15.8
16.0
15.9
15.6
15.7
15.6
15.6
16.3
16.1
16.1
16.2
15.3
15.3
15.2
15.3
15.8
15.7
15.8
15.8
16.1
16.0
16.0
16.0
15.9
16.0
16.0
16.0
Carbon
Monoxide
0.6
0.6
0.6
0.6
0.5
0.4
0.5
0.5
0.5
0.7
0.7
0.6
0.6
0.5
0.5
0.5
0.5
0.6
0.6
0.6
0.5
0.5
0.4
0.5
0.5
0.4
0.7
0.5
0.4
0.4
0.5
0.4
Nitrogen
(By Difference)
78.4
79.2
79.0
78.9
79.3
79.0
79.0
79.0
78.4
78.2
78.1
78.3
78.4
78.8
78.6
78.6
78.6
78.6
78.8
78.6
78.7
78.9
78.9
78.8
78.4
78.8
78.7
78.7
79.1
78.8
78.5
78.8
Clayton Environmental Consultants, Inc
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-35-
Scrubber Water Sampling Results
Table X displays the total dissolved solids, total suspended
solids, pH, fluoride content, and the measured sample temperature
for the scrubber outlet and inlet water samples acquired during
the four particulate tests and the two fluoride tests.
Total dissolved solids in the outlet scrubber liquor ranged
from 0.492 to 0.777 gram/liter. Total dissolved solids in the
inlet scrubber water ranged from 0.300 gram/liter to 0.566 gram/
liter during the course of the tests.
At the scrubber outlet,total suspended solids ranged from
0.200 gram/liter to 0.371 gram/liter. Total suspended solids
in the inlet scrubber water ranged from 0.039 gram/liter to 0.300
gram/liter.
The pH of the outlet scrubber water, as measured in the labora-
tory, ranged from 2.70 to 3.58. The inlet scrubber water pH
ranged from 4.80 to 7.60. The inlet scrubber water was considerably
more acidic during the first particulate test compared with the
other three particulate tests and two fluoride tests (5.21 during
P-l versus 7.55 average pH of all other tests). As previously
indicated, blast furnace cooling water was supplied to the scrubber
during the first particulate test only, while plant service water
was supplied during all other tests. These data indicate that
acidification of the scrubber water is occurring either by the
absorption of the acidic fluoride species or the absorption of
sulfur dioxide. During acquisition of scrubber water samples
throughout the study, a subtle but distinct odor of sulfur dioxide
was noted at the scrubber water discharge point.
-------
-36-
Fluoride content measured in the outlet scrubbing liquor ranged
from 6.19 to 29.9 milligrams/liter. The inlet scrubber water
ranged from 0.536 to 20.3 milligrams/liter of fluoride. In general,
the data displayed in Table X indicate that in all cases, measurable
increases in fluoride concentrations in the scrubbing liquor occur
in passing through the venturi scrubber.
As noted in the delineation of process operations, throughout
the first particulate test blast furnace cooling water was used in
the venturi. This fact is obviated by the temperature measurements,
taken in the field, of the scrubber water samples. In general,
during the first particulate test, the inlet scrubbing liquor was
at 98°F as compared to approximately 75° to 77°F for all other tests.
Similarly, the outlet scrubbing liquor was 112° to 115°F during the
course of the first particulate test and approximately 107° to 110°F
during the remaining tests. Examination of the data in Table X
shows that total dissolved solids, suspended solids, pH} and fluoride
content in the scrubber water is measurably higher during the course
of the first particulate test than during the course of the other
three particulate tests and two fluoride tests.
The exact times of scrubber water sample acquisition are de-
lineated in Appendix K.
-------
TABLE X
SUMMARY OF SCRUBBER WATER ANALYSES
Granite City Steel
Granite City, Illinois
May 20-23, 1975
Sampling
Location
S crubber
Water
Inlet
Scrubber
Water
Outlet
Hopper
Drain
Test
No.
Particulate
#1
Particulate
#2
Fluoride #1
Particulate
#3
Fluoride #2
Particulate
#4
Particulate
#1
Particulate
#2
Fluoride #1
Particulate
#3
Fluoride #2
Particulate
#4
Particulate
#4
1975
Date
5/20
5/21
5/21
5/22
5/22
5/23
5/20
5/21
5/21
5/22
5/22
5/23
5/23
Run
No.
1
2
3
Comp*
Comp*
Comp*
Comp*
Comp* .
1
2
3
Comp*
Comp*
Comp*
Comp*
Comp*
1
Time
09:23
10:29
11:30
10:09, 11:29 & 12:35
15:38, 16:44 & 17:45
09:15, 10:15 & 11:17
14:30, 15:25 & 16:34
09:05, 10:05 & 11:05
09: 25
10:32
11:34
10:14, 11:33 & 12:40
13:51, 16:50 & 17:47
09: 20, 10: 1'8 & 11:22
14:35, 15:30 & 16:37
09:11, 10:13 & 11:09
12: 05
Scrubber Water Data
Total
Dissolved
Solids
(gm/1)
0.517
0.540
0.566
0.325
0.325
0.300
0.331
0.330
0.777
0.723
0.706
0.506
0.492
0.550
0.548
0.522
0.749
Total
Suspended
Solids
(gm/1)
0.265
0.276
0.300
0.039
0.043
0.049
0.048
0.040
0.371
0.340
0.313
0.200
0.220
0.245
0.236
0.214
3.312
pH
5.28
4.80
5.55
7.60
7.45
7.58
7.58
7.52
3.12
3.00
3.10
2.70
2.78
3.58
3.00
2.70
6.60
Fluoride
(mg/1)
20.3
16.6
18.0
0.536
0.557
0.789
0.666
0.556
27.4
15.5
29.9
6.19
13.3
9.11
8.78
11.7
43.2
Temp .
(°F)
98
98
75
76
75
77
76
115
112
107
107
110
108
108
115
Composite of three samples. Indicated temperatures are averages
-------
-38-
Sinter Line Feed Sampling Results
Table XI summarizes the results of sulfur and fluoride content
determinations of the sinter line feed materials which were sampled
during the course of the particulate tests. Bulk samples were ac-
quired from each of the nine hoppers and the sinter line strand at
the beginning, in the middle, and at the end of each particulate
and fluoride test. The three samples so acquired from each source
of material were composited. From that composite, moisture content,
sulfur, and fluoride weight percentages were determined.
Although samples were acquired for each particulate and fluoride
test, only the results associated with samples acquired during the
second particulate test were analyzed and included in Table XI.
Additionally, in those instances where visual observation indicated
a sudden abnormal condition in any of the feed materials, additional
samples were analyzed -and the results presented in Table XI. The
weight percent determinations of sulfur and fluoride presented in
Table XI are on a wet basis. In the Process Description section of
this report, the mass flowrates of each feed were measured on a wet
basis. As such, the data presented in Table XI can be used directly
in conjunction with flowrate measurements of each feed material to
determine total: sulfur and fluoride input to the process from the
nine raw material 'feed hoppers.
The nine hoppers feed raw materials to the" conveyor belt,'which
supplies the strand, as follows (see Process Description section):
1. Rerun sinter fines,
2. Belmont ore fines,
3. Belmont ore fines,
4. Mill scale,
5. Fines from the open hearth furnace,
-------
-39-
6. Blastfurnace flue dust,
7. Track back (floor sweepings which fall off the back of the
feed conveyor) ,
8. Dolomite fines, and
9. Coke breeze.
The following observations constituted the only known fluctua-
tions in material feeds. As indicated, special analyses were con-
ducted under those conditions and are included in the summary pre-
sented in Table XI.
During the first particulate test the sixth hopper was inopera-
tive while the other eight hoppers were operational. During all other
particulate and fluoride tests, all hoppers were operational except
the seventh hopper (Track Back). As such, the analysis for this
material, which is presented in Table XI, was acquired during test
P-l.
During the third particulate test, the rerun sinter f.ines changed
in color from a dry, black substance to a wet, brown substance.
During the first third of the fourth particulate test, the rerun
sinter fines were again brown in color but dry. During the second
particulate test the rerun sinter fines became "fuming, very hot,
and odorous." Therefore, Table XI presents the analytical results
for this feed material as it was sampled during tests P-2, P-3, and
P-4.
No other atypical feed material conditions were observed during
the course of the sampling program. The strand mix was sampled
during the beginning, at the middle, and at the end of each particu-
late and fluoride test. The samples were composited and the
analytical results are displayed in Table XI. Because the strand
-------
-40-
mix constitutes the sinter process feed, the results for all four
particulate tests and two fluoride tests are presented in Table XI.
The data in Table XI indicate that the material contributing
the largest percent of sulfur, on a weight basis, to the strand
mix includes the open hearth furnace fines and the rerun fines. These
and the other materials contribute sulfur to the extent that the
sulfur content of the strand mix ranges from 0.0779 percent to 0.0953
percent with an average of 0.0914 percent on a wet basis. On a dry
basis, sulfur content of the strand mix ranges from 0.084 percent
to 0.104 percent with an average of 0.0996 percent by weight. The
fraction of fluoride in the strand mix ranged from 0.0172 percent to
0.0458 percent with an average of 0.0288 percent on a wet basis.
On a dry basis, the fluoride content of the strand mix ranged
from 0.0187 to 0.0494 percent with an average of 0.0337 percent.
Moisture content of the strand ranged from 7.25 percent to 9.24
percent with an average of 8.21 percent as measured during three
of the four particulate tests and the two fluoride tests.
The mill scale feed from the fourth hopper was analyzed for
chloroform-ether soluble material. A known weight of the thoroughly
mixed sample was placed in a soxhlet (recirculating condenser-boiling
flask apparatus) and extracted using chloroform for three hours.
The sample was then extracted in a similar manner using ether. The
resulting solutions were mixed and evaporated to dryness at room
temperature to a constant weight. Results indicate that, on a wet
basis, 0.0063 gram of chloroform-ether soluble material is found
in one gram of the bulk sample (0.63% by weight) obtained during
particulate test P-2.
-------
-41-
The sample was-not pre-crushed because it was felt that the
"organic materials" present in the mill scale were deposited on
the surface of the solids by the nature of the process from which
mill scale is derived. Since the organic materials are those com-
pounds soluble in chloroform-ether, the results are comparable to
chloroform-ether soluble fractions of particulate matter as pre-
viously reported. The other hopper feed materials are expected to
contribute negligible amounts of chloroform-ether soluble matter.
The exact times of bulk sample acquisition are delineated in
Appendix K.
-------
TABLE XI
SUMMARY OF SINTER LINE FEED ANALYSES FOR SULFUR AND FLUORIDE
Granite City Steel
Granite City, Illinois
May 20-23, 1975
Hopper
No.
1
2
3
4
5
6
7**
8
9
_
_
_
_
-
-
Sample
Acquired
During
Test
P-2
P-3
P-4
P-2
P-2
P-2
P-2
P-2
P-l
P-2
P-2
P-l .
P-2
P-3
P-4
F-l
F-2
Material
Designation
Rerun Fines
Rerun Fines
Rerun Fines
Ore Fines
Ore Fines
Mill Scale
Open Hearth Furnace Fines
Blast Furnace Dust
Track Back (Sweepings)
Dolomite
Coke Breeze
Strand Mix
Strand Mix
Strand Mix
Strand Mix
Strand Mix
Strand Mix
Weight
Percent
Sulfur
(wet basis)*
0.0504
0.0508
0.0268
<0.001
<0.001
0.0193
0.159
0.0326
0.0334
<0.001
0.0230
0.0953
0.0944
0.0949
_
0.0944
0.0779
Weight
Percent
Fluoride
(wet basis)*
0.0191
0.0195
0.0175
0.0029
0.0025
0.0029
0.122
0.0369
0.0556
0.0063
0.0210
0.0344
0.0236
0.0172
0.0181
0.0338
0.0458
Weight
Percent
Moisture
3.06
2.33
4.29
12.2
12.4
3.35
5.56
18.6
16.5
4.35
18.0
8.40
9.24
7.82
_
8.35
7.25
N5
I
A wet basis is used to facilitate computations of mass flowrates of sulfur and
fluoride from feed rate data (see Process Description, Table XV ).
