&EPA
United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EMB Report 80-LWA-3
Air
Lightweight Aggregate
Industry
(Clay, Shale, and Slate)
Emission Test Report
Texas Industries, Inc.
Clodine, Texas
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0 EMISSION TEST REPORT °
METHOD DEVELOPMENT AND TESTING FOR
CLAY, SHALE, AND SLATE AGGREGATE INDUSTRY:
Texas Industries, Inc.
Clodine, Texas
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
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CONTENTS
Figures iv
Tables v
Quality Assurance Element Finder
1. Introduction 1-1
2. Process Operation 2-1
3. Summary of Results 3-1
Rotary kiln exhaust-scrubber 3-1
Clinker cooler exhaust-fabric filter 3-14
Process samples 3-29
Fugitive emissions from the kiln 3-31
4. Sample Locations and Test Methods Used 4-1
Kiln exhaust scrubber outlet 4-1
Clinker cooler fabric filter inlet 4-4
Clinker cooler fabric filter outlet 4-4
Velocity and gas temperature 4-7
Molecular weight 4-7
Particulate 4-7
Sulfur dioxide 4-8
Nitrogen oxides 4-9
Particle size distribution 4-9
Process samples 4-n
Volatile organic carbon sampling ' 4-11
5. Quality Assurance 5-1
6. Discussion of Results 6-1
References R-l
11
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Appendix A
Appendix B
Appendix C
Appendix D
Appendix E
Appendix F
Appendix G
CONTENTS (continued)
Page
Computer printout and example calculation A-l
Raw field data B-l
Raw laboratory data C-l
Sampling and analytical procedures D-l
Calibration procedures and results E-l
Quality assurance summary F-l
Project participants and sampling log G-l
111
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FIGURES
Number Paqe
3.1-1 Particle Size Distribution - Kiln Exhaust
Scrubber Outlet 3-7
3.2-1 Particle Size Distribution - Clinker Cooler
Exhaust - Fabric Filter Inlet 3-21
3.2-2 Particle Size Distribution - Clinker Cooler
Exhaust - Fabric Filter Outlet 3-22
4-1 Process Flow Sheet 4-2
4.1-1 Kiln Exhaust Scrubber Outlet 4-3
4.2-1 Clinker Cooler Fabric Filter Inlet 4-5
4.3-1 Clinker Cooler Fabric Filter Outlet 4-6
4.9-1 Particle Size Sampling Points for Circular
Stack 4-10
5-1 Example Meter Box Audit Calculation 5-5
5-2 Example Meter Box Audit Calculation 5-6
5-3 Example Meter Box Audit Calculation 5-7
IV
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TABLES
Number Page
3.1-1 Summary of Flue Gas Conditions - Kiln Exhaust 3-3
3.1-2 Summary of Particulate Emission Data - Kiln
Exhaust 3-4
3.1-3 Summary of Sulfur Dioxide Results- Kiln
Exhaust 3-9
3.1-4 Summary of Nitrogen Oxide Emission Data - Kiln
Exhaust 3-11
3.1-5 Summary of Visible Emissions Data - Kiln
Exhaust 3-13
3.2-1 Summary of Flue Gas Conditions - Clinker Cooler
Fabric Filter Inlet 3-15
3.2-2 Summary of Flue Gas Conditions - Fabric Filter
Outlet 3-16
3.2-3 Summary of Particulate Emission Data - Fabric
Filter Inlet 3-17
3.2-4 Summary of Particulate Emission Data - Fabric
Filter Outlet 3-18
3.2-5 Summary of Visible Emissions Data - Clinker
Cooler Exhaust 3-24
3.2-6 Summary of Sulfur Dioxide Results - Fabric
Filter Inlet 3-25
3.2-7 Summary of Nitrogen Oxide Results - Fabric
Filter Outlet 3-27
3.2-8 VOC Monitoring Data - Fabric Filter Outlet. 3-28
3.3-1 Summary of Process Sample Analysis 3-30
3.3-2 Summary of Trace Metal Analysis 3-32
v
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TABLES (continued)
Number Page
5-1 Particulate Equipment Calibration Summary 5-3
5-2 Example Blank Filter and Reagent Analysis 5-8
5-3 Audit Report - S02 Analysis 5-9
5-4 Audit Report - NO Analysis 5-10
JC
VI
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QUALITY ASSURANCE ELEMENT FINDER
Title page
Table of contents
Project description
QA objective for measurement of data in
terms of precision, accuracy, completeness,
representativeness, and comparability
Sampling procedures
Sample custody
Calibration procedures and frequency
Analytical procedures
Data reduction, validation, and
reporting
Internal quality control checks and
frequency
Performance and system audits and
frequency
Preventive maintenance procedures and
schedules
Specific routine procedures used to
assess data precision, accuracy, and
completeness of specific measurement
parameters involved
Corrective action
Quality assurance reports to management
Location
Section Page
11
1 1-1
Appendix F F-2
Appendix D D-l
Appendix C C-l
Appendix E E-l
Appendix D D-l
Appendix F F-2
Appendix F F-5
Appendix F F-3
Appendix F F-6
Appendix F F-4
Appendix F F-5
Appendix F F-6
VII
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SECTION 1
INTRODUCTION
During the week of February 22, 1981, PEDCo Environmental
personnel conducted an emission sampling program at Texas Indus-
tries, Inc., (TXI) lightweight aggregate facility located in
Clodine, Texas. The purpose of this test program was to provide
data to assess the need for New Source Performance Standards
(NSPS) emission 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 rea-
sons :
1. The plant is one of the best controlled coal-fired
lightweight aggregate plants that use wet scrubbers,
dry cyclones, and fabric filters for emissions 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
detailed below:
0 Coal-fired rotary kiln (No. 3) whose emissions are
controlled by a medium-energy wet scrubber and,
0 Reciprocating grate clinker cooler whose emissions are
controlled by a dry multicyclone and a fabric filter.
Particulate concentrations and mass emission rates were
measured at the final exit stack serving the kiln and at the
inlet to and outlet from the fabric filter serving the clinker
1-1
-------
cooler by U.S. Environmental Protection Agency (EPA) Method 5.*
Flue gas flow rates, temperature, moisture content, and composi-
tion [oxygen (0-), carbon dioxide (CO-)/ and carbon monoxide
(CO)] were measured in conjunction with the particulate tests.
Sulfur dioxide (SO-) concentrations and mass emission rates were
measured at the inlet to and outlet from the wet scrubber serving
the kiln and at the inlet to the fabric filter serving the
clinker cooler by EPA Method 6.* Nitrogen oxides (NO ) concen-
J\
tration in the flue gas exiting the scrubber and the fabric
filter was also determined by EPA Method 7.* In addition, the
particle size distribution of particulate matter exiting the kiln
scrubber and the clinker cooler was determined. Volatile organic
carbon (VOC) content of the exit gas from the kiln and clinker
cooler control devices was determined using a continuous hydro-
carbon monitor with a flame ionization detector (FID). Visible
emission observations were made on each exit stack during the
particulate tests by EPA Method 9.* Additionally, a visible
determination of fugitive dust emissions from the kiln seals (raw
charge and product charge) was made during each particulate test
by proposed EPA Method 22.**
Representative samples of the kiln feed material (clay) and
coal used to fire the kiln were collected during each particulate
test for determination of sulfur content, moisture, density, and
ash content (coal only). In addition, composite samples of the
*
40 CFR 60, Appendix A, Reference Methods 5, 6, 7, and 9, July 1,
1980.
**
45 FR, pp. 76426-9.
1-2
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coal and clay were analyzed for trace metal content. Samples of
the scrubber water effluent and final aggregate product were also
collected for trace metal and sulfate analyses.
Messrs. Jeff Shuler, Rick Cooper, and Lalit Banker [Midwest
Research Insitute (MRI)] monitored process operation and col-
lected process samples throughout the test period. Mr. Jay
Lindholm, TXI, observed the test program and assisted in process
sample collection.
1-3
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SECTION 2
PROCESS OPERATION
The TXI plant in Clodine, Texas, operates three kiln lines
for clay aggregate production. Testing was conducted on the
newest process line, Kiln No. 3, and its associated pollution
control equipment.
The kiln process is continuous and operates 24 hours per
day, 7 days per week, except for required maintenance periods.
The kiln can be fired with either natural gas or pulverized coal.
All tests were conducted while the kiln was burning coal.
Exhaust gases from the feed end of the kiln are treated in a
low energy wet scrubber (W.W. Sly Impinjet) to remove particu-
late.
