Report No. 76-IOB-3
AIR POLLUTION
EMISSION TEST
O ! I 111 ^H EVELETH TACONITE
Eveleth, Minn.
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
-------
SOURCE TESTING STUDY
AT AN
IRON ORE BENEFICIATION FACILITY
EVELETH TACONITE COMPANY
EVELETH, MINNESOTA
REPORT NO. 76-IOB-3
TESTING CONDUCTED BY THE
EMISSION MEASUREMENT BRANCH
0 A Q P S
EPA
November 17 to 21, 1975
REPORT PREPARED
BY
ROBERT M. MARTIN
-------
TABLE OF CONTENTS
Page
I. INTRODUCTION 1
II. SUMMARY AND DISCUSSION OF RESULTS 3
Particulates
Visible Emissions
High Volume Sampling
Asbestos
so2
III. PROCESS DESCRIPTION-.AND OPERATION 16
IV. LOCATION OF SAMPLING PORTS - 28
V. SAMPLING AND ANALYTICAL PROCEDURES 36
Particulate
Asbestos
so2
VI. PARTICLE SIZING SUMMARY AND DISCUSSION OF RESULTS 37
FIGURES
25
1. Diagram of Crushing Operation
2. Diagram of Concentrator 26
3. Diagram of Pellet Plant 27
4. Diagram of Drying Operation and Venturi Scrubber ' 29
. 5. Location of Sampling Points, Inlet Point A 30
6. Location of Sampling Points, Outlet Point B 31
7. Modifications to Method 5 Sampling Train 32
8. Diagram of Ducon Scrubber System 33
9. Location of Sampling Points, Outlet Point D, and
Detail of Straightening Vane Installation 34
10. Location of Sampling Points, Inlet Point C 35
-------
TABLES
Page
I. Summary of Particulate and SCL Data 5
II. Computer Printout of Data English Inlet Point A 6
III. Computer Printout of Data Metric Inlet Point A 7
IV. Computer Printout of Data English Outlet Point B 8
V. Computer Printout of Data Metric Outlet Point B 9
VI. Computer Printout of Data English Inlet Point C 10
VII. Computer Printout of Data Metric Inlet Point C 11
VIII. Computer Printout of Data English Outlet Point D 12
IX. Computer Printout of Data Metric Outlet Point D 13
X. Plant Operating Data 22
XI. Summary of Particle Size Results 41
APPENDICES
APPENDIX A - Project Participants
APPENDIX B - Particulate Field Data Sheets
APPENDIX C - S02 Field Data Sheets
APPENDIX D - Particle Size Field Data
. APPENDIX E.- Visible Emissions Data Sheets
APPENDIX F - Sample Number Log
APPENDIX G - Laboratory Analysis Data Sheets
APPENDIX H - Miscellaneous Data Sheets - Preliminary
Traverse-Moisture Orsat, etc.
-------
I. INTRODUCTION
The Emission Measurement Branch of the Environmental Protection
Agency conducted a series of tests November 17-20, 1976, at the Eveleth
Taconite Company in order to obtain emission data from an iron ore
beneficiation plant. The purpose of the test was two-fold. First, to
determine if particulate or S0? emissions are sufficiently significant
to justify the development of a new source performance standard for this
industry, and, second, to determine if asbestos emissions pose a
hazardous pollutant problem.
The sources of interest were the grate discharge end and the main
waste gas stream of the grate-kiln type pelletizing furnaceboth of which
were controlled by wet scrubbers.
The emissions of interest were particulate mass and asbestos in the
grate discharge end emissions and particulate mass, asbestos, S0?, and
particle size in the waste gas stream. Vixible emission readings were
attempted but were abandoned due to adverse weather conditions. High
volume sampling was also attempted using the Rader* automatic sampling
device but was unsuccessful due to high moisture and low ambient temperatures,
This report presents the particulate and S0? results from the test.
Recent preliminary electron microscope analyses of testings samples from
Eveleth did not indicate the presence of asbestos. Theoretically, the
tailing samples should have a higher percentage of asbestos than the ore
or the iron concentrate (if asbestos is present at all) because of the
*Mention of trade names or commercial products in this publication does
not constitute endorsement or recommendation for use by EPA.
-------
beneficiation techniques utilized at iron ore plants e.g. magnetic and
gravity separation. Thus, the Agency currently does not plan to
analyze the Eveleth emissions from asbestos content.
-------
II. SUMMARY AND DISCUSSION OF RESULTS
Particulate Results
Table I summarizes the results of particulate mass and SO,, emissions
from the two sources sampled.
(Venturi Scrubber (Points A & B))
The sampling was conducted according to Method 5 with the substitution
of mi Hi pore filters rather than the usual glass fiber filters. The
millipores were used so that subsequent asbestos analysis could be performed.
Due to construction material of the millipore filters, sample box temper-
atures were maintained below 200°F. Stainless steel probes were used on
the inlets and glass-lined probes were used on the outlets.
On the inlet of the waste gas scrubber (Point A) modifications of
the Method 5 train were required due to the unusual duct configuration.
The filter was attached to the probe at a 75 angle and enclosed in a
protective box. The filter was then attached to the impingers by means
of a flexible teflon tube (Figure 4). This created problems on the first
run as the impinger box was accidently pulled over causing it to fall
and break. Consequently this run was abondoned.
In the data on Point B, Run 1 is based on saturation at the stack
temperature of 127°F. The other two runs are based on actual moisture
collected. The average outlet concentration of the Venturi Scrubber
(Point B) is .0852 G/SCF versus 2.1675 on the inlet (Point A) indicating
an efficiency 96.1 percent of the control device.
(Ducon Scrubber (Points C & D))
-------
A preliminary traverse on the outlet to the Ducon Scrubber
(Point D) indicated extreme cyclonic flow. Straightening vanes were
installed and the cyclonic flow was eliminated.
No other problems occurred and the sampling on these points
proceeded uneventfully.
The data on the Ducon Scrubber indicated an average outlet
concentration of .00514 G/SCF and inlet concentration of 3.5561 G/SCF
indicating an efficiency of 99.85 percent for the Ducon Scrubber.
Tables II thru IX shows data printouts for individual points.
Figures 1 thru 7 illustrate the sampling points and details of the
individual locations.
-------
TABLE 1
SUMMARY OF PARTICULATE AND S02 DATA
RUM NO.
1 A
1 n
2A
3A
AVG
IB
2B
3B
AVG
1C
2C
3C
AVG
ID
2D
3D
AVG
STACK
TEMP °F
207
251
229
127
125
137
130
193
190
177
187
78
73
68
73
STACK FLOW
SCFM
282,249
300,825
291,537
273»044
273,627
278,880
275,184
13,59.3
1 3,552
13,523
13,556
13,254
13;i97
13,149
13,200
% I
120.1
104.8
112.4
103.0
107.8
109.8
106.9
113.8
107.3
106.6
109.2
99.4
97.8
100.4
99.2
LOADING FRONT
G/SCF
2.7183
1.6166
2.1675
0.05384
0. 11010
0.09163
0.08519
4.0868
3.3329
3.2587
3.5561
0.00734
0.00479
0.00329
0.00514
LOADING TOTAL
G/SCF
2.7195
1.6194
2.1695
0.05584
0.11079
0.09198
0.08620
4.0872
3.3230
3.2590
3.5564
0.00751
0.00531
0.00355
0.00546
SOo
PPM
Ifi ?Q
10.04
9.56
11.96
< 0.23
2.67
15.29
6.06
**
_ _
*Sample Lost
**No S02 requested
-------
TABLE II
Point A - Dryer -
PANICULATE S ' 1 M ' i A 3
p, p c; f 3 i D T , 0 r^
_D A T E_ £LE_ Ril U
sjf A r K' i_^ s- ft
MF'i II '-IF OF RUN
. _ A V G 04 T F. f C F P 1 = S "i VI P
VOl n^Y GAS~MFT::?> C 0 M D'
A V G "AS M F T ~ R T - M o
VO!, D3Y GAS-'; TO C '.)'> 0
TO ' A 1. H 7 1 C J I ' P C T~ o
V 0 1 H 7 n / A 3 .1 ? - S T D COMD
P F R C - ^ T M 0 T S f 1 1 .} H T Y VOL
M 0 I F F 94 C T T 0 M n i Y GAS '
P F '? C r- M T r c) ? R Y VOL, 0 r< Y
P F R C "-" N T 0 7 R Y VOL. n 3 Y '
P F R C c N T CO RY VII, n-RY
P F R C r M T ' ? 3 Y VOl. DRY '
M 0 1. * " ' 1 1 A 3 ;j T - H 3 Y S T K GAS
vi 0 L ': C ! 1 1 A R J T -, S r X G A S
A V r, -, T A C K T F M P <= * $ T 1) -1 c
M F T S A M ° 1. T V G ' 0 T IT S
STACK P R F S : !J < F . A R S 0 1 :J T F
AVG STACK K A S VFLOCTTY '
STK. PIOJ-7ATF. 0 "! Y , S TO CN
AC VIM. STACK FLO'-JRAFF
PF JC--MT T SOKT MF rr c
P A R T T C 1 1 1 . A T F U T - P A 9 T I A 1 ..