** Hopper No. 7 was in use only during Test P-l.
-------
-43-
Summary of Visible Emission Resultj?
Opacity measurements were made by certified opacity readers.
Measurements of emissions opacity from the scrubber outlet stack
and from the building were made every 15 seconds. Tables XII-1 to
XII-16 list the summary of average opacities as they were calculated
by averaging 24 consecutive readings made during a six-minute inter-
val and reporting the average to the nearest tenth percent opacity
(as requested). Each table contains 40 sets of average opacities
corresponding to 24 readings in each set or 960 opacity readings
from each source for each of two observers and conducted during
each of the four particulate tests (except Observer No. 1 during P-4).
The two visible emissions observers were located east-southeast
of both the stack and building visible emissions. A steam plume was
occasionally observed masking the opacity of the stack. However,
this masking was only observed occasionally and therefore when it
occurred opacity readings were taken just above the stack outlet,
just before the condensing of the steam plume. In general, the
stack visible emissions were lofting towards the north. A complete
schematic diagram showing the observers' position with respect to the
stack and building visible emissions is provided in Figure 2.
Emissions from the far end of the building (that is, building visible
emissions) were generally black in color and intermittent in nature.
These emissions are from the discharge hood, control system, and
fugitive emissions from the cooler, screens, and sinter transfer
points. The emissions designated as "building" had the machine
discharge and sinter product handling system as their source. As
such they are not strictly fugitive emissions, uncontrollable by a
windbox, discharge, or pug mill control system. At the time of
-------
_44-
testing and opacity observations, it was unclear as to what sources
contributed to,and were to be included in, the emissions designated
as "building." As such, these data reflect a conglomerate of sources.
In gene.al,the emissions recorded as building are the higher
of either the fugitive emissions from the discharge hood or the
exhaust emissions from the control system used on various operations.
Tables XII-1 through XII-4 display the average opacities of the
stack emissions as determined by observer No. 1. Tables XII-5
through XII-8 display the average opacities of the stack emissions
as obtained by the second observer. Tables XII-9 through XII-12
display the average opacities of building emissions as determined
by observer No. 1. Tables XII-13 through XII-16 display the average
opacities of building emissions determined by observer No. 2.
In general, opacity readings obtained by the two observers are
in relatively good agreement. Tables XII-1 through XII-16 include
graphical plots of opacity as a function of time throughout each
test. Tables XII-1 and XII-5 show that the opacity remained essen-
tially constant between 30% and 35% throughout the first partlcu-
; '
late test with a peak in opacity occurring at about the first half
hour into the test. Similarly, Tables XII-2 and XII-6 show that
both observers recorded a steady decrease in opacity during the
first hour of the second particulate test followed by a sudden
incr.ease and "a sinusoidal type variation in stack opacity there-
after. Tables XII-3 and XII-7 show that the average opacities during
the course of the third particulate test ranged between 10 and 20%
for the --first ha-l"f -of the test as recorded by both observers and
varied somewhat between 0 and 107, during the second half of the
test. Tables XII-4 and XII-8 indicate that the opacity of stack
emissions varied somewhat at about the 4070 level for the fir st
-------
-45-
half of the test and dropped suddenly varying at about the 15-20%
level during the latter part of the test.
The opacity of building emissions as recorded by both observers
are in relatively good agreement. Wide and rapid fluctuatioi. of
building emissions occurred throughout the first particulate test
as indicated in Tables XII-9 and XII-13. Similarly, Tables XII-10
and XII-14 indicate that building emissions opacity increased
markedly during the first half hour of the second particulate test
then dropped off and oscillated for the remainder of the test.
During the fourth particulate test building emissions opacity remained
at a fairly constant and low level, near 10% opacity, as recorded
by both observers and as shown in Tables XII-12 and XII-16.
Table XIII displays the overall averages of scrubber outlet
stack opacity during each of the four particulate tests. Also
displayed are the ranges of opacities recorded by each observer
during the tests. The table shows clearly that the average
opacities and ranges recorded by the two independent observers are
in good agreement.
An attempt was made to correlate the average stack opacity and
the measured outlet particulate concentrations for each test by
conducting regression analyses. Two regression analyses were con-
cucted wherein the degree of correlation was measured in considering:
(1) average stack opacity to be a linear function of the measured
total particulate concentration in the stack gas (actual, i.e., grains
per actual cubic foot), or (2) the measured concentration of total
particulate (actual) to be a linear function of the logarithm of
the reciprocal stack gas transmittance. The two corresponding cor-
relation coefficients are 0.297 and 0 .316 , respectively,using the
four data points contained in Table XIII. Since a correlction
-------
-46-
coefficient of unity represents an exact fit of the data to the
proposed correlation (and 0.95 is regarded as a minimum correlation
coefficient to characterize a meaningful correlation), it is con-
cluded that neither of these"models" is adequate to demonstrate a
correlation between stack gas opacity and total particulate concen-
tration measured in the stack gas.
The correlation utilized concentrations expressed in actual
stack gas volumes since this more closely approximates the physical
conditions which determine the opacity of visible emissions from a
gas density view, point. Similarly, total particulate concentrations
were utilized because plume cooling likely caused partial condensa-
tion of condensible particulate.
However, examination of the data in Table XIII shows that,
qualitatively, "high" opacities generally correspond to high
outlet stack gas total particulate concentrations except for the
fourth test. The first test, for which the highest average opa-
city has been recorded by both observers, resulted in the highest
measured total particulate concentration. The second and third
tests, for which the lowest average opacities have been recorded
by both observers, resulted in lower total particulate concentra-
tions. However, the lowest concentration measured, which was ob-
tained from the fourth particulate test, does not correspond to the
lowest measured stack gas opacity.
A complicating factor in attempts to correlate average opacity
with average total particulate concentration is the effect of con-
densible parti-culate. Since this portion of the emissions can have
a significant impact on their visibility, attempts were made to
include this factor in a correlation. Because the condensible
-------
-47-
hydrocarbon concentration and the relative fraction of condensible
total particulate varied from test to test, relationships between
average opacity and condensible hydrocarbon concentration as well
as between average opacity and the ratio "condensible concentra-
tion/total concentration" were considered. There was no general
relationship found that adequately included all of the four data
points available.
From these observations, it appears that a trend in opacity
decrease occurs as measured total particulate concentrations decrease
However, with only four data points, a single "outlier" biases
heavily any attempted correlation.
-------
TABLE XII-1
SUMMARY OF VISIBLE EMISSIONS
Granite. City Steel
Granite City, Illinois
Date:
Type of
5/20/75
Sintering
Stack
Discharge:
South
Reddish-gray
200 ft
Discharge:
Height of Point of
Wind Direction:
Color of Plume: __
Observer No.: 1
Distance from Observer to Discharge
Direction of Observer from Discharge
Height of Observation Point:
Description of Background:
Type of Plant:
Location of Discharge:
Description of Sky: Par t ly
Wind Velocity:
Detached Plume:
Duration of
Point:
Point:
WNW of observer
cloudy
703 fpm
Yes
Observa tion:
1/4 mile
4 hours
ESE
bOtt.
Gray, hazy
SUMMARY OF AVERAGE OPACITY
Set
Number
1
2
3
A
5
6
7
8
9
10
11
12
, "
14
15
16
17
18
19
20
Time
Start
0915
0921
0927
0933
0939
0945
0951
0957
1003
1009
1015
1021
1027
1033
1039
1045
1051
1057
1103
1109
End
0921
0927
0933
0939
0945
0951
0957
1003
1009
1015
1021
1027
1033
1039
1045
1051
1057
1103
1109
1115
Opa city
Sum
760
740
760
860
945
845
840
850
850
710
815
815
840
740
635
865
800
800
805
775
Average
31.7
30.8
31.7
35.8
39.4
35.2
35.0
35.4
35.4
29.6
34.0
34.0
35.0
30.8
26.5
36.0
33.3
33.3
33.5
32.3
Set
Number
21
22
23
24
25
26
27
28
29
30
31
' 32
33
34
35
36
37
38
39
40
Time
Start
1115
1121
1127
1133
1139
1145
1151
1157
1203
1209
1215
1221
1227
1233
1239
1245
1251
1257
1303
1309
End
1121
1127
1133
1139
1145
1151
1157
1203
1209
1215
1221
1227
1233
1239
1245
1251
1257
1303
1309
1315
Opacity
Sum
. 825
' 840
825 .
730
830
815
830
825
795
825
840
835
840
835
840
825
830
840
845
830
Average
34.4
35.0
34.4
30.4
34.6
34.0
34.6
34.4
33.1
34.4
35.0
34.8
35.0
34.8
35.0
34.4
34.6
35.0
35.2
34.6
Sketch Showing How Opacity Varied With Time:
Opacity
50
30
20
10
1
-- !
i
"(
_...
i
...
-
_
i
....
._.
.
.._
i
...
i
i
....
L
i
..
, '
.
...
, .
1-
1
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...
-
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i
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f
2
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1
,
t
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3
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.-
T
>
...
»'«
> ' i
r
.1
-
J
i
4
Time, hours
-------
-49-
TABLE XII-2
SUMMARY OF VISIBLE EMISSIONS
Granite City Steel
Granite City, Illinois
pate:
Type of
5/21/75
Sintering
Stack
Discharge;200
SW
Yellow
ft
Discharge:
Height of Point of
Wind Direction:
Color of Plume:
Observer No.: 1
Distance from Observer to Discharge
Direction of Observer from Discharge
Height of Observation Point:
Description of Background;
Type of Plant
Location of Discharge: _
Description of Sky:Clear
Wind Velocity:
Detached Plume
Duration of
Point:
Point:
VJNW of observer
to partly cloudy
866 fpm
No
Observa tion:
1/4 mile
4 hours
ESE
60 ft.
Gray (haze) to light blue
SUMMARY OF AVERAGE OPACITY
Set
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Time
Start
0910
0916
0922
0928
0934
0940
0946
0952
0958
1004
1010
1016
1022
1028
1034
1040
1046
1052
1058
1104
End
0916
0922
0928
0934
0940
0946
0952
0958
1004
1010
1016
1022
1028
1034
1040
1046
1052
1058
1104
1110
Opacity
Sum
750
700
665
540
475
310
205
170
180
645
715
360
695
215
350
295
385
200
440
370
Average
31.2
29.2
27.7
22.5
19.8
12.9
8.5
7.1
1 7.5
. 26.9
29.8
15.0
29.0
9.0
14.6
12.3
16.0
8.3
18.3
15.4
Set
Number
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Time
Start
1110
1116
1122
1128
1134
1140
11.46
1152
1158
1204
1210
1216
1222
1228
1234
1240
1246
1252
1258
1304
End
1116
1122
1128
1134
1140
1146
1152
1158
1204
1210
1216
1222
1228
1234
1240
1246
1252
1258
1304
1310
Opacity
Sum
. 295
' 260
155
100
180
195
210
725
465
620
360
70
85
155
170
125
70
. 85
165
120
Average
12.3
10.8
6.5
4.2
7.5
8.1
8.8
30.2
19.4
25.8
15.0
2.9
3.5
6.5
7.1
5.2
2.9
3.5
6.9
5.0
Sketch Showing How Opacity Varied With Time:
JU
Opacity
' 4 U
i n
J U
9 n
f. U
1r\
U
0
7!