The other major process equipment on this line is a recipro-
cating grate clinker cooler. Clinker cooler emissions are con-
trolled by a multicyclone dust collector followed by a fabric
filter.
Specific production data and coal consumption figures are
maintained in a confidential file in the office of the Emission
Standards and Engineering Division, U.S. EPA. Process data were
collected by personnel from MRI.
2-1
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SECTION 3
SUMMARY OF RESULTS
This section details results obtained from the emission
sampling program. All emission samples and plume observation
(visible emission) data were collected simultaneously from the
kiln and clinker cooler sources. Results are reported separately
for each source.
Example calculations are contained in Appendix A. Raw field
and laboratory data sheets are contained in Appendices B and C.
Appendix D details the sampling and analytical procedures used
during this test program. Equipment calibration procedures and
results are contained in Appendix E. Appendix F addresses
quality assurance considerations pertinent to this test project.
A list of project participants is given in Appendix G.
3.1 ROTARY KILN EXHAUST
Particulate and particle size tests were conducted on the
kiln exhaust scrubber exit stack. Visible emission observations
were also performed during each particulate test. In addition,
S02 tests were simultaneously conducted before and after the wet
scrubber. NO tests were conducted concurrently with the SO-
ji &
tests on the scrubber exit stack. Tests were also conducted to
determine the VOC content of the exit gas stream.
3-1
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Particulate sampling and analytical procedures followed
those described in EPA Method 5 of the Federal Register* except
that an ether-chloroform extraction was performed on the impinger
contents to determine condensible organic and inorganic frac-
tions. Particle size sampling and analytical procedures followed
those described in "Procedures Manual for Inhalable Particulate
Sampler Operation" recently developed for EPA by Southern Re-
search Institute. S02 sampling and analytical procedures
followed those described in EPA Method 6* except that large
impingers were used instead of the midget impingers described in
Method 6. NO sampling and analytical procedures followed those
A.
described in EPA Method 7.* Visible emission observations were
conducted using procedures described in EPA Method 9 of the
Federal Register.* VOC content was determined using an FID.
3.1.1 Flue Gas Conditions and Particulate Emissions
Summaries of the measured flue gas and particulate emission
data 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) and 0% moisture] are expressed as dry standard
cubic meters per hour (dscmh) and dry standard cubic feet per
hour (dscfh). Particulate concentrations are reported in milli-
grams per dry standard cubic meter (mg/dscm) and grains per dry
standard cubic foot (gr/dscf). Emission rates are expressed in
kilograms per hour (kg/h) and pounds per hour (Ib/h). The
40 CFR 60, Appendix A, Reference Methods 5, 6, 7, and 9, July 1,
1980.
3-2
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TABLE 3.1-1. SUMMARY OF FLUE GAS CONDITIONS
KILN EXHAUST SCRUBBER OUTLET
Run
No.
SOM5-1
SOM5-2
SOM5-3
Date
(1981)
2/23
2/23
2/24
Average
Volumetric flow rate
Actual3
acmh
51 ,487
52,212
52,262
51 ,987
acfh
1,818,251
1,843,829
1,845,611
1,835,897
Standard
dscmh
35,873
37,296
35,222
36,130
dscfh
V, 266, 836
1,317,104
1,243,849
1,275,930
Temperature
°C
78
78
81
79
°F
172
173
178
174
Moisture
%
17.5
15.2
19.3
17.3
°2'
%^
15.2
15.8
15.2
15.4
co7,
5T
4.0
3.8
4.0
3.9
CO,
%
0.0
0.0
0.0
0.0
tJ
I
Volumetric flow rate in actual cubic meters per hour (acmh) and actual cubic feet per hour (acfh) at
stack conditions.
Volumetric flow rate 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.) and 0% moisture.
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TABLE 3.1-2. SUMMARY OF PARTICULATE EMISSIONS DATA
KILN EXHAUST SCRUBBER OUTLET
Run
No.
SOM5-1
SOM5-2
SOM5-3
Date
(1981)
2/23
2/23
2/24
Average
Concentration
Filterable
mg/dscm
90.3
90.2
108.3
96.3
gr/dscf
0.0395
0.0394
0.0473
0.0421
Condensible
Organic
mg/dscm
1.8
1.9
1.2
1.6
gr/dscf
0.0008
0.0008
0.0005
0.0007
Inorganic
mg/dscm
30.7
28.5
33.9
31.0
gr/dscf
0.0134
0.0124
0.0148
0.0135
Mass emission rate
Filterable
kg/h
3.2
3.4
3.8
3.5
Ib/h
7.1
7.4
8.4
7.6
Condensible
Organic
kg/h
.06
.07
.04
.06
Ib/h
.14
.16
.09
.13
Inorganic
kg/h
1.1
1.1
1.2
1.1
Ib/h
2.4
2.3
2.6
2.4
Concentration in milligrams per dry standard cubic meter (mg/dscm) and grains per dry standard cubic
foot (gr/dscf).
DMass emission rate in kilograms per hour (kg/h) and pounds per hour (Ib/h).
-------
product of the concentration and the volumetric flow rate is the
mass emission rate. The filterable particulate data in Table
3.1-2 represents 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 repre-
sent 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 36,100 dscmh (1,276,000
dscfh) with an average temperature of 79 °C (174°F). The moisture
content averaged 17.3 percent; and the oxygen, carbon dioxide,
and carbon monoxide contents average 15.4, 3.9, and 0.0 percent,
respectively.
Filterable particulate concentration averaged 96 mg/dscm
(0.04 gr/dscf) with a corresponding average mass emission rate of
3.5 kg/h (7.6 Ib/h). The organic and inorganic concentrations
averaged 1.6 mg/dscm (0.0007 gr/dscf) and 31 mg/dscm (0.0135 gr/
dscf) with corresponding average mass emission rates of 0.06 kg/h
(0.13 Ib/h) and 1.1 kg/h (2.4 Ib/h).
It should be noted that there was a longitudinal crack in
the stack wall approximately 0.9 m (3 ft) in length, located
approximately 2m (6 to 8 ft) upstream of the sampling ports.
Duct tape was used to seal the crack prior to testing. This
crack probably caused some in-leakage of ambient air. However,
it is felt that this caused no bias in the emission results.
3-5
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3.1.2 Particle Size Distribution
A total of five 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
sampling data to obtain the moisture content and gas composition
in order to determine the flow rate of the stack gas through the
impactor.
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 are contained
in Appendix A of this report.
Figure 3.1-1 presents the average distribution curve for the
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 speci-
fied number of test runs. All particle size results are based on
aerodynamic diameters and unit density (1 g/cm^). The data point
distribution for these runs indicate that 50 percent of the
particles by weight (cut size) were less than 2.1 microns in
diameter. The calculated mass grain loading averaged 106 mg/dscm
(0.046 gr/dscf) which compares favorably with the mass loading
obtained from the particulate tests.
3-6
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SOPS-2 •
SOPS-3 o
SOPS-4 *
SOPS-5 •
PARTICLE SIZE, microns
Figure 3.1-1. Particle size distribution, kiln exhaust scrubber outlet.
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3.1.3 Sulfur Dioxide
Table 3.1-3 presents a summary of results for S02 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 [36,130 dscmh ( 1,275,930 dscfh)].
The inlet mass emission rates were calculated from the measured
concentrations and the average outlet flow rate corrected for
excess air for each individual SO2 test run. Analysis was con-
ducted on site by EPA Method 6.*
Sulfur dioxide concentration at the inlet to the wet scrub-
ber averaged 724 mg/dscm (275 ppm; 4.52 x 10 Ib/dscf) with a
corresponding average mass emission rate of 21.0 kg/h (46.3
Ib/h). Run SIM6-6 is considered an outlier and is not included
in the overall data averages. Flue gas temperature averaged
338°C (640°F) with an average oxygen content of 15.1 percent.
Sulfur dioxide concentrations at the scrubber exit stack
averaged 511 mg/dscm (194 ppm; 3.19 x 10 Ib/dscf) with a cor-
responding average mass emission rate of 18.5 kg/h (40.7 Ib/h).
Flue gas temperature averaged 77°C (170°F). Oxygen content aver-
aged 16.2 percent.
40 CFR 60, Appendix A, Reference Method 6, July 1, 1980.
3-8
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TABLE 3.1-3. SUMMARY OF SULFUR DIOXIDE DATA
Run
No.