o A R T T C 1 1 1 A T F J f _ '' 0 '" A I
: PFKC_TM?TNGF9 CATCH
PART . i o An-a n. . srn CM
P A R T _. 1 0 A n - T i' I. , S r r> C M
DART, LOAD-PTL.Srn p ,\) 3
PART, i. o A n - T L , s r n c 'J si
PART, !OAn~?TI..SrK CM
PART, i o 4 n - r ! L . s r K c ^
o A R T T C F '-1 T S - o A ? T T ^ L
P A R T T C F M T S - T 0 T A L
PART F^TS/jr.P'^n FH PTL
PART F M i s / w r. o ? n F n T n
P F R C N T F V C c S : A T }
Inlet -
Y ' IH
LJJUJLS -
FT?
MIN
I N '. H G
T "i . H ? 0
HCF
n F G '. F
DSCF
Ml.
SCF
n F G . F
T M ', H G
0 S C F M
A C FM
MG
MG
GR /nSCF
r, .? / o s c F
1 ? Y CO?
1 ? °X CO?
GR / ACF
G R / A C F
I R /HR
I R /H3
i R / r o t
I R /TON
Venturi Scrubber
!GLI3H TUTS
1
11^18-^7.5 1
1_DJ> 0.^
9A. 0
'.A70.
4 /. . 7 7
101.9
40 . 74
1 8S . 0
17.7
1 .4
. o
79 . 0
?9 .01
77 .OA
?07 , 0
1
?7.9?
7S . A04
? R ? ^ 4 9 .
4 A ? A 9 4 .
1 ?0 . 1
7190.70
.0
? . 7 1 9 4 7
7 ^ . "^ 0 1 ^ 7 1
1 . AS7^0
AS7A . S'A
AS79 . ?1
+ Ir > V -V * -> ', V ',- if
* * - ': V 't * * V V >
1 SAO . S
i
i
i'i
t
? AVER.A.GE - |
1-1S-7S ^
10?'QOJ
9 A . 0
i
.600 ... . . . ......
4 1 . A S |
101.9 j
1 0 ? . 0 ':
'U ^ ^
1 I . ^
1.4
19 .A
'.0
79 . 0
?9 . 01
?7 .7A
? S 1 . 0
1
77.70
80. ^ S ? 77.9A8
^.0 ..')«?_ 5.. _?91S\7, .. __
4 9 1 A ^ 1 . 4 7 7 1 A ^ .
104.8 117.4
"* 9 7 / , A 0 S ' 8 4 . 1 S
^ 9 S 4 . S 0 S^89.0S
? . -1
1 , A 1 A , ? ? , 1 A 7 S 0
1.A194^ 7.1A94S
7 . 8 S A 7 R 18.S7^S7
"*., 8 'i 0 « 1 1 8 , S 9 S 7 9
. 9 « '. A 4 1 . 7 P ' 9 7
.9 )0"^S 1 . ^741 A
41 A8 . AO S7i7? . S7;
417S.7? S'!;7/.47
> -' :> V ' -V '.- + -r '- r V * V.- r
V > -> rV Sr - V V ' ;!r V V > * -.',-
1 SAO , S 1 SAO .«?
*
PI. 4 NT : FV^I. r rn rACO'n r'F
i o c A T T i v : F v - 1 : r H , :-i r >j
0 0 F R A T 0 J : F M R
-------
TABLE III
JPo.ijlt..A.j^_pryer - Inlet - Venturi. Scrubber.__
0 A R T T C 1 1 I A f F
i A rt Y
IF r u c
r s
DF
n a JF
STAC
fJFT
v n i
A V/G
vni
TO VA
vni
^FR C
M n i c
PFRC
UFR C
S
M
0
0
D
1
H
=
'.:
r
n.
i
?
A
R
)
F
N
R
£
<}
T
Y
S
Y
H
T
j
T
T
P c 9 C " '-J T
T PT
_S.;i
7F "<
F 0
M C
l: ! C
G A
ME
G 4
? 1
V A
MQ
4JLL
CO
0?
CO
__ L2.
T
'J
F
S
T
C
p
I
T
>
ilM
--
r-
i
J
S
"1
R ' I
° :)
MF
vr
1. 1.
Til
^
T
r
n
F
>
-II >
?; n
': ^
-
)
c
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C'1V!
CT^
rn
(F 8
n )v.
R Y V/ T L
fULJ/jlL.-
H Y V 0 1 ,
KY vni ,
n
c
GL
D
UMITS 1 ? AVFRAGF
M? 9 . 4 7 A 9.47A
M T N 9 A . 0 9 A . 0
I'.HG 7 * ? '. 0 7 7V?. O7!
'IP. -1 ; . H ? 0 1 7 . n 1 R 1 S . ? 4 0
o M n n M * 1 . ? 7 1 . 1 R
F) F G . C V* . "* VR . R
i n 'i '-I T; ' 1.1^ 1.07
ML 1RS.O 1 n p o
T-jr) 'vu ?s '14
VOL 17.7 i i . 3
AS R?^- R"!7
m Y ' 19A 19A - ,
n?Y - '.o '. o
n '* Y . . . von _ 79 n .......
JAQ L.E£HLA.lL._J.T_-^S.rJ!:__G-AJ_
AVG STACK TFMP-RATiHF
MFT
r,TAC< PRF=; 1HF. AR^OL'JTF
.AY£_^XA.CJ84., 1_5,
S " R 9 . 0 S
PA
DA
PA
PA
PA
DA
D A
W A
P A
DA
RT,
RT.
RT.
RT .
RF.
^T,
L040
LOAD
1 . 0 A n
I.OAO
i o A n
H T T C F M T
RI_l.C_V>JJ.
R T F M T S /
R T F M T S /
-PT
_D r
-T >'
-PT
-, r r
. , s r n c
. , s r n c
. . s T o c
. i s F n c
. . S F K C
. ,STK C
S-PARTTIL.
I F PRO F 0
'. J T PRO F 0
N
M
»)
N
N
P
T
M G / N M V
M G / '1 M <
% 1 ? °/: co?
M G / A '-n
M G / A M ^
K G / H R
k' G / H R
T L K G / M r 0 N
"I KR/Mr.QN
A ? ? 0 . A 7
A??7;,, 1 R
s von . os
s v3; 4 1 . * s
^ 7 9 ? . S 4
^ 7 9 4 '. 0 7
_? 9 R_4 .^ 1
* + <- '< * -A >V -'.- '.-
* A ' ': ~v * * .'(..,t
^AP^
V70S
^1709
'71 7 A4
?PA^
1 R90
-.V V * * * .V
1 -f ,>.*.**-
.4S' 49AO.
, R A 49 A4 .
. S 4 4 ? S
^^r. A?S
. VR VO
.3.1 ^0
. R 3 ? 4
. -L-I ? 4
v -.- ..- * * > v :,
_V ,V V -V * * -.c .:
14.
ii.
?7 .
3IL.
^A.
15.
