Report No. 77-SPP-18
Without Appendices
O
m
CATERPILLAR TRACTOR COMPANY
DECATUR, ILLINOIS
FINAL REPORT
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 STUDY
at a
MANUFACTURING FACILITY
Caterpillar Tractor Company
Decatur, Illinois
April 4-7, 1977
Prepared for the
U.S. Environmental Protection Agency
Emission Measurement Branch
Research Triangle Park, North Carolina 27711
Prepared by
Clayton Environmental Consultants, Inc,
25711 Southfield Road
Southfield, Michigan 48075
Project 77-SPP-18
Task 28
Contract No. 68-02-1408
-------
I £ _B _L E .2! .c.P.N.ll.Nl.s
Page
I. Introduction 1
II. Summary and Discussion of Results 2
III. Location of Sampling Points .,, 20
IV. Sampling and Analytical Procedures .,,..,,, r .,,.. 21
FIGURES
FIGURE 1 Side View of Baghouse and Accompanying Ductwork
Boiler No. 2 Baghouse Outlet
FIGURE 2 Plan View of Baghouse and Accompanying Ductwork
Boiler No. 2 Baghouse Outlet
FIGURE 3 Schematic Diagram of Sampling Location
Boiler No. 2 Baghouse Outlet
FIGURE 4 Schematic Diagram of Sampling Point Locations
Boiler No. 2 Baghouse Outlet
FIGURE 5 Schematic Diagram of Particulate Sampling Train
Boiler No. 2 Baghouse Outlet
TABLES
TABLE I Summary of Particulate Concentrations (English Units)
Boiler No. 2 Baghouse Outlet
TABLE II Summary of Particulate Concentrations (Metric Units)
Boiler No. 2 Baghouse Outlet
TABLE III Summary of Particulate Emission Rates (English Units)
Boiler No. 2 Baghouse Outlet
TABLE IV Summary of Particulate Emission Rates (Metric Units)
Boiler No. 2 Baghouse Outlet
TABLE V Summary of Chloroform-ether Extractable Particulate
Boiler No. 2 Baghouse Outlet
TABLE VI Summary of Ultimate Coal Analyses
Boiler No. 2 Baghouse Outlet
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11
TABLES .(continued)
TABLE VII
TABLE VIII
(1 - 6)
TABLE IX
Summary of Coal Heating Values
Boiler No. 2 Baghouse Outlet
Summary of Visible Emissions
Summary of Exhaust Gas Composition
Boiler No. 2 Baghouse Outlet
APPENDICES
APPENDIX A
APPENDIX B
APPENDIX C
APPENDIX D
APPENDIX E
APPENDIX F
APPENDIX G
APPENDIX H
APPENDIX I
Project Participants
EPA Draft Method 17
Particulate Field Data Sheets
Particulate Train Auxiliary Temperature Data
Sampling Summary Sheets
Visible Emissions Field Data Sheets
Special Wash and Particulate Weight Data
Calibration Data
Example Calculations
-------
I. INTRODUCTION
The U.S. Environmental Protection Agency (EPA) retained
Clayton Environmental Consultants, Inc. to conduct a series of
emission tests at the Caterpillar Tractor Company facility lo-
cated at Decatur, Illinois. The purpose of this study was to
provide EPA with data relevant to the establishment of source
performance standards for coal-fired steam generation processes.
This study was commissioned as Project 77-SPP-18 of Task 28,
Contract No. 68-02-1408
The Caterpillar Tractor Company produces earth-moving equip-
ment at the facility of interest. The unit sampled is a coal-
fired boiler that supplies steam for plant operations. Boiler
emissions are controlled by a fabric-filter baghouse system manu-
factured by Standard-Havens Company.
Clayton Environmental Consultants, Inc. simultaneously col-
lected samples of the stack gas stream for determination of gas
composition and particulate emissions leaving the baghouse stack.
Plume opacities were observed and samples were taken of coal fed
to the boiler and fly ash captured by the baghouse during each
sampling period. EPA representatives monitored the emissions
test program, the steam production process, and the baghouse
operation during the source test program.
All sampling activities were performed during the week of
April 4, 1977. The following sections of this report present the
summary and discussion of results, location of sampling points, and
sampling and analytical procedures.
Mention of a specific company or product does not constitute endorse-
ment by the EPA.
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- 2 -
II. SUMMARY AND DISCUSSION OF RESULTS
Particulate Sampling Results
A total of six particulate tests were completed during the bag
house study. The first three tests were conducted utilizing the
pulsed jet bag-cleaning process. The latter three tests utilized
the reverse airflow cleaning method.