SIM6-1
SIM6-2
Date
(1981)
2/26
2/26
Sample
location
Kiln exhaust scrubber
inlet
Average
SIM6-3
SIM6-4
2/26
2/26
Kiln exhaust scrubber
inlet
Average
SIM6-5
SIM6-6
2/26
2/26
Kiln exhaust scrubber
inlet
Average
SOM6-1
SOM6-2
2/26
2/26
Kiln exhaust scrubber
outlet3
Average
SOM6-3
SOM6-4
2/26
2/26
Kiln exhaust scrubber
out! eta
Average
SOM6-5
SOM6-6
2/26
2/26
Kiln exhaust scrubber
outlets
Average
Concentration
ppm
273
286
280
299
267
283
251
88*
251
183
194
189
214
185
200
186
204
195
mg/dscm
718
753
736
785
702
744
660
231*
660
481
509
495
562
485
524
.489
537
513
Ib/dscf x 10-^5
4.48
4.70
4.59
4.90
4.38
4.64
4.12
1.44*
4.12
3.00
3.18
3.09
3.51
3.03
3.27
3.05
3.35
3.20
Mass
emission rate
kg/h
19.9
19.8
19.9
24.3
21.7
23.0
19.2
6.7*
19.2
17.4
18.4
17.9
20.3
17.5
18.9
17.7
19.4
18.6
Ib/h
43.9
43.7
43.8
53.6
48.0
50.8
42.2
14.7*
42.2
38.3
40.5
39.4
44.8
38.7
41.8
38.9
42.8
40.9
0?,
%
15.3
15.0
15.2
15.3
15.3
15.3
14.8
14.8
14.8
16.6
16.6
16.6
16.1
16.1
16.1
16.0
16.0
16.0
Temperature
°C
338
338
338
338
338
338
338
338
338
77
77
77
77
77
77
77
77
77
°F
640
640
640
640
640
640
640
640
640
170
170
170
170
170
170
170
170
170
CO
I
10
Mass emission rates in kilograms per hour (kg/h) and pounds per hour (Ib/h) calculated using average
measured flow obtained from the particulate tests [36,130 dscmh (1,275,930 dscfh)].
*0utlier - not included in averages.
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3.1.4 Nitrogen Oxides
Table 3.1-4 summarizes nitrogen oxides emission data. Three
tests, each consisting of four grab samples collected at fifteen
minute intervals, were conducted on the kiln exhaust scrubber
outlet. Concentrations are reported in milligrams per dry
standard cubic meter (mg/dscm), parts per million by volume
(ppm), and pounds per dry standard cubic foot (Ib/dscf). Emis-
sion 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 tests and corrected to
standard conditions [36,130 dscmh (1,275,930 dscfh)].
Nitrogen oxides concentrations averaged 287 mg/dscm (150
-4
ppm; 0.18 x 10 Ib/dscf) with a corresponding mass emission rate
of 10.4 kg/h (23 Ib/h).
3.1.5 Volatile Organic Carbon (VOC)
Hydrocarbon monitoring was conducted at the kiln scrubber
outlet from 13:06 to 14:00 on February 26, 1981. The detection
range on the continuous FID was set at 0 to 1000 parts per mil-
lion (ppm) by volume throughout the monitoring period. Gas
standards of 399.9 ppm and 891 ppm methane were used to calibrate
the monitor. Zero air containing less than 0.1 ppm total hydro-
carbon was used to set the instrument baseline.
Some problems occurred during the sampling due to high mois-
ture content of the scrubber outlet system. Though the sample
line and probe were heated sufficiently to prevent moisture con-
densation, the internal temperature of the monitor was not high
3-10
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TABLE 3.1-4. SUMMARY OF NITROGEN OXIDES EMISSIONS DATA
KILN EXHAUST SCRUBBER OUTLET
Run
No.
1
Date
(1981)
2/26
Sample
No.
SON1A
SON1B
SONIC
SON1D
Average
2
2/26
SON2A
SON2B
SON2C
SON2D
Average
3
2/26
SON3A
SON3B
SON3C
SON3D
Average
Concentration a
ppm
147
172
170
139
157
140
141
151
157
147
158
121
153
150
146
mg/dscm
282
330
325
266
301
268
270
289
300
282
302
231
294
287
279
Ib/dscf x 10-*
0.1758
0.2058
0.2031
0.1661
0.1877
0.1674
0.1683
0.1803
0.1870
0.1758
0.1886
0.1441
0.1832
0.1791
0.1738
Mass u
emission rate
kg/h
10.2
11.9
11.8
9.6
10.9
9.7
9.7
10.4
10.8
10.2
10.9
8.3
10.6
10.4
10.1
Ib/h
22.4
26.3
25.9
21.2
24.0
21.4
21.5
23.0
23.9
22.5
24.1
18.4
23.4
22.9
22.2
Concentrations of NO/ as N02 in parts per million (ppm) by volume, milligrams
per dry standard cubic meter (mg/dscm), and pounds per dry standard cubic
foot (Ib/dscf).
3Mass emission rate in kilograms per hour (kg/h) and pounds per hour (Ib/h)
calculated using average measured flow obtained from the particulate tests
[36,130 dscmh (1,275,930 dscfh)].
3-11
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enough to prevent a moisture buildup in the sample rotameter.
This created problems with the hydrogen flame and, subsequently,
only one hour of hydrocarbon monitoring data was obtained.
During the hour of continuous monitoring, the hydrocarbon
concentrations varied from 140 ppm to 220 ppm with an average
concentration of 175 ppm as methane. This average concentration
corresponds to an emission rate of 4.2 kg/h (9.3 Ib/h) base:d on
the measured flow rate of 36,130 dscmh (1,275,930 dscfh) and the
molecular weight of methane (16 Ib/lb mole). As the methane
content was not measured separately, this concentration may
include some methane. A copy of the strip chart printout for
this test is in Appendix B.
3.1.6 Visible Emissions
Visible emissions surveys were conducted at the kiln scrub-
ber outlet during each particulate test. Visible emissions were
read in 6-minute sets throughout each particulate test. Table
3.1-5 contains a summary of visible emissions for the scrubber
outlet. Opacities during Test 1 ranged from 0 to 15 percent,
with an average of 5 percent for all sets. During Test 2,
opacities ranged from 5 to 10 percent, with an average of 8
percent for all sets. Opacities observed during Test 3 ranged
from 0 to 15 percent, with an average of 3 percent for all sets.
During the fabric filter repeat test opacities ranged from 0
to 10 percent, with an average of 6 percent for all sets.
3-12
-------
TABLE 3.1-5.
SUMMARY OF VISIBLE EMISSIONS DATA
- SCRUBBER OUTLET -
February 23, 1981
Test 1
Test 2
Set No.
SOVE-1-1
SOVE-1-2
SOVE-1-3
SOVE-1-4
SOVE-1-5
SOVE-1-6
SOVE-1-7
Time
1030-1035
1049-1054
1107-1112
1124-1129
1144-1149
1206-1211
1225-1230
Average
% opacity
3
5
4
5
5
7
9
Range
0-5
0-10
0-5
5-10
5-10
5-10
5-15
Set No.
SOVE-2-1
SOVE-2-2
SOVE-2-3
SOVE-2-4
SOVE-2-5
SOVE-2-6
SOVE-2-7
Time
1512-1517
1535-1540
1552-1557
1612-1617
1630-1635
1647-1652
1703-1708
Average
% opacity
8
9
9
7
8
10
8
Range
5-10
5-10
5-10
5-10
5-10
10
5-10
Test 3
February 24, 1981
Test 4 (Repeat test)*
SOVE-3-1
SOVE-3-2
SOVE-3-3
SOVE-3-4
SOVE-3-5
SOVE-3-6
SOVE-3-7
0912-0917
0931-0936
0947-0952
1004-1009
1024-1029
1040-1045
1100-1105
0
0
0
2
3
5
10
0
0
0-5
0-5
0-5
0-10
5-15
SOVE-4-1
SOVE-4-2
SOVE-4-3
SOVE-4-4
SOVE-4-5
SOVE-4-6
1345-1350
1402-1407
1421-1426
1440-1445
1500-1505
1520-1525
4
9
9
9
1
1
0-5
5-10
5-10
5-10
0-5
0-5
*Tests repeated on fabric filter after completion of tests at scrubber.
observations continued on scrubber exit stack.
VE
3-13
-------
3.2 CLINKER COOLER EXHAUST
Particulate and particle size distribution tests were con-
ducted simultaneously at the inlet to and outlet from the Aero-
pulse fabric filter serving the clinker cooler. Visible emission
observations were made at the fabric filter outlet during each
particulate test. In addition, sulfur dioxide (SO,,) tests were
conducted at the fabric filter inlet while nitrogen oxides (NO )
X
and volatile organic carbon (VOC) concentrations were measured at
the fabric filter outlet to quantify these emissions. It should
be noted that during the first day of testing (2/23), two sets of
particulate tests were run simultaneously at each location. The
initial outlet test was voided due to an excessive post-test leak
rate while the initial inlet test was acceptable. The second
inlet test was voided due to an excessive post-test leak rate
while the second outlet test was acceptable. Therefore, the
initial inlet test and the second outlet test, though not run
simultaneously, are shown as such for data reporting purposes.
