&EPA
United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EM B Report 80- LWA-4
Air
Lightweight Aggregate
Industry
(Clay, Shale, and Slate)
Emission Test Report
Vulcan Materials Company
Bessemer, Alabama
-------
0 EMISSION TEST REPORT °
METHOD DEVELOPMENT AND TESTING FOR
CLAY, SHALE, AND SLATE
AGGREGATE INDUSTRY
Vulcan Materials Company
Bessemer, Alabama
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
March 1982
-------
CONTENTS
Figures iv
Tables v
Quality Assurance Element Finder vi
1. Introduction 1-1
2. Process Operation 2-1
3. Summary of Results 3-1
Rotary kiln exhaust 3-1
Clinker cooler exhaust 3-17
Process samples 3-29
Fugitive emissions 3-31
4. Sample Locations and Test Methods Used 4-1
Scrubber inlet 4-1
Scrubber outlet 4-4
Clinker cooler exhaust 4-4
Velocity and gas temperature 4-7
Molecular weight 4-7
Particulates 4-7
Sulfur dioxide 4-8
Nitrogen oxide 4-9
Particle size distribution 4-9
Hydrocarbon emissions 4-10
Process samples 4-12
Visible and fugitive emissions 4-12
5. Quality Assurance 5-1
6. Discussion of Results 6-1
References R-l
11
-------
Appendix A
Appendix B
Appendix C
Appendix D
Appendix E
Appendix F
Appendix G
CONTENTS (continued)
Page
Computer printout and example calculations 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 sample log G-l
111
-------
FIGURES
Number Paqe
3-1 Particle Size Distribution - Kiln Exhaust
Scrubber Inlet 3-9
3-2 Particle Size Distribution - Kiln Exhaust
Scrubber Outlet 3~10
3-3 Particle Size Distribution - Clinker Cooler
Exhaust 3-23
4-1 Sampling Plan and Process Flow Sheet, Vulcan
Materials Company 4-2
4-2 Scrubber Inlet Sample Location 4-3
4-3 Scrubber Outlet Sample Location 4-5
4-4 Clinker Cooler Sample Location 4-6
4-5 Particle Size Sampling Points for Circular Stack 4-11
5-1 Example Audit Report for Scrubber Inlet 5-6
5-2 Example Audit Report for Scrubber Outlet 5-7
5-3 Example Audit Report for Clinker Cooler Outlet 5-8
IV
-------
TABLES
Number Page
2-1 Process Data Recorded During the Emission Test
at Vulcan Materials Company, Bessemer,
Alabama 2-2
3-1 Summary of Flue Gas Conditions - Kiln Exhaust
Scrubber Inlet and Outlet 3-3
3-2 Summary of Particulate Emissions Data - Kiln
Exhaust Scrubber Inlet and Outlet 3-4
3-3 Summary of Sulfur Dioxide Data 3-13
3-4 Summary of Nitrogen Oxide Emissions Data -
Scrubber Outlet 3-15
3-5 Hydrocarbon Emissions from Scrubber Outlet 3-16
3-6 Summary of Visible Emissions Data - Scrubber
Outlet 3-18
3-7 Summary of Flue Gas Conditions - Clinker Cooler
Exhaust 3-20
3-8 Summary of Particulate Emission Data - Clinker
Cooler Exhaust 3-21
3-9 Summary of Visible Emissions Data - Clinker
Cooler Exhaust 3-27
3-10 Summary of Sulfur Dioxide Results - Clinker
Cooler Exhaust 3-28
3-11 Summary of Process Sample Analysis Results 3-30
3-12 Summary of Fugitive Emissions Data 3-32
5-1 Field Equipment Calibration Summary 5-3
5-2 Example Blank Filter and Reagent Analysis 5-9
5-3 Audit Report - S02 Analysis 5-11
5-4 Audit Report - NOX Analysis 5-12
v
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QUALITY ASSURANCE ELEMENT FINDER
(1) Title page
(2) Table of contents
(3) Project description
(4) Project organization and responsi-
bilities
(5) QA objective for measurement of data
in terms of precision, accuracy, com-
pleteness, representativeness and
comparability
(6) Sampling procedures
(7) Sample custody
(8) Calibration procedures and frequency
(9) Analytical procedures
(10) Data reduction, validation, and
reporting
(11) Internal quality control checks and
frequency
(12) Performance and system audits and
frequency
(13) Preventive maintenance procedures and
schedules
(14) Specific routine procedures used
to assess data precision, accuracy and
completeness of specific measurement
parameters involved
(15) Corrective action
(16) Quality assurance reports to management
vi
Location
Section Page
11
1 1-1
Appendix F F-2
Appendix F F-2
Appendix D D-l
Appendix C C-l
Appendix E E-l
Appendix D D-l
Appendix F F-3
Appendix F F-5
Appendix F F-3
Appendix F F-6
Appendix F F-4
Appendix F F-5
Appendix F F-6
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SECTION 1
INTRODUCTION
During the week of July 13, 1981, personnel from PEDCo
Environmental conducted an emission sampling program at the
lightweight aggregate facility of Vulcan Materials Company in
Bessemer, Alabama. 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 (clay, shale, and slate) and, if
warranted, to develop such limits.
Comprehensive testing was conducted on two specific sources
detailed below:
Coal-fired rotary kiln (No. 1), whose emissions are
controlled by a medium-energy wet scrubber.
Reciprocating grate clinker cooler, whose emissions are
controlled by a settling chamber.
Particulate concentrations and mass emission rates were
measured at the inlet to and the outlet from the wet scrubber
serving the kiln exhaust and at the clinker cooler exit stack.
U.S. Environmental Protection Agency (EPA) Method 5 was used in
these measurements.* Flue gas flow rates, temperature, moisture
content, and composition [oxygen (02) , carbon dioxide (CO,,) , and
carbon monoxide (CO)] were measured in conjunction with the
40 CFR 60, Appendix A, Reference Method 5, July 1, 1981.
1-1
-------
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 clinker cooler exit
stack by EPA Method 6.* Nitrogen oxide (NO ) concentration in
X
the flue gas exiting the scrubber was also determined by EPA
Method 7.* In addition, the particle size distribution of
particulate matter entering and exiting the kiln scrubber and
exiting the clinker cooler stack was determined using in-stack
cascade impactors. Volatile organic carbon (VOC) content of the
exit gas from the kiln was determined by EPA Method 25.* 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 specified process
locations was made during each particulate test by EPA Method 9.*
Representative samples of the kiln feed material (shale) 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). Samples of the scrubber water influent
and effluent and final aggregate product were also collected for
analyses of total sulfate. The pH of the scrubber water was
also determined.
Messrs. Richard Cooper and Lalit Banker [Midwest Research
Institute (MRI)] monitored process operation and collected
process samples throughout the test period. Mr. Frank Clay (EPA
Task Manager) observed the test program.
40 CFR 60, Appendix A, Reference Methods 6, 7, 9, and 25,
July 1, 1981.
1-2
-------
SECTION 2
PROCESS OPERATION
The process operation and summary of data monitored during
the test period are shown in Table 2-1. Process data were col-
lected and tabularized by personnel from MRI.
The Vulcan plant in Bessemer, Alabama, operates two kiln
lines for shale lightweight aggregate production. Testing was
conducted on Kiln No. 1 and its associated pollution control
equipment.
The raw material (shale) is quarried from a pit located
approximately 0.8 kilometers (km) (0.5 miles) from the plant.
Trucks transport the shale to crushers where it is reduced to a
feed size of less than 1.91 centimeters (cm) [3/4 inches (in.)]
and transferred by belt conveyor to a semi-enclosed shed for
storage. The semi-enclosed shed had a storage capacity of ap-
proximately 13,610 megagrams (Mg) (15,000 tons). Belt conveyors
transport the raw material from the storage shed to a feed hopper
for charging to the kiln.
The No. 1 kiln measures 56.4 meters (m) [185 feet (ft)]
in length and 2.7 m (12 ft) in diameter and is designed to
process approximately 32 Mg (35 tons) of raw material per hour.
