REPORT NO. 76-LIM-12
CD
-
O
FINAL REf ORT
Kilns 4, 5, and 6
MARTIN-MARIETTA CHEMICAL CORPORATION
Woodville, Ohio
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
-------
EMISSION TEST REPORT
Project No. 76-LIM-12
Kilns 4, 5, and 6
MARTIN-MARIETTA CHEMICAL CORPORATION
Woodville, Ohio
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Air Quality Planning and Standards
Emission Standards and Engineering Division
Emission Measurement Branch
Research Triangle Park, North Carolina 27711
Auaust 1976
-------
TABLE OF CONTENTS
Page
I. Introduction 1
II. Summary of Results 3
III. Process Description and Operation 14
IV. Location of Sampling Points 18
V. Sampling and Analytical Procedures 22
APPENDICES
Appendix A - Complete Results and Sample Calculation
Appendix B - Complete Process Operation Data
Appendix C - Field Data
Appendix D - Laboratory Report
Appendix E - Project Participants
-------
I. INTRODUCTION ' .
Under the Clean Air Act of 1970 the Environmental Protection Agency
is charged with the establishment of standards of performance for new or
modified stationary sources which may contribute significantly to air
pollution. A performance standard is based on the best emission reduction
systems which have been shown to be technically and economically feasible.
In order to set realistic performance standards, accurate data on
pollutant emissions is usually gathered from the stationary source category
under consideration.
The three rotary kilns at the Martin Marietta Chemical Corporation, -
Woodville, Ohio are equipped with a baghouse for air pollution control and
were selected by OAQPS for an emission testing program. In addition to
obtaining atmospheric sulfur dioxide emission data, testing was conducted
at each of the three inlet streams in attempt to quantify any sulfur dioxide
removal by the baghouse. .
Kiln No. 4 is a rotary unit producing 720 tons per day of soft-burned
dolomitic lime. Kiln No. 5 is a rotary unit producing 960 tons per day of
soft-burned lime. Kiln No. 6 is also a rotary unit, producing 400 tons
per day of dead-burned dolomite. Kilns 4 and 5 are equipped with feed
preheaters. Each of the three exhaust streams passes through separate
mechanical particulate collectors before they are combined at the entrance
plenum to the shared baghouse. The baghouse is a Western Precipitation
-------
closed, vacuum-type with reverse-air cleaning. There are twenty-two .
compartments, with each compartment equipped with a separate fan and
exhaust stack.
The fuel used in each kiln is high sulfur (2.4-4%) coal.
Samples were collected before and after the baghouse to determine
total gas flow rates, gas composition, and sulfur dioxide emissions.
Samples of the coal, feed, and product for each kiln were also collected.
Testing was conducted by Emission Measurement Branch personnel during
January 26-31, 1976.
-------
II. SUMMARY OF RESULTS
The testing program at this facility was divided into two phases
because of the number of sampling locations involved. The first phase
was an evaluation of the three baghouse inlet streams to determine gas
flow rates, composition, and SOp concentration. The second phase was
the determination of the baghouse outlet S02 concentration and gas
composition. During outlet testing, each of the three inlet streams
were monitored so that inlet flow rate and gas composition could be
determined.
. Run Numbers 1-3 represent data obtained during Phase one. Each run
consisted of two S02 samples, one moisture determination sample, one inte-
grated gas sample, and a velocity traverse at each of the three sites.
Continuous SOp analyzers were operated so that an independent measurement
of SCL could be obtained. Nearly all of the S02 determinations by EPA
Method 6 and instrumental techniques were unsuccessful due to accumulation
of particulates in the sampling interface systems. Attempts were made to
modify the interface so that valid samples could be obtained but no workable
solution was found.
No valid SO^ determinations by Method 6 were obtained at Kilns 4 or 5.
The only run supported by instrumental results at Kiln 6 was Run 1. Very
early in the day on January 27, all three instruments were performing
properly and continuous monitoring was possible. However, the sample lines
to the analyzers quickly became clogged with particulate and after mid-day
-------
no further valid data were obtained. The results of inlet testing are
presented in Tables 1 to 3 as Run Numbers 1-3.
After it was determined that SC^ testing at'the.inlet was not
possible, the equipment was moved to the baghouse outlet for Phase 2.