The sample procedures used to perform these tests are
described in Section 3.1 of this report. Concentration and mass
emission rate data are expressed in units identical to those used
in Section 3.1.
3.2.1 Flue Gas Conditions and Particulate Emissions
Tables 3.2-1 and 3.2-2 summarize the flue gas conditions
monitored in conjunction with the particulate tests at the fabric
filter inlet and outlet test locations, respectively. Tables
3.2-3 and 3.2-4 present the particulate emissions data for each
location.
3-14
-------
TABLE 3.2-1. SUMMARY OF FLUE GAS CONDITIONS
CLINKER COOLER FABRIC FILTER INLET
Run
No.
BIM5-1
BIM5-3
BIM5-4
Date
(1981)
2/23
2/24
2/24
Average
Volumetric flow rate
Actual9
acmh
37,678
38,627
38,756
38,354
acfh
1,330,578
1,364,079
1,368,664
1,354,440
Standardb
dscmh
29,705
29,383
28,106
29,065
dscfh
1,049,024
1,037,659
992,545
1,026,409
Temperature
°C
98
109
128
112
°F
209
228
263
234
Moisture,
%
<1.0
1.1
1.1
1.0
o2,
r
19.6
20.2
20.3
20.0
co?,
IT
0.0
0.3
0.0
0.1
CO,
%
0.0
0.0
0.0
0.0
Ul
Volumetric flow rate in actual cubic meters per hour (acmh) and actual cubic feet per hour (acfh) at
stack conditions.
Volumetric flow rate 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) and 0% moisture.
-------
TABLE 3.2-2. SUMMARY OF FLUE GAS CONDITIONS
CLINKER COOLER FABRIC FILTER OUTLET
Run
No.
BOM5-2
BOMS -3
BOM5-4
Date
(1981)
2/23
2/24
2/24
Average
Volumetric flow rate
Actual3
acmh
46,108
45,895
45,559
45,854
acfh
1,628,217
1,620,754
1,608,881
1,619,284
Standard
dscmh
37,537
36,981
35,693
36,737
dscfh
1,325,599
1,305,979
1,260,476
1,297,351
Temperature
°C
85
90
100
92
°F
185
194
212
197
Moisture,
%
1.1
<1.0
<1.0
<1.0
S"
19.6
20.2
20.3
20.0
C02,
%
0.0
0.3
0.0
0.1
CO,
%
0.0
0.0
0.0
0.0
OJ
Volumetric flow rate in actual cubic meters per hour (acmh) and actual cubic feet per hour (acfh) at
stack conditions.
'Volumetric flow rate 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).
-------
TABLE 3.2-3. SUMMARY OF PARTICULATE EMISSIONS
CLINKER COOLER FABRIC FILTER INLET
Run
No.
BIM5-1
BIM5-3
BIM5-4
Date
(1981)
2/23
2/24
2/24
Average
Concentration
Filterable
mg/dscm
193.8
172.8
195.2
187.3
gr/dscf
0.0847
0.0755
0.0853
0.0818'
Condensible
Organic
mg/dscm
0.64
0.16
1.50
0.77
gr/dscf
0.0003
0.0001
0.0007
0.0004
Inorganic
mg/dscm
1.17
0.16
0.37
0.57
gr/dscf
0.0005
0.0001
0.0002
0.0003
Mass emission rate
Filterable
kg/h
5.8
5.1
5.5
5.5
Ib/h
12.7
11.2
12.1
12.0
Condensible
Organic
kg/h
0.020
0.005
0.040
0,022
Ib/h
0.04
0.01
0.09
0.05
Inorganic
kg/h
0.030
0.005
0.010
0.015
Ib/h
0.08
0.01
0.02
0.04
CJ
H
-J
Concentration in milligrams per dry standard cubic meter (mg/dscm) and grains per dry standard cubic foot
(gr/dscf).
Mass emission rate in kilograms per hour (kg/h) and pounds per hour (Ib/h).
-------
TABLE 3.2-4. SUMMARY OF PARTICULATE EMISSIONS
CLINKER COOLER FABRIC FILTER OUTLET
Run
No.
BOM5-2
BOM5-3
BOM5-4
Date
(1981)
2/23
2/24
2/24
Average
Concentration a
Filterable
mg/dscm
6.3
5.7
8.2
6.7
gr/dscf
0.0027
0.0025
0.0036
0.0029
Condensible
Organic
mg/dscm
0.82
2.33
3.40
2.18
gr/dscf
0.0004
0.001
0.0015
0.001
Inorganic
mg/dscm
0.49
0.11
4.87
1.82
gr/dscf
0.0002
<0.0001
0.0021
0.0008
Mass emission rate
Filterable
kg/h
0.23
0.21
0.29
0.24
Ib/h
0.52
0.47
0.64
0.54
Condensible
Orqanic
kg/h
0.03
0.09
0.12
0.08
Ib/h
0.07
0.19
0.27
1.77
Inoraanic
kg/h
0.020
0.004
0.170
0.065
Ib/h
0.040
0.009
0.383
0.144
00
Concentration in milligrams per dry standard cubic meter (mg/dscm) and grains per dry standard cubic foot
(gr/dscf).
Mass emission rate in kilograms per hour (kg/h) and pounds per hour (Ib/h).
-------
At the fabric filter inlet, the volumetric flow rate aver-
aged 29,100 dscmh (1,026,000 dscfh) with temperature and moisture
contents averaging 112°C (234°F) and 1.0 percent, respectively.
Oxygen and carbon dioxide contents averaged 20.0 and 0.1 percent,
respectively. Filterable particulate concentration averaged 187
mg/dscm (0.082 gr/dscf) with a corresponding mass emission rate
of 5.5 kg/h (12 Ib/h). The condensible organic and inorganic
concentrations averaged 0.77 mg/dscm (0.0004 gr/dscf) and 0.57
mg/dscm (0.0003 gr/dscf), respectively. The corresponding mass
emission rates averaged 0.02 kg/h (0.05 Ib/h) for each fraction.
At the fabric filter outlet, the volumetric flow rate aver-
aged 36,700 dscmh (1,297,000 dscfh) with temperature and moisture
contents averaging 92°C (197°F) and less than 1 percent, respec-
tively. Oxygen and carbon dioxide contents averaged 20.0 a,nd 0.1
percent. Prior to conducting tests at this location, measure-
ments were obtained to determine the degree of turbulent flow in
the stack as detailed in Method 2 of the Federal Register.*
Each traverse point was checked by aligning the face openings of
the pitot tube perpendicular to the stack cross-sectional plane;
designated "0° reference." Null (zero) pitot readings obtained
at 0° reference indicated an acceptable flow condition at a given
point. Several traverse points exhibited unacceptable (>10°
angular rotation to obtain null reading) flow characteristics.
However, the overall average for all points was less than 10°
indicating an acceptable flow condition existed in the stack.
Turbulent flow conditions of this type would tend to bias the
40 CFR 60, Appendix A, Reference Method 2, July 1, 1980.
3-19
-------
velocity measurements high thus explaining the approximately 20
percent discrepancy in inlet and outlet flow measurements.
Filterable particulate concentration averaged 6.7 mg/dscm (0.003
gr/dscf) with a corresponding mass emission rate of 0.24 kg/h
(0.54 Ib/h). The condensible organic and inorganic concentra-
tions averaged 2.2 mg/dscm (0.001 gr/dscf) and 1.8 mg/dscm
(0.0008 gr/dscf), respectively. Organic and inorganic mass
emission rates averaged 0.08 kg/h (1.8 Ib/h) and 0.07 kg/h (0.14
Ib/h).
The particulate removal efficiency of the fabric filter
averaged 96.4 percent based on the average inlet and outlet, par-
ticulate concentrations on a mg/dscm basis.
3.2.2 Particle Size Distribution
A total of five samples each were collected from the fabric
filter inlet and outlet test locations. The first test at each
site was a preliminary run and is not considered representative;
therefore, it is not included in the overall data averages. The
sampling and analytical procedures as well as the data reduction
technique are described in Section 3.1.2 and Appendix A of this
report.
