-------
2.0 SUMMARY AND DISCUSSION OF TEST RESULTS
2.1 Introduction
The results of the emission test program conducted at the
Homestake Gold Mine in Lead, South Dakota are presented
throughout this section. Tables 2-1 through 2-22 and
Figures 2-1 through 2-4 summarize the results of the tests
for the following parameters!
Particulate Emissions
Trace Element Concentration
Particle Size Distribution
Visible and Fugitive Emissions
Process Samples
These results are discussed briefly in this section, and
detailed discussions are presented in Section 5.0, "Sam-
pling and Analytical Procedures" and in various related
appendices. Particulate samples were collected
simultaneously at the following test locations: Secondary
Crusher Inlet, Conveyor Transfer Inlet, Ore Storage
Reclaim Inlet, and Baghouse Outlet. Preliminary pitot
traverses and moisture measurements were made at each
sampling location and the test parameters for isokinetic
sampling were determined based on these data.
Several problems were encountered during the test pro-
gram. The actual flow rate in the stack at the Ore Stor-
age Reclaim Inlet had increased after the preliminary
measurements had been made. After sampling for 30 minutes
into the first test, the test engineers became aware of
this increased velocity. To compensate for this increased
velocity and to maintain proper isokinetic sampling, the
nozzle was replaced with one of a smaller diameter.
-3-
-------
Other problems were also encountered with the mining pro-
cess during the second and third tests which had a major
effect on the entire test program. Extremely wet ore
emanating from the mine caused blinding of the bags in the
baghouse. Approximately two hours were required while the
bags were manually lanced by mine operators before each
test. Also, the mine operators periodically needed to
provide the miners with supplies which required several
hours. In addition, at approximately 1350 daily, there
was a change in plant personnel causing a slowdown or halt
in process operation. It took over one hour for plant
operations to return to normal. Finally, the plant was
closed on Thursdays for maintenance purposes, which
prohibited testing on that day.
In order to avoid serious delays with the test program,
several modifications to the sampling procedures were
made. The sampling time at every inlet location was de-
creased significantly from five minutes per traverse point
to three minutes per traverse point. At the outlet loca-
tion, the sampling time was decreased further to two min-
utes per traverse point. These sampling modifications al-
lowed for successful completion of the test program while
maintaining proper isokinetic sampling.
2.2 Particulate Emissions
The results for the particulate sampling at the four test
locations are summarized in.Tables 2-1 through 2-8. A
summary of the emissions entering and exiting the baghouse
appears in Tables 2-9 and 2-10. The stack volumetric flow
rates for the inlet columns represent the sum of the indi-
vidual volumetric flow rates measured for the Primary
Crusher Inlet, Conveyor Transfer Inlet and Ore Storage
Reclaim Inlet locations during that particular test.
-4-
-------
The additional data presented in Tables 2-9 and 2-10, with
the exception of total particulate measured in Ib/hr
(English) and Kg/hr (metric), represent the average of the
data collected at the three inlet locations for each test
run. The total particulate emission rate for the inlet,
measured in Ib/hr (English) and Kg/hr (metric),
constitutes the sum of the particulate matter sampled for
each test at the three inlet locations.
The collection efficiency of the baghouse is also included
in Tables 2-9 and 2-10. These calculations are based on
particulate concentration, measured in gr/SCFD.
2.3 Particle Size Distribution
Three particle size distribution tests were conducted at
each of the following locations: Primary Crusher Inlet,
Conveyor Transfer Inlet and Ore Storage Reclaim Inlet.
Only one test, with a duration of 137 minutes, was re-
quired at the Baghouse Outlet location. Tables 2-11
through 2-14 and Figures 2-1 through 2-4 display the re-
sults of these tests. Composite plots of the particle
size distribution for tests 1, 2 and 3 at each location
are presented.
The initial test conducted at the Ore Storage Reclaim In-
let produced results which were not representative of the
existing process conditions. Therefore, this test was not
included when compositing the particle size distribution
data for this location.
