United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EMB Report 80-IBR-9
October 1980
Air
Industrial Boilers
Emission Test Report
Sorg Paper Company
Middletown, Ohio
-------
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
EMISSION MEASUREMENT BRANCH
MAIL DROP 13
RESEARCH TRIANGLE PARK, NORTH CAROLINA 27711
"FINAL REPORT
EMISSION TEST PROGRAM: INDUSTRIAL BOILER OPERATION
*
CONDUCTED AT
SORG PAPER COMPANY
MIDDLETOWN, OHIO
CONTRACT NUMBER 68-02-2819
TASK ASSIGNMENT 24
EPA PROJECT NUMBER 80-IBR-7
YRC PROJECT NUMBER 01-9517-24
-------
TABLE OF CONTENTS
Page
List of Figures i
List of Tables ' ii
Preface iii
1.0 INTRODUCTION 1
2.0 SUMMARY AND DISCUSSION OF TEST RESULTS 3
2.1 Introduction 3
2.2 Particulate Results 3
2.3 Gas Composition Results 3
2.4 Visible Emissions Observation Results 4
2.5 Fuel Samples Results 4
2.6 Particle Size Distribution Results 4
3.0 PROCESS DESCRIPTION AND OPERATION 18
3.1 Separate Filing Iff
4.0 TESTING LOCATIONS 19
4.1 Sampling Locations 19
4.2 Emission Observation Locations 21
5.0 SAMPLING AND ANALYTICAL PROCEDURES . 24
5.1 Introduction 24
5.2 Sampling Apparatus 24
5.3 Preliminary Measurements 26
5.4 Particulate 26
5.5 Gas Composition 31
5.6 Fuel Samples 31
5.7 Particle Size Distribution 33
6.0 APPENDICES 40
6.1 Complete Computer Data Printouts
6.1.1 Multiclone Inlet - Particulate Tests
6.1.2 Scrubber Outlet - Particulate Tests
6.1.3 Multiclone Inlet - Particle Size
Distribution Tests
6.2 Calculation Formulae
6.3 Field Data Sheets
6.3.1 Multiclone Inlet - Particulate Tests
6.3.2 Scrubber Outlet - Particulate Tests
6.3.3 Multiclone Inlet - Particle Size
Distribution Tests
6.3.4 Visible Emission Field Data
-------
6.4 Calibration Data
6.4.1 Visible Emissions Certification
6.4.2 Orifice and Meter Calibration Data
6.4.3 Pitot Tube Calibration Data
6.4.4 Nozzle Calibration Data
6.5 Laboratory Data
6..6 Project Participants
6.7 Work Assignment
-------
LIST OF FIGURES
Fi9ure Page
2-1 Particle Size Distribution - Multiclone Inlet - Tests 15
1-3
2-2 Particle Size Distribution - Multiclone Inlet - Test 16
4 - Soot Blow
4-1 Multiclone Inlet - Test Port and Sampling Point 20
Locations
4-2 Scrubber Outlet - Test Port and Sampling Point 22
Locations
4-3 Visible Emissions Observations - Position of Observer 23
- Tests 1-4
5-1 Modified Particulate Sampling Train 28
5-2 Andersen Stack Sampler and Preseparator 37
38
5-3 Andersen Sampling Train
-------
LIST OF TABLES
Table Page
2-1 Summary of Emission Test Results - Multiclone Inlet - 6
English Units
2-2 Summary of Emission Test Results - Multiclone Inlet -
Metric Units 7
2-3 . Summary of Emission Test Results - Scrubber Outlet -
English Units 8
2-4 Summary of Emission Test Results - Scrubber Outlet -
Metric Units 9
2-5 Gas Stream and Particulate Data Summary - Comparison
of Inlet and Outlet - English Units 10
2-6 Gas Stream and Particulate Data Summary - Comparison
of Inlet and Outlet - Metric Units H
2-7 Gas Composition Results - Inlet and Outlet 12
2-8 Summary of Coal Analysis - Tests 1-4 ^3
2-9 Particle Size Distribution Test Results - Multiclone
Inlet 14
2-10 Summary of Opacity Observations - Scrubber Outlet
Stack 17
11
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PREFACE
The work reported herein was conducted by personnel from York
Research Corporation (YRC), Radian Corporation and the United
States Environmental Protection Agency (USEPA).
The scope of the work, issued under EPA Contract Number 68-02-
2819, Work Assignment Number 24, was under the supervision of
YRC Project Director, Mr. James W. Davison. Mr. Roger A.
Kniskern, YRC Project Manager, was responsible for summarizing
the test and analytical data contained in this report. Analy-
ses of the samples were performed at the YRC laboratory in
Stamford, Connecticut under the direction of Mr. Robert Q.
Bradley.
Mr. Robert Phillips of Radian Corporation was responsible for
monitoring the process operations during the testing program.
Personnel from Radian Corporation will provide the Process
Description and Operations section which will be filed separately
from this report (refer to Section 3.1).
Personnel from the Sorg Paper Company in Middletown, Ohio,
whose assistance and guidance contributed greatly to success of
the test program, included Mr. Jeff Downs, Power House Super-
visor.
Mr. Dennis Holzschuh of the Office of Air Quality Planning and
Standards, Emission Measurement Branch, USEPA, served as Tech-
nical Manager and was responsible for coordinating the emission
test program.