1
,
....
1
r
--
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h
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t
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r
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i
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i
2
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i
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-
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1
'
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i
i
3
|.
i
T
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i
i-
1
'
-
1
...
1
\
...
1
...
1 1
....
.
' '
\
1 '
4
Time , hours
-------
-50-
TABLE XII-3
SUMMARY OF VISIBLE EMISSIONS
Granite City Steel
Granite City, Illinois
ate
ype
5/22/75
Sintering
of Discharge:
Height of Point of
Wind Direction:
Stack
Discharge:200
WNW
ft,
Sky:
Sunny
fcolor of Plume: Yellowish-white
Observer No.: i
Distance from Observer to Discharge
Direction of Observer from Discharge
lleight of Observation Point:
Description of Background:
Type of Plant:
Location of Discharge:WNW oi^ observer
Description of
Wind Velocity:
Detached Plume:
Duration
Point:
Point:
450 fpm
No
of
Observa tion:
1/4 mTle
4 hours
ESE
60 ft.
Light blue and hazy to sunny
SUMMARY OF AVERAGE OPACITY
Set
Number
1
2
3
4
5
6
7
8
9
10
11
12
. 13
14
15
16
17
18
19
20
Time
Start
0910
0916
0922
0928
0934
0940
0946
0952
0958
1004
1010
1016
1022
1028
1034
1040
1046
1052
1058
1104
End
0916
0922
0928
0934
0940
0946
0952
0958
1004
1010
1016
1022
1028
1034
1040
1046
1052
1058
1104
1110
Opa city
Sum
400
455
420
355
335
375
330
315
355
290
180
250
350
245
235
255
265
260
225
50
Average
16.7
19.0
17.5
14.8
14.0
15.6
13.8
13.1
14.8
. 12.1
7.5
10.4
14.6
10.2
9.8
10.6
11.0
10.8 .
9.4
2.1
Set
Number
21
22
23
24
25
26
27
28
29
30
31
: 32
33
34
35
36
37
38
39
40
Time
Start
1110
1116
1122
1128
1134
11'; 0
1146
1152
1158
1204
1210
1216
1222
1228
1234
1240
1246
1252
1258
1304
End
1116
1122
1128
1134
1140
1146
1152
1158
1204
1210
1216
1222
1228
1234
1240
1246
1252
1258
1304
1310
Opacity
Sum
. 110
' 150
. 640
650
210
155
145
230
165
60
55
200
175
175
135
100
125
105
125
125
Average
4.6
6.2
26.7
27.1
8.8
6.5
6.0
9.6
6.9
2.5
2.3
8.3
7.3
7.3
5.6
4.2
5.2
4.4
5.2
5.2
Sketch Showing How Opacity Varied With Time:
Opcicity
J w
0
J f\
J U
OA
1f\
U
_-
i
-
i
.
.
1
-
' ^
_.
I
1 '
i
--
._.
i
r i
...
. '
-
<
__
t
",
»
|
1
(
-'
t '
1
I'
1
»
_
...
<
t
.
>
I
.._.
r
(
i
' <
' 4
r
i
_
f
»
i
i i
1!
1
i*
...
..T. .-
i
> i
>
>
i
....
i
»
u.
1
t
I
1
1
i
1
> I'
-------
TABLE XII-4
SUMMARY OF VISIBLE EMISSIONS
Granite City Steel
Granite City, Illinois
Discharge: Stack
Date: 5/23/75
Type of
Height of Point of Discharge:200 ft,
Wind Direction: SE
Color of Plume:
Observer No.:
Sintering
WNW of observer
Yellow-white
Type of Plant:
Location of Discharge:
Description of Sky: Hazy, sunny
Wind Velocity: _
Detached Plume:
Duration of Observation:
600 fpm
No
3 hours
Distance from Observer to Discharge Point:
Direction of Observer from Discharge Point:
Height of Observation Point:
Description of Background:
1/4 mile
ESE
60 ft.
Bluish-gray - No obstructions
SUMMARY OF AVERAGE OPACITY
Set
Number
1
2
3
4
5
6
7
8
9
10
11
12
. 13
14
15
16
17
18
19
20
Time
Start
0900
0906
0912
0918
0924
0930
0936
0942
0948
0954
1000
1006
1012
1018
1024
1030
1036
1042
1048
1054
End
0906
0912
0918
0924
0930
0936
0942
0948
0954
1000
1006
1012
1018
1024
1030
1036
1042
1048
1054
1100
Opacity
Sum
900
800
805
975
990
980
895
945
910
1000
980
925
890
825
865
940
965
720
460
400
Average
37.5
33.3
33.5
40.6
41.2
40.8
37.3
39.4
37.9
41.7
40.8
38.5
37.1
24.4
36.0
39.2
40.2
30.0
19.2
16.7
Set
Number
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Time
Stai-t
1100
1106
1112
1118
1124
1130
1136
1142
1148
1154
End
1106
1112
1118
1124
1130
1136
1142
1148
1154
1200
Opacity
Sum
. 565
' 455
315
100
185
800
410
205
240
265
Average
23.5
19.0
13.1
4.2
7.7
33.3
17.1
8.5
10.0
11.0
Sketch Sho\
50
Opacity
(70 40
30
20
10
v 0
tfing How Opacity Varied With Time:
_J
...
>
<
--
-
-
i
-
"i
>.
i
1
Lt... T_
i
- :
...
»
1
-
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I
i
. 1
i
_
1
>
*
\
..
(
\
l
<
t
- -[.
1
1
T
1 «
_
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i
1
!
|
_
1
IT
1 2
i
'I
i
i
i i
-
1
- 1
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-
""
_
...
-
..
4
-
!
i "
i
1 T
i
1 !
-
i
t
3 4
-------
TABLE XII-5
SUMMARY OF VISIBLE EMISSIONS
Granite City Steel
Granite City, Illinois
5/20/75
Stack
Discharge:200
South
Reddish-gray
ft,
Date:
Type of Discharge:
Height of Point of
Wind Direction:
Color of Plume:
Observer No.: 2
Distance from Observer to Discharge
Direction of Observer from Discharge
Height of Observation Point:
Description of Background:
Sinteri ng
Type of Plant:
Location of Discharge: ^
Description of Sky: Partly cloudy
Wind Velocity: 703 fpm
Detached Plume: Yes
Duration of Observation: 4 hours
Point:
Point:
of observer
1/4 mile
ESE
60 ft.
Gray, hazy
SUMMARY OF AVERAGE OPACITY
Set
Number
1
2
3
4
5
6
7
8
9
10
11
12
. 13
14
15
16
17
18
19
20
Time
Start
0915
0921
0927
0933
0939
0945
0951
0957
1003
1009
1015
1021
1027
1033
1039
1045
1051
1057
1103
1109
End
0921
0927
0933
0939
0945
0951
0957
1003
1009
1015
1021
1027
1033
1039
1045
1051
1057
1103
1109
1115
Opacity
Sum
700
745
780
840
990
820
810
825
835
840
850
855
865
805
735
835
785
820
860
840
Avera ge
29.2
31.0
32.5
35.0
41.2
34.2
33.8
34.4
' 34.8
35.0
* 35.4
35.6
36.0
33.5
30.6
34.8
32.7
34.2
35.8
35.0
Set
Number
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Time
Start
1115
1121
1127
1133
1139
1145
1151
1157
1203
1209
1215
1221
1227
1233
1239
1245
1251
1257
1303
1309
End
1121
1127
1133
1139
1145
1151
1157
1203
1209
1215
1221
1227
1233
1239
1245
1251
1257
1303
1309
1315
Opacity
Sum
. 840
' 840
. 840
770
840
765
840
825
810
840
840
840
840
840
840
840
840
840
840
840
Average
3iCTiWiy _ *
_..
.. ...
k_.
i-
'...
i
-
r
.-..i
r ~
-
r
(
i
>
* <
j
2
H
K
- 1
N
L"
-
»
i
i
-
3
' <
-
i i
> i
...
i
-
-
> i
-
> .
» ,
^1
-
- <
>- 4
A
Time » hours
-------
-53-
TABLE XII-6
SUMMARY OF VISIBLE EMISSIONS
Granite City Steel
Granite City, Illinois
Date:
Type of
Height
Wind
Color
5/21/75
Stack
Discharge:
SW
200 ft
Yellowish
Discha rge:
of Point of
Direction:
of Plume:
Observer No.: 2
Distance from Observer to Discharge
Direction of Observer from Discharge Point:
Height of Observation Point:
Description of Background:
Type of Plant: Sintering
Location of Discharge:
, Description of Sky: ___
Wind Velocity:
Detached Plume:
Duration of
Point:
WNW of observer
Clear
866fpm
No
Observation:
1/4 mile
4 hours
ESE
60 ft.
Light blue sky with some haze
SUMMARY OF AVERAGE OPACITY
Set
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Time
Start
0910
.0916
0922
0928
0934
0940
0946
0952
0958
1004
1010
1016
1022
1028
1034
1040
1046
1052
1058
1104
End
0916
0922
0928
0934
0940
0946
0952
0958
1004
1010
1016
1022
1028
1034
1040
1046
1052
1058
1104
1110
Opa city
Sum
720
720
650
505
445
370
315
310
310
800
520
410
475
115
340
180
240
350
355
295
Avera ge
30.0
30.0
27.1
21.0
18.5
15.4
13.1
12.9
12.9
.-33.3
21.7
17.1
19.8
4.8
14.2
7.5
10.0
14.6 .
14.8
12.3
Set
Number
21
22
23
24
25
26
27
28
29
30
31
: 32
33
34
35
36
37
38
39
40
Time
Start
1110
1116
1122
1128
1134
1140
1146
1152
1158
1204
1210
1216
1222
1228
1234
1240
1246
1252
1258
1304
End
1116
1122
1128
1134
1140
1146
1152
1158
1204
1210
1216
1222
1228
1234
1240
1246
1252
1258
1304
1310
Opacity
Sum
. 165
180
80
70
85
225
80
350
230
225
135
110
120
245
210
310
280
230
125
120
Avera ge
6.9
7.5
3.3
2.9
3.5
9.4
3.3
14.6
9.6
"9.4
5.6
4.6
5.0
10.2
8.8
12.9
11.7
9.6
5.2
5.0
Sketch Showing How Opacity Varied With Time:
c O
Opacity
(7°) AO
7 4 U
j n
J U
on
In
(j
i
-
-
1
I
...
,
I
-
<
-
1
_
._.
i
i
-
<
...
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i
i
._..
I
I
k '
1,. .
....
i
-
1
i
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i
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i
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...
