United States
Environmental Protection
Agency
Office of Air Quality EMB Report 80-LWA-2
Planning and Standards Maw 1QR1
Research Triangle Park NC 27711 'tay 'yo '
Air
Lightweight Aggregate
Emission Test Report
Arkansas Lightweight
Aggregate Corporation
W. Memphis, Arkansas
-------
0 EMISSION TEST REPORT °
METHOD DEVELOPMENT AND TESTING FOR
CLAY, SHALE, AND SLATE AGGREGATE INDUSTRY:
Arkansas Lightweight Aggregate Corporation,
West Memphis, Arkansas,
ESED 80/12
By
PEDCo Environmental, Inc.
11499 Chester Road
Cincinnati, Ohio 45246
Contract No. 68-02-3546
Work Assignment No. 1
PN 3530-1
EPA Task Manager
Frank Clay
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
EMISSION MEASUREMENT BRANCH
EMISSION STANDARDS AND ENGINEERING DIVISION
RESEARCH TRIANGLE PARK, NORTH CAROLINA 27711
May 1981
-------
CONTENTS
Page
Figures iii
Tables iv
1. Introduction 1-1
2. Process Operation 2-1
3. Summary of Results 3-1
Rotary kiln exhaust 3-1
Clinker cooler exhaust 3-15
Process samples 3-21
Fugitive emissions from the kiln 3-24
4. Sample Locations and Test Methods Used 4-1
Clinker cooler multicyclone outlet 4-1
Kiln exhaust scrubber outlet 4-1
Velocity and gas temperature 4-5
Molecular weight 4-5
Particulate 4-6
Sulfur dioxide 4-6
Nitrogen oxide 4-7
Particle size distribution 4-7
Process samples 4-8
5. Quality Assurance 5-1
Particulate 5-1
Sulfur dioxide 5-3
Nitrogen oxide 5-3
6. Discussion of Results 6-1
References R-l
Appendix A Computer printout and sample calculation A-l
Appendix B Raw field data B-l
Appendix C Raw laboratory data C-l
Appendix D Sampling and analytical procedures D-l
Appendix E Calibration procedures and results E-l
Appendix F Project participants and sample log F-l
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FIGURES
Number Paqe
3.1-1 Particle Size Distribution for Runs SOPS-2
Through SOPS-5 - Kiln Exhaust 3-7
3.1-2 Particle Size Distribution for Runs SOPS-6
Through SOPS-9 - Kiln Exhaust 3-8
3.2-1 Particle Size Distribution for Runs CCPS-2
Through CCPS-5 - Clinker Cooler Exhaust 3-19
3.2-2 Particle Size Distribution for Runs CCPS-6
Through CCPS-9 - Clinker Cooler Exhaust 3-20
4-1 Process Flow Sheet and Sampling Plan for
Arkansas Lightweight Aggregate Corporation 4-2
4.1-1 Clinker Cooler Multicyclone Outlet 4-3
4.2-1 Kiln Exhaust Scrubber Outlet 4-4
4.8-1 Particle Size Sampling Points for Circular Stack 4-9
111
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TABLES
Number Page
2-1 Process Data for Emission Test at Arkansas Light-
weight Aggregate Plant, West Memphis, Arkansas;
October 20-23, 1980; ESED Project 80/12; MRI
Project 4659-L 2-2
2-2 EPA Process Data 2-4
3.1-1 Summary of Flue Gas Conditions - Kiln Exhaust
Scrubber Outlet 3-3
3.1-2 Summary of Particulate Emission Data - Kiln
Exhaust Scrubber Outlet 3-4
3.1-3 Summary of Sulfur Dioxide Results - Kiln Exhaust
and Scrubber Inlet and Outlet 3-10
3.1-4 Summary of Nitrogen Oxide Emission Data - Kiln
Exhaust Scrubber Outlet 3-13
3.1-5 Summary of Visible Emissions Data - Kiln Exhaust 3-14
3.2-1 Summary of Flue Gas Conditions - Clinker Cooler
Cyclone Exhaust 3-16
3.2-2 Summary of Particulate Emission Data - Clinker
Cooler Cyclone Exhaust 3-17
3.2-3 Summary of Visible Emissions Data - Clinker
Cooler Cyclone Exhaust 3-22
3.3-1 Summary of Process Sample Analysis 3-23
3.3-2 Summary of Trace Metal Analysis - Scrubber
Water Samples '3-25
3.3-3 Summary of Trace Metal Analysis - Solid Samples 3-26
5.1-1 Comparative Particulate Results 5-2
5.1-2 Example Blank Filter Analysis 5-4
5.3-1 NO Analytical Audit Results 5-5
iv
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SECTION 1
INTRODUCTION
During the week of October 20, 1980, PEDCo Environmental
personnel conducted an emission sampling program at Arkansas
Lightweight Aggregate Corporation's West Memphis, Arkansas, fa-
cility. The purpose of this test program was to provide data to
assess the need for New Source Performance Standards (NSPS) emis-
sion limits for selected processes in the lightweight aggregate
industry and, if warranted, to develop such limits.
This plant was selected for testing for the following
reasons:
1. The plant is one of the best controlled coal-fired
lightweight aggregate plants that use wet scrubbers and
dry cyclones for emission control; and
2. The arrangement of pollution control devices on process
equipment appears to be representative of future plants.
Comprehensive testing was conducted on two specific sources
as detailed below:
0 Coal-fired rotary kiln whose emissions are controlled
by a settling chamber and medium-energy wet scrubber
and,
0 Reciprocating grate clinker cooler whose emissions are
controlled by a dry multicyclone.
Particulate concentrations and mass emission rates were mea-
sured at the final exit stacks serving the kiln and clinker
1-1
-------
cooler by U.S. Environmental Protection Agency (EPA) Method 5.*
Flue gas flow rates, temperature, moisture content, and composi-
tion [oxygen (02), carbon dioxide (CO-), and carbon monoxide
(CO)] were measured in conjunction with the particulate test
runs. Sulfur dioxide (SO-) concentrations and mass emission
rates were measured at the inlet to and outlet from the wet
scrubber serving the kiln by EPA Method 6.* Nitrogen oxide (NO )
j\
concentration in the flue gas exiting the scrubber was also
determined by EPA Method 7.* In addition, the particle size
distribution of particulate matter exiting the kiln and clinker
cooler control devices was determined.
Representative samples of the kiln feed material (clay) and
the coal used to fire the kiln were collected during each parti-
culate test for determination of sulfur content, moisture, den-
sity, and ash content (coal only). Samples of scrubber water
influent and effluent were collected for trace metal analysis.
Though not specified in the test plan, samples of the final
aggregate product and dust captured by the clinker cooler multi-
cyclone were also collected and analyzed for sulfur.
Visible emission observations were made for each exit stack
during the particulate tests by EPA Method 9. Additionally, a
visible determination of fugitive dust emissions from the kiln
seals (charging and product discharge) was made during each
§
particulate test by proposed EPA Method 22.
Federal Register, Vol. 42, No. 160, August 18, 1977.
"*" Federal Register, Vol. 39, No. 219, November 12, 1974
§ Federal Register, Vol. 45, No. 224, November 18, 1980
1-2
-------
Mr. Jeff Shuler [Midwest Research Institute (MRI)] monitored
process operation throughout the test period. Mr. Frank Clay,
EPA Task Manager, observed the test series.
1-3
-------
SECTION 2
PROCESS OPERATION
v
The process operation and summary of data monitored during
the test period are presented below. Data was collected by per-
sonnel from MRI.
Arkansas Lightweight Aggregate Corporation employs a pulver-
ized coal-fired rotary kiln for the production of lightweight ag-
gregate from surface-mined clay. The kiln operation is contin-
uous, 24 hours per day, 7 days per week except for required main-
tenance. Kiln capacity is approximately 680 megagrams (Mg) per
24-hour day (750 tons per day). The kiln is fired with pulver-
ized coal, and small amounts of natural gas are used for tempera-
ture control. Exhaust gases from the feed end of the kiln are
treated by a settling chamber followed by a medium-energy scrub-
ber (Fuller/Dracco type CAA, Size 92).