Figures 3.2-1 and 3.2-2 present the distribution curvess for
each set of four samples collected at the inlet and outlet test
locations. Individual data points for each test were plotted
manually. The distribution curve was plotted manually and repre-
sents the best-fit average curve for the specified number of test
runs. All particle size results are based on aerodynamic diam-
eters and unit density (1 g/cm ).
3-20
-------
ro
•M
•M
W.I
40
M
to
10
s
t
1
•.1
-tt
ill
i
tli?
m
ia
! i-
iU
II
i in
tBIPS-2 •
±BIPS-3 o
EBIPS-4 •
^IPS-5 •
^Extrapolate —
-*t
1.0
10.0
Jf~»
100
PARTICLE SIZE, microns
Figure 3.2-1. Particle size distribution, fabric filter inlet.
-------
I
N)
to
-: = _+1
-+t
1
SJ--»
100
PARTICLE SIZE, microns
Figure 3.2-2. Particle size distribution, fabric filter outlet.
-------
Samples BIPS-2 through 5 were collected at the fabric filter
inlet. The data point distribution for these runs indicate most
of the particles were less than 15 microns in diameter. Samples
BOPS-2 through 5 were collected at the fabric filter outlet. The
data point distribution for these runs is somewhat distorted due
to the extremely low particulate grain loading encountered at
this site. Tests were conducted for ninety minutes with an
average impactor catch of approximately 3-5 mg total. Approxi-
mately 80 percent of the total catch was recovered from the
acetone rinse of the nozzle and the remaining fraction was dis-
tributed primarily between the third and sixth stages of the
impactor. The cut points for these stages range from 6 microns
for stage 3 to 1 micron for stage 6. The results from this
particle size data are misleading due to the very low catches on
the individual stages of the impactor. The distribution shown
in Figure 3.2-2 indicate that the typical descriptor of means
diameter is inappropriate. Most of the particles at the outlet
of the fabric filter were less than 6 microns.
3.2.3 Fabric Filter Visible Emissions
Visible emissions surveys were conducted at the fabric fil-
ter outlet during each particulate test. Visible emissions were
read in six-minute sets throughout each test. Table 3.2-5 con-
tains a summary of visible emissions data. No visible emissions
could be detected by the observer during the testing period.
3.2.4 Sulfur Dioxide
Table 3.2-6 presents a summary of results for SO? tests con-
ducted at the fabric filter inlet. For each test, the SO~
3-23
-------
TABLE 3.2-5. SUMMARY OF VISIBLE EMISSIONS DATA
- CLINKER COOLER FABRIC FILTER OUTLET -
February 23, 1981
Test 1
Test 2
Set No.
BOVE-1-1
BOVE-1-2
BOVE-1-3
BOVE-1-4
BOVE-1-5
BOVE-1-6
BOVE-1-7
BOVE-1-8
Time
1019-1024
1040-1045
1058-1103
1115-1120
1134-1139
1156-1201
1215-1220
1234-1239
Average
% opacity
0*
0
0
0
0
0
0
0
Range
0*
0
0
0
0
0
0
0
Set No.
BOVE-2-1
BOVE-2-2
BOVE-2-3
BOVE-2-4
BOVE-2-5
BOVE-2-6
Time
1525-1530
1544-1549
1601-1606
1621-1626
1639-1644
1655-1700
Average
% opacity
0*
0
0
0
0
0
Range
0*
0
0
0
0
0
Test 3
February 24, 1981
Test 4 (Repeat test)
BOVE-3-1
BOVE-3-2
BOVE-3-3
BOVE-3-4
BOVE-3-5
BOVE-3-6
BOVE-3-7
0921-1026
0939-0944
0955-1000
1013-1018
1037-1042
1050-1055
1109-1114
0*
0
0
0
0
0
0
0*
0
0
0
0
0
0
BOVE-4-1
BOVE-4-2
BOVE-4-3
BOVE-4-4
BOVE-4-5
BOVE-4-6
1335-1340
1352-1357
1411-1416
1430-1435
1450-1455
1509-1514
0*
0
0
0
0
0
0*
0
0
0
0
0
The zero percent opacity indicates that no visible emissions were observed
by the certified observer.
3-24
-------
TABLE 3.2-6. SUMMARY OF SULFUR DIOXIDE RESULTS
CLINKER COOLER FABRIC FILTER INLET
Run
No.
BIM6-1
BIM6-2
Average
BIM6-3
BIM6-4
Average
BIM6-5
BIM6-6
Date
(1981)
2/26
2/26
2/26
2/26
2/26
2/26
Average
Concentration *
ppm
<1
<1
<1
<1
<1
<1
<1
<1
<1
mg/dscm
0.0
0.0
0.0
0.0
0.0
0,0
0.0
0.0
0.0
Ib/dscf x TO-5
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
Mass
emission rate
kg/h
0.0
0.0
0,0
0.0
0.0
0.0
0.0
0.0
0.0
Ib/h
0-0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
02,
%
20.5
20.5
20.5
20.5
20.5
20.5
20.5
20.5
20.5
Temperature
°C
99
99
99
99
99
99
99
99
99
°F
210
210
210
210
210
210
210
210
210
Below minimum detectable limit.
3-25
-------
concentration averaged less than 1 part per million by volume
which is below the minimum detectable limit of the analytical
method.*
3.2.5 Nitrogen Oxides
Table 3.2-7 summarizes the NO emission data collected from
J\.
the fabric filter outlet. A total of four grab samples were col-
lected to quantify these emissions. The NO concentration aver-
JC
aged 2.5 ppm (4.8 mg/dscm) with a corresponding average mass
emission rate of 1.8 kg/h (0.4 Ib/h) based on the measured
concentrations and average volumetric flow rate monitored during
the particulate tests [36,737 dscmh (1,297,351 dscfh)].
3.2.6 Volatile Organic Carbon (VOC)
Hydrocarbon monitoring was conducted at the baghouse outlet
from 12:03 to 15:58 on February 24, 1981. The detection range on
the monitor was set at 0 to 50 parts per million throughout the
monitoring period. A gas standard of 40.4 ppm methane in hydro-
carbon-free air was used to set the instrument span and zero air
containing less than 0.1 ppm total hydrocarbon was used to estab-
lish the instrument base line. Span and zero settings were
checked before and after the four-hour sampling period and no
calibration drift was noted.
Table 3.2-8 presents the hourly and overall average concen-
trations measured. The overall average concentration was 3.9 ppm
as methane. The highest concentration measured was 7.8 ppm and
the lowest concentration measured was 1.5 ppm.
40 CFR 60, Appendix A, Reference Method 6, July 1, 1980.
3-26
-------
TABLE 3.2-7. SUMMARY OF NITROGEN OXIDES RESULTS
CLINKER COOLER FABRIC FILTER OUTLET
Run
No.
1
Date
(1981)
2/26
Sample
No.
BON1A
BON1B
BON1C
BON1D
Average
Concentration
ppm
2.0
2.2
2.1
3.7
2.5
mg/dscm
3.9
4.3
4.0
7.1
4.8
Ib/dscf x 10-"
0.2431
0.2679
0.2531
0.4432
0.3018
Mass; .
emission rate
kg/h
0.14
0.16
0.15
0.26
0.18
Ib/h
0.32
0.35
0.33
0.58
0.40
Concentrations of NOX as N02 in parts per million (ppm) by volume, milligrams
per dry standard cubic meter (mg/dscm), and pounds per dry standard cubic
foot (Ib/dscf).
"'Mass emission rate in kilograms per hour (kg/h) and pounds per hour (Ib/h)
calculated using average measured flow obtained from the particulate tests
[36,737 dscmh (1,297,351 dscfh)].
3-27
-------
TABLE 3.2-8. VOC MONITORING DATA, CLINKER COOLER FABRIC FILTER OUTLET
Monitoring period
(24 h time)
12:03 to 13:03
13:03 to 14:03
14:03 to 15:03
15:03 to 15:58
Average
Date
(1981)
2/24
2/24
2/24
2/24
2/24
Average VOC concentrations
ppm as methane3
4.9
3.0
4.0
3.8
3.9
Emission rate
lb/hb
0.3
0.2
0.2
0.2
0.2
ppm as methane - part per million by volume measured by comparison to
methane response.
DBasis: average measured flow rate of 1,297,351 dscfh and molecular weight
of 16 Ib/lb mole (methane).
3-28
-------
The average concentration of 3.9 ppm corresponds to a mass
emission rate of 0.2 Ib/h as methane based on a measured gas flow
rate of 36,737 dscmh (1,297,351 dscfh). As the methane content
was not measured separately, this concentration may include some
methane.