Six runs were performed at the outlets. During each run an SOp
sample was collected simultaneously at six of the twenty-two outlets.
An integrated bag sample was also collected at the outlet for gas composi-
tion analysis and SC^ measurement. During each run, the velocity was
monitored and an integrated gas sample was obtained for composition analysis
at each inlet. The results of testing at each location are presented in
Tables 1-3 for the inlet streams and Table 4 for the baghouse outlet. The runs
designated as 6, 7, and 6/7 were performed while Kiln No. 4 was not operating.
Only combustion air was passing through the kiln during those tests.
In the course of six runs at the baghouse outlet during normal operation,
thirty-six S02 samples were obtained. Each of the twnety-two compartments
was sampled at least once. Attempts were made to vary the timing of testing
so that sampled compartments represented operation in various phases of
a compartment operation except cleaning.
The sulfur dioxide concentrations measured at the baghouse exhausts
ranged from 25 to 747 ppmv, dry, during the course of the six runs. There
is a definite concentration gradient ranging from higher values from the
compartments near the entrance plenum down to lower values at the end of
the baghouse fartherest away from the inlet. This is probably due to incom-
plete mixing and stratification between the inlet streams. From the limited
amount of SCL data available for the inlet streams, Kiln 6 had SOp concen-
trations of about 1000 ppm, while Kilns 4 and 5 had 130 and 25 respectively.
-------
TABLE 1. Summary of Results, Inlet From No. 4 K1ln
Run Number
Date
Time
% M, Percent Moisture
Md, Vol. Fraction Dry Gas
% C02
* 02
% \\2
CO, ppm
MWd, Dry Gas Molecular Wt.
MW, Gas Molecular Wt.
Ts, Stack Temperature, °F
Vs, Gas Velocity, FPM
Q, , Standard Gas Flow Rate,
DSCFM
Qa, Actual Flow Rate, ACFM
ppm S02, Method 6
ppm S02, Instrument
CSQ , Concentration, Ib/DSCF
MS02> s°2 Mass Rate, Ib/hr
4-1
1/27/76
3.62
0.964
13.4
12.9
73.7
-
30.66
30.20
380
4226
61280
99620
I
130 —
4-2
1/27/76
3.86
0.961
13.4
13.0
73.6
-
30.66
30.17
382
4181
60340
98560
I
— *+
4-3
1/28/76
3.52
0.965
14.5
12.0
73.5
-
30.8
30.35
342
4103
31890
96720
I
-
4-4
1/29/76
3.83
0.962
10.9.
14.9
74.2
-
30.34
29.87
351
3770
55690
88870
-
>10
4-5
1/29/76
3.83
0.962
15.9
11.9
72.2
-
31.02
30.53
339
-
-
. -
. >10
4-4/5
1/29/76
3.83
0.962
-
-
-
-
30.68
30.20
347
4086
60650
96320
-
-
4-6
1/30/76
2.98
0.97
7.1
14.9
78.0
.-
29.73
29.38
468
3401
43460
80170
-
-
4-7
1/30/76
2.98
0.97
-
-
-
-
29.08
28.75
468
3417
43670
80470
-
<10 '
4-6/7
1/30/76
2.98
0.97
-
-
-
-
29.41
29.07
461
3412
43930
80420
. -
<• •
. 4-8
1/31/76
5.57
0.944
17.9
10.8
71.4
-
31.29
30.55
387
4262
58820
100480
-
<10
4-9
1/31/76
5.57
0.944
16.4
11.6
72.0
-
31.09
30.36
381
4688
65150
110510
-
<10
4-8/9
1/31/76
5.57
0.944
• -
-
-
31.19
30.45
359
4403
62840
03790
-
-
4-10
1/31/76
5.57
0.944
17.5
11.4
71.1
-
31.14
30.4
368
4218
59550
99440
-
<10
4-11
1/31/76
5.57
0.944
16.8
8.6
74.6
-
31.03
30.3
366
4164
58920
98I6U
-
<10
*I denotes analysis Interference
-------
TABLE 2. Summary of Results, Inlet from No. 5 K1ln
Run Number
Date
Time
% M, Percent Moisture
Md, Vol. Fraction Dry Gas
% CO?
