Report No. 76-LIM-10
SSION T
O
ALLIED PRODUCTS COMPANY
Montevallo, Alabama
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
-------
Particulate, Sulfur Dioxide, Nitrogen Oxides, and Carbon
Monoxide Emission Measurements from Lime Kilns
EMB Projects Report No.
76-LIM-10
Plant Tested
Allied Products Company
Montevallo, Alabama
September 15, 16,. and 17, 1975
Prepared for
Environmental Protection Agency
Office of Air Quality Planning and Standards
Emission Measurement Branch
Research Triangle Park
North Carolina 27711
by
T. L.. Peltier, M. T. Thalman
and W. R. Peairheller
Monsanto Research Corporation
Dayton Laboratory
1515 Nicholas Road
Dayton, Ohio
Report Reviewed by Jason Burbank
Contract No. 68-02-1*104 , Task No. 20
-------
TABLE OP CONTENTS
Page
I. .Introduction ' .1
II. Summary of Results 4
III. Process Description and Operation 31
IV. Location of Sampling Points 35
V. Sampling and Analytical Procedures 39
Appendices
A. Complete Particulate Results
i
B. Complete NO Results and Sample Calculation
C. Complete S02 Results, .Calculations, and Continuous
Monitoring Report
D. Complete CO Results
E. Complete Visible Emissions Results
F. Field Test Data Sheets
G. Process Operation Field Data Sheets
H. Sample Identification Log
I. Analytical Data Sheets
J. The Brinksฎ Cascade Impactor
K. Sampling and Analytical Procedures
L. Test Log
M. Project Participants
11
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LIST OP TABLES
Table . Page
1 Summary of Particulate Emissions (Metric) 5
2 Summary of Particulate Emissions (English) 6
3 Summary of NO Emissions ' .7.
X
4 Summary of S02 Emissions by Dynascience S02 9
Monitor
5 Summary of S02 Emissions by EPA Method 6 ' 1*1
6 Summary of Total Sulfur Content of Coal, 16
Product and Scrubber Water
7 Summary of Brinksฎ Particle Sizing Results 17
(Metric')'Using Unit Density
8 Summary of Brinksฎ Particle Sizing Results 18
(English) Using Unit -Density
9 Summary of Brinksฎ Particle Sizing Results 19
(Metric) Using Actual Density
10 Summary of Brinksฎ Particle Sizing Results 20
(English) Using Actual Density
11 Summary of CO Emissions 28
12 Summary, of Visible Emissions 30
13 Summary of Lime Kiln Operating Data Taken 34
During Sampling
Appendix
A-l . Particulate Emission Data (Metric)
A-2 Particulate Emission Data (English)
B-l NO Results
X
D-l CO Results
iii
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LIST OP FIGURES
Figure . Page
1 ' Dynascience S02 Results - 9/15/75 Inlet ' n
2 Dynascience S02Results - 9/16,17/75 Outlet 12
. 3 Dynascience S02 Results - 9/17/75 Inlet 13
4-6 Particle Size Data (Unit Density) ' 22-24
7-9 Particle Size Data (Actual Density) 25-27
10 . Inlet to Venturi on No. 3 Kiln 36
11 ' Outlet of Venturi Scrubbers 37
Appendix
E-l Summary, of visible emissions for Ob.server 1
E-2 Summary of visible emissions for Observer 2
E-3 Summary of visible emissions for Observer 3
F-l S02 Data from Dynascience Strip Chart - Inlet
F-2 S02 Data from Dynascience Strip Chart - Outlet
iv
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SECTION I
INTRODUCTION
Under the Clean Air Act of 1970, the Environmental Protection
Agency is given the responsibility, of establishing performance
standards for new installations or modifications .to existing
installations in stationary source categories. As a con-
tractor ,. Monsanto Research Corporation (MRC), under the EPA's
"Field Sampling of Atmospheric Emissions" Program, was asked
to undertake a sampling program to provide emission data from
the Allied Products Company in Montevallo, Alabama.
The field test work was directed by Jason Burbank, Field
Testing Section, Emission Measurement Branch.. The sampling
was performed by MRC with Thomas L. Peltier asTeam Leader.
This report tabulates the data collected from the exhaust of
No. 3 lime kiln at the Allied Products Company during the
sampling program of September 15, 16, and 17, 1975.
A venturi scrubber is used to control the particulate emissions
from the kiln, which burns both natural gas and pulverized
coal. Particulate, sulfur dioxide, nitrogen oxides, and car-
bon monoxide emissions were measured at the outlet of the
venturi scrubber. Sulfur dioxide levels and particle size
distribution at the inlet were also determined. Total sulfur
content of the coal feed, calcined lime, and scrubber feed
and discharge water was determined, as well as pH and total
-------
suspended solids (TSS) of the scrubber feed and discharge
water.
Particulate emissions from the scrubber were measured ac-
cording to procedures described in the Federal Register,
Vol. 36, .No. 159, August, 1971, Method 5, "Determination of
Particulate Emissions from Stationary Sources."
Method 1, "Sample and Velocity Traverses for Stationary
Sources"; Method 2, "Determination of Stack Gas Velocity and
Volumetric .Flow Rate (Type S P'itot Tube)"; and Method 3,
"Gas Analysis for Carbon Dioxide, Excess Air and Dry Molecu-
lar Weight" are other procedures that were required for 'the
Method 5 tests. Method 6, "Determination of Sulfur Dioxide
Emissions from Stationary Sources" and Method 7, "Determina-
tion -of Nitrogen Oxide Emissions from Stationary Sources"
were performed according to the procedures in the Federal
Register, Vol. 36, No. 2^7, December 23, 1971.' Method 9,
"Visual Determination of the Opacity of Emissions from
.Stationary Sources" of the Federal Register, Vol. 39, No. 219,
November 12, 197^, was performed on the exhausts of -the bag-
house. The -carbon monoxide sampling and analysis on the
exhaust gases of the lime kiln were performed according to
Method 10, "Determination of Carbon Monoxide Emissions from
Stationary Sources," of the Federal Register, Vol. 39, No. 47,
March 8, 1974.
The EPA also conducted a sampling project during the sampling
at Allied Products Company. A continuous S02 monitoring
device, a Dynascience Air Pollution Monitor, was used on both
the inlet and outlet of the venturi. Results from that sam-
pling program are included in Appendix C.