The other major process equipment on this production line is
a reciprocating grate clinker cooler. Particulate emissions from
the clinker cooler are controlled by a dry multiclone.
Tables 2-1 and 2-2 summarize the production and process data
monitored during the test period.
2-1
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TABLE 2-1. PROCESS DATA FOR EMISSION TEST AT ARKANSAS LIGHTWEIGHT
AGGREGATE PLANT, WEST MEMPHIS, ARKANSAS: OCTOBER 20-23, 1980;
ESED PROJECT 80/12; MRI PROJECT 4659-L
Production report, Monday, October 20
Coal input, tons
Gas input, MCF*
Clay input, tons
Product output, yd3
First
shift
0
509
278.7
317.7
Second
shift
11.65
205
298.8
340.6
Third
shift
16.90
55
317.0
361.4
24- h
Total
28. 55
769
894.5
1019.7
Product density (average composite): 33 lb/ft3
Production report, Tuesday, October 21
Coal input, tons
Gas input, MCF
Clay input, tons
Product output, yd3
First
shift
18.81
36
317.7
362.2
Second
shift
17.99
29
317.2
361.6
Third
shift
17.56
45
317.4
361.8
24- h
Total
54.36
110
952.3
1085.6
Product density (average composite): 33 lb/ft3
^Million cubic feet.
(continued)
2-2
-------
TABLE 2-1 (continued)
Production report,
First
shift
Coal input, tons 17.76
Gas input, MCF 19
Clay input, tons 313.3
Product output, yd3 357.2
Product density (average composite)
Wednesday,
Second
shift
18.44
10
316.8
361.2
: 33 lb/ft3
October 22
Third
shift
16.85
36
315.7
359.9
24- h
Total
53.05
65
945.8
1078.3
Production report, Thursday, October 23
First Second
shift shift
Coal input, tons 17.80 NA
Gas input, MCF 29 NA
Clay input, tons 313.3 NA
Product output, yd3 357.2 NA
Product density (average composite): 33 lb/ft3
Third
shift
NA
NA
NA
NA
24- h
Total
NA
NA
NA
NA
NA=Not applicable; testing was completed before second shift began,
therefore, only first shift data were collected.
2-3
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TABLE 2-2. PROCESS DATA-ERA METHOD 5; TUESDAY, OCTOBER 21
Elapsed
time
(min)
Test No. 1
Start-9:23 a.m.
0
15
30
45
60
75
90
105
120
135
Test No. 2
Start-2:05 p.m.
0
15
30
45
60
75
90
105
120
135
Air to
coal mill
(°F)
395
375
360
370
405
407
390
410
430
425
420
410
420
420
410
405
430
410
425
410
Air from
coal mill
(°F)
172
162
158
158
165
162
155
165
170
173
166
160
166
166
164
162
170
165
168
166
Kiln
back end
temp.
(°F)
715
716
714
723
725
725
729
727
727
726
728
729
722
730
726
724
725
727
724
732
Kiln
front end
temp.
(°F)
1566
1576
1569
1569
1577
1580
1582
1576
1580
1575
1582
1592
1595
1600
1598
1602
1605
1616
1605
1610
Kiln firing
hood
draft
(in. water).
-0.05
-0.05
-0.04
-0.04
-0.05
-0.05
-0.05
-0.04
-0.04
-0.04
-0.05
-0.04
-0.04
-0.05
-0.05
-0.04
-0.05
-0.04
-0.05
-0.05
Scrubber
ID fan
draft
(in. water)
6.4
6.4
6.4
6.4
6.4
6.4
6.4
6.4
6.4
6.4
6.4
6.4
6.4
- 6.4
6.4
6.4
6.4
6.4
6.4
6.4
(continued)
-------
TABLE 2-2 (continued). PROCESS DATA-ERA METHOD 5; WEDNESDAY, OCTOBER 22
tn
Test Nos. 3
Start-10:20
Elapsed
time
(min)
and 4*
a.m.
0
15
30
45
60
75
90
105
120
135
150
165
180
Air to
coal mill
(°F)
425
415
430
440
405
445
435
445
440
450
445
415
445
Air from
coal mill
(°F)
176
172
177
182
174
184
182
186
183
182
181
175
180
Kiln
back end
temp.
(°F)
722
720
725
721
716
718
717
711
704
706
708
703
712
Kiln
front end
temp.
(°F)
1560
1555
1556
1550
1530
1525
1537
1517
1512
1513
1520
1510
1542
Kiln firing
hood
draft
(in. water)
-0.05
-0.05
-0.04
-0.05
-0.04
-0.04
-0.04
-0.04
-0.02
-0.04
-0.06
-0.05
-0.04
Scrubber
ID fan
draft
(in. water)
6.4
6.4
6.4
6.4
6.4
6.4
6.4
6.4
6.4
6.4
6.4
6.4
6.4
*Conducted simultaneously.
(continued)
-------
TABLE 2-2 (continued). PROCESS DATA-ERA METHOD 6; THURSDAY, OCTOBER 23
to
Elapsed
time
(min)
-95
-35
-20
Start-10:20 a.m. 0
20
40
60
80
100
120
140
160
180
200
220
240
260
280
300
320
340
360
375
Air to
coal mill
(°F)
420
460
415
437
405
380
405
395
405
410
420
430
450
450
440
460
465
455
415
415
410
400
400
Air from
coal mill
(°F)
185
190
178
182
170
165
174
173
174
170
174
178
184
186
180
185
187
184
172
171
168
165
164
Kiln
back end
temp.
(°F)
711
706
710
715
713
711
708
704
705
706
709
708
705
704
701
705
702
703
699
702
703
707
710
Kiln
front end
temp.
(°F)
1526
1520
1527
1552
1540
1532
1517
1497
1522
1530
1620
1622
1620
1624
1610
1614
1593
1539
1542
1554
1551
1656
1636
Kiln firing
hood
draft
(in. water)
-0.05
-0.05
-0.05
-0.05
-0.05
-0.05
-0.04
-0.05
-0.05
-0.02
-0.04
-0.05
-0.06
-0.05
-0.04
-0.04
-0.05
-0.05
-0.05
-0.05
-0.05
0.00
-0.05
Scrubber
ID fan
draft
(in. water)
5.8
6.0
6.0
6.0
6.0
6.2
6.2
6.2
6.2
6.2
6.3
6.3
6.3
6.3
6.3
6.4
6.4
6.4
6.4
6.4
6.4
6.4
6.4
-------
SECTION 3
SUMMARY OF RESULTS
This section details results obtained from the emission sam-
pling program. All emission samples and plume observation data
were collected simultaneously from the kiln and clinker cooler
exhaust stacks. Results are reported separately for each source.
It should be noted that the scrubber serving the kiln experienced
feedwater pump malfunction during the second particulate and par-
ticle size test runs; the malfunction resulted in a fluctuation
in scrubber water level throughout this period. A discussion of
the effects that this malfunction may have had on the test re-
sults is contained in Section 6 of this report.
Example calculations are contained in Appendix A. Field and
laboratory data sheets are contained in Appendices B and C. Ap-
pendix D details the sampling and analytical procedures used during
this test program. Equipment calibration procedures and results
are contained in Appendix E.
3.1 ROTARY KILN EXHAUST
Particulate and particle size tests were conducted on the
kiln exhaust immediately after the pollution abatement system,
which consisted of a settling chamber followed by a wet scrubber.
Visible emission observations were also performed during ecich
3-1
-------
particulate test run. In addition, S02 tests were simultaneously
conducted before and after the wet scrubber. Nitrogen oxide
tests were conducted at the scrubber outlet simultaneously with
the SO- tests.
