United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EMB Report 80-GYP-2
November 1980
Air
v>EPA Gypsum Industry
Emission Test Report
U.S. Gypsum Company
Shoals, Indiana
-------
SOURCE EMISSION TEST REPORT
United States Gypsum Company
Shoals/ Indiana
No. 4 Kettle Calciner Baghouse
Rock Dryer Baghouse
Board End Sawing Baghouse
Other Process Emission Test Points
David A. Ralston
Assistant Project Scientist
Barry Jae-^so
Project watiag
Air Testing
RFW Report No: 0300-81-21
Contract No: 68-02-2816
Work Assignment No. 20
Prepared by
Roy F. Weston, Inc.
Designers - Consultants
West Chester, Pennsylvania
19380
-------
TABLE OF CONTENTS
SUMMARY 1
INTRODUCTION 5
PROCESS DESCRIPTION AND OPERATION 7
Plant Description 7
Process Equipment Tested . 7
Rock Dryer 7
Kettle Calciner 7
Stucco Storage and Transfer 12
Board Forming Line 12
Plaster Mixing and Bagging 12
Emission Controls 12
Process Conditions During Testing 16
Continuous Kettle Calciner 16
Rock Dryer 16
Stucco Storage and Transfer 23
Board End Sawing 23
Mixing and Bagging 23
Other Process Operations 24
DESCRIPTION OF PARTICULATE TEST LOCATIONS 27
No. 4 Kettle Calciner Baghouse Inlet
Duct 27
No. 4 Kettle Calciner Baghouse Dis-
charge Stack 27
Rock Dryer Baghouse Inlet Duct 27
Rock Dryer Baghouse Discharge Stack 27
Board End Sawing Baghouse Discharge
Stack 27
DESCRIPTION OF SAMPLING TRAINS 33
Particulate Sampling Trains 33
Particle Size Distribution Sampling
Apparatus 36
111
-------
TABLE OF CONTENTS
(continued)
Page
TEST PROCEDURES 39
Preliminary Tests 39
Formal Tests 39
No. 4 Kettle Calciner Baghouse
Inlet Duct 39
No. 4 Kettle Calciner Baghouse
Discharge Stack 40
Rock Dryer Baghouse Inlet Duct 40
Rock Dryer Baghouse Discharge
Stack 41
Board End Sawing Baghouse Dis-
charge Stack 41
Other Test Points 41
ANALYTICAL PROCEDURES 43
Particulate Sample Recovery 43
Particulate Analyses 43
Particle Size Sample Recovery and
Analyses 44
TEST RESULTS AND DISCUSSION 45
APPENDIX A -- RAW TEST DATA
APPENDIX B -- LABORATORY REPORTS
APPENDIX C -- SAMPLE CALCULATIONS
APPENDIX D -- EQUIPMENT CALIBRATION RECORDS
APPENDIX E -- PROJECT PARTICIPANTS
IV
-------
LIST OF TABLES
Table No. Title Page
1 Emission Tests Conducted at USG, Shoals,
Indiana Plant 8
2 Control Equipment Parameters 13
3 Stucco Storage and Transfer System 14
4 Bag Replacement Schedules 15
5 Process Data from Continuous Kettle:
Run No. 1 17
6 Process Data from Continuous Kettle:
Run No. 2 18
7 Process Data from Continuous Kettle:
Run No. 3 19
8 Process Data from Rock Dryer:
Run No. 1 20
9 Process Data from Rock Dryer:
Run No. 2 21
10 Process Data from Rock Dryer:
Run No. 3 22
11 No. 4 Kettle Calciner Baghouse Inlet Duct
Summary of Test Data: English Units 51
12 : Metric Units 52
13 No. 4 Kettle Calciner Baghouse Discharge
Stack
Summary of Test Data: English Units 53
14 : Metric Units 54
15 Rock Dryer Baghouse Inlet Duct
Summary of Test Data: English Units 55
16 : Metric Units 56
17 Rock Dryer Baghouse Discharge Duct
Summary of Test Data: English Units 57
18 : Metric Units 58
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LIST OF TABLES
Table No. Title Page
19 Board End Sawing Discharge Duct
Summary of Test Data: English Units 59
20 : Metric Units 60
21 No. 4 Kettle Calciner Baghouse Inlet Duct
Summary of Test Results: English Units 61
22 : Metric Units 62
23 No. 4 Kettle Calciner Baghouse Discharge
Duct
Summary of Test Results: English Units 63
24 : Metric Units 64
25 Rock Dryer Baghouse Inlet Duct
Summary of Test Results: English Units 65
26 : Metric Units 66
27 Rock Dryer Baghouse Discharge Duct
Summary of Test Results: English Units 67
28 : Metric Units 68
29 Board End Sawing Discharge Duct
Summary of Test Results: English Units 69
30 : Metric Units 70
31 Rock Dryer Baghouse Inlet Duct
Particle Size Distribution - Run No. 1 71
32 Rock Dryer Baghouse Inlet Duct
Particle Size Distribution - Run No. 2 73
33 Rock Dryer Baghouse Inlet Duct
Particle Size Distribution - Run No. 3 75
34 Rock Dryer Baghouse Discharge Stack
Particle Size Distribution 77
35 Board End Sawing Baghouse Discharge Stack
Particle Size Distribution 79
36 No. 4 Kettle Calciner Baghouse Discharge
Stack
Summary of Visible Emissions 81
VI
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LIST OF TABLES
(continued)
Table No. Title Page
37 Rock Dryer Baghouse Discharge Stack
Summary of Visible Emissions 83
38 Board End Sawing Baghouse Discharge Stack
Summary of Visible Emissions 85
39 Scoring and Chamfering Operation Cyclone
Discharge Stack
Summary of Visible Emissions 86
40 Surge Bin Baghouse Discharge Stack
Summary of Visible Emissions 87
41 Packer Baghouse Discharge Stack
Summary of Visible Emissions 88
42 No. 5 Upper and Lower Mixer Stations
Summary of Fugitive Emissions 89
43 Scoring/Chamfering Operation Station 5
Packer Station
Board End Sawing Station
Summary of Fugitive Emissions 90
VII
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LIST OF FIGURES
Figure No. Title Page
1 Block Flow Diagram for Shoals Board Plant 9
2 Direct Fired, Co-Current, Rotary Dryer 10
3 Diagram for Calcining Kettle
(Modified for Continuous Operation) 11
4 No. 4 Kettle Calciner Baghouse Inlet Duct
Port and Sampling Point Locations 28
5 No. 4 Kettle Calciner Baghouse Discharge
Stack
Port and Sampling Point Locations 29
6 Rock Dryer Baghouse Inlet Duct
Port and Sampling Point Locations 30
7 Rock Dryer Baghouse Discharge Stack
Port and Sampling Point Locations 31
8 Board End Sawing Baghouse Discharge Stack
Port and Sampling Point Locations 32
9 Particulate Sampling Train
EPA Method 5 34
10 Particulate Sampling Train
EPA Method 5 35
11 Particle Size Distribution Sampling
Apparatus
Anderson 2000 Inc. 37
12 Rock Dryer Inlet
Particle Size Distribution Results
Run No. 1 72
13 Rock Dryer Inlet
Particle Size Distribution Results
Run No. 2 74
14 Rock Dryer Inlet
Particle Size Distribution Results
Run No. 3 76
ix
-------
LIST OF FIGURES
(continued)
Figure No. Title Page
15 Rock Dryer Outlet
Particle Size Distribution Results
Run No. 1 78
16 Board End Sawing
Particle Size Distribution Results
Run No. 1 80
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SUMMARY
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 United States
Gypsum Company's Shoals, Indiana plant.
The program was designed to quantify selected process emissions
and to determine collector performance. The locations tested,
plus the number and types of tests performed at each site, are
indicated below:
Number of Test Repetitions by Type
Source Description
No. 4 Kettle Calciner
Baghouse Inlet Duct
No. 4 Kettle Calciner
Baghouse Discharge Stack
Rock Dryer Baghouse
Inlet Duct
Rock Dryer Baghouse
Discharge Stack
Board End Sawing
Baghouse Discharge Stack
Scoring/Chamfering Operation
(Station No. 5 and Cyclone
Discharge Stack)
Surge Bin Baghouse
Discharge Stack
Packer Baghouse Discharge
Stack
Board End Sawing Station
No. 5 Upper Mixer Station
No. 5 Lower Mixer Station
Particu-
late
Particle
Size
Distri-
bution
Visible
Emission
Fugitive
Emission
3
3
3
3
-1-
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The following test protocol was used during the survey:
Parameter
Particulate
Particle Size Distribution
Visible Emission
Fugitive Emission
Test Method
EPA 5
Andersen 2000, Inc.2
EPA 93.
EPA 22
Particulate matter concentration and mass rate results are sum-
marized below:
No. 4 Kettle Calciner Baghouse Inlet Duct
Test
Number
1
2
3
Date
6-3-80
6-3-80
6-4-80
Particulate Concentration
Grains/DSCF
96.7
113.
119.
Series Average
Particulate
Mass Rate
Pounds/Hour
467.
507.
515.
497.
No. 4 Kettle Calciner Baghouse Discharge Stack
Test
Numbe r
1
2
3
Date
6-3-80
6-3-80
6-4-80
Particulate Concentration
Grains/DSCF
0.020
0.006
0.011
Series Average
Average collector efficiency = 99.99%.
Particulate
Mass Rate
Pounds/Hour
0.093
0.028
0.050
0.057
iCode of Federal Regulations, Title 40, Part 60, Appendix A,
"Standards of Performance for New Stationary Sources," August
18,1977.
2Operating Manual for Andersen 2000, Inc., "Mark III Particle
Sizing Stack Samplers," Andersen 2000, Inc., P.O. Box 20769,
Atlanta, Georgia.
3Federal Register, Vol. 39, No. 219, November 12, 1974.
4Draft method, revised July 28, 1978.
-2-
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Rock Dryer Inlet Duct
Test Particulate Concentration
Number Date Grains/DSCF
1 6-5-80 3.24
2 6-6-80 4.18
3 6-6-80 4.13
Series Average
Rock Dryer Discharge Stack
Test Particulate Concentration
Number Date Grains/DSCF
1 6-5-80 0.004
2 6-6-80 0.004
3 6-6-80 0.005
Series Average
Average collector efficiency = 99.87%.
Particulate
Mass Rate
Pounds/Hour
208.
257.
253.
239.
Particulate
Mass Rate
Pounds/Hour
0.302
0.275
0.341
0.306
Board End Sawing Baghouse Discharge Stack
Test
Number
1
2
3
Date
6-5-80
6-5-80
6-5-80
Particulate Concentration
Grains/DSCF
0.002
0.007
0.010
Series Average
Average collector efficiency = 99.91%.
Particulate
Mass Rate
Pounds/Hour
0.066
0.197
0.307
0.190
This efficiency was calculated based on an estimate of uncon-
trolled emissions from the plant's board end sawing operation.
See Appendix C, Sample Calculations, for estimate workup. Note
that the board end sawing baghouse inlet duct was not sampled
due to the presence of large particulate (up to 6" long by 1/2"
wide) which could not be collected representatively using a
standard Method 5 train.
Detailed particulate, particle size distribution, visible and
fugitive emission test data and test results are presented in
the Test Results and Discussion Section.
-3-
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INTRODUCTION
The Emission Measurement Branch of the U.S. Environmental Pro-
tection Agency contracted Roy F. Weston, Inc. (WESTON) to
conduct a source testing and analysis program at the United
States Gypsum Company's Shoals, Indiana facility. The objec-
tive of the testing program was to measure emission parameters
relating to the gypsum ore processing operations at the plant.
The locations tested, plus the number and types of tests per-
formed at each site, are listed below:
1. No. 4 Kettle Calciner Baghouse Inlet Duct
a. Three particulate tests by EPA Method 5.
2. No. 4 Kettle Calciner Baghouse Discharge Stack
a. Three particulate tests by EPA Method 5.
b. Three opacity tests by EPA Method 9 simultaneously
with the three particulate tests.
3. Rock Dryer Inlet Duct
a. Three particulate tests by EPA Method 5.
b. Three particle size distribution tests by cascade
impaction (Andersen).
4. Rock Dryer Discharge Stack
a. Three particulate tests by EPA Method 5.
b. One particle size distribution test by cascade impac-
tion (Andersen).
c. Three opacity tests by EPA Method 9 simultaneously
with the three particulate tests.