V * -V
_t_i_V
OA
79
OS
4A
19
9R
?P
V V
PFRCFNT -
ATR
1 SAO. S
1 s A n . s
1 S A 0 . S
-------
.TABLE IV
Point. B - Outlet - Dryer -
P ARTICULATE SUM-IAR
n F S C R I P.TJ 0 N
nATEOFRUN''
STACK A 9 F 4
NFT TIMF OF RUN
R A R 0 M F T 3 T 0 P ? F S ' 1 13 F
AVG ORIFICF P .? F 3 DROP
\/DI n '} Y KAS-MFT-.? rtl.Mn
AVG G A S M F T - R T F M P
\/oi n 9 Y GASi-ivrn r o N n
TOTAL H P 0 C 0 L '. F C T F n
u n i WOT \/ a D 1 !5 e T n r r\ M n
P E R C F N T MOISTURE R Y V 0 L
M n i n cOArTTIN n " v ft AC
PERCCNT CO? RY VOL. n R Y
p p p r : M T no n v y n i rv T y
"PERCENT co RY VOL. DRY
opprcMT VJ? R v VOI. DRY '
MOLFCULAR W T ~ TH Y STK GAS
M 01 Prill A R 'J T - S r ^ GAS
AVG STACK FEMPFRATIHE
NFT S A M P 1 I M G ^ 0 T N T S
STACK P R F S .; 1 n F . ABSOLUTE
AVG STACK GAS VFIOCTTY '
STK F L 0 vJ R A T F , D R Y . S T D C N
ACTUAI STACK FI.OWRATF
P F R C F N T I S 0 K I \l F T I C
P A R T I C U I 4TF UP- PARTIAL
PARTICULATF WT~ TOTAL
PFRC T M D T N_G F R C A T r: H
PART. L 0 A D --= P T L . S T n C N
PART lOAO-ri'i.STn TN
Y I M F ! G
DAI T S
FTP
WIN
LN HG
I * '. H 7 0
n c F
n E G '. F
n s c F
ML
c r c
0 E G '. F
I N . H G
F.PS
0 S C F M
ACFM
MG
MG
GR /nSCF
G s / n s r. F
PART'. LOA n-PTL.STn CN 3 '\?°t. COP
PAST lOAn-Ti'Lf^rn TNJ ^ 19V rm
PART'. LOAO-PTL.STK CN
D A s T ' i o A n -JT ; i , s r * r N
PARTIC FMIS-PA3TIAL
PARTTC CM T S Tn r A I
PART FMIS/UT PRO FD PTL
DAQJ cyIS''JT 3 ' n en -[-PL
P F R C F M T F X-C F S ", AIR
. G? /ACF
G R / A C F
I R /HR
L R / H R
I B /TON
Venturi Scrubber
L I 5 H UNITS
1
11..-.1R.-75
7 a . S ? 8 -
9 A'. 0
? 8 a 1
'.79A
U 7 0 S -
79 . 1
A A A °
A .-\
. w ' '
1 V. 8
0 Z O
1 .9
101
79 0
? 9 '. 0 7
0 7 S A
1 ?7 . 0
1
P 8 . 8 7
77 . 1 7 A
P 7 7 0 A A .
. 10^.0
1 s A , o n
1 A1 .80
'. 0 S 3 8 A
0 ^ sa A
. ^ A 0 0 S
, 0 A 0 A 0
o '' 1 9 0
1 ? A . 0 1
* * * 4 -V -V i -V -.V *
1 087 .7
?
1-ls-.lS--.75
7.8 . S3 R_
9 (S '. 0
"pa H 1
1 . 1 P 0
A 9 19
79 . A
A A AS
1 AA.O
A O 0
1 ? .9
R 7 1
1,7
10 X
'. n
79 0
?9 .04
77 A ?
1 PS. 0-
1
P8 .87
7 A . p9S
P77AP7 .
_ 33.9.5 2.0. ..._
107.8
^ ^ "< . s o
33S. AO
A
.11010
11079
.7771 S
7 8 ? 0 A
, 0 8 T; 7 S
0 8 A ? 7
PS8.P?
P-S9 -84
* -.V -V < -i > * -ft >
1 PAO .A
^ AVERAGE
-70 c ? o
9A. 0
°8 AO
.880
SO A 7
71 ..0
A P A 0
17S . 0
o ;> n
HI . /^ / . - -
1 4 . A
o ^ /
1.8
i O *»
'.0
7 O /^
? 9 . 0 A
77 ' A A
137.0
1
?8 . AA
ai . s ^a 78 . ^ vA
? 7 8 S " 0 , ? 7 S 1 8 A .
109.8 1 OA.9
__PR.8 . 00 pS9 ... 17
P89.10 PAP. 17
'A 1-. -S.
. 0 9 1 A 3 . 0 8 S 1 9
OO1Q8 08APO-
'. A 1 0 8 A .S7AO?
A1 3 1 9 S8 ~> A^
'. OAAA7 '. OA3SA
OAA7? OAA^O-
P19.03 P01.09
P19 87 °03 A7-
********************
11S9.A 11AP..S
.
PLANT: F v = L - T H T A c o N T T F
I 0 C A T I 0 N : F V P L " T H . M T N i '.
8
.
t
-------
TABLE V
Point B
PARTIC ULATF. SIIM'-1A
r» » T C C\ C ' D 1 1 «.|
STACK A R F '^
N F T f I M F OF R \ 1 N ' '
i^AROMFTRIP P "? F S " ' ) A' F
AVG ORIFICF PRFS D 1 0 P
v n L n P Y r, a s -r M F T ^ ^ f 0 fJ D
AVG HAS MFTPR TEMP
v 0 I n R Y G a s - 3 T n r i/j n
TOTAL H ? 0 C 0 L !.. F C T F n
VOI H70 VAPOR-STD C 0 N D
PFRCFMT MO IS TURF RY VOL
MOLF FRACTION. .DRY GAS
. PFRCFNT CO? RY VOL, DRY
_.. PFRCFNT 0? RY VOI. DRY '
PFRCFMT CO RY VOL, DRY
PFRCFMT ''17 RY VOI. DRY '
M 0 L F C U L A H U T * D R Y ' S T K GAS
M n L P C 1 1 1 A R m T -r-S- f K GAS'
AVG STACK FFMPFRAT'nF
- N P T S A M P L I 1 G P 0 T -M T S
STACK PRESSURE, ARSOL'JTF.
STK FLOUR ATE, O.RY.STO CN
A-C-T-I IAI STACK F I Q 'J ? A T F
PFRCFNT I S 0 K T N E T I C
PAl°TICULATF U--F =-P A R T I A L
P ARTICULATE WF~ TOTAL
PART, LOAD«.OTL,SFD CN
P i R T L<~>An-TrL'Srn r M
PART. I..OAD-DFL,SFD CN si
PART., i OAD~T i L . s ro CM a
PART. LOAD-PTL »S'TK CN
PART. IOAD-TTL.SFK CN
PARTIC F MIS -PARTIAL
PARTIC P 'ITS-TOTAL'
DART FMIS/WT °RD FD PTL
P 4 R T F M T S / J r P R D FT T H
PERCFNT FXCFS.I AIR
. .. . i_i : ? o : 5 A
- Outlet
,R Y T N
1 1 M T T S
M I M
M ' " H G
MM. H?0
D F G '. C
n >J M ^
ML
'-i M T,
'
D E G . C
M ! '. H G
""1 / 2
D ' -J M 7 / M
A M 7 / M
MG
MG
M G / N -v| 7
1 ?5C CO?
1 7 V, CO?
M G / A -1 7
MGJ A.±3_
K G / H R
K G / H R
K G / M T 0 N
K G / M T 0 N
- Dryer - Venturi
METRIC UNITS
1 *l -1 R 7- ^ 1
7 797
' r. '
94.0
771 7 7
? 0 . ? 1 R
^ O * r
1 ? /.
nn
19,1
79.0
79.07
07 5/1
5? '. R
1
^ 7 COT
7777.
1 n *> o R
1 r z n ,-\
1 4 1 . R 0
7 A
177.71
1^7 79
7 7 R , 1 4
sn7 . n9
97.45
9 R 'f R q
57 . 1 A
5 9 '. ? R
* + * it x * -> .V * 5V -V
* * TV * * -V * * 'r -1- -V
1 OR7 .7
Scrubber
->
7 707
?« . A4R
1 79
1 7?
144.0
,70
.R71
1 .7
19 7
79 0
79.04
777. 70
07 o c r.
7 7 4 R .
1 07 .R
775,40
i.
7 5 1 '. 9 4
757 57
177R.40
.1.7..R.9 ,^0
191 .44
1.9 7. , R S
117.17
1 17. R4
* * v -.v * * -v -v
> -V * -V * -V -V >
1.740. /^
7 AVFRAGF
.
94.0
7 ? 4 A. A.
77.75?
71 .7
1 77
175.0
.77 ; ' .
