O
REPORT NO. 76-SPP-14
WITHOUT APPENDICES
FINAL REPORT
Salt River Project, Navajo Station
Page, Arizona
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
-------
STATIONARY SOURCE TESTING OF A GOAL-FIRED
STEAM GENERATOR
AT
THE NAVAJO POWER PLANT
PAGE, ARIZONA
by
Emile Baladi
Midwest Research Institute
EPA Project Report No. 76-SPP-14
FINAL REPORT
EPA Contract No. 68-02-1403
MRI Project No. 3927-L(32)
For
Environmental Projection Agency
Research Triangle Park
North Carolina 27711
Attn: Mr. C. E. (Gene) Riley
-------
PREFACE
The work reported herein was conducted by Midwest Research Insti-
tute under Environmental Protection Agency Contract No. 68-02-1403, Task 32.
The project was under the supervision of Mr. Paul C. Constant, Jr.,
Head, Environmental Measurements Section of the Environmental and Materials
Sciences Division. Mr. Emile Baladi served as project leader and was assisted
by Messrs. Tom Merrifield, John LaShelle, Bob Stultz, and Paul Constant.
Analysis of the samples was done under the supervision of Dr. James Spigarelli.
MIDWEST RESEARCH INSTITUTE
Paul C. Constant, Jr.
Project Manager
L. J. Shannon, Director
Environmental and Materials
Sciences Division
June 6, 1977
ii
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TABLE OF CONTENTS
Page
I. Introduction* ........ .......... 1
II* Summary and Discussion of Results .............. 3
A* Particulate Tests* ................. 3
B* Opacity Measurements ................ 3
C. Coal Tests 3
III. Location of Sampling Points ..... ...*.. 11
A. Particulate Sampling Location 11
B. Coal Sampling Location 11
IV. Sampling and Analytical Procedures* * •*.. 14
A. Sampling ...................... 14
B* Analysis *•••• 14
Appendix A - Field Log. 16
Appendix B - Analytical Data of Particulate Samples .......... 26
Appendix C - Computer Printout of Particulate Sampling Parameters
and Loadings ...................... 32
Appendix D - Sample Calculations. .............. 41
Appendix E - Particulate Field Data .................. 47
Appendix F - Opacity Field Data Sheets 68
Appendix G - Coal Field Data Sheets and Analyses Results. ......* 92
iii
-------
TABLE OF CONTENTS (concluded)
LIST OF FIGURES
No. Title
1 Schematic Illustration of the Sampled Stack* •••••••• 2
2 Plant Layout Showing Opacity Observer Locations. ...... 6
3 Schematic Top View of Particulate Sampling Location. • • • • 12
4 Schematic Illustration of Coal Sampling Location of a
Typical Pulverizer Bin 13
5 Particulate Emission Train 15
LIST OF TABLES Page
No. Title Page
1 Summary of Results in Metric Units ............. 4
2 Summary of Results in English Units 5
3 Summary of Visible Emissions •••...........•. 7
4 Location of Particulate Sampling Points. ....«•.... 11
IV
-------
I. INTRODUCTION
The U.S. Environmental Protection Agency (EPA) is considering a
revision of the particulate emission standard of performance for new fossil
fuel-fired steam generators of at least 250 x 10 Btu heat input per hour.
The purpose of this project is to quantify particulate emissions from new
coal-fired steam generators as part of the standard revision.
The testing was performed by Midwest Research Institute (MRI) dur- '
ing the period of November 30 to December 3, 1976, on Unit No. 1 of the Navajo
Generating Station, Page, Arizona. The station consists of three generating
units with maximum output of approximately 900 Mw. Six participants built
this station on land leased from the Navajo Indian tribe. These participants
are Salt River Project, Los Angeles Department of Water and Power, Arizona
Public Service Company, Nevada Power Company, Tucson Gas and Electric Com-
pany, and the U.S. Bureau of Reclamation. The station operation is managed
by Salt River Project, Phoenix, Arizona.