5. Board End Sawing Baghouse Discharge Stack
a. Three particulate tests by EPA Method 5.
b. One particle size distribution test by cascade impac-
tion (Andersen).
c. Three opacity tests by EPA Method 9 simultaneously
with the three particulate tests.
-5-
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6. Board End Sawing Station
a. Three fugitive tests by EPA Method 22.
7. Scoring/Chamfering Operation
a. Three opacity tests by EPA Method 9 on cyclone stack
discharge.
b. Three fugitive tests by EPA Method 22 on Station
No. 5.
8. Surge Bin Baghouse Discharge Stack
a. Three opacity tests by EPA Method 9.
9. Packer Baghouse Discharge Stack
a. Three opacity tests by EPA Method 9.
b. Three fugitive tests by EPA Method 22.
10. No. 5 Upper Mixer Station
a. Three fugitive tests by EPA Method 22.
11. No. 5 Lower Mixer Station
a. Three fugitive tests by EPA Method 22.
-6-
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PROCESS DESCRIPTION AND OPERATION
PLANT DESCRIPTION
The United States Gypsum, Shoals, Indiana plant produces wall-
board and plaster products from gypsum ore mined about one mile
from the plant. A simplified flow diagram for the process used
at the Shoals 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 571K (300°F) to remove 75 percent
of its water of hydration and thus form calcium sulfate hemihy-
drate (CaS04«l/2H20). This process is known as calcining.
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 cor-
rect size, and shipped to distributors.
PROCESS EQUIPMENT TESTED
The emission tests conducted at the Shoals plant are shown in
Table 1. A brief description of the major processing equipment
tested at the plant is provided in the following sections.
Rock Dryer
The rock dryer employed at the Shoals plant is a direct-fired,
co-current rotary dryer. As crushed wet gypsum is passed
through the dryer, surface moisture is evaporated by hot combus-
tion gases. A schematic diagram of this type of dryer is shown
in Figure 2.
Kettle Calciner
The calciner used at the Shoals plant is a continuous kettle
calciner. As finely ground gypsum is fed to the kettle, hot
combustion gases are passed through flues inside the kettle to
provide an indirect transfer of heat to the ore. The heating of
the ore causes the chemical reaction which produces stucco. A
schematic diagram of the calcining kettle is shown in Figure 3.
-7-
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Table 1 Emission Tests Conducted at USG,
Shoals, Indiana Plant
Process
Tested
Continuous
Kettle Calciner
Rock Dryer
Board End
Sawing
Board End
Sawi ng
Paper Scoring
Plaster Mixing
and Begging
Stucco Storage
and Transfer
11 Pin Mixer
n Pin Mixer
Date
6/3/80
6/4/80
6/5/80
6/6/80
6/5/80
6/6/80
6/2/80
6/3/80
6/3/80
6/4/80
6/10/80
6/3/80
6/4/80
Control
Method
Baghouse
Baghouse
Baghouse
Capture
Hood
Capture
Cyclone
Capture
Baghouse
Test
Type
Particulate Loading
Particle Size
Visible Emissions
Particulate Loading
Particle Size
Visible Emissions
Particulate Loading
Particle Size
Visible Emissions
Visible Emissions
Device/ Visible Emissions
Device/ Visible Emissions
Inleta
Test
EPA-5(3)
Banco (1)
N/A
EPA-5(3)
Andersen (3)
N/A
-
EPA-22
EPA-22
EPA-22
Baghouse Visible Emissions
Capture
Capture
Device Visible Emissions
Device Visible Emissions
EPA-22
EPA-22
Outleta
Test
EPA-5(3)
Bahcojl)
EPA-9
EPA-5(3)
Andersen (1)
EPA-9
EPA-5(3)
Andersen (1)
EPA-9
EPA-22
EPA-9
EPA-9
EPA-9
-
-
'Numbers in parenthesis represent the number of individual tests performed at the site.
-------
I I Baghouse
^ A1r Flow
> Process Flow
Vent
Vent
GL-
Vent
Load
Vent
L-JS
FIGURE 1 BLOCK FLOW DIAGRAM FOR SHOALS BOARD PLANT
-9-
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Feed chule
Combustion
(urnoce
Burner
o
I
* 't'' ^^ i
-------
Valve to close
the overflow
into hot-pit
Kettle shell
Burneri
Combustion chamber
Refractory
Masonry
Brick
factory
SoMom discharge
closed in
continuous
operation
Hot pit
Vertical cross section
continuous calcining kettle. Stucco is discharged continuously by introducing compressed air
into an oversow channel inside (solid arrowrJL. .
Heat Hows from the firebox, around baffles* through the ffues and out the stack (broken arra**sL
FIGURE 3 DIAGRAM OF CALCINING KETTLE
(MODIFIED FOR CONTINUOUS OPERATION)2
-11-
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Stucco Storage and Transfer
The stucco storage and transfer system tested at the plant em-
ploys an air conveyor to transfer stucco from a conveyor belt to
a 27.2 Mg (30 ton) surge bin and conventional screw conveyors to
transfer the stucco from the bin to the board forming line.
Board Forming Line
The two boardlines tested at the Shoals plant are of average
size and together are capable of producing about 51 million
square meters (550 million square feet) of wallboard per year on
a half-inch basis. The process operations tested on the board-
lines, which include board end sawing, paper scoring, and pin
mixing, are typical of those used throughout the gypsum indus-
try.
Plaster Mixing and Bagging
The plaster mixing and bagging unit at the Shoals plant is typi-
cal of those used throughout the gypsum industry.
EMISSION CONTROLS
Fabric filter dust collectors are used at the Shoals plant to
control gypsum particulate emissions. Dust-laden gases exiting
the rock dryer and the kettle calciner are vented to separate
baghouses. The dryer has four Buell cyclones upstream of the
baghouse. Emissions from conveyors, bucket elevators, and stor-
age bins are vented to fabric filter dust collectors. Boardline
emissions from dry mixing, and board end sawing, are also con-
trolled by baghouses. Paper scoring and pin mixing emissions
from one of the boardlines are controlled by a cyclone only.
Pin mixing on the other boardline is vented to a baghouse. Emis-
sions from the plaster mixing and bagging operation are vented
to a separate baghouse.
Design and operating parameters for the baghouses tested at the
Shoals plant are given in Table 2. Estimated operating capaci-
ties for the process units vented to the stucco storage and
transfer baghouse are given in Table 3.
Normal replacement frequencies and most recent replacement dates
for bags in the dust collectors tested are shown in Table 4.
-12-
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Table 2 Control Equipment Parameters
Process Baghouse Number Bag Dimensions Cloth Area Fabric Design Air to Cloth
Unit Manufacturer of bags (dlam.x length (square ft.) Type Air Flow Ratio
Name (Cleaning Type) In Inches) (mJ/sec)(ACFM) (feet/min.)
i
U)
i
Continuous
calclner
kettle
Rock
dryer
Flex Kleen 80 6 x 84
(reverse
pulse)
Flex Kleen 160 6 x 84
(reverse
pulse)
800 Orion 1.89 4.000 5:1
Felt
1.600 Orion 4.72 10.000 6.25:1
Felt
Duration of Frequency Pressure of
Cleaning Cycle of Cleaning pulse
(sec.) (pslg)
0.1 10 sec 90
0.1 10 sec 90
i
(
Board end Dracco
sawing (shaker)
80
25 x 117
4.560
Dacron
2.83 6.000
1.3:1
60
15 mln
N/A
Nixing and Flex Kleen
bagging (reverse
pulse)
144
5 x 112
1.584 (suited 1.42 3.000
to 300"F)
2:1
0.1
10 sec
90
Stucco Wheel abrator 144
5 x 112
1.584
Dacron
1.42 3,000
2:1
60
15 mln
N/A
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Table 3 Stucco Storage and Transfer System
Process Unit Name Estimated Operating Capacity9
Storage Bin 27.2 Mg (30 Tons)
H A1r Conveyor (transfers 24.5 Mg/hr (27 TPH)
t" stucco to storage bin)
Screw conveyor (stucco 24.5 Mg/hr (27 TPH)
to admix)
Admix conveyor 27.2 Mg (30 TPHb)
P1n m1xerb 48.1 Mg (53 TPH)
aTPH = Tons per hour
b
Operating capacity Includes stucco plus additives,
-------
Table 4 Bag Replacement Schedules
Ul
i
Process Unit Name
Continuous kettle
Rock dryer
Board end sawing
Stucco transfer and storage
Mixing and bagging
Last Date of Bag Replacement
2/29/80
1/26/80
3/23/80
4/21/79
5/28/80
(20 new bags)
Normal Replacement Frequency9
(months)
10-12
10-12
12
12
12
aThese values are estimates.
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CONSULTANTS
PROCESS CONDITIONS DURING TESTING
In order to ensure that the ore dryer, calciner, boardline, and
plaster operations were operating at representative steady-state
conditions during the testing, various process parameters were
monitored.
All processes operated normally during the emission testing.
The operating condition of each of the processes is discussed in
the following sections.
Continuous Kettle Calciner
During the emission testing of the continuous kettle calciner,
the calciner was operating at full capacity, producing 11.5 tons
of calcined gypsum or stucco per hour. The average heat usage
of the unit during the testing was 0.85 KJ/g (0.73 million Btu/
ton) of product. The unit was burning natural gas. The stucco
product from the kettle contained combined moisture of 5.7 per-
cent during the testing. Process data collected during each of
the three EPA Method 5 test runs on the continuous kettle are
shown in Tables 5, 6, and 7, respectively. The kettle operated
normally during all three test runs.
Rock Dryer
During the emission testing, the rock dryer was operating at 92
percent of design capacity, producing 70 tons of dry rock per
hour. Process data collected during the EPA Method 5 test runs
is shown in Tables 8, 9, and 10, respectively. The average heat
usage of the dryer during the testing was 0.08 KJ/g (0.07 mil-
lion Btu/ton) of dried rock. The dryer was burning natural
gas. The free moisture content of the ore entering the dryer
was 1 to 1.5 percent, and the free moisture content of the
exiting rock was less than 0.5 percent.
Some fluctuation in the dryer temperature was observed through-
out the testing of the dryer. These fluctuations were due to
the fact that the automatic controller on the dryer was out of
service and the fuel firing rate was under manual control.
Changes in the free moisture content of the gypsum feed would
require a different firing rate. Manual changes in the firing
rate were made whenever the dryer operating temperature varied
significantly from a desired value. The length of time required
for restabilization of the temperature, which ranged from 10 to
30 minutes, was dependent on the extent of the deviation from
the desired temperature at the time the firing rate was reset.
-16-
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Table 5 Process Data From Continuous Kettle: Run No. 1
Plant:
Location:
Date:
USG
Shoals, Indiana
6/3/80
Locdl
Time
9:05- a.m.
9:19
9:2&
9:34
9:46
10:30
10:5S
11:20
11:30
12:25
Flue Gas Stucco Process Gas
Temperature Temperature Stack
K (°F) K (°F) (Inches
416
415
414
415
414
415
414
414
290
288
285
287
285
287
286
285
377 (220
377 (220
377
377
377
377
377
377
220
220
220
220
220
220
-1.
-1.
-0.
-1.
-0.
-1.
-1.
-1.
414 (285) 377 (220) -1.
414 (285) 377 (220) -1.
Draft
H20)
1
2
9
0
9
1
1
1
1
2
Fabric Filter
Pressure
(Inches H
2.5
-
-
2.5
-
2.5
-
2.8
2.8
•"
Drop
20)
Measured at point where flue gas leaves the kettle.
5Same as process gas exit temperature.
^
'Static pressure at point where process gas leaves kettle.
-------
Table 6 Process Data From Continuous Kettle: Run No. 2
Plant:
Location:
Date:
USG
Shoals, Indiana
6/3/80
00
I
Local
Time
1:25 p.m.
2:00
2:21.
2:54
3:13
3:26
3:40
4:07
Flue Gas Stucco Process
Gasc
Temperature Temperature Stack Draft
K (°F) K (°F) (Inches
414
414
414
414
414
414
413
414
285
285
285
285
285
285
284
285
377
377
377
377
377
377
377
377
220
220
220
220
220
220
220
220
-1
-1
-1
-1
-1
-1
-1
-1
H20)
.1
.0
•
•
*
•
•
•
Fabric Filter
Pressure
(Inches \
2.7
2.7
2.7
2.6
-
-
2.6
™
Drop
<2o)
Measured at point where flue gas leaves the kettle.