Particulate sampling and analytical procedures followed EPA
Method 5* except that an ether-chloroform extraction was per-
formed on the impinger contents to determine condensible organic
and inorganic fractions. Particle size sampling and analytical
procedures followed those described in "Procedures Manual for
Inhalable Particulate Sampler Operation," recently developed by
Southern Research Institute for EPA. Visible emission observa-
tions were conducted by EPA Method 9. Sulfur dioxide sampling
and analytical procedures followed EPA Method 6* except that large
impingers were used instead of the midget impingers specified by
EPA Method 6. Nitrogen oxide sampling and analytical procedures
followed EPA Method 7.*
3.1.1 Flue Gas Conditions and Particulate Emissions
Summaries of the measured flue gas and particulate emission
data from the kiln exhaust are presented in Tables 3.1-1 and
3.1-2. Volumetric flow rates are expressed in actual cubic:
meters per hour (acmh) and actual cubic feet per hour (acfh) at
stack conditions. Flow rates corrected to standard conditions
[20°C and 760 mm Hg (68°F and 29.92 in. Hg)] are expressed as dry
standard cubic meters per hour (dscmh) and dry standard cubic
Federal Register, Vol. 42, No. 160, August 18, 1977.
Federal Register, Vol. 39, No. 219, November 12, 1974.
3-2
-------
TABLE 3.1-1. SUMMARY OF FLUE GAS CONDITIONS -
KILN EXHAUST SCRUBBER OUTLET
Run
No.
SOP-1
SOP- 2
SOP-3d
SOP-4d
Date
(1980)
10/21
10/21
10/22
10/22
Average
Flue qas flow
Metric
acmha
154,157
148,096
138,546
152,016
148,204
L
dscmh
97,717
99,438
88,453
95,804
95,353
English
acfha
5,443,963
5,229,943
4,892,190
5,368,349
5,233,736
dscfh0
3,450,833
3,511,597
3,123,661
3,383,256
3,367,337
Temperature
°C
78
67
81
81
77
°F
173
153
177
177
170
Moisture,
%
24.0
22.1
23.0
24.0
23.3
o,,c
%
14.0
14.7
15.1
15.1
14.7
co?,c
%
5.7
5.0
4.4
4.4
4.9
CO,C
%
0
0
0
0
0
U)
'Flue gas flow in actual cubic meters per hour (acmh) and actual cubic feet per hour (acfh) at stack conditions.
5Flue gas flow in dry standard cubic meters per hour (dscmh) and dry standard cubic feet per hour (dscfh).
Standard conditions = 20°C and 760 mm Hg (68°F and 29.92 in. Hg).
%
'Orsat analysis of integrated bag samples.
Sampling conducted simultaneously.
-------
TABLE 3.1-2. SUMMARY OF PARTICULATE EMISSION DATA - KILN
EXHAUST SCRUBBER OUTLET
Run
No.
SOP-1C
SOP-2
SOP- 3d
SOP-4d
Date
(1981)
10/21
10/21
10/22
10/22
Average
Concentration3
Filterable
mg/dscm
495.9
325.4
775.5
882.3
661.1
gr/dscf
0.2167
0.1422
0.3388
0.3855
0.2888
Condensible
Organic
mg/dscm
3.0
3.0
5.6
3.3
4.0
gr/dscf
0.0013
0.0013
0.0024
0.0014
0.0017
Inorganic
mg/dscm
305.5
337.8
322.7
237.7
299.4
gr/dscf
0.1334
0.1476
0.1410
0.1039
0.1308
Mass emission rate
Filterable
kg/h
48.5
32.4
68.6
84.5
61.8
Ib/h
106.8
71.3
151.2
186.3
136.3
Condensible
Organic
kg/h
0.30
0.30
0.49
0.32
0.37
Ib/h
0.66
0.65
1.10
0.70
0.82
Inorganic
kg/h
29.9
33.6
28.5
22.8
28.3
Ib/h
65.8
74.1
62.9
50.2
62.4
Concentration expressed as milligrams per dry standard cubic meter and grains per dry standard cubic foot.
Standard conditions = 20°C and 760 mm Hg (68°F and 29.92 in. Hg).
Mass emission rate expressed as kilograms per hour and pounds per hour.
°Excluded from average. See p. 3-5.
Samples collected simultanteously.
-------
feet per hour (dscfh). Particulate concentrations are reported
in milligrams per dry standard cubic meter (mg/dscm) and grains
per dry standard cubic foot (gr/dscf). Emission rates are ex-
pressed in kilograms per hour (kg/h) and pounds per hour (Ib/h).
The product of the concentration and the volumetric flow rate is
the mass emission rate. The filterable particulate data in Table
3.1-2 represent material collected in the sample probe and on the
filter, both of which were heated to approximately 121°C (250°F).
The condensible organic and inorganic fractions represent mate-
rial that condensed out or was trapped in the impinger section of
the sample train at a temperature of approximately 20°C (68°F).
The volumetric flow rate averaged 95,353 dscmh (3,367,337
dscfh) at an average temperature of 77°C (170°F). The moisture
content averaged 23.3 percent; and the oxygen, carbon dioxide,
and carbon monoxide contents averaged 14.7, 4.9, and 0.0 percent,
respectively. Because the gas stream appeared saturated and con-
tained water droplets, two moisture determinations were made:
the first involved calculations based on the water collected in
the sampling trains, and the second involved psychrometric calcu-
lations. In each case, the lower value was used as the correct
moisture content according to EPA Method 4.*
Filterable particulate concentration averaged 661 mg/dscm
(0.289 gr/dscf) with a corresponding average mass emission rate
of 61.8 kg/h (136.3 Ib/h). Results from Run SOP-1 were excluded
from the average because of a nonisokinetic sampling condition.
Federal Register, Vol. 42, No. 160, August 18, 1977
3-5
-------
The organic and inorganic concentrations averaged 4.0 mg/dsc:m
(0.0017 gr/dscf) and 299 mg/dscm (0.131 gr/dscf) with correspond-
ing average mass emission rates of 0.37 kg/h (0.82 Ib/h) and 28.3
kg/h (62.4 Ib/h).
3.1.2 Particle Size Distribution
A total of nine particle size samples were collected from
the scrubber outlet during the particulate test runs. The first
test was a preliminary run and is not considered representative;
therefore, it is not included in the overall data averages.
Sampling and analytical procedures followed those described in
"Procedures Manual for Inhalable Particulate Sampler Operation,"
developed by Southern Research Institute (SRI) for EPA. Data
obtained from the particulate test runs were combined with sam-
pling data to obtain average flow rates, moisture content, and
gas composition.
Data were reduced by computer programs in "A Computer-Based
Cascade Impactor Data Reduction System," developed by SRI for
2
EPA. Individual computer printouts for each test and brief
descriptions of each program used are contained in Appendix A of
this report.
Figures 3.1-1 and 3.1-2 present the average distribution
curve for each set of four samples collected. Individual data
points for each test were plotted manually. The distribution
curve was plotted manually and represents the best-fit average
curve for the specified number of test runs. All particle size
results are based on aerodynamic diameters and unit density (1
g/cc).
3-6
-------
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w.t
••
t
I
M
9J
•.1
£*
-H-
ttS
M
ill
LEGEND:
RUN NO.
;SOPS-2 -
SSOPS-3 - O
:SOPS-4 - a
-.SOPS-5 - O
EXTRAPOLATED-.-—
It llllgllllllBIIIUIIIimilHIIIIillg
1.0
10.0
PARTICLE SIZE, microns
Figure 3.1-1. Particle size distribution for Runs SOPS-2 through SOPS-5 - kiln exhaust.
-------
U)
I
00
RUN NO.
t£SOPS-6 -
_SOPS-7 - O
3SOPS-8 -
ltsoPS-9 - a
EXTRAPOLATED
t.t
PARTICLE SIZE, microns
Figure 3.1-2. Particle size distribution for Runs SOPS-6 through SOPS-9 - kiln exhaust.