-
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1
..
t
0
Time t hours
-------
TABLE XII-7
SUMMARY OF VISIBLE EMISSIONS
Granite City Steel
Granite City, Illinois
Date:
5/22/75
Type of Plant: Sintering
Stack
Location of Discharge: WNW of observer
Description of Sky: cl ear
Wind Velocity:
Detached Plume:
Type of Discharge:
Height of Point of "D is c ha r g e : 2 00 ft
Wind Direction: WNW
Color of Plume: Yellowish-white
Observer No.: 2 Duration of Observation:
Distance from Observer to Discharge Point: 1/4 mile
Direction of Observer from Discharge Point:
Height of Observation Point:
Description of Background:
450 fpm
No
4 hours
ESE
60 ft,
Light blue sky with haze
SUMMARY OF AVERAGE OPACITY
Set
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Time
Start
0910
0916
0922
0928
0934
0940
0946
0952
0958
1004
1010
1016
1022
1028
1034
1040
1046
1052
1058
1104
End
0916
0922
0928
0934
0940
0946
0952
0958
1004
1010
1016
1022
1028
1034
1040
1046
1052
1058
1104
1110
Opacity
Sum
250
260
280
275
250
240
255
325
345
260
145
250
370
280
305
275
270
300
270
130
Average
10.4
10.8
11.7
11.5
10.4
10.0
10.6
13.5
14.4
10.8
6.0
10.4
15.4
11.7
12.7
11.5
11.2
12.5
11.2
5.4
Set
Number
21
22
23
24
25
26
27
28
29
30
31
' 32
33
34
35
36
37
38 '
39
40
Time
Start
1110
1116
1122
1128
1134
1140
1146
1152
1158
1204
1210
1216
1222
1228
1234
1240
1246
1252
1258
1304
End
1116
1122
1128
1134
1140
1146
1152
1158
1204
1210
1216
1222
Opacity
Sum
. 95
' 60
. 345
340
135
15
185
250
180
105
135
265
1228 175
1234
1240
1246
1252
1258
1304
1310
140
100
45
165
135
110
130
Average
4.0
2.5
14.4
14.2
5.6
0.6
7.7
10.4
7.5
4.4
5.6
11.0
7.3
5.8
4.2
1.9
6.9
5.6
4.6
5.4
Sketch Showing Hew Opacity Varied With Time:
Opacity
50
30
20
- i
»
_l.
.,..
rr
-------
-55-
TABLE XII-8
SUMMARY OF VISIBLE EMISSIONS
Granite City Steel
Granite City, Illinois
>ate
5/23/75
Stack
Discharge:200
SW
ft.
Yellowish-white
Type of Discharge:
"Height of Point of
Wind Direction:
Color of Plume:
observer No.: 2
Distance from Observer to Discharge
irection of Observer from Discharge
leight of Observation Point: |
Description of Background:
Sintering
Type of Plant
Location of Discharge:WNW of observer
Description of Sky: Clear and hazy
Wind Velocity:
Detached Plume
Duration of
Point:
Point:
600 fpm
No
Observa tion:
1/4 mile
4 hours
ESE
60 ft
Light blue sky___with haze
SUMMARY OF AVERAGE OPACITY
Set
Number
1
2
3
4
5
6
7
8
9
10
11
12
. 13
14
15
16
17
18
19
20
Time
Start
0900
0906
0912
0918
0924
0930
0936
0942
0948
0954
1000
1006
1012
1018
1024
1030
1036
1042
1048
1054
End
0906
0912
0918
0924
0930
0936
0942
0948
0954
1000
1006
1012
1018
1024
1030
1036
1042
1048
1054
1100
Opa city
Sum
1030
980
810
670
890
1000
805
640
720
830
855
805
825
735
870
875
900
855
750
795
Average
42.9
40.8
33.8
27.9
37.1
41.7
33.5
26.7
1 30.0
34.6
35.6
33.5
34.4
30.6
36.2
36.5
37.5
35.6
31.2
33.1
Set
Number
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Time
Start
1100
1106
1112
1118
1124
1130
1136
1142
1148
1154
1200
1206
1212
1218
1224
1230
1236
1242
1248
1254
End
1106
1112
1118
1124
1130
1136
1142
1148
1154
1200
1206
1212
1218
1224
1230
1236
1242
1248
1254
1300
Opacity
Sum
. 815
950
815
360
380
745
505
450
265
335
370
465
530
395
285
270
365
345
265
205
Average
34.0
39.6
34.0
15.0
15.8
31.0
21.0
18.8
11.0
14.0
15.4
19.4
22.1
16.5
11.9
11.2
15.2
14.4.
lloO
8.5
Sketch Showing How Opacity Varied With Time:
50
Opacity -1-|
C/O
40
30
20
10
t i
T-
J..-.LL
Time ,, hours
-------
-56-
TABLE XII-9
SUMMARY OF VISIBLE EMISSIONS
Granite City Steel
Granite City, Illinois
Date: __
Type of
5/20/75
Wind
Color of
'Observer
Distance
Discharge:
t of Point of
Direction:
Plume:
No. :
from
Building
Discharge:
South
50 ft.
Reddish-gray
Observer to Discharge
Direction of Observer from Discharge
Height of Observation Point:
Description of Background:
Type of Plant: Sintering
Location of Discharge: WNW of observer
Description of Sky: Partly cloudy
VJind Velocity: 703 fpm
Detached Plume: Yes
Duration of Observation: 4 hours
Point: 1/4 mile
Point:
ESE
60 ft.
Gray, hazy
SUMMARY OF AVERAGE OPACITY
S.
e t
Number
1
2
3
4
5
6
7
8
9
10
11
12
. 13
14
15
16
17
18
19
20
Time
Start
0915
0921
0927
0933
0939
0945
0951
0957
1003
1009
1015
1021
1027
1033
1039
1045
1051
1057
1103
1109
End
0921
0927
0933
0939
0945
0951
0957
1003
1009
1015
1021
1027
1033
1039
1045
1051
1057
1103
1109
1115
Opa city
Sum
0
0
260
1080
1010
805
455
295
665
560
830
635
770
880
350
180
30
200
175
180
Average
0
0
10.8
45.0
42.1
33.5
19.0
12.3
27.7
23.3
34.6
26.5
32.1
36.7
14.6
7.5
1.2
8.3 :
7.3
7.5
S_ _
e t
Number
21
22
23
24
25
26
27
28
29
30
31
: 32
33
34
35
36
37
38
39
40
Time
Start
1115
1121
1127
1133
1139
1145
1151
1157
1203
1209
1215
1221
1227
1233
1239
1245
1251
1257
1303
1309
End
1121
1127
1133
1139
1145
1151
1157
1203
1209
1215
1221
1227
1233
1239
1245
1251
1257
1303
1309
1315
Opacity
Sum
. 90
' 205
. 105
70
400
565
840
445
270
110
230
175
435
120
460
545
210
265
220
235
Average
3.8
8.5
4.4
2.9
16.7
23.5
35.0
18.5
11.2
4.6
9.6
7.3
18.1
5.0
19.2
22.7
8.8
11.0
9.2
9.8
Sketch Showing How Opacity Varied With Time:
Opucity
50
40
30
20
10
..!..
i I
I I !
J !_
I
1
I l
"hue . hours
-------
-57-
TABLE XII-10
SUMMARY OF VISIBLE EMISSIONS
Granite City Steel
Granite City, Illinois
5/21/75
Building
Discharge ;20,0
SW
Yellow
ft
Date: __
Type of Discharge:
Height of Point of
Wind Direction:
Color of riume:
Observer No.: 1
Distance from Observer to Discharge
Direction of Observer
Height of Observation
Description of Background:
Sintering
Type of Plant
Location of Discharge: __
Description of Sky:clear
Wind Velocity:
Detached
Duration
Point: 1/4 mile
WNW of observer
to partly cloudy
866 fpm
No
Plume:
of Observation:
4 hours
m Dis
nt :
:
charge
Poin
t:
Gray
60
(h
ESE
ft.
aze )
to
light
b
lue
SUMMARY OF AVERAGE OPACITY
Set
Number
1
2
3
4
5
6
7
8
9
10
11
12
. 13
14
15
'16
17
18
19
20 '
Time
Start
0910
0916
0922
0928
0934
0940
0946
0952
0958
1004
1010
1016
1022
1028
1034
1040
1046
1052
1058
1104
End
0916
0922
0928
0934
0940
0946
0952
0958
1004
1010
1016
1022
1028
1034
1040
1046
1052
1058
1104
1110
Opacity
Sum
320
445
770
1030
1200
1475
625
630
415
360
460
1100
1580
1005
750
975
655
470
385
535
Average
13.3
18.5
32.1
42.9
50.0
61.5
26.0
26.2
17.3
15.0
19.2
45.8
65.8
41.9
31.2
40.6
27.3
19.6
16.0
22.3
Set
Number
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Time
Start
1110
1116
1122
1128
1134
1140
1146
1152
1158
1204
1210
1216
1222
1228
1234
1240
1246
1252
1258
1304
End
1116
1122
1128
1134
1140
1146
1152
1158
1204
1210
1216
1222
1228
1234
1240
- 1246
1252
1258
1304
1310
Opacity
Sum
. 775
' 665
410
360
390
620
1505
1000
1375
11S5
1080
770
185
335
340
475
595
130
95
80
Average
32.3
27.7
17.1
15.0
16.2
25.8
62.7
41.7
57.3
49.4
45.0
32.1
7.7
14.0
14.2
19.8
24.8
5.4
4.0
3.3
Sketch Showing How Opacity Varie^d With Time:
Opacity
(7.) 40
en
40
an
J V
*"
10
0
1
1
- -
_._
1
....
1
<
-
1
-
_
__
1
: (
1
--
]
-
4
L
1
_
-
t
-
...
<
I-.
..
(
.-.
1
2
1
-
r
t
-
\
(
\
-
1
<
3
...
> L
;
:
|
i
i
r
M
.
:
1
k
-
' <
-
i
1
ft
~~"
.
.
I
. I
t
j
r
I
i
;
i
i.
/i
T < in r> hnurn
-------
-58-
TABLE XII-11
SUMMARY OF VISIBLE EMISSIONS
Granite City Steel
Granite City, Illinois
Date: 5/22/75
Type of Discharge:
Height of Point of
Wind Direction:
Color
Sintering
Building
Discharge:
WNW
50 ft,
Sky:
Sunny
Yellowish-white
of Plume:
Observer No.: 1
Distance from Observer to Discharge
Direction of Observer from Discharge
Height of Observation Point:
Description of Background:
Type of Plant:
Location of Dis^T7arge:WNW of observer
Description of
Wind Velocity:
Deta ched
Duration
Point:
Point:
450 fptn
Plume:
of Observation:
No
4 hours
1/4 mile
ESE
60 ft.
Light blue and hazy to sunny
SUMMARY OF AVERAGE OPACITY
Set
Number
1
2
3
4
5
6
7
8
9
10
11
12
. 13
14
15
16
17
18
19
20
Time
Start
0910
0916
0922
0928
0934
0940
0946
0952
0958
1004
1010
1016
1022
1028
1034
1040
1046
1052
1058
1104
End
0916
0922
0928
0934
0940
0946
0952
0958
1004
1010
1016
1022
1028
1034
1040
1046
1052
1058
1104
1110
Opacity
Sum
1020
470
370
385
1285
1175
825
800
730
565
580
585
290
210
255
240
235
250
85
40
Avera ge
42.5
19.6
15.4
16.0
53.5
49.0
34.4
33.3
' 30.4
23.5
24.2
24.4
12.1
8.8
10.6
10.0
9.8
10.4
3.5
1.7
Set
Number
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Time
Start
1110
1116
1122
1128
1134
1140
1146
1152
1158
1204
1210
1216
1222
1228
1234
1240
1246
1252
1258
1304
End
1116
1122
1128
1134
1140
1146
1152
1158
1204
1210
1216
1222
1228
1234
1240
1246
1252
1258
1304
1310
Opacity
Sum
. 200
250
850
920
225
190
940
275
285
240
465
310
205
320
210
235
180
150
250
195
Average
8.3
10.4
35.4
38.3
9.4
7.9
39.2
11.5
11.9
10.0
19.4
12.9
8.5
13.3
8.8
9.8
7.5
6.2
10.4
8.1
Sketch Showing How Opacity Varied With Time:
Opacity
50
30
10
0
<
'
-
-
..
...