Copies of the strip chart printouts for this test are in
Appendix B.
3 . 3 -PROCESS SAMPLES
Table 3.3-1 summarizes results from analysis of process
samples collected during each particulate test. Clciy and coal
samples were collected at approximately 20 minute intervals.
Clay samples were collected from the kiln feed conveyor and coal
samples after the pulverizer prior to entering the kiln. In ad-
dition, samples of the final aggregate product and scrubber water
influent and effluent were collected in order to determine total
sulfate content.
The clay analytical data was characterized by an avera.ge
sulfur content of less than 0.02 percent and a moisture content
averaging 3.85 percent. The coal analytical data was character-
ized by an average sulfur content of 1.59 percent and an average
ash content of 11.8 percent. The sulfur content of the final
product averaged less than 0.02 percent. The sulfate concentra-
tion of the scrubber effluent averaged 900 milligrams per liter
(mg/1). Though not specified in the NSPS test request, a compos-
ite influent sample was analyzed for sulfates. The recirculated
scrubber water influent showed an average sulfate concentration
of 760 mg/1. 3_29
-------
TABLE 3.3-1. SUMMARY OF PROCESS SAMPLE ANALYSIS
Particulate
Run No.
1
2-3
1-3
Date
(1981)
2/23
2/24
2/23-24
2/24
Sample
type
Coal
Clay
Coal
Clay
Final
product
Scrubber
efflu-
ent
Scrub-
ber in-
fluent
Density,
g/ml
1.15
2.40
1.15
2.54
_
-
_
Moisture,
%
1.94
3.75
1.90
3.68
_
-
_
Ash, %
dry basis
11.30
-
12.27
-
_
-
_
Sulfur, %
dry basis
1.56*
<.02b
1.61?
<.02b
<.02b
900 mg/lc
760 mg/lc
JASTM D3177.
3ASTM D2234.
'Method C-427. Standard Methods for the Examination of Water and Wastewater,
Nth Edition.
3-30
-------
Table 3.3-2 sumarizes results from the trace metal analysis
performed on process samples collected during the particulate
tests. All results are reported in micrograms per gram (yg/g)
except where noted.
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 particulte tests, no fugitive emissions were ob-
served from either end of the rotary kiln.
*45 FR, pp 76426-9.
3-31
-------
TABLE 3.3-2. SUMMARY OF TRACE METAL ANALYSIS
Element
Ca
Mg
K
Na
Si
Ba
Mn
AT
Cr
Cu
Zn
Ti
Sr
V
Li
Y
Fe
Coal3
3.1%
0. 384%
0. 568%
0.480%
9.6%
630
470
4.2%
46
100
540
0.244%
250
73
7.5
19
4.0%
Clay3
0.65%
0.71%
0.53%
0.40%
28%
370
700
6.6%
62
19
77
0.38%
66
92
40
23
3.2%
Final
product3
0.82%
0.79%
0.58%
0.46%
34%
360
430
7.4%
70
24
94
0.490%
80
110
52
25
3.9%
Scrubber
effluent3
320
33
10
62
12
0.080
2.2
<0.05
<0.001
<0.001
0.058
<0.005
1.1
0.008*
0.18
<0.002
0.040*
Elements not
detected
P
W
Pt
B
Hg
Tl
Mo
Sb
Au
Te
Ni
Bi
Be
As
In
Se
Ag
Pb
Cd
Co
Sn
U
Composite samples per category.
*Indicates values less than five times the detection limit.
3-32
-------
SECTION 4
SAMPLE LOCATIONS AND TEST METHODS USED
Figure 4-1 presents a simplified process flow sheet depict-
ing the sample locations and type of testing conducted at each
site.
The following is a description of the sample locations used
to conduct sampling for particulate, sulfur dioxide, nitrogen
oxide, and particle size distribution.
4.1 KILN EXHAUST WET SCRUBBER OUTLET
Particulate, sulfur dioxide, nitrogen oxides, particle size
distribution, and volatile organic carbon contents were measured
at the wet scrubber outlet as shown in Figure 4.1-1. Two sample
ports, 90° off-center, were located 10.3 duct diameters down-
stream and 2.4 duct diameters upstream from the nearest flow
disturbances in the 1.2 meter (3.94 ft) I.D. round stack. Twelve
traverse points, six per port, were used to traverse the cross-
sectional area of the stack for the particulate test runs. Each
point was sampled for 10 minutes yielding a total test time of
120 minutes. Sulfur dioxide, nitrogen oxides, and volatile
organic carbon sampling was conducted using constant rate sample
techniques by placing the respective probe tips near the center
of the stack.
4-.1
-------
Ornfll -to
COOLING „
AIR
?) SAMPLE POINT
— » SOLIDS FLOW
--»• AIR/GAS FLOW
CD
CLAY
I
ROTARY
KII N
NO. 3
1
1
1
t '
CLINKER
COOLER
I
i
DRY
CYCLONE
I©
i
FABRIC
FILTER
*
STACK
STACK
|0
>^ WET r. nrv.-
• SCRUBBER *JLUDC
•• PRODUCT
®
^CAPTURED PARTICULATE
©
* CAPTURED PARTICULATE
Sample type
Particulate
so2
Particle size
Opacity
Fugitive dust
N0x
Raw material
VOC
Trace metals
Sample points
4,9,11
3,4,9
4,9,11
4,11
Kiln seals
4,11
1,2,5,6
4,11
1,2.5,6
No. of samples
3
6
4
4
4
12,4
Composite
Continuous
Composite
Test method
EPA 5
EPA 6
Impactor
EPA 9
EPA 22
EPA 7
a
FID
b
aCoal samples: sulfur content; density, percent moisture; and 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 samples collected.
4-2
-------
I.D.
1.2 m
(3.94 ft)
O
NIPPLE
LENGTH
15 cm(6 in.)
FLOW
T
UPSTREAM
2.9 m, 2.4 dd
(9.5 ft)
DOWNSTREAM
12.3 m, 10.3 dd
(40.4 ft)
TRAVERSE POINT
NO.
1
2
3
4
5
6
DISTANCE*
in.
2.1
6.9
13.9
33,1
40.1
44.9
cm
5.33
17.53
35.30
84.10
101.85
114.05
2 TRAVERSES
6 SAMPLING POINTS
*Distance not including
nipple length.
CROSS
SECTION
ROTARY
KILN NO.3
I.D.
in. 1.2 m
(3.94 ft)
Figure 4.1-1. Wet scrubber outlet.
4-3
-------
4.2 CLINKER COOLER FABRIC FILTER INLET
Particulate and sulfur dioxide concentrations as well as
particle size distribution were measured at the clinker cooler
fabric filter inlet as shown in Figure 4.2-1. Two sample ports,
90° off-center, were located 2.0 duct diameters downstream and
1.3 duct diameters upstream from the nearest flow disturbances
in the 1.0 meter (3.28 ft) I.D. round stack. Forty-eight t3:averse
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 yielding a total test time of
120 minutes.
Sulfur dioxide sampling was conducted at a constant sampling
rate by placing the probe tip near the center of the duct.
4.3 CLINKER COOLER FABRIC FILTER OUTLET
Particulate and particle size distribution were measured at
the clinker cooler fabric filter outlet as shown in Figure 4.3-1.
Six sample ports were located 3.8 duct diameters downstream and
0.8 duct diameters upstream from the nearest flow disturbances in
the 0.7 x 0.96 m (2.3 x 3.15 ft) rectangular stack. Thirty-six
traverse points, six per port, were used to traverse the cross-
sectional area of the stack for the particulate test runs. It
should be noted that the sample points as depicted in Figure
4.3-1 were not located according to procedures described in EPA
Method 1* for rectangular ducts. However, no significant bias in
the particulate measurements occurred, based on comparisons with
it
40 CFR 60, Appendix A, Reference Method 1, July 1, 1980.
4-4
-------
FROM
DRY
CYCLONEI
1 ,
NIPPLE
LENGTH
10.2 cm (4 in.)_
UPSTREAM
l^ 1.3 m (4.27
— »-n
\|
1 m (3.28 ft)
I.D.
1
— »l
ft) -I
N
>
i.
TO BAGHOUSE
•>
i
2.0 m (6.56 ft)
DOWNSTREAM
10.2 cm
(4 in.)
VERTICAL
PORT
CROSS
SECTION
PORT
I.D.
1 m (3.28 ft)
*Distance not including
nipple length.
TRAVERSE POINT
NO.
1
2
3
4
5 '
6
TAL 7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
DISTANCE*
in.