-------
Samples SOPS-2 through SOPS-5 were collected during the
first and second particulate test runs. Scrubber operation prob-
lems occured midway through the second particulate test, but did
not seem to affect the particle size results as evidenced by the
data point distribution for these runs. The data show that 50
percent of the particles by weight were less than 2.4 microns in
diameter.
Samples SOPS-6 through SOPS-9 were collected during the
third particulate test. The data point distribution for these
runs indicate that 50 percent of the particles by weight were
less than 2.1 microns in diameter.
3.1.3 Sulfur Dioxide
Table 3.1-3 presents a summary of results for S0« tests con-
ducted simultaneously before and after the wet scrubber. Concen-
trations are reported in parts per million by volume (ppm), mil-
ligrams per dry standard cubic meter (mg/dscm), and pounds per
dry standard cubic foot (Ib/dscf). Mass emission rates are
reported in kilograms per hour (kg/h) and pounds per hour (Ib/h).
The outlet mass emission rates were calculated from the measured
concentrations and the average outlet flow rate measured during
the particulate test runs [95,353 dscmh (3,367,337 dscfh)]. The
inlet mass emission rates were calculated from the measured con-
centrations and the average outlet flow rate corrected for excess
air for each individual test run. Analysis was conducted on site
by EPA Method 6.*
Federal Register, Vol. 42, No. 160, August 18, 1977
3-9
-------
TABLE 3.1-3.
SUMMARY OF SULFUR DIOXIDE RESULTS - KILN EXHAUST
SCRUBBER INLET AND OUTLET
Test
No.
1
2
3
1
2
3
Run
No.
SIS-2
SIS-3
Date
(1980)
10/23
Sample
location
Scrubber inlet
Average
SIS-4
SIS-5
10/23
Scrubber inlet
Average
SIS-6
SIS-7
10/23
Scrubber inlet
Average
SOS-1
SOS- 2
10/23
Scrubber outlet
Average
SOS-3
SOS-4
10/23
Scrubber outlet
Average
SOS-5
SOS-6
10/23
Scrubber outlet
Average
Concentration8
ppn
306
371
338
353
349
351
344
331
338
197
163
180
191
182
187
188
184
186
mg/dscm
804
976
890
927
918
923
905
871
888
517
428
473
501
479
490
493
482
488
Ib/dscf x 10"5
5.02
6.09
5.56
5.79
5.73
5.76
5.65
5.44
5.55
3.23
2.67
2.95
3.13
2.99
3.06
3.08
3.01
3.05
Mass b
emission rate.
kg/h
64.1
80.0
72.1
76.0
73.9
75.0
72.8
70. g
71.5
49.4
40.8
45.1
47.8
45.7
46.8
47.0
46.0
47.0
Ib/h
141.4
176.3
158.9
167.5
162.9
165.2
160.5
154.7
157.6
108.9
90.0
99.5
105.4
100.7
103.0
103.6
101.5
102.6
Temperature
C
232
232
232
227
227
227
227
227
227
60
60
60
62
61
62
61
61
61
F
450
450
450
440
440
440
440
440
440
140
140
140
144
143
144
143
143
143
Moisture,
t
21
18
20
16
13
15
14
12
13
16
19
18
19
19
19
19
19
19
C02.
%
5.2
5.2
5.2
4.8
4.8
4.8
5.4
S.4
5.4
4.0
4.0
4.0
3.6
3.6
3.6
4.2
4.2
4.2
02.
13.6
13.8
'13.7
13.8
13.2
13.5
13.2
13.2
13.2
14.8
14.8
14.8
14.8
14.4
14.6
14.4
14.4
14.4
Concentration in parts per million by volume, milligrams per dry standard cubic meter, and pounds per dry standard cubic foot.
Emission rate in kilograms per hour and pounds per hour.
-------
Sulfur dioxide concentration at the inlet to the wet scrub-
ber averaged 900 mg/dscm (342 ppm; 5.62 x 10~ Ib/dscf) with a
corresponding average mass emission rate of 72,9 kg/h (160.6
Ib/h). Flue gas temperature averaged 229°C (445°F) with oxygen
and carbon dioxide contents averaging 13.5 and 5.1 percent.
Moisture content averaged 15.7 percent and was determined gravi-
metrically by weighing each impinger in the sample trains to the
nearest 0.1 gram before and after each test.
Sulfur dioxide concentration at the scrubber exit stack
averaged 483 mg/dscm (184 ppm; 3.02 x 10 Ib/dscf) with a cor-
responding average mass emission rate of 46.1 kg/h (101.7 Ib/h).
Flue gas temperature averaged 61°C (143°F) with an average mois-
ture content of 18.4 percent determined gravimetrically. Oxygen
and carbon dioxide contents averaged 14.6 percent and 3.9 percent.
The isopropanol fraction of the sample train, normally dis-
carded per EPA Method 6, was retained in order to investigate
possible ammonium sulfite interference with the SO,., analytical
procedure. Selected samples from both the inlet and the outlet
sample trains were analyzed by ion chromatography for sulfates
(SO ~) and sulfites (S03~). Concentrations of both species were
found to be at or below the detectable limits of the analytical
method. These data indicate that ammonium sulfite is not present
in sufficient quantity to cause a bias in the measured SO frac-
tion.
3-11
-------
3.1.4 Nitrogen Oxides
Table 3.1-4 summarizes nitrogen oxides emission data. Three
tests, consisting of four grab samples each, were conducted on
the kiln exhaust scrubber outlet. Concentrations are reported in
milligrams per dry standard cubic meter (mg/dscm), parts per mil-
lion by volume (ppm), and pounds per dry standard cubic foot
(Ib/dscf). Emission rates are reported in kilograms per hour
(kg/h) and pounds per hour (Ib/h), and were calculated from the
average flue gas flow rate measured during the particulate test
runs corrected to standard conditions.
Nitrogen oxide concentrations averaged 400 mg/dscm (209 ppm;
-4
0.250 x 10 Ib/dscf) with a corresponding mass emission rate of
38.1 kg/h (84.0 Ib/h).
3.1.5 Kiln Exhaust Visible Emissions
Visible emissions surveys were conducted at the kiln scrub-
ber outlet during each particulate test. Condensed water vapor
was present in the kiln outlet plume; therefore, visible emis-
sions were observed beyond the point in the plume where the; steam
dissipated.
Visible emissions were read in 6-minute sets throughout each
particulate test. Table 3.1-5 contains a summary of visible
emissions for the kiln outlet. Opacities during Test 1 ranged
from 5 to 40 percent, with an average of 19 percent for all sets.
During Test 2, opacities ranged from 5 to 85 percent, with an
average of 27 percent for all sets. Scrubber operation problems
occurred several times during Test 2, during which there were
3-12
-------
TABLE 3.1-4. SUMMARY OF NITROGEN OXIDE EMISSION
DATA - KILN EXHAUST SCRUBBER OUTLET
Run
No.
1
2
3
Sample
No.
SONO-1A
SONO-1B
SONO-1C
SONO-1D
Date
(1980)
10/23
Average
SONO-2A
SONO-2B
SONO-2C
SONO-2D
10/23
Average
SONO-3A
SONO-3B
SONO-3C
SONO-3D
10/23
Average
Concentration3
ppm
199
216
217
216
212
210
210
186
188
199
222
204
219
219
216
mg/dscm
381
415
415
415
406
402
402
356
359
380
426
389
420
418
413
Ib/dscf x 10-4
0.238
0.259
0.259
0.259
0.254
0.251
0.251
0.222
0.224
0.237
0.266
0.243
0.262
0.261
0.258
Mass .
emission rate
kg/h
36.3
39.5
39.6
39.5
38.7
38.3
38.3
33.9
34.2
36.2
40.6
37.2
39.9
39.9
39.4
Ib/h
80.1
87.1
87.3
87.1
85.4
84.5
84.3
74.6
75.5
79.7
89.4
81.9
88.1
88.0
86.9
Concentration of NOX as nitrogen dioxide (N02) in parts per million by volume
(ppm), milligrams per dry standard cubic meter (mg/dscm), and pounds per dry
standard cubic foot (Ib/dscf).