-------
The following sections of this report include: (1) summary
of results, (2) process description and operation, .(3) loca-
tion of sampling points, (4) sampling and analytical proce-
dures. Appendices include all field, data and analytical
data from this sampling project.
-------
SECTION II
SUMMARY OF RESULTS
Summaries of the particulate emissions from the No. 3 lime
kiln are given in Tables 1 and 2. Three Method 5 tests were
performed on the outlet of the venturi scrubber, which was
used to control the particulate emissions from the kiln.
Emissions of filterable particulate, as measured by the probe '
and filter catch, averaged 24.664 Ib/hr or 10.232 Kg/hr, at
a concentration of .0304 gr/dscf or 63.6 mg/Nm3. The con-
centration data is reported in dry standard cubic feet (DSCF)
where standard conditions are 68ฐF and 29.92 inches Hg. The
metric conditions are 20ฐC and 760 mm Hg for normal cubic
meters (Nm3).
The Method-7 nitrogen oxide results are given in Table 3.
Grab flasks were taken on two different days with eight flasks
being used one day and four flasks the next for a total of
twelve samples. Table 3 gives an average NO emission rate
A
for each set of four samples taken' on the two days and also
an overall average for the two days of sampling. An average
flow rate of 2693- Nm3/min (95091 dscfm) was used -to convert
the concentration of grab flask to an emission rate for the
kiln. All twelve grab flasks gave fairly close results, since
none of the values deviates more than ฑ 30 ppm from the 103
parts per million (ppm) overall average for two days of sam-
pling. However the NO concentration from a lime kiln can
X
vary by as much as 100$ during normal operation.
-------
Table 1. SUMMARY OF PARTICULATE EMISSIONS (Metric)
Run Number
Date
Volume of Gas Sampled - Nm3
Percent Moisture by Volume
Average Stack Temperature - ฐC
Stack Volumetric Flow Rate - NmVmin
Percent Isokinetic
Run Time - Minutes
Particulates - Front Half
mg
mg/Nm3
Kg/hr
Particulates - Total
mg
mg/Nm3
Kg/hr
1
9-15-75
1
19
64
2748
100
120
119
' 68
11
131
76
12
73
.86
.5
30
.8
330
.90
.0
.526
2
9-16-75 '
1.
18.
64-
27^7
100.
120
85.
49.
8.
93.
53-
8.
73
77
5
20
1
085
00
6
82.5
3
Average
9-16-75
1.
20.
66
.2583.
102.
120
121.
72.
11.
131.
78.
12.
66
91
6
30
9.
281
30
9 .
211
1
19
'65
. 2693
120
108
63
10
118
69
11
.71
.85
.60
.6
.232
.74
.5
.187
Percent Impinger Catch
9.5
8.4
7-6
8.5
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Table 2. SUMMARYOF PARTICULATE EMISSIONS (English)
a\
Run Number
Date
Volume- of Gas Sampled - dscf
Percent Moisture by Volume
Average Stack Temperature - ฐF
Stack Volumetric Flow Rate - dscfm
Percent Isokinetic
Run Time - Minutes
Particulates - Front Half
- mg
gr/dscf
Ib/hr
Particulates - Total
mg
gr/dscf
Ib/hr
1
9-15-75
. 61.14
19.86
148
97037
100. 5
120
119-30
o. 0300
24.977 '
131-90
0.0332 .
27.615
2
9-16-75
61.18
18.77
147
97021
100.5
120
85.20
0.0214
17.824
93.00
-0.0234
. 19.456
3
9-16-75
58.69
20.91
151
91216
102.6
.120
-.121.30
0.0318
24.870
131.30
0.0345
26.921
Average
60.34
19.85
149
95091
120 .
108.60
0.0277
22.557
118.74
0.0304
24.664
Percent Impinger Catch
9.6
8.4
7.6
8.5
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Table 3. SUMMARY OF NO EMISSIONS
X
Date . Run
9-16-75
9-16-75
9-16-75
9-16-75
9-16-75
9-16-75
9-16-75
9-16-75
9-17-75
9-17-75
9-17-75
9-17-75
Total Average
No.
1
2
3
4
1
2
3
4
1
2
3
4
Time
936
. 937
938
939
1404
1405
1406
1407
1024
1044
1104
1124
ppma
107
129
119
131
122
101
100
104
96
100
111
77
65
104
89
104
gr/Nm3
0.203
0.245
0.226
0.248 .
0.231
0.192
0.190
0.197
0.182
0.190
0.211
0.146
0.123
0.197
0.169
0.197
Ib/dscf
x 10~5
1.27
1.53
1.41
1.55
1.44
1.20
1.19
1.23
1.14
1.19
1.31
0. 91
0.77
1.23
1.06
1.23
Kg/hrb
32.80
39-59
36.52
40.07
37 . 2-4
31.02
30.70
31.83
29.41
30.74
34.09
23-59
19-87 .
31.83
'. 27-34
31-77
lb/hrc
72.46
82.29
80.45
88.43
82.16
68'. 46
67.89
70.18
65.04
67-89
74.74
51.92
43-93
70.18
60.19
70.08
a - parts per million by volume
b - Flow rate used was estimated to be 2693 Nm3/min .
c - Flow rate used was estimated to be 95,091 dscfm
-------
While MRC personnel were performing the Method 6 sampling on
the inlet to the venturi scrubber, EPA personnel were per-
forming S02 sampling using the Dynasciences Continuous Monitor.
A report of this testing is included in Appendix C. A dis-
cussion of the sampling operations and the results of the
sampling are included in the report. An average SC>2 concen-
tration in ppm' for the inlet and outlet is included in Table
4. Copies of the original strip charts are included in
Appendix P.. Figures 1, 2 and 3 are a graphical description
of the Dynascience data.