Typically, the No. 1 kiln processes approximately 26.3 Mg (29
2-1
-------
TABLE 2-1. PROCESS DATA RECORDED DURING THE
AT VULCAN MATERIALS COMPANY, BESSEMER,
EMISSION TEST
ALABAMA
Time
Kiln,
rpm
Aggregate weight
kg/m3
lb/ft3
Feed end temperature
°C
°F
Tuesday, July 14, 1981d
7:30
8:00
8:30
9:00
9:30
10:00
10:30
11:00
11:30
12:00
12:30
1:00
1:30
2:00
2:30
3:00
3:30
4:00
4:30
2.8
2.8
2.8
2.8
2.8
2.8
2.8
2.8
2.8
2.8
2.8
2.8
2.8
2.8
2.8
2.8
2.8
2.8
2.8
657
705
689
769
721
737
689
785
769
705
753
721
689
737
721
753
657
641
673
41
44
43
48
45
46
43
49
48
44
47
45
43
46
45
47
41
40
42
593
599
593
593
593
593
593
593
593
593
593
593
593
593
593
593
593
593
593
1100
1110
1100
1100
1100
1100
1100
11100
1100
II 100
11100
1100
1100
1100
1100
1100
1100
1100
1100
Wednesday, July 15, 1981
7:30
8:00
8:30
9:00
2.8
2.8
2.8
2.8
641
721
752
785
40
45
47
49
593
593
593
593
1100
1100
1100
1100
(continued)
2-2
-------
TABLE 2-1 (continued)
Time
Kiln,
rpm
Aggregate weight
kg/m3
lb/ftj
Feed end temperature
°C
°F
Wednesday, July 15, 1981 (continued)
9:30
10:00
10:30
11:00
11:30
12:00
12:30
1:00
1:30
2:00
2:30
3:00
3:30
4:00
2.8
2.8
2.8
2.8
2.8
2.8
2.8
2.8
2.8
2.8
2.8
2.8
2.8
2.8
737
769
737
705
721
689
721
737
705
673
705
657
641
673
46
48
46
44
45
43
45
46
44
42
44
41
40
42
593
593
593
593
599
599
593
593
593
593
593
593
593
593
1100
1100
11100
1100
1110
1110
1100
1100
1100
1100
1100
1100
1100
1100
Thursday, July 16, 1981'
7:00 to 2:30
3:00
3:30
4:00
2.8
2.8
2.8
No emissior
801
577
705
tests conduct
50
36
44
2d
593
582
582
1100
1080
1080
Friday, July 17, 1981'
7:30
8:00
8:30
9:00
9:30
10:00
10:30
11:00
2.8
2.8
2.8
2.8
2.8
2.8
2.8
2.8
769
721
657
737
705
705
752
705
48
45
41
46
44
44
47
44
571
593
593
593
593
593
593
593
1060
1100
1100
1100
1100
1100
1100
1100
(continued)
2-3
-------
TABLE 2-1 (continued)
Time
Kiln,
rpm
Aggregate
kg/m3
weight
Ib/ft3
Feed end
temperature
°C
°F
Friday, July 17, 1981° (continued)
11:30
12:00
12:30
1:00
1:30
2:00
2.8
2.8
2.8
2.8
2.8
2.8
769
737
785
769
833
801
48
46
49
48
52
50
593
593
593
593
593
593
1100
1100
1100
1100
1100
1100
Raw material feed rate: 26.3 Mg/h (29 tons/h)
(633,364 ft3). Coal: 762.6 Mg (840.75 tons).
bRaw material feed rate: 26 Mg/h (29 tons/h).
(663,668 ft3). Coal: 819.0 Mg (902.9 tons).
cRaw material feed rate: 26 Mg/h (29 tons/h).
(664,064 ft3). Coal: 844.1 Mg (930.5 tons).
dRaw material feed rate: 26 Mg/h (29 tons/h).
(665,045 ft3). Coal: 880.4 Mg (970.6 tons).
. Natural gas: 18,786 m
Natural gas: 18,795 rrT'
Natural gas: 18,806 nT'
Natural gas: 18,834 nT'
Note: The natural gas and coal usage meters are read and recorded at the
beginning of each shift. (The difference in the readings from one
day to the next indicates the amount of fuel consumed in each 24-h
period.)
2-4
-------
tons) of raw material per hour which yields a final production
rate of 21 Mg (23 tons) per hour. The kiln is fueled primarily
by pulverized coal, and natural gas is used to fuel the pilot
flame. The operating temperature of the kiln is approximately
1150°C (2100°F). Natural gas is the primary fuel used for the
reheating process. Once the temperature of the coal mill reaches
93°C (200°F), pulverized coal is used as the primary fuel to fire
the kiln. The kiln temperature climbs to 1480°C (2700°F) during
the reheating and settles to 1150°C (2100°F) as the coal feed
rate increases to normal and the natural gas is cut off.
The No. 1 kiln rotates at approximately 2.8 revolutions per
minute (rpm). The raw material slowly heats up as it travels
through the kiln and physically expands (bloats) as volatile
organic components are released. The raw material residence time
in the kiln is approximately 45 to 50 minutes. The expansion
reduces the density of the shale to within a range of 640 to 800
kilograms per cubic meter (kg/m ) [40 to 50 pounds per cubic foot
(Ib/ft )]. The expanded product, or clinker, is discharged from
the kiln through a 1.2 by 1.8 m (4 by 6 ft) opening at the back
end of the kiln onto a reciprocating grate called a clinker
cooler. As the hot clinker moves across the grate, one large fan
forces air upward through the grate to cool the clinker. Product
of acceptable size falls through the grate onto a conveyor belt
for transfer to storage piles. Oversize material falls from the
grate onto the ground where it is periodically picked up by a
front end loader and transferred to a crusher for supplemental
2-5
-------
crushing prior to storage. The product is also transferred by
conveyor belt from the storage piles to crushers to reduce the
size of the product and then to a screen house for sizing. The
product is transferred from the crushing/screening area to open
stockpiles where it is stored until sold.
The No. 1 rotary kiln exhaust emissions (particulate and
some S02) are controlled by a medium energy wet scrubber (Ducon
Dynamic, UW4, Model IV, Size 144). The scrubber stack is ap-
proximately 1.5 m (5 ft) in diameter and 15 m (50 ft) high. The
stack outlet is approximately 30 m (100 ft) above grade. The
scrubber water is discharged to an open ditch which empties into
a holding pond. Periodic checks of the scrubber water by plant
personnel indicate the pH is very low, resulting in scrubber
corrosion. A system for feeding caustic soda to the scrubber
water is, therefore, being installed to adjust the pH. The
scrubber water is recirculated from the holding pond to the wet
scrubber by eight 7.5-kilowatt (kW) [10-horsepower (hp)] pumps.
The clinker cooler emissions from the No. 1 kiln process line are
controlled by a settling chamber. Vulcan ceased operation of the
induced draft fan located downstream from the settling chamber
several years ago for energy conservation purposes. Essentially,
the system now operates under a natural draft flow. Since the
I.D. fan no longer operates, some of the exhaust gas, which
normally would be vented through the exit stack, is emitted from
the oversize clinker exit area. Consequently, fugitive emission
observations were made at the exit area during the particulate
tests at this location.
2-6
-------
No instrumentation was present to indicate the water flow
rate to the wet scrubber or the inlet and outlet gas flow rates
and temperatures and pressure drops for the settling chamber and
wet scrubber. The settling chamber and wet scrubber, including
the pumps supplying water to the wet scrubber, were operating
normally during the emission tests. The water sprays used to
suppress visible particulate emissions at the transfer points in
the product stockpiling area and the raw material unloading sta-
tion were operating normally.
2-7
-------
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
sources. Results are reported separately for each source.
Appendix A contains complete printouts of field data, re-
sults tabulation, and example calculations. Appendices B and C
present field and laboratory data sheets. Appendix D details the
sampling and analytical procedures used during this test program.
Appendix E shows equipment calibration procedures and results.
Appendix F addresses quality assurance considerations pertinent
to this test project.
3.1 ROTARY KILN EXHAUST
Particulate and particle size tests were simultaneously con-
ducted at the inlet to and outlet of the wet scrubber serving the
kiln exhaust gas stream. Visible emission observations were also
performed during the particulate testing. In addition, S02 tests
were simultaneously conducted before and after the scrubber.
Tests for NO and VOC content in the scrubber exhaust gas were
JC
performed concurrent with the SO- tests.
3-1
-------
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. The particle size sampling and analytical procedures used
at the scrubber and clinker cooler exhaust test locations fol-
lowed those described in the "Procedures Manual for Inhalable
Particulate Sampler Operation" recently developed for EPA by
Southern Research Institute (SRI). At the scrubber inlet an
Andersen Heavy Grain Loading Impactor was used. Analytical
procedures followed those described in the manufacturer's in-
struction manual. Sampling and analytical procedures for S02
followed those described in EPA Method 6* except that large
impingers were used instead of the midget impingers specified in
Method 6. Sampling and analytical procedures for NO followed
X
those described in EPA Method 7.* Visible emission observcitions
were conducted using procedures described in EPA Method 9* of the
Federal Register. EPA Method 25* was used in determining the VOC
content of the exhaust stream.
3.1.1 Flue Gas Conditions and Particulate Emissions
Tables 3-1 and 3-2 summarize the flue gas conditions and
particulate emissions data collected at the scrubber inlet and
outlet test locations. Since particulate emissions are expressed
in pounds per hour and kilograms per hour, volumetric flow rates
are also expressed in actual cubic meters per hour (acmh) and
actual cubic feet per hour (acfh) at stack conditions. Flow
*
40 CFR 60, Appendix A, Reference Methods 5, 6, 7, 9, and 25,
July 1, 1981.
3-2
-------
TABLE 3-1. SUMMARY OF FLUE GAS CONDITIONS
Scrubber inlet
Run
No.
SIP-1
SIP-2
SIP-3
Date,
1981
7/14
7/15
7/15
Average
Volumetric flow rate
Actual3
acmh
171,720
182,195
185,868
179,928
acfh
6,064,204
6,434,122
6,563,847
6,354,058
Standard
dscmh
66,980
70,186
70,564
69,243
dscfh
2,365,364
2,478,580
2,491,944
2,445,296
Temperature
°C
415
413
422
417
°F
779
775
792
782
Moisture
%
7.2
8.4
8.5
8.0
02»
%
14.5
14.2
13.8
14.2
C02,
%
5.5
5.5
5.8
5.6
CO,
%
0.0
0.0
0.0
0.0
Scrubber outlet
SOP-1
SOP-2
SOP-3
7/14
7/15
7/15
Average
103,886
106,055
107,452
105,798
3,668,666
3,745,268
3,794,620
3,736,185
70,052
71,543
71,403
70,999
2,473,854
2,526,506
2,521,561
2,507,307
65
63
65
64
149
145
148
147
21.2
21.4
22.1
21.6
14.6
14.4
14.8
14.6
5.5
5.3
5.6
5.5
0.0
0.0
0.0
0.0
U)
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 zero percent moisture.
-------
TABLE 3-2. SUMMARY OF PARTICULATE EMISSIONS DATA
Kiln exhaust scrubber inlet
Run
No.