111
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1.0 INTRODUCTION
Section 111 of the Clean Air Act of 1970 charges the Adminis-
trator of the United States Environmental Protection Agency
(USEPA) with the responsibility of establishing federal stan-
dards of performance for new stationary sources which may sig-
nificantly contribute to air pollution. When promulgated,
these standards of performance for new stationary sources
(NSPS) will reflect the degree of emission limitation achiev-
able through application of the best demonstrated emission con-
trol technology. To assemble this background information, the
USEPA utilizes emission data obtained from controlled sources
involved in the particular industry under consideration.
Based on the above criteria, the USEPA1s Office of Air Quality
Planning and Standards (OAQPS) selected the Sorg Paper Company
in Middletown, Ohio as a site to conduct -an emission test pro-
gram. York Research Corporation (YRC), under EPA Contract:
Number 68-02-2819, Work Assignment Number 24, was requested by
the USEPA to conduct the emission test program at Sorg Paper.
This request was based on a pre-survey conducted at the plant
on March 19, 1980. The test program was designed to provide a
portion of the emission data base required for establishing the
SPNSS for industrial boilers. This plant is considered to
employ process and emission control technology representative
of industrial boiler facilities.
There is one industrial boiler that produces process steam for
the operations at the Sorg Paper plant. Emissions from the
boiler are controlled by a multiclone followed by a venturi
scrubber.
Emission sampling was conducted during the week of April 21,
1980 at the following test locations:
-------
Inlet to Multiclone
Scrubber Outlet
Concurrent tests performed at the inlet and outlet locations
provided data on velocity, moisture, ga's composition and parti-
culate emission rates. A total of four tests were conducted
during the test program, three while the boiler was operating
normally, and one during a typical soot blow cycle. Samples
were collected and analyzed in accordance with the prescribed
EPA methods. One coal sample was taken during each test run.
Visible emissions observations were conducted on the scrubber
outlet stack to obtain average percent opacity measurements.
Four particle size distribution tests were performed at the
inlet location.
The following sections of this report include:
Summary and Discussion of Test Results
Process Description and Operation
Location of Sampling Points
Sampling and Analytical Procedures
-------
2.0 SUMMARY AND DISCUSSION OF TEST RESULTS
2.1 Introduction
The results of the emission test program conducted at: the
Sorg Paper Company in Middletown, Ohio during the week of
April 21, 1980 ,are presented throughout this section.
Samples were collected concurrently at the multiclone in-
let and the scrubber outlet. Preliminary pitot traverses
and moisture measurements were conducted at each location,
and the parameters necessary to maintain proper isokinetic
sampling were determined based on these preliminary
tests. All samples were sealed in clean containers and
transported to the YRC laboratory in Stamford, Connecticut
for analyses. Problems encountered in the sampling pro-
gram and deviations from normal sampling procedures are
discussed in Section 5.0, "Sampling and Analytical Pro-
cedures".
2.2 Particulate Results
The results of the particulate emission tests conducted at
the two locations are summarized in Tables 2-1 through 2-8
(refer to Appendix 6.3 for field data sheets). A compari-
son of the data from-the inlet and outlet locations, as
well as the removal efficiency of the multiclone and
scrubber, are presented in Tables 2-5 and 2-6. The col-
lection efficiency calculations are based on particulate
concentration. The average removal efficiency for the
four tests was 98.47%.
2.3 Gas Compositon Results
The results of the gas composition analyses are shown in
Table 2-7. Orsat analyses were performed on the flue
-------
gases at each sampling location. The field data sheets
for these analyses appear in Appendix 6.3.
2.4 Visible Emissions Observation Results
Visible emissions observations were conducted on the
scrubber outlet stack simultaneously with the particulate
emission tests. Summaries of these observations appear in
Table 2-10. The locations from which these observations
were made are presented in Figure 4-5. The average
opacity observed during the test program did not exceed
three percent. The field data sheets for these observa-
tions may be found in Appendix 6.3.
2.5 Fuel Samples Results
Samples of the coal used in the boiler were obtained by a
member of the YRC test team during each of the four par-
ticulate tests. The results of the analyses appear in
Table 2-8.
2.6 Particle Size Distribution Results
The results of the particle size distribution tests con-
ducted at the inlet location are summarized in Table 2-10
and illustrated in Figures 2-1 and 2-2. (Refer to
Appendix 6.3 for field data sheets). Three tests were
conducted under normal conditions and one test was run
during the soot blow cycle.
It was not possible to perform particle size distribution
tests at the outlet location due to the size of the
ports. It was necessary to use a heating collar on the
Andersen sampler because of the moisture content in the
stack gas at this location. The heating collar adds
-------
approximately one half inch to the diameter of the sampler
which made it impossible to fit it through the port
opening.
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TABLE 2-1
SUMMARY OF EMISSION TEST RESULTS
MULTICLONE INLET
SORG PAPER COMPANY
.MIDDLETOWN, OHIO
(English Units)
Date
Time
Volume Of Dry Gas Sampled (DSCF)b
Percent Moisture By Volume
Average Stack Temperature, °F
Stack Volumetric Flow Rate (DSCFM)C
Percent Isokinetic
Total Particulate - Filter Catch
and Front Half Acetone
mg
gr/DSCF
Ib/hr
Test 1
4/23/80
0911-1140
80.90
3.3
340
24241
99.6
14259.63
2.71460
564.05
Test 2
4/23/80
1340-1519
57.24
5.8
280
25465
100.6
9010.95
2.42429
529.15
Test 3a
4/23/80
1615-1754
57.83
4.4
285
25340
102.2
10332.98
2.75163
597.65
Test 4
4/24/80
0914-1053
59.52
6.0
280
25295
105.3
7828.86
2.02562
439.18
Average
63.97
4.9
296
25085
101.9
10358.10
2.47904
532.51
aSoot blow conducted during this test for 7 minutes (1628-1635).
bDry Standard Cubic Feet at 68°F, 29.92 inches Hg.