2.4 Visible Emissions
Visible emissions observations were performed simultane-
ously at the following test locations: Primary Crusher
Inlet, Conveyor Transfer Inlet, Grizzly Screens Area, Bag-
-5-
-------
house Outlet and Exterior of Crusher Building. The emis-
sions were observed while particulate sampling-was being
conducted. Summaries of these observations appear in
Tables 2-15 through 2-19, and the locations from which
these emissions were being observed are shown in Section
4.4, Figures 4-9 trough 4-11. The average opacity ob-
served for any of the five test locations did not exceed
zero percent. The field data sheets for these observations
may be found in Appendix 6.5.
2.5 Fugitive Emissions
Fugitive emissions observations were performed simultane-
ously with the opacity observations at the following test
locations: Primary Crusher, Conveyor Transfer Area,
Grizzly Screen Area, and Exterior of Crusher Building. No
fugitive emissions were observed at the baghouse outlet.
The results of the observations are summarized in Table
2-20, and the location from which these emissions were
being observed are shown in Section 4.4, Figures 4-9
through 4-11. There were considerable fugitive emissions
observed at the primary crusher, resulting in emission
frequencies exceeding ten percent. However, at the
remaining test locations, the frequency of emissions rarely
exceeded zero percent.
2.6 Process Samples
Ore samples were taken by TRW personnel to ascertain whether
a correlation might be made between ore moisture content and
uncontrolled (inlet) and controlled (outlet) emission
factors. Grab samples of the gold ore were taken from the
following process streams: (1) conveyor outlet from primary
crusher, (2) conveyors at entrance to grizzly screens
(composite sample), (3) beneath grizzly screen (north), (4)
-6-
-------
beneath grizzly screen (south). The moisture content at
each of the sample points for each of the three test runs
are shown in Table 2-21.
2.7 Trace Element Analysis
One particulate sample was analyzed for trace elements.
The filter from the Primary Crusher Inlet, Test 1 was
analyzed for various elements by spark source mass
spectroscopy (SSMS). The results of these analyses appear
in Table 2-22.*
* The results for more than one test program were reported.
The results for this test program are circled on the report,
see Appendix 6.7.2.
-7-
-------
TABLE 2-1
SUMMARY OF EMISSION TEST RESULTS
PRIMARY CRUSHER INLET
HOMESTAKE GOLD MINE
LEAD, SOUTH DAKOTA
(ENGLISH UNITS)
Date
Time
Volume of Dry Gas
Sampled (DSCF)a
Percent Moisture By
Volume
Average Stack
Temperature, 8F
Stack Volumetric Flow
Rate (DSCFM)b
Percent Isokinetic
Production Rate
(Ton/24 Hours)
Total Particulate
Filter Catch and
Front Half Acetone
Wash
mg
gr/DSCF
Ib/hr
Ib/ton ore
Test 1
1-15-80
1155-1520
123.62
1.5
67.9
1828
94.6
2971.5
1840.73
0.22930
3.59
0.0290
Test 2
1-16-80
1015-1233
86.87
1.9
65.0
1904
97.2
2992.5
1599.15
0.28349
4.63
0.0371
Test 3 Average
1-16-80
1435-1600
79.99 96.83
1.6 1.7
70.0 67.6
1938 1890
96.3 96.0
2992.5 2985.5
2164.09 1867.99
0.41663 0.30981
6.92 5.05
0.0555 0.0406
i
aDry Standard Cubic Feet at 68°F, 29.92 inches Hg.
bDry Standard Cubic Feet Per Minute at 68°F, 29.92 inches Hg.
-8-
-------
TABLE 2-2
SUMMARY OF EMISSION TEST RESULTS
PRIMARY CRUSHER INLET
HOMESTAKE GOLD MINE
LEAD, SOUTH DAKOTA
(METRIC UNITS)
Date
Time
Volume of Dry Gas
Sampled (DNm^)a
Percent Moisture By
Volume
Average Stack
Temperature, °C
Stack Volumetric Flow
Rate (DNm3/min)b
Percent Isokinetic
Production Rate
(Mg/24 Hours)
Total Particulate
Filter Catch and
Front Half Acetone
Wash
mg
gr/DNm3
kg/hr
kg/Mg ore
Test 1
1-15-80
1155-1520
3.50
1.5
19.9
52
94.6
2699
1840.73
524.73
1.63
0.0145
Test 2
1-16-80
1015-1233
2.46
1.9
18.3
54
97.2
2654
1599.15
648.74
2.10
0.0190
Test 3
1-16-80
1435-1600
2.27
1.6
21.1
55
96.3
2654
2164.09
953.40
3.14
0.0284
Average
2.74
1.7
19.8
54
96.0
2669
1867.99
708.96
2.29
0.0206
aDry Normalized Cubic Meters at 20°C, 760mm Hg.
bDry Normalized Cubic Meters Per Minute at 20°C, 760mm Hg.
