United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EMB Report 80-GYP-1
November 1980
Air
Gypsum Industry
Emission Test Report
Gold Bond Building
Products
Wilmington,
North Carolina
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SOURCE EMISSIONS TEST REPORT
GOLD BOND BUILDING PRODUCTS
Wilmington, North Carolina
No. 2 Calcidyne Baghouse and
Rock Dryer Baghouse
:ey D. O'Neill
Project Scientist
March 1981
•t
Barry ^4 Jadwson
Project Manager
Air Testing
Weston Report No. 0300-81-19
Contract No. 68-02-2816
Work Assignment No. 18
Prepared by
ROY F. WESTON, INC.
Designers-Consultants
Weston Way
West Chester, Pennsylvania
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TABLE OF CONTENTS
LIST OF TABLES
LIST OF FIGURES
SUMMARY 1
INTRODUCTION 4
PROCESS DESCRIPTION AND OPERATION 6
Plant Description 6
Process Equipment Tested 6
Rock Dryer 6
Calcidyne Unit 6
Stucco Storage and Transfer 11
Board Forming Line 11
Emission Controls 11
Process Conditions During Testing 15
Rock Dryer 15
Direct Contact Calciner 15
Stucco Transfer and Storage 19
Board End Sawing 19
Other Process Operations 19
Process Description References 20
DESCRIPTION OF PARTICULATE TEST LOCATIONS 21
No. 2 Calcidyne Baghouse Inlet Duct 21
No. 2 Calcidyne Baghouse Outlet Stack 21
Rock Dryer Baghouse Inlet Duct 21
Rock Dryer Baghouse Outlet Stack 21
DESCRIPTION OF SAMPLING TRAINS 26
Particulate Sampling Trains 26
Particulate Size Distribution Sampling Apparatus 29
TEST PROCEDURES • 31
Preliminary Tests 31
Formal Tests 31
No. 2 Calcidyne Baghouse Inlet Duct 31
11
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TABLE OF CONTENTS
(continued)
No. 2 Calcidyne Baghouse Outlet Stack 32
Rock Dryer Baghouse Inlet Duct 32
Rock Dryer Baghouse Outlet Stack 33
Other Test Points 33
ANALYTICAL PROCEDURES 34
Particulate Sample Recovery 34
Particulate Analyses 34
Particulate Size Sample Recovery and Analyses 35
TEST RESULTS AND DISCUSSION 36
APPENDIX A — Raw Test Data
APPENDIX B — Laboratory Reports
APPENDIX C — Sample Calculations
APPENDIX D — Equipment Calibration Data
APPENDIX E -- Project Participants
iii
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LIST OF TABLES
Table
No. Title Page
1 Emission Test Conducted at Gold Bond,
Wilmington, N.C. Plant 8
2 Control Equipment Parameters 12
3 Stucco Transfer and Storage System 13
4 Bag Replacement Schedules 14
5 Process Data from the Rock Dryer: Run No. 1 16
6 Process Data from the Rock Dryer: Runs No.2
and 3 17
7 Free Moisture of Gypsum Rock 18
8 No. 2 Calcidyne Baghouse Inlet Duct
Summary of Test Data - English Units 37
9 No. 2 Calcidyne Baghouse Inlet Duct
Summary of Test Data - Metric Units 38
10 No. 2 Calcidyne Baghouse Outlet Stack
Summary of Test Data - English Units 39
11 No. 2 Calcidyne Baghouse Outlet Stack
Summary of Test Data - Metric Units 40
12 Rock Dryer Baghouse Inlet Duct
Summary of Test Data - English Units 41
13 Rock Dryer Baghouse Inlet Duct
Summary of Test Data - Metric Units 42
14 Rock Dryer Baghouse Outlet Stack
Summary of Test Data - English Units 43
15 Rock Dryer Baghouse Outlet Stack
Summary of Test Data - Metric Units 44
iv
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LIST OF TABLES
(continued)
Table
No. Title Page
16 No. 2 Calcidyne Baghouse Inlet Duct
Summary of Test Results - English Units 45
17 No. 2 Calcidyne Baghouse Inlet Duct
Summary of Test Results - Metric Units 46
18 No. 2 Calcidyne Baghouse Outlet Stack
Summary of Test Results - English Units 47
19 No. 2 Calcidyne Baghouse Outlet Stack
Summary of Test Results - Metric Units 48
20 Rock Dryer Baghouse Inlet Duct
Summary of Test Results - English Units 49
21 Rock Dryer Baghouse Inlet Duct
Summary of Test Results - Metric Units 50
22 Rock Dryer Baghouse Outlet Stack
Summary of Test Results - English Units 51
23 Rock Dryer Baghouse Outlet Stack
Summary of Test Results - Metric Units 52
24 No. 2 Calcidyne Baghouse Inlet Duct
Particle Size Distribution - Run 1 53
25 No. 2 Calcidyne Baghouse Inlet Duct
Particle Size Distribution - Run 2 55
26 No. 2 Calcidyne Baghouse Inlet Duct
Particle Size Distribution - Run 3 57
27 No. 2 Calcidyne Baghouse Outlet Stack
Particle Size Distribution - Run 1 59
28 Rock Dryer Baghouse Inlet Duct
Particle Size Distribution - Run 1 61
29 Rock Dryer Baghouse Inlet Duct
Particle Size Distribution - Run 2 63
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LIST OF TABLES
(continued)
Table
No. Title Page
30 Rock Dryer Baghouse Inlet Duct
Particle Size Distribution - Run 3 65
31 Rock Dryer Baghouse Outlet Stack
Particle Size Distribution - Run 1 67
32 No. 2 Calcidyne Baghouse Outlet Stack
Summary of Visible Emissions - 19 May 1980 69
33 No. 2 Calcidyne Baghouse Outlet Stack
Summary of Visible Emissions - 20 May 1980 70
34 Rock Dryer Baghouse Outlet Stack
Summary of Visible Emissions - 21 May 1980 71
35 Rock Dryer Baghouse Outlet Stack
Summary of Visible Emissions - 22 May 1980 72
36 Stucco Baghouse Outlet Stack
Summary of Visible Emissions - 27 May 1980 73
37 Mean Fugitive Emission Values 74
VI
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LIST OF FIGURES
Figure
No. Title Page
1 Block Flow Diagram for Wilmington Board Plant 7
2 Direct-Fired, Co-Current, Rotary Dryer 9
3 Calcidyne Flash Calcimer 10
4 No. 2 Calcidyne Baghouse Inlet Duct
Port and Sampling Point Locations 22
5 No. 2 Calcidyne Baghouse Outlet Stack
Port and Sampling Point Locations 23
6 Rock Dryer Baghouse Inlet Duct
Port and Sampling Point Locations 24
7 Rock Dryer Baghouse Outlet Stack
Port and Sampling Point Locations 25
8 Particulate Sampling Train
EPA Method 5 27
9 Particulate Sampling Train
EPA Method 5 28
10 Particle Size Distribution Sampling
Apparatus 30
vii
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SUMMARY
i
The Emission Measurement Branch of the U.S. Environmental Pro-
tection Agency contracted Roy F. Weston, Inc. (Weston) to con-
duct a source testing and analysis program at Gold Bond Build-
ing Products' Wilmington, North Carolina gypsum processing
facility.
The primary objectives of the testing program were to determine
collector particulate removal efficiencies, and to quantify
particulate emissions to the atmosphere from two baghouse-con-
trolled sources at the plant (No. 2 calcidyne and rock dryer).
This objective was achieved by performing a series of three
particulate tests utilizing EPA Method 5* procedures at each
baghouse inlet duct and outlet stack location. In addition,
visual determinations of plume opacities were made simulta-
neously with each particulate test at the two source discharge
points according to EPA Method 92 protocol. A singular
Anderson® cascade impactor3 test was performed at each
stack exhaust location and three Anderson® cascade impactor
tests were conducted at each of the baghouse inlet locations.
In addition, frequency of fugitive emissions (by EPA Method
224) was monitored at several points in the processing opera-
tion.
Particulate matter and visible emissions results are summaried
as follows:
No. 2 Calcidyne Baghouse Inlet Duct
Test Particulate Concentration Particulate Emission Rate
Number Date Grains/DSCF Pounds/Hour
1 5-19-80 22.0 288.
2 5-20-80 21.6 284.
3 5-20-80 21.2 269.
Series Average - 280.
^''Standards of Performance for New Stationary Sources," Code
of Federal Regulations, Title 40, Part 60, Appendix A, 18 August
1977.
2Federal Register, Vol. 39, No. 219, 12 November 1974.
3Qperating Manual for Anderson 2000, Inc., "Mark III Particle
Sizing Stack Samplers," Anderson 2000, Inc., P.O. Box 20769,
Atlanta, Georgia.
4Draft Method, Revised 28 July 1978.
-1-
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No. 2 Calcidyne Baghouse Outlet Stack
Test
Number
Date
1 5-19-80
2 5-20-80
3 5-20-80
Series Average
Particulate
Concentration
Grains/DSCF
0.021
0.024
0.026
Particulate
Emission
Rate
Pounds/Hour
0.282
0.325
0.335
0.314
Maximum
Recorded
Opacity
Percent
5
5
5
Test
Number
Date
1 5-21-80
2 5-22-80
3 5-22-80
Series Average
Rock Dryer Baghouse Inlet Duct
Particulate Concentration
Grains/DSCF
50.7
51.9
51.2
Particulate Emission Rate
Pounds/Hour
4f900.
5,070.
5,180.
5,050.
Rock Dryer Baghouse Outlet Stack
Test
Number
Date
1 5-21-80
2 5-22-80
3 5-22-80
Series Average
Particulate
Concentration
Grains/DSCF
0.027
0.019
0.018
Particulate
Emission
Rate
Pounds/Hour
2.69
1.83
1.77
2.10
Maximum
Recorded
Opacity
Percent
5
5
0
Test
Number
1
2
3
Stucco Baghouse Outlet Stack
Date
Maximum Recorded Opacity
Percent
5-27-80
5-27-80
5-27-80
15
10
5
-2-
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The average measured particulate removal efficiency of the
No. 2 Calcidyne Baghouse was 99.89%; that of the Rock Dryer
Baghouse was 99.96%.
Detailed particulate, particle size distribution, visible and
fugitive emission test data, and test results are presented in
the section "Test Results and Discussion."
-3-
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INTRODUCTION
The Emission Measurement Branch of the U.S. Environmental Pro-
tection Agency contracted Weston to conduct a source testing
and analysis program at Gold Bond Building Products'
Wilmington, North Carolina gypsum processing facility. The
objective of the testing program was to measure various
emission parameters relating to milling, drying, and packaging
operations at the plant.
The locations tested, plus the number and types of tests per-
formed at each site, are listed below:
1. No. 2 Calcidyne Baghouse Inlet Duct
a. Three particulate tests by EPA Method 5.
b. Three particle size distribution tests
by cascade impaction (Anderson*?} .
2. No. 2 Calcidyne Baghouse Outlet Stack
a. Three particulate tests by EPA Method 5.
b. One particle size distribution test by
cascade impaction (Anderson**) .
c. Three opacity tests by EPA Method 9
simultaneous with particulate tests.
3. Rock Dryer Baghouse Inlet Duct
a. Three particulate tests by EPA Method 5.
b. Three particle size distribution tests
by cascade impaction (Anderson®) .
4. Rock Dryer Baghouse Outlet Stack
a. Three particulate tests by EPA Method 5.
b. One particle size distribution test by
cascade impaction (Anderson®) .
-4-
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c. Three opacity tests by EPA Method 9
performed concurrently with partic-
ulate tests.
5. Board End Sawing
a. Three EPA Method 22 fugitive emission tests.
6. Score Wheel
a. Three EPA Method 22 fugitive emission tests.
7. Admix Conveyor
a. Three EPA Method 22 fugitive emission tests.
8. Fiberglass Shredder
a. Three EPA Method 22 fugitive emission tests.
9. Vermiculite Addition Process
a. One EPA Method 22 fugitive emission test.