GDry Standard Cubic Feet Per Minute at 68°F, 29.92 inches Hg.
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TABLE 2-2
SUMMARY OF EMISSION TEST RESULTS
MULTICLONE INLET
SORG PAPER COMPANY
MIDDLETOWN, OHIO
(Metric Units)
Test 1
Test 2
Test 3a
Test 4
Average
Date
4/23/80
4/23/80
4/23/80
4/24/80
Time
0911-1140
1340-1519
1615-1754
0914-1053
Volume Of Gas Sampled (DNm3)b
Percent Moisture By Volume
Average Stack Temperature, °C
Stack Volumetric Flow Rate (DNm3/min)c
Percent Isokinetic
2.29
3.3
171.1
686
99.6
1.62
5.8
137.8
721
100.6
1.64
4.4
140.6
718
102.2
1.69
6.0
137.8
716
105.3
1.81
4.9
146.8
710
101.9
Total Particulate - Filter Catch
and Front Half Acetone
mg
mg/DNmJ
kg/hr
14259.63
6212.03
255.85
9010.95
' 5547.69
240.02
10332.98
6296.78
271.09
7828.86
4635.39
199.21
10358.10
5672.97
241.54
aSoot blow conducted during this test for 7 minutes (1628-1635).
bDry Normalized Cubic Meters at 20°C, 760mm Hg.
cDry Normalized Cubic Meters Per Minute at 20°C, 760mm Hg.
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TABLE 2-3
SUMMARY OF EMISSION TEST RESULTS
SCRUBBER OUTLET
SORG PAPER COMPANY
MIDDLETOWN, OHIO
(English Units)
Date
Time
Volume Of Dry Gas Sampled (DSCF)b
Percent Moisture By Volume
Average Stack Temperature, °F
Stack Volumetric Flow Rate (DSCFM)C
Percent Isokinetic
Total Particulate - Filter Catch
and Front Half Acetone
mg
gr/DSCF
Ib/hr
lb/106 Btu
Test 1
4/23/80
0918-1144
94.38
8.5
111.6
30290
103.8
167.67
0.02736
7.10
0.0658
Test 2
4/23/80
1340-1525
67.46
10.6
120.5
29970
105.0
285.17
0.06510
16.72
0.157
Test 3a
4/23/80
1615-1805
65.56
11.1
121.4
28631
106.8
169.81
0.03989
9.79
0.109
Test 4
4/24/80
0910-1055
68.78
9.8
103.0
30527
105.1
85.84
0.01922
5.03
0.0479
Average
74.04
10.0
114.1
29854
105.2
177.1
0.03789
9.66
0.0953
aSoot blow conducted during this test for 7 minutes (1628-1635).
bDry Standard Cubic Feet at 68°F, 29.92 inches Hg.
cDry Standard Cubic Feet Per Minute at 68°F, 29.92 inches Hg.
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TABLE 2-4
SUMMARY OF EMISSION TEST RESULTS
SCRUBBER OUTLET
SORG PAPER COMPANY
MIDDLETOWN, OHIO
(Metric Units)
Date
Time
Volume Of Gas Sampled (DNm3)b
Percent Moisture By Volume
Average Stack Temperature, °C
Stack Volumetric Flow Rate (DNm3/min)c
Percent Isokinetic
Total Particulate - Filter Catch
and Front Half Acetone
mg
mg/DNmJ
kg/hr
kg/106 etu
Test 1
4/23/80
0918-1144
2.67
8.5
44.2
858
103.8
167.67
62.60
3.22
0.0298
Test 2
4/23/80
1340-1525
1.91
10.6
49.2
849
105.0
285.17
' 148.98
7.59
0.0712
Test 3a
4/23/80
1615-1805
1.86
11.1
49.7
811
106.8
169.81
91.28
4.44
0.0494
Test 4
4/24/80
0910-1055
1.95
9.8
39.4
864
105.1
85.84
43.98
2.28
0.0217
Average
2.10
10.0
45.6
846
105.2
177.12
86.71
4.38
0.0432
aSoot blow conducted during this test for 7 minutes (1628-1635).
bDry Normalized Cubic Meters at 20°C/ 760mm Hg.
GDry Normalized Cubic Meters Per Minute at 20°C, 760mm Hg.
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TABLE 2-5
GAS STREAM AND PARTICIPATE DATA SUMMARY
COMPARISON OF INLET AND OUTLET
SORG PAPER COMPANY
MIDDLETOWN, OHIO
(English Units)
Test 1
Test 2
Test 3a
Test 4
Average
Location
Inlet Outlet
Inlet Outlet
Inlet Outlet
Inlet Outlet
Inlet Outlet
Date
4/23/80
4/23/80
4/23/80
4/24/80
Volume of Gas
Sampled (DSCF)a
Percent Moisture
By Volume
Average Stack
Temperature, °F
Stack Volumetric
Flow Rate (DSCFM)b
Percent Isokinetic
Total Particulate
Filter Catch and
Front Half Acetone
mg
gr/DSCF
Ib/hr
Removal
Efficiency, %c
80.90
3.3
340
24241
99.6
14259.63
2.71460
564.05
98.