14.4
.R5A
1 .R
1 9 7
'.0
79 0
7 7 A A
5R .7
O/. OC-7 0-7 O-77
7R97. 779? .
1 n s ? n 1 n A ^ T
109.8 104.9
o o o _ n n ._. o c n 1 7
?R9. 1 0 74? .17
A 1 S
709.48 194.94
-7 1-0. _A R - 197 ?-7-. -
1 797 .R3 1 71 R,'1 5
157.10 145.40
1 57.49 1 A7 . 1 4
99.75 91 .71
99 ,77 9? ,79
* * * * * * * -* :V * * * :'t -V *****
-t * ft ;V .V > * * * Vt -V -T -t V * * * A :'r
1 1 59.4 1147.5
-------
TABLE VI
Point C - Inlet - Kiln - Ducon Scrubber
PARTICULAR SUMMARY IN FNG'LISH UNITS
..OF.S..C R T P T I 0 N
UNITS
AVER A_G E.
HATF OF 9UN
NFT TIMF OF RUN
_B.A Jlfl .MJLT. ?.JJL_P_< £ SJ
AVG ORIFICE P3F<5
_V_QJ _ D ft.Y... JG AS.*. M. E T _
AVG GAR M E T F. R T =
_y_QJ _ D.3Y G.A-S
TOTAL
_y_QJ
H ? 0
PFRCF.NT
C 0 L I. E C
_aS - 5.T_
MOIRPUU
PERCENT CO? RY V
P F R C F N T ._ 0 ? BY V 0
P F R C F N T CO R V v ')
P F R C F N T
MOLECULAR 'JT^.0:^
_MOL_F.C' I L A R JT^Sr
R'TAC'K"
_____LTJ>_
iMIN
tJ^JE__ I.N ..H.G .
HRQP IN.H70
5_CD.ND_. D.C.F
IP 0 E G . F
.C.dND D.S-CLE
FFO ML
g C UN D. S JC.F
R Y VOL
LfiflLS
0 L , (1 R Y
L , DRY '
_JL..S O.n._
A 4 . 0
-_?R...S.9..
1.040
_.?;_9.. 3.1....
8S. S
_JXA..S.8 ...
14.7
7.0 ...
,1.9
98.1_._
,n
2J_, fi.._
',0
.7_9-.A.
AVG RTACK f E M P F
Jj_FJ S A M P_L I N G _^ 0_
RTACK P R E S : U .< E ,
AVG RTACK GAS
R T K F L 0 U R A T F .
ACTUAL STACK FL
P F R C F N T I S 0 K 1 '! F
JJLBJ-UCIJJL.A-r F W.
PARTICULAFF WT---
JLEJLC.-IJJ1J1 I N G E-RC.
PART. LOAO-PTL.
1 s r < GAS
: GAS
1 A r u :^ F
NTS
78.8 4
78.^4
0 E G . F 1 9 T> . 0
1
78,84
78.49
190.0
?8
78
17'
_?.8 ...S9 .
1.100
..7.7 . ?7._.
90 . S.
74,0
1...1 4
.3,7
._ JAR.-
.O
__2JL..Q
..0
.. fl.
84
49
.0
_.1_
?8 . ^7
OTAL
T C H
rD CN
GR/OSCF
G.5L/J).S C
CO?
PART. LOAD^PTL,S
PARTIC FMIR-PA--JTIAL
A RJ.I C ._F_M_T_S -1.0.1 A..L
,. 0 7 8 S 4
fl 7 8 r? 3
47 A. 1 A
4.7 A . "
13SS?.
._1.81.4S_...
1 07 . 3
7.4-1.7,, Jt
7417.70
. 0 _' _
3 , 3 7 7 8 S
3-. .3?..? 9 8
* * * .V ;V * -.V * * *
A.*--**Jt.iV.A.*..*..A
? .4804?
?.. 4805?
3 8 S . 9 9
JS-..5 0 I
A4.0
'1 . 0 ? 0
__37. .-78
9S.O
3 4..1.0.
17.4
S.9..
. 1 -7
...9.R3-
,0
7JL..O..
. o
.7-9 . 0
4
>*..
0
_1_
78.3?
_83..A98
1 3 S 7 \.
_17_47_1.._
1 OA. A
771 A .^O
.'. 0-
3.7S871
i 1.7 8 3
1 09
8114.
T . SSA
4...
.7
S7
-..0
1 3
> 'V > * * * :'< * -V * * * * -.V * *
?.
_.?.
41
DART
PART
PF.RC
FM
FM
FNT
TS
TR
F
/UT 3
/UT P
X C F S ;
PO Fn
Rn FH
A I R
T TL
LB
I R
/TON
/TON
+ **-* >
* * -V -V *
* * * -V *
V ******
* .V * * -V -V
******
* -.v > * * -v *
V * .V * -i > *
****** -.v
* -V *
If jy .y
> .v *
7 .. S 7 0 8 7
?.. S7.1 08
377.73 413.?9
_377_'.76. --413. .32.
* * ***-*********** >v
* * > A > -^ » > * jr_*_*. \ * *> *_
*>***>****** V * * * *
PLANT: FVFLCTH FACONITF
10
-------
TABLE VII
Point C -
P A R T I C ' 1 L A f F S '.'J M !
flFSCRTPTTON
DATF OF RUN
STACK ARFA
NFT TIME OF RUM
RAROMFT3IC P^FS'-'URF
AVG 0 R I F T C F PIES DlOP
VOL DRY GAS-MFTr-'S COND
AVG GAS METFR TFMP
VOL DRY G A S - " T D C 0 N 0
TOTAL H ? 0 COLLFCTF.n
VOL H?0 VAPOR-STD COND
PERCENT ^ o i s T 1 1 a F R Y VOL
MOLF FRACTION ORY GAS
PERCENT co? RY VOL. DRY
PFRTENIT 0? RY VOI. DRY
i PERCENT CO R Y VOL, n R Y
PERCENT M ? R Y VOL. n R Y
MOLECULAR WT-DRY STK GA
MOIFCIIIAR U T » S P K GAS '
AVG STACK T F M P F .? A T U '? F
MFT S AMPl' T.'-J £.:__;> 0 T -JTS
STACK 0RES ^HF .' ARSOl'J.T
AVG STACK GAS VFIOCITY
STK FLO '.-/RATE, r> 3 Y , S T 0 C
ACTIKL STACK Fl.OWR.ATF
PERCENT TSOKINETTC
PARTICULATF U T » P A R T I A L
P A R T I C ! 1 L A T E U T - V 0 T A L
PERC IMPINGE R CATCH
PART. LOAD-PTL.STn C N
PART, lOAO-TTL.STn CN
PART. LOAD.PTL.Sro CN a
PART'. L o A n - T " L , s r D c v 3
PART. LOAD-PTl. ,STK CN
PART . I.OAD-T fL . S T K CN
PARTIC E^IS-PARTIAL
PARTIC FMTS~TOTAL
PART FMIS/WT PRO FO ° T L
DART F M T '$ / u r PRO F n TCI
PERCENT EXCESS AIR
Inlet - Kiln
A 9 Y IN ME
UNITS
M?
MIN
M ! '. H G '
M :-] . H 7 0
0 E G . C
ML
S
D E G ', C
E M <\ . H G
J4/S
A M 3 / .-!
MG
MG
M G / N M 3
M G / N 'A T,
1 7 X CO?
1 9f, CO?
M G / A ;-1 T,
M G / A -1 3
KG /H?
K G / H R
K G / M T 0 N
KG /MTON
- Ducon Scrubber
TRIG UNITS
1
' 3?S
A4 . 0
7?A . 1 9
1.11
?9 .7
1 . 04
14.7
.0?
1 .9
'.981
n
?1 , n
. 0
790
? 8 . « 4
89.4
1
7 1 9 . 3 '<
?A 1 7A
113.8
97flR, "0
9709.70
.0
9 3 S ? .. 1 R
93S3 . OS
******>*>*
* * > ' 'r * * * * *
7 0 4 4 . 8 A
7 0 4 S , S ?
? 1 S . 9 8
' ? 1 A '. 0 0
+ * * vr * i * \ * *
*_*. *_i>Jeji_.'f A *
**********
'
1 1 -.? 0 - 7 S -
A4. 0
7?A. 1 9
?7 .9AO
1,0^
.97
?4, 0
*'?