10. Stucco Baghouse Outlet Stack
a. Three opacity tests by EPA Method 9.
All tests were conducted during the period 19 through 27 May
1980 by Weston personnel, and were observed by Mr. Dennis P.
Holzschuh, EPA Technical Manager.
Test data and test result summaries are presented in Tables 8
through 23 of this report. Particle size distribution results
are shown in Tables 24 through 31. Also included in this
report are descriptions of the test locations, test equipment,
test procedures, and sample recovery and analytical methods
used during the test program. Raw test data, laboratory
reports, sample calculations, equipment calibration records,
and a list of project participants are provided in Appendices A
through E, respectively.
-5-
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PROCESS DESCRIPTION AND OPERATION
PLANT DESCRIPTION
The Gold Bond Building Products Wilmington, North Caroline plant
produces wallboard from gypsum ore mined in Halifax, Nova
Scotia. The ore is shipped to the plant by ocean-going freight-
er. A simplified flow diagram for the process used at the
Wilmington plant is shown in Figure 1. Ore stockpiled at the
plant is crushed to about minus 5 cm (2 inches) and then dried
to remove surface moisture. The dry ore is further ground
to about 90 percent minus 100 mesh in a grinding mill. The
ground crude gypsum, primarily calcium sulfate dihydrate
(CaS04 • 2H20), is heated to around 571°K (300°F) to remove 75
percent of its water of hydration and thus form calcium sulfate
hemihydrate (CaS04 • 1/2H20). This process is known as calcin-
ing. The calcined gypsum or stucco is mixed with starch, water,
and other additives to form a slurry. The slurry is spread
between two paper sheets and formed into wet wallboard. The
wallboard is subsequently dried in a multi-deck kiln, trimmed to
the correct size, and shipped to distributors.
PROCESS EQUIPMENT TESTED
The emission tests conducted at the Wilmington plant are shown
in Table 1. A brief description of the major processing equip-
ment tested at the plant is provided in the following sections.
Rock Dryer
The rock dryer employed at the Wilmington plant is a direct-
fired, co-current rotary dryer. As crushed wet gypsum is passed
through the dryer, surface moisture is evaporated by hot com-
bustion gases. A schematic diagram of this type of dryer is
shown in Figure 2.
Calcidyne Unit
The calciner used at the Wilmington plant is a direct-contact
flash calciner of National Gypsum's own patented design. The
Calcidyne unit is a continuous calciner in which gypsum is cal-
cined through direct contact with hot gases. A schematic dia-
gram of the unit is shown in Figure 3.
-6-
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Halifax
Ship
Ship to Shore
Conveyor
Stockpile
Belt Conveyor
Hammermi11
M Baghouse dust collector
_> Air/water flow
> Process flow
A
g£r *» Vent
Screw Conveyors
and
Bucket Elevator A
I i
Grinding J 1 Vent
Mill
Landplaster
Storaae and
Transfer •
A
Flash _ -4_J Vent
Calciners I /
,____„/
Stucco Storage
and Transfer
Vent
Warehouse
Sawing and
Bundling
/\
Board Drying
Kiln
A
Knife
A
Board Mixing
and Forming
A
Vent
Figure 1. Block Flow Diagram for Wilmington Board Plant
-7-
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TABLE, 1 . EMISSION TESTS CONDUCTED AT GOLD BOND, WILMINGTON. N.C. PLANT
i
CO
I
PROCESS TESTED
Direct contact
calciner
Rock Dryer
DATE
5/19/80
5/21 /ao
CONTROL METHOD
Fabric Filter
Fabric Filter
TEST TYPE
Participate loading
Particle size
Visible Emission
Participate loading
Particle size
Visible emission
INLET TEST
3 EPA-5
3 Andersen
M/A
3 EPA-5
3 Andersen
N/A
OUTLET TEST
3 EPA-5
1 Andersen
EPA-9
3 EI'A-5
1 Andersen
EPA-9
Stucco Storage
and Transfer
(2 storage bins,
5 screw conveyors,
2 bucket elevators,
admix conveyor,
and air conveyor)
Board end-sawing
Paper scoring
Accelerator addition
Fiberglass Sbredder
Verm kill ite
Addition
5/27/00
Fabric Filter
Visible emission
5/19/00
5/20/00
5/20/00
5/21/80
5/21/00
5/21/00
5/22/80
5/22/80
Capture Hood/
Fabric Filer
Capture Hood/
Fabric Filter
Capture Hood/
Fabric Filter
Capture Hood/
Fabric Filter
Capture Hood/
Fabric Filter
Visible emission
Visible emission
Visible emission
Visible emissions
Visible emissions
EPA-9
EPA-22
EPA-22
EPA-22
EPA-22
EPA-22
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Feed chule
Combuslion
lurnoce
Burner
vo
Figure 2 Direct-Fired, Co-Current, Rotary Dryer
-------
Feed spout
Calcidyne.
-Inlet to fabric
filter dust collector
urner
ecircu-
lation
fan
Product discharge
to conveyor
Figure 3 Calcidyne Flash Calciner
-10-
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Stucco Storage and Transfer
The stucco storage and transfer system used at the plant employs
conventional screw conveyors and bucket elevators to transfer
stucco from the Calcidyne units to two 150-ton storage bins and
from the storage bins to the board forming line.
Board Forming Line
The boardline tested at the Wilmington plant is of average size,
capable of producing about 23 million square meters (250 million
square feet) of wallboard per year on a half-inch basis. The
process operations tested on the boardline, which include board
end sawing, paper scoring, accelerator addition, fiberglass
shredding, and vermiculite addition, are typical of those used
throughout the gypsum industry.
EMISSION CONTROLS
Fabric filter dust collectors are used at the Wilmington plant
to control gypsum particulate emissions. Dust-laden gases exit-
ing the rock dryer and the direct contact calciner are vented to
separate baghouses. Emissions from screw conveyors, bucket
elevators, and storage bins are vented to two fabric filter dust
collectors: one collector for transfer and storage of dried
gypsum or landplaster, and a second collector for transfer and
storage of calcined gypsum or stucco. Boardline emissions,
which include emissions from mixing, paper scoring, fiberglass
shredding, accelerator addition, and board end sawing, are also
controlled by baghouses.
Design and operating parameters for the baghouses tested at the
Wilmington plant are given in Table 2. Design parameters for
the process units vented to the stucco storage and transfer bag-
house are given in Table 3. The values for process rate and air
flow given in Table 3 are design values and only approximate
actual values.
Normal replacement frequencies and the most-recent replacement
dates for bags in the dust collectors tested are shown in Table
4. Inspections of the rock dryer baghouse and the stucco trans-
fer baghouse on May 17 and May 24, respectively, indicated that
the filter bags were in need of replacement.
-11-
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TABLE 2. CONTROL EQUIPMENT PARAMETERS
Process
Unit
Name
Direct
Contact
Calclner
Rock Dryer
Stucco
Transfer
naghouse
Manufacturer
Flcx-Kleen
(reverse pulse)
Ray Jet
(reverse pulse)
Ray Jet
(reverse pulse)
Number of
Dags
96
192
120
Hag Dimensions
(diam X length
In inches)
6 X 84
6 X 108
6 X 108
Cloth Area
(square feet)
960
2880
1800
Fabric
Type
Nomex
Nomcx
Dacron
Design
Air Flow
(ACFH)
4100
14800
9030
Duration
of pulse
(sec)
0.1
0.1
0.1
Frequency
of pulse9
(sec)
10
10
10
Pressure
of pulse
90
90
90
These values are approximate; they are varied automatically to maintain a set pressure drop across the filter.
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TABLE 3 . STUCCO TRANSFER AND STORAGE SYSTEM
OJ
I
Process Unit Description
Two storage bins
Admix screw conveyor
Bucket elevator feeding storage
bins by way of screw conveyors
Bucket elevator feeding board
plant screw conveyors
2 screw conveyors feeding bins from
bucket elevator
Air conveyor
Screw conveyor for stucco recycle
from 3 calciner baghouses
Main stucco conveyor to board
plant pin mixer
Main stucco conveyor from calciners
Paper scoring
Design Capacity
150 tons each
25 TPH b
55 TPH
35 TPH
55 TPH each
30 TPH
10 TPH
25 TPH
25 TPII
N/AC
Air Flow (ACFMf
390 (each)
390
990
990
780 (each)
220
390
390
1220
2100
Mote should be made that these values are the design values and only approximate actual operating values.
JTPII=Tons per hour
:N/A=Not applicable
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Table 4
Bag Replacement Schedules
Process Unit
Name
Last Date of
Bag Replacement
Normal Replacement
Frequency
(Months)
Direct Contact Calciner 1/20/80
Rock Dryer 5/17/80
Stucco Transfer 5/24/80
4-6
9
12
-14-
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Process Conditions During Testing
In order to ensure that the rock dryer, calciner, and boardline
operations were operating at representative steady-state condi-
tions during the testing, various process parameters were moni-
tored.
All processes and emission control equipment were operated at
normal conditions during the emission testing except for the
stucco storage and transfer baghouse. The operating conditions
of each of the processes tested are discussed separately in the
following sections.
Rock Dryer
During the emission testing, the rock dryer at the Wilmington
plant was running at its normal operating rate, producing 30
tons of dry rock per hour. This operating rate is 60 percent
of the design capacity of the dryer. Process data collected
during the EPA Method 5 test runs is shown in Tables 5 and 6.
The average heat usage of the dryer during the testing was 0.20
million Btu/ton of dried rock. The dryer was burning high sul-
fur No. 6 fuel oil with a heating value of 149,100 Btu/gallon.
The temperature of the rock exiting the dryer was approximately
155 to 160°F. The results of measurements of the free mois-
ture content of the ore entering and exiting the dryer are shown
in Table 7. Due to a rainstorm that occurred on the evening of
20 May 1980, the ore may have been slightly wetter than normal
during the emission tests on the dryer. This additional mois-
ture should not affect the test results. The pressure drop
through the fabric filter was constant at 2.5 inches of water.
Direct Contact Calciner
During the emission testing of the direct contact calciner, or
Calcidyne unit, the calciner was operated at full capacity,
reported as 7.0 tons per hour of calcined gypsum or stucco by
plant personnel. Various process parameters were monitored dur-
ing each of the three EPA Method 5 test runs on the direct con-
tact calciner. The data show a seven-percent increase in the
fuel usage rate between the first and second test runs. This
increase in fuel usage is probably the result of a slight change
in the operating rate of the unit. Wilmington plant personnel
indicated, however, that the unit was producing approximately
seven tons per hour during the entire test. Other process
parameters monitored indicate that the calciner was operating at
steady-state conditions throughout the testing. The pressure
drop through the fabric filter dust collector was constant
throughout the test at a value of 3.4 inches of water.
-15-
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Table 5
Process Data from the Rock Dryer: Run No. 1
Plant:
Location:
Date:
Local
Time
10:16 AM
11:06
11:45
12:00 PM
12:45
1:00
1:33
Gold Bond
Wilmington, N.C.
5/21/80
Dryer
Temperature
°C (°F)
104 (220)
104 (220)
104 (220)
104 (220)
104 (220)
104 (220
104 (220)
Fuel
3 Usage
m /hr (gal/min)
0.16 (0.69)
- 0.15 (0.66)
0.15 (0.65)
0.14 (0.62)
0.13 (0.59)
0.16 (0.69)
0.15 (0.66)
-16-
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Table 6
Process Data from the Rock Dryer: Runs No. 2 and 3
Plant:
Location:
Date:
Local
Time
8:41
10:00
11:35
12:39
1:15 PM
2:10
2:33
Gold rtond
Wilmington, N.C.