1 <
>
,t
>
1
> 1
> i
i
._
i
....
i
t
> (
,
1 i
-
»
-
i
i
t
{
t
2
.- 1
1
I
L _. i
i
I
k
>
i
-
i
<
t
»
I
, <
-
1
3
i
;
i
1
i
I
r
..(..^
...
f-
<
t i
i
k
t
>_i
i
»
...(
4
-------
TABLE''xi i-12
SUMMARY OF VISIBLE EMISSIONS
Granite City Steel
Granite City, Illinois
Date:
Type of
5/23/75
Sintering
Building
Discharge: 5Q_
SE
Yellow-white
ft.
Discharge:
Height of Point of
Wind Direction:
Color of Plume:
Observer No.: 1
Distance from Observer to Discharge
Direction of Observer from Discharge
Height of Observation Point:
Description of Background:
Type of Plant:
Location of Discharge:^NW of observer
Description of Sky: Hazy, sunny
Wind Velocity:
Detached Plume:
Duration of Observation: 3 hours
Point:
Point:
600 fpm
No
1/4 mile
ESE
60 ft.
Bluish gray - No obstruction
SUMMARY OF AVERAGE OPACITY
Set
Number
1
2
3
4
5
6
7
8
9
10
11
12
. 13
14
15
16
17
18
19
20
Time
Start
0900
0906
0912
0918
0924
0930
0936
0942
0948
0954
1000
1006
1012
1018
1024
1030
1036
1042
1048
1054
End
0906
0912
0918
0924
0930
0936
0942
0948
0954
1000
1006
1012
1018
1024
1030
1036
1042
1048
1054
1100
Opacity
Sum
305
345
185
160
135
90
95
215
295
215
235
390
240
185
160
115
150
120
125
75
Avera ge
12.7
14.4
7.7
6.7
5.6
3.8
4.0
9.0
12.3
9.0
9.8
16.2
10.0
7.7
6.7
4.8
6.2
5.0 ,
5.2
3.1
Set
Number
21
22
23
24
25
26
27
28
29
30
31
: 32
33
34
35
36
37
38
39
40
Time
Start
1100
1106
1112
1118
1124
1130
1136
1142
1148
1154
End
1106
1112
1118
1124
1130
1136
1142
1148
1154
1200
Opacity
Sum
-j-V'tJ7PtiJ" t 'Tj*^*^^^-'
. 55
65
690
30
35
120
155
315
65
65
Average
TfJ>^*rP**iTByiff^'ff->lJT>t^TTrjP
2.3
2.7
28.8
1.2
1.5
5.0
6.5
13.1
2.7
2.7
Sketch Showing How Opacity Varied With Time:
50
Opacity
(?) /n
0 A
J U
1 n
1 U
0
i
....
-T
...
-
i
-
...
-
-
-
'
t
-
i
i
--
-
, '
(
...
l
1
-
._1
'
~
--
>..
-
i
-
t
1
"* """
<
_
, <
^
i 5
2
._
( l
-
...
«
i
'
> ^
^
1-
\\
<
i
_
t i
3
....
.
.
-
.
r
- - ! .
It
i
i
..(..
4
Time , hours
-------
-60-
TABLE XII-13
Da te :
Type of
5/20/75
SUMMARY OF VISIBLE EMISSIONS
Granite City Steel
Granite City, Illinois
Type of Plant:
Sintering
Di scharge :-
Building
Height of Point of Discharge: 50ft,
Wind Direction: South
Plume:
No. :
Color of
Observer
Reddish-gray
Location of Discharge:
Description of Sky:
Wind Velocity:
Detached
Duration
WNW of observer
Partly cloudy
703 fpm"
P1 urn e :
of Observation:
Yes
4 hours
Distance from Observer to Discharge Point:
Direction of Observer from Discharge Point:
Height of Observation Point:
Description of Background: ___
1/4 mile
ESE
60 ft.
Gray, hazy
SUMMARY OF AVERAGE OPACITY
Set
Number
1
2
3
4
5
6
7
8
9
10
11
12
. 13
14
15
16
17
18
19
20
Time
S tart
0915
0921
0927
0933
0939
0945
0951
0957
1003
1009
1015
1021
1027
1033
1039
1045
1051
1057
1103
1109
End
0921
0927
0933
0939
0945
0951
0957
1003
1009
1015
1021
1027
1033
1039
1045
1051
1057
1103
1109
1115
Op a city
Sum
0
0
295
1130
1070
1020
500
310
665
690
930
720
565
910
625
390
215
375
245
75
Avera ge
0
0
12.3
47.1
44.6
42.5
20.8
12.9
27.7
28.8
38.8
30.0
23.5
37.9
26.0
16.2
9.0
15.6 .
10.2
3.1
Set
Number
21
22
23
24
25
26
27
28
29,
30
31
32
33
34
35
36
37
38
39
40
Time
Start
1115
1121
1127
1133
1139
1145
1151
1157
1203
1209
1215
1221
1227
1233
1239
1245
1251
1257
1303
1309
End
1121
1127
1133
1139
1145
1151
1157
1203
1209
1215
1221
1227
1233
1239
1245
1251
1257
1303
1309
1315
Opacity
Sum
, 230
290
60
215
495
590
860
415
315
275
245
250
425
220
560
645
275
240
240
240
Average
9.6
12.1
2.5
9.0
20.6
24.6
35.8
17.3
13.1
11.5
10.2
10.4
17.7
9.2
23.3
26.9
11.5
10.0
10.0
10.0
Sketch Showing How Opacity Varied With Time:
J \J
Opacity
(7°) / n
0 f\
j U
7 n
1/\
U
-1
--
--
i
J
...
~
-
i
--
1
i
I
"1
...
"«
>
...
I
i
i
i
1
-
__
> '
J
-
-
r
i
*
i
«
-
i
r
--
i
-
-
i
i
i
-i
~
«
--
...
>
>
<
.
t
--
<
>
-
<
...
i
i
j
-
"i
i
i
i
1
, i'
!
^
l
i
. 1
1
1
-
I
-
M
» '
Time , hours
-------
SUMMARY
-61-
TABLE XII-14
OF VISIBLE EMISSIONS
Granite City Steel
Granite City, Illinois
5/21/75
Bui Id in g __
Discharge: 50 ft,
SW ZZZZI
Yellowish
Date:
[Type of Discharge:
Height of Point of
Wind Direction:
Color of Plume:
Observer No.: 2
Distance from Observer to Discharge
Direction of Observer from Discharge
Height of Observation Point: ^______
Description of Background:
Type of Plant
Location of Discharge:
Description o£ Sky:
Wind Velocity:
Detached Plume:
Duration of
Point:
Point:
Sintering
WNW of observer
'Clear
866 fpm
No
Observation: 4 hours
1/4 mile
ESE
60 ft.
Light blue sky with some haze
SUMMARY OF AVERAGE OPACITY
Set
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Time
Start
0910
0916
0922
0928
0934
0940
0946
0952
0958
1004
1010
1016
1022
1028
1034
1040
1046
1052
1058
1104
End
0916
0922
0928
0934
0940
0946
0952
0958
1004
1010
1016
1022
1028
1034
1040
1046
1052
1058
1104
1110
Opacity
Sum
370
430
750
1035
1350
1070
710
780
495
480
405
1020
1335
1025
660
1275
650
630
715
835
Average
15.4
17.9
31.2
43.1
56.2
44.6
29.6
32.5
20.6
. 20.0
' 16.9
42.5
55.6
42.7
27.5
53.1
27.1
26.2
29.8
34.8
Set
Number
21
22
23
24
25
26
27
28
29
30 :
31
32
33
34
35
36
37
38
39
40
Time
Start
1110
1116
1122
1128
1134
1140
1146
1152
1158
1204
1210
1216
1222
1228
1234
1240
1246
1252
1258
1304
End
1116
1122
1128
1134
1140
1146
1152
1158
1204
1210
1216
1222
1228
1234
" 1240
1246
1252
1258
1304
1310
Opacity
Sum
. 865
' 655
. 390
310
220
510
690
520
615
420
475
335
400
550
525
775
720
545
315
290
Average
36.0
27.3
16.2
12.9
9.2
21.2
28.8
21.7
25.6
17 . 5
19.8
14.0
16.7
22.9
21.9
32.3
30.0
22.7
13.1
12.1
Opacity
Sketch Showing How Opacity Varied With Time:
50
40
30
20
10
, ,«
J
1
--
,
-
1
-
<
-
-
.
4
-
>
j
k
e
-
(
"
.
<
_..
i
-
__
i
-
__
.
i
\
~
f
<
i
1
p
i
i
-
1
1
(
i
-
t
1
-
i
...
-
i
I
r
-
"<
>
*
<
i
..
>
{
>
i
i
--
P4...
-------
-62-
TABLE XII-15
SUMMARY OF VISIBLE EMISSIONS
Granite City Steel
Granite City, Illinois
5/22/75
Building
50 ft,
bate:
type of Discharge:
Height of Point of
Wind Direction:
Color of Plume:
Observer No.:
Distance from Observer to Discharge
Direction of Observer from Discharge
Height of Observation Point:
Description of Background:
Discharge:
WNW ~~
Yellowish-white
2
Type of Plant:
Location of Discharge:
Description of Sky:
Wind Velocity:
Detached Plume:
Duration
Point:
Point:
Sintering
WNW of observer
Clear
450 fpm
No
of
Observa tion:
1/4 mile
4 hours
ESE
60 ft.
Light blue sky with haze
SUMMARY OF AVERAGE OPACITY
Set
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Time
Start
0910
0916
0922
0928
0934
0940
0946
0952
0958
1004
1010
1016
1022
1028
1034
1040
1046
1052
1058
1104
End
0916
0922
0928
0934
0940
0946
0952
0958
1004
1010
1016
1022
1028
1034
1040
1046
1052
1058
1104
1110
Opacity
Sum
800
370
410
365
1320
995
785
1020
995
710
675
505
325
345
320
285
260
320
245
195
Avera ge
33.3
15.4
17.1
15.2
55.0
41.5
32.7
42.5
41.5
- 29.6
28.1
21.0
13.5
14.4
13.3
11.9
10.8
13.3 ,
10.2
8.1
Set
Number
21
22
23
24
25
26
27
28
29
30
31
: 32
33
34
35
36
37
38
39
40
Time
Start
1110
1116
1122
1128
1134
1140
1146
1152
1158
1204
1210
1216
1222
1228
1234
1240
1246
1252
1258
1304
End
1116
1122
1128
1134
1140
1146
1152
1158
1204
1210
1216
1222
1228
1234
1240
1246
1252
1258
1304
1310
Opacity
Sum
, 215
' 200
. 785
680
410
325
660
465
435
310
485
330
250
230
295
255
220
165
150
190
Average
t*VfriTl'**i'rHa» 9ryf*tf&r3'rrJ?u*f**
9.0
8.3
32.7
28.3
17.1
13.5
27.5
19.4
18.1
12.9
20.2
13.8
10.4
9.6
12.3
10.6
9.2
6.9
6.2
7.9
Sketch Showing How Opacity Varied With Time:
Sft
Opacity
(7-) / ft
x ' 40
on
jU
?n
I. U
Irt
U
0
- - -
i
-
»
t
-
\
4
I
*
1
<
....
i
i
-
-
I
t
-
,
-
1
i
-
1
...
.
>
"'
I
i i
'" (
'
i
i
i
4
(
<
2
....