? 1 n
.0
79 o
? 8 . 8 4
?R.49.-._
87 .8
719.33
Sit'
107.3-
7417 .40
7417 .70
'.0
7*03.94
7 A 0 i- , ? 4
***** :V .V * * *
v * * * * :< ,v -.v * *
SA7A^A
17S. 08
17S . 09
* * < * * * * * * *
**********
'. ^ ? S '
A4 . 0
?S.908
1 . OA
'.97
'. 0?
.1.7
.983
?1 . 0
79 0
? 8 . R 4
80. A
1
7 1 9 . 3 7-
A9S.
1 0 A . A
7? 1 S . 7 0
7?1 A.T;O
.0
74S7 .1 A
7 4 S 7 I 7 8
AV.E.RA.G.E
? S . 9 S7
384.
SO A .
1 09. ? '
^113 97
81 1 4. S7
r 0 '
^ 81 37. 7 A
81 38 .3A
* * * ,v * ********** -,v * *
* -V * -V * * * * A V * * * * * * i- .V
S 7 A. 8 . 7 1
S7A9 . 19
171 .34
171 '. 3 S
* * * * ;.- * * -v * *
-^^j!^k.A-±A^.:fJf.
**********
(«, 1 * 3 . ? 4
A1 AT; . A 9
187.47
....1.87.48 .
* * ******
*_ * * -V V * ;V -y
********
11
-------
TABLE VIII
Point D - Outlet - Kiln Ducon Scrubber
PARTICULATF SUMMARY 'IN ENGLISH UNITS
DESCRIPTION UNITS 1 ? 3 AVERAGE
DATE
STAC
NET
RARO
AVG
VOI.
AVG
VOL
TOTA
VOL
PFRC
MOLF
PFRC
PERC
PFRC
PFRC
MOLF
MOLF
AVG
NET
STAC
AVG
STK
ACTII
PFRC
PART
PART
PFRC
PART
PART
PART
PART
PART
PART
PART
PART
DART
PART
PFRC
OF RUN
K AREA
TIME OF RUN
M E T ,U C P R F S -ilJ ?
OR I F I CF PRFS D
DRY GAS-MFTFR
G A S M F T F R T F M P
F
3
C
DRY G A S - " T D CON
L H P 0 COLIFCTF.D
H ? 0 VAPOR-STD
FNT MOISriHF R
F R A C T 1.0 N D ;< Y
PNT CO? RY VOL.
F N T 0 ? R Y VOL,
FNT CO RY VOL,
FNT M 7 BY VOL,
CULAR UT-O'^Y S
C
Y
G
f
T
CilLAR WT^STK GA
STACK TFM&FRA TU
SAMPLING POINT
K PRFSSIHP, AR
STACK GAS V F. L 0
F L 0 M R A T F . m Y ,
<\ L STACK F L 0 W R
P N T T S 0 K I N F T I C
ICULATF UFvPAR
TCULATF W T -t T 0 r
. IMPINGE R CATC
'. LOAD-PTL.SFO
. LOAn-Tri.Srn
. L 0 A D = P T L , S T D
t I.OAO-T n_ , s rn
. lOAD^Ti'L.STK
1C FMI'S-PARTIA
1C F M I S -TOTAL
F M I S / U T p 3 D f.
F M I S / W T P 3 D F
ENT FXCFS i A I R
S
S
C
s
A
T
A
H
L
D
n
0
p
ONO
D
OND
VOL
A
n
n
D
K
s
0
S
R / '
RY '
GAS
P
L'lTF
I TY
TO C N
T
I
L
C
C
C
C
C
C
E
AL
N
N
N n)
ft 1 *~1
M nl
N
N
PTL
T f L
F
M
IN .
I N '. H
D
DFG
DS
S
T
I
H
C
C
M
C
OEG
IN
DS
A
GR /D
GR /n
1 75C
1 ?%
GR /
GR /
LB
LR
IB /
LB /
._*»
F
C
C
S
S
C
C
A
7f
?
N
G
0
F
F
F
L .
F
'. F
HG
PS
FM
FM.
MG
MG
CF
CF
0?
0?
CF
CF
HR
/HR
TON
TON
11-70-7S
4.909
64.0
78. S9
7 .800
SS . 19
60.0
S4. 1 ^
. o
.no
.9S7
?0 .7
'. n
79 . 0
7 8 . 8 *
78. M
78 . 0
1
?. 8 . 1 9
S 0 . 6 8 S
1 * ? S 4 '.
99 . 4
7 S . 8 0
? 6 . 4 0
. 007^4
, o n 7 s 1
-, ^ 0 0 4 S
.00667
.RS
*** + *^-**-A
*>*->** V \ *
1^?69'.?
11-70,75
4.909
64, 0
?8 . S9
? .700
SS. 0
. o
. 00
1.0
.990
. S
.0
79. 0
? S . 9 0
? 8 . 8 0
7^.0'
1
?8 . 1 0
4 8 . 4 S 4
1 4 ? 7 0 .
97.8
1 6 . S 0
. _1 R , ^ n
9.8
.00479
. 0 n S T, 1
_, 0 0 4 4 ^
.00491
.₯ -A * * * -,V -V -V * -V
* -> * * * -\ :, -,v > *
S7S8 .4*
11.70,75
4.909
64. 0
?8.SO
? . 8 0 0
S4.98
ss.o
S4.P7
.0
.00
4.7
'. 0
?1 . 0
.0
79.0
? 8 . 8 4
? 8 . V?
68.0
1
?.8. 10
49.699
.1.3.149..
1 46^7 .
100.4
11.60
' nn^p
* * -.V * * -V : -, -.V
* * + * -;.- * -,v > *
.00^18
.40
* * * * -v > * -v *
A- > -V ->*** + >
* A V ***** -V
49.61/5
1 3?00..
1461?.
99.7
17 .97
19.07
6.4
. 0 0 S 1 4
.OOS46
,V * * * -V -> * -V * *
'.0046^
.0049?
. S8
.6?
* -.v -> * -v * * > -v *
-V * * * * -V -> * V vt
PLANT: FVFL-TH TACONITF
LOCATION: FVC|_RTH .
12
-------
TABLE IX
Poi
P ARTICULATE S'JMM
HFSCRIPTTON
HATE OF RUN
STACK ARFA
NET TIME OF RUN
RARO METRIC ^ESJIHE
AVG ORIFICE P ^ ff S 0 * 0 P
VOL DRY GAS-METER CO.NO
AVG GAS MET PR TEMP
VOL DRY GAS-'lTD COND
TOTAL H?0 C D L * E C T F 0
VOL H?0 VAPOR-STD COND
PERCENT MOISTURE 3Y VOL
MOLE FRACTION. OR Y GAS
PERCENT CO? BY VOL, DRY
PERCl-NT 0? RY VOL. DRY
PERCENT CO RY VOL. T)r!Y
P F R C F N T '! ? BY VOL. 0 R Y
MOLECULAR WT-?DRY STK GA
MOLECULAR U T * S T K GAS
AVG STACK TEMPERATURE.
NET S A M P L I'M G POINTS
STACK PRES -JURE . ABSOLUT
AVG STACK GAS. VELOCITY
STK FLOW RATE, O^Y.STD C
ACTUAL STACK FLOW RATE
PERCENT T S 0 K I N E T I C
' DARTTCULATE WT~PARTIAL
PARTICIPATE u T*. TOTAL
'PERC IMPINGED CATCH
PART. LOAO-PTL.STT) CN
PART. LOAO-TTL.Srn CN
PART. L 0 A 0 - P T L . S T 0 C N a
PART. i.. o A n = T r L . s r o c N a
PART. 1. 0 A n -r ? T L , S T K C N
PART'. LOAD^Tri.srK CN
PARTIC E M i s ~ 0 A R T i A L
P A R T I C F M I S - T 6 T A L
PART FMIS/WT PRO FD PTL
PART F M I S / y T PRO F "=) TTL
nt D - Outlet
A R Y IN ME
' UNITS
" M?
MIN
M M . H' G
MM. HPT)
DM3
DEG . C
D N M 3
ML
S
DEG .C
E MM.HG
M/S
N D '-I M 3 / M
A M 3 / M
MG
MG
M G / M M 3
M G / N ''I 3
1 ? X CO?
1PX CO?