SIP-1C
SIP-2
SIP-3
Date,
1981
7/14
7/15
7/15
Average
Concentration9
Filterable
mg/dscm
54,353
62,883
61,936
59,724
gr/dscf
23.7
27.5
27.1
26.1
Condensible
Organic
mg/dscm
135.0
2.4
3.7
47.0
gr/dscf
0.059
0.001
0.002
0.021
Inorganic
mg/dscm
868.3
96.1
129.7
364.7
gr/dscf
0.379
0.042
0.057
0.159
Mass emission rate
Filterable
kg/h
3,640
4,413
4,730
4,261
Ib/h
8,025
9,729
9,634
9,129
Condensible
Organic
kg/h
9.0
0.2
0.3
3.2
Ib/h
19.9
0.4
0.5
6.9
Inorganic
kg/h
58.2
6.8
9.2
24.7
Ib/h
128.2
14.9
20.2
54.4
Kiln exhaust scrubber outlet
SOP-1
SOP-2
SOP-3
7/14
7/15
7/15
Average
94.5
100.9
100.4
98.6
0.041
0.044
0.044
0.043
1.68
1.18
1.51
1.46
0.0007
0.0005
0.0007
0.0006
35.8
34.5
34.7
35.0
0.016
0.015
0.015
0.015
6.6
7.2
7.2
7.0
14.6
15.9
15.8
15.4
0.12
0.08
0.11
0.10
0.26
0.19
0.24
0.23
2.5
2.5
2.5
2.5
5.5
5.4
5.5
5.5
OJ
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).
Broken filter frit (see page 3-5).
-------
rates corrected to standard conditions [20°C and 760 mm Hg (68°F
and 29.92 in.Hg) and zero percent moisture] are expressed as dry
standard cubic meters per hour (dscmh) and dry standard cubic
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
expressed 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
fraction 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).
At the scrubber inlet, the volumetric flow rate averaged
69,200 dscmh (2,445,000 dscfh), temperature averaged 417°C
(782°F), and moisture content averaged 8.0 percent. Oxygen and
carbon dioxide contents averaged 14.2 and 5.6 percent, respec-
tively. Filterable particulate concentration averaged 59,724
mg/dscm (26.1 gr/dscf), and the corresponding mass emission rate
averaged 4261 kg/h (9129 Ib/h). The condensible organic and
inorganic concentrations averaged 47 mg/dscm (0.021 gr/dscf) and
365 mg/dscm (0.16 gr/dscf), respectively. The corresponding mass
emission rates averaged 3.2 kg/h (6.9 Ib/h) and 24.7 kg/h (54.4
Ib/h) for each fraction.
3-5
-------
During Test No. SIP-1, the filter frit support ruptured due
to a high pressure drop across the frit and heat fatigue. Sub-
sequently, some filterable sample loss did occur. However, the
particulate was captured in the impinger section of the sample
train resulting in the higher organic and inorganic fractions
measured by ether-chloroform extraction for this run.
At the scrubber outlet, the volumetric flow rate averaged
71,000 dscmh (2,507,000 dscfh), temperature averaged 64°C (147°F),
and moisture content averaged 21.6 percent. Oxygen and carbon
dioxide contents averaged 14.6 and 5.5 percent, respectively.
Filterable particulate concentration averaged 98.6 mg/dscm (0.043
gr/dscf), and the corresponding mass emission rate averaged 7.0
kg/h (15.4 Ib/h). The condensible organic and inorganic con-
centrations averaged 1.5 mg/dscm (0.0006 gr/dscf) and 35 mg/dscm
(0.015 gr/dscf), respectively. Organic and inorganic mass emis-
sion rates averaged 0.10 kg/h (0.23 Ib/h) and 2.5 kg/h (5.5
Ib/h).
The particulate removal efficiency of the scrubber averaged
99.8 percent, based on the average inlet and outlet particulate
concentrations on a mg/dscm basis.
Since the inlet test location did not meet the minimum
criteria set forth in EPA Method 1*, measurements were made to
determine the degree of turbulent flow in the duct as detailed in
Method 2 of the Federal Register.* Each traverse point was
checked by aligning the face openings of the pitot tube
*
40 CFR 60, Appendix A, Reference Methods 1 and 2, July 1, 1981
3-6
-------
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. The
overall average for all points was considerably less than 10
degrees indicating an acceptable flow condition existed in the
duct. Turbulent flow conditions of this type tend to bias the
velocity measurements high. The average inlet and outlet flow
measurements agree to within 5 percent, indicating results
obtained from this location are representative based on between-
test reproducibility and subsequent velocity profile data.
3.1.2 Particle Size Distribution
A total of two samples were collected at the scrubber inlet
and four samples at the outlet test sites. An Andersen Heavy
Grain Load Impactor was used at the scrubber inlet. Sampling and
analytical procedures followed those described in the manufac-
turer's specification manual. An Andersen cascade impactor was
used at the scrubber outlet. Sampling and analytical procedures
followed those described in the "Procedures Manual for Inhalable
Particulate Sampler Operation" developed by Southern Research
Institute for EPA. Data obtained from the particulate test runs
were combined with sampling data to obtain average flow rates,
moisture content, and gas composition.
Data were reduced by computer programs as described in "A
Computer-Based Cascade Impactor Data Reduction System" developed
2
by SRI for EPA. Individual computer printouts for each test and
3-7
-------
brief descriptions of each program used are contained in Appendix
A of this report.
Figure 3-1 presents the distribution curves for the samples
collected at the scrubber inlet. Individual data points for each
test were plotted manually. Run SIPS-1 was conducted on July 15
during the second and third particulate tests. The calculated
mass loading was 65,000 mg/dscm. Run SIPS-2 was conducted on
July 16 approximately one hour after the kiln had been stabilized
from being down most of the day. The calculated mass loading for
this run was 40,000 mg/dscm. Run SIPS-1 is considered more
representative of actual particle size distribution for this
source. All particle size results are based on aerodynamic
diameters and unit density (1 g/cm ). The data point distribu-
tion for these runs indicates that 50 percent of the particles by
weight were less than 20 ym in diameter.
Figure 3-2 presents the average distribution curves for
samples collected at the scrubber outlet. Sample Nos. SOPS-1,2,3
were considered non-representative due to overloading of individ-
ual impactor stages, therefore they are not graphically pre-
sented. The data indicate most of the particles are either large
(>10 ym) or small (<3 ym) with little if any variation from these
two points. The largest percentage of particles were collected
in the impactor precutter (acetone rinse of nozzle) and the
remaining particles collected on impactor Stages 5, 6, and 7.
These stages exhibited cut-points of 2.3, 1.1, and 0.7 microns,
respectively, for the specific test runs presented here. The
3-8
-------
U)
I
vo
tt.»
n.t
• I ! ! !
!•
S
I
M
•.I
1.1
nil
±±±
::±t
t
±i±
S
&
ItmiriW;
UL
rn-_
-*t
i.o
10.0
100
PARTICLE SIZE, microns
Figure 3-1. Particle size distribution - kiln exhaust scrubber inlet.
-------
tt.t
•••iiimimiiiiiimiiiiiiMiiiiiiKiiiiiiiniiiiiMiw
10
I
—+t
-41
....I tlUllMliUt U+ lillL
PARTICLE SIZE, microns
Figure 3-2. Particle size distribution - scrubber outlet.
-------
PARTICLE SIZE, microns
Figure 3-2 (continued)
-------
smaller particles are probably formed by condensation of volatile
matter within the kiln.
3.1.3 Sulfur Dioxide
Table 3-3 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) ,,
milligrams 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 and pounds per hour. The inlet
mass emission rates were calculated from the measured concentra-
tions and the average flow rate measured during the inlet par-
ticulate test runs (2,445,296 dscfh) . The outlet mass emisssion
rates were calculated in a similar manner using the average
measured flow rate from the outlet particulate tests (2,507,307
dscfh). Analyses were conducted, on site by EPA Method 6.*
Sulfur dioxide concentrations at the inlet to the wet scrub-
ber averaged 1576 mg/dscm (592 ppm; 9.72 x 10~ Ib/dscf), and the
corresponding average mass emission rate was 107.8 kg/h (237.6
Ib/h). Flue gas temperature averaged 417°C (782°F), and oxygen
content averaged 14.4 percent.
Sulfur dioxide concentrations at the scrubber exit stack
averaged 381 mg/dscm (143 ppm; 2.35 x 10 Ib/dscf), and the
corresponding average mass emission rate was 26.7 kg/h (58 ,,8
Ib/h). Flue gas temperature averaged 64°C (147°F), and oxygen
content averaged 14.7 percent.
*
40 CFR 60, Appendix A, Reference Method 6, July 1, 1981.
3-12
-------
TABLE 3-3. SUMMARY OF SULFUR DIOXIDE DATA
Scrubber inlet0
Run
No.
SIS-1
SIS-2
Date,
1981
7/17
7/17
Average
SIS-3
SIS-4
7/17
7/17
Average
SIS-5
SIS-6
7/17
7/17
Average
Concentration
ppm
390
660
525
628
635
632
603
635
619
mg/dscm
1038
1757
1398
1672
1691
1682
1605
1691
1648
Ib/dscf x 10-!>
6.40
10.85
8.63
10.31
10.42
10.37
9.89
10.43
10.16
Mass
emission rate
kg/h
70.9
120.3
95.6
114.3
115.6
115.0
109.7
115.6
112.7
Ib/h
156.4
265.2
210.8
252.0
254.9
253.5
241.9^
254.9
248.4
o?,
%
13.4
13.4
13.4
14.5
14.5
14.5
14.4
14.4
14.4
Temperature
°C
417
417
417
417
417
417
417
417
417
°F
782
782
782
782
782
782
782
782
782
Scrubber outlet
SOS-1
SOS- 2
7/17
7/17
Average
SOS- 3
SOS-4
7/17
7/17
Average
SOS- 5
SOS-6
7/17
7/17
Average
131
191
161
158
176
167
119
82
101
349
508
429
421
469
445
317
218
268
2.15
3.14
2.65
2.60
2.90
2.75
1.95
1.34
1.65
24.5
35.7
30.1
29.6
32.9
31.3
22.2
15.2
18.7
54.0
78.6
66.3
65.2
72.6
68.9
48.9
33.6
41.3
14.5
14.5
14.5
14.9
14.9
14.9
14.7
14.7
14.7
64
64
64
64
64
64
64
64
64
147
147
147
147
147
147
147
147
147
Mass emission rates are based on the average stack gas flow rate determined
during the inlet particulate tests (69,243 dscmh and 2,445,296 dscfh),.
