o-EPA
United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EMB Report 80-LWA-6
February 1982
Air
Lightweight Aggregate
Industry
(Clay, Shale, and Slate)
Emission Test Report
Galite Corporation
Rockmart, Georgia
-------
EMISSION TEST REPORT
METHOD DEVELOPMENT AND TESTING FOR
CLAY, SHALE, AND SLATE
AGGREGATE INDUSTRY
Galite Corporation
Rockmart, Georgia
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
U.S. ENVIRONMENTAL PROTECTION AGENCY
EMISSION MEASUREMENT BRANCH
EMISSION STANDARDS AND ENGINEERING DIVISION
RESEARCH TRIANGLE PARK, NORTH CAROLINA 27711
April 1982
-------
CONTENTS
Figures iv
Tables vi
Quality Assurance Element Finder . vii
1. Introduction 1-1
2. Process Operation 2-1
Process description 2-3
Air pollution control system 2-7
Conclusions and recommendations 2-9
3. Summary of Results 3-1
Rotary kiln exhaust 3-1
Clinker cooler exhaust 3-26
Fugitive emissions 3-36
Process samples 3-36
4. Sampling Locations and Test Methods 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 . 4-13
5. Quality Assurance 5-1
6. Discussion of Results 6-1
References R-l
11
-------
CONTENTS (continued)
Appendices
A Computer printouts and example calculations A-l
B Raw field data B-l
C Raw laboratory data C-l
D Sampling and analytical procedures Ei-1
E Calibration procedures and results E-l
F Quality assurance summary F-l
G Project participants and sample log G-l
111
-------
FIGURES
Number Page
2-1 Simplified Process Flow Diagram for the
Lightweight Aggregate Plant at Galite
Corporation, Rockmart, Georgia 2-2
3-1 Velocity Profile Across East Traverse of
Scrubber Outlet 3-8
3-2 Velocity Profile Across North Traverse of
Scrubber Outlet 3-9
3-3 Particle Size Distribution - Scrubber Inlet 3-11
3-4 Average Particle Size Distribution for the
Scrubber Outlet 3-14
3-5 Particle Size Distribution for Run No. SOPS-1 3-15
3-6 Particle Size Distribution for Run No. SOPS-6 3-16
3-7 Particle Size Distribution for Run No. SOPS-3 3-17
3-8 Particle Size Distribution for Run No. SOPS-7 3-18
3-9 Particle Size Distribution for Run No. SOPS-8 3-19
3-10 Average Particle Size Distribution for the
Clinker Cooler 3-30
3-11 Particle Size Distribution for Run No. CCPS-1 3-31
3-12 Particle Size Distribution for Run No. CCPS-4 3-32
3-13 Particle Size Distribution for Run No. CCPS-5 3-33
3-14 Particle Size Distribution for Run No. CCPS-7 3-34
3-15 Particle Size Distribution for Run No. CCPS-8 3-35
4-1 Sampling Plan and Process Flow Sheet for Galite
Corporation 4-2
IV
-------
FIGURES (continued)
Number Page
4-2 Scrubber Inlet Sampling Location 4-3
4-3 Scrubber Outlet Sampling Location 4-5
4-4 Clinker Cooler Sampling Location 4-6
4-5 Particle Size Sampling Points for Circular
Stacks 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
-------
TABLES
Number Page
2-1 Process Data Obtained During Emission Tests
at Galite Corporation, Rockmart, Georgia 2-4
3-1 Summary of Flue Gas Conditions 3-4
3-2 Summary of Particulate Emissions Data 3-5
3-3 Summary of Sulfur Dioxide Data 3-20
3-4 Summary of Nitrogen Oxide Emissions Data
Scrubber Outlet 3-22
3-5 Hydrocarbon Emissions from Scrubber Outlet 3-24
3-6 Summary of Visible Emissions Data
Scrubber Outlet 3-25
3-7 Summary of Flue Gas Conditions
Clinker Cooler Outlet 3-27
3-8 Summary of Particulate Emissions Data 3-28
3-9 Summary of Visible Emissions Data - Clinker
Cooler Outlet 3-37
3-10 Summary of Visible Emissions Data - Fugitive
Sources 3-30
3-11 Summary of Process Sample Analysis 3-44
3-12 Summary of Trace Element Data 3-45
5-1 Field Equipment Calibration 5-3
5-2 Example Blank Filter and Reagent Analysis 5-9
5-3 Audit Report - S02 Analysis 5-10
5-4 Audit Report - NO Analysis 5-11
X
6-1 Scrubber Efficiency Summary 6-3
VI
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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 manage-
ment
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 February 21, 1982, personnel from PEDCo
Environmental conducted an emission sampling program at the
lightweight aggregate facility of Galite Corporation in Rockmart,
Georgia. The purpose of this test program was to provide data to
assess the need for New Source Performance Standards (NSPS) for
selected processes in the lightweight aggregate industry (clay,
shale, and slate) and, if warranted, to develop such limits.
Comprehensive testing was conducted on 1) a coal-fired
rotary kiln (No. 1), whose emissions are controlled by a medium-
energy wet scrubber, and 2) a reciprocating grate clinker cooler,
whose emissions are controlled by a settling chamber.
Particulate concentrations and mass emission rates were
measured at the inlet and outlet of the wet scrubber serving the
kiln exhaust and at the clinker cooler exit stack. U.S. Environ-
mental Protection Agency (EPA) Method 5 was used in these mea-
surements.* Flue gas flow rates, temperature, moisture content,
and composition [oxygen (0_), carbon dioxide [CO-)/ and carbon
monoxide (CO)] were measured in conjunction with the particulate
40 CFR 60, Appendix A, Reference Method 5, July 1, 1981.
1-1
-------
tests. EPA Method 6* was used to measure sulfur dioxide (SO-)
concentrations and mass emission rates at the inlet and outlet of
the wet scrubber serving the kiln. Nitrogen oxide (NO ) concen-
X
tration in the flue gas exiting the scrubber was determined by
EPA Method 7.* In addition, the particle size distribution of
particulate matter entering and exiting the kiln scrubber was
determined along with the distribution of particulate exiting the
clinker cooler stack. The volatile organic carbon (VOC) content
of the scrubber exhaust gas 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 (slate) 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 scrubber water influent, and
effluent, final aggregate product, and captured particulate
(clinker cooler settling chamber) were also collected during each
particulate test for sulfur analyses. In addition, the scrubber
water samples and captured particulate were analyzed for trace
metal content. The pH of the scrubber water and the density of
the final aggregate product were also determined.
*
40 CFR 60, Appendix A, Reference Methods 6, 7, 9, and 25, July
1, 1981.
1-2
-------
Mr. Lalit Banker and Ms. Mary Sauer [Midwest Research
Institute (MRI)] monitored the process operation and collected
process samples throughout the test period. Mr. Frank Clay (EPA
Task Manager) observed the test program.
1-3
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SECTION 2
PROCESS OPERATION
Emission tests were conducted on the No. 1 rotary kiln and
clinker cooler exhaust gas streams at Galite Corporation, Rock-
mart, Georgia, from February 22 through 27, 1982. Galite Cor-
poration is a subsidiary of Big River Industries of Baton Rouge,
Louisiana. This plant was selected for emissions testing for the
following reasons: (1) the raw material (slate) at the plant is
one of the three feedstocks used in the production of lightweight
aggregate and (2) the types and arrangement of pollution control
devices on the process equipment appear to be representative of
future plants. The process operations during the tests were mon-
itored by Lalit Banker and Mary Sauer while Frank Clay of EPA
monitored the emission tests.
The Galite plant has two process lines (rotary kilns 1 and
2). The No. 2 kiln was not operating at the time of the test. A
simplified flow diagram of the No. 1 rotary kiln process line
with associated pollution control equipment is presented in
Figure 1. The control equipment tested was the wet scrubber on
the rotary kiln exhaust gas stream and the settling chamber on
the clinker cooler exhaust gas stream.
2-1
-------
STACK
to
I
CRUSHED
COAL
SETTLING
CHAMBER
4
RAW MATERIAL
FROM
CRUSHING, SCREENING,
AND STORAGE
FEED BOX/
SETTLING
CHAMBER
ROTARY KILN NO. 1
WET
SCRUBBED
TO LANDFILL
PRODUCT TO
CRUSHING, SCREENING,
AND STORAGE
SLURRY POND
CREEK
SOLIDS FLOW
AIR/GAS FLOW
(A)-© PROCESS SAMPLE LOCATIONS
CD-(6) EMISSION SAMPLE LOCATIONS
Figure 2-1. Simplified process flow dianram for the lightweight aggregate plant
at Galite Corporation, Rockmart, Georgia.
-------
Process parameters obtained by MRI during the emission tests
are presented in Table 1. The raw material feed rate averaged
about 30 Mg/h (33 tons/h) for the duration of the tests. The
mean coal feed rate in the kiln was approximately 2,090 kg/h
(4,610 Ib/h), while the mean natural gas feed rate was approxi-
mately 31 m /h (1,090 ft3/h). Product density ranged from 577 to
673 kg/m (36 to 42 Ib/ft ) during the emission tests. The above
readings were taken from the beginning to the end of the tests,
and the figures in Table 1 represent averages for the total test
duration.
The settling chamber and wet scrubber, including the pump
supplying water to the wet scrubber, were operating normally dur-
ing the emission tests. The water sprays used to suppress vis-
ible particulate emissions in the process were operating normally
during the emission tests. Fugitive emissions were visible from
the crushing and screening operations, clinker cooler discharge,
and kiln seals.
2.1 PROCESS DESCRIPTION
The slate is mined from a quarry on plant grounds. The
slate is crushed, screened, and stored in piles or enclosed
silos. Belt conveyors transport the crushed slate from the stor-
age silo to the feed box where it is charged to the rotary kiln.
The No. 1 kiln measures 57.9 meters (m) [190 feet (ft)] in
length and 3.7 m (12 ft) in diameter. A dam, which measures 46
centimeters (cm) by 5 cm [18 inches (in.) by 2 in.], is located
2-3
-------
TABLE 2-1. PROCESS DATA OBTAINED DURING EMISSION TESTS AT GALITE CORPORATION, ROCKMART, GEORGIA
Date
02/23/82a
02/24/82
02/25/82
02/26/82
02/27/82
Test
Paniculate test No. 1
on clinker cooler
Particulate test No. 2
on clinker cooler
Particulate test No. 1
on wet scrubber
Particulate test No. 3
on clinker cooler
Particulate test No. 2
on wet scrubber
Particulate test No. 3
on wet scrubber
S02 and VOC tests
S02 and VOC tests
NO tests
X
Test
duration
12:20 p.m.
to
03:43 p.m.
02: 10 p.m.
to
04:20 p.m.
02:12 p.m.
to
04:33 p.m.
09:05 a.m.
to
n- !•> a m
. i j a . in .
09:05 c.ro.
to
11:21 a.m.
12:47 p.m.
to
02:58 p.m.
09:55 a.m.
to
11:40 a.m.
09:15 a.m.
to
10:45 a.m.