-9-
-------
TABLE 2-3
SUMMARY OF EMISSION TEST RESULTS
CONVEYOR TRANSFER INLET
HOMESTAKE GOLD MINE
LEAD, SOUTH DAKOTA
(ENGLISH UNITS)
Date
Time
Volume of Dry Gas
Sampled (DSCF)a
Percent Moisture By
Volume
Average Stack
Temperature, °F
Stack Volumetric Flow
Rate (DSCFM)b
Percent Isokinetic
Production Rate
(Ton/24 Hours)
Total Particulate
Filter Catch and
Front Half Acetone
Wash
mg
gr/DSCF
Ib/hr
Ib/ton ore
Test 1
1-15-80
1210-1540
61.77
2.1
68.9
4335
106.1
2971.5
1080.63
0.26942
10.01
0.0808
Test 2
1-16-80
1020-1236
49.06
1.5
68.7
5455
105.3
2992.5
1433.80
0.45011
21.05
0.169
Test 3
1-16-80
1445-1612
42.19
3.0
68.9
4887
107.2
2992.5
707.13
0.25810
10.81
0.0867
Average
51.00
2.2
68.8
4893
106.2
2985.5
1073.85
0.32588
13.96
0.112
aDry Standard Cubic Feet at 68°F, 29.92 inches Hg.
bDry Standard Cubic Feet Per Minute at 68°F, 29.92 inches Hg.
-10-
-------
TABLE 2-4
SUMMARY OF EMISSION TEST RESULTS
CONVEYOR TRANSFER INLET
HOMESTAKE GOLD MINE
LEAD, SOUTH DAKOTA
(METRIC UNITS)
Date
Time
Volume of Dry Gas
Sampled (DNm3)a
Percent Moisture By
Volume
Average Stack
Temperature, *C
Stack Volumetric Flow
Rate (DNm3/min)b
Percent Isokinetic
Production Rate
(Mg/24 Hours)
Total Particulate
Filter Catch and
Front Half Acetone
Wash
mg
gr/DNm3
kg/hr
kg/Mg ore
Test 1
1-15-80
1210-1540
1.75
2.1
20.5
123
106.1
2699
1080.63
616.53
4.54
0.0403
Test 2
1-16-80
1020-1236
1.39
1.5
20.4
154
105.3
2654
1433.80
1030.03
9.55
0.0864
Test 3
1-16-80
1445-1612
1.19
3.0
20.5
138
107.2
2654
707.13
590.63
4.90
0.0443
Average
1.44
2.2
20.5
139
106.2.
2669
1073.85
745.73
6.33
0.0569
aDry Normalized Cubic Meters at 20°C, 760mm Hg.
bDry Normalized Cubic Meters Per Minute at 20°C, 760mm Hg.
-11-
-------
TABLE 2-5
SUMMARY OF EMISSION TEST RESULTS
ORE STORAGE RECLAIM INLET
HOMESTAKE GOLD MINE
LEAD, SOUTH DAKOTA
(ENGLISH UNITS)
Date
Time
Volume of Dry Gas
Sampled (DSCF)a
Percent Moisture By
Volume
Average Stack
Temperature, *F
Stack Volumetric Flow
Rate (DSCFM)b
Percent Isokinetic
Production Rate
(Ton/24 Hours)
Total Particulate
Filter Catch and
Front Half Acetone
Wash
mg
gr/DSCF
Ib/hr
Ib/ton ore
Test 1
1-15-80
1151-1539
90.82
2.2
55.7
7791
108.5
2971.5
238.25
0.04040
2.70
0.0218
Test 2
1-16-80
1022-1235
41.14
1.6
67.3
7874
100.2
2992.5
161.81
0.06058
4.09
0.0328
Test 3
1-16-80
1435-1602
46.39
1.9
62.1
8417
105.7
2992.5
102.40
0.03399
2.45
0.0196
Average
59.45
1.9
61.7
8027
104.8
2985.5
167.49
0.04499
3.08
0.0248
aDry Standard Cubic Feet at 68°F, 29.92 inches Hg.
bDry Standard Cubic Feet Per Minute at 68°F, 29.92 inches Hg.