5/22/80
Dryer
Temperature
or / oc\
\ I
104 (220)
104 (220)
104 (220)
104 (220)
104 (220)
104 (220)
104 (220)
m3/hr
0.17
0.15
0.15
0.14
0.15
0.15
0.14
Fuel
Usage
(gal/min)
(0.76)
(0.65)
(0.67)
(0.63)
(0.68)
(0.67)
(0.63)
-17-
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Table 7
Free Moisture of Gypsum Rock3
Date
5/21/80
5/22/80
Wet Rock
(Weight percent
free water)
6.0%
7.6%
Dry Rock
(Weight percent
free water)
1.0%
<0.5%
aFree moisture is measured by drying ore sample for one hour at 160°F.
-18-
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Stucco Transfer and Storage
The transfer and storage system was operating at normal capacity
during the emission testing. One of the storage bins was three-
fourths full, and the other was one-half full.
An inspection for fugitive emissions from each of the sources
vented to the stucco transfer baghouse was performed. No vis-
ible emissions were observed from any of the sources during the
inspection.
Test data from the stucco transfer and storage baghouse show
higher-opacity readings than expected because the fabric filter
bags had been changed on May 24 and were in operation only sev-
eral hours prior to the testing. The EPA-Method 9 test on the
stucco storage and transfer baghouse is not representative of
normal fabric filter operation. The filter bags were not in
operation long enough to allow a filter cake to form on the bags
and, therefore, were not operating at maximum efficiency.
Board End Sawing
During the board end sawing testing, the board line was running
regular, one-half inch board, eight feet in length for two-
thirds of the testing, and regular, one-half inch board, twelve
feet in length for the remainer of the testing. The board line
was operating at normal speed during the testing.
Other Process Operations
The remaining processes tested, which include paper scoring,
accelerator addition, fiberglass shredding, and vermiculite
addition, were all tested under normal operating conditions.
-19-
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PROCESS DESCRIPTION REFERENCES
1. U.S. Environmental Protection Agency. Sodium Carbonate
Industry - Background Information for Proposed Standards.
Research Triangle Park, North Carolina. EPA-450/3-80-029a.
p. 3-30.
-20-
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DESCRIPTION OF PARTICULATE TEST LOCATIONS
NO. 2 CALCIDYNE BAGHQUSE INLET DUCT
Two 4-inch I.D. test ports, 90° apart, were installed on a
staight section of the 12-inch I.D. metal stack at a location
that was 12 diameters (12 feet) downstream and 6 diameters (6
feet) upstream from the nearest flow disturbance. EPA Method 1
criteria for this test location required a minimum of 12 trav-
erse points. See Figure 4 for port and sampling point loca-
tions.
NO. 2 CALCIDYNE BAGHOUSE OUTLET STACK
Two 4-inch I.D. test ports were placed at right angles on a
straight section of the 11 1/4-inch I.D. metal stack serving
the baghouse outlet. The ports were located 5.2 diameters
downstream and 2 diameters upstream from the nearest flow
disturbance. Stack geometry required the use of 20 sampling
points (10 per axis). Figure 5 illustrates port and sampling
point locations.
ROCK DRYER BAGHOUSE INLET DUCT
Two 4-inch test ports were placed, 90° apart, on the
25 1/2 -inch I.D. duct at a location which was 1.0 diameter
downstream and 1.0 diameter upstream from the nearest gas
stream flow disturbance. Forty-eight sampling points (24 per
axis) were required for testing. See Figure 6 for port and
sampling point locations.
ROCK DRYER BAGHOUSE OUTLET STACK
Two 4-inch I.D. test ports were installed, 90° apart, on a
straight section of the 27 1/2-inch I.D. metal stack. The
ports were placed 5.2 diameters (143 inches) downstream and 1.3
diameters (35 inches) upstream from the nearest flow disturb-
ance. EPA Method 1 required a minimum of 32 traverse points
(16 per axis) for particulate sampling at this location. See
Figure 7 for port and sampling point locations.
-21-
-------
• 12 inches-
Duct Cross-Sectional Plan
Traverse
Point
Number
1
2
3
4
5
6
Distance From
Inside Near
. x Wall
:" inches
1/2
1 3/4
31/2
81/2
101/2
11 1/2
To
t
6 feet
I
|
12
-
eet
f
J
X
\
Flow
Direction
j
Baghou
r
D
Y
Duct Elevation
Grating
Figure 4 No. 2 Calcidyne Baghouse Inlet Duct
Port and Sampling Point Locations
-22-
-------
Stack Cross-Sectional Plan
Traverse.
Point
Number
1
2
3
4
5
6
7
8
9
10
Inside Near
Wall
Inches
1/2
7/8
1 5/8
2 1/2
37/8
73/8
83/4
95/8
103/8
103/4
t I
82 inches
60 inches
O
X
D
Y
Roof
'Line
Stack Elevation
Figure 5 No. 2 Calcidyne Baghouse Outlet Stack
Port and Sampling Point Locations
-23-
-------
Distance From
.Traverse^
.Point .
Number..
1
2
3
4
5
6
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Inside Near
Wall
Inches
' ' 1/2
3/4
1 3/8
2
o c/8
33/8
44 lO A
\
O
X
1/8 /
t
24 inches
D t
1 \
24 inches
4 Platform
Level
5 / X
57/8 / Rock \
67/8 / Dryer X
10 1/8 ' X
153/8
17 1/4
181/2 Duct Elevation
195/8
201/2,
21 3/8
22 1/8
223/4
23 1/2
241/8
245/8
25
Figure 6 Rock Dryer Baghouse Inlet Duct
Port and Sampling Point Locations
-24-
-------
Roof
Line~
Duct Cross-Sectional Plan
Traverse
Point
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Distance From
Inside Near
Wall
Inches
1/2
1 3/8
23/8
33/8
45/8
6
73/4
10 1/4
171/8
193/4
21 1/2
227/8
241/8
25 1/8
261/8
27
o
X
35 inches
P-
Y
143 inches
ID Fan
Stack Elevation
Figure 7 Rock Dryer Baghouse Outlet Stack
Port and Sampling Point Locations
-25-
-------
DESCRIPTION OF SAMPLING TRAINS
PARTICIPATE SAMPLING TRAINS
The test train utilized for particulate sampling at the outlet
locations was the standard EPA Method 5 train (see Figure 8).
A stainless steel nozzle was attached to a heated (~250°F)
borosilicate glass probe which was connected directly to a
borosilicate filter holder containing a 9-cm Reeve Angel 900 AF
glass fiber filter. The filter holder was maintained at
approximately 250°F in a heated chamber, and was connected by
vacuum tubing to the first of four Greenburg-Smith impingers
which were included in the train to condense the moisture in
the gas stream. Each of the first two impingers contained 100
ml of distilled water, the third was dry, and the final
impinger contained 200 grams of dry preweighed silica gel. The
first, third, and fourth impingers were modified Greenburg-Smith
types; the second was a standard Greensburg-Smith impinger.
All impingers were maintained in a crushed ice bath. An RAC
control console with vacuum pump, dry gas meter, a calibrated
orifice, and inclined manometers completed the sampling train.
Flue gas temperature was measured by means of a calibrated
Type K thermocouple which was connected to a direct readout
pyrometer. The thermocouple sensor was positioned adjacent to
the sampling nozzle.
Gas velocity was measured using a calibrated "S"-type pitot
tube provided with extensions and fastened alongside the sam-
pling probe. Gas stream composition (carbon dioxide, oxygen,
and carbon monoxide content) was determined utilizing Orsat
apparatus to analyze stack gas samples.
Figure 9 shows the EPA Method 5 train utilized at the No. 2
Calcidyne and Rock Dryer Baghouse inlet sites. The test train
shown is identical to the one just described, except a rigid
glass connection is used between the back half of the filter
holder and the first impinger, rather than the flexible vacuum
tubing.
-26-
-------
0.75 to 1 in.
1
Temperature Sensor
t
2 0.75 in.
t
Pilot Tube
Temperature Sensor
/I
Sampling^
Nozzle^ —
Probe
Temperature Controlled
Heated Area
Stack Wall
t
Reverse-Type
Pilot Tube
Pitol Manometer' Thermometers
Orifice
Thermometer
Air Tight Pump
Check Valve
-Vacuum
Line
Figure 8 Particulate Sampling Train -EPA Method 5
-------
I
tvj
CD
I
/TEMPERATURE
SENSOR
0.75 TO 1 in.
_i
REVERSE-TYPE
PITOT TUBE
THERMOMETER
CHECK VALVE
VACUUM LINE
VACUUM GUAGE
HEATED AREA
FILTER HOLDER
THERMOMETERS
DRY GAS
METER
PITOT MANOMETER
IMPINGERS
ORIFICE
AND
MANOMETER
ICE BATH
Figure 9 Particulate Sampling Train - EPA Method 5
-------
PARTICULATE SIZE DISTRIBUTION SAMPLING APPARATUS
A stainless steel nozzle was connected directly to an 8-stage
Anderson® cascade impaction device which separated the par-
ticles according to their effective aerodynamic particle diam-
eters. A glass fiber filter was used to capture any particles
that passed through the impactor substrates to permit the meas-
urement of total particulates. The filter holder was main-
tained at stack temperature and was connected by vacuum tubing
to the first of four Greenburg-Smith impingers which were
included in the train to condense the moisture in the gas
stream. All impingers were maintained in a crushed ice bath.
An RAC control console with vacuum pump, dry gas meter, a cali-
brated orifice, and inclined manometers completed the sampling
train (Figure 10).
-29-
-------
Thermometer
Nozzle
Reverse-Type
Pilot Tube
Air Tight Pump
Check Valve
Pilot Manometer' Thermometers
Orifice
Ice Bath
Vacuum Gauge
Vacuum
Line
Figure 10 Particle Size Distribution Sampling Apparatus
-------
TEST PROCEDURES
PRELIMINARY TESTS
Preliminary test data were obtained at each sampling location.
Stack geometry measurements were recorded and sampling point
distances calculated. A preliminary velocity traverse was per-
formed at each test location utilizing a calibrated "S"-type
pitot tube and a Dwyer inclined manometer to determine velocity
profiles. A check for the presence or absence of cyclonic flow
was conducted at each test location prior to formal testing.
Stack gas temperatures were observed with a direct readout
pyrometer equipped with a chromel-alumel thermocouple.
Preliminary test data was used for nozzle sizing and nomagraph
set-up for isokinetic sampling procedures.
Calibration of the probe nozzles, pitot tubes, metering sys-
tems, probe heaters, temperature gauges, and barometer were
performed as specified in Section 5 of EPA Method 5 test pro-
cedures (see Appendix D for calibration records) .
FORMAL TESTS
No. 2 Calcidyne Baghouse Inlet Duct
A series of three tests was conducted at the No. 2 Calcidyne
Baghouse inlet duct to measure the concentration and mass rate
of particulate matter entering the baghouse. Twelve traverse
points (six per port axis) were sampled for 5 minutes each,
resulting in a total test time of 60 minutes.
During particulate sampling, gas stream velocities were meas-
ured by inserting a calibrated "S"-type pitot tube into the
stream adjacent to the sampling nozzle. The velocity pressure
differential was observed immediately after positioning the
nozzle at each point, and sampling rates were adjusted to main-
tain isokinetic sampling. Stack gas temperatures were also
monitored at each point with the pyrometer and thermocouple.
Additional temperature measurements were made at the final
impinger and at the inlet and outlet of the dry gas meter.
Test data were recorded at each traverse point during all test
periods. Leak checks were performed according to EPA Method 5
instructions prior to and after each run and/or component
change. Tables 8 and 9 present a summary of test data for each
of the three runs. Test result summarization appears in Tables
16 and 17.
-31-
-------
One sampling point located at a site of average velocity was
selected from particulate traverse data for particle size dis-
tribution testing. The gas stream was sampled isokinetically
at that point for 20 seconds which permitted collection of suf-
ficient samples for analysis without overloading the filter
substrates. Sample volume, temperature, and pressure data were
recorded during sampling. See Tables 24 through 26 for distri-
bution plots.