1.0
1.3
2.1
3.1
4.1
5.3
6.4
7.6
9.1
10.8
12.8
15.8
23.8
26.8
28.8
30.4
31.9
33.1
34.3
35.4
36.4
37.4
38.2
38.5
cm
2.54
3.30
5.33
7.87
10.41
13.46
16.26
19.30
23.11
27.43
32.51
40.13
60.45
68.07
73.15
77.22
81.03
84.07
87.12
89.92
92.46
95.0
97.03
97.79
2 TRAVERSES
48 SAMPLING POINTS
Figure 4.2-1. Clinker cooler fabric filter inlet.
4-5
-------
'»
UPSTREAM
-.68 m
(2.2
i
i
3 ft)
DOWNSTREAM
-3.2 m
(10.5 ft)
1
*
/ .BACKSIDE /
/ PORTS /
r X^C"
1 'S ^i/
1
FRONTSIDE ,
PORTS '
1
1
l.D.
(2.30 ft)
I
1
I
1
1
1
1
L
*Vj
-.96 m
(3.15 ft)
V
r
• *
TRAVERSE POINT
NO.
1
2
3
4
5
6
DISTANCE*
In.
1.7
5.6
11.3
26.8
32.5
36.3
cm
4.32
14.22
26.70
68.07
82:. 55
92!. 20
6 TRAVERSES
36 SAMPLING POINTS
*Distance from inside nipple.
CROSS SECTION
EQUIVALENT ROUND
1
-.9
(3.1
i
i
> m
? ft)
•1 »6 »1 »6 »1 ,6
•6«1 »6 »1 »6 »1
1 — 1 1 — 1 L_l
2LW
= .84 m (2.74 ft)
Figure 4.3-1. Clinker cooler fabric filter outlet.
4-6
-------
the calculated particle size mass loading [0.0029 gr/dscf (par-
ticulate) versus 0.0023 gr/dscf (particle size)] and plume
observation data. Each point was sampled for 3.3 minutes yield-
ing a total test time of 118.8 minutes. The test and analytical
procedures used at each site are described briefly below.
4.4 VELOCITY AND GAS TEMPERATURE
A type S pitot tube and an inclined draft gauge manometer
were used to measure the gas velocity pressure (AP). Velocity
pressures were measured at each sampling point across the duct to
determine an average value according to the procedures outlined
in Method 2 of the Federal Register.* The temperature at each
sampling point was measured using a thermocouple and potentiom-
eter.
4.5 MOLECULAR WEIGHT
Flue gas composition was determined utilizing procedures
described in Method 3 of the Federal Register.* A bag sample was
collected during each particulate, sulfur dioxide, and nitrogen
oxides test run. The bag contents were analyzed using an Orsat
Gas Analyzer.
4.6 PARTICULATE
Method 5, as described in the Federal Register,* was used to
measure particulate grain loading at each test location. All
tests were conducted isokinetically by traversing the cross-sec-
tional area of the stack and regulating the sample flow rate
40 CFR 60, Appendix A, Reference Methods 2, 3, and 5, July 1,
1980.
4-7
-------
relative to the flue gas flow rate as measured by the pitot tube
attached to the sample probe. A sampling train consisting of a
heated, glass-lined probe, a heated 87 mm (3.4 in.) diameter
glass fiber filter (Reeve Angel 934 AH), and a series of Greenburg-
Smith impingers was employed for each test. 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 temper-
ature, desiccated to a constant weight, and weighed on an ana-
lytical balance. Total filterable particulate matter was deter-
mined by adding these two values. The contents of the impinger
section of the sampling train were recovered and analyzed for
organic and inorganic content by ether-chloroform extraction.
4.7 SULFUR DIOXIDE
The test procedure used was as described in Method 6 of the
Federal Register* except for the replacement of the midget im-
pingers 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 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 analyzed for
40 CFR 60, Appendix A, Reference Method 6, July 1, 1980.
4-8
-------
sulfate content onsite using the barium-thorin titration
method.
4.8 NITROGEN OXIDES
Sampling and analytical procedures used followed those
described in EPA Method 7 of the Federal Register.* A total of
three tests, each consisting of four grab samples taken at
approximately 15 minute intervals, were conducted on the scrubber
exit stack. Four samples were collected at the fabric filter
outlet test location. Samples were obtained and shipped to the
laboratory for analysis.
4.9 PARTICLE SIZE DISTRIBUTION
Particle size samples were obtained using an Andersen 2000
Mark III Source Cascade Impactor. This is an in-stack, multi-
stage cascade impactor which has a total of eight stages with
particle size cut-offs ranging nominally from 0.5 to 15 microns,
followed by a back-up filter stage. Substrates for the Andersen
were 64 mm glass fiber filters. A constant sampling rate was
maintained through the test period. Sampling rates were set for
isokinetic sampling as long as the sample rate did not exceed the
recommended flow rate for the impactor (0.70 acfm).
A total of five impactor runs were conducted at each sam-
pling site. Sampling point locations for the circular stacks
were located as shown in Figure 4.9-1. At least one impactor run
was conducted at each sampling point. In the rectangular stack
of the clinker cooler fabric filter outlet, a point of average
*
40 CFR 60, Appendix A, Reference Method 7, July 1, 1980.
4-9
-------
Figure 4.9-1. Particle size sampling points for circular stack.
4-10
-------
velocity was sampled. The procedures used followed those recom-
mended in the "Procedures Manual for Inhalable Particulate
Sampler Operation" recently developed for EPA by the Southern
Research Institute.
4.10 PROCESS SAMPLES
Samples of the coal and clay fed to the kiln were collected
at approximately twenty minute intervals during the particulate
sampling. 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 and final
aggregate product were collected and analyzed for trace metals
and sulfur content.
4.11 VOC SAMPLING
Sampling for volatile organic compounds was performed using
a Malloy FID hydrocarbon analyzer. With this system, samples
were drawn from the stack through heat-traced teflon sample line,
maintained at 120°C (250°F), and injected directly to an FID. A
five point calibration of the system was performed before and
after each monitoring period using gas standards of methane in
air. Zero and span checks were performed at the mid-point of the
monitoring period. Approximately one-half day of continuous VOC
monitoring was performed at the designated sites.
4-11
-------
SECTION 5
QUALITY ASSURANCE
Quality assurance is one of the main facets of stack sam-
pling since the end product of testing is to produce representa-
tive emission results. Quality assurance guidelines provide:
detailed procedures and actions necessary for defining and pro-
ducing acceptable data. Four documents were used in this test
program to provide the required guidance to help insure the
collection of acceptable data and define when data quality is
unacceptable. These documents are the source specific test plan
prepared by PEDCo and reviewed by the Emissions Measurement
Branch, the EPA Quality Assurance Handbook Volume III, EPA-600/4-
77-027b, the draft PEDCo Environmental Emission Test Quality
Assurance Plan and the PEDCo Environmental Laboratory Quality
Assurance Plan. The last two quality assurance plans are PEDCo's
general guideline manuals that define the company's standard
operating procedures followed by the emission testing groups and
the laboratory groups.
More detail on the Quality Assurance procedures are provided
in Appendix F. This includes QA objective; data reduction;
quality control checks; performance and system audits; preventive
maintenance; precision, accuracy and completeness; corrective
action; and quality assurance reports to management.
5-1
-------
Relative to this specific test program, outlined below are
steps taken to insure quality data for the testing and analytical
procedure used.
0 Calibration of field sampling equipment. Calibration
guidelines are described in more detail in Appendix E.
0 Train configuration and calculation checks.
0 Onsite quality assurance checks such as:sample train,
pitot tube, and orsat line leak checks.
0 Use of designated analytical equipment and sampling
reagents.
Sampling equipment used to conduct particulate, S0_, and NO
4b J^.
testing are listed in Table 5-1 along with calibration guidelines
and limits. In addition to the pre- and post-test calibration, a
field audit was performed on the meter boxes used for particulate
and SO,, sampling. An EPA supplied critical orifice was used for
this audit. Figures 5-1 through 5-3 show an example audit run for
each dry gas meter.
To check the reliability of the analytical method used to
analyze the filters used for particulate and particle size tests,
sets of filters, preweighed in the lab, were resubmitted for
replicate analysis. Table 5-2 summarizes the results of the
blank filter and reagent analysis.
Audit solutions prepared by the EPA were used to check the
analytical procedures and reagents used for SO, and NO sample
£• a
analysis. The results of the analytical audit are presented
in Tables 5-3 and 5-4. Sulfur dioxide and NO audit tests show
H
good analytical technique.