94.38
8.5
111.6
30290
103.8
167.67
0.02736
7.10
99
57.24
5.8
280
25465
100.6
9010.95
2.42429
529.15
97.
67.46
10.6
120.5
29970
105.0
285.17
0.06510
16.72
31
57.83
4.4
285
25340
102.2
10332.98
2.75163
597.65
98.
65.56
11.1
121.4
28631
106.8
169.81
0.03989
9.79
55
59.52
6.0
280
25295
105.3
7828.86
2.02562
439.18
99.
68.78
9.8
103.0
30527
105.1
85.84
0.01922
5.03
05
63.97
4.9
296
25085
101.9
10358.10
2.47904
532.51
98.
74.04
10. (
114.]
29854
105.2
177.1
0.03789
9.66
47
aDry standard cubic feet measured at 68°F, 29.92 in. Hg.
t>Dry standard cubic feet per minute measured at 68°F, 29.92 in. Hg
cBased on gr/DSCF.
blow conducted during this test for 7 minutes (1628-1635).
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TABLE 2-6
GAS STREAM AND PARTICULATE DATA SUMMARY
COMPARISON OF INLET AND OUTLET.
SORG PAPER COMPANY
MIDDLETOWN, OHIO
(Metric Units)
Test 3d
Test 1
Test 2
Test 4
Average
Location
Inlet
Outlet
Inlet Outlet
Inlet Outlet
InletOutlet
InletOutlet
Date
4/23/80
4/23/80
4/23/80
4/24/80
Volume of Gas
Sampled (DNrn3)3
Percent Moisture
By Volume
Average Stack
Temperature, °C
2.29
3.3
171.1
2.67
8.5
44.2
Stack Volumetric Flow
Rate (DNm3/min.)b
Percent Isokinetic
Total Particulate
Filter Catch and
Front Half Acetone
mg
mg/DNm3
kg/hr
Removal
Efficiency, %-
686
99.6
14259.63
6212.03
255.85
98 . '
858
103.8
167.67
62.60
3.22
39
1.62
5.8
137.8
721
100.6
9010.95
5547.69
240.02
97.
1.91
10.6
49.2
849
105.0
285.17
148.98
7.59
31
1.64
4.4
140.6
718
1 102.2
10332.98
6296.78
271.09
98
1.86
11.1
49.7
811
106. -8
169.81
91.28
4.44
.55
1.69
6.0
137.8
716
105.3
7828.86
4635.39
199.21
99.
1.95
9.8
39.4
864
105.1
85.84
43.98
2.28
05
1.81
4.9
146.8
710
101.9
10358.10
5672.97
241.54
98
2.10
10.0
45.6
846
105.2
177.1
86.71
4.38
.47
aDry normalized cubic meters, measured at 20°C, 760mm Hg.
^Dry normalized cubic meters per minute, measured at 20°C, 760mm Hg.
GBased on mg/DNm .
dSoot blow conducted during this test for 7 minutes (1628-1635).
11
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TABLE 2-7
SUMMARY OF GAS COMPOSITION RESULTS
SORG PAPER COMPANY
MIDDLETOWN, OHIO
Gas Composition
(Dry Percent Basis)
Location
Multiclone Inlet
Scrubber Outlet
Date
4/23/80
4/23/80
4/23/80
4/24/80
4/23/80
4/23/80
4/23/80
4/24/80
Test No.
1
2
3
4
1
2
3
4
% co2
9.0
9.4
9.0
9.4
8.6
8.8
8.5
8.4
% 02
10.4
10.0
10.7
10.0
10.1
10.8
11.3
10.9
% CO*
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
% N2*
80.6
80.6
80.3
80.6
81.3
80.4
80.2
80.7
*Calculated By Difference
12
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TABLE 2-8
COAL ANALYSIS (DRY BASIS)
SORG PAPER COMPANY
MIDDLETOWN, OHIO
Test No.
Date
4/23/80
2
4/23/80
4/23/80
4/24/80
% Ash
% Volatiles
% Fixed Carbon
% Sulfur
% Carbon
% Hydrogen
% Nitrogen
% Oxygen
% Moisture
BTU/Lb.
9.94
35.36
54.70
1.25
68.66
4.22
1.11
14.82
10.01
13,146
6.36
38.46
55.18
1.06
70.03
3,
1,
99
47
17.09
5.35
14,009
7.52
36.10
56.38
0.98
70.09
4.62
1.07
15.72
6.99
13,387
9.48
36.02
54.50
0.96
64.42
4.96
1.22
14.96
8.11
13,227
13
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TABLE 2-9
PARTICLE SIZE DISTRIBUTION TEST RESULTS
MULTICLONE INLET
SORG PAPER CORPORATION
MIDDLETOWN, OHIO
Particulate
Test Concentration-Total Particle Size
# Date Time (Min.) . gr/DSCF Range (Microns)
1 4/23/80 0.50 2.28830 >12.96
12.96-8.08
8.08 - 5.46
5.46 - 3.71
3.71 - 2.37
2.37 - 1.17
1.17 - 0.71
0.71 - 0.46
<0.46
2 4/23/80 0.50 2.49726 >13.30
13.30 - 8.29
8.29 - 5.61
5.61 - 3.81
3.81 - 2.43
2.43 - 1.20
1.20 - 0.73
0.73 - 0.47
<0.47
3 4/23/80 0.50 2.68082 >13.96
13.96 - 8.70
8.70 - 5.89
5.89 - 4.00
4.00 - 2.56
2.56 - 1.27
1.27 - 0.77
0.77 - 0.50
<0.50
Mass In Size
Range (%)
78.86
7.51
4.10
2.49
2.09
1.46
1.09
0.49
1.89
65.71
8.85
5.73
4.10
4.27.