Emission rate in kilograms per hour and pounds per hour.
3-13
-------
TABLE 3.1-5. SUMMARY OF VISIBLE EMISSIONS DATA
- KILN EXHAUST
Ul
Test 1
Set No.
KSVE-1A
KSVE-1B
KSVE-1C
KSVE-1D
KSVE-1E
KSVE-1F
Time
0926-0932
0952-0958
1014-1020
1038-1044
1100-1106
1122-1128
Average
X Opacity
12
16
22
16
21
27
Range
5-25
10-25
10-30
10-20
15-30
15-40
Test 2
Set No.
KSVE-2A
KSVE-2B
KSVE-2C
KSVE-20
KSVE-2E
KSVE-2F
KSVE-2G
Time
1413-1419
1433-1439
1514-1520
1533-1537
1607-1613
1617-1623
1637-1643
Average
? Opacity
19
55
25
31
21
22
19
Range
10-30
5-85
20-30
20-40
15-30
15-25
15-25
Test 3
Set No.
KSVE-3A
KSVE-3B
KSVE-3C
KSVE-3D
KSVE-3E
KSVE-3F
KSVE-3G
Time
1023-1029
1047-1053
1119-1125
1136-1142
1154-1200
1225-1231
1315-1321
Average
% Opacity
27
23
21
30
23
25
32
Range
10-35
15-30
15-25
20-35
15-30
20-30
25-40
-------
excursions in opacity. Opacities observed during Test 3 ranged
from 10 to 40 percent, with an average of 26 percent for all
sets.
3.2 CLINKER COOLER EXHAUST
Particulate and particle size tests as well as visible emis-
sion observations were conducted on the exit stack of the dry
multicyclone serving emissions from the reciprocating grate
clinker cooler. Particulate sampling and analytical procedures
followed EPA Method 5* except that an ether-chloroform extraction
was performed on the impinger contents to determine condensible
organic and inorganic content. Particle size sampling and ana-
lytical procedures followed those described in "Procedures Manual
for Inhalable Particulate Sampler Operation," recently developed
for EPA by Southern Research Institute. Visible emission obser-
vations were made by EPA Method 9. Concentration and mass emis-
sion rate data are expressed in units identical to those used in
Section 3.1 of this report.
3.2.1 Flue Gas Conditions and Particulate Emissions
Summaries of the measured flue gas and particulate emission
data from the clinker cooler exhaust are presented in Tables
3.2-1 and 3.2-2.
The filterable particulate data reported in Table 3.2-2
represent matter collected in the sample probe and on the filter,
*
Federal Register, Vol. 42, No. 160, August 18, 1977.
f Federal Register, Vol. 39, No. 219, November 12, 1974
3-15
-------
TABLE 3.2-1. SUMMARY OF FLUE GAS CONDITIONS - CLINKER
COOLER CYCLONE EXHAUST
Run
No.
CCP-1
CCP-2
d
CCP-3
d
CCP-4
Date
(1980)
10/21
10/21
10/22
10/22
Average
Flue qas flow
Metric
acmha
38,079
40,928
39,426
38,329
39,191
u
dscmh
30,545
32,143
31,983
30,462
31,283
English
acfha
1,344,737
1,445,353
1,392,315
1,353,552
1,383,989
L
dscfh0
1,078,683
1,135,100
1,129,466
1,075,745
1,104,749
Temperature
°C
85
96
85
88
89
°F
186
204
185
190
191
Moisture,
%
2.2
1.5
1.2
2.5
1.9
Oo,C
c.
%
17.6
20.6
19.9
19.9
18.8
ro c
L,U^ ,
L
%
2.3
0.0 .
0.9
0.9
1.6
CO,C
%
0.0
0.0
0.0
0.0
0.0
*Flue gas flow in actual cubic meters per hour (acmh) and actual cubic feet per hour (acfh) at stack conditions.
''Flue gas flow in dry standard cubic meters per hour (dscmh) and dry standard cubic feet per hour (dscfh).
Standard conditions = 20°C and 760 nm Hg (68°F and 29.92 in. Hg).
«
'Orsat analysis of integrated bag samples.
Sampling conducted simultaneously.
-------
TABLE 3.2-2. SUMMARY OF PARTICULATE EMISSION DATA - CLINKER
COOLER CYCLONE EXHAUST
Run
No.
CCP-1
CCP-2
CCP-3C
CCP-4C
Date
(1981)
10/21
10/21
10/22
10/22
Average
Concentration3
Filterable
mg/dscm
246.5
180.4
107.6
167.9
175.6
gr/dscf
0.1077
0.0778
0.0470
0.0733
0.0764
Condensible
Organic
mg/dscm
1.35
1.52
1.05
2.22
1.54
gr/dscf
0.0006
0.0007
0.0005
0.0010
0.0007
Inorganic
mg/dscm
0.98
0.11
0.94
3.85
1.48
gr/dscf
0.00040
0.00003
0.00040
0.00170
0.00060
Mass emission rate
Filterable
kg/h
7.5
5.8
3.4
5.1
5.5
Ib/h
16.6
12.8
7.6
11.3
12.1
Condensible
Organic
kg/h
0.04
0.05
0.03
0.07
0.05
Ib/h
0.09
0.11
0.07
0.15
0.11
Inorc
kg/h
0.030
0.004
0.030
0.120
0.050
anic
Ib/h
0.070
0.008
0.070
0.260
0.100
OJ
I
Concentration expressed as milligrams per dry standard cubic meter and grains per dry standard cubic foet.
Standard conditions = 20°C and 760 mm Hg (68°F and 29.92 in. Hg).
"Vlass emission data expressed as kilograms per hour and pounds per hour.
'Samples collected simultaneously.
-------
both of which were heated to approximately 121°C (250°F). The
condensible organic and inorganic fractions represent material
that condensed out or was trapped in the impinger section of the
sample train at a temperature of approximately 20°C (68°F).
The volumetric flow rate averaged 31,283 dscmh (1,104,749
dscfh) at an average temperature of 89°C (191°F). The moisture
content averaged 1.9 percent; and oxygen, carbon dioxide, and
carbon monoxide contents averaged 18.8, 1.6, and 0.0 percent,
respectively.
Filterable particulate concentrations averaged 175.6 mg/dscm
(0.076 gr/dscf) with a corresponding mass emission rate of 5.5
kg/h (12.1 Ib/h). The condensible organic and inorganic concen-
trations averaged 1.5 mg/dscm (0.0007 gr/dscf) each with a corre-
sponding mass emission rate of 0.05 kg/h (0.105 Ib/h).
3.2.2 Particle Size Distribution
A total of nine samples were collected from the clinker
cooler cyclone exhaust. The first test was a preliminary ran and
is not considered representative; therefore, it is not included
in the overall data averages. The sampling and analytical pro-
cedures as well as the data reduction technique are the same as
those described in Section 3.1.2 and Appendix A of this report.
Figures 3.2-1 and 3.2-2 present the distribution curves for
each set of four samples collected. Individual data points for
each test were plotted manually. The distribution curve was
plotted manually and represents the best-fit average curve for
the specified number of test runs. All particle size results are
based on aerodynamic diameters and unit density (1 g/cc).
3-18
-------
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vo
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M.I
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it_
Ill
TT
FT
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M-t
11 ,.,
t
Ti . n'."i'r"rr
» -
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IDE!
LEGEND:
RUN NO.
ICCPS-3 - O
CCPS-5 - O
EXTRAPOLATED •""
Illi'llllllliVllil.il
— t
T >
1.0
10.0
100
PARTICLE SIZE, microns
Figure 3.2-1. Particle size distribution for Runs CCPS-2 through CCPS-5 - clinker cooler exhaust.