11:30 a.m.
to
01:30 p.m.
Raw
material feed rate
Hg/h
29.996
30.027
29.361
29.804
30.400
30.391
30.241
tons/h
33.064
33.098
32.365
32.853
33.510
33.500
33.335
Coal feed rate
kg/h
2,022
2.075
2.082
2.139
2.171
2.084
2,074
Ib/h
4.457
4.574
4,589
4.715
4,786
4,594
4,573
Natural .
gas feed rate
nrVh
26
34
27
27
40
31
31
ft3/h
920
1.200
960
960
1,400
1,100
1.100
Mean
product density
kg/m3 .
628
617
625
630
601
597
588
lb/ft3
39.2
38.5
39.0
39.3
37.5
37.3
36.7
'
Mean back end
temperature
°C
385
412
420
428
451
456
448
°F
725
774
788
802
844
852
839
M
I
Simultaneous particulate test on wet scrubber was voided due to (1) excessive leakage during the post-test leak check for the inlet test
.and (2) loss of sample during recovery for the outlet test.
'Based on 24-h averages, except for tests conducted on 2/27/82.
-------
approximately 4.3 cm (14 ft) from the back end (feed end) of the
kiln. The dam increases the residence time of the raw material
in the kiln and four sets of lifters improve heat exposure. The
kiln rotates at approximately 3.25 revolutions per minute (rpm)
during normal operation. It is designed to process approximately
36 megagrams (Mg) (40 tons) of raw material per hour at capacity.
At the time of the test, approximately 30 Mg (33 tons) of raw
material per hour were processed in the kiln. The raw material
feed is weighed continuously on a scale before it enters the
kiln. There is no continuous monitoring of actual production.
Production figures [in cubic yards (yd )/day of product] are com-
puted from application of a bloating factor equal to 1.05 to the
raw material feed (in tons/day). The bloating factor is computed
by the company and is based on experience with material loss in
the process. Shipping yardage figures are obtained from informa-
tion on the filled volume of the trucks transporting the finished
product and the number of trucks filled each day.
The kiln is fueled primarily by crushed coal. Although the
raw material feed rate is kept constant during normal operation,
minor adjustments to the coal feed rate are made frequently to
control the operating temperature of the kiln. Galite uses coal
with an average heating volume of 2.9 x 10 Joules (J) per kg
[12,500 British thermal units per pound (Btu/lb)], an ash content
of approximately 12 percent, and a sulfur content of approxi-
mately 1 percent. Natural gas with an average heating value of
2.4 x 106 J/kg (1,030 Btu/ft3) is used primarily to fuel the
pilot flame.
2-5
-------
The firing zone (front end) extends about 9 m (30 ft) into
the kiln, and temperatures in this zone range from 1149° to
1177°C (2100° to 2150°F). Mid-kiln temperatures range from 982°
to 1038°C (1800° to 1900°F). Temperatures in the feed end (back
end) of the kiln range from 371° to 454°C (700° to 850°F) and are
monitored continuously. Plant personnel stated that the shutdown
period for the kiln is 48 hours. Bringing the kiln back up to
operating temperature takes 36 to 48 hours. Natural gas is the
primary fuel used for the reheating process.
The raw material slowly heats up as it travels through the
kiln and physically expands (bloats) as volatile organic compo-
nents are driven off. The residence time of the raw material in
the kiln is approximately 45 minutes. Density of the product is
measured hourly by plant personnel who weigh a bucket of known
volume filled with the hot product.
The expanded product, or clinker, is discharged from the
kiln into a clinker cooler. The clinker cooler consists of four
compartments with a reciprocating grate for the circulation of
air through the hot clinker. As the hot clinker is moved across
the grate, four fans force air upward through the grate to cool
the clinker. Approximately 100 percent of the hot exhaust air
from the first compartment and 50 percent from the second com-
partment is recycled to the kiln to conserve combustion heat and
to the coal mill to dry and preheat the coal. The gas stream
recycled to the coal mill passes through a cyclone for dust re-
moval prior to heating the coal. The remaining exhaust air from
2-6
-------
the clinker cooler is ducted through a settling chamber and is
released to the atmosphere through a stack.
Product of acceptable size falls through the reciprocating
grate onto a conveyor belt for transport to the clinker silo for
storage prior to crushing. Oversize material falls from the
grate onto the ground where it is periodically picked up by a
front end loader and transported to a storage pile for supple-
mental cooling and crushing. If the density or the temperature
of the product is too high for the conveyor belt system, the
doors to the conveyor belt are temporarily closed, and the pro-
duct falls from the grate onto the ground.
The product is crushed and screened to three sizes: (1) 100
mesh to 4.8 millimeter (mm) (100 mesh to 3/16 in.), (2) 4.8 to
9.5 mm (3/16 to 3/8 in.), and (3) 9.5 to 19 mm (3/8 to 3/4 in.).
The fines and the mid-size product are used mainly for concrete
blocks while the larger size is used principally for structural
concrete mix. Blends of product sizes are made to consumer
specification. The screened product is stored in enclosed silos.
Galite normally ships approximately 80 percent of its product by
truck and 20 percent by rail. The company employs 50 workers and
operates 365 days per year, 24 hours per day. Galite aims for
actual kiln operation of approximately 80 to 90 percent of
working days.
2.2 AIR POLLUTION CONTROL SYSTEM
The exhaust gases leaving the No. 1 rotary kiln pass through
a settling chamber to remove the heavier particulate matter. The
2-7
-------
waste material is landfilled on-site. The kiln exhaust emissions
are controlled by a medium energy wet scrubber [Fuller/Dracco
Type CAA (Compressed Air Atomizing Scrubber), Size 125-S]. A
336-kilowatt (kW) [450 horsepower (hp)] induced draft (ID) fan,
located between the scrubber and the stack, pulls the exhaust gas
stream from the kiln through the scrubber. The cleaned gas
stream is vented to the atmosphere through a stack approximately
27 m (90 ft) high and 1.8 m (6 ft) in diameter.
Fresh water for the scrubber is pumped from a creek adjacent
to the plant into a storage tank. The water is transferred from
the storage tank to the scrubber by a 20-hp pump with a capacity
of approximately 3,407 liters per minute (liter/min) [900 gallons
per minute (gpm)]. This pump also supplies water to the rest of
the plant. Plant personnel estimate that water enters the scrub-
ber at a rate of about 400 to 450 gpm. The dirty gas flowing
downward through the contact cylinder of the scrubber is con-
tacted countercurrently by a high velocity atomized water spray
introducted near the base of the scrubber. Water is also intro-
duced through two spray bars at the top of the scrubber and one
at the gas inlet to the scrubber. Dust particles are captured by
the liquid droplets and accumulate at the scrubber base. A mist
eliminator is present in the scrubber and was assumed by plant
personnel to be operating during the tests. The scrubber efflu-
ent is pumped to a settling pond at the quarry end of the plant.
The water is pumped from the pond and is discharged to the creek.
2-8
-------
The discharge point is located close to the inlet water pipe for
the scrubber water, and therefore, some mixing of fresh creek
water and recycled plant water occurs. Plant personnel estimate
that the influent scrubber water is typically 90 percent fresh
water. No instrumentation is present at the plant to measure the
scrubber pressure drop, inlet and outlet gas flow rates and tem-
peratures, or inlet and outlet liquid flow rates.
The clinker cooler emissions from the No. 1 kiln process
line are controlled by a baffled settling chamber. The collected
dust is discharged to the conveyor where it is combined with the
product. The clinker cooling air is pulled through the settling
chamber by a 45-kW (60-hp) fan and is exhausted through a stack
approximately 1.2 m (4 ft) in diameter and 12.2 m (40 ft) high.
No instrumentation is available to measure the inlet and outlet
gas flow rates and the temperatures across the chamber.
Water sprays are used to suppress visible particulate emis-
sions from the crushing and screening operations and other mate-
rial handling and transfer points. The flow rates for the water
sprays are not available.
2.3 CONCLUSIONS AND RECOMMENDATIONS
The process and control systems operated normally for the
duration of the tests. The production rate during the test was
kept constant at about 83 percent of the kiln design capacity.
2-9
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SECTION 3
SUMMARY OF RESULTS
This section details the results of the emission sampling
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.
The first set of particulate tests at the kiln exhaust
scrubber were voided due to an excessive post-test leak and loss
of sample during the recovery phase. These data are not included
in this report.
Appendix A contains complete printouts of field data,
results tabulation, and example calculations. Appendices E 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 the quality assurance considerations perti-
nent to this test project.
3.1 ROTARY KILN EXHAUST
Particulate and particle size tests were simultaneously
conducted at the scrubber inlet and outlet test locations.
Visible emission observations were performed during the particu-
late testing. Tests for sulfur dioxide were also conducted
3-1
-------
simultaneously at the scrubber inlet and outlet test locations,
and tests for NO and VOC content in the scrubber exhaust gas
X
were performed concurrent with the SO- tests.
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 fractions.
At the scrubber inlet, an instack thimble was placed prior to the
Method 5 filter because of the heavy particulate loading. The
particle size sampling and analytical procedures used at the
scrubber and clinker cooler exhaust test locations followed those
described in the "Procedures Manual for Inhalable Particulate
Sampler Operation," which was recently developed for EPA by
Southern Research Institute (SRI). At the scrubber inlet,
particle size distribution was determined by a Bacho centrifugal
analysis of collected samples from the particulate tests.
Analytical procedures followed those described in ASME Power Test
Code 28-1965. Sampling and analytical procedures for SO»
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 and fugitive emission
observations 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.
40 CFR 60, Appendix A, Methods 5, 6, 7, 9, and 25, July 1,, 1981.
3-2
-------
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
rates corrected to standard conditions [20°C and 760 mmHg (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 sampling train at a temperature of approximately
20°C (68°F) or less.
At the scrubber inlet, the volumetric flow rate averaged
41,900 dscmh (1,479,500 dscfh), the temperature averaged 475°C
(887°F), and the moisture content averaged 6.4 percent. Oxygen
and carbon dioxide contents averaged 13.5 and 6.6 percent,
3-3
-------
TABLE 3-1. SUMMARY OF FLUE GAS CONDITIONS
Scrubber Inlet
Run
No.
SIP-1
SIP-2
SIP-3
Date
(1982)
2/24
2/25
2/25
Test time,
24-h clock
1412-1633
905-1121
1247-1458
Average
Volumetric flow rate
Actual3
acmh
110,460
119,623
118,233
116,105
acfh
3,900,828
4,224,440
4,175,348
4,100,205
Standard
dscmh
40,074
43,197
42.416
41,896
dscfh
1,415,199
1,525,493
1,497,909
1,479,533
Temperature
°C
473
473
478
475
°F
883
884
893
887
Moisture,
%
5.9
6.7
6.7
6.4
02«
%
13.8
13.6
13.1
13.5
C02,
S
6.7
6.9
6.2
6.6
CO,
I
0.0
0.0
0.0
0.0
Scrubber outlet
SOP-1
SOP- 2
SOP- 3
2/24
2/25
2/25
1412-1631
905-1119
1247-1456
Average
108.202
109,815
109,986
109,334
3,821,084
3,878,050
3,884,081
3,861,072
82,079
85,265
84,523
83,956
2,898,582
3,011,100
2,984,887
2,964,856
53
51
52
52
127
124
126
126
14.12°
12.98C
13.61C
13.57
16.3
16.4
15.8
16.2
4.2
4.0
4.1
4.1
0.0
0.0
0.0
0.0
OJ
I
'volumetric flow rate 1n 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 mmHg (68°F and 29.92 in.Hq) and zero percent moisture.
cSee Page 3-6.