DMass emission rates are based on the average stack gas flow rate determined
during the outlet particulate tests (70,999 dscmh and 2,507,307 dscfh).
3-13
-------
3.1.4 Nitrogen Oxides
Table 3-4 summarizes data on emissions of nitrogen oxides.
Three tests, each consisting of four grab samples collected at
15-minute intervals, were conducted on the kiln exhaust scrubber
outlet. Concentrations are reported in milligrams per dry stan-
dard cubic meter, parts per million by volume, and pounds per dry
standard cubic foot. Emission rates, reported in kilograms per
hour and pounds per hour, were calculated from the average flue
gas flow rate measured during the particulate test runs corrected
to standard conditions (2,507,307 dscfh).
Nitrogen oxide concentrations averaged 356 mg/dscm (186 ppm;
-4
0.22 x 10 Ib/dscf), and the corresponding mass emission rate
was 25.3 kg/h (55.7 Ib/h).
3.1.5 Hydrocarbon Emissions From the Kiln Scrubber Outlet
Sampling for hydrocarbon emissions from the scrubber outlet
at Kiln No. 1 was accomplished using the procedures of EPA
Method 25* for the determination of total gaseous nonmethane
organics (TGNMO). A total of four one-hour samples were col-
lected at the scrubber outlet. Test Nos. 1 and 2 were conducted
simultaneously on one day. Test Nos. 3 and 4 were conducted in
sequence on the following day. The results of the Method 25
sampling are presented in Table 3-5. In the Method 25 analytical
procedure, all nonmethane organics are oxidized to carbon dioxide
and reduced to methane before measurement with a flame ionization
detector (FID). Therefore, organic concentrations are expressed
*
40 CFR 60, Appendix A, Reference Method 25, July 1, 1981.
3-14
-------
TABLE 3-4. SUMMARY OF NITROGEN OXIDE EMISSIONS DATA
SCRUBBER OUTLET3
Run
No.
1
Date,
1981
7/17
Average
2
7/17
Average
3
7/17
Average
Sample
No.
SON-1A
SON-IB
SON-1C
SON-ID
SON-2A
SON-2B
SON-2C
SON-2D
SON-3A
SON-3B
SON-3C
SON-3D
Concentration.
ppm
187
173
191
196
187
181
191
175
197
186
176
189
191
183
185
mg/dscm
358
331
365
375
357
346
365
335
377
356
337
362
365
350
354
Ib/dscf x 10-*
0.2236
0.2065
0.2284
0.2341
0.2232
0.2163
0.2283
0.2096
0.2355
0.2224
0.2105
0.2257
0.2280
0.2180
0.2206
Mass
emission rate
kg/h
25.4
23.5
26.0
26.6
25.4
24.6
25.9
23.9
26.8
25.3
23.9
25.7
25.9
24.8
25.1
Ib/h
56.1
51.8
57.3
58.7
56.0
54.2
57.2
52.6
59.0
55.8
52.8
56.6
57.2
54.7
55.3
Mass emission rates are based on the average stack gas flow rate determined
during the scrubber outlet particulate tests (70,999 dscmh and 2,507,307
dscfh).
3-15
-------
TABLE 3-5. HYDROCARBON EMISSIONS FROM SCRUBBER OUTLET
Test
No.
SO-25-1
SO-25-2
SO-25-3
SO-25-4
Date,
1981
7/16
7/16
7/17
7/17
Average
Sampling time, 24-h
Start
1500
1500
905
1045
Finish
1600
1600
1035
1200
NMOa
concentration
ppm as CH4
134
231
378
128
218
Gas stream
flow rate
dscmh
70,999
70,999
70,999
70,999
70,999
dscfh
2,507,307
2,507,307
2,507,307
2,507,307
2,507,307
Hydrocarbon emission rate
expressed as methaneb
kg/h
6.3
10.9
17.9
6.0
10.3
Ib/h
13.9
24.0
39.5
13.2
22.7
u>
aNMO = Nonmethane organics measured and expressed as methane (CH.).
L "
Based on the molecular weight of methane, 16 g/q-mole (16 Ib/lb-mole).
-------
in ppm as methane and emission rates were calculated based on the
molecular weight of methane (16 g/g-mole).
The nonmethane organic concentration in the outlet stack
varied from 128 ppm to 378 ppm with an average value of 218 ppm
as methane. The average emission rate of nonmethane organic
compounds was 10.3 kg/h (22.7 Ib/h) as methane.
3.1.6 Visible Emissions
Each particulate test included a survey of visible emissions
at the kiln scrubber outlet. Visible emissions were read in 6-
minute sets throughout each particulate test. Table 3-6 sum-
marizes the findings. For each test, opacities ranged from 0 to
5 percent and averaged less than 1 percent for all sets.
3.2 CLINKER COOLER EXHAUST
Particulate emissions and particle size distribution tests
were performed at the clinker cooler exhaust stack. Visible
emissions were observed at the outlet stack during each particu-
late test. In addition, S02 tests were performed simultaneously
with the scrubber test locations.
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 content. Particle size sampling and analytical
procedures followed those described in "Procedures Manual for
Inhalable Particulate Sampler Operation", recently developed for
EPA by Southern Research Institute. Visible emission
*
40 CFR 60, Appendix A, Reference Method 5, July 1, 1981.
3-17
-------
TABLE 3-6. SUMMARY OF VISIBLE EMISSIONS DATA
SCRUBBER OUTLET
Test 1 (7/14/81)
Set No.
SOVE- -1
SOVE- -2
SOVE- -3
SOVE- -4
SOVE- -5
SOVE- -6
SOVE- -7
SOVE- -8
SOVE- -9
SOVE- -10
SOVE- -11
SOVE- -12
SOVE- -13
SOVE-1-14
SOVE-1-15
Time
1035 - 1040
1047 - 1052
1059 - 1104
1111 - 1116
1123 - 1128
1135 - 1140
1147 - 1152
1159 - 1204
1211 - 1216
1223 - 1228
1240 - 1245
1252 - 1257
1304 - 1309
1316 - 1321
1328 - 1333
Average
% opacity
1
1
1
0
0
1
1
1
0
0
0
2
0
1
0
Range
0-5
0-5
0 - 5
0-5
0-5
0-5
0-5
0 - 5
0
0
0
0-5
0-5
0-5
0
Test 2 (7/15/81)
Set No.
SOVE-2-1
SOVE-2-2
SOVE-2-3
SOVE-2-4
SOVE-2-5
SOVE-2-6
SOVE-2-7
SOVE-2-8
SOVE-2-9
SOVE-2-10
SOVE-2-1 1
SOVE-2-1 2
SOVE-2-13
SOVE-2-14
Time
0900 - 0905
0912 - 0917
0924 - 0929
0936 - 0941
0948 - 0953
1000 - 1005
1012 - 1017
1024 - 1029
1036 - 1041
1048 - 1053
1100 - 1105
1112 - 1117
1124 - 1129
1136 - 1141
Average
% opacity
4
2
1
2
0
1
0
1
1
0
0
0
0
0
Range
0 - 5
0-5
0 - 5
0 - 5
0 - 5
0 - 5
0
0 - 5
0 - 5
0-5
0
0
0
0
Test 3 (7/15/81)
Set No.
SOVE-3-1
SOVE-3-2
SOVE-3-3
SOVE-3-4
SOVE-3-5
SOVE-3-6
SOVE-3-7
SOVE-3-8
SOVE-3-9
SOVE-3-10
SOVE-3-1 1
SOVE-3-1 2
Time
1355 - 1400
1407 - 1412
1419 . 1424
1431 - 1436
1443 - 1448
1455 - 1500
1507 - 1512
1519 - 1524
1531 - 1536
1543 - 1548
1555 - 1600
1607 - 1612
Average
% opacity
0
0
0
1
0
0
2
1
0
1
0
1
Range
0-5
0-5
0
0 - 5
0
0-5
0-5
0 - 5
0
0 - 5
0
0 - 5
u>
I
H«
00
-------
observations were made by EPA Method 9.* Sulfur dioxide tests
were conducted using EPA Method 6.* Concentration and mass
emission 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 3-7
and 3-8.
The filterable particulate data reported in Table 3-8 -
represent matter 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 material
that condensed out or was trapped in the impinger section of the
sample train at a temperature of approximately 20°C (68°F). All
velocity measurements were obtained using an S type pitot tube
and a 0-0.635 cm (0-0.25 in.) inclined manometer due to the low
flow (natural draft) situation encountered at this site.
The volumetric flow rate averaged 11,800 dscmh (415,300
dscfh), temperature averaged 197°C (386°F), and the moisture
content averaged 2.1 percent. The oxygen and carbon dioxide
contents averaged 20.1 and 0.0 percent, respectively.
Filterable particulate concentration averaged 147 mg/dscm
(0.064 gr/dscf) with a corresponding average mass emission rate
of 1.7 kg/h (3.8 Ib/h). The organic and inorganic concentrations
averaged 0.63 mg/dscm (0.0003 gr/dscf) and 24 mg/dscm (0.01
*
40 CFR 60, Appendix A, Reference Methods 6 and 9, July 1, 1981.
3-19
-------
TABLE 3-7. SUMMARY OF FLUE GAS CONDITIONS
CLINKER COOLER OUTLET
No.