Flue gas samples were drawn from the stack of Unit No. 1 (Figure
1). Coal samples were collected from the bins prior to the pulverizers.
In summary, MRI tests conducted for this project consisted of:
1. Three EPA Method 5 particulate runs.
2. Three integrated gas samples collected simultaneously with
the particulate runs.
3. Three coal samples composited during the particulate runs.
4. Opacity reading (Method 9) of the stack emission during Runs
Nos. 1 and 2 of the particulate tests.
No parallel test for particulates was conducted by the plant per-
sonnel during the testing period. However, the plant's continuous emission
monitoring devices (S02» NOX, and opacity) which are located at the same
sampling platform (see Figure 1) were operational during the particulate
sampling.
Section II of this report is a summary and discussion of results.
Section III presents the location of sampling points. Section IV presents
the sampling and analytical procedures. The appendices comprise raw field
data, as well as results of the analysis performed by MRI.
-------
Discharge
to Atmosphere
Outer Shell (Concrete)
Inner Stack (Steel)
Sampling Ports
Sampling
Platform
JQ
Figure 1 - Schematic Illustration of the Sampled Stack
-------
II. SUMMARY AND DISCUSSION OF RESULTS
The starting of the first and second run was delayed several times
due to process problems. Appendix A, which contains the field log, lists
these problems in chronological order. The analytical data for the particu-
late samples are listed in Appendix B.
A. Particulate Tests
Three particulate runs were accomplished. Tables 1 and 2 present
a summary of the results for these runs in metric and English units, re-
spectively. The total particulate data include the catches on the probe,
cyclone, filter, and impingers (see Table B-l, Appendix B).
A computer printout of the particulate sampling parameters and
loading is contained in Appendix G. Appendix D contains sample calculations
of particulate emissions. The particulate field data are contained in Ap-
pendix E.
B. Opacity Measurements
Opacity readings were recorded from the discharge point of the
tested Unit No. 1 stack (see Figure 1). Schematic plant layout showing ob-
server locations is depicted in Figure 2. Table 3 presents a summary of the
visible emission results. The 6-min average percent opacity fluctuated be-
tween 10 and 32%. Opacity data were reduced according to EPA Method 9
(Federal Register. Vol. 39. No. 219, November 12, 1974).
The plant's optical transmissometer, which is located at the same
sampling platform, was operational throughout the testing period. However,
no transmissometer data are included in this report.
Appendix F contains the opacity field data sheets.
C. Coal Tests
During each run a sample of coal was taken by MRI from each hopper
of the operational pulverizer of Unit No. 1. The hoppers were sampled sequen-
tially repeatedly for the period of a particulate run forming one composite
sample per run for a total of three composite samples from the test. These
three MRI composite samples were shipped to EPA for analysis. The results
of the analyses performed are given in Appendix G.
-------
TABLE 1
SUMMARY OF RESULTS IN METRIC UNITS
Run No«
Date
Sampling Location
Volume of gas sampled, dscmS/
Percent moisture by volume
Average stack gas temp., °c£'
Stack gas volumetric flow rate, dscmmfi'
Stack gas volumetric flow rate,
Percent isokinetic
Percent oxygen
Particulate-Probe and Filter
12/1/76
2
12/1/76
3,
12/2/76
Unit 1 Outlet
3.769
7.8
134.8
52,981.3
93,615.7
100.2
7.1
Unit 1 Outlet
2.483
7.8
131.5
50,843.2
88,976.2
103.2
7.1
Unit 1 Outlet
2.410
7.2
134.1
50,049.4
87,569.3
101.7
6.7
Average
2.887
7.6
133.5
51,291.3
90,033.7
101.7
7.0
mg/dscmE'
mg/acmE'
kg/hr-E/
g/106 cal. heat input£'
376.80
99.77
56.46
317.089
0.16666
245.89
98.81
56.50
301.380
0.16506
178.97
74.11
42.35
222.501
0.12031
267.22
90.90
51.77
280.323
0.15068
Particulate - Total
mg
mg/dscm
mg/acm
kg/hr
g/10b cal—' heat input
Percent impinger catch
a/
dscm
o.