Tables I and II summarize the particulate concentrations at
actual and standard conditions in English and metric units, re-
spectively. Tables III and IV present the corresponding emission
rates in English and metric units, respectively. The tabulations
include in-stack, out-of-stack, and overall filterable particulate
as well as back-half and total particulate. In-stack tabulations
represent the 47-mm filter, filter holder, front half rinses and
nozzle rinses. The out-of-stack tabulation represents the glass-
probe rinses, the back half of the 47-mm filter holder, the front
half of the 110-mm filter holder and the 110-mm filter« The over-
all value is the summation of the in and out-of-stack values0
During pulsed jet operations, the total particulate emission
rate ranged from 4.1 to 12.3 pounds per hour with an average value
of 7.8 pounds per hour. The overall filterable particulate emis-
sion rates on these tests ranged from 0.90 to 2.6 pounds per hour
with an average value of 1.6 pounds per hour.
During reverse airflow operations, the total particulate
emission rate ranged from 5.5 to 8.1 pounds per hour, averaging
7.0 pounds per hour. Overall filterable particulate ranged from
0.40 to 0.75 pound per hour, averaging 0.57 pound per hour.
Table V presents the chloroform-ether extractable portion of
each fraction in terms of percentage. For overall filterable and
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- 3 -
total particulate, these portions averaged 18.1 and 9.0 percent,
respectively, during pulsed jet operation. For tests during re-
verse airflow operation, the chloroform-ether extractable portions
averaged 63.3 and 10.4 percent for the overall filterable and total
particulate, respectively.
Coal Analysis Results
A composite coal sample was taken during each test from the
three hoppers feeding the boiler. The results of the ultimate
analyses are shown for each sample in Table VI, and the heating
value of each sample is shown in Table VII.
Summary of Visible Emission Results
Visible emissions emanating from the baghouse stack were
observed during the testing by a certified opacity reader provided
by Clayton Environmental Consultants. (See Figure 2.) Opacities
were observed during each particulate sampling run and for approx-
imately one-half hour before and after each run. The observer
took an opacity reading every 15 seconds during the observation
period. These readings are summarized in Tables VIII-1 through
VIII-6. A series of 6-minute averages are shown for each observa-
tion period.
No opacity reading were taken during Particulate Tests 1
and 3 due to unfavorable plume visibility. For Test 1 the weather
conditions of dark, low clouds precluded reliable measurements.
For Test 3 the weather conditions of dark clouds, high winds? snow
and approaching darkness also prevented valid readings. Plume
opacities in all tests observed averaged below 5-percent opacity
for all 6-minute periods. The highest single readings recorded
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- 4 -
were several occurences of 5-percent opacity during Particulate
Test 2. All individual opacity readings taken during Particulate
Tests 4, 5 and 6 were below five percent.
Integrated Gas Samples
Integrated gas samples collected simultaneously with the six
particulate tests were analyzed by an on-site Orsat analyzer. The
results are summarized in Table IX» Percent excess air ranged from
70.2 to 115.
Fly Ash Samples
No analysis was requested on the fly ash samples taken during
each test from the baghouse ash hoppers. The samples were stored
forlaterusage.
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- 5 -
TABLE I
SUMMARY OF RESULTS (ENGLISH UNITS)
BOILER NO. 2 BAGHOUSE OUTLET
Caterpillar Tractor Company
Decatur, Illinois
April 4-7, 1977
RUN NO.
DATE
SAMPLING CONDITION
Volume of Gas Sampled, dscf
Percent Moisture by Volume
Average Stack Gas Temperature, °F
Stack Gas Volumetric Flowrate, dscfm1
Stack Gas Volumetric Flowrate, acfm
Percent Isokinetic
Percent Oxygen
Percent Excess Air
1
4/4/77
Pulse
Jet
Cleaning
233.9
5.7
318
19,000
31,500
96.9
10.8
102.6
2
4/5/77
Pulse
Jet
Cleaning
148.6
5.3
333
21,800
35,800
.97.6
9.6
81.5
3
4/5/77
Pulse
Jet
Cleaning
142.6
5.8
337
20,600
34,300
98.8
8.8
70.2
Average
for
Pulse
Jet
Cleaning
175.0
5.6
329
20,500
33,900
97.8
9.7
84.8
4
4/6/77
Reverse
Air
Cleaning
147.4
5.1
332
21,700
35,200
97.2
10.5
96.0
5
4/7/77
Reverse
Air
Cleaning
164.7
5.7
325
17,900
29,500
96.5 '
9.7
83.2
6
4/7/77
Reverse
Air
Cleaning
165.5
5.1
315
17,900
28,500
97.3
11.4
115.4
Average
for
Reverse
Air
Cleaning
159.2
5.3
324
19,200
31,100
97
10.5
98.2
dscf
°F
dscfm
a cfm
Dry standard cubic feet
Degrees Fahrenheit
Dry standard cubic feet per minute
Actual cubic feet per minute
Clayton Environmental Consultants, Inc
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- 6 -
TABLE II
SUMMARY OF RESULTS (METRIC UNITS)
BOILER NO. 2 BAGHOUSE OUTLET
Caterpillar Tractor Company
Decatur, Illinois
April 4-7, 1977
RUN NO.