CCP-1
CCP-2
CCP-3
Date,
1981
7/14
7/15
7/15
Average
Volumetric flow rate
Actual a
acmh
19,748
19,521
19,125
19,465
acfh
697,376
689,365
675,396
687,379
Standard
dscmh
11,438
11,874
11,968
11,760
dscfh
403,918
419,309
422,646
415,291
Temperature
°C
218
194
178
197
°F
424
381
353
386
Moisture,
%
2.0
1.8
2.4
2.1
o2,
5T
20.3
19.8
20.2
20.1
co?,
r
0.0
0.0
0.0
0.0
CO,
%
0.0
0.0
0.0
0.0
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 zero percent moisture.
-------
TABLE 3-8. SUMMARY OF PARTICULATE EMISSIONS DATA
Clinker cooler outlet
Run
No.
CCP-1
CCP-2
CCP-3
Date,
1981
7/14
7/15
7/15
Average
Concentration3
Filterable
mg/dscm
120.3
144.2
176.8
147.1
gr/dscf
0.053
0.063
0.077
0.064
Condensible
Organic
mg/dscm
0.57
0.23
1.08
0.63
gr/dscf
0.0003
0.0001
0.0005
0.0003
Inorganic
mg/dscm
19.3
27.9
24.4
23.9
gr/dscf
0.008
0.012
0.011
0.010
Mass emission rate
Filterable
kg/h
1.4
1.7
2.1
1.7
Ib/h
3.0
3.8
4.7
3.8
Condensible
Organic
kg/h
0.006
0.002
0.013
0.007
Ib/h
0.014
0.006
0.028
0.016
Inorganic
kg/h
0.22
0.33
0.29
0.28
Ib/h
0.49
0.73
0.64
0.62
Ul
I
NJ
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).
-------
gr/dscf), and the corresponding mass emission rates averaged
0.007 kg/h (0.016 Ib/h) and 0.28 kg/h (0.62 Ib/h).
3.2.2 Particle Size Distribution
A total of four particle size samples were collected from
the clinker cooler outlet during the particulate test runs. An
Andersen cascade impactor was used for these tests. Section
3.1.2 and Appendix A describe the sampling and analytical proce-
dures and the data reduction techniques used, respectively.
Figure 3-3 presents the distribution curve for each set of
four samples collected. Individual data points for each test
were plotted manually. The distribution curve was plotted
manually for each individual test. All particle size results are
based on aerodynamic diameters and unit density (1 g/cm ). The
data show that 50 percent of the particles by weight were less
than 20 ym.
3.2.3 Clinker Cooler Visible Emissions
Visible emissions were surveyed at the clinker cooler outlet
during each particulate test. Visible emissions were read in 6-
minute sets throughout each test. Table 3-9 summarizes the;
visible emissions data. No visible emissions from the stack were
detected by the certified observer during the test period.
3.2.4 Sulfur Dioxide
Table 3-10 summarizes the results of SO,, tests conducted at
the clinker cooler outlet. For each test, the S07 concentration
averaged less than 1 ppm by volume, which is below the minimum
detectable limit of the analytical method.* It should be noted
40 CFR 60, Appendix A, Reference Method 6, July 1, 1981.
3-22
-------
CO
I
ro
5 it
Ui
oe It
UJ
a.
I
I
I
t.t
±tt
ffl
ilU
I I
I III II! II
11
in i
1
I
:RUN ccPS-3
H
Hit
ill III
—«.$
1
—•
1.0
10.0
100
PARTICLE SIZE, microns
Figure 3-3. Particle size distribution - clinker cooler exhaust.
-------
K)
ML*
^- ,^_
m (t
»-
oc W
Ul
a.
I
t
t
•.1
tf
ill
s
illi
ill!
1RUN CCPS-4C
m
I
1.0
10.0
100
PARTICLE SIZE, microns
Figure 3-3 (continued)
-------
u>
I
tsj
Ul
PARTICLE SIZE, microns
Figure 3-3 (continued)
-------
U)
I
to
en
•M
•M
M
!•
8
t
M
•.t
1.1
liu
111
lidl
Ilii
ill!
i
±tt
a
RUN CCPS-6
tt±I
iiii
-41
1.0
10.0
100
PARTICLE SIZE, microns
Figure 3-3 (continued)
-------
TABLE 3-9. SUMMARY OF VISIBLE EMISSIONS DATA
CLINKER COOLER OUTLET
Test 1 (7/14/81)
Set No.
CCVE-1-1
CCVE-1-2
CCVE-1-3
CCVE-1-4
CCVE-1-5
CCVE-1-6
CCVE-1-7
CCVE-1-8
CCVE-1-9
CCVE-1-10
CCVE-1-1 1
CCVE-1-12
CCVE-1-1 3
CCVE-1-14
Time
1041 - 1046
1053 - 1058
1105 - 1110
1117 - 1122
1129 - 1134
1141 - 1146
1153 - 1158
1205 - 1210
1217 - 1222
1234 - 1239
1246 - 1251
1258 - 1303
1310 - 1315
1322 - 1327
Average
% opacity
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Range
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Test 2 (7/15/81)
Set No.
CCVE-2-1
CCVE-2-2
CCVE-2-3
CCVE-2-4
CCVE-2-5
CCVE-2-6
CCVE-2-7
CCVE-2-8
CCVE-2-9
CCVE-2-10
CCVE-2-11
CCVE-2-12
Time
0906 - 0911
0918 - 0923
0930 - 0935
0942 - 0947
0954 - 0959
1006 - 1011
1018 - 1023
1030 - 1035
1042 - 1047
1054 - 1059
1106 - 1111
1118 - 1123
Average
% opacity
0
0
0
0
0
0
0
0
0
0
0
0
Range
0
0
0
0
0
0
0
0
0
0
0
0
Test 3 (7/15/81)
Set No.
CCVE-3-1
CCVE-3-2
CCVE-3-3
CCVE-3-4
CCVE-3-5
CCVE-3-6
CCVE-3-7
CCVE-3-8
CCVE-3-9
CCVE-3-10
CCVE-3-1 1
Time
1401 - 1406
1413 - 1418
1425 - 1430
1437 - 1442
1449 - 1454
1501 - 1506
1513 - 1518
1525 - 1530
1537 - 1542
1549 - 1554
1601 - 1606
Average
% opacity
0
0
0
0
0
0
0
0
0
0
0
Range
0
0
0
0
0
0
0
0
0
0
0
to
-------
TABLE 3-10. SUMMARY OF SULFUR DIOXIDE RESULTS
CLINKER COOLER OUTLET
Run
No.
CCS-1
CCS-2
Date,
1981
7/17
7/17
Average
CCS-3
CCS-4
7/17
7/17
Average
CCS- 5
CCS- 6
7/17
7/17
Average
Concentration a
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 10'°
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,
%
20.2
20.2
20.2
20.3
20.3
20.3
20.1
20.1
20.1
Temperature
°C
197
197
197
197
197
197
197
197
197
°F
386
386
386
386
386
386
386
386
386
Below minimum detectable limit, when 0.001 N barium perchlorate was used to
increase the minimum detectable limit.
3-28
-------
that the normality of the barium perchlorate solution used in
analyses of these samples was changed to 0.001 N to increase the
detectable limit.
3.3 PROCESS SAMPLES
Table 3-11 summarizes results from analysis of process
samples collected during each particulate test. Shale and coal
samples were collected at approximately 30-minute intervals.
Shale samples were collected from the kiln feed conveyor and coal
samples after the pulverizer, before the coal entered the kiln.
Samples of the final aggregate product and scrubber water efflu-
ent were also collected for determination of total sulfates.
One scrubber influent sample was collected by PEDCo personnel
at the end of the test program for sulfate analyses and pH
determination.
The analytical data on shale showed an average sulfur con-
tent of 0.11 percent and an average moisture content of 0.61
percent. The analytical data on coal showed an average sulfur
content of 2.03 percent and an average ash content of 17.8 per-
cent. The sulfur content of the final product averaged less than
0.02 percent. The sulfate concentration of the scrubber influent
sample was 1770 milligrams per liter (ml). The sulfate concen-
tration of the effluent samples averaged 1890 ml/liter. The
scrubber influent showed a pH of 4.0 and composite samples of the
effluent a pH of 3.95.
3-29
-------
TABLE 3-11. SUMMARY OF PROCESS SAMPLE ANALYSIS RESULTS
Participate
Run No.
1
2-3
1-3
Date,
1981
7/14
7/15
7/14-15
Sample
type
Coal
Shale
Coal
Shale
Final
product
Scrubber
influent
Scrubber
effluent
Density,
g/cm^
2.52
2.60
2.23
-
-
Moisture, %
as received
6.95
0.63
6.61
0.58
_
-
-
Ash, %
dry basis
16.87
18.67
_
-
-
Sulfur, %
dry basis
except where
noted
2.11?
0.12b
1.95*
0.09°
<0.02b
1770 mg/lc
1890 mg/lc
(average)
aASTM D3177.
ASTM D2234, as received basis.
Concentration in milligrams per liter.
3-30
-------
3.4 FUGITIVE EMISSIONS
Fugitive emissions were surveyed during each particulate
test using procedures described in EPA Method 9.* Separate
surveys were performed at the following locations: raw material
crushing, clinker discharge chute, final product crushing and
screening, and the kiln seals (charge and product). A 30-minute
survey was conducted at each location during the particulate
tests. Table 3-12 summarizes the results of the fugitive e:mis-
sion survey.