526.00
139.27
78.82
442.645
0.23265
28.37
358.19
143.94
82.31
439,023
0.24045
31.35
274.07
113.48
64.86
340.73
0.18423
34.70
386.09
132.23
75.33
407.466
0.21911
31.47
Dry standard cubic meters
C = Degrees Celsius
dscmm = Dry standard cubic meters per minute
acmm = Actual cubic meters per minute
b/ mg/dscm = Milligrams per dry standard cubic meter
acm = Actual cubic meter
kg/hr = Kilograms per hour
c/ g/10 cal = Grams per million calories
-------
TABLE 2
SUMMARY OF RESULTS IN ENGLISH UNITS
Run No*
Date
Sampling Location
Volume of gas sampled} dscf—
Percent moisture by volume
Average stack gas temp., °F
Stack gas volumetric flow rate, dscfmii'
Stack gas volumetric flow rate, acfmS/
Percent isokinetic
Percent oxygen
Particulate-Probe and Filter
gr/dscfk/
gr/acf£/
Ib/hri/
lb/K)6 Btu heat
Particulate - Total
mg
gr/dscf
gr/acf
Ib/hr
lb/106 Btu£/ heat input
12/1/76
12/2/76
3_
12/2/76
Unit 1 Outlet
133.10
7.8
274.8
1,871,005
3,305,991
100.2
7.1
376.80
0.04360
0.02467
699.06
0.09263
526.00
0.06086
0.03444
975.87
0.12930
Unit 1 Outlet
87.70
7.8
268.7
1,795,502
3,140,028
103.2
7.1
245 .89
0.04318
0.02469
664.43
0.09174
358.19
0.06290
0.03597
967.89
0.13364
Unit 1 Outlet
85.11
7.2
273.4
1,767,468
3,092,463
101.7
6.7
178.97
0.03238
0.01851
490.53
0.06686
274.07
0.04959
0.02834
751.19
0.10239
Average
101.97
7.6
272.3
1,811,618
3,179,494
101.7
7.0
267.22
0.03972
0.02262
618.01
0.08374
386.09
0.05778
0.03292
898.32
0.12178
a/ dscf = Dry standard cubic feet
°F = Degrees Fahrenheit
dscfm = Dry standard cubic feet per minute
acfm = Actual cubic feet per minute
b/ mg = Milligrams
gr/dscf = Grains per dry standard cubic foot
gr/acf = Grains per actual cubic foot
Ib/hr = Pounds per hour
c/ lb/10^.BTu = Pounds per million British thermal units
-------
o
X
u
'i
oo
o<3
c
o
15
_Q
w>
Q
Observer
Location (P.M. )
Recreation
Area
/ I
Road
Road
Parking
Lot
Entrance
Station
O
O
o
Cooling
Towers
o
o
o
OJ
O)
o
oo
~o
o
U
Observer
Location (A.M. ).
Figure 2 - Plant Layout Showing Opacity Observer Locations
6
-------
TABLE 3
MIDWEST RESEARCH INSTITUTE
SUMMARY OF VISIBLE EMISSIONS
Date: 12/1/76
750"
Type of Plant; Coal-Fired Steam Generator
Type of Discharge:Particulate Height of Point of Discharge:.