-------
OJ
I
ro
o
N.t
M.1
n
M
M
3
tst
V)
n M
UJ
oe tt
t
1
M
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iu
1*1
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. L.
4
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itt
LJ-
^i
Ir-+»
iLEGEND:
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CCPS-9 - A
.EXTRAPOLATED-
•i
-+*
—+1
- o
_i
—t
9
1.0
10.0
100
PARTICLE SIZE, microns
Figure 3.2-2. Particle size distribution for Runs CCPS-6 through CCPS-9 - clinker cooler exhaust.
-------
Samples CCPS-2 through CCPS-5 were collected during the
first and second particulate test runs. The data point distri-
bution indicates that 50 percent of the particles by weight were
less than 24 microns in diameter.
Samples CCPS-6 through CCPS-9 were collected during the
third particulate test and show that 50 percent of the particles
by weight were less than 13 microns in diameter.
3.2.3 Clinker Cooler Exhaust Visible Emissions
Visible emissions surveys were conducted at the clinker
cooler outlet during each particulate test. Visible emissions
were read in 6-minute sets throughout each particulate test.
Table 3.2-3 contains a summary of visible emissions for the
clinker cooler outlet. Opacities during Test 1 ranged from 5 to
30 percent, with an average of 16 percent for all sets. During
Test 2, opacities ranged from 10 to 30 percent, with an average
of 18 percent for all sets. Opacities observed during Test 3
ranged from 5 to 25 percent, with an average of 12 percent for
all tests.
3.3 PROCESS SAMPLES
Table 3.3-1 summarizes results from the analysis of process
samples collected during the particulate test runs. Clay and
coal samples were collected at approximately 20-minute intervals
during each particulate test. Clay samples were collected from
the kiln feed conveyor and coal samples after the pulverizer but
before the kiln. In addition, single samples of the final pro-
duct and dust captured by the clinker cooler multicyclone were
3-21
-------
TABLE 3.2-3. SUMMARY OF VISIBLE EMISSIONS DATA
- CLINKER COOLER EXHAUST
to
Test 1
Set No.
CCVE-1A
CCVE-1B
CCVE-1C
CCVE-10
CCVE-1E
CCVE-1F
Time
0937-0943
1001-1007
1022-1028
1046-1052
1108-1114
1131-1137
Average
% Opacity
8
12
17
16
20
22
Range
5-15
5-30
10-25
10-25
15-25
15-25
Test 2
Set No.
CCVE-2A
CCVE-2B
CCVE-2C
CCVE-20
CCVE-2E
CCVE-2F
CCVE-2G
Time
1423-1429
1443-1449
1459-1505
1523-1529
1545-1551
1557-1603
1629-1635
Average
% Opacity
22
19
17
22
16
15
16
Range
20-30
15-25
10-20
15-30
15-20
10-20
10-20
Test 3
Set No.
CCVE-3A
CCVE-3B
CCVE-3C
CCVE-3D
CCVE-3E
CCVE-3F
CCVE-3G
Time
1036-1042
1056-1102
1127-1133
1144-1150
1202-1208
1233-1239
1256-1302
Average
% Opacity
8
8
9
17
14
13
12
Range
5-15
5-15
5-15
10-25
10-20
10-15
10-15
-------
TABLE 3.3-1. SUMMARY OF PROCESS SAMPLE ANALYSIS
Parti cul ate
Run No.
1
2
3
Duplicate
trains
2
Date
(1980)
10/21
10/21
10/22
10/21
Sample
type
Coal
Clay
Coal
Clay
Coal
Clay
Final
product
Clinker
cooler
hopper
catch
Density,
g/ml
1.14
2.49
1.00
2.57
1.09
2.34
- "
_
Moisture,
%
3.51
21.65
3.24
19.34
2.94
24.00
' „
_
Ash, %
dry basis
9.04
-
9.21
-
8.27
-
_
_
Sulfur, %
dry basis
l,.92a
2,.19b
1..643
2.12b
1..483
K
2.13b
1.63b
1.57b
ASTM D3177.
ASTM D2234.
3-23
-------
collected during the second particulate test in order to deter-
mine the sulfur content.
The clay analytical data was characterized by an average
sulfur content of 2.15 percent and an average moisture content of
21.7 percent. The coal analytical data were characterized by an
average sulfur content of 1.68 percent and an average ash content
of 8.84 percent. The sulfur contents of the final product and
the multicyclone hopper catch were 1.63 percent and 1.57 percent;
these results indicate that a substantial part of the sulfur in
the raw clay remains as such.
Table 3.3-2 summarizes results from the trace metal analysis
performed on scrubber influent and effluent water samples, which
were collected during the particulate test runs. All results are
reported in parts per million (ppm) by volume. Table 3.3-3 sum-
marizes results of the trace metal analysis performed on the sol-
id fraction, which was filtered from the water samples. Results
are reported in parts per million by volume and, in some cases,
percent by weight.
3.4 FUGITIVE EMISSIONS FROM THE KILN
Fugitive emissions surveys were conducted to determine the
magnitude of any leaks around the kiln seals. These surveys were
conducted during each particulate test using the procedure of
Draft EPA Method 22.*
Three fugitive surveys were conducted for 15 minutes, at
each end of the kiln during each particulate test. During each
of the three particulate tests, no fugitive emissions were
observed from either end of the rotary kiln.
Federal Register, Vol. 45, No. 224, November 18, 1980.
3-24
-------
TABLE 3.3-2. SUMMARY OF TRACE METAL ANALYSIS
- SCRUBBER WATER SAMPLES
Element
A1
Sb
As
Ba
Be
Bi
B
Cd
Ca
Cr
Co
Cu
Au
In
Fe
Pb
Li
Mg
Mn
Ag
Mo
Ni
P
Pz
K
Sc
Si
Ag
Na
Su
Te
Tl
Sn
Ti
U
V
W
Y
Zn
Test No. 1
effluent-ppm
240
<0.032
<0.057
0.096
<0.0005
<0.05
16
0.080
610
0.16
0.43
0.096
<0.03
<0.05
0.71
<0.084
0.54
190
57
<0.03
0.11
0.94
0.50
<0.03
69
<0.08
170
<0.001
51
3.2
<0.1
<0.1
<0.12
0.18
<0.06
0.13
<0.03
0.52
1.1
Test No. 2
effluent-ppm
250
<0.032
<0.057
0.10
<0.0005
<0.05
17
0.080
630
0.16
0.49
0.093
<0.03
<0.05
0.50
<0.084
0.57
210
66
<0.03
0.11
1.1
0.94
<0.03
76
<0.08
160
<0.001
56
3.1
<0.1
<0.1
<0.12
0.18
<0.06
0.14
<0.03
0.54
1.1
Test No. 3
effluent-ppm
370
<0.032
<0.057
0.15
<0.0005
<0.05
23
0.080
570
0.14
0.62
0.049
<0.03
<0.05
0.70
<0.084
0.86
260
80
<0.03
0.11
1.4
0.96
<0.03
100
<0.08
180
<0.001
77
3.8
<0.1
<0.1
<0.12
0.096
<0.06
0.056
<0.03
0.64
1.3
Composite
influent-ppm
0.37
<0.032
<0.057
0.69
<0.0005
<0.05
0.21
<0.008
71
<0.001
<0.006
<0.001
<0.03
<0.05
<0.008
<0.084
0.003
26
0.012
<0.03
0.015
0.022
0.27
<0.03
6.2
<0.08
13
<0.001
13
0.52
<0.1
<0.1
<0.12
<0.005
<0.06
<0.003
<0.03
<0.002
0.007
3-25
-------
TABLE 3.3-3. SUMMARY OF TRACE METAL ANALYSIS
- SOLID SAMPLES
(ppm except as indicated)
Elements
A1
Sb
As
Ba
Be
Bi
B
Cd
Ca
Cr
Co
Au
In
Fe
Pb
Li
Mg
Mn
HQ
Mo
Ni
P
Pt
K
Se
Ag
Na
Sr
Te
Tl
Sn
Ti
U
V
W
Y
Zn
Test No. 1
4.9%
<8
<14
660
<0.12
<13
3.2%
1.7
1.2%
69
50
<8
<13
5.5%
65
68
5900
350
<8
21
420
480
<8
1.5%
<20
<0.5
4.2%
80
<25
<25
<50
3900
<15
160
<8
3.3
180
Test No. 2
4.92;
<8
<14
660
<0.12
<13
3.2%
1.5
1.2%
66
42
<8
<13
5.12
60
72
5800
290
<8
27
401
420
-------
SECTION 4
SAMPLE LOCATIONS AND TEST METHODS USED
Figure 4-1 is a simplified process flow sheet depicting the
sample locations and type of testing conducted at each site. The
following is a description of the sample locations used to con-
duct sampling for particulate, sulfur dioxide and nitrogen oxide
emissions, and particle size distribution.