DATE
SAMPLING CONDITION
Volume of Gas Sampled, dscm
Percent Moisture by Volume
Average Stack Gas Temperature, °C
Stack Gas Volumetric Flowrate, dscmm
Stack Gas Volumetric Flowrate, a cmm
Percent Isokinetic
Percent Oxygen
Percent Excess Air
1
4/4/77
Pulse
Jet
Cleaning
6.62
5.7
159
538
892
96.9
10.8
102.6
2
4/5/77
Pulse
Jet
Cleaning
4.21
5.3
167
617
1014
97.6
9.6
81 .5
3
4/5/77
Pulse
Jet
Cleaning
4.04
5.8
169
583
971
98.8
8.8
70.2
Ave rage
for
Pulse
Jet
Cleaning
.4.96
5.6
165
579
959
97.8
9.7
84.8
4
4/6/77
Reverse
Air
Cleaning
4.17
. 5.1
167
615
997
97.2
10.5
96
5
4/7/77
Reverse
Air
Cleaning
4.66
5.7
163
507
835
96.5 '
9.7
83.2
6
4/7/77
Reverse
Air
Cleaning
4.69
5.1
157
507
807
97.3
11.4
115.4
Average
for
Reverse
Air
Cleaning
4.51
5.3
162
543
880
97
10.5
98.2
dscm = Dry standard cubic meters
°C = Degrees Celsius
dscmm = Dry standard cubic meters per minute
acmm = Actual cubic meters per minute
Clayton Environmental Consultants, Inc.
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- 7 - TABLE III
SUMMARY OF RESULTS FOR PART.ICULATES (ENGLISH UNITS)
BOILER NO. 2 BAGHOUSE OUTLET
Caterpillar Tractor Company
Decatur, Illinois
April 4-7, 1977
RUN NO.
DATE
SAMPLING CONDITION
Nozzle and Instack Filter Catch, mg1
gr/dscf
lb/hrj .
lb/10°BTU heat input
2
Probe and Filter Catch, mg
gr/dscf
Ib/hr
lb/106BTU heat input
Nozzle, Instack Filter Catch, and
Probe and Outstack Filter Catch, mg
gr/dscf
Ib/hr
lb/106BTU heat input
Total Catch, mg
gr/dscf
Ib/hr
lb/106BTU heat input
1
4/4/77
Pulse
Jet
Cleaning
*
*
N/A3
*
*
N/A
0.007
1.2
N/A
0.042
6.9 .
N/A
2
4/5/77
Pulse
Jet
Cleaning
*
*
N/A
X.
*\
*
N/A
0.005
0.90
N/A
0.066
12.3
N/A
3
4/5/77
Pulse
Jet
C leaning
*v
*
N/A
*
*
N/A
0.015
2.6
N/A
0.023
4.1
N/A
Average
for
Pulse
T o 1-
jet
Cleaning
-v
*
N/A
*
*
N/A
0.009
1.6
N/A
0.044
7.8
N/A
4
4/6/77
Reverse
Air
Cleaning
0.002
0.44
N/A
0.002
0.31
N/A
0.004
0.75
N/A
0.030
5.5
N/A
5
4/7/77
Reverse
Air
Cleaning
0.001
0.11
N/A-
0.003
0.46
N/A
0.004
0.57
N/A
0.049
7.5
N/A
6
4/7/77
Reverse
Air
Cleaning
0.001
0.09
N/A
0.002
0.31
N/A
0.003
0.40
N/A
0.053
8.1
N/A
Average
for
Reverse
A -i f
A j. r
Cleaning
0.001
0.21
N/A
0.002
0.36
N/A
0.004
0.57
N/A
0.044
7.0
N/A
^Acetone nozzle combined with acetone probe wash.
mg = Milligrams
gr/dscf = Grains per dry standard cubic feet
Ib/hr = Pounds per hour
lb/!06BTU heat input = Pounds per million British thermal units
Filter located outside stack (250°F, EPA Method 5 conditions).
Coal feed rate not available.
Clayton Environmenta1 Consultants , Inc
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- 8 - TABLE IV
SUMMARY OF RESULTS FOR PARTICULATES (METRIC UNITS)
BOILER NO. 2 BAGHOUSE OUTLET
Caterpillar Tractor. Company
Decatur, Illinois
April 4-7, 1977
RUN NO.