-------
TABLE 3-2. SUMMARY OF PARTICULATE EMISSIONS DATA
U)
Ul
Kiln exhaust scrubber inlet
Test
No.
SIP-1
SIP-2
SIP-3
Date
(1982)
2/24
2/25
2/25
Average
Concentration3
Filterable
mg/dscm
31,462
42,568
45,476
39,835
gr/dscf
13.8
18.6
19.9
17.4
Condensible
Organic
mg/dscm
16.1
15.2
20.1
17.1
gr/dscf
0.0070
0.0066
0.0088
0.0075
Inorganic
mg/dscm
44.9
26.8
23.9
31.9
gr/dscf
0.0196
0.0117
0.0104
0.0139
Mass emission rate
Filterable
kg/h
1,261
1,839
1,929
1,676
Ib/h
2,779
4,054
4,252
3,695
Condensible
Organic
kg/h
0.64
0.65
0.85
0.71
Ib/h
1.4
1.4
1.9
1.6
Inorq
kg/h
1.8
1.2
1.0
1.3
anic
Ib/h
4.0
2.5
2.2
2.9
Kiln exhaust scrubber outlet
SOP-1
SOP- 2
SOP- 3
2/24
2/25
2/25
Average
5°7.0
758.3
577.7
644.3
0.261
0.331
0.252
0.281
4.25
4.87
3.85
4.32
0.0019
0.0021
0.0017
0.0019
17.0
15.7
17.9
16.9
0.0074
0.0069
0.0078
0.0074
49.0
61.6
48.8
54. 1
inn.o
112.5
107. (=
115.4
0.35
0.42
0.33
0.37
0.77
0.92
0.72
0.80
1.4
1.3
1.5
1.4
3.1
2.9
3.3
3.1
Concentration in milligrams per dry standard cubic meter (mg/dscm) and grains per dry standard cubic foot
(gr/dscf).
Mass emission rate 1n kilograms per hour (kg/h) and pounds per hour (Ib/h).
-------
respectively. The filterable particulate concentration averaged
39,835 mg/dscm (17.4 gr/dscf), and the corresponding mass emis-
sion rate averaged 1676 kg/h (3695 Ib/h). The condensible
organic and inorganic concentrations averaged 17.1 mg/dscm
(0.0075 gr/dscf) and 31.9 mg/dscm (0.0139 gr/dscf), respectively.
The corresponding mass emission rates averaged 0.71 kg/h (1.6
Ib/h) and 1.3 kg/h (2.9 Ib/h) for each fraction.
At the scrubber outlet, the volumetric flow rate averaged
84,000 dscmh (2,965,000 dscfh), the temperature averaged 52°C
(126°F), and the moisture content averaged 13.6 percent. Oxygen
and carbon dioxide contents averaged 16.2 and 4.1 percent,
respectively. Because the gas stream was saturated and contained
water droplets, two moisture determinations were made: the first
involved calculations based on the water collected in the sam-
pling trains, and the second involved psychrometric calculations.
In each case, the lower value (saturation at stack temperature)
was used as the correct moisture content in all calculations, as
determined by EPA Method 4.*
Filterable particulate concentration averaged 644 mg/dscm
(0.281 gr/dscf), and the corresponding mass emission rate aver-
aged 54 kg/h (119 Ib/h). The condensible organic and inorganic
concentrations averaged 4.3 mg/dscm (0.0019 gr/dscf) and 17
mg/dscm (0.0074 gr/dscf), respectively. Organic and inorganic
mass emission rates averaged 0.40 kg/h (0.80 Ib/h) and 1.4 kg/h
(3.1 Ib/h).
*
40 CFR 60, Appendix A, Reference Method 4, July 1, 1981.
3-6
-------
Measurements were made to determine the degree of turbulent
flow at each test location as detailed in Method 2 of the Federal
Register.* Select traverse points were checked by aligning the
face openings of the pitot tube perpendicular to the stack
cross-sectional plane, designated "0 degree reference." Null
(zero) pitot readings obtained at 0 degree reference indicates an
acceptable flow condition at a given point. A pitot tube angular
notation of ^10 degrees to achieve a null reading is considered
acceptable. Data from the clinker cooler and scrubber inlet test
locations indicated acceptable flow conditions for particulate
testing. At the scrubber outlet test location, the degree of
angular rotation ranged from 0 to 25 degrees with an overall
average of approximately 13 degrees. Typical velocity profiles
from this source are presented in Figure 3-1 (east traverse) and
Figure 3-2 (north traverse). Turbulent flow conditions of this
type would tend to bias the velocity measurements high, thus
introducing a positive bias in the calculated pollutant mass
emission rates from this source. This conclusion is substanti-
ated by a comparison of scrubber inlet and outlet flow rates on a
standard basis and corrected for air inleakage (including the
cold air bleedin). The measured scrubber outlet flows averaged
approximately 20 percent higher than the corrected inlet flow
rates.
One other source condition that should be addressed is the
effect of scrubber water reentrainment. The outlet gas stream
*40 CFR 60, Appendix A, Reference Method 2, July 1, 1981.
3-7
-------
1.2
1.0
o
CM
•-= 0.8
D-
**
O
LU
n:
0.6
0.4
0.2
I 1 T
I I
RUN NO. SOP-1
(EAST PORT)
£(!>••••••]
TJ"'^
I I T
I
I I
0 10 20 30 40 50 60 70 80 90 100
PERCENT DIAMETER
Figure 3-1. Velocity profile across east traverse of scrubber outlet.
3-8
-------
1.2
1.0
o
C\J
0.8
>- 0.6
LJ
O
0.4
0.2
1 I I
1 I I I I I
RUN NO. SOP-1
(NORTH PORT)
j I
I .lllillitlT
0 10 20 30
40 50 60 70 80 90 100
PERCENT DIAMETER
Figure 3-2. Velocity profile across north traverse
of scrubber outlet.
3-9
-------
was saturated as previously mentioned and a heavy plume water
fallout was observed throughout the test period. This fallout
resulted in heavy spotting of clothes and sample equipment. The
average ratio of probe catch to filter catch was 1227 mg to 126
mg. The entrained water droplets laden with particulate matter
were collected in the sample probe, subsequently dried by the
probe heat, and recovered and measured as filterable particulate.
3.1.2 Particle Size Distribution
Three samples were collected at the scrubber inlet and eight
samples at the outlet test sites. Data obtained from the partic-
ulate test runs were combined with sampling data to obtain
average flow rates, moisture content, and gas composition.
At the scrubber inlet, particle size distribution was
determined by a Bacho centrifugal analysis of collected samples
from the particulate tests. The Bacho analyzer utilizes the
centrifugal separation technique to segregate the particulcite
into eight different size ranges. Figure 3-3 presents the
average distribution curve for the three samples collected at the
scrubber inlet. Individual data points for each test were
plotted manually. The results of the average distribution curve
show that the size of the particulate emissions was fairly
consistent during the three sampling runs. The data point
distribution for these runs indicates that 50 percent of the
particulate by weight was less than 13.5 ym in diameter.
3-10
-------
u>
ii .;;..;..14-.,- ;;i
TEST SPECIFIC
NO. GRAVITY
SIP-1 2.54 O
SIP-2 2.73
SIP-3 Z.64 O
;:ri!!H r
-»
1.0
10.0
PARTICLE SIZE, micrometers
Figure 3-3. Particle size distribution - scrubber inlet.
-------
An Andersen cascade impactor was used to collect eight
particle size samples at the scrubber outlet test site. Sample
Nos. SOPS-3, 7, and 9 were considered nonrepresentative due to an
overloading of individual impactor stages; therefore, they are
not graphically presented.
Sampling and analytical prcedures followed those described
in the "Procedures Manual for Inhalable Particulate Sampler
Operation," which was developed by Southern Research Institute
for EPA. Individual and average particle distribution curves
were determined by use of a computer program detailed in the
CIDRS Manual. Each specific program is briefly described here.
The CIDRS Manual can provide details if described.
MPPROG - The basic program calculated stage D,_0 cut-points
and cumulative distributions by two slightly different
methods for each sampling run. The table of output, which
was calculated by Lung Dynamics, assumed a particle density
of 1 g/cm , calculated specific Cunningham correction
factors, and yielded aerodynamic diameters. The next table,
identified as Mercer, assumed both a unit particle density
and a unit Cunningham factor to yield aerodynamic impaction
diameters. Results in both tables were determined by
reducing data according to the D,-n method, which assumed a
stage collection efficiency of 50 percent, as opposed to the
Picknett method, which required stage efficiency curves.
All particle size results discussed in this report were
based on aerodynamic diameters unless stated otherwise.
Example calculations and additional data were included in
the output.
SPLIN 1 - For each sample run, a best-fit curve was calcu-
lated for size ranges, including real data, and extrapolated
to the maximum particle diameter selected. Coefficients
were stored for later use. This program has no tabular
output.
3-12
-------
STATIS - This program averaged the curves calculated in
SPLIN 1 for a minimum of three sampling runs, removed
outliers according to the upper 5 percent significance level
procedure in the QA Handbook,* and calculated results for
cumulative and differential distributions with 50 percent
confidence intervals. All output was tabular, and curves
were manually plotted with extrapolated portions indicated
by dash lines. Averages for less than three runs were
calculated through duplication of data sets, but confidence
intervals were invalid.
Figure 3-4 presents the average particle size distribution
curve for the five acceptable samples collected at the scrubber
outlet. Figures 3-5 through 3-9 present the individual particle
size distribution curves for each of the five sampling runs. All
particle size results are based on aerodynamic diameters and unit
density (1 g/cm ).
The results of the particle size runs show that the majority
of particulate was collected in the precutter of the impactor and
accounted for about 60 percent of the total filterable particu-
late emissions. The majority of the remaining particulate
collected in the impactor was between 0.4 and 2.5 ym, which
accounted for about 20 percent of the total filterable particu-
late collected by the impactor.
3.1.3 Sulfur Dioxide
Table 3-3 presents a summary of results for SO- tests
conducted simultaneously before and after the wet scrubber.
Concentrations 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
Quality Assurance Handbook, Volume III, EPA 600/4-77-027b,
August 1977.
3-13
-------
c~fi
U)
I
PARTICLE SIZE, micrometers
Figure 3-4. Average particle size distribution for the scrubber outlet.
-------
en
PARTICLE SIZE, micrometers
Figure 3-5. Particle size distribution for Run No. SOPS-1.