-------
TABLE 2-6
SUMMARY OF EMISSION TEST RESULTS
ORE STORAGE RECLAIM INLET
HOMESTAKE GOLD MINE
LEAD, SOUTH DAKOTA
(METRIC UNITS)
Date
Time
Volume of Dry Gas
Sampled (DNm5)a
Percent Moisture By
Volume
Average Stack
Temperature, *C
Stack Volumetric Flow
Rate (DNm3/min)b
Percent Isokinetic
Production Rate
(Mg/24 Hours)
Total Particulate
Filter Catch and
Front Half Acetone
Wash
mg
gr/DNm3
kg/hr
kg/Mg ore
Test 1
1-15-80
1151-1539
2.57
2.2
13.2
221
108.5
2699
238.25
92.44
1.22
0.0108
Test 2
1-16-80
1022-1235
1.16
1.6
19.6
223
100.2
2654
161.81
138.62
1.85
0.0167
Test 3
1-16-80
1435-1602
1.31
1.9
16.7
238
105.7
2654
102.40
77.79
1.11
0.0100
Average
1.68
1.9
16.5
227
104.8
2669
167.49
102.95
1.40
0.0126
aDry Normalized Cubic Meters at 20°C, 760mm Hg.
bDry Normalized Cubic Meters Per Minute at 20°C, 760mm Hg.
-13-
-------
TABLE 2-7
SUMMARY OF EMISSION TEST RESULTS
BAGHOUSE OUTLET
HOMESTAKE GOLD MINE
LEAD, SOUTH DAKOTA
(ENGLISH UNITS)
Date
Time
Volume of Dry Gas
Sampled (DSCF)a
Percent Moisture By
Volume
Average Stack
Temperature, »F
Stack Volumetric Flow
Rate (DSCFM)b
Percent Isokinetic
Production Rate
(Ton/24 Hours)
Total Particulate
Filter Catch and
Front Half Acetone
Wash
mg
gr/DSCF
Ib/hr
Ib/ton ore
Test 1
1-15-80
1157-1531
114.18
1.6
60.4
17476
104.3
2971.5
59.25
0.00799
1.20
0.0097
Test 2
1-16-80
1019-1249
87.57
1.9
60.0
18669
104.7
2992.5
43.25
0.00761
1.22
0.0098
Test 3
1-16-80
1434-1618
81.77
1.4
60.0
18422
106.3
2992.5
21.25
0.00411
0.65
0.0052
Average
94.51
1.6
60.1
18189
105.1
2985.5
41.44
0.00657
1.02
0.0082
aDry Standard Cubic Feet at 68°F, 29.92 inches Hg.
bDry Standard Cubic Feet Per Minute at 68°F, 29.92 inches Hg.
-14-
-------
TABLE 2-8
SUMMARY OF EMISSION TEST RESULTS
BAGHOUSE OUTLET
HOMESTAKE GOLD MINE
LEAD, SOUTH DAKOTA
(METRIC UNITS)
Date
Time
Volume of Dry Gas
Sampled (DNm5)a
Percent Moisture By
Volume
Average Stack
Temperature, fC
Stack Volumetric Flow
Rate (DNm3/min)b
Percent Isokinetic
Production Rate
(Mg/24 Hours)
Total Particulate
Filter Catch and
Front Half Acetone
Wash
mg
gr/DNm3
kg/hr
kg/Mg ore
Test 1
1-15-80
1157-1531
3.23
1.6
15.8
495
104.3
2699
59.25
18.29
0.54
0.0048
Test 2
1-16-80
1019-1249
2.48
1.9
15.5
529
104.7
2654
43.25
17.40
0.55
0.0050
Test 3
1-16-80
1434-1618
2.32
1.4
15.6
522
106.3
2654
21.82
9.40
0.29
0.0026
Average
2.68
1.6
15.6
515
105.1
2669
41.44
15.03
0.46
0.0041
aDry Normalized Cubic Meters at 20°C, 760mm Hg.
bDry Normalized Cubic Meters Per Minute at 20°C, 760mm Hg.