-
M
<
i
>
<
»
4
t-l
(
>
(
' i
1
3
<
>
i
«
..
f ,
f
i
>
^ i
t '
<
'-i
K
4
-------
TABLE XII-16
SUMMARY OF VISIBLE EMISSIONS
Granite City Steel
Granite City, Illinois
Date:
type of
5/23/75
Building
Discharge: 50 ft
SW
Yellowish-white
Discharge:
lleight of Point of
Win'd Direction:
Color of Plume:
Observer No.: 2
Distance from Observer to Discharge
Direction of Observer from Discharge
Height of Observation Point:
Description of Background:
Type of Plant
Location of Discharge:
Description of Sky:
Wind Velocity:
Detached Plume:
Duration
Point:
Point:
Sintering
WNW of observer
Clear and hazy
600 fpm
No
of
Observa tion:
1/4 mile"
4 hours
ESE
60 ft.
Light blue sky with haze
SUMMARY OF AVERAGE OPACITY
S j_
e t
Number
1
2
3
4
5
6
7
8
| 9:;
' 10
11
12
, 13
i' 14
15
16
17
18
19
r 20
Time
Start
0900
0906
0912
0918
0924
0930
0936
0942
0948
0954
1000
1006
1012
1018
1024
1030
M036
.1042
1048
1054
End
0906
0912
0918
0924
0930
0936
0942
0948
i 0954
1000
1006
1012
1018
1024
1030
1036
1042
1048
1054
1100
Opa city
Sum
505
665
385
270
245
240
250
295
; 300
240
240
305
240
240
240
240
245
240
240
240
Average
21.0
27.7
16.0
11.2
10.2
10.0
10.4
12.3
i 12.5
- 10.0
10.0
12.7
10.0
10.0
10.0
10.0
10.2
10.0
10.0
10.0
C* f*. *
Set
Number
21
22
23
24
25
26
27
28
29
30
31
' 32
33
34
35
36
37
38
39
40
Time
Start
1100
1106
1112
1118
1124
1130
1136
1142
1148
1154
1200
1206
1212
: 1218
1224
1230
1236
1242
1248
1254
End
1106
1112
1118
1124
1130
1136
1142
1148
1154
1200
1206
1212
1218
1224
1230
1236
1242
1248
1254
1300
Opacity
Sum
. 265
; 240
- 480
210
230
240
370
345
210
170
265
410
370
295
290
390
345
125
115
130
Average
11.0
10.0
20.0
8.8
9.6
10.0
15.4
14.4
8.8
7.1
11.0
17.1
15.4
12.3
12.1
16.2
14.4
5.2
4.8
5.4
Sketch Showing How Opacity Varied With Time:
Opacity
J\J
0
t
i n
jU
") (\
i u
U
0
j
....
_.
_.
--
...
i
> 1
1
~
t
P_
1
i
\
_.
-
-
, i
>
-
--
2
>
<
t "
(
__
r
1
4
r
<
3
<
>
1
i ,
:
< i
.
»
r «
~
'j
4
Time, hours
-------
-64-
Visible
Emissions
Observer
#2
o
0 .
OV"
Observer Y\
#1 \£
Conveyor
Transfer
Station
Building
Emissions
Conveyor
Back of
Building
Auxiliary
Stack
Sinter
Building
S crubber
Outlet
Stack
Conveyor
FIGURE 2
SCHEMATIC DIAGRAM OF VISIBLE EMISSIONS OBSERVATION LOCATIONS
Granite City Steel
Granite City, Illinois
-------
TABLE XIII
AVERAGE OUTLET STACK VISIBLE EMISSIONS
DURING PARTICULATE TESTS
Granite City Steel
Granite City, Illinois
May 20-23, 1975
Particu-
late
Test
Number
1
2
3
4
Date
5/20
5/21
5/22
5/23
Samp ling
Period
09:31 - 12:23
09:50 - 13:07
09:15 - 11:57
09:02 - 11:52
Average
Opacity
Observer
No. 1
34.1
12.4
12.6
29.0
Observer
No. 2
34.8
.10.8
10.2
31.2
Range
of
Opacities
Observer
No. 1
10 - 45
0-40
0-35
0-50
Observer
No. 2
15 - 45
0-35
0-20
5-50
Measured Outlet
Total Particulate
Concentrations
o
mg/Am
88.6
77.8
75.1
68.7
mg/DNM3
121
101
98.4
90.3
gr/ACF
0.039
0.034
0.033
0.030
gr/DSCF
0.053
0.044
0*043
0.039
-------
-66-
III. PROCESS DESCRIPTION AND OPERATION
The sintering process converts the charge material into an
agglomerated product that is suitable for blast furnace feed
material. The charge consists of iron ore fines and iron-bearing
wastes (such as blast furnace flue dust, mill scale, and miscel-
laneous fines), flux (limestone, dolomite, or both), coke breeze
or coal, and water. The charge is thoroughly mixed and placed on
the sinter strand (a continuous moving grate), and combustion air
is drawn through the top of the bed over its active length. The
sinter bed is approximately 12 inches thick. The top surface of
the material is ignited in a gas-fired or oil-fired combustion
furnace. Once the coke breeze is ignited, the combustion is self-
\
supporting to the end of the sinter bed the flame front moving
down through the bed. The combustion temperature range is 2400 to
2700°F. Typical heat input to the combustion furnace is approxi-
mately 150,000 Btu per ton of sinter produced. In order to provide
a uniform distribution of combustion air, the sections under the
bed are separated into a number of compartments known as windboxes.
After the combustion is complete, the sinter cake is often crushed
and screened. The undersize is collected in the hot return fines
bin for recycling on the strand and the balance is fed to a cooler.
Fines from the cooler and the cold screening operation are also
recycled. Figure 3 shows a simplified schematic diagram of a
sintering process.
Process Description
Granite City Steel has a typical traveling grate single strand
machine that was built in 1958. It normally operates 24 hours per
-------
PUG MILL
MAIN WINDBOX FAN
MECHANICAL
COLLECTOR
MATERIAL FEED BINS
STRAND
VFEED
HOPPER
COLD
SCREENING
TO BLAST
FURNACE
Figure 3. Simplified schematic diagram of a sintering process
Granite City Steel
Granite City, Illinois
-------
-68-
day. The charge material comes from nine storage bins that feed
onto a common belt conveyor. Material from these bins plus returns
from the hot screens are sent to a pug mill for proper mixing.
Water is added to the mixture in the pug mill to achieve the proper
moisture content. From the pug mill, the feed is placed on the
strand by a swinging spout feeder. The strand is eight feet wide
and the layer of charge material is 14 inches deep. Each pallet
is 42 inches long. Either natural gas or coke oven gas is burned
in the ignition hood. As the sinter product is discharged from
the strand it is crushed, screened, and sent to a rotary cooler.
A process flow diagram of Granite City Steel is shown in Figure 4.
The strand drive and the material feed turn tables are controlled
by rheostats. A gauge records the strand speed and another keeps
a running count of the traveling-grate pallets. There are also
temperature gauges for each windbox. A belt scale measures the
total feed except hot returns and water. However, plant'personnel
report that the gauges and scales are very inaccurate, therefore,
readings from these could not be relied upon.
The design production of the strand is 130 tons/hour. The
maximum production is 150 tons/hour and the normal production
is 120 tons/hour. Typical burden characteristics are as follows:
Constituents Percent
Ore 43
Reclaim
Oily (mill scale) 20
Nonoily (EOF fines) 8
Coke breeze 7
Limestone 10
Dolomite 12
-------
SCRUBBER
-.FAN
SCRUBBER
MAIN WINDBOX
FAN
MECHANICAL
COLLECTOR
ROTOCLONE
265
HOPPER AND
SWINGING SPOUT
FEEDER
FLOW RATES ARE AVERAGE VALUES OBTAINED DURING TEST F-2.
BELMONT FINES
PROCESSED SLAG FROM OLD OPEN HEARTHS
(OPEN HEARTHS NO LONGER IN USE).
FOUR CYCLONES IN PARALLEL.
SINTER MACHINE
MAINWINDBOX
FINES
wwvwv
FINES
ALL VALUES ARE IN ton/hr.
i
ON
TO RERUN
FINES BIN
FURNACE
108
Figure' 4. Process flow diagram.
Granite City Steel
Granite City, Illinois
-------
-70-
This produces a sinter that is between self-fluxing and super-
fluxing. That is, the base-to-acid ratio is greater than one. The
normal strand speed is approximately 70 to 80 inches/minute.
The windbox emissions are controlled by cyclones and a venturi
scrubber. The pug mill is controlled by a rotoclone and the dis-
charge is controlled by a baghouse. Four Buell cyclones, model 15,
type FAC, in parallel comprise primary windbox controls. The dimen-
sions of each cyclone are as follows: core height - 66-1/2 inches;
body height - 65 inches; body diameter - 50 inches; inlet dimensions-
14-1/4 inches x 31-3/4 inches; and outlet diameter - 26-3/4 inches.
An American Air Filter venturi scrubber (model AAF L76) was installed
in September, 1973. The unrestricted throat size is 10 inches x 176
2
inches or 12.2 ft . A plate can be inserted in one end of the throat
2
to restrict the size to 10 inches x 150 inches or 10.4 ft . Restricting
the throat size increases the pressure drop. The design pressure
drop is 55 inches W.G. Two water pumps, each with a capacity of 1300
gpm, feed the scrubber through 44 water sprays. Design water flow to
the scrubber is 2500 gpm. The scrubber inlet design is 180,000 scfm
(dry), 300°F, and 0 inches W.G. Outlet design conditions from the mist
eliminator are 289,700 acfm,118°F, and -55 inches W.G.
Process Operation
Only eight of the nine feed bins were used during the week of
testing. There were separate bins for rerun fines (from the
cooler), two bins of ore (Belmont fines), mill scale, sinter plant
fines (process slag from old open hearths that are no longer in use),
blast furnace flue dust, dolomite fines, and coke breeze. Pan tests
for each bin were made to determine the hourly feed rates at the
approximate start, middle, and end of each test. In addition the
strand speed and feed density were measured at the same
-------
-71-
intervals. In the pan test, a sample was taken by allowing a pan
of known weight and length to pass under the feed table of each
component at a known conveyor speed. After collecting each compo-
nent, the pan and its contents were weighed. Component feed rates
were then calculated as follows:
r - 0.03 c x s -7- p (1)
where:
r = component feed rate, ton/hr.
c = collected sample weight, Ib
s = conveyor speed, ft/min
p = pan length, ft.
For all tests except P-l, the pan was passed under the feed
table twice. This effectively doubled the actual pan length.
The reason for this was to increase precision since some of the
samples collected in test P-l were as small as one pound.
The strand speed was determined by measuring the elapsed time
required for the strand to travel a known distance. The feed
density was determined by taking a sample of the material as it is
placed on the strand. This was placed in a container of known
volume and weighed.
Total feed to the strand was calculated using strand speed,
bed depth and width, and feed density. The average feed density
for each test was used in these calculations. The equation used
is as follows:
F = 2.083 x 10"^ xSxBxWxp (2)
where:
F = total feed, ton/hr
S - strand speed, in./min.
-------
-72-
B = bed depth, in.
W = strand width, ft.
p = feed density, lb/ft3
There is no system for measuring the facility's production
rate. Approximate production was calculated by a formula derived
by the plant personnel for inventory purposes. The formula is as
follows:
P = [(S x 60 -5 L) x C - R| x K (3)
where:
P = production (to blast furnace), ton/hr
C = 1.4, empirical constant
S = strand speed, in./min.
K = 0.76, empirical constant
L = pallet length, 42 in.