No. 2 Calcidyne Baghouse Outlet Stack
Three Method 5 tests were performed at the baghouse outlet
stack. Forty traverse points (20 per axis) were sampled for 3
minutes each, yielding a 120-minute test period for the first
test run; for test runs two and three, 20 traverse points (10
per axis) were sampled for 5 minutes each, yielding a 100-minute
test period. With the permission of the Administrator, the
nozzle size was increased from 0.195 inch to 0.225 inch during
test runs two and three. The larger nozzle ensures sufficient
sample collection, but allows for a reduction in test time from
120 minutes for the first test to 100 minutes for the second and
third tests.
Sampling procedures were identical to those previously de-
scribed. Tables 10 and 11 show the test data summaries, and
Tables 18 and 19 present test results.
One particle size distribution sample was collected isokinet-
ically at a point of average velocity over a 60-minute period.
Sample volume, temperature, and pressure data were recorded
every 5 minutes during sampling. See Table 27 for particle
distribution results.
Visual determinations of plume opacity were performed by a cer-
tified observer according to EPA Method 9 procedures during the
three particulate test runs. Summaries of results are pre-
sented in Tables 32 and 33.
Rock Dryer Baghouse Inlet Duct
Three test runs were conducted by EPA Method 5 procedures at
the inlet to the Rock Dryer Baghouse. A total of 48 traverse
points (24 per axis) were sampled for 2 minutes each, resulting
in a total test time of 96 minutes per run. Tables 12 and 13
show test data, and Tables 20 and 21 show test result summaries.
Three particle size distribution tests were performed at a
point of average velocity. Total sample time for each run was
20 seconds. Tables 28 through 30 show particle size distri-
bution results.
-32-
-------
Rock Dryer Baghouse Outlet Stack
Three 96-minute Method 5 test runs were performed at the bag-
house outlet stack. Thirty-two traverse points (16 per axis)
were sampled for 3 minutes each. Tables 14 and 15 show test
data, and Tables 22 and 23 present test result summaries.
One particle size distribution test was performed at a point of
average velocity over a 60-minute period. Readings were record-
ed at 5-minute intervals. Table 31 presents the particle size
distribution plot.
Visual determinations of plume opacity were performed by a cer-
tified observer in conjunction with the particulate tests. Sum-
maries of test results are presented in Tables 34 and 35.
OTHER TEST POINTS
The visible and fugitive emission tests conducted at the remain-
ing test points were one hour in duration each.
-33-
-------
ANALYTICAL PROCEDURES
PARTICULATE SAMPLE RECOVERY
At the conclusion of each test, the sampling trains were disman-
tled, openings sealed, and the components transported to the
field laboratory. Sample integrity was assured by maintaining
chain-of-custody records, which will be supplied upon request.
A consistent procedure was employed for sample recovery.
1. The glass fiber filter(s) was removed from its holder
with tweezers and placed in its original container
(petri dish), along with any loose particulate and fil-
ter fragments (sample type 1).
2. The probe and nozzle were separated, and the internal
particulate rinsed with acetone into a borosilicate con-
tainer while brushing a minimum of three times until no
visible particles remained. Particulate adhering to the
brush was rinsed with acetone into the same container.
The front half of the filter holder was rinsed with
acetone while brushing a minimum of three times. The
rinses were combined (sample type 2) and the container
sealed with a Teflon-lined closure. Fluid levels were
marked to determine whether or not leakage occurred
during transport. The container was labeled to
clearly identify its contents.
3. The total liquid in impingers 1, 2, and 3 was measured,
the value recorded, and the liquid discarded.
4. The silica gel was removed from the last impinger
and immediately weighed.
5. An acetone sample was retained for blank analysis.
PARTICULATE ANALYSES
The filters (sample type 1) and any loose fragments were desic-
cated for 24 hours and weighed to the nearest 0.1 milligram to
a constant weight.
The acetone wash samples (sample type 2) were evaporated at
ambient temperature and pressure in tared beakers, and desiccat-
ed to a constant weight. All sample residue weights were
adjusted by the acetone blank value.
-34-
-------
The weight of the material collected on the glass fiber fil-
ter (s) plus the weight of the residue of the acetone nozzle/
probe/front-half filter holder washes represents the "total"
EPA Method 5 catch. Complete laboratory results are presented
in Appendix B of this report.
PARTICULATE SIZE SAMPLE RECOVERY AND ANALYSES
The cascade impactor substrates and any loose fragments were
carefully removed from their support plates with tweezers and
placed in individual containers (petri dishes) for shipment to
Weston's laboratory.
Each cascade impactor filter was fired at 525°C and pre-
weighed to the nearest 0.1 milligram to constant weight at
Weston's laboratory prior to on-site application. Subsequent
to Weston's exposure, the cascade impactor substrates, back-up
filters, and any loose fragments were desiccated for 24 hours
in the laboratory, and weighed to the nearest 0.1 milligram to
constant weight.
-35-
-------
TEST RESULTS AND DISCUSSION
Particulate test data and test result summaries are presented
in Tables 1 through 8 of this report. Tables 24 through 31
list the particle size distribution results for all locations.
No unusual sampling difficulties or process operating problems
were encountered during any of the test periods/ except for the
Stucco Baghouse which needed rebagging. A Weston Method 9
observer returned to the plant site on 27 May 1980 to conduct
the visible emission tests on the baghouse stack following com-
pletion of collector maintenance.
The amount of particulate matter discharged to the atmosphere
from the No. 2 Calcidyne Baghouse outlet was ^ 0.026 grains/
DSCF and ^ 0.34 pounds/hour. Baghouse particulate collection.
efficiency averaged 99.89%. No visible emission readings above
5 percent were recorded during any of the test periods.
The average Rock Dryer Baghouse particulate collection effi-
ciency was 99.96%. The particulate matter discharged to the
atmosphere was ^0.027 grains/DSCF and ^2.69 pounds/hour.
All visible emission readings were 5% or lower.
/
At the Stucco Baghouse, the highest opacity reading noted dur-
ing the first test was 15% (one reading). The highest opacity
reading recorded during run 2 was 10% (one reading). All read-
ings during run 3 were ^5%. Readings >5% were likely due to
the newly installed bags which, upon start-upf had an inad-
equate filter dust cake to assist in filtration.
-36-
-------
Table 8
No. 2 Calcidyne Baghouse Inlet Duct
Test Data
SUMMARY OF TEST DATA
(English Units)
Test Run Number
Test Date
Test Period
Sampling Data
Sampling Duration, minutes
Nozzle Diameter, inches
Barometric Pressure, inches mercury
Average Orifice Pressure Differential, inches water
Average Dry Gas Temperature at Meter, °F
Total Water Collected by Train, ml
Standard Volume of Water Vapor Collected, cubic feet
Dry Gas Meter Calibration Factor, dimensionless
Sample Volume at Meter Conditions, cubic feet
Sample Volume at Standard Conditions, cubic feet^
Gas Stream Composition
C02, percent by volume
02, percent by volume
CO, percent by volume
N2, percent by volume
Moisture in Gas Stream, percent by volume
Mole Fraction of Dry Gas
Molecular Weight of Dry Gas
Molecular Weight of Wet Gas
Gas Stream Velocity and Volumetric Flow
Static Pressure, inches water
Absolute Pressure, inches mercury
Average Temperature, °F
Pitot Tube Calibration Coefficient, dimensionless
Total Number of Traverse Points
Velocity at Actual Conditions, feet/second
Stack/duct Cross-Sectional Area, square feet
Volumetric Flow at Actual Conditions, cubic feet/minute
Volumetric Flow at Standard Conditions, cubic feet/minute
Percent Isokinetic
Unit/Process Operations Data
5-19-80
1358-1532
60.0
0.224
30.1
1.3
117.
469.0
22.1
0.989
37.9
34.6
7.7
9.3
0.0
83.0
38.9
0.611
29.6
25.1
-2.3
29.9
370.
0.84
12.0
83.3
0.785
3920.
1520.
5-20-80
0917-1030
60.0
0.195
30.0
0.67
107.
380.0
17.9
0.989
28.0
25.9
8.2
9.5
0.0
82.2
40.9
0.591
29.7
24.9
-2.2
29.8
373.
0.84
12.0
87.2
0.785
4110.
1530.
3
5-20-80
1315-1436
60.0
0.195
30.0
0.60
112.
389.
18.
0.989
26.5
24.3
8.6
8.3
0.0
83.1
43.0
0.570
29.7
24.7
-2.5
29.8
369.
0.84
12.0
87.0
0.785
4100.
1480.
108.6 106.5 103.5
Monitored by Radian Corporation Personnel
istandard Conditions = 68°F (20°C) and 29.92 inches (760 mm) mercury, dry basis.
-------
Table 9
No. 2 Calcidyne Baghouse inlet Duct
SUMMARY OF TEST DATA
(Metric Units)
Test Data
U)
CD
Test Run Number 123
Test Date 5-19-80 5-20-80 5-20-80
Test Period 1358-1532 0917-1030 1315-1436
Sampling Data
Sampling Duration, minutes 60.0 60.0 60.0
Nozzle Diameter, centimeters 0.569 0.495 0.495
Barometric Pressure, millimeters mercury 764.54 762.0 762.0
Average Orifice Pressure Differential, millimeters water 33.02 17.02 15.24
Average Dry Gas Temperature at Meter, °C 47. 47. 44.
Total Water Collected by Train, ml 469.0 380.0 389.7
Volume of Water Vapor Collected, standard cubic meters 0.626 0.507 0.518
Dry Gas Meter Calibration Factor, dimensionless 0.989 0.989 0.989
Sample Volume at Meter Conditions, cubic feet 1.073 0.793 0.750
Sample Volume at Standard Conditions, cubic meters1 0.980 0.733 0.688
Gas Stream Composition
C02, percent by volume 7.7 8.2 8.6
02, percent by volume 9.3 9.5 8.3
CO, percent by volume 0.0 0.0 0.0
N2, percent by volume 83.0 82.2 83.1
Moisture in Gas Stream, percent by volume 38.9 40.9 43.0
Mole Fraction of Dry Gas 0.661 0.591 0.570
Molecular Weight of Dry Gas 29.6 29.7 29.7
Molecular Weight of Wet Gas 25.1 24.9 24.7
Gas Stream Velocity and Volumetric Flow
Static Pressure, millimeters water -58.42 -55.88 -63.50
Absolute Pressure, millimeters mercury 759.46 756.92 756.92
Average Temperature, °C 188. 189. 187.
Pitot Tube Calibration Coefficient, dimensionless 0.84 0.84 0.84
Total Number of Traverse Points 12.0 12.0 12.0
Velocity at Actual Conditions, meters/second 25.39 26.58 26.52
Stack/Duct Cross-Sectional Area, square meters 0.073 0.073 0.073
Volumetric Flow, Wet Actual Conditions, cubic meters/minute 111. 116. 116.
Volumetric Flow, Dry Standard Conditions, cubic meters/minute 43. 43. 42.
108.6 106.5 103.5
Percent Isokinetic
Unit Operations Data
Monitored by Radian Corporation Personnel
Standard Conditions = 68°F (20°C) and 29.92 inches (760 nun) mercury, dry basis.
-------
Table 10
Test Data
No. 2 Calcidyne Baghouse Outlet Stack
SUMMARY OF TEST DATA
(English Units)
u>
ID
Test Run Number
Test Date
Test Period
Sampling Data
Sampling Duration, minutes
Nozzle Diameter, inches
Barometric Pressure, inches mercury
Average Orifice Pressure Differential, inches water
Average Dry Gas Temperature at Meter, °F
Total Water Collected by Train, ml
Standard Volume of Water Vapor Collected, cubic feet
Dry Gas Meter Calibration Factor, dimensionless
Sample Volume at Meter Conditions, cubic feet
Sample Volume at Standard Conditions, cubic feet*-
Gas Stream Composition
CO2, percent by volume
02, percent by volume
CO, percent by volume
N2, percent by volume
Moisture in Gas Stream, percent by volume
Mole Fraction of Dry Gas
Molecular Weight of Dry Gas
Molecular Weight of Wet Gas
Gas Stream Velocity and Volumetric Flow
Static Pressure, inches water
Absolute Pressure, inches mercury
Average Temperature, °F
Pitot Tube Calibration Coefficient, dimensionless
Total Number of Traverse Points
Velocity at Actual Conditions, feet/second
Stack/duct Cross-Sectional Area, square feet
Volumetric Flow at Actual Conditions, cubic feet/minute
Volumetric Flow at Standard Conditions, cubic feet/minute
Percent Isokinetic
Unit/Process Operations Data
5-19-80
1400-1630
120.0
0.195
30.1
0.99
93.