-15-
-------
TABLE 2-9
PARTICULATE AND EMISSION DATA SUMMARY
GASES ENTERING AND EXITING THE BAGHOUSE
HOMESTAKE GOLD MINE
LEAD, SOUTH DAKOTA
(ENGLISH UNITS)
Location
Date
Volume of Dry Gas
Sampled (DSCF)a
Percent Moisture By
Volume
Average Stack
Temperature, °F
Stack Volumetric Flow
Rate (DSCFM)b
Percent Isokinetic
Total Particulate
Filter Catch and
Front Half Acetone
Wash
gr/DSCF
Ib/hr
Run 1
Inlet Outlet
1-15-80
92.07 114.18
1.93 1.6
64.2 60.4
13954 17476
103.1 104.3
0.17971 0.00799
16.3 1.20
Run 2
Inlet Outlet
1-16-80
59.02 87.57
1.7 1.9
67.0 60.0
15233 18669
100.9 104.7
0.26473 0.00761
29.77 1.22
Run 3
Inlet Outlet
1-16-80
56.19 81.77
2.2 1.4
67.0 60.0
15242 18422
103.1 106.3
0.23624 0.00411
20.18 0.65
Average
Inlet Outlet
69.09 94.51
1.0 1.6
66.0 60.1
14810 18189
102.4 105.1
0.22689 0.00657
22.09 1.02
Collection Efficiency
Percent c 95.55 97.13 98.26 96.98
aDry Standard Cubic Feet at 68°F, 29.92 inches Hg.
t>Dry Standard Cubic Feet Per Minute at 68°F, 29.92 inches Hg.
GCollection Efficiency Based on Particulate Concentration in gr/DSCF.
-------
TABLE 2-10
PARTICULATE AND EMISSION DATA SUMMARY
GASES ENTERING AND EXITING THE BAGHOUSE
HOMESTAKE GOLD MINE
LEAD, SOUTH DAKOTA
(METRIC UNITS)
Location
Date
Volume of Dry Gas
Sampled (DNm3)a
Percent Moisture By
Volume
Average Stack
Temperature, °C
Stack Volumetric Flow
Rate (DNm3/min)b
Percent Isokinetic
Total Particulate
Filter Catch and
Front Half Acetone
Wash
mg/DNm3
Kg/hr
Run 1
Inlet Outlet
1-15-80
2.61 3.23
1.9 1.6
17.9 15.8
396 495
103.1 104.3
411.23 18.29
7.39 0.54
Run 2
Inlet Outlet
1-16-80
1.71 2.48
1.7 1.9
19.4 15.5
431 529
100.9 104.7
605.80 17.40
13.5 0.55
Run 3
Inlet Outlet
1-16-80
1.59 2.32
2.2 1.4
19.4 15.6
431 522
103.1 106.3
540.61 9.40
9.15 0.29
Average
Inlet Outlet
1.95 2.68
1.9 1.6
18.9 15.6
420 515
105.1
519.21 15.03
10.02 0.46
Collection Efficiency
Percent c 95.55 97.13 98.26 96.98
aDry Standard Cubic Meters at 20°C, 760mm Hg.
t>Dry Standard Cubic Meters Per Minute at 20°C, 760mm Hg.
cCollection Efficiency Based on Particulate Concentration in
-------
TABLE 2-11
SUMMARY OF PARTICLE SIZE DISTRIBUTION TESTS
CONDUCTED ON THE PRIMARY CRUSHER INLET
HOMESTAKE GOLD MINE
LEAD, SOUTH DAKOTA
Total Particle
Test . Particulate Size
Test Time, Concentration, Range,
Number Date Timea Min.. gr/DSCF Microns
Mass in
Size Range,
%
1 1/16/80 1024-1037 30 0.18874 >11.78
1124-1131 11.78-7.35
1149-1154 7.35-4.98
4.98-3.39
3.39-2.17
2.17-1.08
1.08-0.66
0.66-0.44
<0.44
2 1/16/80 1208-1228 30 0.22348 >14.25
14.25-8.89
8.89-6.03
6.03-4.11
4.11-2.64
2.64-1.32
1.32-0.81
0.81-0.54
<0.54
3 1/16/80 1244-1304 20 0.28446 >14.37
14.37-8.97
8.97-6.08
6.08-4.14
4.14-2.66
2.66-1.33
1.33-0.82
0.82-0.54
<0.54
28.23
10.75
6.29
3.15
1.37
1.00
0.58
0.26
48.37
61.48
17.92
11.02
3.62
3.52
1.85
0.46
0.06
0.06
44.65
11.28
11.02
10.16
10.56
8.77
2.90
0.65
0.01
See field data sheets for plant shutdown intervals,
-18-
-------
IOO.O
90.0
99.99 99.9 99.8
99 98
FIGURE 2-1
PARTICLE SIZE DISTRIBUTION
COMPOSITE OF TESTS 1,2 and 3
PRIMARY CRUSHER INLET
HOMESTAKE. GOLD MINE
LEAD, SOUTH DAKOTA
95
1 0.5 02 0.1 0.05 0.01
100.0
0.1
Legend 0
Ell!