DATE
SAMPLING CONDITION
Nozzle and Instack Filter Catch, trig
mg/ d s cm
Kg/hr^
g/106Cal4 heat input
2
Probe and Filter Catch, mg
mg/ d s cm
Kg/hr
g/106Cal heat input
Nozzle, Instack Filter Catch, and
Probe and Outstack Filter Catch, mg
mg/ ds cm
Kg/hr
g/106Cal4 heat input
Total Catch, mg
mg/ d s cm
Kg/hr
g/106Cal heat input
1
4/4/77
Pulse
Jet
Cleaning
J-
j-
N/A3
*
*
N/A
16.8
0.54
N/A
97.3
3.1
N/A
2
4/5/77
Pulse
Jet
Cleaning
*
*
N/A
*
*
N/A
11.0
0.41
N/A
151
5.6
N/A
3
4/5/77
Pulse
Jet
Cleaning
.j,
*
N/A
*
*
N/A
34.3
1.2
N/A
52.9
1.8
N/A
Average
for
Pulse
Jet
Cl eaning
*
*
N/A
*
*
N/A
20.7
0.72
N/A
100
3.5
N/A
4
4/6/77
Reverse
Air
Cleaning
5.4
0.20
N/A
3.8
0. 14
N/A
9.2
0.34
N/A
67. 7
2.5
N/A
5
4/7/77
Reverse
Air
Cleaning
1.7
0.05
N/A
6.9
0.21
N/A
8.5
0.26
N/A
111
3.4
N/A
6
4/7/77
Reverse
Air
Cleaning
1.3
0.04
N/A
4.6
0.14
N/A
6.1
0.19
N/A
121
3.7
N/A
Averag e
for
Reverse
Air
Cleaning
2.8
0.10
N/A
5. 1
0.16
N/A
7.9
0.26
N/A
99.9
3.2
N/A
*Acetone nozzle wash combined with acetone probe wash.
mg = Milligrams
gr/dscf - Grains per dry standard cubic feet
Ib/hr = Pounds per hour
lb/10°BTU heat input = Pounds per million British thermal units
Filter located outside stack (250°F, EPA Method 5 conditions).
3
4
Coal feed- rate not available
mg/dscm = Milligrams per dry standard cubic meter:
Kg/hr = Kilograms per hour
g/106Cal = Grams per million calories
Clayton Environmental Consultants, Inc.
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- 9 -
TABLE V
SUMMARY OF CHLOROFORM-ETHER EXTRACTABLE PARTICULATE
BOILER NO. 2 BAGHOUSE OUTLET
Caterpillar Tractor Company
Decatur, Illinois
April 4-7 , 1977
Samp ling
Cond it ion
Pulse
Jet
Cleaning
Reverse
Airflow
Cleaning
Test
No .
1
2
3
AVERAGE
4
5
6
AVERAGE
Chloroform-ether Extractable Portion, Percent
Filterable Particulate
In-Stack
*'<
*
*
*
39.6
75 .3
89.3
68.1
Out-of-Stack
*
*
*
*
56.0
53.2
89.7
66.3
Overa 11
5.3
27.4
21.7
18.1
46.1
57.2
86.5
63.3
Back-ha If
Particulate
4.3
2.2
12.3
6.3
10.4
4.2
3.3
6.0
Total
Particulate
4.5
4.1
18.4
9.0
15.3
8.3
7.5
10.4
* Acetone nozzle wash combined with acetone probe wash
Clayton Environmental Consultants, Inc.
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TABLE VI
SUMMARY OF ULTIMATE COAL ANALYSES
BOILER NO. 2 BAGHOUSE OUTLET
Caterpillar Tractor Company
Decatur, Illinois
April 4-7, 1977
Species
Carbon
Hydrogen
Oxygen**
Nitrogen
Ash
Sulfur
TOTAL
Mois ture
Ultimate Coal Analysis,.- Percent
Test No. 1
As
Received
65.15
5.24
15.46
1.43
10.65
2.07
100.00
8.8
Dry
71.34
4.69
8.47
1.57
11.66
2.27
100,00
Test No. 2
As
Re ceived
65 .69
5.19
15.78
1.52
10.03
1.79
100.00
8.8
Dry
71.94
4.62
8.83
1.67
10.98
1.96
100.00
Test No. 3
As
Re ce ived
64.94
5.30
15.36
1.42
11.36
1.62
100.00
8.5
Dry
71.01
4.76
8.49
1.55
12 .42
1.77
100.00
Test No. 4
As
Re ce ived
67.47
5.12
16.00
1.55
8.00
1.86
100.00
8.4
Dry
73.75
4.56
9.22
1.69
8.75
2.03
100.00
Test No. 5
As
Re ce ived
67.49
5.19
16.31
1.56
7.81
1.64
100.00
9.0
Dry
74.19
4.61
9.10
1.72
8.58
1.80
100.00
Test No. 6
As
Rece ived
67.35
5 .23
16.23
1.47
8.19
1.53
100.00
8.6
Dry
73.66
4.68
9.42
1.61
8.96
1.67
100.00
o
I
* Analysis done using ASTM D Methods:
D3173 - Moisture
D3174 - Ash
D3177 - Sulfur
D3178 - Carbon & Hydrogen
D3179 - Nitrogen
** Oxygen content is calculated by the difference between 100 percent and the sum
of the other six fractions present. Clayton Environmental Consultants, Inc
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- 11 -
TABLE VII
SUMMARY OF COAL HEATING VALUES
BOILER NO. 2 BAGHOUSE OUTLET
Caterpillar Tractor Company
Decatur, Illinois
April 4-7, 1977 -
Test .
No.