Location of Pischarge:Outlet Stack 1 Height of Observation Point: Ground Level
Distance from Observer to Discharge Pointir^ltSOO1 Duration: 321 min
Direction of Observer from Discharge Point: E.S«E»
Descript. of Background:Sky_ wind Direction; N.E« Color of Plume; Pale
Descript. of Sky: Clear Wind Velocity^ mph Detached Plume: Yes
SUMMARY OF TIME AND AVERAGE OPACITY
Set No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Start
0847:00
0853:00
0859:00
0905:00
0911:00
0917:00
0923:00
0929:00
0935:00
0941:00
0947:00
0953:00
0959:00
1005:00
1011:00
1017:00
1023:00
1029:00
1035:00
1041:00
End
0852:45
0858:45
0904:45
0910:45
0916:45
0922:45
0928:45
0934:45
0940:45
0946:45
0952:45
0958:45
1004:45
1010:45
1016:45
1022:45
1028:45
1034:45
1040:45
1046:45
Sum
260
240
240
265
275
240
240
240
290
240
240
260
355
655
610
685
775
515
365
435
Avg.
10.8
10.0
10.0
11.0
11.5
10.0
10.0
10.0
12.1
10.0
10.0
10.8
14.8
27.3
25.4
28.5
32.3
21.5
15.2
18.1
Set No.
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Start
1047:00
1053:00
1059:00
1105:00
1111:00
1117:00
1123:00
1129:00
1135:00
1141:00
1147:00
1153:00
1159:00
1205:00
1211:00
1217:00
1223:00
1229:00
1235:00
1241:00
End
1052:45
1058:45
1004:45
1110:45
1116:45
1122:45
1128:45
1134:45
1140:45
1146:45
1152:45
1158:45
1204:45
1210:45
1216:45
1222:45
1228:45
1234:45
1240:45
1246:45
Sum
430
415
380
385
380
340
240
240
275
320
265
255
240
240
275
370
385
645
475
655
Avg.
17.9
17.3
15.8
16.0
15.8
14.2
10.0
10.0
11.5
13.3
11.0
10.6
10.0
10.0
11.5
15.4
16.0
26.9
19.8
27.3
-P
c
0)
y
-P
•H
O
Sketch showing how opacity varied with time:
See Next Page
Time, hours
7
-------
TABLE 3 (Continued)
MIDWEST RESEARCH INSTITUTE
SUMMARY OF VISIBLE EMISSIONS
Type of Plant: Coal-Fired Steam Generator
Date: 12/1/76
Height of Point of Discharge: 750'
Type of Discharge: Particulate
Location of Discharge: Outlet Stack 1 Height of Observation Point: Ground Level
Distance from Observer to Discharge Point: "4,500* Duration:_321 min
Direction of Observer from Discharge Point: E.S.E.
Descript. of Background: Sky Wind Direction: N»E. Color of Plume: Pale
Descript. of Sky: Clear Wind Velocity: 5 mph Detached Plume: Yes
SUMMARY OF TIME AND AVERAGE OPACITY
Set No.
41
42
43
44
45
46
47
48
49
50
51
52
53
54
15
16
17
18
19
20
Start
1247:00
1253:00
1259:00
1305:00
1311:00
1317:00
1323:00
1329:00
1335:00
1341:00
1347:00
1353:00
1359:00
1405:00
End
1252:45
1258:45
1304:45
1310:45
1316:45
1322:45
1328:45
1334:45
1340:45
1346:45
1352:45
1358:45
1404:45
1407:45
Sum
655
675
490
545
400
440
390
410
390
360
420
370
360
180
Avg.
27.3
28.1
20.4
22.7
16.7
18.3
16.2
17.1
16.2
15.0
17.5
15.4
15.0
15.0
Set No.
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Start
End
Sum
Avg.
Sketch showing how opacity varied with time:
9:47
10:47
11:47
Time, Hours
12:47
13:47
8
-------
TABLE 3 (Continued)
MIDWEST RESEARCH INSTITUTE
SUMMARY OF VISIBLE EMISSIONS
Date: 12/1/76
Type of Plant: Coal-Fired Steam Generators
Type of Discharge: Particulate Height of Point of Discharge; 750*
Location of Discharge: Outlet Stack 1 Height of Observation Point:ground Level
Distance from Observer to Discharge Point: ~1,500* Duration: 65 min
Direction of Observer from Discharge Point: S »S «W.