Same as process gas exit temperature.
%
'Static pressure at point where process gas leaves kettle.
-------
Table 7 Process Data From Continuous Kettle: Run No. 3
i
H
vo
Plant: USG
Location: Shoals, Indiana
Date: 6/4/80
Local
Time
8:35 a.m.
9:02
9:17
9:28
9:58
10:23
Flue Gasa Stucco Process Gasc
Temperature Temperature Stack Draft
K (°F) K (°F) (Inches H20)
414
414
414
413
413
413
285
285
285
284
284
284
377
377
377
377
377
377
220) -1.1
220) -1.1
220 -1.2
220) -1.2
220) -1.1
220) -1.2
Fabric Filter
Pressure Drop
(Inches H20)
2.5
2.5
2.5
—
Measured at point where flue gas leaves the kettle.
}Same as process gas exit temperature.
*
'Static pressure at point where process gas leaves kettle.
-------
Table 8 Process Data From Rock Dryer: Run No. 1
Plant:
Location:
Date:
USG
Shoals, Indiana
6/5/80
i
to
o
I
Local
Time
6:06 p.m.
6:32
6:45
6:55
7:10
7:30
Rock Dryer Fabric Filter
Temperature Temperature Pressure Drop
K (°F) K (°F) (Inches HgO)
322
324
325
326
326
326
120
124
126
127
127
127
333
337
335
335
335
335
140
147
144
143
143
144
2.1
2.1
2.2
2.1
2.1
2.1
Measured at point where rock exits dryer.
-------
Table 9 Process Data From Rock Dryer: Run No. 2
Plant:
Location:
Date:
USG
Shoals, Indiana
6/6/80
i
to
Local
Time
Rocka Dryer Fabric Filter
Temperature Temperature Pressure Drop
K (°F) K (°F) (Inches H20)
7:56 a.m.
8:11
8:20
8:30
8:49
9:33
9:40
9:53
10:20
10:35
10:53
327
327
325
325
325
326
326
326
326
327
326
130
127
125
126
126
127
127
128
128
129
128
340 (152) 2.4
334 (142) 2.4
333 (140
334 (142
335 (143
336 (146
337 (148
337 (148
337
337
336
2.4
2.4
2.4
2.4
-
2.5
148) 2.5
148)
146) 2.6
Measured at point where rock exits dryer.
-------
Table 10 Process Data From Rock Dryer: Run No. 3
Plant:
Location:
Date:
USG
Shoals, Indiana
6/6/80
I
ro
to
i
Local
Time
11:36 a.m.
11:50
11:58
12:06
12:15
12:25
12:38
12:45
12:55
1:00
1:15
1:25
Rock Dryer Fabric Filter
Temperature Temperature Pressure Drop
K (°F) K (°F) (Inches H20)
326
327
327
327
327
128
129
130
130
130
328 (131
329 (132
329
329
329
329
329
132
132
132
132
132
337
338
338
339
339
340
341
341
340
340
341
341
147) 2.6
149) 2.6
149
150
150
152
154
154
152
152
154
154
2.6
2.6
2.6
2.6
2.6
2.6
2.6
2.6
-
2.6
Measured at point where rock exits dryer.
-------
Estimates of the effect of the temperature fluctuations on the
air flow rate through the dryer show that the maximum variation
in the flow rate during all three test runs should be no greater
than two percent.
The dryer at the Shoals plant has a small heater downstream of
the four small Buell cyclones which are at the outlet of the
dryer. The emission tests performed on the inlet to the collec-
tor were performed downstream of the heater. The purpose of the
heater is to heat the process gases entering the baghouse.
Heating these gases reduces the risk that wet particulate matter
will enter the baghouse and blind the filter bags. The burner on
the heater is rated at 440 KJ/sec (1.5 million Btu/hour). The
instrumentation used to measure the natural gas usage of the
rock dryer measured the sum of the main dryer burner and the
heater. Between the first and second test runs, the heater was
inadvertently left off. Some difference in the temperature of
the gas stream entering the baghouse may be observed between the
first and second test runs because the temperature set-point on
the heater controller was moved by maintenance and operation
personnel.
Stucco Storage and Transfer
Tne storage and transfer system was operating at normal capacity
during the emission testing.
Board End Sawing
During the board end sawing testing, the No. 2 boardline was
running regular, one half inch board, 12 feet in length. The
line was operating at a rate of 47.9 meters per minute (157 feet
per minute).
Mixing and Bagging
The plaster mixing and bagging operation was operated by a
single operator during the testing. Generally, the process is
operated by two operators, one person working the batch mixer
and a second working the bagging machine. During the testing,
the operator would mix a single batch of plaster, about 1,453
Kg (3,200 pounds), and then return to the bagging machine. Al-
though operation with a single operator is somewhat abnormal for
this plant, the test data should still be representative since
both emission sources, mixing and bagging, were in continuous
operation. During most of the testing, the plant was bagging
normal plaster which is about 99-percent stucco; during the re-
mainder of the testing, the plant was bagging a special plaster
-23-
-------
containing 13-percent perlite. The plaster was being put in
50-lb bags at the rate of 500 bags per hour.
Other Process Operations
The remaining processes tested, which include paper scoring and
pin mixing, were tested under normal operating conditions.
-24-
-------
PROCESS DECRIPTION 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.
2. Permit Application for Construction at Sweetwater, Texas
plant. United States Gypsum Company. Texas Air Control
Board, Austin, Texas. 19 June 1979.
-25-
-------
DESCRIPTION OF PARTICULATE TEST LOCATIONS
NO. 4 KETTLE CALCINER BAGHOUSE INLET DUCT
Three 3 1/2" I.D. test ports, one inch apart, were placed on a
straight section of the 11 3/4" x 17 1/2" metal duct at a loca-
tion 8.2 diameters (101) downstream and 6.6 diameters (81)
upstream from the nearest flow disturbances. EPA Method 1
criteria for this test location required a minimum of 9 traverse
points. See Figure 4 for port and sampling point locations.
NO. 4 KETTLE CALCINER BAGHOUSE DISCHARGE STACK
Two 3 1/2" I.D. test ports, 90° apart, were placed on a
straight section of the 12" I.D. metal stack at a location
> eight diameters ( >8') downstream and three diameters
upstream from the nearest flow disturbances. Eight sampling
points (4 per port) were required for testing. See Figure 5
for port and sampling point locations.
ROCK DRYER BAGHOUSE INLET DUCT
;
Two 3 1/2" I.D. test ports were placed at right angles on the
23 1/4" I.D. metal stack, less than 1 diameter from both
upstream and downstream flow disturbances. The test site
required a minimum of 32 traverse points (16 per port). Figure
6 illustrates port and sampling point locations.
ROCK DRYER BAGHQUSE DISCHARGE STACK
Two 3 1/2" I.D. test ports were placed 90° apart on the
23 3/4" I.D. metal duct leading from the Rock Dryer Baghouse.
The ports were placed 12.6 diameters (25') downstream and 6.1
diameters (12*) upstream from the nearest gas stream flow dis-
turbances. EPA Method 1 required a minimum of 8 traverse points
(4 per port) for this test location. See Figure 7 for port and
sampling point locations.
BOARD END SAWING BAGHOUSE DISCHARGE STACK
Two 3 1/2" I.D. test ports were placed at right angles on the
11 1/2" I.D. metal stack 15.6 diameters downstream and 5.2 diam-
eters upstream from the nearest flow disturbances. The test
site required a minimum of 8 traverse points (4 per port). Fig-
ure 8 illustrates port and sampling point locations.
-27-
-------
Traverse
Point'
Number
1
2
3
Distance From
Inside Near
Wall, Inches
2
57/8
93/4
•171/2"-
To
Baghouse
Gas Row Direction
8'
t
10'
Platform-
)
f
11 3/4"
poo
~X Y *
Duct Elevation
Port
3/4": -
J-* - —14 5/8"
Duct Cross-Sectional Plan
FIGURE 4 PORT AND SAMPLING POINT LOCATIONS -
NO. 4 KETTLE CALCINER BAGHOUSE INLET DUCT
-28-
-------
Traverse
Point
Number
1
2
3
4
Distance From
Inside Near
Wall, Inches
3/4
3
9
11 1/4
Platform.
PortX
PortY
Duct Cross-Sectional Plan
T
o
Y
From
Baghouse
Stack Elevation
To
»Atmosphere
FIGURE 5 PORT AND SAMPLING POINT LOCATIONS -
NO. 4 KETTLE CALCINER BAGHOUSE DISCHARGE
STACK
-29-
-------
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
3/8
1 1/8
2
27/8 .
37/8
51/8
65/8
83/4
141/2
165/8
181/8
193/8
203/8
21 1/4
221/8
227/8
Baghouse
Cyclone
From
Dryer
Duct Elevation
PortY
PortX
Duct Cross-Sectional Plan
RGURE 6 PORT AND SAMPLING POINT LOCATIONS
ROCK DRYER BAGHOUSE INLET DUCT
-30-
-------
Traverse
Point
Number
1
2
3
4
Distance From
Inside Near
Wall, Inches
1 5/8'
57/8
173/4
221/8
PortY
PortX
Stack Cross-Sectional Plan
To Atmosphere^
T
/v»
^19'
Roof
Level
O
Y
Fan
Stack Elevation
Test
•Platform
FIGURE 7 PORT AND SAMPLING POINT LOCATIONS -
ROCK DRYER BAGHOUSE DISCHARGE STACK
-31-
-------
Fan After
Baghouse
Duct Cross-Sectional Plan
Traverse
Point
Number
1
2
3
4
Distance From
Inside Near
Wall, Inches
3/4
27/8
85/8
103/4
RGURE 8 PORT AND SAMPLING POINT LOCATIONS -
BOARD END SAWING BAGHOUSE DISCHARGE STACK
-32-
-------
DESCRIPTION OF SAMPLING TRAINS
PARTICULATE SAMPLING TRAINS
The test train utilized for particulate sampling at the Board
End Sawing Baghouse Discharge Stack was the standard EPA Method
5 train (see Figure 9) .
A stainless steel nozzle was attached to a heated (•—250°F)
borosilicate glass probe which was connected directly to a boro-
silicate filter holder containing a 9-cm Reeve Angel 900 AF
glass fiber filter. The filter holder was maintained at approx-
imately 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 con-
tained 200 grams of dry pre-weighed silica gel. The first,
third, and fourth impingers were modified Greenburg-Smith types;
the second was a standard Greenburg-Smith impinger. All
impingers were maintained in a crushed ice bath. A 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 pyrom-
eter. 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 sampling
probe. Gas stream composition (carbon dioxide, oxygen, and car-
bon monoxide content) was determined utilizing Orsat apparatus
to analyze stack gas samples. Gas stream composition proved to
be ambient air with the exception of the Rock Dryer inlet and
outlet test sites which contained products of combustion.
Figure 10 shows the EPA Method 5 train utilized at the No. 4
Kettle Calciner Baghouse and at the Rock Dryer Baghouse loca-
tions. The test train shown is identical to the one described
above, 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.
-33-
-------
0.75 to 1 in.
1
Temperature Sensor
t
2 0.75 in.
t
Pitot Tube
Probe
Temperature Controlled
Heated Area
Thermometer
Temperature Sensor y
Nozzle
Reverse-Type
Pitot Tube
Pitot Manometer/ Thermometers
Orifice
Vacuum Gauge
Air Tight Pump
Check Valve
•Vacuum
Line
FIGURE 9 PARTICULATE SAMPLING TRAIN -
EPA METHOD 5
-------
U)
en
I
.TEMPERATURE
SENSOR
0.76 TO 11n.
THERMOMETER
CHECK VALVE
THERMOMETERS
VACUUM LINE
ACUUM GUAGE
HEATED AREA
FILTER HOLDER
NOZZLE/HEATED -
PROBE
REVERSE-TYPE
PITOT TUBE
ORIFICE
AND
MANOMETER
PITOT MANOMETER'
IMPINGERS
ICE BATH
FIGURE 10 PARTICULATE SAMPLING TRAIN-ERA METHOD 5
-------
PARTICLE SIZE DISTRIBUTION SAMPLING APPARATUS
A stainless steel nozzle was connected directly to an 8-stage
Andersen cascade impaction device which separated the particles
according to their effective aerodynamic particle diameters. A
solid glass fiber filter was used to capture any particles that
passed through the impactor substrates to permit the measure-
ment of total particulate. The filter holder was maintained 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. A RAC control
console with vacuum pump, dry gas meter, calibrated orifice, and
inclined manometers completed the sampling train (Figure 11).