4.21
2.61
1.86
2.66
71.76
6.33
5.41
3.16
3.31
2.85
2.33
1.84
3.02
4 4/23/80
(Soot
Blow)
0.50
3.90866
>9.77
9.77 - 6.08
6.08 - 4.10
10
,78
4,
2
1,
2.78
1.76
76 - 0.86
0.86 - 0.51
0.51 - 0.32
<0.32
84.28
2.60
3.91
2.21
2.42
1.37
1.13
0.86
1.21
14
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IOO.O
90.0
99.99 99.9 99.8 99
PARTICLE SIZE DISTRIBUTION
MULTICLONE INLET
95 90 80706050403020 10 5 2 1 0.5 OJt 0.10.05 0.01 ,000
l-Testr:?:-;:.trrrt±d
O.I
0.2
0.0 005 1 0^ 0.5 1 2 5 10 20 30 40 50 60 70 80 90 95 98 99 99.899.9 99.99
CUMULATIVE PER CENT BY WEIGHT LESS THAN(Dp)
O.I
FIGURE 2-1
15
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PARTICLE SIZE DISTRIBUTION
MULTICLONE INLET
99.99 99.9 99.8 9998 95 90 80706050403020 10 5 2 . 1 0.5 12 0.1 0.05 0.01
100.0
Test 4 - SOOT BLOW
0.2
O.I
0.01 0.05 0.1 0.2 0.5 1 2
10
2030405060 70 80 90 95 9899
99.8 99.9 99.99
O.I
CUMULATIVE PER CENT BY WEIGHT LESS THAN(Dp)
FIGURE 2-2
16
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TABLE 2-10
SUMMARY OF OPACITY OBSERVATIONS
SCRUBBER OUTLET STACK
SORG PAPER COMPANY
Date
Time(s)
Test No.
Test Condition
Six Minute
Interval
0-5
6-11
12-17
18-23
24-29
30-35
36-41
42-47
48-53
54-59
60-65
66-71
72-77
78-83
84-89
90-95
96-101
102-107
108-113
114-119
120-125
126-131
132-137
138-143
4/23/80
0917-1144
1
Normal
Average
Opacity
0.0
.0.0
0.6
0.2
0.0
0.0
0.0
0.0
1.7
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
4/23/80
1338-1425
2
Normal
Average
Opacity
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.8
0.0
0.0
0.0
0.0
0.0
0.0
0.0 ,
0.0 b
4/23/80
1618-1802
3
Soot Blow a
Cycle
Average
Opacity
0.4
0.8
0.8
0.0
0.0
0.0
0.0
0.0
2.1
0.2
0.0
0.0
0.0
0.0
0.0
0.4
0.0
0.0'C
4/24/80
0910-1055
4
Normal
Average
Opacity
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'd
Soot blow lasted for 7 minutes, 1628-1635
BBased on 4.5 min. observation
on 3.0 min. observation
dBased on 3.5 min. observation
17
-------
3.0 PROCESS DESCRIPTION AND OPERATION
A comprehensive description of the boiler operation at the
Sorg Paper Company, along with process and control equipment
operating parameters, will be provided by engineers from Radian
Corporation.
3.1 Separate Filing
Due to a change in Process Engineers since this project began, the
Process Description is not ready at this time. For this reason the
Process Description will be filed separately from the report.
18
-------
4.0 TESTING LOCATIONS
4.1 Sampling Locations
Particulate sampling was conducted simultaneously at the
inlet and outlet locations.
The locations of the test ports and sampling points were
determined in accordance with EPA Method 1 (Sample and
Velocity Traverses for Stationary Sources)^-.
Multiclone Inlet
The four test ports for the multiclone inlet are located
in the rectangular duct which vents the exhaust gas from
the boiler to the multiclone. The duct dimensions are 60
inches by 36 inches (45 inch equivalent diameter). The
ports are located 1.7 diameters from an upstream bencl in
the duct and 1.8 diameters from a downstream bend (Figure
4-1). Twelve points per port were required for sampling.
During test 1, each point was sampled for 3 minutes, re-
sulting in a total test time of 144 minutes. The sampling
time was reduced to 2 minutes per point for the subsequent
tests 2-4 (refer to Section 5.4, pg. 29).
Particle size distribution samples were obtained at point
A- 2.
Scrubber Outlet
The scrubber outlet stack is 54 inches (inner diameter) at
the sampling location. Two perpendicular test ports are
test methods cited in this report are contained in 40
CFR 60, August 18, 1977.
19
-------
36
Al »B1 . Cl .D
* 9
* O
o e .