Descript. of Background: Sky Wind Direction: Var.
Descript. of Sky; Clear
.Color of Plume: Pale
Wind Velocity;0-5 mph Detached Plume: Yes
SUMMARY OF TIME AND AVERAGE OPACITY
Set No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Start
1545:00
1551:00
1557:00
1603:00
1609:00
1615:00
1621:00
1627:00
1633:00
1639:00
1645:00
End
1550:45
1556:45
1602:45
1608:45
1614:45
1620:45
1626:45
1632:45
1638:45
1644:45
1650:45
Sum
305
240
240
240
240
240
240
240
240
240
240
Avg.
12.7
10.0
10.0
10.0
10.0
10.0
10.0
10.0
10.0
10.0
10.0
Set No.
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Start
End
Sum
Avg.
20
Sketch showing how opacity varied with time:
c
«
u
<
Q_
£ 10
'3
o
Q.
O
15:45
16:45
Time, Hours
17:45
-------
TABLE 3 (Concluded)
MIDWEST RESEARCH INSTITUTE
SUMMARY OF VISIBLE EMISSIONS
Type of Plant: Coal-Fired Steam Generator
Date: 12/2/76
Height of Point of Discharge; 750'
Type of Discharge: Particulate
Location of Discharge: Outlet Stack 1 Height of Observation Point: Ground Level
Distance from Observer to Discharge Point: --I?500' Duration: 216 min
Direction of Observer from Discharge Point: S»S«W«
Descript. of Background: Sky wind Direction: Calm Color of Plume: Pale
Descript. of Sky; Clear wind. Velocity: Calm Detached Plume: Yes
SUMMARY OF TIME AND AVERAGE OPACITY
Set No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Start
1300:00
1306:00
1312:00
1318:00
1324:00
1330:00
1336:00
1342:00
1348:00
1354:00
1400:00
1406:00
1412:00
1418:00
1424:00
1430:00
1436:00
1442:00
1448:00
1454:00
End
1305:45
1311:45
1317:45
1323:45
1329:45
1335:45
1341:45
1347:45
1353:45
1359:45
1405:45
1411:45
1417:45
1423:45
1429:45
1435:45
1441:45
1447:45
1453:45
1459:45
Sum
400
670
700
680
620
495
480
480
545
480
480
360
465
360
440
480
400
380
360
360
Avg.
16.7
27.9
29.2
28.3
25.8
20.6
20.0
20.0
22.7
20.0
20.0
15.0
19.4
15.0
18.3
20.0
16.7
15.8
15.0
15.0
Set No.
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
Start
1500:00
1506:00
1512:00
1518:00
1524:00
1530:00
1536:00
1542:00
1548:00
1554:00
1600:00
1606:00
1612:00
1618:00
1624:00
1700:00
1706:00
1712:00
1718:00
1724:00
1730:00
End
1505:45
1511:45
1517:45
1523:45
1529:45
1535:45
1541:45
1547:45
1553:45
1559:45
1605:45
1611:45
1617:45
1623:45
1625:45
1705:45
1711:45
1717:45
1723:45
1729:45
1735:45
Sum
360
360
360
370
390
360
360
360
360
360
360
360
360
360
120
240
240
240
240
240
240
Avg.
15.0
15.0
15.0
15.4
16.2
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
10.0
10.0
10.0
10.0
10.0
10.0
Sketch showing how opacity4varied wIMme: 1739'45 16° 10'°
13:00
14:00
15:00 - 16:00
Time, Hours
17:00
18:00
10
-------
III. LOCATION OF SAMPLING POINTS
Particulate samples were drawn from the stack of Unit No. 1 (see
Figure 1). Goal samples were composited from the bins prior to Unit No. 1
pulverizers.