% 02
% N2
CO, ppm
MWd, Dry Gas Molecular Wt.
.MW, Gas Molecular Wt.
Ts , Stack Temperature, °F
Vs, Gas Velocity, FPM
Q,, Standard Gas Flow Rate,
DSCFM
Qa, Actual Flow Rate, ACFM
ppm SOg, Hethod 6
ppm S02, Instrument
CSQ , Concentration, Ib/DSCF
HSQ2> s°2 Mass Rate, Ib/hr
5-1
1/27/76
4.36
0.956
12.9
12.2
74.9
-
30.55
29.99
406
3730
50260
87590
I
25 . .
5-2
1/27/76
3.97
0.960
14.1
12.4
73.5
-
30.74
30.22
367
3890
55110
91350.
I
5-3
1/28/76
5.31
0.947
15.1
11.8
73.1
-
30.89
30.21
370
3963
.55010
93060
I
• -
5-4
1/29/76
6.91
0.931
21.5
8.9
69.6
' -
31.85
30.85
384
4339
57540
101890
-
<10
5-5
1/29/76
6.91
0.931
-
-
-
-
31.12
30.22
. 378
4294
57350
1 00830
-
12
5-4/5
1/29/76
6.91
0.931
-
-
.-
-
31.8
30.85
370
4164
56150
97780
-
-
5-6
1/30/76
5.56
0.944
-
-
-
-
31.12
30.38
358
4538
62460
06570
-
<10
5-7
1/30/76
5.56
0.944.
-
-
-
-
31.12
30.38
360
. -
• -
.
-
<10
5-6/7
1/30/76
5.56
0.944
- •
-
-
-
31.37
30.61
360
3690
50760
86700
-
5-8
1/31/76
4.20
0.958
-
• -
-
-
31.12
30.57 .
349
4001
57200
93960
., -
-
5-9
1/31/76
4.20
0.958
15.3
12.4
72.3
. -
30.94
30.40
345
3886
55820
91250
-
<10
5-8/9
1/31/76
4.20
0.958
-
-
-
-
30.94
30.40
345
43GO
' 62920
102850
-
-
5-10
1/31/76
4.20
0.958
20.9
9.6
69.6
-
31.58
31.01
350
4010
57260
94170
-
<10
5-11
1/31/5
4.20
0.95J
14.3
13.3
72.4
-
30.82
30.28
362
4126
58060
96900
-
10
-------
TABLE 3. Summary of Results, Inlet from No. 6 Kiln
Run Number
Date
Time •
% H, Percent Moisture
Md, Vol. Fraction Dry Gas
% C02
% 02
X N2
CO, ppm
MWd, Dry Gas Molecular Wt.
MW, Gas Molecular Wt.
Ts, Stack Temperature, °F
Vs, Gas Velocity, FPM
Q, , Standard Gas Flow Rate,
DSCFM
Qa, Actual Flow Rate, ACFH
ppm SO?. Method 6
ppm S02, Instrument
CSQ , Concentration, Ib/DSCF
MS02- S02 Mass Rate, Ib/hr
6-1
1/27/76
4.31
0.957
-
-
-
-
30.98
30.42
536
1888
33680
67340
833
W"
6-2
1/27/76
7.62
0.924
17.4
9.4 .
73.2
-
31.15
30.15
536
2084
35880
74330 .
74
580
6-3
1/28/76
6.86
0.931
15.2 .
10.6
74.2
-
30.85
29.96
536
3946
68240
40750
78
' -
6-4
1/29/76
3.67
.963
- -
-
-
-
30.98
30; 49
530
2735
48510
97550
-
- .
6-5
1/29/76
3.67
.963
17.8
8.3
73.9
-
31.18
30.67
536
3477
61310
24020
• -
218
6-4/5
1/29/76
3.67
0.963
-
- '
-
-
31.08
30.59
536
2491
43920
88860
-
-
6-6
1/30/76
4.24
.958
15.5
12.3
72.2
30.98
30.44
541
3170
54650
13070
-
<10
6-7
1/30/76
4.24
0.958.
19.2
8.4
72.4
-
31.4
30.84
546
3838
66070
36890 .