-------
to
PARTICLE SIZE, micrometers
Figure 3-6. Particle size distribution for Run No. SOPS-6.
-------
U)
I
10.0
100
PARTICLE SIZE, micrometers
Figure 3-7. Particle size distribution for Run No. SOPS-3.
-------
U)
M
00
PARTICLE SIZE, micrometers
Figure 3-8. Particle size distribution for Run N'o. SOPS-7.
-------
to
M
VD
PARTICLE SIZE, micrometers
Figure 3-9. Particle size distribution for Run No. SOPS-8.
-------
TABLE 3-3. SUMMARY OF SULFUR DIOXIDE DATA
Scrubber inlet0
Run
No.
SIS-1
SIS-2
Date
(1982)
2/26
2/26
Average
SIS-3
SIS-4
2/26
2/27
Average
SIS-5
SIS-6
2/27
2/27
Average
Concentration
ppm
1,862
2,314
2,088
2,342
2,135
2,239
2,095
2,052
2,074
mg/dscm
4,906
6,093
5,500
6,173
5,628
5,901
5,515
5,403
5,459
Ib/dscf
x 10-5
30.6
38.0
34.3
38.5
35.1
36.8
34.4
33.7
34.1
Mass
emission rate
kg/h
205 '.2
255.0
230.1
258.1
235.2
246.6
230.8
226.1
228.4
Ib/h
452.3
562.1
507.2
568.. 9
518.5
543.7
508.9
498.5
503.7
02,
%
13.0
13.0
13.0
11.8
11.6
11.7
11.6
11.6
11.6
Temperature
°C
519
530
525
524
511
518
525
527
526
°F
968
988
978
977
954
966
979
981
980
Scrubber outlet
SOS-1
SOS-2
2/26
2/26
Average
SOS-3
SOS-4
2/26
2/27
Average
SOS-5
SOS- 6
2/27
2/27
Average
839
940
890
957
879
918
830
840
835
2,213
2,469
2,341
2,517
2,309
2,413
2,180
2,213
2,197
13.8
15.4
14.6
15.7
14.4
15.1
13.6
13.8
13.7
185.3
207.5
196.4
211.2
194.1
202.6
183.3
185.5
184.4
408 . 5
457.4
433.0
465.6
428.0
446,8
404,0
408.9
406.4
16.0
16.0
16.0
15.2
15.8
15.5
15.8
15.8
15.8
53
52
53
51
49
50
49
50
50
127
124
126
123
121
122
121
122
122
Mass emission rates are based on the average stack gas flow rate determined
during the inlet particulate tests (41,896 dscmh and 1,479,534 dscfh).
DMass emission rates are based on the average stack gas flow rate determined
during the outlet particulate tests (83,956 dscmh and 2,964,856 dscfh).
3-20
-------
mass emission rates were calculated from the measured concentra-
tions and the average flow rate measured during the inlet partic-
ulate test run (1,479,534 dscfh). The outlet mass emission rates
were calculated in a similar manner using the average measured
flow rate from the outlet particulate tests (2,964,856 dscfh).
Analyses were conducted on site by EPA Method 6.*
Sulfur dioxide concentrations at the inlet to the wet
scrubber averaged 5620 mg/dscm (2133 ppm, 35.1 x 10 Ib/dscf),
and the corresponding average mass emission rate was 235 kg/h
(518 Ib/h). Flue gas temperature averaged 523°C (975°F), and
oxygen content averaged 12.1 percent.
Sulfur dioxide concentrations at the scrubber exit stack
averaged 2317 mg/dscm. (881 ppm, 14.5 x 10 Ib/dscf), and the
corresponding average mass emission rate was 194.5 kg/h (429
Ib/h). Flue gas temperature averaged 51°C (123°F), and oxygen
content averaged 15.8 percent.
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 at the kiln exhaust scrubber
outlet. Concentrations are reported in milligrams per dry
standard 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 and
corrected to standard conditions (2,964,856 dscfh).
40 CFR 60, Appendix A, Reference Method 6, July 1, 1981.
3-21
-------
TABLE 3-4. SUMMARY OF NITROGEN OXIDE EMISSIONS DATA
SCRUBBER OUTLET3
Run
No.
1
Date
(1982)
2/27
Average
2
2/27
Average
3
2/27
Average
Sample
No.
SON-1A
SON-IB
SON-1C
SON-ID
SON-2A
SON-2B,
SON-2C
SON-2D
SON-3Ab
SON-3B
SON-3C
SON-3D
Concentration
ppm
189
244
208
229
218
207
206
300
201
205
154
215
198
192
202
mg/dscm
363
468
399
439
417
396
394
575
386
392
295
411
380
367
386
Ib/dscf
x 10-4
0.2262
0.2920
0.2488
0.2739
0.2602
0.2472
0.2455
0.3586
0.2405
0. 2444
0.1840
0.2566
0.2370
0.2288
0.2408
Mass
emission rate
kg/h
30.4
39.3
33.5
36.8
35.0
33.2
33.0
48.2
32.3
36.7
24.7
34.5
31.9
30.8
32.4
Ib/h
67.1
86.6
73.8
81.2
77.2
73.3
72.8
106.3
71.3
72.5
54.5
76.1
70.3
67.8
71.4
Mass emission rates are based on the average stack gas flow rate determined
during the scrubber outlet particulate tests (83,956 dscmh and 2,964,856
dscfh).
D0utlier not used in average.
3-22
-------
Nitrogen oxide concentrations averaged 398 mg/dscm (208 ppm,
-4
0.248 x 10 Ib/dscf), and the corresponding mass emission rate
was 34.7 kg/h (73.7 Ib/h).
3.1.5 Hydrocarbon Emissions From the Kiln Scrubber Outlet
Hydrocarbon emissions from the scrubber outlet at Kiln No. 1
were sampled by use of the procedures of EPA Method 25* in order
to determine total gaseous nonmethane organics (TGNMO). Four
1-hour samples were collected at the scrubber outlet. Test No.
SO-VC-1 was voided due to a plug in the sampling probe. Results
of the Method 25 sampling are presented in Table 3-5. In the
Method 25 analytical procedures, all nonmethane organics are
oxidized to carbon dioxide and reduced to methane before measure-
ment with a flame ionization detector (FID). Therefore, organic
concentrations are expressed 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 60 to 141 ppm with an average value of 90 ppm as
methane. The average emission rate of nonmethane organic com-
pounds was 5.4 kg/h (11.1 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
summarizes the findings. For each test, opacities ranged from 0
to 5 percent.
*
40 CFR 60, Appendix A, Reference Method 25, July 1, 1980.
3-23
-------
TABLE 3-5. HYDROCARBON EMISSIONS FROM SCRUBBER OUTLET
Test
No.
SO-VC-1C
SO-VC-2
SO-VC-3
SO-VC-4
Date
(1982)
2/26
2/26
2/26
2/27
Average
Sampl ing
time, 24-h
Start
-
1032
1127
900
Finish
-
1120
1215
1010
NMOa
concentration
ppm as CH4
-
60
141
68
90
Hydrocarbon emission rate
expressed as methaneb
kg/h
-
3.6
8.5
4.1
5.4
Ib/h
-
7.4
17.4
8.4
11.1
aNMO = Nonmethane organics measured and expressed as methane (CH.).
L *
Based on the molecular weight of methane, 16 g/g-mole (16 Ib/lb-mole). Mass
emission rates are calculated using the average gas flow rate measured during
the particulate tests (2,964,856 dscfh).
CSO-VC-1 voided due to plug in sampling probe.
3-24
-------
TABLE 3-6. SUMMARY OF VISIBLE EMISSIONS DATA
SCRUBBER OUTLET
Test 1 (2/23/82)
Set No.
SOVE-1-1
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- -14
SOVE- -15
SOVE- -16
SOVE- -17
SOVE- -18
SOVE- -19
SOVE- -20
SOVE- -21
SOVE- -22
SOVE- -23
SOVE- -24
SOVE -1-25
SOVE- 1-26
SOVE- 1-27
SOVE- 1-28
SOVE- 1-29
Time
1215-1220
1221-1226
1227-1232
1232-1238
1239-1244
1245-1250
1251-1256
1257-1302
1303-1308
1309-1314
1315-1320
1321-1326
1327-1332
1333-1338
1339-1344
1345-1350
1351-1356
1357-1402
1445-1450
1451-1456
1457-1502
1503-1508
1509-1514
1515-1520
1521-1526
1527-1532
1533-1538
1539-1544
1545-1550
Average
1 opacity
1
3
0
0
0
1
1
0
0
0
3
1
0
0
0
0
0
0
3
1
2
2
2
2
1
2
3
1
2
Range
0-5
0-5
0-5
0
0-5
0-5
0-5
0
0
0-5
0-5
0-5
0-5
0-5
0
0
0
0
0-5
0-5
0-5
0-10
0-5
0-5
0-5
0-5
0-5
0-5
0-5
Test 2 (2/24/82)
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-2-12
SOVE -2- 13
SOVE-2-14
SOVE-2-15
SOVE-2-16
SOVE-2-17
SOVE-2-18
SOVE-2-19
SOVE-2-20
SOVE-2-21
SOVE-2-22
SOVE-2-23
SOVE-2-24
Time
1410-1415
1416-1421
1422-1427
1428-1433
1434-1439
1440-1445
1446-1451
1452-1457
1458-1503
1504-1509
1510-1515
1516-1521
1522-1527
1528-1533
1534-1539
1540-1545
1546-1551
1552-1557
1558-1603
1604-1609
1610-1615
1616-1621
1622-1627
1628-1633
Average
t opacity
1
1
1
1
1
0
0
1
0
0
1
0
2
0
0
0
0
0
1
1
0
0
0
0
Range
0-5
0-5
0-5
0-5
0-5
0
0
0-5
0-5
0
0-5
0-5
0-5
0-5
0
0
0-5
0
0-5
0-5
0-5
0-5
0-5
0-5
Test 3 (2/25/82)
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
SOVE-3-13
SOVE-3-14
SOVE -3- 15
SOVE -3- 16
SOVE -3- 17
SOVE-3-18
SOVE-3-19
SOVE-3-20
Time
910-915
916-921
922-927
928-933
934-939
940-945
946-951
952-957
958-1003
1004-1009
1010-1015
1016-1021
1022-1027
1028-1033
1034-1039
1040-1045
1046-1051
1052-1057
1058-1103
1104-1109
Average
Z opacity
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
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
0-5
0
0
0
0
0
0
0
0
0
Test 4 (2/25/82)
Set No.
SOVE -4-1
SOVE -4-2
SOVE -4-3
SOVE-4-4
SOVE-4-5
SOVE -4 -6
SOVE-4-7
SOVE-4-8
SOVE -4 -9
SOVE -4-10
SOVE -4-11
SOVE-4-12
SOVE -4 -13
SOVE-4-14
SOVE-4-15
SOVE-4-16
SOVE -4-1 7
SOVE-4-18
SOVE-4-19
SOVE-4-20
Time
1250-1255
1256-1301
1302-1307
1308-1313
1314-1319
1320-1325
1326-1331
1332-1337
1338-1343
1344-1349
1350-1355
1356-1401
1402-1407
1408-1418
1414-1419
1420-1425
1426-1431
1432-1437
1438-1443
1444-1449
Average
I opacity
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Range
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0
0
0
0
0-5
0
0
0
0
0
0
0
0
I
K)
-------
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.