M G / A 'A 3
M G / A 'I 3
KG /HR
K G / H R
K G / M T 0 N
K G / M T 0 N
- Kiln - Ducon
TRIC UNITS
1
1 1 -PO-7S 1 1
' '.4S4
7P4. 1 9
71 . 1 ?0
1 '. S4
1 S.4
1 . S3
'.00
£'2
P0.7
.0
79. 0
PRi'l
?S. 4
1
714.03
4P3*
Q9 . U
?4 . 40
17.19
/. 7 1 Q ~Z.
ft f I ( V J
14.91
1 S . ? S
. 39
A + *^*,kVi.^.v.nr^
Scrubber
7
-PO-7S
'.4S4
7 ? 4 . 1 9
4 R . 5 R 0
1 '. S?
1 ? , R
1 . SO
. 00
1 .0
..990
,5
?O.S
.0
. 79, 0
?R.90 .
? R . R 0
1
71 3.74
14.749
374.
404.
97. R
1 4. SO
1R.30
9.R
10.97
1 P. 1 4
?43. 19**
?91 .90**
. 10,14
1 1 . ?4
.77
* * * * -> -.v * *
* :> * * * * * *
3
1 I ;r?Or7S
'.4S4
44.0
7P3.90
7 1 . 1 ? 0
1 . S4
1? .R
1 .S4
. 0
.00
4.7
'.9 S3
,0
.0
. 79. .Q
? R . 8 A
PR. 33
PO.O
1
71 3.74
1 S . 1 4R
37?.
414.
100.4
11.40
1 ?. . S 0
7.P
7, S3
R . 1 ?
****** -< *
* * * '> * > * *
4.74
7 . ?9
.-17
, 1R
* * * * V * * *
****** * *
a
"AVERAGE
1 S. 1 ??
374.
414.
9 'P . 2
17.97
19. 07
'4.4
11.77
1 ? .49
**********
* * -v * -.< * * * * >
10.40
1 1 .?4
'. ?R
**********
**********
PERCENT EXCPS i AIR . . 13?4'9.P S7SR.4********************
13
-------
Visible Emissions
Visible emission measurements were attempted but it became
obviously futile due to the massive steam plume and rapid
deterioration of background conditions accompanying an impending
storm.
Those readings which were attempted indicated no visible
emissions but the environment surrounding the base of the stack
and visible evaluation of the filters strongly suggest that, with
the absence of the steam, visible emissions were likely.
That data obtained can be found in the Appendix.
High Volume Sampling
High Volume sampling was attempted using the Rader automatic
instrument. This attempt was made on the exhaust stack of the
dryer (Point B). The nipples on the ports had to be removed to
enable insertion of the large radius probe. On the first attempt
the filter became quite wet and while carrying it to the clean up
area the weight of the water caused the filter to tear. The second
test also resulted in a very wet filter. Through careful handling
it was recovered intact, but there were numerous cracks and obvious
areas of filter loss. Further attempts were discontinued.
14
-------
Asbestos Sampling
Following the participate mass analysis, the filters were sent
.to a contractor for asbestos analysis. As stated earlier, preliminary
asbestos analyses of Eveleth tailings samples did not indicate the
presence of asbestos. Thus, the Agency no longer plans to analyze the
filter catch for asbestos contact.
S02 Sampling
Table I summarizes SCL data collected from Points A & B. Samples
were collected during the particulate tests. The concentrations are
quite low and are bordering on the lower limit of sensitivity for the
method. SO^ sampling was not conducted on Points C & D.
15
-------
III. PROCESS DESCRIPTION AND OPERATION
Process Description
Eveleth Taconite Company is owned by Oglebay Norton and Ford Motor
Company and is managed by Oglebay Norton. Eveleth is situated just south
of Virginia, Minnesota, and is actually located in the bend of the Central
Mesabi Iron Range formation. This is also south and west of the Duluth
Gabbro influence. Eveleth started operations in 1965 and is now producing
2.2 million long tons of pellets per year. They are presently undergoing
an expansion program to raise production capacity to about 6 million long
tons per year of pellets.
The Thunderbird mine of Eveleth which is about 10 miles north of the
Fairlane Plant, operates with 6-cubic-yard shovels. Presently they use
jet piercers for drilling into the ore body.
The crushing circuit at the mine consists of primary crushing to 10
inches and secondary crushing to 4 inches. The primary crusher is a 54-inch
gyratory and the two secondary crushers are 30" x 70" gyratories. The
secondary crusher product is conveyed to coarse ore storage.
The coarse ore storage is a conical building that is open on the
bottom like a large tepee. The ore is dumped in from the top and drawn from
the bottom with gravity chutes. Coarse ore storage is approximately 8,000
tons in the summer and about 4,500 tons in the winter. They use water
sprays on the coarse ore storage area.
Eveleth hauls their coarse ore in 89 car trains from the mine to the
Fairlane fine crusher building, each car holding 70 tons. The rail cars
are bottom dump cars and the dump station holds 12 cars at a time. The 12
cars are dumped in approximately 12 minutes. Eveleth presently is handling
25,000 tpd of ore and the expansion is projected to increase this to
16
-------
60,000 tpd. The present ore grade is averaging about 24 percent magnetic iron
and 33 percent total iron.
Figure 1 depicts flow through the fine crusher building at Fairlane
which contains the 3rd and 4th stages of crushing. The two stages of
crushing reduce the ore to 1/2-inch for rod mill feed.
At the concentrator building, Figure 2, the rod mill reduces the
ore to about 10 mesh in size. The rod mill discharge goes to the magnetic
cobber which rejects about 35 to 40 percent of the weight. The concentrate
from the magnetic cobbers then goes to ball mills where it is ground in
closed circuit with cyclones. The overflow from the ball mill cyclones
goes to hydroseparators. The concentrate coming out of the hydroseparators,
which is the underflow, goes to fine screening. The overflow from the
hydroseparator is tailings and flows to a tailings thickener. The coarse
material rejected in the cobbers is conveyed up to a holding bin and
dumped into a truck and transported to the tailings area for dike construction.
The concentrate from the double-drum rougher magnetic separators is pumped
to cyclones. The concentrate from the triple-drum finishers is then pumped
to the pellet plant.
At the pellet plant, Figure 3, the concentrate is filtered and conveyed
into concentrate holding bins. The concentrate is removed from the bins
by table feeders onto a traveling belt to which bentonite is added. The
concentrate plus bentonite is then fed to balling drums.
The five balling drums at Eveleth are 9 feet in diameter and 31 feet
in length and will process about 80 tons per hour each. The balling drums
discharge onto vibrating screens which reject the fine material and under-
sized pellets. The fine material and undersized pellets are recycled back
17
-------
to the balling drums as feed material. The oversized material passes on to
a traveling grate. Eveleth does not use "gooney ball" breakers on their
screen decks.
A grate-kiln system is used at Eveleth for induration of their iron
ore pellets. The grate is 12 feet wide and 112 feet long. Drying temperatures
are about 750°F with the preheat temperature around 1900 to 2000°F. From
the traveling grate preheat section, the pellet passes into the rotary kiln.
The rotary kiln is 18.5 feet in diameter and 120 feet long and operates at
2450°F. The pellets are discharged from the rotary kiln into an annular
cooler. From the annular cooler the pellets are conveyed either directly
to car-loading or to storage.
During operation, the main waste gases make several passes through
the pellets. Initially, ambient air is forced by a fan through the first
stage annular cooler where it passes through a 36-inch-deep bed of fired
pellets and is heated to about 2000°F. The gases leaving the cooler (first
stage only) pass into the kiln and along with natural gas firing heat the
pellets to a temperature of about 2400°F. Gases leaving the kiln then flow
to a plenum chamber above the traveling grate section of the furnace. Here,
they are used for preheating the green pellets in a downdraft mode. These
gases then pass through a multiplicity of dry cyclone collectors and are
forced downdraft through the drying section of the grate. Waste gases
passing thorugh the drying section then pass through the venturi scrubber
and out the main stack.
Dust Control Devices
The control devices used at Eveleth include both the dry and wet-type
collectors. The primary crusher and ore hauling facilities have Fly Ash
18
-------
Arrester dry mechanical collectors. The largest of these units, at the
truck dumping station, is a 100-hp unit handling about 60,000 scfm of gases.
The remaining units are 40-hp and 75-hp with about 45,000 scfm total gas
flow. The new crusher facilities are designed to use Wheel abrator bag-
houses with 75,000 and 26,000 scfm gas flow. These will be the dry
compressed pulse-air-cleaned units.