-36-
-------
Thermometer
Cascade
Impactor
Vacuum
Tubing
Stack Wall
Nozzle •
t
Reverse-Type
Pitot Tube
L
Probe
W
Pilol Manomeler/Thermometers Bypass Valve Impingers
Orifice
Vacuum Gauge
Air Tight Pump
Check Valve
Vacuum
Line
FIGURE 11 PARTICLE SIZE DISTRIBUTION SAMPLING
APPARATUS -
ANDERSEN 2000, INC.
-------
TEST PROCEDURES
PRELIMINARY TESTS
Preliminary test data was obtained at each sampling location-
Stack geometry measurements were recorded and sampling point
distances calculated. A preliminary velocity traverse was
performed 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 systems,
probe heaters, temperature gauges and barometer were performed
as specified in Section 5 of EPA Method 5 test procedures. See
Appendix D for calibration data.
FORMAL TESTS
No. 4 Kettle Calciner Baghouse Inlet Duct
A series of three tests were conducted at the No. 4 Kettle Cal-
ciner Baghouse Inlet Duct to measure the concentration and mass
rate of particulate matter emissions. Nine traverse points (3
per port axis) were sampled for 3 minutes each resulting in a
total test time of 27 minutes. The Technical Manager approved
the reduced sampling interval due to the high grain loading
(—110 gr/DSCF) encountered.
During particulate sampling, gas stream velocities were measured
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 noz-
zle at each point, and sampling rates were adjusted to maintain
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
-39-
-------
instructions prior to and after each run and/or component
change. Tables 11 and 12 present a summary of test data for
each of the three runs. Test result summarization appears in
Tables 21 and 22.
Condensation problems precluded the use of the cascade impactor
for particle sizing. Particle size distribution analyses were
conducted on the combined filter and cyclone particulate
catches. See Appendix B for results.
No. 4 Kettle Calciner Baghouse Discharge Stack
Three Method 5 tests were performed on the No. 4 Kettle Calciner
Baghouse Discharge Stack. Eight points were traversed (4 per
port) for 12 minutes, each yielding a test period of 96 minutes.
Procedures for isokinetic sampling were identical to those
described for the No. 4 Kettle Calciner Baghouse Inlet Duct.
See Tables 13 and 14 for test data and Tables 23 and 24 for
test result summaries, respectively.
Visual determinations of plume opacity were performed by a cer-
tified observer according to Method 9 procedures during all
three test runs. A summary of results is presented in Table 36.
No particle size distribution tests were conducted at this test
point due to moisture condensation problems.
Rock Dryer Baghouse Inlet Duct
*
Three 64 minute Method 5 test runs were performed at the Rock
Dryer Inlet Duct. A total of 32 points were sampled for two
minutes each per test.
Isokinetic sampling procedures were identical to those previ-
ously described. Tables 15 and 16 show test data summarization
and Tables 25 and 26 present test results.
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 4 minutes for Test Runs 1 and 2f and for 3 min-
utes for Test Run 3. This permitted collection of sufficient
sample for analysis without overloading the filter substrates.
Sample volume, temperature, and pressure data were recorded.
See Tables 31 through 33 for distribution results.
-40-
-------
Rock Dryer Baghouse Discharge Stack
Three Method 5 test runs were conducted on the Rock Dryer Dis-
charge Stack. Eight sampling points (4 per axis) were sampled
for eight minutes each, yielding a test period of 64 minutes.
Sampling procedures were identical to those previously
described. See Tables 17 and 18 for test data and Tables 27 and
28 for test result summaries, respectively.
One particle size distribution test was completed at an average
point of velocity. Total test time was 120 minutes with read-
ings taken every 5 minutes. See Table 34 for particle size dis-
tribution results.
Visual determinations of plume opacity were performed by a cer-
tified observer according to Method 9 procedures during all
three particulate test runs. A summary of results is presented
in Table 37.
Board End Sawing Baghouse Discharge Stack
Three 64 minute Method 5 test runs were conducted at the Board
End Sawing Baghouse Discharge Stack. A total of eight points
(4 per port) were sampled for eight minutes each per test.
Isokinetic sampling procedures were identical to these previ-
ously described. Tables 19 and 20 show test data summarization
and Tables 29 and 30 present test results.
One particle size distribution test was completed at an average
point of velocity. Total test time was 120 minutes with
readings taken every 5 minutes. See Table 35 for particle size
distribution plot.
Three Method 9 plume opacity determinations were performed by a
certified observer during the three particulate test runs. A
summary of results is presented in Table 38.
Other Test Points
The visible and fugitive emission tests conducted at the remain-
ing test points were 1 hour in duration each.
-41-
-------
ANALYTICAL PROCEDURES
PARTICIPATE SAMPLE RECOVERY
At the conclusion of each test, the sampling trains were dis-
mantled, 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.
Tne 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 filter fragments
(Sample Type 1) .
The probe and nozzle were separated, and the internal
particulate rinsed with acetone into a borosilicate
container while brushing a minimum of three times until no
visiole 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 deter-
mine whether or not leakage occurred during transport. The
container was labeled to clearly identify its contents.
The total liquid in impingers one, two and three was
measured, the value recorded, and the liquid discarded.
The silica gel was removed from the last impinger and
immediately weighed.
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 desic-
cated to constant weight. All sample residue weights were
adjusted by the acetone blank value.
-43-
-------
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 pre-
sented in Appendix B of this report.
PARTICLE 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
emissions 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.
-44-
-------
TEST RESULTS AND DISCUSSION
Particulate test data and test result summaries are presented in
Tables 11 through 30 of this section. Tables 31 through 35 list
the particle size distribution of the particulate matter for
all locations. Visible emission test data summaries are shown
in Tables 36 through 41. See Tables 42 and 43 for fugitive
emission test result summaries.
No unusual process operating problems were encountered during
the test periods. However, a visible plume of 20 percent
opacity emanating from the Surge Bin Baghouse (indicating leak-
ing bags) prohibited the conduct of Method 9 tests on the source
until repairs were effected. A WESTON observer returned to the
plant site on 10 June 1980 to perform the visible emission
tests following the completion of collector maintenance.
The following sampling difficulties occurred during the survey:
1. No Andersen particle size distribution tests were
performed at the No. 4 Kettle Calciner Baghouse test
points. Gas stream moisture content of ~70 percent
caused condensation problems on the filter substrates
precluding the use of this technique. At the inlet test
point, the dry filter and cyclone catches were combined
and the resultant sample submitted for sedigraph
particle size distribution analysis. No particle
sizing was conducted at the outlet test point.
2. Test period length for the particulate tests performed
at No. 4 Kettle Calciner Baghouse Inlet Duct was reduced
for practical sampling considerations (particulate
loadings of ~110 grains/DSCF) to 27 minutes as approved
by the EPA Technical Manager.
The quantity of particulate matter discharged to the atmosphere
from the No. 4 Kettle Calciner Baghouse Discharge Stack was
s^O.020 grains/DSCF and ^0.093 pounds/hour. The certified
visible emission observer recorded plume opacities of ^5 per-
cent for this source.
The particulate matter discharged from the Rock Dryer Discharge
Duct was ^0.005 grains/DSCF and ^0.341 pounds/hour. The
opacity readings recorded by the certified observer were ^5
percent.
-45-
-------
The particulate matter discharged from the Board End Sawing Bag-
house Discharge Duct was < 0.010 grains/DSCF and <0.307
pounds/hour. The opacity readings recorded by the certified
observer were < 5 percent.
The particulate removal efficiency of the No. 4 Kettle Calciner
Baghouse averaged 99.99 percent for the three tests; the effi-
ciency of the Rock Dryer Dust Collector averaged 99.87 percent;
the efficiency of the Board End Sawing Baghouse averaged 99.91
percent.
Note that the collection efficiency of the Board End Sawing Bag-
house was calculated based on an estimate of uncontrolled emis-
sions (see Appendix C for estimate workup). The inlet duct was
not sampled due to the presence of large particulate (up to 6"
long by 1/2" wide) which could not be collected representatively
using a standard Method 5 train.
-46-
-------
ANALYTICAL DATA SUMMARY
Sample: U.S. Gypsum
Shoals, Indiana
No. 4 Kettle Calcium Baghouse Inlet
Run 1
Specific Gravity: 1) 2.4633 g/cc
2) 2.4852 g/cc
Average 2.4742 g/cc
Median Particle Size: 6.6 micrometers
% > 104 urn: 0.23
Run 2
Specific Gravity: 1)
2)
Average
Median Particle Size: 7.
% > 104 vm: 0.
Run 3
Specific Gravity: 1)
2)
Average
2.3511 g/cc
2,4261 g/cc
2.3886 g/cc
5 micrometers
35
2.3796 g/cc
2.3981 g/cc
2.3888 g/cc
Median Particle Size: 10.7 micrometers
% > 104 urn: 0.46
-47.
-------
00
I
SAMPLE IDENTIFICATION
Density A'
Prepar
PARTICLE SIZE DISTRIBUTION
£?12 2-7127/t'f t'^-t
ity A'iZ.'_.g/cc LIQUID 5eJ-Sl>f:&£,(l " II- Density 0>&08 g/r* Viscosity ^'^^
aration 0.7^?7j ^IQ^&^^f Jljfffr^ i^2b^/ dy id I^.^V^....-. (T^^j, -^(
DATE _=.
BY
TEMPERATURE
RATE _^//2 START OK^.1^. ura
|oo
EQUIVALENT SPHERICAL DIAMETER, urn
-------
PARTICLE SIZE DISTRIBUTION
vo
SAMPLE IDENTIFICATION
i! i iiiiiii!!!!!!!!!! i
illlllUHIIIIHIIIIII Ullllllllllll HI ill iiiil ii; iliiiiHEisiiiiiii
w •
I 1
1 0.0 0.4 0.$ 0.4 0.1 0.1
O.I
EQUIVALENT SPHERICAL DIAMETER. \m
-------
i
tn
o
SAMPLE IDENTIFICATION
Density ^' I—o/cc
Preparation I
PARTICLE SIZE DISTRIBUTION
7l27/£f
-------
Table 11
No. 4 Kettle Calciner Baghouse Inlet Duct
Summary of Test Data
(English Units)
Test Data
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 Hater Collected by Train, ml
Standard Volume of Hater Vapor Collected, cubic feet
Dry Gas Meter Calibration Factor, dimensionleas
Sample Volume at Meter Conditions, cubic feet
Sample Volume at Standard Conditions, cubic feet1
Gas Stream Composition
C02, percent by volume
°2> percent by volume
CO, percent by volume
Njf percent by volume
Moisture in Gas Stream, percent by volume
Mole Fraction of Dry Gas
Molecular Height of Dry Gas
Molecular Height of Het Gas
Gas Stream Velocity and Volumetric Flow
Static Pressure, inches water
Absolute Pressure, inches mercury
Average Temperature, °F
Pltot Tube Calibration Coefficient, dimensionleas
Total Number of Traverse Points
Velocity at Actual Conditions, feet/second
Stack/duct Cross-Sectional Area, square feet
Volumetric Flow, wet actual cubic feet/minute
Volumetric Flow, dry standard cubic feet/minute
Percent Isoklnetic
Unit/Process Operations Data
1
6-3-80
0932-1110
27.0
0.37S
29.7
0.34
117.
421.2
19.8
1.01
9.36
8.58
0.0
20.9
0.0
79.1
69.8
0.302
29.0
21.3
-0.83
29.6
264.
0.84
9.0
30.2
1.43
2,590.
564.
2
6-3-80
1402-1528
27.0
0.375
29.7
0.34
120.
425.0
20.2
1.01
8.54
7.80
0.0
20.9
0.0
79.1
72.2
0.278
29.0
21.1
-0.82
29.6
264.
0.84
9.0
30.3
1.43
2,600.
522.
3
6-4-80
0838-0959
27.0
0.375
29.8
0.34
100.
421.1
19.8
1.01
7.57
7.18
0.0
20.9
0.0
.1
.4
79.
73.
0.266
29.0
20.9
-0.83
29.7
259.
0.84
9.0
30.
1.
2,610.
505.