822.0
38.7
0.999
65.3
62.8
7.5
10.1
0.0
82.4
31.8
0.619
29.6
25.2
0.50
30.1
341.
0.84
20.0
94.4
0.690
3910.
1610.
5-20-80
0930-1110
100.0
0.225
30.0
1.7
95.
964.3
45.4
1.005
66.5
64.0
8.1
9.8
0.0
82.1
41.5
0.585
29.7
24.8
0.45
30.0
340.
0.84
20.0
98.4
0.690
4070.
1580.
5-20-80
1340-1530
100.0
0.225
30.0
1.6
95.
989.3
46.5
1.005
65.5
63.0
8.2
9.9
0.0
81.9
42.5
0.575
29.7
24.7
0.45
30.0
341.
0.84
20.0
96.8
0.690
4010.
1530.
108.5 101.4 103.3
Monitored by Radian Corporation Personnel
istandard Conditions = 68°F (20°C) and 29.92 inches (760 mm) mercury, dry basis.
-------
Table 11
No. 2 Calcidyne Baghouse Outlet stack
SUMMARY OF TEST DATA
(Metric Units)
Test Data
i
*.
o
Test Run Number
Test Date
Test Period
Sampling Data
Sampling Duration, minutes
Nozzle Diameter, centimeters
Barometric Pressure, millimeters mercury
Average Orifice Pressure Differential, millimeters water
Average Dry Gas Temperature at Meter, °C
Total Water Collected by Train, ml
Volume of Water Vapor Collected, standard cubic meters
Dry Gas Meter Calibration Factor, dimensionless
Sample Volume at Meter Conditions, cubic feet
Sample Volume at Standard Conditions, cubic meters1
Gas Stream Composition
C02, percent by volume
02, percent by volume
CO, percent by volume
N2, percent by volume
Moisture in Gas Stream, percent by volume
Mole Fraction of Dry Gas
Molecular Weight of Dry Gas
Molecular Weight of Wet Gas
Gas Stream Velocity and Volumetric Flow
Static Pressure, millimeters water
Absolute Pressure, millimeters mercury
Average Temperature, °C
Pitot Tube Calibration Coefficient, dimensionless
Total Number of Traverse Points
Velocity at Actual Conditions, meters/second
Stack/Duct Cross-Sectional Area, square meters
Volumetric Flow, Wet Actual Conditions, cubic meters/minute
Volumetric Flow, Dry Standard Conditions, cubic meters/minute
5-19-80
1400-1630
120.0
0.495
764.54
25.15
34.
822.0
1.096
0.999
1.849
1.778
7.5
10.1
0.0
82.4
31.8
0.619
29.6
25.2
12.
764.
172.
0.
40.
28.
0.
111.
46.
7
54
84
0
77
064
5-20-80
0930-1110
100.0
0.572
762.0
43.18
35.
964.3
.286
005
1.
1.
1.883
1.812
8.1
9.8
0.0
82.1
41.5
Percent Isokinetic
Unit Operations Data
108.5
0.585
29.7
24.8
11.43
762.0
171.
0.84
20.0
29.99
0.064
115.
45.
101.4
3
5-20-80
1340-1530
100.0
0.572
762.0
40.64
35.
989.3
1.317
005
.855
1.
1.
1.784
8.2
9.9
0.0
81.9
42.5
0.575
29.7
24.7
11.43
762.0
172.
0.84
20.0
29.50
0.064
114.
43.
103.3
Monitored by Radian Corporation Personnel
Standard Conditions = 68°F (20°C) and 29.92 inches (760 mm) mercury, dry basis.
-------
Table 12
Test Data
Rock Dryer Baghouse Inlet Duct
SUMMARY OF TEST DATA
(English Units)
Test Run Number
Test Date
Test Period
Sampling Data
Sampling Duration, minutes
Nozzle Diameter, inches
Barometric Pressure, inches mercury
Average Orifice Pressure Differential, inches water
Average Dry Gas Temperature at Meter, °F
Total Water Collected by Train, ml
Standard Volume of Water Vapor Collected, cubic feet
Dry Gas Meter Calibration Factor, dimensionless
Sample Volume at Meter Conditions, cubic feet
Sample Volume at Standard Conditions, cubic feetl
Gas Stream Composition
CO2, percent by volume
03, percent by volume
CO, percent by volume
N2, percent by volume
Moisture in Gas Stream, percent by volume
Mole Fraction of Dry Gas
Molecular Weight of Dry Gas
Molecular Weight of Wet Gas
Gas Stream Velocity and Volumetric Flow
Static Pressure, inches water
Absolute Pressure, inches mercury
Average Temperature, °F
Pitot Tube Calibration Coefficient, dimensionless
Total Number of Traverse Points
Velocity at Actual Conditions, feet/second
Stack/duct Cross-Sectional Area, square feet
Volumetric Flow at Actual Conditions, cubic feet/minute
Volumetric Flow at Standard Conditions, cubic feet/minute
Percent Isokinetic
Unit/Process Operations Data
1
5-21-80
1145-1343
1.9
17.8
0.0
80.3
8.5
0.915
29.0
28.1
5-22-80
0845-1037
1.7
17.5
0.0
80.8
8.9
0.911
29.0
28.0
5-22-80
1235-1450
96.0
0.175
30.2
1.1
115.
100.8
4.75
0.989
55.5
50.9
96.0
0.175
30.1
1.1
110.
105.2
4.95
0.989
55.1
51.0
96.0
0.175
30.1
1.1
120.
82.0
3.86
0.989
56.3
51.2
1.5
18.3
0.0
80.2
7.0
0.930
29.0
28.2
-1.9
30.0
215.
0.84
48.0
73.8
3.55
15,700.
11,300.
-1.7
30.0
216.
0.84
48.0
75.0
3.55
16,000.
11,400.
-1.8
30.0
215.
0.84
48.0
76.0
3.55
16,200.
11,800.
99.8 98.9 95.9
Monitored by Radian Corporation Personnel
^-Standard Conditions = 68°F (20°C) and 29.92 inches (760 mm) mercury, dry basis.
-------
Table 13
Rock Dryer Baghouse Inlet Duct
SUMMARY OF TEST DATA
(Metric Units)
Test Data
IV)
i
Test Run Number 1 2
Test Date 5-21-80 5-22-80
Test Period 1145-1343 0845-1037
Sampling Data
Sampling Duration, minutes 96.0 96.0
Nozzle Diameter, centimeters 0.445 0.445
Barometric Pressure, millimeters mercury 767.08 764.54
Average Orifice Pressure Differential, millimeters water 27.94 27.94
Average Dry Gas Temperature at Meter, °C 46. 43.
Total Water Collected by Train, ml 100.8 105.2
Volume of Water Vapor Collected, standard cubic meters 0.135 0.140
Dry-Gas Meter Calibration Factor, dimensionless 0.989 0.989
Sample Volume at Meter Conditions, cubic feet 1.572 1.560
Sample Volume at Standard Conditions, cubic meters^ 1.441 1.444
Gas Stream Composition
CO2, percent by volume 1.9 1.7
02, percent by volume 17.8 17.5
CO, percent by volume 0.0 0.0
N2, percent by volume 80.3 80.8
Moisture in Gas Stream, percent by volume 8.5 8.9
Mole Fraction of Dry Gas 0.915 0.911
Molecular Weight of Dry Gas 29.0 29.0
Molecular Weight of Wet Gas 28.1 28.0
Gas Stream Velocity and Volumetric Flow
Static Pressure, millimeters water -48.26 -43.18
Absolute Pressure, millimeters mercury 762.0 762.0
Average Temperature, °C 102. 102.
Pitot Tube Calibration Coefficient, dimensionless 0.84 0.84
Total Number of Traverse Points 48.0 48.0
Velocity at Actual Conditions, meters/second 22.49 22.86
Stack/Duct Cross-Sectional Area, square meters 0.330 0.330
Volumetric Flow, Wet Actual Conditions, cubic meters/minute 445. 453.
Volumetric Flow, Dry Standard Conditions, cubic meters/minute 320. 323.
98.9
Percent Isokinetic
99.8
5-22-80
1235-1450
96.0
0.445
764.54
27.94
49.
82.0
0.109
0.989
1.594
1.450
1.5
18.3
0.0
80.2
7.0
0.930
29.0
28.2
-45.72
762.0
102.
0.84
48.0
23.16
0.330
459.
334.
95.9
Unit Operations Data
Monitored by Radian Corporation Personnel
Standard Conditions = 68°F (20°C) and 29.92 inches (760 mm) mercury, dry basis.
-------
Test Data
Table 14
Rock Dryer Baghouse Outlet Stack
SUMMARY OF TEST DATA
(English Units)
Test Run Number
Test Date
Test Period
Sampling Data
Sampling Duration, minutes
Nozzle Diameter, inches
Barometric Pressure, inches mercury
Average Orifice Pressure Differential, inches water
Average Dry Gas Temperature at Meter, °P
Total Water Collected by Train, ml
Standard Volume of Water Vapor Collected, cubic feet
Dry Gas Meter Calibration Factor, dimensionless
Sample Volume at Meter Conditions, cubic feet
Sample Volume at Standard Conditions, cubic feet1
Gas Stream Composition
CO2, percent by volume
03, percent by volume
CO, percent by volume
N2, percent by volume
Moisture in Gas Stream, percent by volume
Mole Fraction of Dry Gas
Molecular Weight of Dry Gas
Molecular Weight of Wet Gas
Gas Stream Velocity and Volumetric Flow
Static Pressure, inches water
Absolute Pressure, inches mercury
Average Temperature, °F
Pitot Tube Calibration Coefficient, dimensionless
Total Number of Traverse Points
Velocity at Actual Conditions, feet/second
Stack/duct Cross-Sectional Area, square feet
Volumetric Flow at Actual Conditions, cubic feet/minute
Volumetric Flow at Standard Conditions, cubic feet/minute
Percent Isokinetic
Unit/Process Operations Data
1
5-21-80
1145-1340
1.1
19.3
0.0
79.6
8.3
0.917
29.0
28.0
5-22-80
0845-1035
96.0
0.190
30.2
1.3
95.
104.0
4.90
1.005
55.9
54.1
96.0
0.190
30.1
1.2
91.
120.5
5.67
1.005
55.8
54.3
1.1
19.3
0.0
79.6
9.5
0.905
29.0
27.9
3
5-22-80
1235-1415
96.0
0.190
30.1
1.3
92.
114.3
38
005
56.3
54.6
1.1
19.1
0.0
79.8
9.0
0.910
28.9
28.0
0.78
30.2
200.
0.84
32.0
64.6
4.12
16,000.
11,800.
0.49
30.2
202.
0.84
32.0
63.5
4.12
15,700.
11,400.
0.76
30.2
203.
0.84
32.0
65.3
4.12
16,200.
11,800.
99.6 103.6 100.9
Monitored by Radian Corporation Personnel
Standard Conditions = 68°F (20°C) and 29.92 inches (760 mm) mercury, dry basis.