The Method 6 sulfur dioxide results are also given in Table
5. As can be seen from Table 5, only the first run on the
inlet to the venturi showed any sulfur dioxide by Method 6
testing. The results of the outlet coincide with the results
of the Dynascience Continuous Monitor, which showed a zero
concentration (<5 ppm, the zero drift during the test while
spanned to 500 ppm full scale).' However, the 'results for
Runs 21 and 3-1 showed appreciable S02 concentrations with
the Dynascience (65 to 212 ppm). but none with Method 6. How-
ever, we know this is impossible since the Dynascience Con-
tinuous Monitor was run simultaneously with the runs, on the
inlet. '
These results can probably be best explained by the lime dust
which is collected in the end of the S02 probe. ' The S02 probe
has a glass wool plug for stopping particulates and the glass
wool merely acted as a filter for the lime dust and the com-
bination of 'the two scrubbed out the S02 giving zero concen-
tration levels on Runs 2-1 and 3-1- Since no velocity traverse
-------
Table 4. . SUMMARY OP S02 EMISSIONS BY THE DYNASCIENCE S02 MONITOR
Corrected 10-Minute Averages of S02 Measurements at the Allied
. Products Lime Plant, Montevallo, Alabama
Test
Date Site .Time
9/15/75 Scrubber 1:05 pm
Inlet
1:15
1:25
1:35
1:45
1:55
' .2:05
2:15
2:25
2:35
2:45
2:55
3 = 05
3 = 15.
3:25
3 = 35
. ' 3:45.
3:55
.4:05
- 4:15-
.. 4:25
Corrected
Average
PPM
139
139
137
126
152
142 .
126 '
144
150
159
236
194
203
252
232
203
.211
207
243
150
174
High
Peak
PPM
177
164 .
194
130
196
.163
142
157
178
'187
29.0
278
282
280
264
246
232
245
312
167
200
Low
Point
PPM
117
122
122
44
128
115
114
128
128
139
170
164
154
221
212
180
189
172
157
125
150
Stack
Temperature
ฐC
449 (84oฐF)
438 (820ฐF)
427 (800ฐF)
421 (790ฐF)
427 (800ฐF)
415 (780ฐF)
427 (800ฐF)
432 (810ฐF)
-------
Table 4 (cont'd). SUMMARY OF S02 EMISSIONS BY THE DYNASCIENCE S02
MONITOR
Corrected 10-Minute Averages of S02 Measurements at the Allied
Products Lime Plant, Montevallo, Alabama
Corrected High Low Stack
Test
Date Site
9/16/75 Scrubber
Outlet
9/17/75 Scrubber
Inlet
9/17/75 Scrubber
Outlet
Time
11:45 am
4-
4:05 pm
10:28 am
10:38
10:48
10:58
11:08
11:18
11:28
11:38
11:48
2:'00 pm
4-
3:15
Average
PPM
0
0
168
159
183
190
. 159
124
101
86
. 156
0
. 0
Peak
PPM
0
0 .
194
190
212
.202
175
142
111
127
173
' 0
0
Point
PPM
. ' 0
0
148
139
158
161
' 141
.105
88
65
128
0
0
Temperature
ฐC
66 (150ฐP)
427 (800ฐF)
66 (150ฐF)
10
-------
Figure 1
9/15/75 INLET
300- -
260--.
!
240-
i
220-
i
200-
180-
160-
by V
~
olume
DYNASCIENCE S02 RESULTS - TEN MINUTE AVERAGES
SHOWING AVERAGE ( ป
PEAK AND LOW VALUES
SCRUBBER INLET
i ,:. i : .
i . .
AT -I
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120- )--
!
100- -. -
i- , . .
'80- -----
i
60-'-
40-
20-,-
CLOCK TIME
9/15/75 -'I
i i '
'. u -1 r 1~
13:05 15 25
35 45 55 14:05 15 25
-h-
35 45 55 15:05 15
i
h-
25
'I-
35
45 55 16:05 15
25
-------
Figure 2 9/16, 9/17/75 OUTLET
'tPPM by Volume
i : : ; j
' . . ' ' ' * " |~ .
, ....,- i " I
O U f| : ' ' . -
c 4 U i ; - .
. :._L_;L.!i .
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9 00- ' i
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160
i h n ' ;
_L -7 \J
DYNASCIENCE S02 RESULTS *-. TEN MINUTE AVERAGES ' .
:.i' . -'::i : ; " ;-.":" _ j -i;;.::.:" j: .'. _- .
'".'.' \:' '! ' ::-:' ; : r . .: '- i ; ' '.. ..'.
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j i . . . . ; :.- .
TOO-' ;
_i_
-------
tPPM by Volume
Figure 3
9/17/75 INLET
DYNASCIENCE S09 RESULTS ,-. TEN MINUTE AVERAGES
H-rrrr
260-
240-J--
i
220- -----
i
200
180-
SHOWING AVERAGE (),
PEAK AND LOW VALUES AT
SCRUBBER INLET
_;. ; .
140- -
120- -
100-
80-
t
60-'
i
40-
i
20
;. . _i_ ._.
!
; ., . , , | .- i , , .
'I ": . i : : ' ! ' ' j i ' !
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\ <
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.
0--
4-.
10:28 38 48 58 11:08 18 28 38 48 CLOCK TIME + 9/17/75
-------
Table 5. SUMMARY OP S02 EMISSIONS BY EPA METHOD 6
Run Number
Date
Volume of Gas Sampled
Nm3
dscf
S02 Concentration
ppm
g/Nm3
Ib/dscf x 1CT5
S02 Emissions
a
Kg/hrc
Ib/hr
a
1-1-
9-16
.0235
.829
61
.160
1.00
16.3-
36
1-0
9-16
.0235
.795
o'
0
0
0
0
2-1
9-17
.0235
.832
0*
0*
0*
0
. 0
2-0
9-17
.0228
.805
0
0
0
0
0
'.3-1
9-17
.0223
..788
0*
0*
0*
0
0
3-0
9-17
.0233
.824
0
0
0 .
0
0
a - Flow rate used - 1699 Nm3/min (Estimated - see explanation pp. 7)
b - Flow rate used - 60,000 dscfm (Estimated - see explanation pp. 7)
*Suspected sampling problems - see discussion pp. 8
-------
was performed at the inlet,'the flow rate used in the deter-
mination of the emission rate there is an estimated value.