The fine crushing plant now contains six American Air Filter Rotoclones
with a total gas flow of about 120,000 scfm. Two of these units are also
used on the rod mill feeders. The fine ore surge storage area has a Fly
Ash Arrestor dry collector handling about 4,000 cfm with a 7-1/2-hp motor.
This, however, is being changed to a baghouse.
A unique feature at Eveleth is the use of a venturi scrubber on the
waste gases from the grate-kiln indurating system. The waste gas flow has
four venturi scrubbers with two water eliminators. The solids from the
venturi go to the concentrate thickener and filter. The venturi operates
with about a 9-inch water gauge pressure drop. Corrosion has been a problem
on these units, primarily because of some sulfur oxide emissions which cause
acidic conditions in the scrubber. Eveleth is presently feeding about 3
tons per day of liquid caustic to neutralize scrubber water in an attempt
to decrease the corrosion in the venturi scrubber. This is done at a cost
of about $100,000 per year. The venturi scrubber was put in operation in
1971 with mild steel construction and corrosion problems were experienced
within two weeks of initial operation. The new pellet plant which is also
designed with a venturi scrubber will use special alloys for construction
in order to reduce or eliminate the corrosion problem. Eveleth is the only
plant in the industry to use a venturi collector for the main waste gas
emissions.
19
-------
The grate feed, grate discharge (grate return area) and kiln discharge
points each utilize Ducon UW-4 wet scrubbers for dust collection. The
pellet loadout transfer point utilizes an American Air Filter Type W
Rotoclone. The cooler exhaust is emitted directly to the atmosphere via
a stack.
20
-------
-5-
PROCESS OPERATION DURING TEST
A. Sites A and B - Main Waste Gas Stack
The first emission source tested at Eveleth was the main waste gas effluent
from the grate-kiln system which was operating with a Ducon venturi scrubber
collector. Sites A and B were the inlet gases and outlet gases for the scrubber;
three separate samples were taken at each site.
During operation, the main waste gases make several passes through the pellets.
Initially, ambient air is forced by a fan through the first stage annular cooler
where it passes through a 36-inch-deep bed of fired pellets and is heated to about
2000 F. The gases leaving the cooler (first stage only) pass into the kiln and
along with natural gas firing heat the pellets to a temperature of about 2400 F.
Gases leaving the kiln then flow to a plenum chamber above the traveling grate
section of the furnace. Here, they are used for preheating the green pellets in a
downdraft mode. These gases then pass through a multiplicity of dry cyclone
collectors and are forced downdraft through the drying section of the grate. . Waste
gases passing through the drying section then pass through the venturi scrubber and
out the main stack.
The first stack samples at Sites A and B were started at 10:40 a.m. on November
18. The plant was operating with four balling drums running at a capacity of about
360 tons per hour of green balls. Other pertinent operating data during this period
is shown in Table 1. Near the end of this run, a problem developed in the support
mechanism for the inlet sample train (Site A) and the glass filter disk was broken.
The sample was recovered but is only about 80 percent completed.
The second samples at Sites A and B were started at 2:30 p.m. on November 18,
again with the plant operating at about 360 tons per hour of green balls. Four
balling drums were operating when the test began and the fifth drum came on line
at 3:10 p.m. The production rate, however, did not change significantly during
the entire sampling period. Data on this run are also shown in Table 1.
21
-------
TABLE 1. PLANT OPERATING DATA DURING STACK SAMPLING PERIODS
ro
ro
Sites A and B
Production Rate of Green
Balls, tons/hr
Pellet Bed Depth, inches
Grate Speed, inches/min.
Kiln Speed, rph
Temperatures, F
First pass gases
No. 2 fan outlet
Drying zone
Preheat zone
Burning zone
Feed Totalizer, No. 17 Belt,
tons/hr
Undersize Return Totalizer,
No. 20 Belt, tons/hr
Scrubber Water pH
First
Sample
360
7
195
70
840-880
100
700
770-800
2250-2330
376(a)
14.6
8
Second
Sample
360
6.8
175-190
70
830-900
100
700
800-830
2350
:376(a)
14.6^
8
Third
Sample
330
7
160
67
800-900
120
650
880
2350
317(b)
' 13.7
10
Sites C and D
First
Sample
300
6.7
175
65
900-920
100
680
800
2370
288(C)
10.2(C)
8
Second
Sample
300
6.8
120
65
880-900
100
660
800
2350
288(C)
10.2(C)
8
Third
Sample
300
6.6
155
65
870-900
100
650
770
2270
288(C)
10.2(c)
8
(a) Average for 5-hour period on 11-18-75.
(b) Average for 6-hour period on 11-19-75.
(c) Average for 5-hour period on 11-20-75.
-------
The third and final samples at Sites A and B were obtained on November 19.
The Site A sample, inlet to scrubber, was taken between 11:20 a.m. and 1:20 p.m.
and the Site B sample, outlet of scrubber or stack, was taken between 12:30 and
2:30 p.m. Production rate during both periods was about 330 tons per hour with
four balling drums in operation.
B. Sites C and D - Grate Discharge Area
The second emission source at Eveleth was a Ducon collector operating on the
plenum chamber between the grate machine and kiln. Dust emissions at this source
therefore would be from dried pellets which have been preheated to about 800 F.
Prior to conducting these tests a straightening vane was positioned in the stack
for the Ducon outlet and this apparently eliminated much of the cyclonic flow
patterns peculiar to the Ducon units. Total waste gas from this source is about
15,000 scfm.
Three separate samples were taken at Sites C and D on November 20, 1975. The
samples were started at about 10:40 a.m., 1:00 p.m., and 3:00 p.m., respectively.
During each period, the pellet plant was producing about 300 tons per hour of
green balls with four of the balling drums in operation. Other pertinent operating
.data are shown in Table 1.
Generally, the production rate was somewhat lower on November 20 than earlier
in the week, reportedly because of insufficient feed material coming from the
concentrator. It is believed however that this would have only minor influence on
the dust loadings for Sites C and D.
During each of the six stack sampling periods, a sample was obtained of the
green ball feed to the grate furnace. These samples, identified below, will be
retained at Battelle to be used for later analysis.
23
-------
-8-
Green Ball Sample
Identification Code
Sites A and B:
First Sample S-75-000-342
Second Sample S-75-000-343
Third Sample S-75-000-344
Sites C and D:
First Sample S-75-000-345
Second Sample S-75-000-346
Third Sample S-75-000-347
24
-------
EVELETH TACONITE COMPANY
FINE CRUSHER BLDG.
FAIRLANE FACILITIES
CRUDE ORE FKOM
RAILROAD DUMP POCKET
OVERSIZE FROM THIRD 4 FOURTH
STAGE CRUSHER
\
FOURTH STAGE
CONE CRUSHER
to
ro c
in -s
FOURTH STAGE
ORE BIN
THIRD STAGE
CONE CRUSHER
TO FINE ORE
SURGE PILE
RETURNED TO FOURTH
STAGE CONE CRUSHER
OVERSIZE
UNDERSIZE
-------
EVELETH TACONITE COMPANY
CONCENTRATOR
FAIRLANE FACILITIES
**v»
-p-
Q-.
o
ro c
en -j
(T)
ro
ftOM FINE ORE
SURGE BUILDING
CONCENTRATE HYDROSEPARATOR
DOUBLE DRUM ROUGHER
TAILINGS HYDROSEPARATOR
CONCENTRATE
TAILINGS
TO MILL REUSE WATER FEED-
-------
EVELETH TACONITE COMPANY
PELLET PLANT
FAIRLANE FACILITIES
FROM CONCENTRATOR
DIRECTION OF FLOW
TO PELtET LOADING
-------
IV. LOCATION OF SAMPLING PORTS
(Waste Gas Scrubber)
Figure 1 shows the relative location of sampling points
across the Ventrui Scrubber controlling the waste gas emissions. The
sampling points on the inlet (Point A) are shown on Figure 2. Forty-
eight points were required due to the configuration of the ductwork.
The location of points at the outlet (Point B) are presented
in Figure 3. Twenty-four points, 6 on each 90° radius, were
selected to keep the simultaneous sampling coordinated with time.
The inlet ports were located in a horizontal plane on an inclined
duct 12 feet wide by 8 feet 6 inches deep. The duct being inclined
approximately 15 in the direction of flow. This required modification
to Method 5 as shown in Figure 4.