-------
Table 15
Rock Dryer Baghouse Outlet Stack
SUMMARY OF TEST DATA
(Metric Units)
Test Data
Test Run Number
Test Date
Test Period
Sampling Data
Sampling Duration, minutes
Nozzle Diameter, centimeters
Barometric Pressure, millimeters mercury
Average Orifice Pressure Differential, millimeters water
Average Dry Gas Temperature at Meter, °C
Total Water Collected by Train, ml
Volume of Water Vapor Collected, standard cubic meters
Dry Gas Meter Calibration Factor, dimensionless
Sample Volume at Meter Conditions, cubic feet
Sample Volume at Standard Conditions, cubic metersi
Gas Stream Composition
CO2, percent by volume
02, percent by volume
CO, percent by volume
N2, percent by volume
Moisture in Gas Stream, percent by volume
Mole Fraction of Dry Gas
Molecular Weight of Dry Gas
Molecular Weight of Wet Gas
Gas Stream Velocity and Volumetric Flow
Static Pressure, millimeters water
Absolute Pressure, millimeters mercury
Average Temperature, °C
Pitot Tube Calibration Coefficient, dimensionless
Total Number of Traverse Points
Velocity at Actual Conditions, meters/second
Stack/Duct Cross-Sectional Area, square meters
Volumetric Flow, Wet Actual Conditions, cubic meters/minute
5-21-80
1145-1340
96.0
0.483
767.08
33.02
35.
104.0
0.139
1.005
Percent Isokinetic
Unit Operations Data
583
1.532
1.1
19.3
0.0
79.6
8.3
0.917
29.0
28.0
19.
767.
93.
0.
32.
81
08
84
0
19.69
0.383
453.
Volumetric Flow, Dry Standard Conditions, cubic meters/minute 334.
99.6
5-22-80
0845-1035
96.0
0.483
764.54
30.48
33.
120.5
0.161
1.005
580
1.538
1.1
19.3
0.0
79.6
9.5
0.905
29.0
27.9
12.45
767.08
94.
0.84
32.0
19.35
0.383
445.
323.
103.6
5-22-80
1235-1415
96.0
0.483
764.54
33.02
33.
114.3
0.152
1.005
594
1.546
1.1
19.1
0.0
79.8
9.0
0.910
28.9
28.0
19.30
767.08
95.
0.84
32.0
19.90
0.383
459.
334.
100.9
Monitored by Radian Corporation Personnel
istandard Conditions = 68°F (20°C) and 29.92 inches (760 mm) mercury, dry basis.
-------
Test Data
Table 16
No. 2 Calcidyne Baghouse Inlet Duct
SUMMARY OF TEST RESULTS
(English Units)
Test Run Number
Test Date
Test Time
Gas Flow
Standard Cubic Feet/Minute, dry
Actual Cubic Feet/Minute, wet
Particulates
Front-Half Wash Residue Catch Fraction, g
Filter Catch Fraction, g
Total Particulates, g
Particulate Emissions^
5-19-80
1358-1532
1,520.
3,920.
34.9505
14.4848
49.4353
5-20-80
0917-1030
1,530.
4,110.
27.7273
8.4989
36.2262
5-20-80
1315-1436
1,480.
4,100.
21.6266
11.7345
33.3611
i
£»
Ln
Grains/Dry Standard Cubic Foot2
Pounds/Hour
22.0
288.
21.6
284.
21.2
269.
^Based on Total Particulates captured by train.
2Standard Conditions = 68°F and 29.92 inches Hg.
-------
Table 17
No. 2 Calcidyne Baghouse Inlet Duct
SUMMARY OF TEST RESULTS
(Metric Units)
Test Data
Test Run Number
Test Date
Test Period
Gas Stream Volumetric Flow Rates
Dry standard cubic meters/minute^
Wet actual cubic meters/minute
Particulate Laboratory Results
Front-half Wash Residue Fraction, g
Filter Catch Fraction, g
Total Particulate Catch Weight, g
Particulate Emission Results
Grams/dry standard cubic meter
Kilograms/hour
5-19-80
1358-1532
43.
111.
34.9505
14.4848
49.4353
50.3
131.
5-20-80
0917-1030
43.
116.
27.7273
8.4989
36.2262
49.4
129.
5-20-80
1315-1436
42.
116.
21.6266
11.7345
33.3611
48.5
122.
istandard Conditions = 68°F (20°C) and 29.92 (760 mm) inches mercury, dry basis.
-------
Test Data
Table 18
No. 2 Calcidyne Baghouse Outlet Stack
SUMMARY OF TEST RESULTS
(English Units)
Test Run Number
Test Date
Test Time
Gas Flow
Standard Cubic Feet/Minute, dry
Actual Cubic Feet/Minute, wet
Particulates
Front-Half Wash Residue Catch Fraction, g
Filter Catch Fraction, g
Total Particulates, g
Particulate Emissions1
5-19-80
1400-1630
1,610.
3,910.
0.0346
0.0489
0.0835
5-20-80
0930-1110
1,580.
4,070.
0.0422
0.0574
0.0996
5-20-80
1340-1530
1,530.
4,010.
0.0267
0.0780
0.1047
Grains/Dry Standard Cubic Foot-*
Pounds/Hour
Baghouse Particulate Removal Efficiency, percent
Visible Emissions^
0.021
0.282
99.90
0.024
0.325
99.89
0.026
0.335
99.88
>10 percent opacity, minutes observed
5 percent opacity, minutes observed
0 percent opacity, minutes observed
Observation Period, minutes
0
6 3/4
113 1/4
120
0
27 1/4
72 3/4
100
0
33
67
100
^Based on Total Particulates captured by train.
2Standard Conditions = 68°F and 29.92 inches Hg.
^Opacity results listed are in minutes of the observed reading during the test period.
-------
Table 19
No. 2 Calcidyne Baghouse Outlet Stack
SUMMARY OF TEST RESULTS
(Metric Units)
Test Data
Test Run Number
Test Date
Test Period
Gas Stream Volumetric Flow Rates
Dry standard cubic meters/minute^
Wet actual cubic meters/minute
Particulate Laboratory Results
Front-half Wash Residue Fraction, g
Filter Catch Fraction, g
Total Particulate Catch Weight, g
Particulate Emission Results
5-19-80
1400-1630
46.
111.
0.0346
0.0489
0.0835
2
5-20-80
0930-1110
45.
115.
0.0422
0.0574
0.0996
5-20-80
1340-1530
43.
114.
0.0267
0.0780
0.1047
Grams/dry standard cubic meter
Kilograms/hour
Baghouse Particulate Removal Efficiency, percent
0.048
0.128
99.90
0.055
0.147
99.89
0.059
0.152
99.88
istandard Conditions = 68°F (20°C) and 29.92 (760 mm) inches mercury, dry basis.
-------
Test Data
Table 20
Rock Dryer Baghouse Inlet Duct
SUMMARY OF TEST RESULTS
(English Units)
VO
I
Test Run Number
Test Date
Test Time
Gas Flow
Standard Cubic Feet/Minute, dry
Actual Cubic Feet/Minute, wet
Particulates
Front-Half Wash Residue Catch Fraction, g
Filter Catch Fraction, g
Total Particulates, g
Particulate Emissions1
Grains/Dry Standard Cubic Foot2
Pounds/Hour
5-21-80
1145-1343
11,300.
15,700.
151.2811
15.8951
167.1762
50.7
4900.
5-22-80
0845-1037
11,400.
16,000.
155.7670
15.5035
171.2705
51.9
5070.
3
5-22-80
1235-1450
11,800.
16,200.
156.2056
13.5177
169.7233
51.2
5180.
l-Based on Total Particulates captured by train.
2Standard Conditions = 68°F and 29.92 inches Hg.
-------
Table 21
Rock Dryer Baghouse Inlet Duct
SUMMARY OF TEST RESULTS
(Metric Units)
Test Data
Ul
o
i
Test Run Number
Test Date
Test Period
Gas Stream Volumetric Flow Rates
Dry standard cubic meters/minute^
Wet actual cubic meters/minute
Particulate Laboratory Results
Front-half Wash Residue Fraction, g
Filter Catch Fraction, g
Total Particulate Catch Weight, g
Particulate Emission Results
Grams/dry standard cubic meter
Kilograms/hour
5-21-80
1145-1343
320.
445.
151.2811
15.8951
167.1762
116.
2223.
5-22-80
0845-1037
323.
453.
155.7670
15.5035
171.2705
119.
2300.
5-22-80
1235-1450
334.
459.
156.2056
13.5177
169.7233
117.
2350.
istandard Conditions = 68°F (20°C) and 29.92 (760 mm) inches mercury, dry basis.
-------
I
Ul
Test Data
Table 22
Rock Dryer Baghouse Outlet Stack
SUMMARY OF TEST RESULTS
(English Units)
Test Run Number
Test Date
Test Time
Gas Flow
Standard Cubic Feet/Minute, dry
Actual Cubic Feet/Minute, wet
Particulates
Front-Half Wash Residue Catch Fraction, g
Filter Catch Fraction, g
Total Particulates, g
Particulate Emissions^
Grains/Dry Standard Cubic Foot2
Pounds/Hour
Baghouse Particulate Removal Efficiency, percent
Visible Emissions-*
5-21-80
1145-1340
11,800.
16,000.
5-22-80
0845-1035
11,400.
15,700.
5-22-80
1235-1415
11,800.
16,200.
0.0307
0.0620
0.0927
0.027
2.69
99.95
0.0222
0.0434
0.0656
0.019
1.83
99.96
0.0149
0.0470
0.0619
0.018
1.77
99.97
2:10 percent opacity, minutes observed
5 percent opacity, minutes observed
0 percent opacity, minutes observed
Observation Period, minutes
0
22 1/4
73 3/4
96
0
3 3/4
96 1/4
100
0
0
117
117
1-Based on Total Particulates captured by train.
2Standard Conditions = 68°F and 29.92 inches Hg.
^Opacity results listed are in minutes of the observed reading during the test period.
-------
Table 23
Rock Dryer Baghouse Outlet Stack
SUMMARY OF TEST RESULTS
(Metric Units)
Test Data
ro
i
Test Run Number
Test Date
Test Period
Gas Stream Volumetric Flow Rates
Dry standard cubic meters/minute1
Wet actual cubic meters/minute
Pacticulate Laboratory Results
Front-half Wash Residue Fraction, g
Filter Catch Fraction, g
Total Particulate Catch Weight, g
Particulate Emission Results
5-21-80
1145-1340
334.
453.
0.0307
0.0620
0.0927
5-22-80
0845-1035
323.
445.
0.0222
0.0434
0.0656
5-22-80
1235-1415
335.
459.
0.0149
0.0470
0.0619
Grams/dry standard cubic meter
Ki1ograms/hour
Baghouse Particulate Removal Efficiency, percent
0.062
1.22
99.95
0.043
0.83
99.96
0.041
0.80
99.97
^•Standard Conditions = 68°F (20°C) and 29.92 (760 mm) inches mercury, dry basis.
-------
Table 24
Particle Size Distribution
Run: 1
Date: 5-19-80
Location: Gold Bond Building Products
Sampling Location: No. 2 Calcidyne Inlet
Traverse Point No. Sampled: X-3
Pbar (in. Hg)
Stack Temp (°F)
Sample Time (min.)
Sample Volume (cf)
Moisture (% H_0)
30.1
370
0.333
0.254
38.9
Meter Temp (F) 119.
Flow Setting, AH 2.0
(in. H20)
Nozzle Diameter (in.)0.252
Sample Flow Rate (at stack conditions): 1.14 cfm
Plate
No.
1
2
3
4
5
6
7
8
Backup
Filter
TOTAL
Net Wt.
(mg)
324.9
12.4
19.5
16.8
7.2
2.4
0.0
0.7
4.1
387.5
Percent
83.9
3.2
5.0
4.3
1.9
0.6
0.0
0.1
1.0
100.0
Cumulative
Percent
100.0
16.2
13.0
7.9
3.6
1.7
1.1
1.1
1.0
EAD
(microns)
10.7
6.8
4.5
3.2
2.0
1.0
0.6
0.4
— — — —
-53-
-------
No. 2 Calcidyne Baghouse Inlet Duct
Run 1
I
Ul
^.