1
2
3
4
5
6
Heating Value
of Coal
As Received
Basis
(BTU/lb)
11, 688
11, 745
11, 588
12,039
10, 963
12, 029
Dry Basis
(BTU/lb)
12, 798
12, 863
12,671
13,162
12,052
13, 154
Dry Basis
(Cal/g)
22, 908
23,025
22, 681
23, 560
21, 573
23, 546
Clayton Environmental Consultants, Inc
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- 12 -
TABLE VIII-1
SUMMARY OF VISIBLE EMISSIONS
Caterpillar Tractor Company
Decatur, Illinois
Date: ,
Type of Discharge:
4/5/77
Stack
135'
SE
Gray
Height of Point of Discharge:
Wind Direction:
Color of Plume:
Observer No.: 1
Distance from Observer to Discharge
Direction of Observer from Discharge Point:
Height of Observation Point:
Type of Plant: Coal-fired steam power
Location of Discharge: East end or, plant
Description of Sky:
Wind Velocity:
De tached
Duration
Point:
P 1 urn e :
Overcast
25-30 mph
No
Observation: 43 min
300f
Southeas t
Ground level
Description of Background: Overcast with occasional snow flurries
SUMMARY OF AVERAGE OPACITY
Set
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
Time
Start
11:00
11:06
11:12
11: 18
11:24
11:30
11:36
11:42
14
15
16
17
18
19
20
End
11:05
11:11
11:17
11:23
11: 29
11:35
11:41
11:43
Opa city
Sum
5
0
0
0
5
0
10
0
Average
0.2
0
0
0
0.2
0
0.4
0
Set
Number
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Time
Start
End
Opacity
Sum
Average
Sketch Showing How Opacity Varied With Time:
Opacity
0.4
0.2 '
I
Time, hours
-------
- 13 -
TABLE VIII-2
SUMMARY OF VISIBLE EMISSIONS
Date: ,
Type of Discharge:
Height of Point of
Wind Direction:
Color of Plume:
Observer No.:
Distance from
Direction of
Height of
Description of
Caterpillar Tractor Company
Decatur, Illinois
4/5/77
Stack
Discharge
SE
135
Sky:
Gray
Observer to Discharge
Observer from Discharge
Observation Point:
Background:
Type of Plant:coal-fired steam power
Location of Discharge :East end of plant
Description of
Wind Velocity:
Detached Plume:
Duration
Point:
Point:
Overca st
25-30 mpT
No
of
Observation: 3
300~
hrs . 5 min
Southeast
Ground level
Overcast with occasional snow flurries
SUMMARY OF .AVERAGE OPACITY
Set
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
Time
Start
12:45
12:51
12:57
13:03
13:09
13:15
13:21
13:27
13:33
13:39
13:45
13:51
13:57
14 i 14:03
15
16
17
18
19
20
14: 09
14: 15
14:21
14:27
14:33
14:39
End
12:50
12: 56
13:02
13:08
13:14
13: 20
13:26
13:32
13:38
13:44
13:50
13:56
14:02
14: 08
14: 14
14: 20
14:26
14:32
14:38
14:44
Opacity
S um
0
0
10
5
0
0
0
0
0
0
0
0
0
0
0
0
0
15
0
0
Average
0
0
0.4
0.2
0
0
0
0
0
0
0
0
0
0
0
0
0
0.6
0
0
Set
Number
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Time
Start
14 45
14 51
14 57
15 03
15 09
15 15
15 21
15 27
15 33
15 39
15 45
End
14 50
14 56
15 02
15 08
15 14
15 20
15 26
15 32
15 38
15 44
15 50
Opacity
Sun
0
0
0
0
0
0
0
0
0
0
0
Average
0
0
0
0
0
0
0
0
0
0
0
Sketch Showing ttov Opacity Varied With Time:
Ooacity
0.6
0.4 I
0.2
0
Time, hours
-------
- 14 -
TABLE "VIII-3
SUMMARY OF VISIBLE EMISSIONS
Caterpillar Tractor Company
Decatur, Illinois
Date:
Type of
4/6/77
Stack
Discharge
SE
135
Gray
Discharge:
Height of Point of
Wind Direction:
Color of Plume:
Observer No.: 1
Distance from Observer to Discharge
Direction of Observer from Discharge
Height of Observation Point:
Description of Background:
Type of Plant:Coa1-fired steam plant
Location of Discharge :East end of plant
Description of Sky: Partly cloudy
Wind Velocity:
Detached Plume
Duration
Point:
Point:
10-20 mph
No
of
Observation: 42
150~
min
Southeast
Ground level
Partly cloudy
SUMMARY OF .AVERAGE OPACITY
Set
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Time
Start
09:58
10:04
10: 10
10: 16
10:22
10:28
10:34
End
10:03
10:09
10: 15
10: 21
10:27
10:33
10:40
Opacity
S urn
0
0
0
0
0
0
0
Average
0
0
0
0
0
0
0
Set
Number
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Time
Start
End
Opacity
Sum
Average
Sketch Showing How Opacity Varied With Time:
Opacity
0
Time, hours
-------
- 15 -
TABLE VIII-4
SUMMARY OF VISIBLE EMISSIONS
Caterpillar Tractor Company
Decatur , Illinois
Date: ,
Type of Discharge:
Height of Point of
Wind Direction:
Color of Plume:
Observer No.:
Distance from
Direc tion
Height of
Description of
4/6/77
Stack