R = rerun fines from bin No. 1, ton/hr
During the test week, (May 19-23, 1975), the strand ignition
fuel alternated between coke oven gas and natural gas. Coke oven
gas was used exclusively on May 20. Natural gas was used from
11:00 a.m. to 4:30 p.m. on May 21 with coke oven gas burned at all
other times that day. On May 22, coke oven gas was used until
11:30 a.m. then natural gas was used until 10:00 a.m. on May 23.
Coke oven gas was then burned until the end of testing.
The basicity (base-to-acid ratio) of the sinter was measured
each shift by plant personnel. The results for the shifts during
which tests were made are given in Table XIV.
-------
-73-
TABLE XIV
BASICITY OF THE SINTER
Shift
7 a .m . - 3p.m.
3p .m.-llp .m .
Date, 1975
5/20
1.48
1.39
5/21
1.36
1.41
5/22
1.40
1.49
5/23
1.51
No
Test
A gauge to measure pressure drop across the throat of the
scrubber, located on the strand main floor, was not operating.
Therefore, for the purposes of the tests, the company installed a
manometer at the scrubber throat. Also, prior to the tests the
scrubber inlet water flow meter was removed since it was not
functioning. At the end of the first day of testing, however, the
plant personnel attached a differential pressure gauge to the existing
flangt taps across the 8.526-inch diameter knife-edge orifice in the
12-inch water inlet pipe. Readings of the manometer and the dif-
ferential pressure gauge were recorded approximately every half
hour during the tests.
Water inlet flow was calculated by two methods. One method was
by the equation used by Granite City Steel personnel to calculate
flow as follows:
Q = 1000/J h (4)
where:
Q = flow rate, gpm
h = pressure drop across the orifice, ft. W.G.
-------
-74-
An alternate method was also used to calculate water flow
through the orifice. This was by using equations from Perry' s
'".he.mical Engineer's Handbook, Fourth Edition, as follows:
w = KA/s/(2 gc (P1-P2)+ 2 gp (Zl-z2)) (, (5)
where:
w = weight rate of discharge, Ib/sec.
K = C/^yi-p** = 0.807
C = 0.697 (from "Fluid Mechanics" by A.G. Hansen)
p = d2/di = 0.7105
A = 0.396 ft2
gc = 32.2 lbm-ft/lbf-sec2
^p = pressure drop across orifice, lb/ft2
g = 32.2 ft/sec2
C = 62.4 lb/ft3
£±z = vertical distance between pressure taps = 0.167 ft. 2
Equation 4 yields flow rates 12 percent lower than Equation 5.
The scrubber water supply came from the Mississippi River.
There was no water recirculation during the testing. All of the
scrubber effluent went to a settling pond.
Process Operation During Tests
Table XV lists process material rates during the tests. Raw
field data are presented in Appendix I. In the table, the sum of 1
the rerun fines plus the total raw feed does not equal the strand \
j;
burden because fines from the hot screens, the discharge control
syste-i, and the mechanical collectors on the windbox exhaust are
charged directly into the pug mill (see Figure 4). '
The sintering process is normally a 24-hour per day operation.
However, during the week of testing it was only operating two shifts
per day because there was a reduced sinter demand by the blast
-------
TABLE XV
PROCESS MATERIAL RATES SUMMARY (tons/hr)
Granite City Steel
Granite City, Illinois
May 20-23, 1975
Material
Ore3
Reclaima
Mill scale
Sinter plant finesb
Blast furnace flue dust
Coke breeze3
Dolomite8
Hopper
Number
2&3
4
5
6&7
9
8
Total raw feedc
Rerun fines3 >d
Strand burden6
Production^
Test Number and 1975 Date
P-l
5/20
87
16
16
11
4.2
27
161
26
264
108
P-2
5/21
73
14
16
8.8
7.2
20
139
51
257
93
F-l
5/21
71
11
15
4.9
6.0
19
127
52
264
92
P-3
5/22
69
13
17
8.9
5.8
25
139
39
267
104
F-2
5/22
73
10
19
9.4
5.5
24
141
28
265
108
P-4
5/23
78
9.2
15
8.3
4.1
24
139
26
248
105
a Calculated by pan test method (including moisture, see Table XI)
° Processed slag from old open hearths (open hearths no longer in use).
c All feed bins except rerun fines.
^ Feed bin No. 1 (cold returns from cooler).
e Material actually put on the strand, calculated using strand speed and feed density.
f Calculated using formula provided by Granite City Steel
-------
-76-
furnace shop. Since the strand was started up cold each morning,
the tests were not started until the process had reached normal
conditions. Reliable readings of the windbox temperatures
were not available, therefore they could not be used as a guideline.
The sinter plant operator's judgment was used to determine when
the process had reached normality. They felt that two revolutions
of the strand gate (approximately 1-1/2 hours) would be needed to
bring the system up to temperature. At least two hours was allowed
between start-up and testing to ensure the system was at equilibrium.
Therefore, the test results should not be affected by start-up.
Normal operation includes stopping the strand occasionally for
five minutes or less. There are various reasons for this, including
the cleaning of plugging in the pug mill. These brief stops are
typical for all sinter plants. Thus the test results for periods
when the brief stops occurred are representative of normal operation,
The strand speed was normal, generally between 80 and 90 in./min,
The total raw strand burden remained approximately the same (about
260 ton/hr) throughout all tests. Production for all tests, except
tests P-2 and F-l, also remained relatively constant at about 105
ton/hr. Since production stayed at this level throughout most of
the test week, and within the normal production range, representa-
tive test results should be obtained. Production during tests
P-2 and F-l decreased to approximately 92 ton/hr. This was because
the increase in rerun fines that occurred during these tests
decreased production (when calculated using the equation provided
by Granite City Steel). However, increase in reruns may not be
indicative of a decrease in production. This is because of the
lag time in transferring rerun fines from the cooler to the bin.
The fact that the total strand feed remained approximately equal
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-77-
throughout all tests indicates that production levels were also
about the same for all tests. Production levels for all tests
should represent typical operation.
For the test week, the basicity ranged from 1.36 to 1.51.
This is indicative of a sinter that is between self- and super-
fluxed, which is the normal product at the facility.
In summary, the process operated normally during all tests.
The strand was bedded to full depth and strand speed was within
the normal range.
Control System Operation During Tests
The control equipment data are listed in Tables XVI-1 through
XVI-4. The design pressure drop across the venturi is 55 in. W.G.
The average pressure drop observed during the first test-(test P-l)
was approximately 44 in. W.G. This was below the design of 55 in.
W. G.. but was representative of the normal operation prior to the
test series. Records of the usual pressure drop were not available
since the monitor in the control room was not functioning and the
manometer at the venturi throat was not installed until just before
the tests .
After the first day of testing, the company inserted a plate in
the throat of the venturi to restrict the flow and raise the pres-
sure drop. This was.done without prior knowledge by EPA or the pro-
ject contractors.
With the plate inserted in the scrubber throat, the pressure
drop increased to approximately 51 in. W.G. This is close to the
design conditions so the test results should be representative of
good operation.
The pressure drop across the venturi was observed to be less
than usual prior to testing on May 23 (test P-4) . The plant perso.nnel
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TABLE XVI-1
VENTURI PARAMETERS
Granite City Steel
Granite City, Illinois
May 20-23, 1975
Test Number
Date, 1975
Time
Venturi pressure drop,
in. W.G.
Water pipe orifice pressure
drop , in. W.G.
Calculated water
flow, gpm
Method la
Method 2
P-l
5/20
09:20
43
c
09:55
43
10:28
43.5
11:00
43
11:30
43.5
12: 10
44
12:43
44
00
I
Method used by Granite City Steel..
Calculated using formula in Perry's Chemical Engineer's Handbook.
Differential pressure gauge not yet installed.
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TABLE XVI-2
VENTURI PARAMETERS
Granite City Steel
Granite City, Illinois
May 20-23, 1975
Test Number
Date, 1975
Time
Venturi pressure drop,
in. W.G.
Water pipe orifice
pressure drop,
in. W.G.
Calculated
water flow,
gpm
Method la
Method 2b
P-2
5/21
09:35
51
53
2100
2380
10:08
52
53
2100
2380
10:45
51
49
2020
2290
11: 18
51
49
2020
2290
11:48
51
49.5
2030
2300
12:20
51
54
2120
2410
13:00
51
53
2100
2380
F-l
5/21
15:38
51
52
2080
2360
16:19
51
54
2120
2410
16:48
51
52
2080
2360
17:24
51
53
2100
2380
17:45
51
52
2080
2360
18: 20
51.5
53
2100
2380
Method used by Granite City Steel.
Calculated using formula in Perry's Chemical Engineer's Handbook.
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TABLE XVI-3
VENTURI PARAMETERS
Granite City Steel
Granite City, Illinois
May 20-23, 1975
Test Number
Date, 1975
Time
Venturi pressure drop,
in. W.G.
Water pipe orifice
pressure drop, in. W.G.
Calculated water
flow, gpm
Method la
Method 2b
P-3
5/22
09: 15
51.5
53
2100
2380
09:52
52
52.5
2090
2370
10:15
52
52
2080
2360
10:53
52
52
2080
2360
11:20
51
42
1870
2110
12:00
51
53
2100
2380
F-2
5/22
14:29
51
53
2100
2380
15:06
52
52.5
2090
2370
15:27
50.5
52.5
2090
2370
15:59
51.5
53
2100
2380
16:33
51
52.5
2090
2370
17:08
51
52.5
2090
2370
I
00
o
I
Method used by Granite City Steel.
Calculated using formula in Perry's Chemical Engineer's Handbook.
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TABLE XVI-4
VENTURI PARAMETERS
Granite City Steel
Granite City, Illinois
May 20-23, 1975
Test Number
Date, 1975
Time
Venturi pressure drop, in.W.G.
Water pipe orifice pressure
drop, in. W.G.
Calculated water
flow, gpm
Method la
Method 2b
P-4
5/23
09:07
49
53
2100
2380
09:43
51
53
2100
2380
10:06
51
53.5
2110
2400.
10:43
51
53
2100
2380
11:05
51
53
2100
2380
11:45
50.5
53
2100
2380
I
00
Method used by Granite City Steel.
Calculated using formula in Perry's Chemical Engineer's Handbook
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-82-
were informed and the situation corrected (pressure drop back to
normal) within the first ten minutes of the test.
Data showing the normal rate of water flow to the scrubber was
unavailable since the flow meter was inoperative. The design flow
is 2500 gpm. After a differential pressure gauge was installed,
\
the flow was calculated to be 2100 gpm to 2400 gpm (depending on
the calculation method used). Plant personnel reported that to
the best of their knowledge, the water supply system was "wide open"
but that it was possible that the pumps were not receiving all the
water they are capable of pumping. Since the calculated water flow
is approximately at design level, and the water supply system was
reported to be operated as usual, the flow rates are representative
of normal operation.
One of the water pumps was down from approximately 10:00 a.m.
to 11:30 a.m. on May 21 (during test P-2). Plant personnel did not
inform EPA or project contractor of the shut down until after the
test was completed. No unusual decrease in pressure drop across
the water inlet orifice was recorded during the period that the
pump was out of service. Plant personnel felt that the reason a
large decrease in pressure drop was not observed may be that the
pumps starve for water when operating concurrently, so when one
pump was down, the other was capable of handling almost all of the
supply. Since there was not a large variation in pressure drop
across the orifice and calculated water flow, the test results for
P-2 should not be seriously affected.
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-83-
IV. LOCATION OF SAMPLING POINTS
The exhaust gases, after passing through the venturi scrubber,
a mist eliminator, and a second fan, passed into a round stack
which exhausts to the atmosphere as shown in Figure 5. The outlet
sampling location, located on the 116-inch diameter stack, is shown
in Figure 5. Four ports, located at right angles, were used to
access the 24 sampling points in the outlet sampling cross section
as shown in Figure '. The points, 12 on a diameter, comprised 24
equal quadrant-annular areas. This number of points is consistent
with the minimum requirement specified in Method 1 (FR V.36, n.247
December 23, 1971).