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 the "Procedures Manual for
Inhalable Particulate Sampler Operation," which was recently
developed for EPA by Southern Research Institute. Visible
emission observations were made according to procedures described
in EPA Method 9.* 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 sampling probe and on the
filter, both of which were heated to approximately 121°C (250°F).
The condensible organic and inorganic fractions represent
*40 CFR 60, Appendix A, Reference Methods 5 and 9, July 1, 1981.
3-26
-------
TABLE 3-7. SUMMARY OF FLUE GAS CONDITIONS
CLINKER COOLER OUTLET
U)
I
N)
-J
Run
No.
CCP-1
CCP-2
CCP-3
Date
(1982)
2/23
2/24
2/25
Test time,
24-h clock
1220-1543
1410-1620
905-1115
Average
Volumetric flow rate
Actual3
acmh
58.192
64,209
57,347
59,916
acfh
2,055,032
2,267,501
2,025,191
2,115,908
Standard
dscmh
46,362
52,892
52,206
50,487
dscfh
1,637,241
1,867,862
1,843,612
1.782,905
Temperature
°C
89
75
43
69
°F
191
167
109
156
Moisture,
%
'1.0
<1.0
<1.0
<1.0
02.
%
20.5
20.4
20.5
20.5
C02,
%
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 mmHg (68°F and 29.92 in.Hg) and zero percent moisture.
-------
TABLE 3-8. SUMMARY OF PARTICULATE EMISSIONS DATA
I
N)
00
Clinker cooler outlet
Test
No.
CCP-1
CCP-2
CCP-3
Date
(1982)
2/23
2/24
2/25
Average
Concentration3
Filterable
mg/dscm
157.9
122.1
105.4
128.5
gr/dscf
0.069
0.053
0.046
0.056
Condensible
Organic
mg/dscm
3.17
2.19
1.67
2.34
gr/dscf
0.0014
0.0010
0.0007
0.0010
Inorganic
mg/dscm
7.20
2.19
2.36
3.92
gr/dscf
0.0030
0.0010
0.0010
0.0017
Mass emission rate
Filterable
kg/h
7.3
6.5
5.5
6.4
Ib/h
16.1
14.2
12.1
14.1
Condensible
Organic
kg/h
0.15
0.12
0.09
0.12
Ib/h
0.32
0.26
0.19
0.26
I no re
kg/h
0.33
0.12
0.12
0.19
anic
Ib/h
0.74
0.26
0.27
0.42
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).
-------
material that condensed out or was trapped in the impinger
section of the sampling train at a temperature of approximately
20°C (68°F).
The volumetric flow rate averaged 50,500 dscmh (1,783,000
dscfh), the temperature averaged 69°C (156°F), and the moisture
content averaged less than 1 percent. The oxygen and carbon
dioxide contents averaged 20.5 and 0 percent, respectively.
Filterable particulate concentration averaged 128.5 mg/dscm
(0.056 gr/dscf) with a corresponding average mass emission rate
of 6.4 kg/h (14.1 Ib/h). The organic and inorganic concentra-
tions averaged 2.34 mg/dscm (0.0010 gr/dscf) and 3.92 mg/dscm
(0.0017 gr/dscf), and the corresponding mass emission rates
averaged 0.12 kg/h (0.26 Ib/h) and 0.19 kg/h (0.42 Ib/h).
3.2.2 Particle Size Distribution
A total of eight 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 describes the sampling and analytical procedures and the
data reduction techniques used, respectively. Run Nos. CCPS-2,
3, and 6 were considered nonrepresentative and are not graphi-
cally presented.
Figure 3-10 presents the average particle size distribution
curve for the five acceptable runs conducted at the clinker
cooler outlet test site. Figures 3-11 through 3-15 present the
individual particle size distribution curves for each of the five
3-29
-------
oo
o
-»
PARTICLE SIZE, micrometers
Figure 3-10. Average particle size distribution for the clinker cooler.
-------
U)
I
U)
llfUllillimiiiuimiiirwmiiMiiiMliiiiimiHiiw
IIIIHIIIIIIIIMIIIIIIIimillllMIIIHIIII'IIIHIIIW
10.0
100
PARTICLE SIZE, •tcrometers
Figure 3-11. Particle size distribution for Run No. CCPS-1.
-------
10
I
U)
to
liii
5
i
M
»
m
i^il
t;p
t
flt
TV -
1
m
-*»
—I
1.0
10.0
100
PARTICLE SIZE. Micrometers
Figure 3-12. Particle size distribution for Run No. CCPS-4.
-------
I
u>
U)
111 miiiiiii.iiiiiim;:iiiiiii,tiiii.iiimiiiniiim
1.0 10.0
PARTICLE SIZE, micrometers
Figure 3-13. Particle size distribution for Run No. CCPS-5.
-------
M.t
I
OJ
PARTICLE SIZE, micrometers
Figure 3-14. Particle size distribution for Run No. CCPS-7.
-------
U>
I
CO
U1
IIIHIIIIMIIHIIIIIIIIillllllllHIIIHMIHMIHII
PARTICLE SIZE, micrometers
Figure 3-15. Particle size distribution for Run No. CCPS-8.
-------
sampling runs. All particle size results are based on aerody-
namics diameters and unit density (1 g/cc).
The average particle size distribution for this source shows
that the particulate emissions are fairly evenly distributed by
size and that about 44 percent of the particles are less than 10
ym in diameter. The individual particle size distribution curves
compared closely, and the maximum deviation between the five runs
at two separate cutpoints were 4 percent at 6 ym and 4.5 percent
at 1 ym. This indicates that the size of the particulate emis-
sions were fairly consistent during the testing period.
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.
3.3 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, final product crushing and screening, and kiln seals
(charge and product). Table 3-10 summarizes the results of the
fugitive emission survey.
3.4 PROCESS SAMPLES
Representative samples of the kiln feed material (slate) and
coal used to fire the kiln were collected during each particulate
40 CFR 60, Appendix A, Reference Method 9, July 1, 1981.
3-36
-------
TABLE 3-9. SUMMARY OF VISIBLE EMISSIONS DATA FOR TESTS 1 AND
CLINKER COOLER OUTLET
u>
OJ
Test 1 (2/23/82)
Set No.
CC-1-1
CC-1-2
CC-1-3
CC-1-4
CC-1-5
CC-1-6
CC-1-7
CC-1-8
CC-1-9
CC-1-10
CC-1-11
CC-1-12
CC-1-13
CC-1-14
CC-1-15
CC-1-16
CC-1-17
CC-1-18
CC-1-19
CC- -20
CC- -21
CC- -22
CC- -23
CC- -24
CC- -25
CC- -26
CC- -27
CC- -28
CC-1-29
CC-1-30
Time
1213-1218
1219-1224
1225-1230
1231-1236
1237-1242
1243-1248
1249-1254
1255-1300
1301-1306
1307-1312
1315-1320
1321-1326
1327-1332
1333-1338
1339-1344
1345-1350
1351-1356
1357-1402
1403-1408
1409-1414
1453-1458
1459-1504
1505-1510
1 511 - 1 51 6
1517-1522
1523-1528
1529-1534
1535-1540
1541-1546
1547-1552
Average
% opacity
8.1
11.7
8.5
8.5
7.5
8.1
8.1
7.7
7.1
9.8
8.1
10.0
10.6
16.7
11.7
10.0
6.7
6.9
8.5
7.3
10.2
8.3
8.3
8.1
8.8
7.3
8.5
8.1
7.5
7.5
Range
0-15
10-20
5-10
5-15
5-10
5-15
5-15
5-10
5-10
5-15
5-15
5-15
5-15
10-25
5-20
5-15
5-15
5-10
5-15
5-10
5-15
5-15
5-15
5-15
5-15
5-10
5-10
5-10
5-10
5-10
Test 2 (2/24/82)
Set No.
CC-2-1
CC-2-2
CC-2-3
CC-2-4
CC-2-5
CC-2-6
CC-2-7
CC-2-8
CC-2-9
CC-2-10
CC-2-11
CC-2-12
CC-2-13
CC-2-14
CC-2-15
CC-2-16
CC-2-1 7
CC-2-18
CC-2-19
CC-2-20
CC-2-21
CC-2-223
Time
1405-1410
1411-1416
1417-1422
1423-1428
1429-1434
1435-1440
1441-1446
1447-1452
1453-1458
1459-1504
1522-1527
1528-1533
1534-1539
1540-1545
1546-1551
1552-1557
1558-1603
1604-1609
1610-1615
1616-1621
1622-1627
1628-1632
Average
% opacity
7.5
7.5
9.8
10.4
8.1
7.3
6.0
6.5
6.5
7.3
6.9
5.8
7.3
6.3
6.0
7.5
5.8
6.5
6.3
6.0
5.6
5.0
Range
5-10
5-15
5-15
5-15
5-15
5-10
5-10
5-10
5-10
5-10
5-10
5-10
5-10
5-10
5-10
5-10
5-10
5-10
5-10
5-10
5-10
5
aOnly 5 minutes of readings.
-------
TABLE 3-9 (continued)
U)
I
CO
00
Test 3 (2/25/82)
Set No.
CC-3-1
CC-3-2
CC-3-3
CC-3-4
CC-3-5
CC-3-6
CC-3-7
CC-3-8
CC-3-9
CC-3-10
CC-3-11
CC-3-12
CC-3-13
CC-3-14
CC-3-15
CC-3-16
CC-3-17
CC-3-18
CC-3-19
CC-3-20
Time
0900-0905
0906-0911
0912-0917
0918-0923
0924-0929
0930-0935
0936-0941
0942-0947
0948-0953
0954-0959
1008-1013
1014-1019
1020-1025
1026-1031
1032-1037
1038-1043
1044-1049
1050-1055
1056-1101
1102-1107
Average
% opacity
3.8
3.8
1.9
5.4
5.6
4.6
3.5
4.4
5.0
4.6
2.1
5.6
7.7
4.6
5.2
4.2
3.8
4.8
6.7
6.3
Range
0-5
0-5
0-5
0-10
0-10
0-10
0-5
0-5
0-10
0-10
0-5
0-10
5-10
0-10
0-10
0-10
0-10
0-10
5-10
5-10
Test 4 (2/25/82)
Set No.