I
EFFECTIVE AERODYNAMIC PARTICLE DIAMETER, microns
o o ooooooo— to vA>.p-vnoN-j oovoo
— 10 u> .£- Ul ON ^J OOVOO O O O OOOOOO
/
1
1
/
1
*
'/
/
/t
/
/
/
/•
/
•
0.01 0.05 O.I 0.2 0.5 I 2
10 20 30 40 50 60 70 80
CUMULATIVE PERCENTAGE
( % by weight {diameter)
ao
95
w 98
9.i SS.S
33.83
-------
Table 25
Particle Size Distribution
Run: 2
Date: 5-20-80
Location: Gold Bond Building Products
Sampling Location: No. 2 Calcidyne Inlet
Traverse Point No. Sampled: X-4
bar
Hg)
Stack Temp (F)
Sample Time (min.)
Sample Volume (cf)
Moisture (% H20)
30*°
373.
0.33
0.244
40.9
Meter Temp (F) 105.
Flow Setting, AH 2. 2
(in. H20)
Nozzle Diameter (in.) 0.252
Sample Flow Rate (at stack conditions): 1.15 cfm
Plate
No.
Net Wt,
Percent
Cumulative
Percent
EAD
1
2
3
4
5
6
7
8
Backup
Filter
TOTAL
(mg)
540.0
16.8
24.3
26.0
11.4
0.9
0.6
0.4
0.1
620.5
87.0
2.7
3.9
4.2
1.8
0.2
0.1
0.06
0.04
100.0
100.0
- 13.0
10.3
6.4
2.2
0.4
0.2
0.1
0.04
(microns)
10.7
6.8
4.5
3.2
2.0
1.0
0.6
0.4
— — — —
-55-
-------
No. 2 Calcidyne Baghouse Inlet Duct
Run 2
I
en
i
EFFECTIVE AERODYNAMIC PARTICLE DIAMETER, microns
o o ooooooo— • ro v*> .p- vn c* --J oovoc
_. ro v*> .£• vn ON «»J covo o o o ooooooc
,'t
/
/
/
i
/
/
/
/
/%
7
/
»
0.01 O.OS Q.I 0.2 O.S I
10 20 30 40 SO 60 70 80
CUMULATIVE PERCENTAGE
( % by weight< diameter )
90
96 99
99.99
-------
Table 26
Particle Size Distribution
Run: 3
Date: 5-20-80
Location: Gold Bond Building Products
Sampling Location: No. 2 Calcidyne Inlet
Traverse Point No. Sampled: Y-3
Pbar (in. Eg)
Stack Temp (°F)
Sample Time (min.)
Sample Volume (cf)
Moisture (% H20)
30.0
369.
0.333
0.251
43.0
Meter Temp ( F) 115.
Flow Setting, AH 2.2
(in. H20)
Nozzle Diameter (in.) 0.252
Sample Flow Rate (at stack conditions): 1.21 cfm
Plate
No.
1
2
3
4
5
6
7
8
Backup
Filter
TOTAL
Net Wt.
(mg)
314.5
17.5
21.2
21.8
15.0
5.8
0.6
2.2
0.1
398.7
Percent
78.88
4.39
5.32
5.47
3.76
1.45
0.15
0.55
0.03
100.0
Cumulative
Percent
100.0
21.1
16.7
11.4
5.9
2.2
0.7
0.6
0.03
EAD
(microns)
10.7
6.6
4.5
3.1
1.9
1.0
0.6
0.4
-57-
-------
No. 2 Calcidyne Baghouse Inlet Duct
Run 3
10.0
9.0
8.0
7.0
6.0
o 5.0
u
1 i*.o
es 3.0
i-
LU
<
o 2.0
UJ
_J
u
1
i o 1-0
? 1 8:1
| 0.7
1 °'6
% 0.5
> 0.1*
0
S 0.3
u.
Ul
0.2
0.1
'
J
/
j
1
/
1
/
I
ff
I
1
f
0.01 O.OS O.I 0.2 0.5 I 2
10 20 30 40 50 60 70 80
CUMULATIVE PERCENTAGE
( % by weight
-------
Table 27
Particle Size Distribution
Run:
1 of 1
bar -
Stack Temp (°F)
Date: 5-20-80
Location: Gold Bond Building Products Sample Time (min.)
Sampling Location: No. 2 Calcidyne Outlet Sample Volume (cf)
Traverse Point No. Sampled: X-7 Moisture (% H20)
30.0
340.
60.0
28.3
45.4
1
2
3
4
5
6
7
8
Backup
Filter
TOTAL
Net Wt.
(mg)
8.1
1.6
2.8
2.5
3.6
3.7
0.4
0.8
6.0
29.5
Percent
27.46
5.42
9.49
8.47
12.2
12.54
1.36
2.71
20.35
100.0
Meter Temp ( F) 92.
Flow Setting, AH 0.74
(in. H20)
Nozzle Diameter (in.) 0.181
Sample Flow Rate (at stack conditions): 0.78 cfm
Cumulative
Percent
100.0
5
,1
72.
67.
57.6
49.2
37.0
24.4
23.1
20.4
BAD
(microns)
13.0
8.0
5.4
3.8
2.4
1.2
0.7
0.5
-59-
-------
No. 2 Calcidyne Baghouse Outlet Stack
Run 1
-09-
EFFECTIVE AERODYNAMIC PARTICLE DIAMETER, microns
o o ooooooo— • ro v*> .£• vn ON --j oovoo
_• ro oj .p- vn o"1* -^i oovo o o o ooooooo
• /
/
/
t
/
1
1
1
/
/
/
/
/
/
]/
L
p
0.01 0.05 O.I 0.2 0.5 I 2
10 20 30 40 50 60 70 60
CUMULATIVE PERCENTAGE
( % by weight < diameter)
95
B.I 88.9
99.99
-------
Table 28
Particle Size Distribution
Run:
1
5-21-80
Pbar (in* Hg)
30'2
Date:
Location: Gold Bond Building Products
Sampling Location: Rock Dryer Inlet
Traverse Point No. Sampled: X-10
Stack Temp (F) 215.
Sample Time (min.) 0.333
Sample Volume (cf) 0.305
Moisture (% H20)
8.5
Meter Temp (F) 112.
Flow Setting, AH 2.6
(in. H20)
Nozzle Diameter (in.) 0.224
Sample Flow Rate (at stack conditions): 0.93 cfm
Plate
No.
1
2
3
4
5
6
7
8
Backup
Filter
TOTAL
Net Wt.
(mg)
615.3
24.8
18.3
14.3
10.0
3.2
0.5
1.5
1.9
688.9
Percent
89.32
3.60
2.66
2.08
1.45
0.46
0.07
0.22
0.14
100.0
Cumulative
Percent
100.0
10.7
7.1
4.4
2.3
0.9
0.4
0.4
0.14
BAD
(microns)
11.0
6.9
4.7
3.1
2.0
1.0
0.6
0.4
— — — —
-61-
-------
Rock Dryer Baghouse Inlet Duct
Run 1
-29-
EFFECTIVE AERODYNAMIC PARTICLE DIAMETER, microns
O O OOOOOOO-* KJ U» .p- vn ON *«J OOVDO
... s) u» .p- vn ON *>j oovo o o o ooooooo
/
f
f
/
1
I
1
1
1
1
f
m '
0.01 0.05 O.I 0.2 0.5 I
10 20 30 40 50 80 70 80
CUMULATIVE PERCENTAGE
90
95
98 99
99.8 99.9
99.99
( % by weight
-------
Table 29
Particle Size Distribution
Run: 2
Date: 5-22-80
Location: Gold Bond Building Products
Sampling Location: Rock Dryer Inlet
Traverse Point No. Sampled: X-7
Hg)
3(K1
216.
0.333
0.377
8.9
bar
Stack Temp (°F)
Sample Time (min.)
Sample Volume (cf)
Moisture (% H20)
Meter Temp (°F)
Flow Setting, AH
(in. H20)
Nozzle Diameter (in.) 0.224
111.
3.0
Sample Flow Rate (at stack conditions): 1.16 cfm
Plate
No.
1
2
3
4
5
6
7
8
Backup
Filter
TOTAL
Net Wt.
(mg)
4,900.5
50.8
30.0
24.0
13.2
3.4
1.0
0.7
0.7
5,024.6
Percent
97.53
1.01
0.60
0.48
0.26
0.07
0.02
0.00
0.03
100.0
Cumulative
Percent
100.0
2.5
1.5
0.9
0.4
0.1
0.05
0.03
0.03
EAD
(microns)
9.9
6.2
4.1
2.9
1.8
0.9
0.6
0.4
— — — —
-63-
-------
Rock Dryer Baghouse Inlet Duct
Run 2
. •
in n ~
EFFECTIVE AERODYNAMIC PARTICLE DIAMETER, microns
^ f wn 0* -«J O0^
.:___^_^SiS£SS___i_^_i^li±±l
i q
rd
rp
rp
M
M
M
M
p
tP
q
rp
P
H
•
P
n
P
P
P
P
P
P
p
rq
n
m
n
p
H
h
D
rj
n
n
M
H
H
h
D
n
p
n
H
H
P
h
n
l_l
rp
rp
M
P
P
n
u
n
H
rd
M
n
P
P
M
N
D
rj
rd
M
M
M
Q
R
M
M
M
M
h
P
U
D
rj
M
M
M
n
H
R
h
M
M
M
n
M
P
M
h
1 — n
rd
rd
O
M
n
M
H
h
tP
rp
rp
tP
P
H
p
n
— n
rd
M
p
P
R
U
U
p
PR
UP
tj
M
—
LJ
H
M
h
n
"ZJ
rd
pd
P
U
M
P
P
r 1
1
rp
rp
rp
R
U
U
n
ri
rd
rj
p
h
P
h
h
D
rj
rd
M
M
M
M
M
h
D
rn
rd
P
M
M
P
M
h
D
M
rd
M
M
n
M
M
h
0
rn
H
M
M
M
P
H
U
p
M
n
p
M
M
U
h
Q
P
M
n
M
M
H
n
H
M
p
M
H
U
H
D
rn
rj
M
n
n
n
M
h
M
rd
M
n
P
P
H
h
rn
M
tzi
rn
n
M
h
H
D
rq
M
M
P
M
n
M
M
D
r ]
pp
rp
rp
M
n
M
h
n
r 3
td
rn
M
M
P
M
M
D
r~q
r1
M
M
M
P
n
n
n
1
r 1
rp
M
M
P
P
n
D
Z ]
pp
ip
P
IJ
13
n
1
n
r 1
r 1
H
M
M
n
M
P
0
3
pi
n
n
n
n
n
n
M
M
M
n
P
n
n
n
r — n
r d
pi
rp
M
tP
P
n
r — d
1
r 3
pp
pp
M
P
P
n
^
P
n
n
n
n
n
n
n
n
n
n
n
H
P
P
r 1
r J
[ 1
q
rp
PR
M
P
r d
r J
r 1
rp
pq
R
n
n
0.01 O.OS O.I 0.2 0.5 I
10 20 30 40 50 60 70 80
CUMULATIVE PERCENTAGE
( % by weight
-------
Table 30
Particle Size Distribution
Run: 3
Date: 5-22-80
Location: Gold Bond Building Products
Sampling Location: Rock Dryer Inlet
Traverse Point No. Sampled: X-7
bar '
Stack Temp (°F)
Sample Time (min.)
Sample Volume (cf)
Moisture (% H20)
30.1
215.
0.333
0.383
7.0
Meter Temp ( F) 111.
Flow Setting, AH 3.0
(in. H20)
Nozzle Diameter (in.) 0.224
Sample Flow Rate (at stack conditions): 1.15 cfm
Plate
No.
Net Wt.
Percent
Cumulative
Percent
BAD
1
2
3
4
5
6
7
8
Backup
Filter
TOTAL
(mg)
1,928.7
15.0
16.0
9.0
6.1
3.0
1.9
2.0
0.6
1,982.3
97.30
0.76
0.81
0.45
0.31
0.15
0.10
0.10
0.02
100.0
100.0
2.7
1.9
1.1
0.7
0.4
0.22
0.12
0.02
(microns)
9.9
6.2
4.1
2.9
1.8
0.9
0.6
0.36
-65-
-------
Rock Dryer Baghouse Inlet Duct
Run 3
O.H
p
0
s: 0.3
u.