(Grate Discharge Scrubber)
Illustration of the Sampling locations on the grate discharge
scrubber can be seen on Figure 5. A preliminary traverse indicated cyclonic
flow, consequently straightening vanes were installed to correct this
problem. The location of these vanes can be seen on Figure 6. Also
found in Figure 6 is the location of sampling Points at the outlet
(Point D).
Figure 7 shows the location of 16 individual points on the inlet.
28
-------
ro
Waste Gas From
Grate Preheat Section
Grate Drying Section
FIGURE 4 -Waste Gas Scrubber
-------
i I
(0
CO
o
11
11
II
;. /
12
Tl
+
+
t
+
->
47
FIGURE 5 -Waste Gas Scrubber Inlet, Point A
-------
FIGURE 6 - Waste Gas Scrubber Outlet, Point B
-------
PUU.6Y
co
ro
HEATED
FV UTfcR
SLOPING
DUCT
FIGURE 7 - Point A, Inlet Setup
-------
3 OUTLET O
OJ
ROOF
VANES
FIGURE 8 - Grate Discharqe Ena Scrubber
-------
TOP
CO
o
i i i i i i i i » i i i
t i 111 i M i 111 11
i 11 11 11 11 111 > i i
IL.IJLLLIIJLIJ.L.UJJ
FIGURE 9 - Grate Discharge End Scrubber Outlet, Point D
-------
CO
cn
CJ
18
« I
(A
V
«D
X
+
FIGURE 10- Grate Discharge End Scrubber Inlet, Point C
-------
V. SAMPLING AND ANALYTICAL PROCEDURES
Particulate and Asbestos
Particulate sampling was conducted according to Method 5 as
prescribed in the*FEDERAL REGISTER with minor modifications. A
millipore filter was used in place of the usual glass fiber filter in
order to conduct subsequent asbestos analysis. Asbestos analysis
requires the dissolution of the mi Hi pore filter so that asbestos
fibers can be isolated for microscopic analysis. Use of millipore
filters require that filter temperature be maintained under 200°F to
prevent degradation of the filter.
so2
S02 sampling was conducted according to Method 6 in the
*FEDERAL REGISTER.
*FEDERAL REGISTER, December 23, 1971, Vol 36 - Number 247,
Standards of Performance for New Shationary Sources.
36
-------
Particle Sizing
Table II summarizes Particle Size Data.
Brinks at Inlet A - Notes
The initial attempt to do the particle sizing at the inlet
consisted of lowering the Brink unit into the inlet stack, however,
the unit would not fit into the 3-inch port. The Brink impactor
was placed into the heater box that was fabricated by EPA, however,
the heater and fan did not work. A probe nozzle, 1.5 mm, was
placed on a 1-foot probe (stainless tubing) and placed into the
stack. A 6-foot Teflon connector was used between the probe and
the impactor. During Run 1-1 the impactor was not heated, however,
during the next 2 runs a heating tape was wrapped around the impactor
and used to keep the impactor at approximately 212°F. The first run
lasted 5 minutes and since the loading was not excessive, the length
of the next two runs was increased to 8 minutes and 10 minutes. The
equation used to calculate the orifice A P indicates a A P of 0.11"
^0. However, the vacuum reached 10" Hg. when the A P was 0.04" hLO.
The flow rate was approximately 0.10 ft^/min. which was near the
desired 0.09 ft3/min.
The first 2 runs seemed to provide reasonable results. Run
No. 3 proved to be the exception, with the results of the aluminum
pan weighings proving to be negative. The same balance (one from the
lab at Eveleth Taconite) was used for all the Brinks and Andersen
weighings. A significant amount of particulate was in the probe
37
-------
washings. Since there were no sample bottles the probe was washed
with acetone and the washing placed in a tared beaker, with the
acetone being evaporated in an.oven at 100°C and desiccated before
weighing. The probe washings included everything from the probe
tip to the first stage of impactor. No washing was done on the
rest of the stages. The final filter was difficult to weigh since
the filter was adhering to the rubber gasket in the filter holder.
A very slight greyish color was evident on the final filters even
though no particulate collection was indicated by the weighings.
Anderson At Outlet B
Due to an operator error, the first run was performed at a
flow rate considerably lower than needed for it to be isokinetic.
Also the weighings were suspect (explained on weighing sheet).
The last two runs were performed at an isokinetic flow rate. The
amount of particulate collected during Run No. 2-0 is considerably
more than during Run No. 3-0. No explanation can be given for this.
The probe washing was done using acetone to rinse the nozzle and
the conical part of the Anderson sampler. The filters were weighed
on the metal plates along with the gaskets and crossbars. The
sampler was placed in the stack for approximately 15 minutes before
the run to allow it to reach stack temperature before sampling was
started.
38
-------
Particle Size
Calculations - Brinks
INLET
Flow rate 85.48. (.85) $8 BZB 5" 1>55 = 82 ft/sec-
Nozzle Size for Brinks - No Grease
Needed < 1.0 mm - Used 1.5 mm
Flow rate =0.09 ACFM
This flow rate is higher than Figure 1 allows, however, it must be used
since there is no smaller nozzle.
AH = AHc Qn -
MS.
2^* ro 'S" Ma
AP Tc 1 86
AHC = -p-g- = (0'-75)[iof assumed = 45-5
\f \f
AH = 45.5 (0.09) (1 - .
28.5
29
0.11" HoO .
AH = 0.11" H20
39
-------
Particle Size
Calculations - Anderson
OUTLET
roc
Flow rate = 85.48 (.85) 27.57 x 28.8 2 = 88 ft/sec<
Nozzle size for Anderson from Figure 1
Needed 4.0 mm + .67 ACFM
Used 3.4 mm + .51 ACFM
AH = AHC Qn 0 - FM Q)2 Ps T0 Ms
H2° IT" y ^
AHC =44.1
u -MI in *i\ Ci n\2 (28.8)2 510 27.57
AH - 44.1 (0.51) (1 - .13) 29"
AH = 0.69 ACFM
40
-------
Run
Geometric Mean Diameter
1
Low Limit
Particle Size Results
Brinks - Inlet Point A
Cumulative %
1 2
Gralns/SCDF/Stage
1 2 3
Stage
Cycle
1
2
3
.4
5
F
46.4
3.38
2.04
1.29
.765
.412
.0556
46.3
3.42
2.10
1.32
.774
.407
.0549
46.3
3.43
2.10
1.32
.774
.407
.0549
4.30
2.66
1.57
1.07
.548
.309
4.28
2.74
1.61
1.09
.551
.302
4.28
2.74
1.61
1.09
.551
.302
100
5.0
3.08
2.70
2.31
1.15
0
100
7.55
4.05
4.05
3.05
2.50
0
100
.811
.811
.811
0
0
0
.621
.0125
.0025
.0025
.0075
.0075
0
.331
.0125
0
.0036
.0020
.0090
0
.176
0
0
.0014
0
0
0
24.7
.5
.1 '
.1
.3
.3
0
18.5
.7
0
.2 ,
.11
.5
0
12.3
0
0
.1
0
0
0
Anderson - Outlet B
Run
Stage
1
2
3
4
5
6
7
8
Filter
8.47
18.9
12.3
8.38
5.57
3.18
1.79
.890
.0749
6,73
11.9
7.79
5.30
3.52
2.01
1.13
.560
.0593
12.2
11.8
7.66
5.22
3.46
1.98
1.11
.551
.0588
23.9
14.9
10.2
6.93
4.48
2.26
1.41
.561
15.1
9.44
6.42
4.38
2.83
1.43
.892
.352
14.9
9.29
6.32
4.31
2.79
1.41
.878
.346
_ _
100
72.2
72.2
66.7
53.7
50.0
42.6
42.6
0
100
45.2
28.5
20.6
13.9
4.55
1.68
1.20
0
100
56.5
51.1
51.1
42.4
26.1
15.2
3.27
0
.0204
0
.0041
.0094
.0027
.0054
. 0
.0312
0
.0798
.0244
.0115
. .0098
.0136
.0042
.0007
.0017
0
.0099
.0012
0
.0020
.0037
.0025
.0027
.0007
0
3.0
0
.6
1.4
.4
.8
0
4.6
0
22.9
7.0
3.3
2.8
3.9
1.2
.2
.5
0
4.0
\5
0
.8
1.5
1.0
1.1
.3
0
------- |