-
373
6-6/7
1/30/76
4.25
0.958
-
-
-
-
31.19
30.65
536
2709
47100
96620
-'
-
6-8
1/31/76
4.80 .
0.952
16.9
9.6
73.5
-
31.09
30.46
515
2891
51800
103120
.- -
416
6-9
1/31/76
• 4.80
0.952
13.6
12.0
74.4
-
30.65
30.04
535
3193
56050
1 1 3870
-
75
6-8/9
1/31/76
4.80
0.952
-
-
-
-
30.87
30.25
536
2459
43130
87710
-
-
6-10
1/31/76
4.80
0.952
-
-
-
-
30.98
30.36 .
545
2608
45330
93020
-
400
6-11
1/31/7.
4.80
.0.952
12.7
11.7
75.6
-
30.5
29.90
540
4419
77190
157620
-
373
-------
TABLE 4. Summary of Results, Baghouse Outlet
Run Number
Date
litre
J H, Percent Moisture
Hd, Vol. Fraction Dry Gas
t CO?
X02
I l<2
CO, ppm
Kv'c. [»r... Gas Molecular Wt.
M.V. Gas Molecular Wt.
Ts, Stack Temperature, °F
Vs. Gas Velocity, FPM
*Q, . Standard Gas Flow Rate,
DSCFM
Qa, Actual Flow Rate, ACFM
**ppn SOj , Method 6
ppo SO?, Instrument
CSQ , Concentration, Ib/DSCF
MS02- s°2 I1ass Ratei lb/hr
•Assumed to be equal to total
**Averaae of 6 corona rtmpnt* <«i
0-1
1/Z7/76
145220
-
-
of Inlet
rmlpH* a<
0-2
1/27/76
,
151330
-
-
flows ba
:umoH Ann
0-3
1/28/76
.185140
-
-
;ed on CO
hi flrMj «•
0-4
1/29/76
-
-
-
-
161740
256
63
2 balance
0-5
1/29/76
12.0
13.8
74.2
-
. 290
-
121
57
0-4/5
1/29/76
-
-
-
-
160720
- '
-.
l»0-6
1/30/76
13.5
13.0
73.5
-
160770
240
223
t'»0-7
1/30/76
-
-
-
-
-
194
-
0-6/7
1/30/76
-
-
-
-
141790
-
-
0-8
1/31/76
16.8
11.2
72.0
-
167820
284
152
0-9
1/31/76
-'
-
-
-
177020
194
-
0-8/9
1/31/76
-
-
-
-
168890
-
-
0-10
1/31/76
17.1
10.8
72.1
-
162140
143
116
0-11
/31/76
15.3
12.3
72.4
-
194170
•
190
244
Average
Al 1 Ki In
Fed
15.3
12.0
72.7
-
167420
199
126
3.3X10"11
332
Average
rilnc
5,6 only
Fod
13.5
13.0
73.5
1512tC
217
223
3.6xlO"| •
327 |l
.y».. -3_ H i v bwmpui WIIEM ia a amp i cu( asauiiicu ci|uai f luw TAtfiS*
(UKIln 5 S 6 only. Kiln 4 not being fed.
-------
The ductwork at the baghouse plenum would tend to cause the Kiln 6
stream to stratify at the upper part of the plenum, and thus be picked
up first by the near compartments.
To simplify presentation, the SC^ concentration results for the
six samples were averaged for each run. These averages range from
.121 to 284 ppni, dry, with an overall average of 199 ppm for the six
runs. Individual compartment results are presented in Table 5.
The initial test plan called for calculation of total outlet flow
rate based on measured inlet rates with a correction for any possible
leakage by a C02 balance. Because of the variability in the inlet gas
composition results and the apparent incomplete mixing of the inlet
streams, this approach was not followed. The system was inspected
between the inlet and outlet sample points and was found to be essentially
sealed. Therefore, the outlet standard flow rate can be assumed to be
equal to the sum of the inlet flows. These ranged from 142,000 to 194,000
DSCFM, with an average of 167,400 DSCFM.
Combining this average flow with the overall average concentration,
the S02 mass emission rate is 332 Ib/hr.
During Run No.'s 6 and 7 while Kiln 4 was only being heated (no feed)
the average S02 emission was 217 ppm with an average ges flow of 151,300
DSCFM. Combining the concentration and flow results in a mass emission
rate of 327 Ib/hr.