0
< o
v o
«A12 B12. C12-D
"3
6
.2
>
/
/
/
/
B
TRAVERSE
POINT
1
2
3
4
5
6
7
8
9
10
11
12
DISTANCE FRO]
DUCT WALL (ii
2.5
7.5
12.5
17.5
22.5
27.5
32.5
37.5
42.5
47.5
52.5
57.5
.Si' 9" . 9" , 9" ,4
H« >H H< H<
Test
POEts
flow to
multiclone
1.7 Stack
diameters
'1.8 stack
diameters
to downstream
disturbance
building
edge
stairs
..,,,. r^T-^-r ^»T*-> TMT TTT nnrr
pii>jj-iiv-a-rtj«c. -.»»*»
MULTICLONE INLET -
TEST PORT AND SAMPLING POINT LOCATIONS
FIGURE 4-1
20
-------
located 2 stack diameters from the top of the stack and 5
stack diameters from a downstream disturbance where the
duct diameter increases (Figure 4-2).
Ten sampling points per port were required. Each point
was sampled for 7 minutes, resulting in a total test time
of 140 minutes. The sampling interval was subsequently
reduced to 5 minutes for the remaining tests, yielding a
test time of 100 minutes (refer to Section 5,4, pg. 29).
4.2 Emissions Observation Locations
Visible emissions observations were also conducted while
the particulate tests were run. A certified observer con-
ducted the visual tests in accordance with EPA Method 9
(Visual Determination of the Opacity of Emissions from
Stationary Sources). The observer's location for each
test is shown in Figure 4-3.
21
-------
PORT B
--G
PORT A
TRAVERSE POINT
1
2.
3
4
5
6
7
8
9
10
DISTANCE FROM
STACK; WALL (in)
1.4
4.4
7.8
12.2
18.5
35.5
41.8
46.1
49.5
52.6
2 stack
diameters
5 stack
diameters
SCRUBBER OUTLET STACK
SCRUBBER OUTLET
TEST PORT AND SAMPLING POINT LOCATIONS
FIGURE 4-2
22
-------
steam plume
dissipates
after 20'
WIND
boiler control
building edge
observer on roof
I during Test 1
! (4/23/80)
i ^fence
- *r
observer on
ground level
during Tests
2 and 3
(4/23/80)
-stack
JrT:
~
plume
-sun during
tests 1-4
4 -observer
Scale-1" = 40
WIND
steam plum
dissipates
after 15'
boiler control
building edge
wind
steam plume dissipates
after rising 25'
observer on roof
during Test 4
(4/24/80)
VISIBLE EMISSIONS OBSERVATIONS
POSITION OF OBSERVER - TESTS 1-4
FIGURE 4-3
23
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5.0 SAMPLING AND ANALYTICAL PROCEDURES
5.1 Introduction
This section describes the sampling and analytical pro-
cedures used by YRC at the Sorg Paper Company in
Middletown, Ohio during April 1980.
5.2 Sampling Apparatus
Nozzle
The nozzle, of appropriate diameter, was calibrated
according to procedures outlined in EPA Method 5. The
button-hook nozzle was made of 316 stainless steel.
Probe
The liner for the sample probe was made of 316 stainless
steel. A heating system, capable of maintaining a gas
temperature of 248 + 25°F at the exit end, was built into
the probe. A thermocouple, used to monitor gas tempera-
tures, was attached to the probe. A precalibrated Type S
pitot tube was attached to the probe to allow constant
monitoring of the stack gas velocity. The pitot tube was
constructed in accordance with EPA Method 2.
Filter Holder
A tared fiberglass filter was encased in a borosilicate
glass filter holder. A glass frit supported the filter.
A silicone rubber gasket was used to provide a positive
seal against leakage from around the filter. -The filter
holder was contained in a heated box capable of maintain-
ing a temperature of 248 _+ 25°F. A thermocouple attached
to a pyrometer was used to monitor the temperature inside
the sample box.
24
-------
Impinger Train
The train consisted of a series of four impingers con-
nected with leak-free ground glass fittings. The first,
third and fourth impingers were of the Greenburg-Smith
design, modified by replacing the tip with 1.3 cm ID glass
tube. The tube extends to approximately 1.3 cm from the
bottom of the flask. The second impinger was of the
Greenburg-Smith design with the standard tip. The im-
pinger train was contained in an ice bath to cool the
sample gas stream. A dial type thermometer, capable of
measuring temperatures to within 2°F was placed at the
outlet of the fourth impinger for monitoring purposes.
Metering System
A R.A.C. Train Stack Sampler^ was used for the metering
system. The system consists of the following:
Calibrated orifice
Vertical, inclined, dual manometer
Dry gas meter (capable of measuring volume within 2
percent)
Vacuum gauge
Leak-free pump
Thermometers (capable of measuring temperatures
within 5.4°F)
Electrical controls for sampling
The orifice and dry gas meter were calibrated in accord-
ance with APTD-05762.
1Research Appliance Company, Gibsonia, PA.
J.J., Maintenance, Calibration, and Operation of Iso-
kinetic Source Sampling Equipment, Publ. No. APTD-0576, Office
of Air Programs, EPA, Research Triangle Park, NC 1972.
25
-------
5.3 Preliminary Measurements
Gas Velocity and Temperature
Gas velocity and temperature were measured at each sam-
pling location in accordance with guidelines outlined in
EPA Method 2 (Determination of Stack Gas Velocity and
Volumetric Flow Rate).
The velocity pressure was measured on an inclined, dual
manometer and the temperature was measured on a pyro-
meter. Measurements were recorded at each traverse
point.
Moisture Determination
The moisture content of the stack gas at each test loca-
tion was determined in accordance with guidelines outlined
in EPA Method 4 (Determination of Moisture Content in
Stack Gases).
A sample of the stack gas was extracted at one traverse
point for twenty minutes at each test location. The dry
gas meter readings, orifice pressure differential (in.