5-2
-------
TABLE 5-1. PARTICULATE EQUIPMENT CALIBRATION SUMMARY
in
I
10
Equipment
Meter box
P1tot tube
Digital
Indicator
Thermocoupl es
and stack
thermometers
Orsat
analyzer
Implnger
thermometer
Trip balance
Barometer
Dry gas
thermometer
1.0.
No.
FB-1
FB-2
FB-5
RAC-4
038
179
184
180
208
125
124/219
203
204
128
127
142
143
Many
197
226
FB-1
FB-2
FB-5
RAC-4
Participate sampling
Calibrated
against
Wet test meter
Standard pi tot
tube
Millivolt
signals
ASTM-2F or 3F
Standard gas
ASTM-2F or 3F
Type S weights
NBS traceable
barometer
ASTM-2F or 3F
Allowable
error
Y +0.02 Y
AY £ +0.15
(Y +0.05 Y post-test)
Cp +0.01
0.5*
1.5S
(+2°F saturated)
+0.5X
+Z°F
+0.5 g
+0.10 In.Hg
(0.20 post-test)
+5°F
Actual
error
0.012
0.015
0.041
0.029
0.00
0.01
0.00
0.00
0.00
0.21
0.11/0.10
0.976
1.030
1.082
1.113
0.04
0.02
Avg. 1°F
0.1 g
0.04
2.8°F
1.7°F
2.2°F
1.1-F
Hlthln
allowable
limits
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes/Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
w
ies
Comments
See Appendix E for
full calibration
data
(continued)
-------
TABLE 5-1 (continued)
en
I
Equipment
Probe nozzle
Meter box
Rotameter*
Dry gas meter
thermometer
Implnger
thermometer
Collection
flask
Thermometer
Barometer
I.D.
No.
RAC-4
FB-8
FB-3
Many
Many
N-1
226
Sulfur dioxide sampling
Calibrated
against
Call per
Wet test meter
Bubble buret
ASTM-2F or 3F
ASTM-2F or 3F
500 ml Class A
grad. cycllnder
ASTM-2F or 3F
NBS traceable
barometer
Allowable
error
On +0.004 In.
Y +0.02 Y
(Y +0.05 Y post-test)
+5*
(+10S post-test)
+5°F
+2°F
Nitrogen oxides samp
+10 ml
+2°F
+0.10 In.Hg
(0.20 post-test)
Within
Actual allowable
error limits
0.029 Yes
0.024 Yes
0.019
Yes
1 Yes
1°F Yes
1°F Yes
Avg. 1"F Yes
ling
Yes
0.5°F Yes
0.04 Yes
Conments
See Appendix F for
full calibration
•Not used.
-------
AUDIT REPORT GAMPLF. MF.TEU
Date
Client
f I
Barometerlc pressure (P. » in Hg )
Orifice number
Orifice K factor
Meter box number
Pretest Y
Auditor
Orifice
reading
AH
in H20
*>
Dry gas
meter
reading
v}/vf
ft3
ff/.f
m.i
Try gas
meter
volume
V
,*>
Temperatures
"Snib'icht
T /T
a. af
°F
(r»
fr*
Average
T
a
°F
I.*
Inlet
T .
mi
°F
£*
^
Outlet
T
mo
°F
t,(*
i,
-------
AUDIT REPORT SAMPLE MFTEn BOX
Date
Client
Barometeric pressure (P. » in Hg )
Orifice number
Orifice K factor
X./&
Meter box number
Pretest Y ^
Auditor faA^
Orifice
manometer
reading
AH
in H20
,.i
Dry gas
meter
reading
vj/vf
MfO
fro,<*
Dry gas
meter
volume
V
tf-H
Temperatures
Tfiriblcnt
T /T
a. af
°F
?i
m ( 1203 )( l£.i\-
= ( v.
m
std
- V
m
)( 100 )/( V
act
m
100
act
Figure 5-2. Audit report sample meter box.
-------
AUDIT REPORT SAMPLE METEf! COX
Date
Client
Barometer ic pressure (P. » in Hg )
Orifice number
' t 7
Orifice K factor
X * *>
Meter box number
Pretest Y
Auditor
'")'
Orifice
manometer
reading
AH
in H20
J.V
Dry gas
meter
reading
v,/vf
ftJ
Wti
t*&
Try gas
meter
volume
V
£
,a.H
Temperatures
Ambient
T /T
a af
°F
tf
(*<*
Average
T
a
°r
^
Inlet
Trni
°F
^
^
Outlet
T
mo
°F
tf
^
Average
T
m
°F
(^^
Sampling
time
min
Ifjf
V
rastd
ft3
,a>*
V
mact
ft3
/a.«{
Percent
error
-AT^_
m
std
V
mact
V
mstd
V
mact
error
= ( 17.647 )( Vm )( Y )(
= ( 1203 )( 0 )( K )(
; 17.647 )( /5-/
; 1203 )( i£i{
+ AH/13. 6 )/(
)/( T + 460
460 )
< Vm - Vm >< 10° >/( Vm > = ("
std act act
)( 100
Figure 5-3. Audit report sample meter box.
-------
TABLE 5-2. EXAMPLE BLANK FILTER AND REAGENT ANALYSIS
Sample type
Particulate - 87
mm Reeve Anqel
934 AH #0002079
Particle size
64 mm Reeve
Angel 934 AH
L-69
N-28
L-95
N-26
T-29
N-36
P-29
N-34
B-465
Acetone
blank
H20 blank
Original tare
weight, mg
354.9
131.8
134.3
142.4
135.8
148.6
136.2
146.2
135.8
206.6
109239.7
99827.9
Blank weight,
mg
355.2
132.0
134.8
142.6
135.9
148.9
136.4
146.5
136.0
207.0
109241.9
99828.4
Net weight,
mg
+0.3
+0.2
+0.5
+0.2
+0.1
+0.3
+0.2
+0.3
+0.2
+0.4
+2.1
+0.3
5-8
-------
TABLE 5-S. AUDIT REPORT S02 ANALYSIS
Plant #5 £.7* A.
PN Number
Date samples received
Samples analyzed by £/
Reviewed by
Date analyzed
ijfj
It •'''/
Jiff:±t:i-
Date of Review 3 ••}"*•
Sample
Number
E?A
#3Jt(*
&PA
^3}H
mg S02/dscm
Determined
^^-^ ^
///7.X ^
Source of
Sample
-rvtyjG.
*nJjj/wL
Accepted
Value
*7/.&
//*$. 11
%
Difference
- A.o '/'
- 1.3%
It
5-9
-------
TABLE 5-4. AUDIT REPORT NOY ANALYSIS
rt
Plant
USE PA
PN Number
Date samples received
Date analyzed "3> - ^4- "
Samples analyzed by (j(J . *5 -\-etO qrci.
Reviewed byJ~.Qi/i/ictt _ 7" / ^.
Date of Review
Sample
Number
55 C 1^15
5SC 3^4.2
mg N02/dscm
Determined
loW. 63-
/
5>oH,<2^7
; /
Source of
Sample
T. l<0aq/vu^
T. (JUa^mir t
Accepted
Value
67^3
372.7
•
%
Difference
y-^,^%
+ *.!%
5-10
-------
Sampling equipment, reagents, and analytical procedures for
this test series followed and met all necessary guidelines set
forth for accurate test results as described in Volume III of the
Quality Assurance Handbook.*
*
Quality Assurance Handbook for Air Pollution Measurement Systems,
Volume III, EPA-600/4-77-027b, August 1977.
5-11
-------
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 personnel from MRI.
The measured particulate emissions appear to be representa-
tive based on between-test data reproducibility and comparisons
with the plume observation and particle size distribution data
collected concurrent with the particulate tests.
The measured particulate concentration at the inlet to the
fabric filter (186 mg/dscm) is within 5 percent of the results
obtained from the equivalent site at the first plant evaluated
(176 mg/dscm). The addition of the fabric filter control device
on the clinker cooler line reduces particulate emissions by at
least 96 percent based on test data.
Particulate emission results obtained from the kiln exhaust
scrubber outlet indicated that the control device operated
efficiently throughout the test period.
The process sample analysis shows the clay material used at
this plant processes a low sulfur (<.02 percent) content. There-
fore, it is reasonable to conclude SO,, emissions are generated
6-1
-------
primarily from the combustion of coal (1.59 percent sulfur) in
the kiln. Likewise, NO and VOC emissions are probably generated
X
by coal combustion.
6-2
-------
REFERENCES
1. Southern Research Institute. Procedures Manual for Inhalable
Particulate Sampler Operation. Prepared for EPA under Con-
tract No. 68-02-2118. 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
------- |