As was discussed earlier there was almost no data.obtained at any
of the inlet locations whereby instrumental versus Method 6 S02 concen-
tration results could be compared. At the baghouse outlet, instrumental
-------
TABLE 5. Individual Compartment SC^ Results,
Baghouse Outlet
Date Run No.*
1/29/76 0-4-2L
0-4-1A
0-4-2A
0-4-1L
0-4-1 K
0-4-2D
0-5-1B
0-5-1J
0-5-1H
0-5-2K
0-5-2E
0-5-2B
0-6-2C
0-6-1 B
0-6-2J
0-6-2F
0-6-1 K
0-6-1 F
0-7-1H
0-7-2G
0-7-2H
0-7-1 A
0-7-2A
0-7-1D
0-8- 1G
0-8-1 L
0-8-2C
0-8-2L
0-8-2D
0-8- IB
0-9-1 F
0-9- 1J
0-9-2A
0-9-2E
0-9-2K
0-9-1A
S02 Concentration Run Average
ppmv, dry ppmv, dry
434
61.8
63.1
634
-
85.9 256
48.7
112
229
185
97.4
55.4 . 121
41.3
124
341
235
472
226 240
370
282 ;
315
113
19.1
63.6 194
•".• i ., . i'f .Tii'.'. , -|
226
747
24.6
487
121
99.4 284
147
•• 426 . (• '. .,-,«.-, , ,-,. : .-.,.
86.2
137
306
60.2 194
10
-------
TABLE 5. Individual Compartment SO? Results,
Baghouse Outlet (Continued)
S02 Concentration Run Average
Date Run No.* ppmv, dry ppmv, dry
0-10-1E 153
0-10-1K 280
0-10-2B 49.9
0-10-2F 194
0-10-2J 71.0
OrlO-lB 112 143
0-11-1D 110
0-11-1H 223
0-11-2C 31.7
0-11-2H 333
0-11-2G 284
0-11-1A - 196
Average, Kilns 4, 5, & 6 . 199
Average Kilns 5 & 6 only 217
*Compartment tested identified by last two digits of Run No.
11
-------
comparisons were made by analyzing the bag sample collected for -gas
composition analysis. Due to test run time limitations, only four com-
partments could be sampled. These were generally centrally located. On
a general basis, the SCL concentration in the bag sample was less than
the average of the six Method 6 tests per run. While no conclusive
statement can be made, the results suggest that the Method 6 results were
not invalidated by particulate interference. No accumulations were
observed during testing.
Process samples were collected during each test period. Represen-
tative samples of coal, feed and product were selected for moisture and
sulfur analysis. The results of these analyses are presented in Table 6.
12
-------
Table 6. SUMMARY OF PROCESS SAMPLE ANALYSIS
Kiln No. Run No. Material % Moisture % Sulfur
4
5
6
4
5
6
4
5
6
4
4
5 •
5
6
6
6
4
5
6
4
5
6
4
5
6
1
1
1
4
4
4
5
5
5
4/5
4/5
. 4/5
4/5
4/5
4/5
4/5
6/7
6/7
6/7
8/9
8/9
8/9
10/11
10/11
10/11
Coal • 1.59
1.25
1.11
1.63
1.65
1.50
1.20
1.98
1.08
Limestone 0.95
Lime 0.02
Limestone 0.07
Lime 0.01
Limestone 0.05
Iron 0.13
DBD 0.07
Coal 1.23
Coal 1.05
1.20
1.60
1.64
1.51
1.58
1.45
1.43
3.60
3.38
2.84
2.92
3.80
2.43
3.01
3.43
3.05
<0.01
OiOl
<0.01
<0.01
<0.01
<0.01
<0.01
1,80
3.48
3.34
2.93
2.66
3.41
4.06
2.64
2.40
13
-------
III. Process Description and Operation
Limestone consists primarily of calcium carbonate or combinations of
calcium and magnesium carbonate with varying amounts of impurities. The
most abundant of all sedimentary rocks, limestone is found in a variety of
consistencies from marble to chalk. Lime is a calcined or burned form of
limestone, 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: (Ij quarrying the limestone
raw material; (2) preparing the limestone for kilns by crushing and sizing;
(3) calcining the feed; and (4) optionally processing the quicklime further
by additional crushing and sizing and the 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 Martin Marietta Corporation Woodville Ohio lime plant was source
tested January 26-31, 1976. The Number 4, 5, and 6 rotary kilns and the
Western Precipitation baghouse used to control particulate emissions from
these kilns was source tested. The Number 4, 5, and 6 kilns were built in
1961 and 1962. They were originally designed to produce 300 tons per day
of lime from the dolomitic limestone of their nearby quarry. In 1975,
Kennedy Van Saun stone preheaters were added to the Number 4 and 5 kilns,
raising their production capacity considerably. The-Number 5 kiln had a
feedrate of 80 tons of limestone per hour when the test crew arrived on
14
-------
January 26. They cannot maintain the proper temperatures at this feedrate
so the kiln is usually run at less than 80 tons per hour. The Number 4 kiln
is identical to the Number 5 but it cannot run at nearly as high a feedrate.