The inlet air sampling was conducted in the rectangular duct
leading from the bank of cyclone collectors to the first fan, as
shown in Figure 5. This duct, measuring 106 inches by 116 inches
in cross section, was divided into 48 equal areas, as shown in
Figure 7. Eight, bottom sampling ports were used to access these
48 sampling points at the inlet. The inlet sampling cross section
was positioned less than two equivalent diameters downstream of a
flow disturbance. Therefore, the 48 sampling points utilized were
inconsistent with the minimum requirements specified in Method 1
but are adequate for the determination of inlet particulate .loading
to the scrubber.
For particulate tests, sampling was conducted for three minutes
at each of the 48 sampling points at the inlet. Similarly, samp-
ling was conducted for six minutes at each of the 24 outlet samp-
ling points. To fulfill the requirement of simultaneous inlet and
outlet particulate sampling with respect to both the sampling period
and the sampling time, and to ensure that the impinger contents
did not back up into the filter (because of high negative pressure
in the duct), the inlet sampling station did not shut down during
port changes except when the outlet station changed ports. Two
-------
Inlet Sampling
Loca tion
Stack
Outlet Fan
Outlet Sampling
Location
(Approx. 100 ft. elevation)
Mist
Eliminator
Venturi
(rectangular throat)
Inlet Sampling
Location
FIGURE 5
Schematic of Venturi Scrubber System and Sampling Locations
Granite City Steel
Granite City, Illinois
May 20-23, 1975
-------
-85-
N
T
rf 2 e 5-' «*> S
TT
A
FIGURE 6
Location of Sampling Points in the Outlet Stack
Granite City Steel
Granite City, Illinois
May 20-23, 1975
-------
<-7'/,"*
14'Ar-*
6 j
14'A1*-
. . i/ " .
- 14/z *
-86-
1 T / II
lit) "
- n / / " r-
"* 14 A. -
5 4
4 t 4
3 « » i
.2
1
* *
1
L, !/'/"._
l4/2-
i
l/1/-^
14 /z.
<
^14'A'1
<
> <
> «
>
» - t
i «
LJ LJ LJ L
1 .
J LJ L-
1
J L
* - «
»..
*-7^
^
8-5/61'
17
1
i
17
1
'
-2/3
-2/3
1
'
ii
ii
17-2/3"
106"
f
1
n-2/:
\
1
h
n-2/:
\
8-5/6',
^ i
J I_J
n
ii
B
H
FIGURE 7
Location of Sampling Points in the Inlet Duct
Granite City Steel
Granite City, Illinois
May 20-23, 1975
-------
-87-
port changes were required at the inlet for every port change
required at the outlet. Due to the rapid and efficient method
of port change at the inlet station, this contributed an insig-
nificant error into the measurement of the inlet particulate
concentration.
Ten sampling points were used to gather process samples.
These included the nine raw material hopper feeds and the main
conveyor, or strand (see Process Description). Samples collected
from these sources constituted all those process samples necessary
to characterize the feed materials as they affect the contaminants
influent to the scrubber.
Inlet scrubber water samples were obtained from the spray
manifold adjacent to the venturi throat section. The tapline on
this manifold is less than one foot long and about two inches in
diameter. Consequently, precipitated solids or scale in the tap-
line! were ;minimal.- Nonetheless, the tap was allowed to run free
for a sufficient time to purge the line of any residual materials
that might render the sample non-representative of the actual feed
water.
The outlet scrubbing liquor was sampled in the concrete-lined
drainage ditch which conducts all scrubber draining to the settling
pond. Scrubbing liquor samples were obtained by immersing a sample
bottle immediately below the exit of the pipe which exhausts
scrubbing liquor into the ditch before the scrubbing liquor was
able to mix with the stream in the ditch. Scrubbing liquor effluent
comprised the majority of all flow passing through the drainage
ditch. Other effluents which are subsequently mixed with the
scrubbing liquor effluent included scrubber feed water pump
overflow, and drainage from the settling hopper (normally closed
during scrubber operation).
-------
-88-
As indicated in the summary of visible emissions results, the
two observers who recorded opacities of stack and building emis-
sions were located as shown in Figure 2. These "sampling locations"
provided an unobstructed view of all visible emissions.
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-89-
V. SAMPLING AND ANALYTICAL PROCEDURES
Particulate Sampling and Analysis
Particulate sampling at the scrubber inlet duct and outlet
stack was conducted in accordance with the principles outlined in
EPA Method 5 (Federal Register, December 23, 1971, V. 36, No. 247.
Deviations from this method are noted below:
1. A glass cyclone was placed in the heated filter box to
remove some particulate material prior to filtration.
t
2. Calculation of the average stack gas velocity included
an averaging of the square roots of the product (rather
than the products of the square roots of the averages)
of velocity pressure and absolute stack temperature at
each of the traverse points.
3. Teflon bottles were used for acetone and distilled water
washes used to clean the probe and sampling trains.
4. For both particulate tests and fluoride tests, the heated
probe used for sampling at the outlet stack was glass-lined,
however, the heated probe used for sampling at the inlet
duct was 316 stainless steel (due to the required probe
length) .
5. The configuration was modified so that hydrocarbon samples
could be taken (see Figure 1). Volume of gas removed for
the hydrocarbon sample was added to the volume measured on
the dry gas meter to obtain the total stack gas sampled.
6. Additional thermocouples were added to record train
operation temperatures(see Figure 1).
-------
-90-
The analytical method for the determination of particulate in
accordance with Method 5 is expanded to include the determination
of aqueous and organic soluble fractions. Special precautions
are taken to prevent the settling of the particulate which is.
insoluble in the chloroform-ether extract layer (more dense than
the aqueous fraction) during analysis so that it will not be included
in the organic-soluble fraction catch weight. The details of this
portion of the analytical method are included in Appendix D.
Fluoride Sampling and Analysis
Gaseous and particulate fluoride sampling and analysis at the
scrubber inlet duct and outlet stack was conducted in accordance
with the principles outlined in the proposed EPA Method 13B
(Federal Register, October 23, 1974, V. 39, No. 206),entitled
"Determination of Total Fluoride Emissions From Stationary Sources
Specific Ion Electrode Method." Deviations from this method are
noted below:
1. The absorbing reagent in the impingers was 0. IN sodium
hydroxide, instead of distilled water.
2. A heated probe and cyclone were used in the train in con-
junction with a Whatman #1 filter. The filter was posi-
tioned between the probe and the first impinger.
3. The train was modified to include a modified Greenburg
Smith impinger with 100 ml of 0.1N sodium hydroxide, a
standard Greenburg-Smith impinger with 100 ml of 0.1N
sodium hydroxide, a modified Greenburg-Smith impinger as
a dry trap, a glass wool plug in the adjacent U-connector,
and a modified Greenburg-Smith impinger containing silica gel
-------
Gaseous Hydrocarbon Sampling and Analysis
Integrated samples of the gases in the scrubber inlet duct and
the outlet stack were obtained in accordance with the "Gaseous
Hydrocarbon Test Procedure" delineated in Appendix D. In brief,
non-condensible hydrocarbons were sampled from the particulate
sampling train using a leakless pump which exhausted into a Tedlar
bag (see Figure 1).
The integrated gaseous hydrocarbon samples were analyzed in the
field. A total gaseous hydrocarbon analysis was conducted from the
integrated bag sample using a flame ionization detector. All
hydrocarbons not condensed in the particulate train's impingers were
analyzed and reported as methane. In conjunction with this, a gas
chromatographic technique was employed to identify those hydrocarbons
(in the same integrated sample) within the range of C, through Cg.
Detailed analytical procedures, utilized in the field and in the
laboratory, are included in Appendix D.
Sulfur Oxides Sampling and Analysis
Sulfur dioxide sampling at the scrubber inlet duct and outlet
stack was conducted in accordance with the principles outlined in
EPA Method 6 (Federal Register, December 23, 1971, V. 36, No. 247.
Sulfur, dioxide samples were analyzed by EPA Method 6 with the
modification of passing an aliquot of the sample through an ion-
exchange column prior to titration to remove interfering cations
which may cause erroneously low results. The eluate from the
column was quantitatively transferred to a 125-ml Erlenmeyer flask
and isopropanol was added to yield a final solution of 80% isopropanol
for analys is.
-------
-92-
Carbon Monoxide Sampling and Analysis
Integrated samples of the gases in the scrubber inlet duct and
the outlet stack were acquired in accordance with EPA Method 3
(Federal Register, December 23, 1971, V. 36, No. 247). The percent
of carbon dioxide, oxygen, and carbon monoxide in the gas were
determined prior to each particulate and fluoride test to deter-
mine the molecular weight of the gas.
The grab samples were analyzed for carbon monoxide using the
standard procedure for Orsat operation. The second analytical
technique utilized a Fisher-Hamilton gas partitioner, Model 29
of the molecular sieve type. The unit is calibrated with Matheson
certified gas standards of the following concentrations of carbon
monoxide in N2'
540 ppm CO in N2,
5,042 ppm CO in N2.
The gas partitioner utilized a 6-1/2*ft.' x 1/2-inch column
packed with 42/60 molecular sieve 13X to separate the carbon
monoxide from other gaseous components. Th carbon monoxide was
then detected with a thermal conductivity detector kept at 70°F.
Five-milliliter injections were made using a gas-tight syringe
(Hamilton #1005 LT). The instrument was recalibrated every
morning by injecting a standard at least three times; standards
were also injected between samples to ensure that the instrument
was operating correctly.
The carbon monoxide peak heights of the samples were compared
to the average peak height of the carbon monoxide standards to
determine the concentration of carbon monoxide in the sample:
Sample's peak height
x (Concentration of Standard) =
Standard's peak height
Concentration of Sample
-------
-93-
Scrubber Water Sampling and Analysis
Scrubber vater samples were acquired at the sampling locations
specified previously in accordance with the document "Methods for
Analysis of Material Samples from Sintering Facilities," issued by
the Emission Measurement Branch of EPA to Clayton Environmental
Consultants prior to the beginning of this study. This document is
included in Appendix D.
Scrubber water samples were analyzed for pH, total suspended
solids, total dissolved solids, and fluoride content. The analytical
method for determination of pH was a glass electrode pH meter. The
device was linearized for a range of pH of 4 to 7 for acidic samples
and linearized separately for alkaline samples of a pH of 7 to 10
using the appropriate buffer. The pH measurements were made in the
laboratory.
The analytical procedure for the analysis of fluoride content
is identical to "that employed in EPA Method 13B. .
Process Material Sampling and Analysis
Bulk samples of process feed materials were acquired at the
sampling locations specified previously in accordance with the docu-
ment "Methods of Analysis of Material Samples from Sintering Facilities,'
issued by the Emissions Measurement Branch of EPA to Clayton Environ-
mental Consultants prior to the beginning of this study. This
document is included in Appendix D.
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-94-
As specified in the "Methods for Analysis of Material Samples
from Sintering Facilities," two methods were utilized for the pro-
cess bulk samples. These included ASTM Method D-271-70 for the
analysis of sulfur content in coke (this method requires determina-
tion of moisture) and ASTM Method D-395-70 for the determination of
sulfur in iron ore. Those process samples which were not entirely
composed of coke or coal were analyzed for sulfur utilizing ASTM
Method D-395-70.
Bulk samples were analyzed for fluoride content using the
analytical procedure delineated with EPA Method 13B.
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