4
43
104.9 103.0 97.9
Monitored by Radian Corporation personnel
Standard Conditions • 68°F (20°C) and 29.92 inches (760 mm) mercury, dry basis.
-------
Table 12
No. 4 Kettle Calciner Baghouse Inlet Duct
Summary of Test Data
(Metric Unite)
Teat Data
M
I
Test Run Number
Teat Date
Teat 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 Hater Collected by Train, ml
Volume of Hater Vapor Collected, Standard Cubic Meters
Dry Gas Meter Calibration Factor, dimensionless
Sample Volume at Meter Conditions, cubic meters
Sample Volume at Standard Conditions, cubic meters1
Gas Stream Composition
C02, percent by volume
°2< percent by volume
CO, percent by volume
N2, percent by volume
Moisture in Gas Stream, percent by volume
Mole Fraction of Dry Gas
Molecular Height of Dry Gas
Molecular Height 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, Het Actual Conditions, cubic meters/minute
Volumetric Flow, Dry Standard Conditions, cubic meters/minute
Percent Isokinetic
Unit/Process Operations Data
1
6-3-80
0932-1110
27.0
0.953
754.4
8.6
47.
421.2
.561
.01
0.
1.
0.265
0.243
0.0
20.9
0.0
79.1
69.8
0.302
29.0
21.3
-21.1
751.8
129.
0.84
9.0
9.21
0.133
73.3.
16.0
2
6-3-80
1402-1528
27.0
0.953
754.4
8.6
49.
425.0
0.572
1.01
0.242
0.221
0.0
20.9
0.0
79.1
72.2
0.278
29.0
21.1
-20.8
751.8
129.
0.84
9.0
9.24
0.133
73.6
14.8
3
6-4-80
0838-0959
27.0
0.953
756.9
8.6
38.
421.1
0.561
1.01
0.214
0.203
0.0
20.9
0.0
79.1
73.4
0.266
29.0
20.9
-21.1
754.4
126.
0.84
9.0
9.27
0
73.9
14.3
133
104.9 103.0 97.9
Monitored by Radian Corporation personnel
Standard Conditions - 68°F (20°C) and 29.92 inches (760 mm) mercury, dry basis.
-------
Table 13
No. 4 Kettle Calciner Baghouse Discharge Stack
Summary of Test Data
(English Units)
Test Data
Ul
i
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 Hater 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
COj, percent by volume
°2« 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, wet actual cubic feet/minute
Volumetric Flow, dry standard cubic feet/minute
Percent Isokinetic
Unit/Process Operations Data
1
6-3-80
0932-1150
96.0
0.300
29.7
0.44
118.
1,606.3
75.6
0.990
37.9
34.1
0.0
20.9
0.0
79.1
68.9
0.311
29.0
21.4
0.91
29.7
245.
0.84
8.0
49.7
0.785
2,340.
542.
2
6-3-80
1400-1610
96.0
0.300
29.7
0.46
121.
1,590.8
74.9
0.990
37.5
33.5
0.0
20.9
0.0
79.1
69.1
0.309
29.0
21.4
0.89
29.7
248.
0.84
8.0
50.0
0.785
2,360.
540.
3
6-4-80
0837-1030
96.0
0.300
29.7
0.46
103.
1,722.2
81.1
0.990
37.8
34.9
0.0
20.9
0.0
79.1
69.9
0.301
29.0
21.3
0.95
29.8
238.
0.84
8.0
50.3
0.785
2,370.
538.
104.9 103.3 108.2
Monitored by Radian Corporation personnel
Standard Conditions = 68°F (20°C) and 29.92 inches (760 mm) mercury, dry basis.
-------
Table 14
No. 4 Kettle Calciner Baghouse Discharge Stack
Summary of Test Data
(Metric Units)
Test Data
i
in
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 Hater Vapor Collected, Standard Cubic Meters
Dry Gas Meter Calibration Factor, dimensionless
Sample Volume at Meter Conditions, cubic meters
Sample Volume at Standard Conditions, cubic meters*-
Gas Stream Composition
C02, percent by volume
Oj, percent by volume
CO, percent by volume
Nj, percent by volume
Moisture in Gas Stream, percent by volume
Mole Fraction of Dry Gas
Molecular Height of Dry Gas
Molecular Height of Het 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, Het Actual Conditions, cubic meters/minute
Volumetric Flow, Dry Standard Conditions, cubic meters/minute
Percent Isokinetic
Unit/Process Operations Data
1
6-3-80
0932-1150
96.0
0.762
754.4
11.2
48.
1,606.3
2.141
0.990
1.073
0.966
0.0
20.9
0.0
79.1
68.9
0.311
29.0
21.4
23.1
754.4
118.
0.84
8.0
15.1
0.073
66.3
15.3
2
6-3-80
1400-1610
96.0
0.762
754.4
11.7
49.
1,590.8
2.121
0.990
1.062
0.949
0.0
20.9
0.0
79.1
69.1
0.309
29.0
21.4
22.6
754.4
120.
0.84
8.0
15.2
0.073
66.8
15.3
3
6-4-80
0837-1030
96.0
0.762
754.4
11.7
39.
1,722.2
2.297
0.990
1.070
0.988
0.0
20.9
0.0
79.1
69.9
0.301
29.0
21.3
24.1
756.9
114.
0.84
8.0
15.3
0.073
67.1
15.2
104.9 103.3 108.2
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 Inlet Duct
Summary of Test Data
(English Units)
Test Data
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 Hater Collected by Train, ml
Standard Volume of Nater Vapor Collected, cubic feet
Dry Gas Meter Calibration Factor, dimensionlesa
Sample Volume at Meter Conditions, cubic feet
Sample Volume at Standard Conditions, cubic feet*
Gas Stream Composition
CO2> percent by volume
°2» percent by volume
CO, percent by volume
Nj, percent by volume
Moisture in Gas Stream, percent by volume
Mole Fraction of Dry Gas
Molecular Height of Dry Gas
Molecular Height of Het 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, wet actual cubic feet/minute
Volumetric Flow, dry standard cubic feet/minute
Percent Isokinetic
Unit/Process Operations Data
1
6-5-80
1809-1933
64.0
0.188
30.0
0.92
105.
71.2
3.4
1.01
35.4
33.6
1.3
17.2
0.0
81.6
9.1
0.909
28.9
27.9
-3.2
29.7
174.
0.84
32.0
56.3
2.95
9,950.
7,500.
107.0
2
6-6-80
0934-1056
64.0
0.188
29.8
0.88
110.
68.
3.2
1.01
34.9
32.6
1.1
18.5
0.0
80.4
8.9
0.911
28.9
27.9
-3.1
29.5
173.
0.84
32.0
53.9
2.
9,550.
7,150.
.95
3
6-6-80
1150-1311
64.0
0.188
29.8
88
0
110
68
3
108.9
1.01
35.0
32.7
1.2
18.2
0.0
80.6
9.0
0.910
28.9
27.9
-3.15
29.5
178.
0.84
32.0
54.3
2.95
9,600.
7,150.
109.3
Monitored by Radian Corporation personnel
Standard Conditions
68°F (20°C) and 29.92 Inches (760 mm) mercury, dry basis.
-------
Table 16
Rock Dryer Baghouae Inlet Duct
Summary of Test Data
(Metric Units)
Teat Data
o»
i
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 Hater Collected by Train, ml
Volume of Nater Vapor Collected, Standard Cubic Meters
Dry Gas Meter Calibration Factor, dimensionless
Sample Volume at Meter Conditions, cubic meters
Sample Volume at Standard Conditions, cubic meters1
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 Height of Dry Gas
Molecular Height of Het 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, Het Actual Conditions, cubic meters/minute
Volumetric Flow, Dry Standard Conditions, cubic meters/minute
Percent Isokinetic
Unit/Process Operations Data
1
6-5-80
1809-1933
64.0
0.478
762.0
23.4
41.
71.2
0.096
01
002
0.951
1.3
17.2
0.0
81.6
9.1
0.909
28.9
27.9
-81.28
754.4
79.
0.84
32.0
17.2
0.
282.
212.
274
2
6-6-80
0934-1056
64.0
0.478
756.9
22.4
43.
68.0
0.091
1.01
0.988
0.923
1.1
18.5
0.0
80.4
8.9
0.911
28.9
27.9
-78.74
749.3
78.
0.84
32.0
16.4
0.274
270.
203.
3
6-6-80
1150-1311
64.0
0.478
756.9
22.4
43.
68.4
0.091
1.01
0.991
0.926
1.2
18.2
0.0
80.6
9.0
0.910
28.9
27.9
-80.01
749.3
81.
0.84
32.0
16.6
0.
272.
203.
274
107.0 108.9 109.3
Monitored by Radian Corporation personnel
Standard Conditions ° 68°F (20°C) and 29.92 Inches (760 mm) mercury, dry basis.
-------
Table 17
Rock Dryer Baghouse Discharge Duct
Summary of Test Data
(English Units)
Test Data
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 Hater 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
CC>2, 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 Height of Dry Gas
Molecular Height of Het 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, wet actual cubic feet/minute
Volumetric Flow, dry standard cubic feet/minute
Percent Isokinetic
Unit/Process Operations Data
1
6-5-80
1810-1935
64.0
0.195
30.0
1.14
103.
75.5
3.6
0.990
38.6
36.0
0.9
17.5
0.0
81.6
9.0
0.910
28.8
27.9
0.78
30.0
172.
0.84
8.0
56.0
3.08
10,350.
7,900.
105.7
2
6-6-80
0823-1100
64.0
0.195
29.8
1.12
101.
75.2
3.5
0.990
37.6
35.0
1.1
18.1
0.0
80.8
9.2
0.908
28.9
27.9
0.61
29.8
169.
0.84
8.0
55.8
3.08
10,300.
7,850.
103.6
3
6-6-80
1150-1311
64.0
0.195
29.8
1.04
109.
78.1
3.7
0.990
38.7
35.5
1.2
18.1
0.0
80.7
9.4
0.906
28.9
27.9
0.57
29.8
174.
0.84
8.0
54.0
3.08
9,950.
7,500.
109.6
Monitored by Radian Corporation personnel
Standard Conditions
68°F (20°C) and 29.92 inches (760 mm) mercury.
dry basis.
-------
Table 18
Rock Dryer Baghouse Discharge Duct
Summary of Test Data
(Metric Units)
Test Data
00
I
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 Hater Collected by Train, ml
Volume of Water Vapor Collected, Standard Cubic Meters
Dry Gas Meter Calibration Factor, dimensionless
Sample Volume at Meter Conditions, cubic meters
Sample Volume at Standard Conditions, cubic feet1
Gas Stream Composition
CO2, percent by volume
°2i percent by volume
CO, percent by volume
Nj, 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
Percent Isokinetic
Unit/Process Operations Data
1
6-5-80
1810-1935
64.0
0.495
762.0
29.0
39.
75.5
0.102
0.990
1.093
1.019
0.9
17.5
0.0
81.6
9.0
0.910
28.8
27.9
19.812
762.0
78.
0.84
8.0
17.1
0.286
293.
224.
2
6-6-80
0823-1100
64.0
0.495
756.9
28.4
38.
75.2
0.099
0.990
1.065
0.991
1.1
18.1
0.0
80.8
9.2
0.908
28.9
27.9
15.494
756.9
76.
0.84
8.0
17.0
0.286
292.
222.
3
6-6-80
1150-1311
64.0
0.495
756.9
26.4
43.
78.1
0.105
0.990
1.096
1.005
1.2
18.1
0.0
80.7
9.4
0.906
28.9
27.9
14.478
756.9
79.
0.84
8.0
16.5
0.286
282.
212.
105.7 103.6 109.6
Monitored by Radian Corporation personnel
^Standard Conditions = 68°F (20°C) and 29.92 inches (760 mm) mercury, dry basis.
-------
Table 19
Board End Sawing Discharge Duct
Summary of Test Data
(English Units)
Test Data
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 Hater 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
C°2' percent by volume
03, percent by volume
CO, percent by volume
"2, 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, wet actual cubic feet/minute
Volumetric Flow, dry standard cubic feet/minute
Percent Isokinetic
Unit/Process Operations Data
1
6-5-80
1215-1329
64.0
0.171
30.0
2.43
103.
17.
0.8
0.99
53.7
50.2
0.0
20.9
0.0
79.1
1.6
0.984
28.97
28.80
0.64
30.0
92.