Discharge: 135'
_SE
: Gray
1
Observer to Discharge
of Observer from Discharge
Observation Point:
Backgroundj
Sky:
Type of Plant: Coal-fired
Location of Discharge:gast
Description of
Wind Velocity:
Detached
Duration
Point:
Point:
steam plant
P1 urn e :
of Observation:3
end of plant
Partly cloudy
10-20 mph
No
hrs , 41
300
Southea st
Ground level
Overcast and partly cloudy
SUMMARY OF AVERAGE OPACITY
Set
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Time
Start
13:15
13:21
13: 27
13:33
13:39
13:45
13:51
13:57
14:03
14:09
14: 15
14: 21
14:27
14:33
14:39
14:45
14:51
14:57
15:03
15:09
End
13:20
13:26
13:32
13:38
13:44
13:50
13:56
14:02
14:08
14: 14
14:20
14:26
14:32
14:38
14:44
14:50
14:56
15:02
15:08
15:14
Opacity
Sum
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Average
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Set
Number
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Time
Start
15: 15
15:21
15:27
15:33
15:39
15:45
15:51
15:57
16:03
16:09
16: 15
16:21
16:27
16:33
16:39
16:45
16: 51
End
15: 20
15: 26
15:32
15:38
15:44
15:50
15:56
16:02
16:08
16:14
16: 20
16:26
16:32
16:38
16:44
16: 50
16:56
Opacity
Sum
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Average
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Sketch Showing How Opacity Varied With Time
Opacity
a)
Time, hours
-------
- 16 -
TABLE VIII-5
SUMMARY OF VISIBLE EMISSIONS
Caterpillar Tractor Company
Decatur, Illinois
Date: :
Type of Discharge:
Height of Point of
Wind Direction:
Color of Plume:
Observer No.:
Distance from
Direction of
Height of
Description
4/7/77
Stack
Discharge
SE
135
Gray
Observer to Discharge
Observer from Discharge
Observation Point:
of Background:
Type of Plant: Coal-fired
Location of Discharge:East end of plant
Description of Sky
Wind Velocity:
Detached
Duration
Point: 300
Point:
P1 urn e :
of Observation:
s team power
Partly cloudy
10-15 mph
No
hr , 46 min
Southea st
Ground level
Partly cloudy
SUMMARY OF AVERAGE OPACITY
Set
Number
1
2
3
4
5
6
7
8
9
10
11
12
Time
Start
07:50
07:56
08:02
08:08
08 : 14
08:20
08:26
08:32
08:38
08:44
08:50
08:56
13 09:02
14 i 09: 08
15
16
17
18
19
20
09: 14
09: 20
09:26
09:32
09:38
09:44
End
07:55
09: 01
08:07
08: 13
08:19
08: 25
08:31
08:37
08:43
08:49
08:55
09:01
09:07
09:13
09: 19
09: 25
09: 31
09:37
09:43
09:49
Opacity
S urn
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Average
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Set
Number
21
22
23
24
25
26
27
28
29
30
31
32
33
. 34
35
36
37
38
39
40
Time
Start
09:50
09:56
10:02
10:08
10:14
10:20
10:26
10:32
10:38
10:44
10:50
10:56
11:02
11:08
11:14
11:20
11:26
11:32
11:38
11:44
End
09:55
10:01
10:07
10: 13
10: 19
10:25
10:31
10:37
10:43
10:49
10:55
11:01
11:07
11:13
11:19
11:25
11:31
11:37
11:43
11:49
Opacity
Sum
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Average
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Sketch Showing How Opacity Varied With Time:
Opacity
Time, hours
-------
TABLE VIII-5
(cont inued)
- 17 -
SUMMARY OF VISIBLE EMISSIONS
Caterpillar Tractor Company
Decatur, Illinois
4/7/77
of Discharge: Stack
Date
Type
Height of Point of Discharge: 135'
Wind Direction: SE
Color of Plume:
Observer No.:
Distance from
Direction of
Type of Plant: Coal-fired steam power
Gray
Observer to Discharge
Observer from Discharge Point:
Height of Observation Point:
Description of Background:
Location of Discharge:East end of plant
Description of Sky: Partly cloudy
Wind Velocity:
Detached
Duration
Point:
10-15 mph
No
Plume:
of Observation:
4 hr,46 min
300'
Southeast
Ground level
Partly cloudy
SUMMARY OF AVERAGE OPACITY
Set
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Time
Start
.11:50
11:56
12:02
12:08
12 : 14
12:20
12:26
12:32
End
11:55
12:01
12:07
12:13
12:19
12:25
12:31
12:36
Opacity
Sum
0
0
0
0
0
0
0
0
Average
0
0
0
0
0
0
0
0
Set
Number
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Time
Start
End
Opacity
Sum
Average
Sketch Showing How Opacity Varied With Time:
Opacity
Time , hours
-------
- 18 -
TABLE VIII-6
SUMMARY OF VISIBLE EMIS-SIONS
Caterpillar Tractor Company
Decatur, Illinois
Date:
Type of
4/7/77
Coal-fired steam power
Stack
Dis charge:
East
135