It was seen from an earlier test (7-31 and 8-1-74) by the
Alabama Air Pollution Control Commission that the flow in
dscfm increased from inlet to outlet locations by an average
factor of 1.35. This could be attributed to leakage of am-
bient air into the system between those two points, (a high
negative pressure exists) as well as inaccuracies of velocity
measurement due- to turbulent or cyclonic flow. When this fac-
tor is applied to the situation here, taking into considera-
tion the increased duct disintegration and numerous leaks seen
which were not mentioned in that earlier report, a value of
60,000 dscfm for the inlet flow rate can be estimated. The
design flow rate for the Venturis, as given in the process
description, amounts to 80,000 dscfm.
Table 6 gives the total sulfur results on the coal, product,
scrubber feed water and scrubber exit water. The samples
were collected during the Method 6 inlet runs and are refer-
enced to the runs. The results in-the table show the coal
being burned had an average sulfur content of 1.86%. The
product had an average sulfur content of .005%. The particu-
late in the scrubber feed water had an average sulfur content
of 2.9^%- The particulate in the scrubber exit water had an
average sulfur content of 3-73%.
Table 7-10 presents a summary of the Brinkฎ particle sizing
results, Metric and English, respectively. Three runs were
made on the inlet of the venturi scrubber. As can be seen
from the tables, over 96 percent (weight basis) of the parti-
cles collected in all three runs were in the probe, cyclone
and first stage 'of the impactor, corresponding to a mean aero-
dynamic diameter of >5-0 microns, or a mean actual diameter of
>2.75 microns.
15
-------
Table 6. SUMMARY OF TOTAL SULFUR CONTENT OF COAL, PRODUCT AND SCRUBBER WATER
Date ' 9-16 9-17 9-17
Corresponding EPA 6 Run . 1-1 ' . 2-1 3-1
% Total Sulfur ' '
' Coal
Product
Scrubber Feed H20
pH
TSS, mg/1
g Sulfur/1 filtrate
-------
Table 7. SUMMARY OF BRINKSฎ PARTICLE SIZING'
' RESULTS (METRIC) USING UNIT DENSITY
CASCADE IMPACTOR PARTICLE SIZE DISTRIBUTION FOR RVlN 1 '
INPUT VARIABLE UNHS INPUT OAT*,
CYCLONE
.1
2
3 '
4
5
FILTER
CYCLONE
1
2
3
4
5
f HTER
STAGE
CYCLONE
1
2
3
it
5
FILTER
SAMPLING TIME
PRESSURE DROP
STATIC PRESSURE
P'.RTICLE DENSITY
GAS WOL WT
GAS TEMPERATURE
GAS VISCOS.ITY
GAS DENSITY
63.600
6. 366
0.915
1.000
0.240
0.206
1.100
CASCADE IMPACTOR
INPUT VARIABLE
SAMPLING TIME
PRESSURE DROP
STATIC PRESSURE
PARTICLE DENSITY
BAROMETRIC PRESSU
GAS MOL UT
GAS TEMPERATURE
GAS VISCOSITY
GftS DENSITY
70.600
2.060
1.210
0.490
0.150
0.130
0.400
INPUT VARIABLE
SAMPLING IIME
PRESSURE OHOP
STATIC PRESSURE
PARTICLE DENSITY
BAROMETRIC PRESSU
GAS MOL WT
GAS TEMPERATURE
GAS VISCOSITY
GAS DENSITY
UT OF MATERIAL
73.000
8. 431
1 .004
0.137
0.120
0.092
1.000
MIN
cn HG
CM H20
G/CC
DEG C
POISE
G/CC
4.63 '
2.73
1.67
0.98
0.61
PARTICLE SIZE
UNITS
MIN
CM HG
CM H20
G/CC
RE CM HG
DEG C
POISE
G/CC
5.06
3.00
2. OS
1.09
0.70
UNITS
MIN
CM HG
CM H20
G/CC
RE CM HG
OEG C '
POISE
G/CC
3.73
0.36
0.04
0.04
0.01
0.01
0.05
10.0
3.30
-16.60
1.00
2S.O
90.6
0.00022
0.00095
67.69
6.57
0.94
1.02
0.25
0,21
1.13
DISTRIBUTION FOH
9.56
0.29
0,16
0.07
0.02
0,02
0.05
DPC MG/ALM
4.79
2.63
1 .94
1.02
0.64
8.5S
0.2P
o.i?
0.02
0,01
0,01
0.1?
INPUT 0ซTซ
4.0
2.0?
-15.62
1.00
75.49
26.0
06.7
0.00021
0.00096
94 ,07
2,74
1.61
0,65
0.20
0,20
0.53
INPUT DATA
4,0
S.79
-16.51
1.00
75. ?3
26.1
93.3
0.00022
0.000^4
WT PCNT
93.91
3.09
1 ,26
0.17
fl. 15
0.12
1 .27
100.00 .
12,11
3.55
2.61
1.58
1.34
1 .13
HUN 2
100.00
5.93
3.19
1.58
0.93
0.73
0.53
RUM 3
CUM WT PCNT
100.00
6.0 =
2,99
1.72
1.54
1.39
1.27
17
-------
Table 8. 'SUMMARY OP BRINKSฎ PARTICLE SIZING
RESULTS (ENGLISH) USING UNIT DENSITY
CASCADE INPACTOR PARTICLE SIZE DISTRIBUTION FOR RUN I
CYCLONE
1
2
3
(;
9
FILTER
STATE
CYCLONE
1
2
3
i
5
FILTER
!il A IE
CYCLONE
1
2 '
3
14
5
FILTER
SAMPLING TIME MIN 10.0
PRESSURE DROP ' IN HG 1.30
STATIC PRESSURE IN H20 ' '7.40
PARTICLE DENSITY G/CC 1.00
BAROMETRIC PRESSURE IN HG 29.93
GAS MOL WT 26.0
GAS TEMPERATURE DEG f 195.0
GAS VISCOSITY POISE 0.00022
GAS DENSITY G/CC 0.00095
85.600 131,39 67.69
' - 6.366 lป.63 ,12.83 * 8.57
0.915 2.73 ' l.UO 0.91
1.000 1.87 1.53 1.02
0.210 0.96 0.37 0.25
0.206 0.61 0.32 0.21
1.100 1.69 1.13
CASCADE IHPACTOR PARTICLE SIZE DISTRIBUTION FOR
INPUT VARIABLE UNITS INPUT DATA
SAMPLING-TIME MIN 1.0
PRESSURE DROP IN HG . 0.60
STATIC PRESSURE IN H20 -6.15
PARTICLE DENSITY G/CC 1.00
BAROMETRIC PRESSURE IN HG 29.72
GAS MOL WT 26.0
GAS TEMPERATURE DEG F 168.0
GAS VISCOSITY POISE 0.00021
GAS DENSITY G/CC 0.00096
yT OF MATERIAL OPC BG/ACF WT PCNT
70.600 . ' 337.63 91.07
2.060 5.06 9.62 2.71
1.210 3.00 5,77 1.61
0.190 2.05 2.3ป 0.65
0.150 1.09 0.72 0.20
0.150 0.70 0.72 0.20
0.100 1.91 0.53
CASCADE IMPACTOR PARTICLE SIZE DISTRIBUTION FOR
INPUT VARIABLE' UNITS INPUT DATA
SAMPLING TIME MIN 1.0
PRESSURE DROP IN HG 1.10
STATIC PRESSURE IN H20 -6.50
PARTICLE DENSITY G/CC 'l.OO
UAROMETHIC PRESSURE IN H6 ?9.6?