CC-4-1
CC-4-2
CC-4-3
CC-4-4
CC-4-5
CC-4-6
CC-4-7
CC-4-8
CC-4-9
CC-4-10
CC-4-1 1
CC-4-1 2
CC-4-13
CC-4-14
CC-4-1 5
CC-4-16
CC-4-17
CC-4-18
CC-4-19
CC-4-20
Time
1250-1255
1256-1301
1302-1307
1308-1313
1314-1319
1320-1325
1326-1331
1332-1337
1338-1343
1344-1349
1358-1403
1404-1409
1410-1415
1416-1421
1422-1427
1428-1433
1434-1439
1440-1445
1446-1451
1452-1457
Average
% opacity
3.3
3.3
4.0
4.8
3.1
5.0
4.8
4.2
4.6
3.3
6.0
3.8
8.8
11.9
10.4
7.5
9.8
7.1
6.7
6.5
Range
0-5
0-10
0-10
0-10
0-10
0-10
0-10
0-10
0-10
0-10
0-10
0-10
0-15
5-20
5-15
0-10
5-15
5-15
5-10
0-10
-------
TABLE 3-10. SUMMARY OF VISIBLE EMISSIONS DATA FOR TEST 1 (2/23/82)
FUGITIVE SOURCES
Source
Raw material crusher
Final product screen
Finish material crusher
Kiln inlet
South kiln seal
North kiln seal
Set No.
RC-1-1
RC-1-2
RC-1-3
FP-1-1
FP-1-2
FP-1-3
FC-1-1
FC-1-2
FC-1-3
FC-1-4
KI-1-1
KI-1-2
KI-1-3
KI-1-4
KSS-1-1
KSS-1-2
KSS-1-3
KSN-1-1
KSN-1-2
KSN-1-3
Time
1350-1355
1356-1401
1401-1407
1219-1224
1453-1458
1459-1504
1216-1221
1454-1459
1500-1505
1506-1511
1234-1239
1240-1245
1246-1251
1535-1540
1256-1301
1302-1307
1308-1313
1320-1325
1326-1331
1332-1337
Average
% opacity
15.0
17.1
21.5
0.8
0
0
0
0
0
0
7.9
6.3
6.7
6.3
0
0
0
0
0
0
Range
10-20
15-20
15-30
0-5
0
0
0
0
0
0
5-20
5-10
5-10
5-10
0
0
0
0
0
0
(continued)
3-39
-------
TABLE 3-10 (continued)
SUMMARY OF VISIBLE EMISSIONS DATA FOR TEST 2 (2/24/82)
FUGITIVE SOURCES
Source
Raw material crusher
Final product screen
Finish material crusher
Kiln inlet
South kiln seal
North kiln seal
Set No.
RC-2-1
RC-2-2
Time
1511-1516
1517-1522
Average
% opacity
29.4
30.4
Range
25-35
25-35
Process down
Process down
KI-2-1
KI-2-2
KI-2-3
KSS-2-1
KSS-2-2
KSS-2-3
KSN-2-1
KSN-2-2
KSN-2-3
1410-1415
1416-1421
1540-1545
1429-1434
1435-1440
1552-1557
1449-1454
1455-1500
1605-1610
9.0
9.5
8.1
0
0
0
0
0
0
5-10
5-10
5-10
0
0
0
0
0
0
(continued)
3-40
-------
TABLE 3-10 (continued)
SUMMARY OF VISIBLE EMISSIONS DATA FOR TEST 3 (2/25/82)
FUGITIVE SOURCES
Source
Raw material crusher
Final product screen
Finish material crusher
Kiln inlet
South kiln seal
North kiln seal
(continued)
Set No.
RC-3-1
RC-3-2
FP-3-1
FP-3-2
FC-3-1
FC-3-2
FC-3-3
KI-3-1
KI-3-2
KSS-3-1
KSS-3-2
KSN-3-1
KSN-3-2
Time
0942-0947
0948-0953
0925-0930
0931-0936
0908-0913
0914-0919
1112-1117
1053-1058
1059-1104
1026-1031
1032-1037
1003-1008
1009-1014
Average
% opacity
20.4
20.4
5
5
0
0
0
10
10
0
0
0
0
Range
20-25
20-25
5
5
0
0
0
10
10
0
0
0
0
3-41
-------
TABLE 3-10 (continued)
SUMMARY OF VISIBLE EMISSIONS DATA FOR TEST 4 (2/25/82)
FUGITIVE SOURCES
Source
Raw material crusher
Final product screen
Finish material crusher
Kiln inlet
South kiln seal
North kiln seal
Set No.
RC-4-1
FP-4-1
FP-4-2
FC-4-1
FC-4-2
KI-4-1
KI-4-2
KSS-4-1
KSS-4-2
KSN-4-1
KSN-4-2
Time
1432-1437
1322-1327
1328-1333
1306-1311
1312-1317
1249-1254
1255-1300
1344-1349
1350-1355
1408-1413
1414-1419
Average
% opacity
18.1
5.2
10.6
0
0
8.1
8.8
0
0
0
0
Range
10-35
5-10
5-15
0
0
5-10
5-10
0
ID
0
0
3-42
-------
test for determination of sulfur content, moisture, density, and
ash content (coal only). Samples of scrubber water influent and
effluent and final aggregate product were also collected during
each particulate test for sulfur analysis. In addition, the
scrubber water samples and captured particulate (clinker cooler)
were analyzed for trace metal content. The pH of the scrubber
water and the density of the final aggregate product were also
determined. Table 3-11 summarizes the analytical data.
The analytical data on the raw slate showed an average
sulfur content of 0.69 percent, an average moisture content of
1.04 percent, and an average density of 2.73 g/cm . The sulfur
content of the final product averaged 0.37 percent with an
average density of 2.61 g/cm . The coal data showed on average
sulfur content of 1.47 percent and an average ash content of
14.26 percent. Moisture content averaged 5.2 percent. The
average sulfate concentration of the scrubber influent and
effluent was 27 and 990 mg/liter, respectively. Composite
samples of scrubber influent showed a pH of 7.0, and the effluent
showed a pH of 5.69. Table 3-12 summarizes trace metal data from
the scrubber effluent and captured particulate samples from the
clinker cooler settling chamber.
3-43
-------
TABLE 3-11. SUMMARY OF PROCESS SAMPLE ANALYSIS
10
I
ib.
Test No.
1
2
3
Date
(1982)
2/23
2/24
2/25
Sample type
Coal
Slate (raw)
Final product
Scrubber influent
Scrubber effluent
Coal
Slate (raw)
Final product
Scrubber influent
Scrubber effluent
Coal
Slate (raw)
Final product
Scrubber influent
Scrubber effluent
Density,
g/cm
2.76
2.62
2.77
2.37
2.67
2.83
Moisture,
% as
received
4.82
0.75
5.28
1.57
5.50
0.79
Ash,
% dry
basis
13.28
13.46
16.03
Sulfur, %
dry basis,
except where
noted
1.33?
0-72h
0,41b
18 c
963C
1.68?
0.69b
0.33b
18 c
956C
1.40?
0.66°
0.36°
45 c
1050°
PH
7.11
5.82
6.93
5.58
6.95
5.66
aASTM D3177.
bASTM D2234, as received.
GTotal sulfates in mg/liter.
-------
TABLE 3-12. SUMMARY OF TRACE ELEMENT DATA
Elements3
Al
Sb
As
Ba
Be
Bi
B
Cd
Ca
Cr
Co
Cu
Au
In
Fe
Pb
Li
Mg
Mn
Hg
Mo
Ni
P
Pt
K
Se
Si
Ag
Na
Sr
S
Te
Tl
Sm
Ti
U
V
W
Y
Zn
Captured participate
Test 1
8.1
<7.1
26
680
<0.13
<13
<2.2
3.7
5.7
78
20
36
<7.5
<13
4.6
100
64
1.8
520
<8
<0.49
40
270
<7.5
3.0
<20
26
<0.49
1.0
300
4100
<25
<23
290
4600
<15
160
<7.5
21
150
Test 2
8.3
<7.5
25
660
<0.13
<13
<2.2
3.7
5.3
79
19
34
<7.5
<13
4.5
120
62
1.8
500
<8
<0.50
42
270
<7.5
3.0
<20
28
<0.50
9700
280
3400
<25
<23
300
4500
<15
160
<7.5
21
140
Test 3
7.9
<7.5
24
630
<0.13
<13
<2.2
3.5
7.4
75
19
34
<7.5
<13
4.4
100
59
1.7
620
<8
<0.50
41
270
<7.5
2.9
<20
28
<0.49
9100
380
6300
<25
<23
280
4300
<15
160
<7.5
22
130
Scrubber effluent
Test 1
9.2
<0.032
<0.057
0.11
<0.0005
<0.05
<0.009
<0.002
390
<0.001
0.02
<0.001
<0.03
<0.05
<0.008
<0.084
0.18
32
3.0
<0.032
<0.002
0.027
<0.18
<0.03
14
<0.084
13
<0.002
3.9
1.3
.270
<0.10
<0.09
<0.12
<0.005
<0.06
<0.003
<0.03
<0.002
0.076
Test 2
13
<0.032
<0.057
0.13
<0.0005
<0.05
<0.009
<0.002
370
<0.001
0.02
<0.001
<0.03
<0.05
<0.54
<0.084
0.20
32
3.0
<0.032
<0.002
0.023
<0.18
<0.03
15
<0.084
14
<0.002
4.1
1.3
250
<0.10
<0.09
<0.12
<0.005
<0.06
<0.003
<0.03
<0.002
0.22
Test 3
9.6
<0.032
<0.057
0.17
<0.0005
<0.05
<0.009
<0.002
420
<0.002
0.02
<0.001
<0.03
<0.05
<0.019
<0.084
0.22
31
3.0
<0.032
<0.002
0.017
<0.18
<0.03
16
<0.084
12
<0.002
4.4
1.5
280
<0.10
<0.09
<0.12
<0.005
<0.06
<0.003
<0.03
<0.003
0.075
^Elements: Expressed as ppm (yg/g or yg/ml) except where noted,
3From clinker cooler settling chamber.
3-45
-------
SECTION 4
SAMPLING LOCATIONS AND TEST METHODS
Figure 4-1 presents a simplified process flow sheet depict-
ing the sampling 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 sampling ports, 90 degrees off-center, were located 2.6
duct diameters (dd) downstream and 0.6 dd upstream from the
nearest flow disturbances in the 1.4-m (4.6-ft) I.D. round duct.
Due to extreme heat and inaccessibility, only one of these ports
was used. Twenty-four traverse points (each point was sampled
twice) 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. Constant-
rate sampling techniques were used to sample sulfur dioxide;
emissions by placing the probe tip near the center of the duct.
4-1
-------
SLATE
COAL
COOLING AIR —
_ SAMPLE
© POINT
_*. SOLIDS
FLOW
SLUDGE
(D
PRODUCT
* CAPTURED
PARTICULATE
Sanple type
Particulate
Particulate
so2
Particle size
N0x
voc
Fugitive dust
Stack opacity
Sulfur, ash,
moisture con-
tent
Density, moisture
content, sulfur
Sulfur
Trace metals
Sample point
4.9
3
3,4
3,4,9
4
4
Kiln seals, 10,
11,12,13
4,9
1
2
5,6
5,8
No. of samples
3
3
3
3
12 grab
3
3
3
24
(composite)
24
(composite)
Composite
Composite
Method
EPA 5a
EPA 17a
EPA 6
Impactpr, Bacho
(ASTMD 28-1965)
EPA 7
EPA 25
EPA 9
EPA 9
ASTM D3177,
D3174, D3173,
D2234
ASTM C29,
Gravimetric
D1757
D1757
Mass Spectrom-
etry, I-Cap,
Atomic Adsorp-
tion
'Condensible organic and inorganic fractions will be determined by means
of ether/chloroform extraction.