Gray
Discharge:
Height of Point of
Wind Direction:
Color of Plume:
Observer No.: 1
Distance from Observer, to Discharge
Direction of Observer from Discharge
Height of Observation Point:
Description of Background:
Type of Plant
Location of Discharged, end of boiler plant
Description of Sky: Clear
Wind Velocity:
Detached Plume:
Duration
Point:
Point:
10-15 mph
No
of
Observation: 2
300r
hrs , 20 min
Southea st
Ground level
Clear
SUMMARY OF AVERAGE OPACITY
Set
Number
1
2
3
4
5
6
7
8
9
10
11
Time
Start
12:45
12:51
12: 57
13:03
13:09
13:15
13:21
13:27
13:33
13:39
13:45
12 13:51
13 13:57
14 14:03
15
14:09
16 1^:15
17
18
19
20
14:21
14:27
14:33
14:39
End
12:50
12:56
13:02
13:08
13:14
13:20
13:26
13:32
13:38
13:44
13: 50
13:56
14:02
14:08
14: 14
14: 20
14:26
14:32
14:38
14:44
Opacity
Sum
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Average
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Set
Number
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Time
Start
14:45
14:51
14:57
15:03
End
14: 50
14:56
15:02
15:05
Opacity
S um
0
0
0
0
Average
0
0
0
0
Sketch Showing How Opacity Varied With Time:
Opacity
Time, hours
-------
TABLE IX
SUMMARY OF EXHAUST GAS COMPOSITION
BOILER NO. 2 BAGHOUSE OUTLET
Caterpillar Tractor Company
Decatur, Illinois
April 4-7, 1977
Samp ling
Condition
Pulse
Jet
C leaning
Reverse
Air f low
Cleaning
Test
No.
1
2
3
AVERAGE
4
5
6
AVERAGE
Exhaust Gas Composition
(Percent, Dry Basis)
Carbon
Dioxide
8.4
9.4
10.4
9.4
8.3
9.4
8. 0
8.6
Oxygen
10. 8
9. 6
8. 8
9. 7
10.5
9.7
11.4
10.5
Carbon
Monoxide
<0. 1
<0. 1
<0. 1
<0.1
<0. 1
<0. 1
<0. 1
<0. 1
Nitrogen
and
Inert s
80. 8
81. 0
80.8
80. 9
81. 2
SO. 9
80.6
80. 9
Exce s s Air
(Percent)
103
81.5
70. 2
84.9
96. 0
83. 2
115
98. 1
VO
I
Clayton Environmental Consultants, Inc.
-------
- 20 -
IIIo LOCATION OF SAMPLING POINTS
Figures 1 and 2 show a side view and a plan view, respectively,
of the baghouse with its accompanying ductwork and outlet stack.
These figures depict the sampling locations.
Figure 3, an expanded plan view of the stack, gives the
location of the sampling ports used. The main stack shown in Figure
3 houses and insulates the two smaller, inner stacks that actually
carry the baghouse exhaust. All sampling was done on the larger
inner stack shown with a 4'6" I.D. This stack is of cylindrical
construction and was sampled from two ports separated by 90
degrees, as required by EPA Method 1. (See Figure 1.)
Figure 4 represents a cross-sectiona1 diagram of the stack
showing the points used in the sampling traverse,. The duct was
divided into equal annular areas and 24 points were sampled during
a typical test. Due to extended sampling times, a mutual agreement
resulted in the use of 24 points rather than the standard EPA
requirement of 12 sampling points. Each point was sampled for six
minutes, resulting in a total sampling time of 144 minutes.
-------
- 21 -
V. SAMPLING AND ANALYTICAL PROCEDURES
Particulate matter was sampled from the baghouse outlet stack
using a modified form of EPA draft Method 17 (see Appendix B),
The sampling train used is shown in Figure 5
The in-stack filtration was accomplished with a 47-mm type-
SGA filter held in a stainless steel filter holder. This filter
was followed by a heated 6" glass probe leading to a 110-mm type-
SGA filter held in a glass filter holder. The filter holder
assembly was housed in an insulated enclosure with a heater. The
exiting sampled gas temperature and filter box temperature were
monitored by a thermocouple mounted inside the back half of the
filter holder and in the filter box throughout each test. The
probe and filter box heaters were adjusted periodically in an
effort to keep this temperature at approximately 250°F.
The filter exit gases followed a flexible Teflonv^/ line to the
impinger train shown. In place of the standard tip impinger a
modified impinger was used. Sample moisture was condensed in a
series of the two water-filled (100 ml each) modifed impingers
followed by a dry trap and two silica gel traps each containing
400 grams of silica ge!0 The exit gases leaving the final silica
gel trap were monitored for temperature and held below 68°F.