H20) and meter temperatures were recorded every five
minutes. The calculations for moisture content can be
found in the Appendix.
5.4 Particulate
The particulate emissions from the boiler were determined
in accordance with guidelines outlined in EPA Method 5
(Determination of Particulate Emissions from 'Stationary
Sources).
26
-------
Sampling
The sampling train at each test location consisted of the
nozzle, probe, filter holder, impinger train and metering
system. The sampling apparatus was set up as shown in
Figure 5-1. All connections were leak-free.
The nozzle size was determined using data obtained from
the preliminary measurements. The first and second
impingers were each initially filled with 100 ml of
distilled water. The third impinger was left empty. The
fourth impinger was filled with 300 g of pre-weighed
indicating type silica gel.
During each test, the following data were recorded at each
traverse point:
Point designation
Clock time (24-hour clock)
Dry gas meter reading (Vm,
Velocity pressure (aps, in
Desired pressure drop across orifice (AH, in.
H20)
Actual pressure drop across orifice (AH , in.
H20)
Stack temperature (Ts, °F)
Dry gas meter temperature at inlet and outlet
(Tm, °F)
Vacuum gauge reading (in. Hg)
Sample box temperature (°F)
Dry gas temperature of exit of last impinger
27
-------
MODIFIED PARTICULATE SAMPLING TRAIN
STACK WALL
PITOT TUBE
II
NOZZLI
THERMOCOUPLE
INCLINED
MANOMETER
CAP)
VACUUM GAUGE
THERMOMETER
BY-PASS
:VALVE
IMPINGER TRAIN
FILTER
^HOLDER
3i
THERMOMETERS
DRY GAS
METER
ORIFICE
COARSE
CONTROL
VALVE
PYROMETER
ICE BATH
INCLINED
MANOMETER
(AH)
ES-093
Figure 5-1
28
-------
The relationship of the A p reading with the AH reading is
a function of the following variables:
' Orifice calibration factor
Gas meter temperature
Moisture content of flue gas
Ratio of flue gas pressure to barometric
pressure
Stack temperature
Sampling nozzle diameter
A nomograph was used to correlate all of the above vari-
ables such that a direct relationship between Ap and AH
could be determined by the test technician and isokinetic
conditions could be maintained. Initial and final leak
checks were performed on each sampling train prior to and
upon completion of each test to confirm the presence of a
leak-free system. Leakage rates did not exceed 0.02 cfm
per EPA standards. All measurements were recorded on the
data sheets.
Upon completion of the first test, the sampling procedure
was modified. The volume of dry gas sampled at each loca-
tion was higher than required by EPA Method 5. To compen-
sate for .this, the total sampling time was reduced from 144
minutes to 96 minutes per test at the inlet location,, and
from 140 minutes to 100 minutes at the outlet location for
the remainder of the sampling program.
The plant was operating the boiler at 52,000 Ibs./hr.
throughout the test program. During the fourth test, a
typical soot blow cycle was conducted for 7 minutes.
Sample Recovery
Upon completion of each test, the sampling trains were dis-
assembled to permit sample recovery. The samples were re-
covered in the following manner:
29
-------
Container #1 - The filter was removed from the filter
holder and placed in its original container
which was sealed with adhesive tape.
Container #2 - The nozzle, probe and front half of the
filter holder were rinsed with acetone
three times. The wash was stored in a
. . glass sample jar with a teflon-lined lid.
The jar was sealed with adhesive tape and
the liquid level was marked.
Container #3 - The silica gel was returned to its original
container.
Container #4 - A sample of the acetone reagent was placed
. in a glass sample jar with a teflon-lined
lid which was sealed1with adhesive tape.
Each sample container was labeled with the date, test
location, test number and contents. The volume of water
in the first three impingers was measured and recorded on
the data sheets and the water was discarded.
Sample Analysis
Each sample was analyzed in the following manner:
Container #1 - The filter was removed from its sealed con-
tainer and placed on a tared watch glass.
The filter and watch glass were dessicated
over anhydrous CaSO^ for 24 hours and
weighed to a constant weight. The weight
was recorded to the nearest 0.01 mg.
Container #2 - The acetone washings were transferred to a
tared beaker. The acetone was evaporated
30
-------
at ambient temperature and pressure. The
beaker was dessicated for 24 hours and
weighed to a constant weight. The weight
was recorded to the, nearest 0.01 mg.
Container #3 - The silica gel was weighed on a beam
balance and the weight was recorded to the
nearest 0.1 gram.
Container #4 - The acetone blank was transferred to a.
tared beaker. The acetone was evaporated
at ambient temperature and pressure. The
beaker was dessicated for 24 hours and
weighed to a constant weight. The weight
was recorded to the nearest 0.01 mg. This
weight was subtracted from the final weight
of the contents of container #2 to obtain
the net weight of particulate in the front
half wash.
5.5 Gas Composition
The gas composition was determined in accordance with EPA
Method 3 (Gas Analysis for Carbon Dioxide, Oxygen, Excess
Air and Dry Molecular Weight).
Multi-point integrated gas samples were collected in an
evacuated Tedlar bag with a stainless steel sample line
and vacuum pump. The gas was analyzed for CC>2/ 02 and CO
immediately after collection.
5.6 Fuel Samples (Coal)
Sampling
Individual coal samples were collected by a member of the
YRC test team during each of the four particulate test
31
-------
runs. The samples were placed in glass sample jars with
teflon-lined caps. Each jar was labeled with the date,
test location, test number, contents and sample number.