*
40 CFR 60, Appendix A, Reference Method 9, July 1, 1981.
3-31
-------
TABLE 3-12. SUMMARY OF FUGITIVE EMISSIONS DATA
Raw material crusher
Test 1 (7/14/81)
Set No.
VFC-1-1
VFC-1-2
VFC-1-3
VFC-1-4
VFC-1-5
Time
1035 - 1040
1041 - 1046
1047 - 1052
1053 - 1058
1059 - 1104
Average
% opacity
0
1
0
0
0
Range
0
0 - 5
0
0 - 5
0
Test 2 (//IS/81)
Set No.
VFC-2-1
VFC-2-2
VFC-2-3
VFC-2-4
VFC-2-5
Time
1100 - 1105
1106 - 1111
1112 - 1117
1118 - 1123
1124 - 1129
Average
% opacity
0
0
0
0
0
Range
0
0
0-5
0
0 - 5
Test 3 (7/15/81)
Set No.
VFC-3-1
VFC-3-2
VFC-3-3
VFC-3-4
VFC-3-5
Time
1350 - 1355
1356 - 1401
1402 - 1407
1408 - 1413
1414 . 1419
Average
% opacity
0
0
0
0
0
Range
0
0
0
0
0
Rotary kiln seals
VFK-1-1
VFK-1-2
VFK-1-3
VFK-1-4
VFK-1-5
1110 - 1115
1116 - 1121
1122 - 1127
1128 - 1133
1134 - 1139
0
0
0
0
0
0
0
0
0
0
VFK-2-1
VFK-2-2
VFK-2-3
VFK-2-4
VFK-2-5
1020 - 1025
1026 - 1031
1032 - 1037
1038 - 1043
1044 - 1049
0
0
0
0
0
0
0
0
0
0
VFK-3-1
VFK-3-2
VFK-3-3
VFK-3-4
VFK-3-5
VFK-3-6
VFK-3-7
1425 - 1430
1431 - 1436
1437 - 1442
1443 - 1448
1449 - 1454
1610 - 1615
1616 - 1621
0
0
0
0
0
0
0
0
0
0
0
0
0
0
I
U)
to
Clinker cooler
VCCF-1-1
VCCF-1-2
VCCF-1-3
VCCF-1-4
VCCF-1-5
1150 - 1155
1156 - 1201
1202 - 1207
1208 - 1213
1214 - 1219
5
5
5
5
6
5
5
5 - 10
5
5-10
VCCF-2-1
VCCF-2-2
VCCF-2-3
VCCF-2-4
VCCF-2-5
VCCF-2-6
0900 - 0905
0906 - 0911
0912 - 0917
0918 - 0923
0924 - 0929
1138 - 1143
8
5
5
5
7
6
5-10
5 - 10
5
5
5-10
5-10
VCCF-3-1
VCCF-3-2
VCCF-3-3
VCCF-3-4
VCCF-3-5
VCCF-3-6
VCCF-3-7
1500 - 1505
1506 - 1511
1512 - 1517
1518 - 1523
1524 - 1529
1550 - 1555
1556 - 1601
1
6
6
7
5
6
6
0-5
0-10
5-10
5 - 10
5
0-10
5-10
Final product crusher
VFCF-1-1
VFCF-1-2
VFCF-1-3
VFCF-1-4
VFCF-1-5
1230 - 1235
1236 - 1241
1242 - 1247
1248 - 1253
1254 - 1259
5
3
0
0
0
0 - 10
0-5
0 - 5
0 - 5
0 - 5
VFCF-2-1
VFCF-2-2
VFCF-2-3
VFCF-2-4
VFCF-2-5
VFCF-2-6
0935 - 0940
0941 - 0946
0947 - 0952
0953 - 0958
0959 - 1004
1150 - 1155
2
3
0
1
1
1
0 - 5
0 - 5
0
0-5
0-5
0 - 5
VFCF-3-1
1540 - 1545
0
0
-------
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 subsections describe the sampling sites for
particulates, sulfur dioxide, nitrogen oxide, VOC, and particle
size distribution testing.
4.1 SCRUBBER INLET
Particulates, sulfur dioxide, and particle size distribution
were measured at the inlet to the wet scrubber as shown in Figure
4-2. Two sample ports, 90 degrees off-center, were located 1.8
duct diameters (dd) downstream and 0.3 dd upstream from the
nearest flow disturbances in the 1.99 m (6.54 ft) I.D. round
duct. Forty-eight traverse points, twenty-four per port, were
used to traverse the cross-sectional area of the duct for the
particulate tests. Each point was sampled for 2.5 minutes which
yielded a total test time of 120 minutes. Sulfur dioxide sam-
pling was conducted using constant rate sample techniques by
placing the probe tip near the center of the duct. Particle size
samples were collected at a point of average velocity in the duct
using an Andersen Heavy Grain Loading Impactor.
4-a
-------
SHALE
(D
COAL-
COOLING AIR™*
_ SAMPLE
© POINT
_». SOLIDS
FLOW
-•* AIR/GAS
FLOW
STACK
8)
" CAPTURED
PARTICULATE
SLUDGE
©
PRODUCT
Sample type
Patlculate
S02
Particle size
"°K
ovc
Fugitive dust
Stack opacity
Sulfur, ash, moisture
content
Density, moisture
content, sulfur
Sulfur
Total sul fates,
PH
Sample point
3.4,9
3.4.9
3.4.9
4
4
Kiln seals, 10,
11,12.13
4,9
1
2
5.6
5
(Influent and
effluent)
No. of samples
3
3
3
12 grab
3
3
3
24
(composite)
24
(composite)
Composite
Composite
Method
EPA 58
EPA 6
Impactor
EPA 7
EPA 25
EPA 9
EPA 9
ASTM D3177,
D3174, D3173,
D2234
AS™ C29.
Gravimetric,
D1757
01 757
427-Cb
*Condens1ble organic and Inorganic fractions will be determined by means of
ether/chloroform extraction.
bStindard Methods for the Examination of Water and Uastewater, 14th Edition.
Figure 4-1. Sampling plan and process flow sheet,
Vulcan Materials Company.
4-2
-------
KILN FEED
1
/ IT
/ *
/ 1 1
M \
M \
'/ KILN -
/
1
I
\/
' KNOCKOUT r
CHAMBER L
TRAVERSE
i r\r\ v UI\OL
POINT NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
DISTANCE*
LJ 1
-------
4.2 SCRUBBER OUTLET
Particulates, sulfur dioxide, nitrogen oxide, particle size
distribution, and VOC contents were measured at the wet scrubber
outlet, as shown in Figure 4-3. Two sample ports, 90 degrees
off-center, were located 4.6 dd downstream and 1.7 dd upstream
from the nearest flow disturbances in the 1.97 m (6.46 ft) I.D.
round stack. Thirty-two traverse points, sixteen per port, were
used to traverse the cross-sectional area of the stack for the
particulate test runs. Each point was sampled for 4 minutes,
which yielded a total test time of 128 minutes. Sulfur dioxide,
nitrogen oxide, and VOC sampling was conducted by use of con-
stant-rate sample techniques that placed the respective probe
tips near the center of the stack. Particle size samples were
collected using an Andersen in-stack impactor.
4.3 CLINKER COOLER EXHAUST
Particulate and sulfur dioxide concentrations as well as
particle size distribution were measured at the clinker cooler
exit stack, as shown in Figure 4-4. Two sample ports, 90 degrees
off-center, were located 6 dd downstream and 2.4 dd upstream from
the nearest flow disturbances in the 1.35 m (4.42 ft) I.D. round
stack. Twenty-four traverse points, twelve per port, were used
to traverse the cross-sectional area of the stack for the par-
ticulate test runs. Each point was sampled for 5 minutes, which
yielded 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.
4-4
-------
T
3.4 m
(11.17 ft)
9.09 m
(29.83 ft)
= 1.7 dd
O O
SAMPLE PORTS
4.6 dd
FLOW
t
SCRUBBER
CROSS SECTION
1.97 m (6.46 ft) I.D.
9.53 cm (3.75 in.)
NIPPLE LENGTH
TRAVERSE
POINT NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
DISTANCE*
cm
12.70
19.05
26.37
34.29
42.85
52.71
65.10
83.19
132.41
150.83
163.20
173.05
181.61
189.56
196.85
203.20
in.
5.00
7.50
10.38
13.50
16.87
20.75
25.63
32.75
52.13
59.38
64.25
68.13
71.50
74.63
77.50
80.00
*Includes nipple length.
Figure 4-3. Scrubber outlet test location.
4-5
-------
T
3.29 m
(10.8 ft)
8.08 m
(26.52 ft)
= 2.4 dd
O
= 6 dd
f
NATURAL
DRAFT FLOW
I.D. FAN
(NOT
OPERATING)
FROM SETTLING
CHAMBER
CROSS SECTION
1.35 m (4.42 ft) I.D.
9.53 cm (3.75 in.)
NIPPLE LENGTH
TRAVERSE
POINT NO.
1
2
3
4
5
6
7
8
9
10
11
12
DISTANCE*
cm
12.34
18.54
25.40
33.35
43.18
57.45
96.22
110.49
120.32
128.28
135.13
143.87
in.
4.86
7.30
10.00
13.13
17.00
22.62
37.88
43.50
47.37
50.50
53.20
55.64
*Includes nipple length.
riyiire 4-4. Clinker cooler sample location.
-------
Particle size samples were collected using an Andersen in-stack
impactor. The test and analytical procedures used 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. Velocities were measured
at each sampling point across the duct to determine an average
value. Measurements were made according to the procedures out-
lined in Method 2 of the Federal Register.** The temperature was
also measured at each sampling point by use of thermocouple and
potentiometer.