GAS MOL UT 26.1
GAS TEMPERATURE OEG F POO.O
GAS VISCOSITY POISE 0.00022
GAS DENSITY G/CC 0.00091
WT UF MATERIAL OI'C M(,/Atr WT PCNT
73.600 . 303.il> 93.91
2.131 1.79 '!.<*" 3.0'f
1 .001 2.63 1.13 1.26
0.137 1.91 0,'_ 0.17
.0.120 1.02 0.19 0.15
0,092 0.61 O.jo 0.12
1 .000 ' 1.11 1.27
100.00
12.11
3.55
2.61
1.98
1.31
1.13
RUN 2 .
CUM WT PCNT
100.00
5.93
3.19
1.56
0.93
0,73
0.53
RUN 3
CMM WT PCNT
100,00
s.O')
2.99
1 .72
1 .51
1.39
1.27
18
-------
Table 9. SUMMARY OF BRINKSฎ PARTICLE SIZING
RESULTS (METRIC) USING ACTUAL DENSITY
CASCADE IMPACTOR PAKTICLE SIZE DISTRIBUTION FOR RUN i
INPUT VARIABLE UNITS INPUT DATA
SAMPLING TIME ' MIN
PRESSURE DROP CM HG
STATIC PRESSURE CM H20
PARTICLE DENSITY G/CC
BAROMETRIC PRESSURE CM HG
GAS MOl. WT
GAS TEMPERATURE DEG C
GAS VISCOSITY POISE
STAGE
CYCLONE
1
2
3
4
5
FILTER
"
STAGE
CYCLONE
1
2
3
4
5
1 1LTER
GAS DENSITY
WT OF MATERIAL
65.800 .
8.366
0,915
1.008
0.240
0.206
1.100
CASCAOf IMPACTOR
INPUT VARIABLE
SAMPLING TIME .
PRESSURE DROP
STATIC PRESSURE
PARTICLE DENSITY
BAROMETRIC PRESSI
GAS MOL WT
GAS TEMPERATURE
GAS VISCOSITY
GAS DENSITY
WT OF MATERIAL
70.800
2.060
1.210
0.490
O.lbO
0.150
0.400
CASCADE IMPACTOR
INPUT VARIABLE
SAMPLING TIME
PRESSURE DROP
STATIC PRESSURE
PARTICLE DENSITY
G/CC
UPC MG/ACM
2.51
1.46
0.98 '
0.49
0.29
PARTICLE SIZE
UNITS
MIN
cn HG
CM H20
G/CC
JRE CM HG
DEG C
POISE
6/CC
3.73
0.36
0.04
0 , 0 4 '
0,01
0,01
0.05
10.0
3.30
-16,80
3.25
75.77
28.0
90.6
0.00022
0.00095
WT PCNT
87.88
6.57
0.94
1.03
0.25
0.21
1.13
DISTRIBUTION FOR
DPC MG/ACM
2.75.
1,61
1,09
0,55
0,34
PAKTICLE SIZE
UNITS
MIN
CM HG
CM H20
G/CC
9.56
0,26
0,16
0,07
0.02
0.02
0.05
INPUT DATA
4.0
2.03
-15.62
3.25
75.49
28.0
86.7
0,00021
0,00096
WT PCNT
94.07
2.74
1.61
0.65
0.20
0.20 .
0.53
DISTRIBUTION FOR
UAHUMETPIC PRESSURE CM HG
STAGf.
CYCLONE
1
2
3
4
5
FILTER
GAS MGL WT
GAS TEMPERATURE
GAS VISCOSITY
GAS DENSITY
WT OF MATERIAL
73,800
2.431
1.004
0.137
0.120
0.092
1.000
DEG C
POISE
G/CC
UPC MG/ACM
2.60
1.52
1.02
0.51
0.30
6.59
0.28
0.12
0.02
0.01
0.01
0.12
INPUT DATA
4.0
2.79
-16,51
3.25
75.23
28.1
93.3
0.00022
0,00094
WT PCNT
93.91
3.09'
1.28
0.17
0.15
0.12
1.27
CUM WT PCNT
100,00
12.12
3.55
2.62
1.58
1.31
1.13
RUN 2
CUM WT PCNT
100.00
5.93
3.19
1.58
0.93
0.73
0.53
RUN 3
CUM WT PCNT
100,00
6,09
2.99
1.72
1.54
1.39
1.27
19
-------
Table 10. SUMMARY OP BRINKSฎ PARTICLE SIZING
RESULTS (ENGLISH) USING ACTUAL DENSITY
CASCADE IMPACTOR ^ARTICLE SIZE DISTRIBUTION FOR RUN 1
INPUT VARIABLE UNITS INPUT DATA
SAMPLING TIME MIN
PRLSSUHE DKOP IN H6
STATIC PRESSURE IN H20
PAKIICLE DENSITY G/CC
BAP.OPltTRIC PRESSURE IN HG
GAS MOL WT
GAS TEMPERATURE OEG F
GAS VISCOSITY POISE
STATE
CYCLONE
1
2
3
4
5
FILTER
-
/
STATE
CYCLONE
1
2
3
4
5
FILTER
GAS DENSITY
UT OF MATERIAL
65.600
8.366
0.915
1.006
0.210
0.200
1.100
CASCADE IMPACTOR
INPUT VARIABLE
SAMPLING TIME
PRESSURE DROP
STATIC PRESSURE
PAHTtCLE DENSITY
BAROMLTRIC PRESSL
GAS P10L WT
GAS TEMPERATURE
GAS VISCOSITY
GAS DENSITY
UT OF MATERIAL
70.600
ฃ.060
1.210
0.490
0.150
0.150
1). 400
CASCADE IMPACTOR
INPUT VARIABLE
SAMPLING TIME.