Analysis
Representative samples of the coal obtained during each
test run were analyzed at YRC laboratory in Stamford,
Connecticut in accordance with guidelines outlined in the
following ASTM established procedures.2
Proximate Analysis of Coal
A proximate analysis of coal is defined by ASTM as an
"assay of the moisture, ash, volatile matter and fixed
carbon".3
The standard test methods for these analyses are
designated by ASTM as:
Moisture; Method D3173
Ash; Method D3174
Volatile Matter; Method D3175
Fixed Carbon; There is no direct ASTM method of
determining fixed carbon. It can be calculated according
to the equation;
% Fixed Carbon = 100 - (% Moisture + % Ash + % Volatile
Matter)
^1978 Annual Book of ASTM Standards, Part 26, American
Society of Testing and Materials, Philadelphia, Pennsyl-
vania, 1978, pp. 380-427.
3Ibid, p. 380
32
-------
Ultimate Analysis of Coal
An ultimate analysis of coal is "the determination of
carbon and hydrogen in the material, as found in the
gaseous products of its complete combustion,, the deter-
mination of sulfur, nitrogen and ash in the material as a
whole, and the calculation of oxygen by difference."'*
The standard test methods for these analyses are desig-
nated by ASTM as:
Carbon and Hydrogen; Method D3178
Sulfur; Method D3177
Nitrogen; Method D3179
Ash; Method D3174
Oxygen; There is no direct ASTM method of determining
oxygen. It can be calculated according to the equation:
% Oxygen = 100 - (% Carbon + % Hydrogen + % Sulfur + %
Nitrogen + % Ash)
Moisture; Method D3173
Gross Calorific Value; Method D2015-17
5.7 Particle Size Distribution
The particle size distribution samples were collected
using an Andersen Cascade Impactor. The impactor aero-
dynamically classifies particles into multiple size
ranges. It consists of eight stages and a back-up filter
4Ibid, p. 390
33
-------
(Figure 5-2). Each stage consists of a configuration of
orifices of specific diameters above a collection plate.
Tared glass fiber substrates were used on each stage as
collection media.
Different sized particles are impacted on each stage cor-
responding to the size of the orifices on the plate above
the collection substrates. The range of particle sizes
retained on each substrate varies according to the velo-
city of the gas (as determined by the sample rate), the
gas viscosity and the particle density. Since the ori-
fices are arranged in descending diameters/ the gas velo-
city increases and the particle size collected on each
stage decreases.
Sampling
The sampling apparatus consisted of an Andersen impactor,
eight pre-tared substrates and a pre-tared backup filter,
nozzle, drying tube, vacuum pump, dry gas meter, cali-
brated orifice and manometer. During the soot blow cycle
a preseparator was used to pre-cut particles above 1C)
microns and avoid overloading the collection substrates.
(See Figure 5-3 for sampling train diagram).
The sample train was checked for leaks at the completion
of each sample run. Any leak rate above 0.02 cfm was con-
sidered unacceptable.
Using data obtained from the velocity traverse, a sampling
rate (AH) was calculated. (Refer to Appendix 6.2 for
calculations).
During each test the following data were recorded:
34
-------
Point designation
Clock time (24-hour clock)
Dry gas meter readings (Vm,
Actual pressure drop across orifice ( H, in H20)
Dry gas meter temperatures (Tm, °F)
Pressure drop, in stack (in. Hg)
Vacuum (in. Hg)
Sample Recovery
The Andersen impactor was disconnected from the probe and
brought to the clean-up area. The samples were recovered
in the following manner:
The nozzle and the front half of the impactor
were rinsed with acetone. The rinse was stored
in a clean glass sample ja-r with a teflon-lined
lid. The jar was sealed with adhesive tape and
the liquid level was marked.
Starting with stage I, the fiberglass substrates
were removed from the impactor and returned to
their original containers. There were a total
of 8 substrates and one backup filter for each
sample.
When a preseparator was used, it was rinsed with
acetone and the contents were stored in a sepa-
rate glass sample jar with a teflon lid. The
jar was sealed with adhesive tape and the liquid
level was marked.
Sample Analysis
The samples were analyzed in the following manner:
35
-------
The fiberglass substrates and the backup filters
were dessicated and weighed to a constant
weight. The net weight gain was recorded to the
nearest 0.01 mg.
The acetone rinse was transferred to a tared
beaker. The beaker was heated to a temperature
well below the boiling point until the acetone
was evaporated. The beaker was then dessicated
and weighed to a constant weight. The net
weight gain was recorded to the nearest 0.01
mg.
36
-------
ANDERSEN STACK SAMPLER
JET STAGE (9 TOTAU
NOZZLE
BACKUP FILTER
GLASS FIBER
COLLECTION
SUBSTRATE
CYCLONE PRESEPARATOR
INLST
CORE
ATE HOLDER
I I
FIGURE 5-2
-------
ANDERSEN SAMPLING TRAIN
ANDERSEN
SAMPLER
OAS METER
ORIFICE
MANOMETER
ES-094
FIGURE 6-3
38
-------
YRC PROJECT NO. 01-9517-24
Prepared by:
Laurie Behr
Project Scientist
Emissions Measurement Dept,
Reviewed by:
Roger£ A. Kniskern
Project Manager
Emissions Measurement Dept.
Approved by:
es W. Davison
e President Operations
39
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6.0 APPENDICES
40
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