4.5 MOLECULAR WEIGHT
Flue gas composition was determined by using procedures
described in Method 3 of the Federal Register.** A bag sample
was collected during each particulate, sulfur dioxide, and
nitrogen oxide test run. The bag contents were analyzed by use
of an Orsat Gas Analyzer.
4.6 PARTICULATES
Particulate grain loading was measured at each test location
according to Method 5, as described in the Federal Register.**
All tests were conducted isokinetically by traversing the cross-
sectional area of the stack and regulating the sample flow rate
*
A 0-0.635 cm (0-0.25 in.) manometer was used at the clinker
cooler exit stack.
**
40 CFR 60, Appendix A, Reference Methods 2, 3, and 5, July 1,
1981.
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, and heated 87-mm (3-in.) diameter
glass fiber filter (Reeve Angel 934 AH), and a series of Green-
burg-Smith impingers were used in each test. A heated 316
stainless steel probe was used on the scrubber inlet sample train
due to the high flue gas temperatures at this location. In
addition, a cyclone was placed prior to the heated filter due to
the heavy particulate loading. The nozzle, probe, and filter
holder portions of the sample train were acetone-rinsed 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 constant weight, and weighed on an analytical balance. Total
filterable 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
content by ether-chloroform extraction.
4.7 SULFUR DIOXIDE
The test procedure used was as described in Method 6 of the
Federal Register* except the midget impingers were replaced 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 and in the connecting glassware
between the first and second impingers. A heated quartz glass
probe was used on the scrubber inlet sample train and a cyclone-
*
40 CFR 60, Appendix A, Reference Method 6, July 1, 1981.
4-8
-------
filter assembly was placed prior to the impingers due to the
heavy particulate loading at this location. Each 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 onsite for sulfates by using the
barium-thorin titration method.
4.8 NITROGEN OXIDE
Sampling and analytical procedures were 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. The
samples were shipped to the laboratory for analysis.
4.9 PARTICLE SIZE DISTRIBUTION
Particle size samples from the scrubber and clinker cooler
exit stacks were obtained using an Andersen 2000 Mark III Source
Cascade Impactor. This in-stack, multistage cascade impactor has
a total of eight stages. Particle size cutoffs range from 0.5 to
15 ym and are followed by a backup filter stage. Substrates for
the Andersen were 64-mm glass fiber filters. A constant sampling
rate was maintained through the test period. The rates were set
for isokinetic sampling as long as the rate did not exceed the
recommended flow rate for the impactor (0.70 acfm).
A total of four impactor runs were made at each sampling
site. Sampling point locations for each stack were as shown in
*
40 CFR 60, Appendix A, Reference Method 7, July 1, 1981.
4-9
-------
Figure 4-5. At least one impactor run was made at each sampling
point. Sampling procedures were those recommended in the "Proce-
dures Manual for Inhalable Particulate Sampler Operation," re-
cently developed for EPA by the Southern Research Institute.
Particle size samples from the scrubber inlet were obtained using
an Andersen Heavy Grain Loading Impactor. This in-stack impactor
has a total of three stages. Particle size cutoffs range from 2
to 17 microns (vim) . A total of two samples were collected at a
point of average velocity in the duct.
4.10 HYDROCARBON EMISSIONS
Sampling and analysis for hydrocarbon emissions was con-
ducted using EPA Method 25* for the determination of total gase-
ous nonmethane organics. Samples were collected by drawing gas
from the stack through a dry-ice condensate trap by means of an
evacuated sample tank. Sampling was conducted at a single point
in the stack and a constant sampling rate between 80 and 90
ml/min was maintained. Both the sample tank and the condensate
trap were analyzed to determine the nonmethane organic content of
the exhaust gas.
Analysis of the tank fraction was accomplished by injecting
the sample into an analyzer which separated the nonmethane or-
ganics from CO, C02, and CH., oxidized the components to CO- and
reduced the C0~ to methane for measurement with a flame ioniza-
tion detector (FID).
40 CFR 60, Appendix A, Reference Method 25, July 1, 1981.
4-10
-------
Figure 4-5. Particle size sampling points for circular stack.
4-11
-------
Condensate was recovered by heating the trap and probe line
to 650°C (1200°F), converting the contents to carbon dioxide with
a catalytic oxidizer, and collecting the C0_ in an intermediate
collection tank. The intermediate tank was analyzed by injecting
the contents into the analyzer where the CO- was reduced to
methane and measured with the FID. The total gaseous nonmesthane
organic content was determined by summing the results of the trap
and tank analyses.
4.11 PROCESS SAMPLES
Samples of the coal and shale fed to the kiln were collected
at approximately 30-minute intervals during the particulate;
sampling. Coal samples were collected after the pulverizer, at a
point just before the coal entered the kiln. Shale samples were
collected from the kiln feed conveyor belt. Coal samples were
analyzed for sulfur content, moisture content, and percent ash.
Shale samples were analyzed for sulfur content, density, and
moisture content.
Samples of the influent and effluent from the kiln wet
scrubber and final aggregate product were collected and analyzed
for sulfate content and pH.
4.12 VISIBLE AND FUGITIVE EMISSIONS
Visible and fugitive emission observations were performed
using procedures described in EPA Method 9.* Certified visible
emission readers were utilized for each task.
40 CFR 60, Appendix A, Reference Method 9, July 1, 1981.
4-12
-------
SECTION 5
QUALITY ASSURANCE
Because the end product of testing is to produce representa-
tive emission results, quality assurance is one of the main
facets of stack sampling. Quality assurance guidelines provide
the detailed procedures and actions necessary for defining and
producing acceptable data. Four such documents were used in this
test program to insure the collection of acceptable data and to
provide a definition of unacceptable data. The following docu-
ments comprise 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, which are PEDCo's general guideline manuals, define
the company's standard operating procedures and are followed by
the emission testing groups and the laboratory groups.
Appendix F provides more detail on the quality assurance
procedures, such as 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, the following steps
are taken to insure that the testing and analytical procedures
used will produce quality data.
0 Calibration of field sampling equipment. (Appendix E
describes calibration guidelines in more detail.)
0 Checks of train configuration and calculations.
0 Onsite quality assurance checks, such as sample train,
pitot tube, and Orsat line leak checks, and quality
assurance checks of all test equipment prior to use.
0 Use of designated analytical equipment and sampling
reagents.
Table 5-1 lists sampling equipment used for particulate, SO,,
and NO testing, and the calibration guidelines and limits. In
X
addition to the pre- and post-test calibrations, a field audit
was performed on the meter boxes used for particulate and S02
sampling. PEDCo constructed critical orifices were used for this
audit. Figures 5-1 through 5-3 show an example audit run for
each dry gas meter used for particulate and SO_ testing.
As a check on the reliability of the method used to analyze
the filters for the particulate and particle size tests, sets of
filters that had been preweighed in the lab were resubmitted for
replicate analysis. Table 5-2 summarizes the results of a blank
filter and reagent analysis. In addition, particle size blanks
were run at each exit location to determine if any bias may have
been caused by reaction of flue gas with the impactor substrates.
As expected, no bias was observed.
Audit solutions prepared by the EPA were used to check the
analytical procedures and reagents for SO9 and NO sample
£* J\.
5-2
-------
TABLE 5-1. FIELD EQUIPMENT CALIBRATION - SCRUBBER INLET
Ul
i
GJ
Equipment
Meter box
P1tot tube
Digital
Indicator
Thermocouples
and stack
thermometers
Or sat analyzer
Implnger
thermometer
Trip balance
Barometer
Dry qas
thermometer
Probe nozzle
I.D.
No.
FB-2
024
221
258
NA
232
110
198
227
FB-2
!n-
Out-
4-114
Calibrated
against
Het 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 of 3F
Callper
Allowable
deviation
V +0.02 V
AH P +0.15
(Y +0.05 Y post-test)
Cp +0.01
0.5",
1.57!
(+2* saturated)
+0.5",
+2°F
+0.5 g
+0.10 1n. Hg.
(0.20 post test)
+5°F
On +0.004 1n.
Actual
deviation
-1.9%
0.0
<0.2%
0.0
O.U
<1°F
0.0
0.01
1.5°F
1.8°F
0.001
Within
allowable
limits
/
/
/
/
/
/
/
/
/
/
/
Comments
Used for particulate,
particle size, and
S02 tests.
Particulate only.
-------
TABLE 5-1 (continued)
Scrubber Outlet
tn
i
Equipment
Heter box
PUot tube
Digital
Indicator
Thermocouples
•nd stack
thermometers
Orsat analyzer
Implnger
thermometer
Trip balance
Barometer
Dry gas
thermometer
Probe nozzle
I.D.
No.
FB-9
FB-10
188
125
259
NA
232
109
198
227
FB-9 I
FB-9 0
^-10 I
T5-10 0
5-116
Calibrated
against
Wet test meter
Standard pltot
tube
Millivolt signals
ASTM-2F or 3F
Standard gas
ASTM-2F or 3F
Type S weights
NBS traceable
barometer
ASTM-2F of 3F
Call per
Allowable
deviation
Y +0.02 Y
AH~P +0.15
(Y +0.05 Y post-test)
Cp +0.01
0.5",
1.5T,
(+2* saturated)
+0.5r,
+2°F
+0.5 g
+0.10 In. Hg.
(0.20 post test)
+5°F
On +0.004 In.
Actual
deviation
+0.2%
-0.4%
0.0
<0.25!
<1.0%
+0.1%
-------
TABLE 5-1 (continued)
Clinker Cooler
en
i
en
Equipment
Heter box
PI tot tube
Digital
Indicator
Thermocouples
and stack
thermometers
Orsat analyzer
Implnger
thermometer
Trip balance
Barometer
Dry gas
thermometer
Probe nozzle
I.D.