''American Society for Testing Materials.
Figure 4-1. Sampling plan and process flow sheet for Galite Corporation,
4-2
-------
.8 m . 0.6
KNOCKOUT
CHAMBER
GRADE
TRAVERSE
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*
cm
11.4
13.3
16.5
19.8
23.9
27.4
31.5
36.3
41.4
47.2
54.4
65.0
93.5
104.4
111.3
117.6
122.7
127.3
131.1
134.9
138.7
142.2
145.6
147.3
in.
4.5
5.3
6.5
7.8
9.4
"i0.8
12.4
14.3
16.3
18.6
21.4
25.6
36.8
41.1
43.8
46.3
48.3
50.1
51.6
53.1
54.6
56.0
57.3
58.0
'INCLUDES NIPPLE LENGTH.
CROSS-SECTION
1.4 m (4.6 ft) I.D.
8.9 cm (3.5 in.) LENGTH NIPPLE
NOTE: BOTTOM PORT NOT USED DUE TO
EXTREME HEAT AND INACCESSIBILITY.
Figure 4-2. Scrubber inlet sampling location.
4-3
-------
Particle size analyses were run on the samples obtained in the
thimble during the particulate tests.
4.2 SCRUBBER OUTLET
Particulates, sulfur dioxide, nitrogen oxide, particle size
distribution, and VOC content were measured at the wet scrubber
outlet, as shown in Figure 4-3. Two sampling ports, 90 degrees
off-center, were located 2.5 dd downstream and 4.0 dd upstream
from the nearest flow disturbances in the 1.86-m (6.1-ft) I.D.
round stack. Forty-eight traverse points, 24 per port, were used
to traverse the cross-sectional area of the stack for the partic-
ulate test runs. Each point was sampled for 2.5 minutes, which
yielded a total test time of 120 minutes. Sulfur dioxide,
nitrogen oxide, and VOC sampling were conducted by use of con-
stant-rate sampling techniques that placed the respective probe
tips near the center of the stack. An Andersen in-stack impactor
was used to collect particle size samples at single sampling
points were representative of the average velocity of the stack.
4.3 CLINKER COOLER EXHAUST
Particulate concentrations and particle size distribution
were measured at the clinker cooler exit stack, as shown in
Figure 4-4. Two sampling ports, 90 degrees off-center, were
located 3.0 dd downstream and 2.4 dd upstream from the nearest
flow disturbances in the 1.5-m (5.0-ft) I.D. round stack.
Forty-eight traverse points, 24 per port, were used to traverse
the cross-sectional area of the stack for the particu-
4-4
-------
TRAVERSE
POINT NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
'.5
16
17
18
19
20
21
22
23
24
DISTANCE
cm
12.7
16.0
20.3
24.9
29.7
34.8
40.1
48.8
52.8
60.7
70.1
84.1
121.9
135.9
145.3
153.1
159.8
166.1
171.5
176.5
181.4
185.7
190.0
193.8
1n.
5.0
6.3
8.0
9.8
11.7
13.7
'15.8
18.2
20.8
23.9
27.6
33.1
48.0
53.5
57.2
60.3
62.9
65.4
67.5
69.5
71.4
73.1
74.8
76.3
(-25 ft) = 4 dd
4.6 m
(15 ft)
CROSS-SECTION
1.86 (6.1 ft) I.D.
10.2 cm (4 1n.) LENGTH NIPPLE
Figure 4-3. Scrubber outlet sampling location.
4-5
-------
CROSS-SECTION
1.5 m (5 ft) 1.0.
5.1 on (2 1n.)
LENGTH NIPPLE
TRAVERSE
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*
cm
6.35
•9.9
13.5
17.1
21.1
25.1
29.7
34.5
40.1
46.5
54.1
65.8
96.8
108.2
116.1
122.4
128.0
132.8
137.4
141.5
145.4
149.1
152.7
155.0
in.
2.5
3.9
5.3
6.8
8.3
9.9
11.7
13.6
15.8
18.3
21.3
25.9
38.1
42.6
45.7
48.2
50.4
52.3
54.1
55.7
57.3
58.7
60.1
61.0
•INCLUDES NIPPLE LENGTH.
NC
FLOW FROM
SETTLING
CHAMBER
WO
3.7 m
(-12 ft)
I
i
4.6 m
(~15 ft)
2.4 dd
= 3 dd
Figure 4-4. Clinker cooler sampling location.
4-6
-------
late test runs. Each point was sampled for 2.5 minutes, which
yielded a total test time of 120 minutes. An Andersen in-stack
impactor was used to collect particle size samples at single
sampling points that were representative of the average stack
velocity. The testing and analytical procedures used are de-
scribed 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
outlined in Method 2 of the Federal Register.* The temperature
was also measured at each sampling point by use of thermocouple
and digital readout.
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 test and during each set of
sulfur dioxide and nitrogen oxide tests. 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-
*
40 CFR 60, Appendix A, Reference Methods 2, 3, and 5, July 1,
1981.
4-7
-------
sectional area of the stack and regulating the sampling flow rate
relative to the flue gas flow rate as measured by the pitot tube
attached to the sampling probe. In each test, a sampling train
was used consisting of a heated, glass-lined probe, a heated
87-mm (3-in.) diameter glass fiber filter (Reeve Angel 934 AH),
and a series of Greenburg-Smith impingers. A heated quartz probe
was used on the scrubber inlet sampling train due to the high
flue gas temperatures at this location. In addition, an alundum
thimble and cyclone were placed prior to the heated filter
because of heavy particulate loading. The nozzle, probe, and
filter holder were rinsed with acetone at the end of each test.
The acetone rinse and the particulate caught on the filter media
were dried at room temperature (105°C for scrubber outlet sam-
ples) , desiccated to a constant weight, and weighed on an analyt-
ical 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
40 CFR 60, Appendix A, Reference Method 6, July 1, 1981.
4-8
-------
between the first and second impingers. A heated quartz glass
probe was used on the scrubber inlet sampling train, and an
alundum thimble and cyclone-filter assembly were placed prior to
the impingers due to the heavy particulate loading at this
location. Each test consisted of two 20-minute runs. Each
sampling train was purged with ambient air for 15 minutes after
the completion of each test. The contents of the second and
third impingers (3% hydrogen peroxide) were measured and analyzed
on site for sulfates by use of the barium-thorin titration
method.
4.8 NITROGEN OXIDE
Sampling and analytical procedures were those described in
EPA Method 7 of the Federal Register.* Three tests, each con-
sisting of four grab samples taken at approximately 15-minute
intervals, were conducted at 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 by use of 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 impactor were 64-mm glass
fiber filters.** A constant sampling rate was maintained through-
40 CFR 60, Appendix A, Reference Method 7, July 1, 1981.
**
Whatman Reeve Angel 934 AH.
4-9
-------
out 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).
Eight impactor runs were made at each sampling site.
Sampling point locations for each stack were as shown in Figure
4-5. At least one impactor run was made at each sampling point.
Sampling procedures were those recommended in the "Procedures
Manual for Inhalable Particulate Sampler Operation," which was
recently developed for EPA by the Southern Research Institute.
Particle size analyses were conducted on the scrubber inlet
particulate samples by use of a Bahco centrifugal classifier
that separated the particulate into eight different size ranges.
4.10 HYDROCARBON EMISSIONS
\
EPA Method 25* was used in the sampling and analysis of
hydrocarbon emissions in order to determine total gaseous non-
methane organics. Gas from the stack was drawn through a dry-ice
condensate trap in order to collect the sample in an evacuated
sampling tank. Sampling was conducted at a single point in the
stack and a constant sampling rate was maintained between 80 and
90 (ml/min). Both the sampling tank and condensate trap were
analyzed to determine the nonmethane organic content of the
exhaust gas.
The tank fraction was analyzed by injecting the sample into
an analyzer. The analyzer separated the nonmethane organics from
*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
-------
CO, CO-, and CH., oxidized the components to CO- and reduced the
C02 to methane for measurement with a flame ionization detector
(FID).
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 nonmethane
organic content was determined by summing the results of the trap
and tank analyses.
4.11 PROCESS SAMPLES
Samples of the coal and slate fed to the kiln were collected
at approximately 30-minute intervals during particulate sampling.
Coal samples were collected from the coal bunker before they
entered the pulverizer. Slate samples were collected from the
kiln feed conveyor belt. Coal samples were analyzed for sulfur
content, moisture content, and percent ash. Slate samples were
analyzed for sulfur content, density, and moisture content.
Samples of the influent and effluent from the kiln wet
scrubber and clinker cooler settling chamber were collected and
analyzed for sulfate content and pH (scrubber water only).
An analytical screening for trace elements was performed on
the scrubber effluent and captured particulate samples.
4-12
-------
4.12 VISIBLE AND FUGITIVE EMISSIONS
Visible and fugitive emission observations were performed by
use of procedures described in EPA Method 9.* Certified vissible
emission readers were utilized for each task.
4-13
-------
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 ensure 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 Emission Measurement Branch: the EPA Quality
Assurance Handbook Volume III, EPA-600/4-77-027; 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 ensure that the testing and analytical procedures
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 sampling 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 the sampling equipment used for particulate,
SO- and NO testing as well as the calibration guidelines and
^ J*L
limits. In addition to the pre- and post-test calibrations,, a
field audit was performed on the meter boxes used for particulate
and S0_ sampling. PEDCo constructed critical orifices for use in
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.
Audit solutions prepared by the EPA were used to check the
analytical procedures and reagents for S09 and NO sampling
^ ji
analysis. Tables 5-3 and 5-4 present the results of these
analytical audits. The audit tests show that the analytical
techniques were good.
5-2
-------
TABLE 5-1. FIELD EQUIPMENT CALIBRATION - SCRUBBER INLET
Equipment
Meter box
Pi tot tube
Digital
indicator
Thermocouple
and stack
thermometer
Orsat analyzer
Impinger
thermometer
Trip balance
Barometer
Dry gas
thermometer
Probe nozzle
I.D.
No.
FB-4
180
207
121
232
285
270
225
Inlet
Outlet
4-106
3-118
Calibrated
against
Wet test meter
Standard pitot
tube
Mill ivolt signals
ASTM-2F or 3F
Standard gas
ASTM-2F or 3F
Type S weights
NBS traceable
barometer
ASTM-2F or 3F
Cali per
Allowable
error
Y +0.02 Y
AH (3 +0.15
(Y +_0.05 Y post-test)
Cp +0.01
0.5%
1.5%
(+_2% saturated)
+0.5%
±2°F
±0.5 g
+0.10 in.Hg
(0.20 post-test)
+5°F
Dn ±0.004 in.