Test 1
Test 2
Test 3
-19-
0.2
0.01 0.05 0.1 0.2 0.5 1 2 5 10 20 30 40 50 60 70 80 90 95 98 99 99.8 99.9 99.99
CUMULATIVE PER CENT BY WEIGHT LESS THAN(Dp)
O.I
-------
TABLE 2-12
SUMMARY OF'PARTICLE SIZE DISTRIBUTION. TESTS
CONDUCTED ON THE CONVEYOR TRANSFER INLET
HOMESTAKE GOLD MINE
LEAD, SOUTH DAKOTA
Total
Test Particulate Particle
Test Time, Concentration, Size Range,
Number Date Time3 Min. gr/DSCF Microns
1 1/16/80 1732-1752 20 0.09451 >12.93
12.93-8.07
8.07-5.47
5.47-3.72
3.72-2.39
2.39-1.19
1.19-0.73
0.73-0.48
< 0.48
2 1/16/80 1800-1820 20 0.13018 >13.53
13.53-8.44
8.44-5.72
5.72-3.90
3.90-2.50
2.50-1.25
1.25-0.76
0.76-0.50
<0.50
3 1/16/80 1824-1832 21 0.37751 >12.97
1852-1857 12.97-8.09
1901-1908 8.09-5.48
5.48-3.73
3.73-2.39
2.39-1.20
1.20-0.73
0.73-0.48
<0.48
Mass in Size
Range ,
%
43.76
16.70
14.51
10.61
7.31
5.10
0.91
0.00
1.10
46.35
19.77
15.16
8.98
5.62
3.67
0.45
0.00
0.00
62.90
19.29
8.27
5.45
2.58
1.39
0.12
0.00
0.00
See field data sheets for plant shutdown intervals
-20-
-------
IOO.O
90.0
99.99
FIGURE 2-2
PARTICLE SIZE DISTRIBUTION
COMPOSITE OF TESTS 1,2 and 3
CONVEYOR TRANSFER INLET
HOMESTAKE GOLD MINE
LEAD, SOUTH DAKOTA
99.9 99.8
99 98
95
90
80
1 0.5 0.2 0.1 C.OS 0.01
0.1
0.01 0.05 0.1 0.2 0.5 1
10
20 30 40 50 60 70 80
90 95
98 99
99.8 99.9
Legend
1
A
0
Test 1
Test 2
Test 3
CUMULATIVE PER CENT BY WEIGHT LESS THAN(Dp)
-21-
100.0
9O.O
0.2
99.99
O.I
-------
TABLE 2-13
SUMMARY OF PARTICLE SIZE DISTRIBUTION TESTS
CONDUCTED ON THE ORE STORAGE RECLAIM INLET
HOMESTAKE GOLD MINE
LEAD, SOUTH DAKOTA
Total
Particulate Test Particle
Test Concentration, Time, Size Range,
Number Date Time gr/DSCF Min. Microns
lb 1/16/80 1538-1558 0.00210 ' >12.57
1603-1618 12.57-7.84
1623-1638 50 7.84-5.31
5.31-3.62
3.62-2.32
2.32-1.16
1.16-0.71
0.71-0.45
2 1/16/80 1648-1738 0.00621 50 >12.75
12.75-7.96
7.96-5.39
5.39-3.67
3.67-2.35
2.35-1.17
1.17-0.72
0.72-0.46
<0.46
3 1/16/80 1742-1832 0.01043 50 >12.59
12.59-7.86
7.86-5.32
5.32-3.62
3.62-2.32
2.32-1.16
1.16-0.71
0.71-0.45
<0.45
Mass in
Range ,
%
77.38
22.62
0
0
0
0
0
0
54.24
20.81
12.32
3.83
4.55
1.76
1.04
0.83
0.62
66.15
11.03
9.10
4.30
2.18
2.24
1.43
2.81
0.75
See field data sheet for plant shutdown intervals.