PRESSURE DROP
STATIC PRESSURE
PARTICLE DENSITY
G/CC
DPC MG/ACF
131.59
2.51 12.63
1.16 1.10
0.98 1.55
0.49 0,37
U.29 0,32
1.69
10.0
1.30
-7,40
3.25
29.63
28.0
195.0
0.00022
0.00095
UT PCNT
67.66
6.57
0.94
1.03
0.25
0.21
1.13
PBKTICLE SIZE DISTRIBUTION FOR
UNITS
MlN
IN HG
IN H20
G/CC
IRE IN HG
DEG F
POISE
G/CC
DPC MG/ACF
337,47
2.75 9.62
1.61 5,77
1.09 2.34
0.55 0.71
0.34 0.71
1.91
INPUT DATA
4.0
0.80
-6.15
3.25
29.72
28.0
166.0
0.00021
0.00096
WT PCNT
94.07
2,74
1.61
0.65
0.20
0.20
0.53
PARTICLE SIZE DISTRIBUTION FOR
UNITS
MlN
IN HG
IN H20
G/CC
BAHUftTRIC PRESSURE IN HG
STATE
CYCLONE'
1
2
3
4
3
FILTER
GAS MOL WT
GAS TLNPEftATUKE
GAS VISCOSITY
GAS DLNijITY
WT OF MATERIAL
75.000
2. mi
1.004
0.137
0.120
0.092-
l.UOO
OEG F
POISE
G/CC
UPC MG/ACF
303. UO
2.60 9.99
1.52 4,13
1.02 0,56
0.51 0.49
U.30 0.38
4.11
'INPUT DATA
4.0
1.10
-6.50
3,25
29.62
26.1
200.0
0,00022
0.00094
UT PCNT
93.91
3.09
1.26
0.17
0.15
0.12
1.27
CUM UT PCNT
100.00
12,12
S.55
2.62
1.56
1,34
1.13
RUN 2
CUM UT PCNT
100.00
5.93
3.19
1.56
0.93
0.73
0.53
RUN 3
CUM UT PCNT
100.00
6.09
2.99
1.72
1.54
1.39
1.27
20.
-------
The characteristic particle diameter (listed in Tables 7-10 as
DPC) is the diameter of a spherical particle of unit density
(Ib/cc) for -which 50% of the particles will impact on a given
stage and 50% will pass around to the succeeding stage. The
equivalent aerodynamic diameter (diameter based on a spherical
particle of unit density) is reported in Tables 7 and 8, and
shown in Figures 4, 5, and 6. Not only does this method of
reporting the data form a good standard for comparison between
particles of varying shape and density, but also it is general-
ly the aerodynamic particle size which is of interest to the
tester. The actual diameter can be assumed to be as reported
in Tables 9 and 10, and as shown in Figures 7, 8, and 9- These
values are based on spherical particles with an actual density
of 3.25 g/cc, which is derived from the density of CaO given
in The Handbook of Chemistry and Physics, 53^d edition.
Table 11 presents a summary of the carbon monoxide emissions
from the kiln. The Method 10 testing was done on the exhaust
gases collected in a Tedlar bag. The Orsat analysis was per-
formed on. the same gases as the carbon monoxide analysis. The
integrated sample was collected during the respective Method
5 runs. .
The table -lists the CO concentration in ppm, which was obtained
from the calibration curves for the Beckman NonDispersive In-
frared (NDIR) instrument. Background CO was not measured at
this source.
The same flow rate used to calculate S02 and NO emission rates
X.
was also used for CO emission rates. The .CO concentration in
the Tedlar bags was also determined by using Drager tubes which
involves drawing a small amount of gas through a column of in-
dicating material which changes color to indicate the concen-.
tration of .C'O present. The results from this method are also
listed in Table 11.
21
-------
^x
CO
C
o
o
0)
H:
Q
o
H
0.01
Weight ^ Less Than Stated Size
Figure 4. Particle size data (unit density) Run 1
22
-------
W
C
O
O
H
6
0)
.p
cti
H
Q
(1)
o
H
-P.
OJ
.2
.1
0.01 0.0^ 0.1 0.2 0.5 1
20
30. 10 50 CO
Weight % Less Than Stated Size
Figure 5. Particle size data (unit density) Run 2
23
-------
.w
o
o
H
E
0
-P
0)
Cti
H
Q
0)
rt
PL.
10
9
8
7
.1
0.01 0.05 0.1 0.2 0.5 1
10
20
30 40 50 60
Weight % Less Than Stated Size
Figure 6. Particle size data (unit density). Run 3
-------
CO
c
o
?H
O
0
B
cd
H
o
- jjipj-;
-.^!A-i.- j-|-:||
^prE-hrnrt
m
Ty
Pi
1-ilH-W'!'!
.......|-...|-t.( j.j j i . ..,. r : .._;:;_.:
-.(_,_!_!.
-dm
rjฃirrn-:i;
TJ-4-i-~ ;-i
-t-l-r-H --I"'
.Vital
ฑrฃ j!i:
"*~T'":~(" t
_ : , | ! .1 ._,.!'. _, ' ..; , * ._ ^
_. . | - -j--- >--- . - -
.9,
.8.
ซ7.
'.6;
.5.
.4.
.3.
.2
.1.
11
!--i--i iri;
,-|i- -i-)-,!
....,_,.. .,,..
l-li-l
rnt
-j -r'-t-rr
11= 1L
iw^yii!
1/U-:
-:jrJ4
-La
-''-I !
r II
art
:!lfl
! -ii
i^i
lii
Cif
^
rv-'lij
-'...L
..., -.