No.
FB-3
FB-7
042
207
257
NA
232
107
198
227
FB-3 I
FB-3 0
FB-7 I
FB-7 0
8-108
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 of 3F
Call per
Allowable
deviation
Y +0.02 Y
AH P +0.15
(Y +0.05 Y post-test)
Cp +0.01
0.5",
1.5T,
(+2" saturated)
+0.5*.
+2°F
+0.5 g
+0.10 In. H«j.
(0.20 post test)
+5°F
On +0.004 In.
Actual
deviation
0.8%
0.5%
0.0
Avg.
<0.42%
0.05%
0.1%
<1°F
0.0
0.01
1.2°F
0.7°F
3.5°F
1.4°F
+0.001
Within
allowable
limits
/
' .
'
'
'
'
'
V
/
'
Cownents
Used for particulate
and S02 tests.
FB-7 used for particle
size runs.
Particulate only.
-------
DATE:
AUDIT REPORT SAMPLE METER BOX
CLIENT:
t/oU**/ ft-h
BAROMETRIC
ORIFICE NO.
PRESSURE (P
Kir" ' '
'in. Hg METER BOX NO. F&-T- ^UM^M/ i^
PRE-TEST Y: / OO-3-
ORIFICE K FACTOR: £. ^OGX/cT^ AUDITOR:
Orifice
manometer
reading
AH
in H20
2-^
Dry gas
meter
reading
v./vf
ft3
Y/7.*oz>
yso.voo
_^ O y
Temperatures
Ambient
Tai/Taf
°F
/& -L-
/ & o
Dry gas meter
Inlet
°F
*><6
9 r
Outlet
Toi/Tof
CF
^O
*?/
Duration
of
run
min
/b.^;
Dry gas
meter
volume
Vm
ft3
/3 .6
Average temperatures
Ambient Dry gas
meter
Ta Tm
op op
/<£>/ 91. 7.5-
\td
ft3
^^M*--
Xct
ft3
Audit
Y
Y
deviation
mstd
(17.647)( Vm )(Pbar+ AH/13.6)
(Tm + 460)
/£. .^^^-~
Audit Y
mact
mstd
/^^ _j
\ct
(1203)( 0 )( K )(Pbar)
(T, + 460)1/2
a
/ -2_ - sS-^2-
Y deviation, %
(Y audit - Y pre-test)(1IOO°/0
(Y audit)
9-.^ %>
Audit Y must be in the range, pre-test Y ±0.05 Y
Audit AH@ must be in the range, AH@ ±0.15
Figure 5-1. Meter box audit, scrubber inlet.
5-6
-------
AUDIT REPORT SAMPLE METER BOX
CLIENT:
DATE: ^
BAROMETRIC PRESSURE (P^iJV.S? in. Hg METER BOX NO.
ORIFICE NO. tr PRE-TEST Y:
AUDITOR:
ORIFICE K FACTOR:
t>
Temperatures
Ambient
Tai/Taf
°F
17
.•!*>
Average temperatures
Ambient
Ta
°F
77 <
Dry gas
meter
Tm
°F
/#?. 7.-T
mstd
ft3
n 157
ft3
/'.frt
Audit
Y
/on
Y
deviation
y.^7
V|T1std
(17.647)( Vm )(Pbar + AH/13.6)
(Tffl + 460)
/2JS7
Audit Y
\ct
OL L
Vfnstd
/'^/_
Xct
(1203)( 0 )( K )(P )
(Ta + 460)1/2
a
"-1*7
Y deviation, %
(Y audit - Y pre-test)(100%)
(Y audit)
+ >J
Audit Y "lust be 1n the range, pre-test Y ±0.05 Y
Audit AH@ must be in the range, AH@ +0.15
Figure 5-2. Meter box audit, scrubber outlet.
5-7
-------
AUDIT REPORT SAMPLE METER BOX
•7-'J3-S7 CLIENT:
DATE:
BAROMETRIC PRESSURE (Pbar):3?.6T in. Hg METER BOX NO. jz_
ORIFICE NO. */ PRE-TEST
ORIFICE K FACTOR: $, 2*O X'O*^ AUDITOR:
Orifice
manometer
reading
AH
in H20
2*
Dry gas
meter
reading
Vvf
ft3
0-75-7
&O~7< 7
Temperatures
Ambient
VTaf
°F
97
to i
Dry gas meter
Inlet
vv
°F
/02.
/ »Z-
Outlet
Toi/Tof
°F
?C
*?S~
Duration
of
run
0
min
>tr./
Dry gas
meter
volume
n3
/J.GO
Average temperatures
Ambient
Ta
°F
^H
Dry gas
meter
Tm
°F
*1*l
Vmstd
ft3
/r^-76
Xct
n3
n-lo-i,
Audit
Y
.w
Y
deviation
31-0
Vmstd
(17.647)( Vm )(Pbar + AH/13.6)
(Tm + 460)
Audit Y
mact
mstd
Xct
(1203)( 0 )( K )(P )
(Ta + 460)1/2
a
Y deviation, %
(Y audit - Y pre-test)(100%)
(Y audit)
Audit Y must be 1n the range, pre-test Y iO.05 Y
Audit AH@ must be in the range, AHP +0.15
Figure 5-3. Meter box audit, clinker cooler.
5-8
-------
TABLE 5-2. EXAMPLE BLANK FILTER AND REAGENT ANALYSIS
Sample type
Participate
87 mm Reeve
Angel 934 AH
No. 0002267
Particle size
64 mm Reeve
Angel 934 AH
S-15
J-144
S-39
J-126
S-33
J-134
S-77
J-116
B-462
Acetone
blank
H20 blank
Ether-chloroform
Original tare
weight, mg
359.2
142.1
138.4
143.4
141.0
143.4
136.3
144.6
135.8
206.0
99690.6
93932.9
65872.8
Blank weight,
mg
359.4
142.6
138.6
143.4
141.0
143.4
136.3
144.5
136.1
206.2
99698.6
93972.2
65877.8
Net weight,
mg
+0.2
+0.5
+0.2
0.0
0.0
0.0
0.0
-0.1
+0.3
+0.2
0.02 mg/ga
0.10 mg/ga
0.03 mg/ga
0.01 mg/g used in calculations.
5-9
-------
analysis. Tables 5-3 and 5-4 present the results of these
analytical audits. The audit tests show that the analytical
techniques were good.
The quality assurance procedures specified in Method 25
include oxidation and reduction catalyst checks, complete cali-
bration of the NMO analyzer, use of proper materials of con-
struction for sampling tanks and traps (316 stainless steel), and
checks to determine the blank values for the analyzer and trap
conditioning apparatus carrier gases. In addition, PEDCo has
found it necessary to use the following procedures to check and
prepare sampling equipment before testing. Prior to each test,
all condensate traps are checked for cleanliness using the trap
conditioning apparatus. Traps are heated to 650°C (1200°F) with
carrier gas passing through the trap, and oxidizer, and through
the GC gas sample loop. The sample loop contents are then
injected to the NMO analyzer to determine the level of contami-
nant remaining in the trap. This process is repeated until an
acceptable blank value is obtained. Typical blank values for
traps range from 5 to 10 ppm.
Gas sampling tanks are cleaned by evacuating the tanks and
filling with nitrogen. This procedure is repeated until an
analysis of the tank on the Method 25 analyzer demonstrates that
the tank contains no contaminants from previous sampling jobs.
All tanks to be used in a testing program are checked in this
manner before shipment to the sampling site.
5-10
-------
TABLE 5-3. AUDIT REPORT SO- ANALYSIS
- ONSITE AUDIT -
Plant
PN Number
Date samples received 7' /{,
Samples analyzed £y
Reviewed by
Date analyzed
Date of Review
Sample
Number
mg SC>2/dscm
Determined
Source of
Sample
Accepted
Value
Difference
S3 7 3
lltL
<}//<*
5-11
-------
TABLE 5-4. AUDIT REPORT NO ANALYSIS
Plant
V/ut(?
aa
PN Number
Date samples received
Samples analyzed by
Date analyzed ~1 -
Reviewed by J ', &i mttt T.S- *"• Date of Re view 1- 3~? -$ I 7-JB-S-t
Sample
Number
-7^^0
^HbO
mg N02/dscm
Determined
su^.s
1 4 S, u
Source of
Sample
T U3ac^ae^
T kici^ie^
Accepted
Value
9H.5
itrt
%
Difference
-^3
-o.5
5-12
-------
Chromatograms showing the blank checks for the traps and
tanks used in this test are in Appendix C with the laboratory
results.
The sampling equipment, reagents, and analytical procedures
for this test series were in compliance with all necessary guide-
lines 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.
5-13
-------
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 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 particulate concentration as determined by Method 5 at
the inlet to the wet scrubber compares favorably with the cal-
culated mass loading obtained from the Andersen Heavy Grain
Impactor used at this site (50,000 mg/dscm vs. 53,000 mg/dscm).
In addition, the measured volumetric flow rate compared to within
5 percent of the measured flow at the scrubber outlet test loca-
tion. This difference is attributed to air in-leakage between
the inlet and outlet test locations. Particulate, particle size,
and plume observation data obtained from the source indicate that
the control device operated efficiently throughout the test
period.
6-1
-------
At the clinker cooler, particulate results appear to be
representative of what would be expected from a natural draft
system. It should be noted that the opacity of fugitive emis-
sions from the oversized clinker discharge chute ranged from 5 to
10 percent throughout the test period. No visible emissions were
detected from the clinker cooler exit stack.
The process sample analysis shows the shale material used at
this plant possesses a low sulfur (0.10 percent) content.
Therefore, it is reasonable to conclude S0_ emissions are gen-
erated primarily from 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
------- |