4.1 CLINKER COOLER MULTICYCLONE OUTLET
Particulate concentration and particle size distribution
were measured at the multicyclone outlet as shown in Figure
4.1-1. Two sample ports, 90 degrees off center, were located 7.1
duct diameters downstream and 1.8 duct diameters upstream from
the nearest flow disturbances in the round stack, the inside di-
ameter (I.D.) of which was 1.22 meters (4 ft). Twenty-four tra-
verse points, twelve per port, were used to traverse the cross-
sectional area of the stack for the particulate test runs. Each
point was sampled for 5 minutes, and total test time was 120
minutes.
4.2 KILN EXHAUST SCRUBBER OUTLET
Particulate, sulfur dioxide, and nitrogen oxide concentra-
tions as well as particle size distribution were measured at the
kiln exhaust outlet as shown in Figure 4.2-1. Two sample ports,
4-1
-------
vi/
CLAY
CAPTURED
PARTICULATE
OUTLET
STACK
COAL-
1
ROTARY
KILN
1
OUST
COLLECTOR
&
1
WET
SCRUBBER
(Y)
•- SLUDGE
COOLING
AIR '
INFLUENT
PRODUCT
(l) SAMPLE POINT
^ SOLIDS FLOW
»• AIR/GAS FLOW
CAPTURED
PARTICULATE
SAMPLE TYPE
PARTICULATE
S02
PARTICLE SIZE
OPACITY
FUGITIVE DUST
NOX
RAW MATERIAL
TRACE METALS
SAMPLE POINTS
4,8
3,4
4,8
4,8
KILN SEALS
4
1.2
5,9
NO. OF SAMPLES
4
3
18
3
3
12
24
3
TEST METHOD
EPA 5
EPA 6
IMPACTOR
EPA 9
EPA 22
EPA 7
_a
I-CAPb
sulfur content; density, percent moisture; and
aCoal samples:
percent ash.
Clay samples: sulfur content; density and percent moisture.
Sulfur analysis by Method: ASTM D3177 and ASTM D2234.
I-CAP - Induction Capture Plasma and Atomic Absorption
Spectrophotometry.
Figure 4-1. Process flow sheet and sampling plan
for Arkansas Lightweight Aggregate Corporation.
4-2
-------
CROSS-SECTION
I
OJ
1.22 M (48") I.D.
6.99 CM (2 3/4")
NIPPLE LENGTH
TRAVERSE
POINT
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
TRAVERSE POINT
FROM OUTSIDE
(INCHES)
3.75
5.97
8.41
11.25
14.75
19.84
33.66
38.75
42.25
45.09
47.53
49.74
LOCATION
OF NIPPLE
ATMOSPHERE
1.22 M
—1.0.-
~2.18 M
(86 IN.)
EXHAUST FROM
CLINKER COOLER
~8.66 M
(431 IN.)
GROUND LEVEL
Figure 4.1-1. Clinker cooler multicyclone outlet.
-------
TRAVERSE
POINT
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
TRAVERSE POINT
FROM OUTSIDE
(INCHES)
5.0
5.90
7.20
8.7
10.2
11.8
13.5
15.4
17.6
20.0
23.0
27.5
39.5
43.9
46.9
49.4
51.5
53.5
55.2
56.8
58.3
59.7
61.1
63.0
CROSS-SECTION
LOCATION /$*^ty\
OF NIPPLE / XX \
1.5 M (59") 1.0.
10.16 M (4")
NIPPLE LENGTH
EXHAUST GASES /* *\
FROM KILN FEED__( I.D. A
AND SETTLING V FAN 7 ~~
CHAMBER V ^/
FLOW /*
0*~-
^FLOW
~75 M
(29.5 IN.)
~3.61 M
(142 IN.)
-»-
PORT USED
FOR INLET
S02 TESTS
/
\
\
SCRUBBER
SLUDGE
Figure 4.2-1. Kiln exhaust scrubber outlet.
-------
90 degrees off center, were located 2.4 duct diameters downstream
and 0.5 duct diameters upstream from the nearest flow distur-
bances in the round stack, the I.D. of which was 1.5 meters (4.9
ft). Forty-eight traverse points, twenty-four per port, were
used to traverse the cross-sectional area of the stack for the
particulate test runs. Each point was sampled for 2.5 minutes,
and total test time was 120 minutes.
Sulfur dioxide and nitrogen oxide sampling were conducted at
constant sampling rates by placing the probe tip near the center
of the stack. The test and analytical procedures used are
described briefly below.
4.3 VELOCITY AND GAS TEMPERATURE
A Type S pitot tube and an inclined draft gauge manometer
were used to measure the gas velocity. Velocities were measured
at each sampling point across the duct to determine an average
value according to the procedures outlined by EPA Method 2.* The
temperature at each sampling point was measured with a thermocou-
ple and potentiometer.
4.4 MOLECULAR WEIGHT
Flue gas composition was determined by EPA Method 3.* A bag
sample was collected during each particulate, sulfur dioxide, and
nitrogen oxide test run. The bag contents were analyzed with an
Orsat Gas Analyzer.
Federal Register, Vol. 42, No. 160, August 18, 1977.
4-5
-------
4.5 PARTICULATE
The test procedure used to measure particulate grain loading
at each final exit stack was EPA Method 5.* All tests were con-
ducted isokinetically by traversing the cross-sectional area of
the stack and regulating the sample flow rate relative to the
flue gas flow rate as measured by the pitot tube attached to the
sample probe. The sampling train used for each test consisted of
a heated, glass-lined probe; a heated glass fiber filter (Gelman
Type AE) with a diameter of 87 mm (3 in.); and a series of Green-
burg-Smith impingers. An acetone rinse of the nozzle, probe, and
filter holder portions of the sample train was made at the end of
each test. The acetone rinse and the particulate caught on the
filter media were dried at room temperature, desiccated to a con-
stant weight, and weighed on an analytical balance. Total fil-
terable particulate matter was determined by adding these two
values. The contents of the impinger section of the sampling
train were recovered and analyzed for organic and inorganic con-
tent by ether-chloroform extraction.
4.6 SULFUR DIOXIDE
The test procedure used was EPA Method 6* except for the
replacement of the midget impingers with a series of Greenburg-
Smith impingers. A heated, glass-lined probe preceded the series
of impingers. A plug of glass wool was placed in the tip of the
probe as well as in the connecting glassware between the first
*
Federal Register, Vol. 42, No. 160, August 18, 1977,
4-6
-------
and second impingers. Each inlet and outlet test consisted of
two 30-minute runs. Each sampling train was purged with ambient
air for 15 minutes after the completion of each test. Contents
of the second and third impingers (3% hydrogen peroxide) were
measured, and analyses for sulfur dioxide content were conducted
on site with the barium-thorin titration method. Contents of the
first impinger (80% isopropanol) were recovered and shipped to
the laboratory for the purpose of investigating possible ammonia
interference.