A. Particulate Sampling Location
A schematic illustration of the particulate sampling location was
shown in Figure 1. Four sampling ports are located at a distance of 200 ft
(8 stack diameters) downstream and 425 ft (17 stack diameters) upstream from
any flow disturbance in the stack. These four ports are 90 degrees apart and
located in a plane perpendicular to the flow.
Table 4 gives information on the location of the particulate tra-
verse points. The number of traverse points was determined according to EPA
Method 1 of the Federal Register. Figure 3 is a schematic top view of the
particulate sampling location and traverse points.
B. Coal Sampling Location
There were seven coal pulverizers serving the tested Unit No. 1
boiler. Several of the pulverizers were out of service during the testing.
Coal samples were composited from the input bins to the operational pul-
verizers only. Figure 4 is a schematic illustration of the coal sampling
location of a typical pulverizer bin.
TABLE 4
LOCATION OF PARTICULATE SAMPLING POINTS
Percent Product of
Traverse of Stack Stack Columns 2
Point No. I.D. I.D. (ft) and 3 (ft)
1/4/7/10 4.4 25 1.10
2/5/8/11 14.7 25 3.67
3/6/9/12 29.5 25 7.37
11
-------
Outer Shell
(Concrete)
Window
Figure 3 - Schematic Top View of Particulate Sampling Location
12
-------
Sampling Port
Pulverizer
Figure 4 - Schematic Illustration of Goal Sampling
Location of a Typical Pulverizer Bin
13
-------
IV. SAMPLING AND ANALYTICAL PROCEDURES
Since the results of this undertaking may be used to revise the
emission standard of new coal-fired steam generators, the following methods
were used in sampling and analysis for this project.
A. Sampling
EPA Methods 1 through 5 of the Federal Register (Vol. 36, No. 247,
December 23, 1971) were followed in the sampling for particulate runs. In
addition, the probe and filter holder of the particulate train were main-
tained as closely as possible to 160°G (320°F) as per Federal Register,
October 6, 1975. In order to better monitor this temperature, a thermocouple
was installed immediately after the filter. Simultaneously with the collec-
tion of each particulate sample, an integrated gas sample was collected as
per Federal Register, June 8, 1976. This was accomplished by attaching a
second probe alongside the particulate pitobe. Figure 5 is a schematic il-
lustration of the train used to collect the particulate and gas samples
from the stack.
Data from previous tests were used to set the sampling equipment
for isokinetic sampling. Twelve traverse points were used to sample from
the stack. The sampling time was 15 min per traverse point for a total of
180 min for Run No. 1. Runs Nos. 2 and 3 sampling times were 120 min total
(10 min per traverse point).
Opacity observations were conducted according to EPA Method 9,
Federal Register, Vol. 39, No. 219, November 12, 1974. One observer manned
the observation point (see Figure 2).
During the particulate sampling periods, coal samples were col-
lected from the binds prior to the pulverizers (see Figure 4). Equal volume
grab samples were collected from each operating bin at 5-min intervals.
All of the grab samples were composited into one sample per particulate run.
Appendix G contains the field data sheets of the coal samples.
B. Analysis
EPA Methods 3 through 5 of the Federal Register (Vol. 36, No. 247,
December 23, 1971, and Vol. 36, No. 159, August 17, 1971) were followed in
the analysis of the particulate and gas samples. The coal samples were shipped
to EPA. Analyses of the coal samples were done by Southern Research Institute
(SRI). Methods and results of these analyses are included in Appendix G.
Opacity data were reduced according to EPA Method 9, Federal Register,
Vol. 39, No. 219, November 12, 1974.
14
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Heated
Thermocouple
Reverse-Type'
Pi tot Tube
Heated
Compartment
/impmgers
oo
( }A"
V /Tight
V-^C Pump
Figure 5 - Particulate Emission Train
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