The plant is now in the process of installing a new crushing unit and a hew
cooler for the Number 4 kiln so that it will be able to produce as much
as the Number 5 kiln. In their present status, it is estimated that the
maximum production capacity of the number 4 and 5 kilns are 720 and 960 tons
of lime per day respectively. The Number 6 kiln produces 480 tons per day
of dead burned dolomite (DBD). During the testing all three kilns burned
high sulfur (3 percent) coal.
After leaving the preheater, the kiln off-gas from two BUF kilns go to
separate Research Cottrell Multiclones which have a design pressure drop .
of 3 IWC. A 1000 Hp fan sends the gases from each of the kilns to the
•baghouse. No water or air cooling of these streams is required. The DBD
kiln is not equipped with a preheater. The DBD kiln off-gas goes directly
to a bank of Western Precipitation centrifugal separators which has a
design drop of 1.9 IWC and then directly to the baghouse. Cooling air is
added as required to keep the baghouse inlet below 450°F.
The baghouse was manufactured by Western Precipitation and was put in
operation in June of 1975.. The house has twenty-two compartments and each
compartment is equipped with its own 100 Hp fan mounted on the roof of the
house and discharging to the atmosphere. Each compartment has 672 bags and
9,744 square feet of bag area for a total for the house of 14,784 bags and
214,368 square feet. The pressure drop across each compartment is measured.
The plant was operating normally throughout the inlet testing and was
normal during the outlet testing except for January 30, when the Number 4
15
-------
kiln was shut down. Two sets (6 and 7) of 6 tests were performed on the
baghouse while the kiln was down. During both tests the induced draft
fan was operating and during the second test series the kiln was being fed
pulverized coal. " ~ """•
The operation of the kilns and the baghouse was monitored during the
testing period and the process data that was collected is included in
Appendix B. The process data collected during each test period is summarized
in Table 3-1.
Process samples were collected by the process engineer during the
testing periods. Limestone feed samples were taken at the beginning of
each day and product lime samples were taken at the end of each day. The
plant monitored the sulfur content of the product throughout the testing
and some of this data is shown on the process data sheets. Coal samples
were taken during the test runs. The plant chemist felt the percent sulfur
in the coal during testing was about 2.5 to 3 percent. Three samples of
coal collected by the process engineer on the first day of testing averaged
2.6 percent sulfur when tested by the plant chemist.
16
-------
Table 3-1. SUMMARY OF KILN OPERATING
DATA DURING .SAMPLING .
Test
4
5
6
7
8
9
10
11
Date
1/29/76
1/29/76
1/30/76
1/30/76
1/31/76
1/31/76
1/31/76
1/31/76
Stone Feed Rate (TPH)
#4
54
54
0
0
60
60
60
60
#5
76
76
78
78 •
70
72
72
72
#6*
40
40
40
40
40
40
40
40
Coal Feed Rate (TPH)
#4
3.9
4.0
0
2.6
4.6
4.5
4.4
4.4
#5
6.1
6.1
6.3
6.3
5.7
5.8
6.2
6.1
#6
4.8
4.7
5.1
5.0
5.4
5.4
6.0
5.9
Burning Zone Temperature (°F)
#4
2200
2050
-
2000
2200
2200
2200
2200
.#5
2200
2100
2200
2200
2150
2000
2050
2050
#6 ..