:^
rpl::
=E
C;;
-i-H:
',-r-V
zm:
3S
;! I / J. I
i"^ A i iT
tti
-i-hT
-;-;1-;
TLUr
-[HI
-^r
rm
itn
Utt
ir
^rjrnTTTt'SS?^-: :.-.-ป 1-1 :-:T'^HE:'~"T.7.tril^rr
.!": I-!.-i.-ii (-,-::: | -fi' T-|-;- ."i-!.-:^'-. :r :ri:!:l j.rl4
-.4zt.-.i--.i
-I-I-I--
m
m
~;~^i~
= 3ฃ-_
:Ez
=FR-
&
-i
Tfff
irrr
liu.
.!:r.i.
iff!:
:;:pt:i;
iฑ
-i.rf..
tet
r+t
-4-t-f-f-
-i-i-Fl-
ffi
rK
Upr;.
-rrp
-r-j-r"
T
-rrrr
ffl
dฑ
,-H_|.
K
iTr-
+^
-i
-K-B
:PRT
rm
-|r|:
7H^J7
-, ... i.. -
zfeS
"i-PF
m
rr
m
r-4-
i.'l-V-j
%&
L-f-j-T-
xpr
tp '
ฃrc;:
r?j:;
:^l
-P!
ip;.
rrn:
nit
:p
I! I i'
Trrr"n
rHrr;
!-!-^Lt-
.;-;rj:r
3:!:!:
-j-H-j.
T- i
-I-H.I.
TfF
-ii-
iii. U".i
ฃpฃ
IP
n*r
Tt
t-f*-'
-I-!-.
hit
rn-
t
fi
-i-i
tj
-H
T
T:
0.01 0.05 0.1 0.2 0.5 1
10
20
30
50 60
Weight % Less Than Stated Size
Figure 7. Particle size data (actual density) Run 1
25
-------
n
C
O
o
H
E
0)
-p
-------
CO
C
O
o
H
6
(D
-P
0)
. Cd
cd
0.01 0.05 0.1 0.2
30 40 50 60
Weight % Less Than Stated Size
Figure 9. Particle size data (actual density) Run 3
27
-------
'Table 11. SUMMARY OF CO EMISSIONS
ro
oo
Run Number
Date
Sample Time (24 Hour Clock)
CO Concentration
ppm
g/Nm3
Ib/dscf x 1CT6
CO Emissions
Kg/hra
lb/hrb
1
9-15
1500-1530
35
0.040
2.497
6.46
14.25
2
9-16
1000-1045
18
0.021
1.284
3.39
7.33
3
9-16
1300-1400
104 .
0.119
7.420
1.9.23
42.33
CO by Drager Tubes
ppm
35-40
20
110
a - Flow Rate used - 2693 Nm3/min (Average of '3 Method 5 runs)
b - Flow Rate used - 95091 dscfm (Average of 3 Method 5 runs).
-------
Table 12 presents a summary of the visible emissions. The.
table gives the opacity readings which correspond, in part,
to the third run of the Method 5 tests. The readings we're
taken from 3:00-4:00 p.m. on September 15, 1975 by J. Burbank,
Observer #1, P. Westlin, Observer //2, and K. C. Hustvedt,- Ob-
server #3j of the EPA. The opacity readings were not taken
during each Method 5 run because of the difficulty in reading
the opacity of-the white steam plume against a white sky.
This steam plume would .not evaporate until it reached a height
of approximately 75-150 feet. At this height, any particu-
lates that did exist in the plume, were so well dispersed
that no visible emissions could be detected. It was due to
these reasons that visible emissions measurements were not
taken as originally planned'. Appendix E gives the Complete
Visible Emissions Results including field data sheets, sum-
mary sheets with 6-minute averages, and graphs plotting- opaci-
ty vs. time.
29
-------
Table 12. SUMMARY OF VISIBLE EMISSIONS
OJ
o.
Date
Observer Number
Duration of Observation (min.)
No. of readings at Q% opacity
No. of readings at 5% opacity
9/16/75 9/16/75
1 2
10 48
38 192
2 . ' . . -
9/16/75
3
60
238
2
-------
SECTION III
PROCESS DESCRIPTION AND OPERATION
Limestone consists primarily of calcium carbonate or combina-
tions of calcium and magnesium carbonate with varying amounts
of impurities. Lime is a calcined or burned form of lime-
stone, commonly divided into two basic products quicklime
and hydrated lime. Calcination expels carbon dioxide from .
the. raw limestone, leaving calcium oxide (quicklime). With
the addition of water, calcium hydroxide (hydrated lime) is
formed.
The basic processes in production are (1) quarrying the lime-
stone raw material, (2) preparing the limestone for kilns by
crushing and sizing, (3) calcining the limestone, and (*}) op-
tionally processing the quicklime further by additional
crushing and sizing and then hydration. The majority of lime
is produced in rotary kilns which can be fired by coal, oil,
or gas. Rotary kilns have the advantages of high production
per man-hour and a uniform product but require higher capital
investment and have higher unit fuel costs than most vertical
kilns.
The Allied Products Company lime plant in Monte.vallo, Alabama,
consists of three rotary".kilns located on the edge of the high
calcium limestone quarry'. Two. small older kilns (total pro-
duction capacity about 500 tons of lime per day) are controlled
by. two Ducon scrubbers.. The newest and largest kiln (number 3)
' 31
-------
Is controlled by twin ASE, Incorporated venturi scrubbers.
This kiln is rated at 800 tons of lime per day, however, is
only able to operate at 650 tons per day when coal is used as
fuel.
Alabama coal is used in the kiln and they try to restrict it
to less than 1.25'percent sulfur content because the lime is
used in steel furnaces (U.S.'Steel) -and high sulfur in the
lime effects the steel quality. The plant uses natural gas
to the extent that it is available but there is never enough
natural gas available to run the plant for several days with-
out coal. The plant would need 10,000,000 cubic feet of nat-
ural gas per day if they had no coal (number 3 kiln would use
half of it).
To reduce emissions, 12 Buell cyclones (2 parallel sets) are
used as pre-cleaners and then the gases enter twin venturi
scrubbers.' Two 600 HP fans are located between the scrubbers
and a nine foot diameter stack. The gas flow into the ven-
turis at design amounts'to 182,162 acfm @ 650ฐF, or approxi-
mately 80,000 dscfm. The actual flow rate was.estimated to
be 60,000 dscfm. The water flow through the Venturis was
about 1600 gallons per minute.'