0.84
8.0
83.1
0.72
3,600.
3,400.
104.4
2
6-5-80
1418-1529
64.0
0.171
30.0
2.32
107.
17.6
0.8
0.99
52.4
48.6
0.0
20.9
0.0
79.1
1.7
0.983
28.97
28.79
0.59
30.0
95.
0.84
8.0
81.4
0.72
3,500.
3,300.
103.8
3
6-5-80
1545-1707
64.0
0.171
30.0
2.49
100.
16.1
0.8
0.99
55.1
51.8
0.0
20.9 .
0.0
79.1
1.4
0.986
28.97
28.81
0.63
30.0
90.
0.84
8.0
86.0
0.72
3,700.
3,550.
103.7
Monitored by Radian Corporation personnel
Standard Conditions
68°F (20°C) and 29.92 inches (760 mm) mercury, dry basis.
-------
Table 20
Board End Sawing Discharge Duct
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 Hater Vapor Collected, Standard Cubic Meters
Dry Gas Meter Calibration Factor, dimensionless
Sample Volume at Meter Conditions, cubic meters
Sample Volume at Standard Conditions, cubic meters1
Gas Stream Composition
CC>2, 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 Height of Dry Gas
Molecular Height of Het 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, Het Actual Conditions, cubic meters/minute
Volumetric Flow, Dry Standard Conditions, cubic meters/minute
Percent Isokinetic
Unit/Process Operations Data
1
6-5-80
1215-1329
64.0
0.434
762.0
61.7
39.
17.0
0.023
0.99
1.521
1.422
0.0
20.9
0.0
79.1
1.6
0.984
28.97
28.80
16.256
762.0
33.
0.84
8.0
25.329
0.067
102.
96.3
2
6-5-80
1418-1529
64.0
0.434
762.0
58.9
42.
17.6
0.023
0.99
1.484
1.376
0.0
20.9
0.0
79.1
1.7
0.983
28.97
28.79
14.986
762.0
35.
0.84
8.0
24.811
0.067
99.1
93.4
3
6-5-80
1545-1707
64.0
0.434
762.0
63.2
38.
16.1
0.023
0.99
1.560
1.467
0.0
20.9
0.0
79.1
1.4
0.986
28.97
28.81
16.002
762.0
32.
0.84
8.0
26.213
0.067
105.
101.
104.4 103.8 103.7
Monitored by Radian Corporation personnel
Standard Conditions - 68°F (20°C) and 29.92 inches (760 mm) mercury, dry basis.
-------
Table 21
No. 4 Kettle Calciner Baghouse Inlet Duct
Summary of Test Results
(English Units)
Test Data
Test Number
Test Date
Test Time
Gas Stream Volumetric Flow
Actual cubic feet/minute, wet
Standard cubic feet/minute, dry1
Particulate Lab Results
Front-Half Hash Residue Fraction, g
Filter Catch Fraction, g
Total Particulate Catch Height, g
Particulate Emission Results2
Grains/Dry Standard cubic foot
Pounds/hour
1
6-3-80
0932-1110
2,590.
564.
50.8266
2.9199
53.7465
96.7
467.
2
6-3-80
1402-1528
2,600.
522.
56.5370
0.7599
52.2969
113.
507.
3
6-4-80
0838-0959
2,610.
505.
52.8880
2.4638
55.3438
119.
515.
^Standard Conditions = 68°F (20°C) and 29.92 inches (760 mm) mercury.
Calculated based Total Particulate Catch Height.
-------
Table 22
i
o\
to
I
No.
Test Data
Test Run Number
Test Date
Test Period
Gas Stream Volumetric Flow Rates
Dry standard cubic meters/minute1
Wet actual cubic meters/minute
Particulate Laboratory Results
Front-half Wash Residue Fraction, g
Filter Catch Fraction, g
4 Kettle Calciner Baghouse Inlet Duct
Summary of Test Results
(Metric Units)
1
6-3-80
0932-1110
16.0
73.3
50.8266
2.9199
Total Particulate Catch Weight, g
Particulate Emission Results
Grams/dry standard cubic meter
Kilograms/hour
53.7465
221.
212.
2
6-3-80
1402-1528
14.8
73.6
56.5370
0.7599
52.2969
259.
230.
3
6-4-80
0838-0959
14.3
73.9
52.8880
2.4638
55.3438
272.
234.
^Standard Conditions = 68°F (20°C) and 29.92 inches (760 mm) mercury, dry basis.
-------
Table 23
i
at
Test Data
Test Number
Test Date
Test Time
Gas Stream Volumetric Flow
Actual cubic feet/minute, wet
Standard cubic feet/minute, dry1
Particulate Lab Results
Front-Half Hash Residue Fraction, g
Filter Catch Fraction, g
Total Particulate Catch Height, g
Particulate Emission Results2
Grains/Dry Standard cubic foot
Pounds/hour
Baghouse Collector Performance
Efficiency, percent
No. 4 Kettle Calciner Baghouse Discharge Duct
Summary of Test Results
(English Units)
1
6-3-80
0932-1150
2,340.
542.
0.0389
0.0053
0.0442
0.020
0.093
99.98
2
6-3-80
1400-1610
2,360.
540.
0.0091
0.0041
0.0132
0.006
0.028
99.99
3
6-4-80
0837-1030
2,370.
538.
0.0212
0.0031
0.0243
0.010
0.050
99.99
Standard Conditions = 68°F (20°C) and 29.92 inches (760 mm) mercury.
Calculated based Total Particulate Catch Height.
-------
Table 24
No. 4 Kettle Calciner Baghouse Discharge 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/minute1
Wet actual cubic meters/minute
Particulate Laboratory Results
Front-Half Hash Residue Fraction, g
Filter Catch Fraction, g
Total Particulate Catch Height, g
Particulate Emission Results
Grams/dry standard cubic meter
Kilograms/hour
1
6-3-80
0932-1150
15.3
66.3
0.0389
0.0053
0.0442
0.046
0.042
2
6-3-80
1400-1610
15.3
66.8
0.0091
0.0041
0.0132
0.014
0.013
3
6-4-80
0837-1030
15.2
67.1
0.0212
0.0031
0.0243
0.023,
0.023
^Standard Conditions - 68°F (20°C) and 29.92 inches (760 mm) mercury, dry basis.
-------
Table 25
Rock Dryer Baghouse Inlet Duct
Summary of Test Results
(English Units)
in
i
Test Data
Test Number
Test Date
Test Time
Gas Stream Volumetric Plow
Actual cubic feet/minute, wet
Standard cubic feet/minute, dry1
Particulate Lab Results
Front-Half Wash Residue Fraction, g
Filter Catch Fraction, g
Total Particulate Catch Weight, g
Particulate Emission Rate2
Grains/Dry Standard cubic foot
Pounds/hour
1
6-5-80
1809-1933
9,950.
7,500.
2
6-6-80
0934-1056
9,550.
7,150.
6.3531
0.6837
7.0368
3.23
208.
3
6-6-80
1150-1311
9,600.
7,150.
5.0688
3.7674
8.8362
4.18
257.
4.7256
4.0165
8.7421
4.13
253.
Standard Conditions = 68°F (20°C) and 29.92 inches (760 mm) mercury.
Calculated based Total Particulate Catch Weight.
-------
Table 26
Rock Dryer Baghouse Inlet Duct
Summary of Test Results
(Metric Units)
01
i
Test Data
Test Run Number
Test Date
Test Period
Gas Stream Volumetric Flow Rates
Dry standard cubic meters/minute1
Wet actual cubic meters/minute
Particulate Laboratory Results
Front-Half Hash Residue Fraction, g
Filter Catch Fraction, g
Total Particulate Catch Height, g
Particulate Emission Results
Grams/dry standard cubic meters
Kilograms/hour
1
6-5-80
1809-1933
212.
282.
6.3531
0.6837
7.0368
7.39
94.3
2
6-6-80
0934-1056
203.
270.
5.0688
3.7674
8.8362
9.56
117.
3
6-6-80
1150-1311
203.
272.
4.7256
4.0165
8.7421
9.45
115.
^Standard Conditions « 68°F (20°C) and 29.92 inches (760 mm) mercury, dry basis.
-------
Table 27
Rock Dryer Baghouse Discharge Duct
Summary of Test Results
(English Units)
Test Data
Test Number
Test Date
Test Time
Gas Stream Volumetric Flow
Actual cubic feet/minute, wet
Standard cubic feet/minute, dryl
Participate Lab Results
Front-Half Hash Residue Fraction, g
Filter Catch Fraction, g
Total Particulate Catch Height, g
Particulate Emission Results2
Grains/Dry Standard cubic foot
Pounds/hour
Baghouse Collector Performance
Efficiency, percent
1
6-5-80
1810-1935
10,350.
7,900.
0.0035
0.0069
0.0104
0.004
0.302
99.85
2
6-6-80
0823-1100
10,300.
7,850.
0.0027
0.0066
0.0093
0.004
0.275
99.89
3
6-4-80
1150-1311
9,950.
7,500.
0.0050
0.0072
0.0122
0.005
0.341
99.87
Standard Conditions = 68°F (20°C) and 29.92 inches (760 mm) mercury.
^Calculated based Total Particulate Catch Height.
-------
Table 28
Rock Dryer Baghouse Discharge Duct
Summary of Test Results
(Metric Units)
i
a\ i
oo!
i
Test Data
Test Run Number
Test Date
Test Period
Gas Stream Volumetric Flow Rates
Dry standard cubic meters/minute1
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
1
6-5-80
1810-1935
224.
293.
0.0035
0.0069
0.0104
0.009
0.137
2
6-6-80
0823-1100
222.
292.
0.0027
0.0066
0.0093
0.009
0.125
3
6-4-80
1150-1311
212.
282.
0.0050
0.0072
0.0122
0.011
0.155
^Standard Conditions = 68°F (20°C) and 29.92 inches (760 mm) mercury, dry basis.
-------
Table 29
Board End Sawing Discharge Duct
Summary of Test Results
(English Units)
Test Data
Test Number
Test Date
Test Time
Gas Stream Volumetric Flow
Actual cubic feet/minute, wet
Standard cubic feet/minute, dry*
Particulate Lab Results
Front-Half Hash Residue Fraction, g
Filter Catch Fraction, g
Total Particulates Catch Weight, g
Particulate Emission Results^
Grains/Dry Standard cubic foot
Pounds/hour
1
6-5-80
1215-1329
3,600.
3,400.
0.0026
0.0048
0.0074
0.002
0.066
2
6-5-80
1418-1529
3,500.
3,300.
3
6-5-80
1545-1707
3,700.
3,550.
0.0058
0.0161
0.0219
0.007
0.197
0.0101
0.0240
0.0341
0.010
0.307
^Standard Conditions <* 68°F (20°C) and 29.92 inches (760 mm) mercury.
Calculated based Total Particulate Catch Weight.
-------
Table 30
Board End Sawing Discharge 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/minute1
Wet actual cubic meters/minute
Particulate Laboratory Results
Front-Half Hash Residue Fraction, g
Filter Catch Fraction, g
Total Particulates Catch Weight, g
Particulate Emission Results
Grams/dry standard cubic meters
Kilograms/hour
1
6-5-80
1215-1329
96.3
102.
0.0026
0.0048
0.0074
0.005
0.030
2
6-5-80
1418-1529
93.4
99.1
0.0058
0.0161
0.0219
0.016
0.089
3
6-5-80
1545-1707
101.
105.
0.0101
0.0240
0.0341
0.023
0.139
^Standard Conditions = 68°F (20°C) and 29.92 inches (760 mm) mercury, dry basis.
-------
Table 31
Particle Size Distribution
Run:
1
6-6-80
U.S. Gypsum
bar
29.97
Date:
Location:
Sampling Location: Rock Dryer Inlet
Traverse Point No. Sampled: Y-13
Stack Temp ( F) 172
Sample Time (min.) 4.0
Sample Volume (cf)
Moisture (% H20)
1.794
9.0
Sample Flow Rate (at stack conditions)
Meter Temp ( F) 109
Flow Setting, AH 0.59
(in. H20)
Nozzle Diameter (in.) 0.171
0.46 cfm
Plate
No.
Net Wt.