2780
2700
2700
2650
2760
2720
2720
2620
Baghouse
Pressure Drop
(IWC)
3.6
4.0
4.0
3.5
4.1
-
4.1
4.2
*Plus 1.15 TPH Iron Feed
-------
IV. LOCATION OF SAMPLING POINTS
The sampling location in the No. 4 Kiln inlet to the baghouse was
located in a horizontal run of 65 3/4" diameter ductwork. The sampling
ports were more than eight equivalent downstream and more than two
diameters upstream of any flow disturbance. This represents an ideal
sampling location as defined by Method 1 (FR v36 n247 December 23, 1971).
The duct was equipped with two sampling ports at 90° orientation. The
duct cross section was divided into 12 equal areas as per Method 1.
The sampling location in the No. 5 Kiln inlet was at a point in the
65 3/4" diameter horizontal duct 21' (3.8 diameters) and 26' (4.7 diameters)
from the nearest upstream and downstream disturbances. As per Method 1,
the cross section was divided into 40 equal areas and velocity traverses
were conducted through two ports at 90° orientation.
. The sampling location in the No. 6 Kiln baghouse inlet was at a point
in the 80 3/4" diameter horizontal duct 21' (3.1 diameters) and 32' (4.7
diameters) from the nearest upstream and downstream disturbances. The cross
section was divided into 44 equal areas and traversing was performed
through two ports at 90° orientation.
All gaseous samples at each of the inlet locations were collected
at a single point approximately 36 inches into the duct.
The gaseous sampling locations at the baghouse exit was through a
V hole in the duct from the three-way reverse air control valve to the
fan for each compartment. Diagrams of the baghouse compartment configuration
and the outlet sampling locations are given in Figures 1 and 2 respectively.
Coal samples from each kiln v/ere collected prior to the roller mill
lo
10
-------
Zfi
28
2C
20
26
O
n
D
n
t
O
O
O
n
a
n
D
a
D
n
a
'•
//-
1 :
On~H.fi T
19
-------
PORT
r
2 :
CQTCET
OF
20
-------
at"each kiln during testing. Kiln feed samples were collected before
the preheater at each kiln. Product samples were collected from the
conveyor after the cooler at each kiln.
21
-------
V. SAMPLING AND ANALYTICAL PROCEDURES
The procedures used in this testing were as follows:
1. Velocity determination: Method 1 (F.R. v36 n247 December 23, 1971)
was used to determine and locate the appropriate number of traverse
points. Method 2 was used to determine gas velocity. During
periods when velocity was monitored at a single reference point,
the average stack velocity was calculated, by the use of a
correction factor to relate reference point velocity to average
velocity. These correction factors were determined from tests
where full traverses were performed.
2. Gas composition: Oxygen and carbon dioxide content were deter-
mined by Method 3. An Orsat apparatus was used for analysis.
3. Moisture: The water vapor content was determined by Method 4
except that larger impingers were used and tared silica gel was
included as a final drying agent.
4. Sulfur dioxide: Method 6 was used to measure SO^ concentrations
with the following exceptions:
a. At the baghouse outlet, the sampling probes consisted of six-
foot lengths of unheated V stainless steel/teflon tubing. No
filtration was used prior to the absorbing train.
b. At the inlet locations, a probe specially designed to decrease
particulate pickup was used. This probe has shield gas pick-
up ports to deflect particulate. However, it was found that
this was not adequate to prevent particulate entrainment in the
gas sample.
22
-------
For comparative purposes, two Dynasciences SO? analyzers
and one Dupont Model 461 SCL analyzers were used to monitor the inlet SCL
concentrations. The sample was routed to the analyzers through a condenser
and heated k" teflon sample line by a teflon coated diaphragm pump for
each inlet stream. The sample interface systems quickly became loaded
with particulates and were unusable. The remainder of inlet comparisons
and all outlet comparisons were performed on the bag samples collected for
gas composition analysis.
The process and coal samples were analyzed by ASTM D-271 for moisture
content and ASTM D-1552 (Hi Temperature) for sulfur content.
23
------- |