LU
0.2
0.1
y
/
•
/
/
/
/
'
^
/
•
/
4
'
0.01 0.05 O.I 0.2 O.S I 2
10 20 30 40 SO 60 70 BO
CUMULATIVE PERCENTAGE
( % by weight
-------
Table 31
Particle Size Distribution
Run:
1 of 1
Pbar (in. Hg)
30.1
Date: 5-21-80
Location: Gold Bond Building Products
Sampling Location: Rock Dryer Outlet
Traverse Point No. Sampled: X-6
Stack Temp (°F) 200.
Sample Time (min.) 60.0
Sample Volume (cf) 33.3
Moisture (% H20)
8.3
Meter Temp (°F) 102.
Flow Setting, AH 1.0
(in. H20)
Nozzle Diameter (in.) 0.181
Sample Flow Rate (at stack conditions): 0.58 cfm
Plate
No.
1
2
3
4
5
6
7
8
Backup
Filter
Net Wt.
(mg)
60.2
5.4
5.2
3.0
2.0
2.5
0.6
0.7
1.9
Percent
73.87
6.63
6.38
3.68
2.45
3.07
0.74
0.86
2.32
Cumulative
Percent
100.0
26.1
19.5
13.1
9.4
7.0
3.9
3.2
2.3
BAD
(microns)
14.2
8.7
5.8
4.1
2.5
1.3
0.8
0.5
TOTAL
81.5
100.0
-67-
-------
Rock Dryer Baghouse Outlet Stack
Run 1
-89-
EFFECTIVE AERODYNAMIC PARTICLE DIAMETER, microns
O O OOOOOOO— • N* UJ-t-VnON^J OOVDC
_. N> ' UJ .p- \J1 O\ «vj OOVD O O O OOOOOOC
/
1
f
1
1
t
1
1
1
/
r
J
1
i
i •
0.01 0.05 O.I 0.2 O.S I
10 20 30 40 50 80 70 BO
CUMULATIVE PERCENTAGE
( % by weight
-------
Sur..",ARY OF VISIBLE EMISSIONS
TABLE 32
Date: May 19. 1980
Type of Plant: Gypsum Processing Facility
Type of Discharge: Stack
10' above roof
Height of Point of Discharge:
Wind Direction: Westerly
Color of Plume: White "
Observer No. :
Distance from Observer to Discharge Point:
Direction of Observer from Discharge Point:
Height of Observation Point: 6 feet
Description of Background:
Location of Discharge: #2 Calcidyne Baghouse
Description of Sky: Partly Cloudy
Wind Velocity:
Detached Plume:"
10-15 mph
No
Duration of Observation:
25 feet
1400-1600
South of stack
Sky
Set
Number
1
2
"3
k
S
6
-7 .
8
9
10
11
12
13
li»
15
16
17
18
19
20
SUMMARY OF AVERAGE OPACITY
Time
Start
1400
1406
1412
1418
1424
1430
1436
1442
1448
1454
1500
1506
1512
1518
1524
1530
1536
1542
1548
1554
End
1406
1412
1418
1424
1430
1436
1442
1448
1454
1500
1506
1512
1518
1524
1530
1536
1542
1548
1554
1600
Opacity
Sum
0
0
0
0
0
0
0
0
0
10
5
20
10
15
25
10
5
15
5
10
Average
0
0
0
0
0
0
0
0
0
0.4
0.2
0.8
0.4
0.6
1.0
0.4
0.2
0.6
0.2
0.4
Set
Number
21
22
23
2k
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
1*0
T
Start
me
End
V
Opa
Sum
pity
Average
Opacity
Sketch Showing How Opacity Varied with Time:
1.0
0.75
0.50
0.25 ;
0
1 hour
2 hours
Time, Hours
-69-
-------
SUMMARY OF VISIBLE
TABLE 33
EMISSIONS
May 20. 1980
late:
Type of Discharge: Stack ~
fceight of Point of Discharge: 10' above roof
l/ind Direction: West
Color of Plume: White
Observer No. :
Distance from Observer to Discharge Point;
Direction of Observer from Discharge Point: _
K eight of Observation Point: 6 feeT
escription of Background:
Type of Plant: Gypsum Processing Facility
Location of Discharge: #2 Calcidyne Baghouse
Description of Sky; Partly Cloudy
Wind Velocity: 1U-I5 mph
Detached Plume:"
Duration
25
NO
of Observation:
feet
0934-1513
south of stack
sky
Set
Number
1
2
'3
k
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
SUMMARY OF AVERAGE OPACITY
Time
Start
093^
0940
0946
0952
0958
1004
1010
1016
1022
1028
1034
1040
1046
1052
1058
1104
1110
1333
1339
1345
End
0940
0946
1952
0958
1004
1010
1016
1022
1028
1034
1040
1046
1052
1058
1104
1110
1113
1339
1345
1351
Opacity
Sum
20
15
25
25
30
30
35
40
35
30
35
35
35
45
45
45
20
45
35
55
Average
0.8
0.6
.0
.0
.3
.3
.5
.7
.5
.3
.5
.5
.5
.9
.9
.9
.3
.9
1.5
2.3
Set
Number
21
22
23
2k
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
ko
T
Start
1351
1357
1403
1409
1415
1421
1427
1433
1439
1445
1451
1457
1503
1509
me
End
1357
1403
1409
1415
1421
1427
1433
1439
1445
1451
1457
1503
1509
1513
4
Opacity
Sum
45
40
45
35
45
40
35
40
45
35
25
35
35
25
Average
1.9
.7
.9
.5
.9
.7
.5
.7
.9
.5
.0
.5
.5
.3
Sketch Showing How Opacity Varied with Time:
2.0
Opacity
n
1.0
1 h'our
2 hours
4-
3 hours
Time, Hours
-70-
-------
May 21. 1980
SUMMARY OF VISIBLE EMISSIONS
TABLE 34
Type of Plant:
Gypsum Processing Facility
Stack
Type of Discharge:
I eight of Point of Discharge: 8' above roof
ind Direction: Westerly
Color of Plume: White
bserver No. : ^ .
istance from Observer to Discharge Point: _
irection of Observer from Discharge Point:
eight of Observation Point: ^ feet
escription of Background:
Location of Discharge: Rock Dryer Baqhouse Outlet
Description of Sky; Clear
Wind Velocity: 5-10 mph
Detached Plume:
NO
Duration of Observation:
15 feet
1157-1332 Run 1
South
Clear Blue Sky
Set
Number
1
2
'3
k
5
6
7
8
9
10
11
12
13
U
15
16
17
18
19
20
SUMMARY OF AVERAGE OPACITY
Tl
Start
1157
1203
1209
1215
1221
1227
1233
1239
1245
1251
1257
1303
1309
1315
1321
1327
me
End
1203
1209
1215
1221
1227
1233
1239
1245
1251
1257
1303
1309
1315
1321
1327
1332
Opacity
Sum
35
45
35
35
35
45
40
30
30
30
15
15
10
5
25
15
Average
.5
.9
.5
.5
.5
.9
.7
.3
.3
.3
0.6
0.6
0.4
0.2
1.0
0.6
Set
Number
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
ko
J
Start
me
End
Opa<
Sum
pity
Average
fcketch Showing How Opacity Varied with Time:
2.0_
Opacity
(*)
n
1.0
1
^d
hour
Time, Hours
-71-
-------
May 22, 1980
Type or Discharge: stack
teight of Point of Discharge: 8' above roof
ind Direction: Southeast
Color of Plume: White
Ibserver No. : ^
istance from Observer to Discharge Point:
Direction of Observer from Discharge Point:
height of Observation Point: 6 feet
•escription of Background:
SUMMARY OF VISIBLE EMISSIONS
TABLE .35
Type of Plant:
Gypsum Processing Facility
Location of Discharge: Rock Dryer Baghouse
Description of Sky:_ Partly Cloudy
Wind Velocity:
Detached Plume:
5-10 mph
No
Duration of Observation:
50 feet
0849-1426 Runs 2-3
South
cloudy sky
Set
Number
1
2
'3
k
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
SUMMARY OF AVERAGE OPACITY
Time
Start
0849
0855
0901
0907
0913
0919
0925
0931
0937
0943
0949
0955
1001
1007
1013
1419
1025
1230
1236
1242
End
1855
0901
0907
0913
1919
0925
0931
0937
0943
0949
0955
1001
1007
1013
1019
1025
1028
1236
1242
1248
Opacity
Sum
15
5
10
0
10
0
5
0
5
0
0
10
0
5
s
5
0
0
0
0
Average
0.6
0.2
0.4
0.0
0.4
0.0
0.2
0.0
0.2
0.0
0.0
0.4
0.0
0.2
0.2
0.2
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
T
Start
1248
1254
1300
1306
1312
1318
1324
1330
1336
1342
1348
1354
1400
1406
1412
1418
1424
me
End
1254
1300
1306
1312
1318
1324
1330
1336
1342
1348
1354
1400
1406
1412
1418
1424
1426
Opa
Sum
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
pity
Average
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
00
0.0
0.0
0.0
0.0
Bketch Showing How Opacity Varied with Time:
0.8
0.6
0.4
0.2
Opaci ty
(*)
>
i . . .1 i
1 Kour 2 hours 3 hours 4 hours
Time, Hours
-72-
-------
SUMMARY OF VISIBLE EMISSIONS
TABLE 36
Date: May 27, 1980
Type of Discharge: Stack"
C eight of Point of Discharge: 6' above roof
ind Direction: Southwest
Color of Plume: White
Observer No.: . ^_^ ______
Distance from Observer to Discharge Point: _
Direction of Observer from Discharge Point:
Height of Observation Point: roof level
description of Background: clear
Type of Plant: Gypsum Processing Facility
Location of Discharge: Stucco Baghouse
Description of Sky: Clear
Wind Velocity:
Detached Plume:
No
Duration of Observation:
20 feet
1330-1705 Runs 1-3
West
SUMMARY OF AVERAGE OPACITY
Set
Number
1
2
'3
1*
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Time
Start
1330
1336
1342
1348
135^
1400
1406
1412
1418
1424
1440
•1446
1452
1458
1504
1510
1516
1522
1528
1534
End
1336
1342
1348
1354
1400
1406
1412
1418
1424
1430
1446
1452
1458
1504
1510
1516
1522
1528
1534
1540
Opacity
Sum
90
95
70
110
115
120
60
75
60
75
40
45
60
80
85
55
110
105
65
100
Average
3.8
4.0
2.9
4.6
4.8
5.0
2.5
3.1
2.5
3-1
1.7
1.9
2.5
3-3
3-5
2.3
4.6
4.4
2.7
4.2
Set
Number
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
T
Start
1605
1611
1617
1623
1629
1635
1641
1647
1653
1659
me
End
1611
1617
1623
1629
1635
1641
1647
1653
1659
1705
Opa<
Sum
95
70
90
100
75
75
90
100
95
85
pi ty
Average
4.0
2.9
3-8
4.2
3-1
3-1
3.8
4.2
4.0
3-5
Sketch Showing How Opacity Varied with Time:
Opacity
(*)
5.0
2 '
— n
LJ
— ' '
n n i
-T-i
I""1— r i— PI
_ru
J— L_
u
1 hour
2 hours
3 hours
Time, Hours
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Table 37
Mean Fugitive Emission Values (% Frequency Emission)
For Three Tests at Each Location
Board End Sawing
Test
Test 1
Test 2
Test 3
Site Mean
Test
Test 1
Test 2
Test 3
Site Mean
Test
Test 1
Test 2
Test 3
Site Mean
Test
Test 1
Test 2
Test 3
Site Mean
Test
Test 1
Site Mean
Score Wheel
Test Mean
37.5
35.8
19.2
30.8
Test Mean
0.0
0.0
0.0
0. 0
Admix Conveyor
Test Mean
0.0
0.0
0.0
0. 0
Fiberglass Shredder
Test Mean
0.13
0.22
0.22
0.19
Vermiculite Addition
Test Mean
65.5
65. 5
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