The slurry waste enters two settling tanks (only one in use
at any time) from which the sludge is pumped .to a slurry waste
pond. Water from the waste pond evaporates or returns to the
plant water sump in the bottom of the quarry. This waste water
usually has a pH of greater than 9- Makeup water is estimated
at less than 600 gallons per minute. The amount of waste gen-
erated is about 35 tons per day in the waste pond and about 35
tons per.day of dry material collected from the multicyclones.
Dry material is hauled to a spoil pile where it is wetted and
forms a solid mass. The t-ruck lanes are kept wet t'o -reduce
fugitive emissions.
32
-------
Other process and handling emission control equipment con-
sisted of a 28,000 cfm bag collector on a milling operation,
a 10,000-12,000 cfm baghouse .on handling operations, and a
5,000 acfm at 15'0ฐP Ducon scrubber on a 10 ton/hr hydrator.
The 'slurry collected in the hydrator scrubber is returned to
the process.
The operating parameters of the lime kiln were monitored
during the testing. The process data recorded are listed on
data sheets found in Appendix G. The lime kiln operated nor-
mally throughout the testing. A summary of the operating
data taken during the sampling period appears in Table 13-
The Allied Products venturi scrubber had a large steam plume
which made visible emission readings very difficult.' A small
amount of particulate was visible at times but it was diffi-
cult to quantify because of the 'distance from the stack at
which the steam dissipated. The complete visible emission
results are found in Appendix E.
33
-------
Table 13-. SUMMARY OF LIME KILN OPERATING DATA TAKEN DURING
SAMPLING
Limestone 'Fuel (Coal) Fuel (Gas) Stack
Date Feed Rate Feed Rate Feed Rate Temp. Oxygen
Test' (1975) (TPH) (TPH) (1000 CFM) ฐF %
1 9/15 . 51.6 6.7 15 3^5 0.5
2 9/16 51-6 -. 6.5 15 3^0 ' 0.5
3 .9/16 51.6 5.9 34 3^0 0.5
-------
SECTION IV
LOCATION OF SAMPLING .POINTS
Figure 10 is a diagram of the inlet to the venturi scrubber on
the No. 3 lime kiln. The steel rectangular duct has dimen-
sions measuring 1.37 meters (5^") by 2.7^ meters (108"). The
exhaust gases flow from the Buell cyclones into the duct be-
fore being diverted into the 2 Venturis. The sampling loca-
tion does not .meet the requirements of Method 1 of the Federal
Register. The location is presumed adequate for Method 6 test-
ing, since S02 concentration can be assumed to be uniform.
However, because of the possibility of particle stratification
at the bend immediately preceding the inlet ports, this loca-
tion leaves much to be desired for particle sizing. A sampling
platform is located near the duct and has been used previously.
The temperature of the exhaust gases at this location is 388ฐC
(730ฐF) and the flow rate has been estimated to be 1699 NmVmin.
(60,000 DSCFM).
Locations were available to collect the coal before it was pul-
.verized and the product after it was cooled. The water being
used in .the scrubbers was collected before and after the ven-
turi and analyzed for total suspended solids and acidity.
Figure 11 is a diagram of the outlet of the venturi scrubber.
The stack has an inside diameter of 2.72 meters (107") and has
an overall height of approximately 25.91 meters (85'). The
nearest upstream disturbance is below the sampling ports,
35
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From Kiln
Y
OJ
CT\
Buell Cyclones
o o o
Sampling
Platform
Venturi
To Separator'
Figure 10. Inlet to Venturi on No. 3 Kiln
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Figure 11. Outlet of Venturl Scrubbers
37 .'
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because the inside diameter expands from 2.72 meters (107"')ป
at the sampling ports, to an inside diameter of 3-66 meters
(144") at approximately 12.91 meters (40') below the .ports.
For this reason, a 48 point traverse 'was employed on this
stack. The nearest downstream disturbance, the outlet, is
approximately 10.67 meters (35 feet) from the sampling ports.
The sampling on this stack was performed on scaffolding set
up in front of each 90ฐ port.
Both sets of scaffolding were approximately 15.24 meters (50')
high with sampling platforms 3.66 meters (12') by 1.83 meters
(61) approximately .30 meters (12") away from the edge of the
stack. The two 24-point traverses were performed through two
7.6 cm (3 inch) nipples. The sampling for Methods 5, 6, -7
and 10 was performed through the ports provided in each' stack.
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SECTION V
SAMPLING AND ANALYTICAL PROCEDURES
1. Methods 1 through 4 and 6 and 7 from the Federal Register,
Vol. 36, No. 2*17, December 23, 1971, were followed during '
the sampling at Allied Products in Montevallo, Alabama.
/
2. Method 5 from the Federal Register, Vol. 36, No. 159, Au-
gust 17, 1971j was followed during the particulate sampling
at Allied Products. The clean-up procedures used followed
the guidelines of the above Federal Register, and "Speci-
fications for Incinerator Testing at Federal Facilities,"
U. S. Department of Health, 'Education, and Welfare publica-
tion, October 1967- Analysis of sample was performed ac-
cording to the aforementioned August 17 Federal Register,
with the addition of back half water evaporation, dessica-
tion, and weighing for inorganic matter following ether/
chloroform extraction, as defined in the HEW publication.
3. Method 9 from the' Federal Register, Vol. 39, No. 219, Novem-
ber 12, 197^1, was used to determine the visible emissions.
4. Method 10 from the Federal Register, Vol. 39, No. 47, March
8, 197^, was followed during the carbon monoxide sampling
and analysis.
5. The total sulfur analysis of the coal collected, during the
Method 6 runs was performed according to ASTM D271-70.
The total sulfur analysis of the product and the particu-
late in the scrubber water was performed according to ASTM
Designation: C25-72, "The Standard Methods of Chemical
Analysis of Limestone, Quicklime, and Hydrated Lime," Sec-
tion 23-1, Standard Bromine Method. (See copy in Appendix
K.)
39
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7. The analyses for pH, total suspended solids, and total
dissolved sulfur on the scrubber water was performed ac-
cording to the 1971 edition of "Standard Methods for the
Examination of Water and Wastewater," 13th Edition,
Method #156, pages 330-336 and Method 224C, pages 531-538.
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