Actual
error
-0.036
0.0
0.35%
1.21%
0.1%
1.0°F
0.0 g
0.0
in.Hg
3.0°F
1.3°F
0.001 in.
0.001 in.
Within
allowable
limits
/
/
/
/
/
/
/
/
/
/
/
/
Comments
Used for particulate
and SOp tests
Particulate only
Ul
I
(jO
(continued)
-------
TABLE 5-1 (continued)
SCRUBBER OUTLET
Equipment
Meter box
Pitot tube
Digital
indicator
Thermocouple
and stack
thermometer
Orsat analyzer
Impinger
thermometer
Trip balance
Barometer
Dry gas
thermometer
Probe nozzle
I.D.
No.
FB-1
FB-2
014
219
255
232
104
270
225
Inlet
Outlet
Inlet
Outlet
4-110
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
ASTM-2F or 3F
Call per
Allowable
error
Y +0.02 Y
AH @ +0.15
(Y j-0.05 Y post-test)
Cp +J).01
0.5%
1.5%
(H^2% saturated)
+0.5%
+2°F
+0.5 g
+0.10 in.Hg
(0.20 post-test)
+5°f
+5°F
Dn +0.004 in.
Actual
error
+0.006
-0.019
0.0
0.14%
0.18%
0.1%
1.5°F
0.0 g
0.0
i n . Hg
4.0°F
5.0°F
3.1°F
4.0°F
0.001 in.
Within
al lowable
1 imits
/
/
/
/
/
/
/
/
/
/
/
/
/
/
Comments
Used for particulate
and SOp tests
Used for particle
size tests
Particulate only
U1
I
(continued)
-------
TABLE 5-1 (continued)
ClINKER COOLER OUTLET
Equipment
Meter box
Pitot tube
Digital
indicator
Thermocouple
and stack
thermometer
Orsat analyzer
Impinger
thermometer
Trip balance
Barometer
Dry gas
thermometer
Probe nozzle
I.D.
No.
FB-6
FB-3
032
262
203
232
112
270
225
Inlet
Outlet
Inlet
Outlet
4-110
Calibrated
against
Wet test meter
Standard pitot
tube
Millivolt signals
ASTM-2F or 3F
Standard gas
ASTM-2F or 3F
Type S weights
NBS traceable
barometer
ASTM-2F or 3F
ASTM-2F or 3F
Caliper
Allowable
error
Y +0.02 Y
AH G> +0.15
(Y _+0.05 Y post-test)
Cp +0.01
0.5%
1.5%
(+2% saturated)
+0.5%
+_2°F
+0.5 g
+0.10 in.Hg
(0.20 post-test)
+_5°F
+_5°F
Dn +0.004 in.
Actual
error
+0.008
-0.008
0.0
0.35%
0.61%
0.1%
1.0°F
0.0 g
0.0
i n . Hg
1.0°F
3.0°F
3.0°F
2.7°F
0.002 in.
Within
allowable
limits
/
/
/
/
/
/
/
/
/
/
/
/
/
/
Comments
Used for particulate
tests
Used for particle
size tests
-------
DATE:
BAROMETRIC PRESSURE (P
ORIFICE NO.
AUDIT REPORT DRY GAS METER
CLIENT:
bar
):
in. Hg
ORIFICE K FACTOR:
METER BOX NO.
PRETEST Y: _
AUDITOR:
Orifice
manometer
reading
AH
in H20
// r~\
' fa t
Dry gas
meter
reading
Vvf
ft3
$t,2£0
-------
AUDIT REPORT DRY GAS METER
CLIENT:
/-'.// .'-V
DATE: - ' — '• -
BAROMETRIC PRESSURE (Pbar): o?.40in. Hg METER BOX NO. PC- -'
ORIFICE NO. 7 PRETEST y: . V "/aVO
4/c,/e0
Temperatures
Ambient
VTaf
°F
-&S1/
?&
Dry qas meter
Inlet
°F
5*? /
C-o
Outlet
Toi/Tof
°F
*£f /
5^>
Duration
of
run
min
,r.or
Dry gas
meter
volume
ft3
/1,/ot
Average temperatures
Ambient
Ta
°F
6-7
Dry gas
meter
Tm
°F
SS-
mstd
ft3
/3.1S1
Set
ft3
//.?!'/
Audit
Y
ff^<^
Y
deviation
-------
AUDIT REPORT DRY GAS METER
CLIENT:
DATE: 2/-> .
BAROMETRIC PRESSURE (Pbar): ?*.& in. Hg METER BOX NO. ,~/3if
ORIFICE NO. 10 PRETEST Y: _..
AUDITOR:
ORIFICE K FACTOR:
<*.7? 5 » /» -*
Orifice
manometer
reading
AH
in H20
/.r
Dry gas
meter
reading
ft3'
7oz. *~>
7i'?.m
Temperatures
Ambient
Tai/Taf
°F
~7^
7" ,
a£t
Vmstd
"•";/./
Xct
(1203)( 0 )( K )(P )
(T + 460)1/2
O
,•*-. < *•?'/?. 10 '" ^2^
•T3 5 •*'
Y deviation, %
(Y audit - Y pre-test)(100'£)
(Y audit)
.57- - '-^"
• 57A
Audit Y must be in the range, pre-test Y ±0.05 Y
Figure 5-3. Example audit report for clinker cooler outlet.
5-8
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TABLE 5-2. EXAMPLE BLANK FILTER AND REAGENT ANALYSIS
Sample type
Particulate
87 mm Reeve Angel
934 AH
No. 3530415
Alundum thimble
No. 248
Particle size
64 mm Reeve Angel
934 AH
BE-41
BE-18
BF-17
BD-64
BD-29
BC-68
BD-75
AA-84
B-378
Acetone blank
H20 blank
Ether-chloroform
Original tare
weight, mg
358.6
46,195.1
136.9
128.7
143.0
127.0
142.2
134.3
136.8
133.7
205.0
99,264.7
97,605.8
65,974.8
Blank weight,
mg
358.6
46,197.6
137.1
129.0
143.2
127.2
142.4
134.6
136.9
133.9
205.2
99,267.8
97,613.8
65,980.9
Net weight,
mg
+ 0.2
+ 2.5
+ 0.2
+ 0.3
+ 0.2
+ 0.2
+ 0.2
+ 0.3
+ 0.1
+ 0.2
+ 0.2
0.009 mg/ga
0.013 mg/g£l
0.037 mg/ga
0.01 mg/g used in calculations.
5-9
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TABLE 5-3. AUDIT REPORT - S02 ANALYSIS
Plant
PN Number
Date sample
Samples ana
Reviewed by
Sample
Number
/73-T
^
s received 2>£^
lyzed by Aso+J ^
C^U^L
t^T
mg S02/dscm
Determined
//«./
z>&
?'dl- Date a
U&f
//
Date o
Source of
Sample
(&A)
^)
nalyzed *
f Review
Accepted
Value
/M,9
*M
^-j>:i
3/S/T^
/ /
Difference
-J 3.. o
-H.o
5-10
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TABLE 5-4. AUDIT REPORT - NOV ANALYSIS
X
Plant
PN Number 363>O~ (
Date samples received 3~/~$2- Date analyzed 3>~l~&3- 3-etO^>fUUL (•!'(<- Date of Review 3-«2"82- -/z,
mg N02/dscm
Determined
fcfe5.3JL^
A^3. 87 -
Source of
Sample
T^ Wofjaej^
I . to/H'je/Z.
Accepted
Value
W1.3-
a«.^
Difference
-v./fc ••
-/.^-
5-11
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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 construc-
tion 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 by use of the
trap conditioning apparatus. Traps are heated to 650°C (1200°F)
with carrier gas passing through the trap, oxidizer, and GC
sampling loop. The sampling loop contents are then injected to
the NMO analyzer to determine the level of contaminant 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 them 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. Appendix C contains
pretest equipment blank data and laboratory results. This
appendix also contains chromatograms showing the blank checks for
the traps and tanks used in this test.
5-12
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The sampling equipment, reagents, and analytical procedures
for this test series were in compliance with all necessary
guidelines set forth for accurate test results as described in
Volume III of the Quality Assurance Handbook.*
5-13
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SECTION 6
DISCUSSION OF RESULTS
Overall, the sampling program was executed as planned and,
with the exception of the scrubber inlet test location, no major
problems occurred with either test equipment or sampling activi-
ties. As mentioned previously, only one sampling port was used
for particulate sampling at the scrubber inlet because of extreme
heat and inaccessibility. With increasing distance from down-
stream and upstream disturbances, the effect on the results of
sampling in only one plane would be less significant. Since this
location met only the minimum requirements set forth in EPA
Method 1, however, the particulate data could be biased high; the
magnitude of which is unknown.
As discussed in Section 3 of this report, particulate mass
emission rates at the scrubber outlet are probably biased high
due to the cyclonic flow condition encountered. Since mass;
emission rate data are calculated on the basis of volumetric
flow, the mass emission rate data for each measured pollutant
should be considered on a qualitative basis only.
Both the filter and rinse fractions from this source were
heated to 105°C (221°F) as analytically allowed in the Federal
6-1
-------
Re'gister. * In addition, both fractions were heated to 160°C
(320°F) to preclude sample bias resulting from sulfuric acid mist
retention. No significnt sample weight loss resulted from the
sequential heating.
Table 6-1 summarizes particulate removal efficiency and
scrubber pressure drop data. Despite the fact that the scrubber
lacked an effective mist elimination device system, the particu-
late removal efficiency averaged greater than 98 percent with an
average scrubber pressure drop of 14 inches of water. The
pressure drop data is probably biased high due to frequent
plugging of the inlet sample line. With an effective mist
eliminator, particulate concentration would probably be signifi-
cantly reduced.
The measured particulate emissions from the clinker cooler
appear to be representative based on between-test data reproduci-
bility and comparisons with plume observation and particle size
data from this source.
40 CFR 60, Appendix A, Reference Method 5, July 1, 1981.
6-2
-------
TABLE 6-1. SCRUBBER EFFICIENCY SUMMARY
Participate
Test No.
SIP-1
SOP-1
SIP-2
SOP-2
SIP-3
SOP-3
Sampl ing
location
Scrubber inlet
Scrubber outlet
Scrubber inlet
Scrubber outlet
Scrubber inlet
Scrubber outlet
Concentration,
mg/dscm
31,462
597.8
42,568
758.3
45,476
577.7
Particulate
removal ef-
ficiency, %
98.1
98.2
98.7
Scrubber
pressure.drop,
in.H;?0D
-14.1
-11.1
-17.0
Removal efficiency = 100 x
Inlet - Outlet
Inlet
Scrubber pressure drop in inches of water. A 0 to 36 inch Hg manometer
and pressure taps located immediately before and after the scrubber were
used for this measurement.
6-3
-------
REFERENCES
1. Southern Research Institute. Procedures Manual for Inhal-
able Particulate Sampler Operation. Prepared for EPA under
Contract No. 68-02-3118. November 1979.
R-l
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