4.7 NITROGEN OXIDE
Sampling and analytical procedures used followed EPA Method
7.* Three tests consisting of four grab samples taken at approx-
imately 15-minute intervals were conducted on the scrubber exit
stack. Samples were obtained and shipped to the laboratory for
analysis.
4.8 PARTICLE SIZE DISTRIBUTION
Particle size samples were obtained with an Andersen 2000
Mark III Source Cascade Impactor. This is an in-stack, multi-
stage cascade impactor that has a total of eight stages with
particle size cutoffs ranging nominally from 0.5 to 15 microns,
followed by a backup filter stage. Substrates for the Andersen
were glass fiber filters, each 64 mm (2.5 in.) in diameter. A
constant sampling rate was maintained through the test period.
Sampling rates were set for isokinetic sampling as long as the
Federal Register, Vol. 42, No. 160, August 18, 1977,
4-7
-------
sample rate did not exceed the recommended flow rate for the
impactor (0.70 acfm).
A total of nine impactor runs were conducted at each outlet
sampling site. Sampling point locations for each stack were lo-
cated as shown in Figure 4.8-1. At least two impactor runs were
conducted at each sampling point. The procedures used followed
those recommended in "Procedures Manual for Inhalable Particulate
Sampler Operation," recently developed for EPA by the Southern
Research Institute.
4.9 PROCESS SAMPLES
Samples of the coal and clay fed to the kiln were collected
at approximately 20-minute intervals during the particulate sam-
pling. Coal samples were collected after the pulverizer just
prior to entering the kiln. Clay samples were collected from the
kiln feed conveyor belt. Coal samples were analyzed for sulfur
content, density, moisture content, and percent ash. Clay samples
were analyzed for sulfur content, density, and percent moisture.
In addition to the coal and clay, composite samples of the
influent and effluent from the kiln wet scrubber were collected
and analyzed for trace metal content. Samples of the final
aggregate product and dust captured by the clinker cooler multi-
cyclone were also collected and analyzed for sulfur content.
4-8
-------
Figure 4.8-1. Particle size sampling points for circular stack.
4-9
-------
SECTION 5
QUALITY ASSURANCE
Routine quality control procedures for standard reference
methods were followed throughout this test series. These in-
cluded but were not limited to the following:
0 Calibration of gas meters, thermocouples and potentio-
meters, pressure gauges, thermometers, and pitot tubes.
0 Use of designated equipment.
0 Sample train leak checks.
0 Train configuration and calculation checks.
Detailed calibration procedures and results for equipment
used during this test series are contained in Appendix E of this
report.
In addition, the following quality assurance procedures were
implemented to insure valid, reproducible data.
5.1 PARTICULATE
During the third particulate test, duplicate EPA Method 5
trains were run simultaneously on each stack. The results of
these tests are presented in Table 5.1-1. Results from the tests
conducted on the kiln exhaust show good correlation and repro-
ducibility, considering the entire sampling system.
The reliability of the analytical method used to analyze the
filters for particulate and particle size tests was checked by
5-1
-------
TABLE 5.1-1. COMPARATIVE PARTICULATE RESULTS
Run
No.
CCP-3
CCP-4
SOP-3
SOP-4
Date
(1981)
10/22
10/22
Sample
location
Cl inker cooler
exhaust
Kiln exhaust
Filterable
concentration
mg/dscm
107.6
167.8
775.5
882.3
gr/dscf
0.047
0.073
0.3388
0.3855
Condensible concentration
Inorc
mg/dscm
0.94
3.90
322.6
237.7
amc
gr/dscf
0.0004
0.0017
0.141
0.104
Organic
mg/dscm
1.1
2.2
4.6
3.3
gr/dscf
0.0005
0.0010
0.0024
0.0014
Total
concentration
mg/dscm
109.6
173.9
1103.6
1123.0
gr/dscf
0.0479
0.0757
0.4822
0.4909
en
I
to
Total concentration is the sum of the filterable and condensible concentration.
-------
resubmitting sets of filters, preweighed in the lab, for repli-
cate analysis. Table 5.1-2 summarizes the results of a blank
filter analysis. The results of the blank filter analysis show
good data reproducibility from an analytical standpoint.
5.2 SULFUR DIOXIDE
Audit solutions prepared by EPA were used to check the
analytical procedure and reagents prior to onsite sample anal-
ysis. The results of the analytical audit conducted onsite are
presented below:
Audit solution Measured
Audit sample concentration, concentration, Percent
lot No. ppm ppm difference
0680-1 85.9 86 +0.1
0680-3 429.5 426 -0.8
In addition, calculations relating the theoretical quantity of
SO generated from the combustion of pulverized coal to the quan-
tity of S02 measured at the scrubber inlet show good correlation.
5.3 NITROGEN OXIDE
Audit solutions prepared by EPA were used to check the ana-
lytical procedure and reagents prior to laboratory analysis. The
results of the analytical audit are presented in Table 5.3-1.
5-3
-------
TABLE 5.1-2. EXAMPLE BLANK FILTER ANALYSIS
Sample type and
filter number
Participate -
87-mm Gelman AE
# 0002003
# 0002011
Particle size -
64-mm Reeve
Angel 934 AH
K-83
N-06
K-85
N-92
K-07
N-98
K-67
N-44
B-25
Original tare
weight, mg
357.6
359.7
143.1
140.6
132.3
134.7
144.6
137.4
132.0
134.6
180.6
Blank weight,
mg
358.2
359.9
144.1
140.9
132.3
134.6
145.1
138.0
132.8
135.0
181.1
Net weight,
mg
+0.6
+0.2
+1.0
+0.3
0.0
-0.1
+0.5
+0.6
+0.8
+0.4
+0.5
5-4
-------
TABLE 5.3-1. NO ANALYTICAL AUDIT RESULTS
x
Sample
No.
1293
3251
4535
Audit
concentration,
mg N0?/dscm
99.54
796.31
248.79
Measured
concentration,
mg NOp/dscm
101.2
772.8
245.4
Difference,
%
+1.7
-3.0
-1.4
5-5
-------
SECTION 6
DISCUSSION OF RESULTS
Overall, the sampling program was executed as planned and no
major problems occurred with either test equipment or sampling
activities. In addition, the process operation was characterized
as normal throughout the test period by plant personnel and the
NSPS contractor.
The feedwater pump serving the kiln exhaust scrubber malfunc-
tioned during the second particulate test and periodically
throughout the third test. This malfunctioning probably decreased
the overall particulate removal efficiency of the scrubber and
thus significantly increased particulate concentrations and emis-
sion rates. Both the particulate and the visible emission re-
sults from the source support this conclusion.
Because no obvious malfunctions or process modifications
occurred with the clinker cooler and/or its control device, the
particulate and particle size data appear representative of emis-
sions from the source. It should be noted that the organic con-
centration measured in the back half of the EPA Method 5 sample
trains from both sources was negligible.
The SO- results obtained from tests conducted at the inlet
to the kiln exhaust scrubber are compatible with theoretical cal-
culations of the quantity of S02 generated from the combustion of
coal. Analyses of the final product and the catch from the
6-1
-------
clinker cooler multicyclone hopper indicate that a Icirge percent-
age of sulfur in the clay feed material remains in the clay as it
is processed. Therefore, it is reasonable to conclude that SO-
emissions from this source are caused primarily by the combustion
of pulverized coal in the kiln.
Initially, NO concentrations were expected to be negligi-
X.
ble. The test data, however, show that NO emissions are poten-
X
tially significant and are generated from the combustion of coal
in the kiln.
6-2
-------
REFERENCES
1. Southern Research Institute. Procedures Manual for Inhalable
Particulate Sampler Operation. Prepared for EPA under Con-
tract No. 68-02-3118. November 1979.
2. Southern Research Institute. A Computer-Based Cascade Im-
pactor Data Reduction System. Prepared for EPA under Con-
tract No. 68-02-2131. March 1978.
R-l
------- |