Percent
Cumulative
Percent
BAD
1
2
3
4
5
6
7
8
Backup
Filter
TOTAL
(mg)
346.2
25.9
31.3
44.0
73.7
36.1
5.9
1.3
1.7
566.1
61.1
4.6
5.5
7.8
13.0
6.4
1.0
0.23
0.37
100.0
100.0
38.9
34.3
28.8
21.0
8.0
1.6
0.6
0.37
(microns)
15.0
9.6
6.3
4.5
2.8
1.4
0.90
0.60
-_ —
-71-
-------
FIGURE 12
Run No. 1 Rock Dryer Inlet
EFFECTIVE AERODYNAMIC PARTICLE DIAMETER, microns
o o ooooooo— 10 v*j .p- vn ON -j oovoo
— • ro v*> *- vi ON ->i oovo o o o ooooooo
,
/
^
y
/
/
/
f
A
/•
/
/
j
/•
f
f
1
l
J
f
/
/
0.01 0.05 O.I 0.2 0.5 I
10 20 30 40 50 60 70 80
CUMULATIVE PERCENTAGE
90
95
99 99
99.9 99.9
-------
Table 32
Particle Size Distribution
Run: 2
Date: 6-6-80
Location: U.S. Gypsum
Sampling Location: ROCK Dryer Inlet
Traverse Point No. Sampled: Y-13
bar
29.77
Stack Temp ( F) 172
Sample Time (min.) 4.0
Sample Volume (cf)
Moisture (% H20)
1.796
9.0
Meter Temp ( F) 108
Flow Setting, AH 0.59
(in. H20)
Nozzle Diameter (in.)0.171
Sample Flow Rate (at stack conditions): 0.46 cfm
Plate
No.
1
2
3
4
5
6
7
8
Backup
Filter
TOTAL
Net Wt,
Percent
Cumulative
Percent
EAD
(mg)
271.8
38.7
31.3
78.7
41.2
26.3
6.0
1.9
2.2
498.1
54.6
7.8
6.3
15.8
8.3
5.3
1.1
0.38
0.42
100.0
100.0
45.4
37.6
31.3
15.5
7.2
1.9
0.8
0.42
(microns)
15.0
9.6
6.3
4.5
2.8
1.4
0.90
0.60
-73-
-------
FIGURE 13
-1L-
EFFECTIVE AERODYNAMIC PARTICLE DIAMETER, microns
o o ooooooo— to VO-P-VJION^ oovoo
— 10 \jJ -p- VI ON -*J OOVOO O O O OOOOOO
4
71
/
f
y
/
• •
/
/
/
/
f
/
»
•
f
f
/
0.01 0.05 O.I 0.2 0.5 I
10 20 30 40 50 60 70 80
CUMULATIVE PERCENTAGE
BO
95
-------
Table 33
Particle Size Distribution
Run: 3
Date: 6-6-80
Location: U.S. Gypsum
Sampling Location: Rock Dryer Inlet
Traverse Point No. Sampled: Y-13
Pbar {in' Hg) 29*77
Stack Temp (°F) 172
Sample Time (min.) 3.0
Sample Volume (cf) 1.353
Moisture (% H20) 9.0
Meter Temp (°F) 110
Plow Setting, AH 0.59
(in. H20)
Nozzle Diameter (in.)0.171
Sample Flow Rate (at stack conditions): 0.46 cfm
Plate
No.
1
2
3
4
5
6
7
8
Backup
Filter
TOTAL
Net Wt.
(mg)
149.2
32.3
36.2
28.3
55.6
5.7
2.8
0.9
1.1
312.1
Percent
47.8
10.3
11.6
9.1
17.8
1.8
0.9
0.3
0.4
100.0
Cumulative
Percent
100.0
52.2
41.9
30.3
21.2
3.4
1.6
0.7
0.4
BAD
(microns)
15.0
9.6
6.3
4.5
2.8
1.4
0.90
0.60
-75-
-------
FIGURE 14
Run No. 3 Rock Dryer Inlet
-9Z-- '
EFFECTIVE AERODYNAMIC PARTICLE DIAMETER, microns
o o ooooooo-. ro u> jr vn o\ ^i oovoc
— ro v*> .p- vn ON -^J oovoo o o o oooooc
J
/
•/
/
f
•/
/
/
/
(
/
/
•
/
/
/
/
• /
/
r
0.01 0.05 0.1 0.2 0.5 I
10 20 30 40 50 60 70 80
CUMULATIVE PERCENTAGE
90
95
91 99
99.99
-------
Table 34
Particle Size Distribution
Run: 1
Date: 6-3-80
Location: U.S. Gypsum
Sampling Location: Rock Dryer Outlet
Traverse Point No. Sampled: X-2
Pbar (in. Hg) 29.67
Stack Temp (°F) 184
Sample Time (min.) 120
Sample Volume (cf) 72.660
Moisture (% H20) 9.0
Meter Temp (°F) 108
Flow Setting, AH 1.15
(in. H20)
Nozzle Diameter (in.)0.230
Sample Flow Rate (at stack conditions): 0.55 cfm
Plate
No.
1
2
3
4
5
6
7
8
Backup
Filter
TOTAL
Net Wt,
1.4
13.7
Percent
10.2
100.0
Cumulative
Percent
10.2
BAD
(mg)
7.1
0.2
0.2
0.7
1.1
1.0
1.3
0.7
51.8
1.5
1.5
5.1
8.0
7.3
9.5
5.1
100.0
48.2
46.7
45.2
40.1
32.1
24.8
15.3
(microns)
4.1
2.7
1.8
1.2
0.77
0.39
0.23
0.14
-77-
-------
oo
i
M
O
O
85
o
E
o
oe
UJ
UJ
10.0
2-°
8.0
7.0
6.0
5.0
k.O
3.0
2.0
1.0
0.*8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
FIGURE 15
Run No. 1 Rock Dryer Outlet
0.01 0.05 0.1 0.2 0.5 I
10 20 30 40 50 60 70 80
CUMULATIVE PERCENTAGE
80
95
N 99
99.1 99.9
-------
Table 35
Particle Size Distribution
Pbar (in. Hg)
29.97
Run: 1
wen.
Date: 6-5-80 Stack Temp (°F) 85
Location: U.S. Gypsum Sample Time (min.) 120
Sampling Location: Brd. End Sawing Outlet Sample Volume (cf) 100.732
Traverse Point No. Sampled: X-l Moisture (% H20) 1.5
Meter Temp (°F) 113
Flow Setting, AH 2.4
(in. H20)
Nozzle Diameter (in.)0.171
Sample Flow Rate (at stack conditions): 0.82 cfm
Plate
No.
1
2
3
4
5
6
7
8
Backup
Filter
TOTAL
Net Wt.
(rag)
8.5
1.2
0.5
0.9
5.7
3.2
1.5
0.7
0.8
23.0
Percent
36.9
5.2
2.2
4.0
24.8
13.9
6.5
3.0
3.5
100.0
Cumulative
Percent
100.0
63.1
57.9
55.7
51.7
26.9
13.0
6.5
3.5
EAD
(microns)
11.7
6.8
4.7
3.3
1.9
1.0
0.62
0.42
-79-
-------
O
u
i
00
O
I
O
oc
O
X
O
oc
O
UJ
10.0
§.0
.0
7.0
6.0
5.0
k.O
3.0
2.0
1.0
0.9
0.8
0.7
0.6
0.5
O.k
0.3
o.:
0.1
FIGURE 16
Run No. 1 Board End Sawing
0.01 0.05 0.1 0.2 0.5 1
10 20 30 40 50 60 70 80
CUMULATIVE PERCENTAGE
90
95
M 99
9.1 99.9
-------
Date: June 3, 1980
SUMMARY OF VISIBLE EMISSIONS
TABLE 36
Type of Plant:
Dry Well Board Plant
Type of Discharge; Stack
Location of Discharge; No. 4 Kettle Calciner Exh
Height of Point of Discharge: 2nd level + 50 ftDescription of Sky; Partly cloudy
Wind Direction: West Wind Velocity: 5 mph
Color of Plume: White Detached Plume:
Observer No.:
White
N/A
Yes
Distance from Observer to Discharge Point:
Direction of Observer from Discharge Point:
Height of Observation Pofnt: '
Description of Background:
Duration of Observation:
100 feet
5 hrs 48 minutes
Southwest orStacK
Uround Level
Blue bky
Set
Number
1
2
-3
4
5
6
7
/
8
9
10
11
12
13
• ^
14
15
• ^
16
17
1 t
18
19
• J
20
SUMMARY OF AVERAGE OPACITY
T!
Start
0925
0930
0936
0942
0948
0954
1000
1006
1012
1018
1024
1030
1036
1042
1048
1054
1100
1106
1112
1118
ne
End
0930
0936
0942
0948
0954
1000
1006
1012
1018
1024
1030
1036
1042
1048
1054
1100
1106
1112
1118
1124
Opacity
Sum
5
0
5
0.
0
5
0
0
0
0
0
5
0
0
0
0
0
15
15
5
Average
0.2
0.0
0.2
0.0
0.0
0.2
0.0
0.0
0.0
0.0
0.0
0.2
0.0
0.0
0.0
0.0
0.0
0.6
0.6
0.2
Set
Number
21
22
23
™«^
24
25
26
27
™ /
28
29
~ V
30
J**
31
^ *
32
rf™
33
j j
• 34
J ~
35
J *
36
J»
37
J 1
38
J*+
?Q
Jj
40
T
Start
1124
1400
1406
1412
1418
1424
1430
1436
1442
1448
1454
1500
1506
1512
1518
1524
1530
1536
0830
0836
me
End
1130
1406
1412
1418
1424
1430
1436
1442
1448
1454
1500
1506
1512
1518
1524
1530
1536
1542
0836
0842
Opa<
Sum
0
0
5 .
0
0
0
0
0
5
0
0
5
0
5
5
0
0
0
0
0
;ity
Average
0.0
0.0
0.2
0.0
0.0
0.0
0.0
0.0
0.2
0.0
0.0
0.2
0.0
0.2
0.2
0.0
0.0
0.0
0.0
0.0
Opacity
Sketch Showing How Opacity Varied with Time:
0.8
0.6
0.4
0.2
1 hr
2 hrs
Time, Hours * hrs 5 hrs 6 hrs
-81-
-------
Date: June 3. 1980
Type of Discharge; star.k
SUMMARY OF VISIBLE EMISSIONS
TABLE 36 continued
Type of Plant:
Page 2 of 2
Dry Wall Board Plant
Location of Discharge: MO. h
Height of Point of Discharge;2nd level +
Wind Direction: West
Color of Plume: White
Observer No.:
50'
Description of Sky;Partly Cloudy
Wind Velocity: 5 mph
Detached Plume:
Yes
N/A
Duration of Observation:
100 feet
5 hrs 48 minutes
Distance from Observer to Discharge Point:
Direction of Observer from Discharge Point: Southwest of Stac*.
Height of Observation Point:
Description of Background:
Ground Level
Blue Sky
Set
Number
1
2
'3
4
5
J
6
7
8
9
10
11
12
13
14
15
16
17
• /
' 18
19
20
SUMMARY OF AVERAGE OPACITY
Tl
Start
0842
0848
0854
0900
0906
0912
0918
0924
0930
0936
0942
0948
0954
1000
1006
1012
1018
1024
me
End
0848
0854
0900
0906
0912
09.18
0924
0930
0936
0942
0948
0954
1000
1006
1012
1018
1024
1030
Opacity
Sum
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
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
Set
Number
21
22
23
24
25
*• j
26
27
28
29
™ *
30
^ "
31
J •
32.
Jmm
33
^ ^
• 34
J *
35
* &
36
37
j i
38
39
40
- T
Start
me
End
i
Opa
Sum
pity
Average
Sketch Showing How Opacity Varied with Time:
Opacity
Time, Hours
-82-
-------
Date: June 5-6, 1980
SUMMARY OF VISIBLE EMISSIONS
TABLE 37
Type of Plant:
Dry Wai 1 Board Plant
Type of Discharge; Stack
Height of Point of Discharge: 2nd level + 20'
Wind Direction: West
Color of Plume: White
Observer No.: N/A
Distance from Observer to Discharge Point:
Direction of Observer from Discharge Point:
Height of Observation Point: '
Description of Background:
Location of Discharge: Rock Dryer
Description of Sky:
Wind Velocity: 3~5 mph
Detached Plume: Yes
Partly Cloudy
Duration of Observation: 4 hrs 15 minutes
15 feet
West
TO feet DeTow stacTT
Gray building
Set
Number
1
2
'3
4
5
^
6
7
/
8
9
10
11
12
13
14
15
16
17
* /
18
19
• *
20
SUMMARY OF AVERAGE OPACITY
Time
Start
1810
1815
1821
1827
1833
1839
1845
1851
1857
1903
1909
1915
1921
1927
0930
0935
0941
0947
0953
0959
End
1815
1821
1827
1833
1839
1845
1851
1857
1903
1909
1915
1921
1927
1930
0935
0941
0947
0953
0959
1005
Op<
Sum
0
5
0
0
5
0
0
0
0
0
5
0
0
0
0
0
5
0
5
o.
iclty
Average
0.0
0.2
0.0
0.0
0.2
0.0
0.0
0.0
0.0
0.0
0.2
0.0
0.0
0.0
0.0
0.0
0.2
0.0
0.2
0.0
Set
Number
21
22
23
24
25
fc*/
26
27
*• /
28
29
30
31
32.