With the removal of the standard impinger from the sampling
train and insertion of the modified impinger, this impinger train
configuration permitted higher gas volume sampling, still utilizing
the normal, commericially supplied EPA console pump.
Sample recovery and analytical procedures followed the guide-
lines given in draft Method 17. The rinse procedure utilized an
acetone-only rinse for the sampling train components preceding
-------
- 22 -
and including the front half of the 110-mm filter holder. A water
rinse followed by an acetone rinse was used for the Teflon^-' line
and impinger sampling train components after the 110-mm filter.
Field data sheets for all particulate sampling are presented in
Appendix C. Appendix D contains auxiliary temperature data that
documents the temperatures existing in the particulate sampling
train as shown in Figure 5. Appendix E. contains the sampling
summary sheets for the particulate samples.
In addition to filterable and total particulate, chloroform-
ether extractable fractions of the particulate were determined.
The EPA will perform a final analysis on the particulate samples
for trace metals. ,
Composite coal samples were taken from the three hoppers
feeding the burner for Boiler No 2 The coal samples taken during
each test consisted of five grab samples spaced in time throughout
each 144-minute testo The samples were sealed in plastic containers
to retain their moisture content. An ultimate analysis was performed
on the samples and the heating value of the coal was determined
according to ASTM methods by Warner Laboratories of Cressen, .
Pennsylvania
Fly ash was collected by grab sample taken at the midway
point of each sampling run. The fly ash sample was taken from the
baghouse hopper bins. These samples were stored in glass bottles at
Clayton Environmental Consultants' laboratory,,
Integrated gas samples were taken during each test run accord-
ing to EPA Method 3. The on-site Orsat analysis also followed EPA
Method 3. Field data sheets are included in Appendix C.
-------
- 23 -
Plume opacity was observed according to EPA Method 9. The
position of the observer relative to the baghouse stack is shown
in Figure 2. Field data sheets for all visible emission observa-
tions are included in Appendix F.
Appendices G and H present the special wash and particulate
weight data and the calibration data, respectively. Appendix I
presents example calculations for summarizing the data.
-------
FIGURE 1
SIDE VIEW OF BAGHOUSE AND ACCOMPANYING DUCTWORK
BOILER NO. 2 BAGHOUSE OUTLET
Caterpillar Tractor Company
Decatur, Illinois
April 4-7, 1977
Clayton Environmental Consultants, Inc
-------
FIGURE 2
PLAN VIEW OF BAGHOUSE AND ACCOMPANYING DUCTWORK
BOILER NO. 2 BAGHOUSE OUTLET
Caterpillar Tractor Company
Decatur, Illinois
April 4-7, 1977
N
Boiler
House
Baghouse
Inlet
Duct
Baghouse Stack
Fan
Fan Fan
Baghouse
Outlet
Duct
Opacity
Observer
Loca tion
Baghouse
Opacity
Observer
Location
Clayton Environmental Consultants, Inc
-------
FIGURE 3
SCHEMATIC DIAGRAM OF SAMPLING LOCATION
BOILER NO. 2 BAGHOUSE OUTLET
Caterpillar Tractor Company
Decatur, Illinois
April 4-7, 1977
N
Clayton Environmental Consultants, Inc
-------
FIGURE 4
SCHEMATIC DIAGRAM OF SAMPLING POINT LOCATIONS
BOILER NO. 2 BAGHOUSE OUTLET
Caterpillar Tractor Company
Decatur, Illinois
April 4-7, 1977
Position
1
2
3
4
5
6
7
8
9
10
11
12
Distance
(Inches)
1.1
3.6
6.4
9.6
13.5
19.2
34.8
40.5
44.4
47.6
50.4
52.9
Port A
10 12
»-=--»-.
Port B
Duct Diameter: 4'6"
Clayton Environmental Consultants, Inc
-------
47-mm type-SGA
'filter
Thermocouple
Teflon^ tubing
Inclined
manome ter
Pyrome ter
'[ / .>
lea ted 110-mml
: y p e - S GA c
filter
1 glass J__
v"~
i
jr
A"
/>
^
L
f
f\
i?
l>
f.
\
<,
)
i
,T
i ''
* "j
g"« *
L
>.
P
rr 'f
^*
r
N
, ^ i
T
.».
' *(. *
\
s
^*
'%
^«
/
/ "
'v i.
At'
*l
^
j
,\
100 ml \ /
distilledv
water
Dry
trap
Silica
gel
Thermometer
hermometers
0 r i f i c e
meter /
VaIves
/^ T> Standard
( ^_jjl,eakless
V ypump
/^-^V
FIGURE 5
SCHEMATIC DIAGRAM OF PARTICULATE SAMPLING TRAIN
BOILER NO. 2 BAGHOUSE OUTLET
Caterpillar Tractor Company
Decatur, Illinois
April 4-7 , 1977
Clayton Environmental Consultants, Inc
------- |