33
34
35
^ ^
36
J »
37
J 1
38
^u
39
J J
40
T
Start
1005
1011
1017
1023
1029
1035
1041
1047
1053
1150
1156
1202
1208
1214
1220
1226
1232
1238
1244
1250
me
End
1011
1017
1023
1029
1035
1041
1047
1053
1055
1156
1202
1208
1214
1220
1226
1232
1238
1244
1250
1256
Opa<
Sum
5
0
0
0
0
0
0
5
0
0
0
5
0
5
0
0
10
0
0
0
pity
Average
0.2
0.0
0.0
0.0
0.0
0.0
0.0
0.2
0.0
0.0
0.0
0.2
0.0
0.2
0.0
0.0
0.4
0.0
0.0
0.0
Sketch Showing How Opacity Varied with Time:
0.4 =
Opacity
(*) 0.3
0.2
0.1
Time, Hours
-83-
-------
Page 2 of 2
Date: June 5~6, 1980
Type of Discharge; Stack
Height of Point of Discharge:2nd level + 20'
Wind Direction: West
Color of Plume: White
Observer No.: N/A
Distance from Observer to Discharge Point:
Direction of Observer from Discharge Point:
Height of Observation Pofnt: '
Description of'Background:
SUMMARY OF VISIBLE EMISSIONS
TABLE 37 continued
Type of Plant: Dry Wai 1 Board Plant
^^H^^^ Location of Discharge:^
Description of Sky:
Wind Velocity: ~
Detached Plume:
Rock Dryer
Partly Cloudy
3-5 mph
Yes
Duration of Observation:
15 feet
hrs 15 minutes
West
10 ft. below stack
Gray BuiIding
Set
Number
1
2
"3
k
5
6
7
8
9
10
11
12
13
15
16
17
18
19
20
SUMMARY OF AVERAGE OPACITY
Time
Start
1256
1302
1308
131^
End
1302
1308
1314
1320
Opacity
Sum
0
0
0
5
Average
0.0
0.0
0.0
0.2
Set
Number
21
22
23
2k
25
26
27
28
29
30
31
32
33
35
36
37
38
39
ko
• T
Start
me
End
Opa
Sum
pity
Average
Sketch Showing How Opacity Varied with Time:
Opacity
(*)
1 hr 2 hrs 3 hrs k hrs
Time, Hours
-84-
-------
Date: June 5, 1980
SUMMARY OF VISIBLE EMISSIONS
TABLE 38
Type of Plant:
Type of Discharge; Stack
Height of Point of Discharge: 2nd level
Wind Direction: West
Color of Plume: White
Observer No.:
N/A
Distance from Observer to Discharge Point:
Direction of Observer from Discharge Point:
Height of Observation Point: '
Description of'Background:
Dry Wall Board Plant
Location of Discharge: Board End Sawing
Description of Sky: Clear
Wind Velocity:
Detached Plume:
3 mpn
Yes
Duration of Observation:
90 feet
3 hrs 50 minutes
Northeast
Level
Green trees
Set
Number
1
2
'3
4
5
6
7
8
9
10
11
12
13
1 j
14
15
• ^
16
1 U
17
• /
18
1 w
19
1 ^
20
SUMMARY OF AVERAGE OPACITY
Time
Start
1200
1205
1211
1217
1223
1229
1235
1241
1247
1253
1259
1305
1311
1317
1323
1410
1415
1421
1427
1433
End
1205
1211
1217
1223
1229
1235
1241
1247
1253
1259
1305
1311
1317
1323
1329
1415
1421
1427
1433
1439
Opacity
Sum
0
0
0
0.
0
20
0
0
0
20
10
0
10
75
40
30
0
45
5
10
Average
0.0
0.0
0.0
0.0
0.0
0.8
0.0
0.0
0.0
0.8
0.4
0.0
0.4
3-1
1.7
1.3
0.0
1.9
0.2
0.4
Set
Number
21
22
23
24
25
26
27
•• /
28
29
™ ^
30
* w
31
•^ •
32
^^
33
jj
34
J •
35
JJ
•it
JW
37
j i
3fl
j°
39
jj
40
T
Start
1439
1445
1451
1457
1503
1509
1515
1600
1605
1611
1617
1623
1629
1635
1641
1647
1653
1659
1705
me
End
1445
1451
1457
1503
1509
1515
1520
1605
1611
1617
1623
1629
1635
1641
1647
1653
1659
1705
1711
Opa<
Sum
1.10
30
5
0
15
75
85
40
80
10
40
45
5
10
10
70
40
0
0
;ity
Average
4.6
1.3
0.2
0.0
0.6
3.1
3.5
1.7
3-3
0.4
1.7
1.9
0.2
0.4
0.4
2.9
1.7
0.0
0.0
Sketch Showing How Opacity Varied with Time;
5-0
Opacity
(*)
4.0'
3.0-
2.0-
n
1 hr
Time, Hours
3 hrs
-»-
4 hrs
-85-
-------
Date: June 3, 1980
Type of Discharge; Stack
SUMMARY OF VISIBLE EMISSIONS
TABLE 39
Type of Plant:
Height of Point of Discharge: 2nd level + 3(
Wind Direction: West
Color of Plume: white
Observer No.: N/A ^
Distance from Observer to Discharge Point:
Direction of Observer from Discharge Point:
Height of Observation Point: '
Description of Background:
Dry Wall Board Plant
Location of Discharge:_
Description of Sky:
Wind Velocity:
Detached Plume:
Scoring & Chambering
Partly Cloudy
5 moh
Yes
Duration of Observation:3 hours
50 feet
South of stack
11 ft. below stack
Forest
Set
Number
1
2
'3
4
5
6
7
8
9
10
11
12
13
14
15
• ^
16
17
1 /
18
19
1 *
20
SUMMARY OF AVERAGE OPACITY
T1
Start
0830
0835
0841
0847
0853
0859
0905
0911
0917
1200
1205
1215
1220
1226
1232
1238
1244
1250
1256
1302
me
End
0835
0841
0847
0853
0859
0905
0911
0917
0922
1205
1208
1220
1226
1232
1238
1244
1250
1256
1302
1308
Opacity
Sum
240
260
315
340
235
215
240
250
140
230
150
265
340
265
280
235
245
250
300
255
Average
10.0
10.8
13-1
14.2
9-8
9.0
10.0
10.4
8.8
9-6
12.5
11.0
14.2
11.0
11.7
9.8
10.2
10.4
12.5
10.6
Set
Number
21
22
23
24
25
26
27
28
29
~ J
30
^ w
31
j *
32
^^
33
-/•*
34
*/ •
35
Jtf
36
Vw
37
j I
38
^ **
39
JJ
40
Tj
Start
1308
1314
1550
1555
1601
1607
1613
1619
1625
1631
1637
1643
1649
me
End
1314
1315
1555
1601
1607
1613
1619
1625
1631
1637
1643
1649
1650
Opa<
Sum
260
35
230
220
155
150
175
185
170
160
180
195
25
:ity
Average
10.8
8.8
9.6
9-2
6.5
6.3
7.3
7-7
7-1
6.7
7-5
8.1
1.0
Sketch Showing How Opacity Varied with Time:
Time, Hours
-86-
-------
Date: June 10» 198°
SUMMARY OF VISIBLE EMISSIONS
TABLE 40
Type of Plant: Dry Wall Board Plant
Type of Discharge; Stack
Height of Point of Pischarge:2nd level + 20'
Wind Direction: East
Color of Plume: "White
Observer No.:
Location of Discharge: Surge Bin
Description of Sky: Clear
Wind Velocity:
Detached Plume:"
2 mph
Yes
N/A ^_
Distance from Observer to Discharge Point:
Direction of Observer from Discharge Point;East of stack
Height of Observation Pomt:
Description of Background:
Duration of Observation: 3 hrs
20 feet
20 ft below stack
Forest
Set
Number
1
2
'3
k
5
6
7
8
9
10
11
12
13
1 J
14
15
* J
16
1 O
17
• /
18
* w
19
1 3
20
SUMMARY OF AVERAGE OPACITY
Time
Start
1245
1250
1256
1302
1308
1314
1320
1326
1332
1338
1348
1353
1359
1405
1411
1417
1423
1429
1435
1441
End
1250
1256
1302
1308
1314
1320
1326
1332
1338
1344
1353
1359
1405
1411
1417
1423
1429
1435
1441
1447
Opacity
Sum
10
20
15
10
10
10
20
15
15
20
20
10
20
15
5
5
20
10
15
5
Average
0.4
0.8
0.6
0.4
0.4
0.4
0.8
0.6
0.6
0.8
0.8
0.4
0.8
0.6
0.2
0.2
0.8
0.4
0.6
0.2
Set
Number
21
22
23
24
25
26
27
28
29
~ *
30
*
31
32
33
j j
• 34
J •
35
JJ
•»(.
JO
37
j i
38
j«
39
j j
40
T
Start
1450
1455
1501
1507
1513
1519
1525
1531
1537
1543
s
me
End
1455
1501
1507
1513
1519
1525
1531
1537
1543
1549
Opa
Sum
15
10
5
5
5
5
5
0
10
5
fity
Average
0.6
0.4
0.2
0.2
0.2
0.2
0.2
0.0
0.4
0.2
Sketch Showing How Opacity Varied with Time:
0.8 -
Opacity
0.4
0.2
1 hr
Time, Hours 2 hrs
3 hrs
-87-
-------
Date: June 4-5. 1980
Type of Discharge; Stack
Height of Point of Discharge: 2nd level + 25'
SUMMARY OF VISIBLE EMISSIONS
TABLE 41
Type of Plant: Dry Wai 1 Board Plant
^^^miH Location of Discharge:_
Description of Sky:
Baggage & Packing
Part 1y Cloudy
Wind Direction: N/A
Color of Plume: White
Observer No. : N/A
Distance from Observer to Discharge Point:
Direction of Observer from Discharge Point:
Height of Observation Point:
Description of Background:
Wind Velocity:
Detached Plume:
Duration of Observation
15 feet
Northeast of stack
2nd level + 25 ft.
Gray Building
3 mph
No
: 3 hours
Set
Number
1
2
'3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
• -j
20
SUMMARY OF AVERAGE OPACITY
Time
Start
0900
0905
0911
0917
0923
0929
0935
0941
0947
0953
1130
1135
1141
1147
1153
1300
1305
1-311
1317
1323
End
0905
0911
0917
0923
0929
0935
0941
0947
0953
0959
1135
1141
1147
1153
1159
1305
1311
1317
1323
1329
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
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
w
31
J •
32
-------
Table 42
No. 5 Upper and Lower Mixer Stations
Mean fugitive emission values (percent frequency emission) for
three tests at each location are presented.
Test 1
Test 2
Test 3
Site Mean
No. 5 Upper Mixer Station
Test Mean
0.0
0.0
0.0
0.0
No. 5 Lower Mixer Station
Test 1
Test 2
Test 3
Site Mean
Test Mean
0.0
8.06
28.81
12.29
-89-
-------
Table 43
Scoring/Chamfering Operation Station 5
Test Mean
Test 1 0.0
Test 2 0.0
Test 3 0.0
Site Mean 0.0
Packer Baghouse Discharge Station (Bagging Unit)
Test Mean
Test 1 42.50
Test 2 54.31
Test 3 30.56
Site Mean 42.45
Board End Sawing Baghouse Inlet Station
Test Mean
Test 1 0.0
Test 2 1.25
Test 3 0.0
Site Mean 0.42
-90-
------- |