Results not representative of existing process conditions and should
therefore be disregarded.
-22-
-------
FIGURE 2-3
PARTICLE SIZE DISTRIBUTION
COMPOSITE OF TESTS 2 AND 3
ORE STORAGE RECLAIM INLET
HOMESTAKE GOLD MINE
LEAD, "SOUTH DAKOTA;
0.5 0.2 0.1 0.05 0.01
100.0
SOD
ZOO
30O
200
10.0
9.0
ao
7.0
6.0
8.0
4.0
3.0
2.0
a
Q
OT
O
(C
O
UJ
N
UJ
O
p
ec
a.
0.2
1.0
0.9
0.8
0.7
0.6
0.9
O.4
0.9
0.2
0.1
0.01 0.05 0.1 0.2 O5 1 2
10 -20 30 40 50 60 70 80 90 95 98 99
99.8 99.9 99.99
Legend
Q Test 3
CUMULATIVE PER CENT BY WEIGHT LESS THAN(Dp)
-23-
-------
TABLE 2-14
SUMMARY OF PARTICLE SIZE DISTRIBUTION TEST
CONDUCTED ON BAGHOUSE OUTLET
HOMESTAKE GOLD MINE
LEAD, SOUTH DAKOTA
Total Particle
Test Particulate Size
Test Time, Concentration, Range,
Number Date Time3 Min. gr/DSCF Microns
1 1/15/80 1201-1308 0.00229 >15.75
1319-1349 15.75-9.83
1404-1405 ' 9.83-6.66
1452-1531 137 6.66-4.53
4.53-2.90
2.90-1.45
1.45-0.89
0.89-0.59
<0.59
Mass in
Size Range,
%
92.06
3.50
0.00
0.00
0.00
4.44
0.00
0.00
0.00
See field data sheets for plant shutdown intervals.
-24-
-------
FIGURE 2-4
PARTICLE SIZE DISTRIBUTION
BAGHOUSE OUTLET
HOMESTAKE GOLD MINE
LEAD,- SOUTH DAKOTA
99.99 99.9 99.8
99 98 95 90
80 70
0 005 0.01 ,oo.O
O.I
0.2
0.01 0.05 0.1 0.2 0.5 1 2 5 10 20 30 40 SO 60 70 80 90 95 96 99 99.8 99.9 99.99
CUMULATIVE PER CENT BY WEIGHT LESS THAN(Dp)
O.I
-25-
-------
TABLE 2-15
SUMMARY OF VISIBLE EMISSIONS OBSERVATIONS
PRIMARY CRUSHER INLET
HOMESTAKE GOLD MINE
LEAD, SOUTH DAKOTA
DATE
TIME3
TEST NO.
Six Minute
Interval
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
1/15/80
1155-1523
1
0
0
0
0
.0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1/16/80
1020-1236
2
.Average Opacity, %
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Oc
-
-
-
-
1/16/80
1435-1603
3
0
0
0
0
0
0
0
0
0
0
0
0
0
0
ob
-
-
-
See Field Data Sheet for plant shutdown intervals.
Based on 4 minute interval.
Based on 3 minute interval.
-26-
-------
TABLE. .2-16
SUMMARY OF VISIBLE EMISSION OBSERVATIONS
CONVEYOR TRANSFER INLET
HOMESTAKE GOLD MINE
LEAD, SOUTH DAKOTA
DATE
TIMES
TEST NO.
Six Minute
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
1/15/80
1151-1517
1
Interval
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1/16/80
1020-1236
2
Average Opacity. %
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
b
0
1/16/80
1435-1612
3
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
h
0
See field data sheets for plant shutdown intervals.
Based on 2 minute interval.
-27-
-------
TABLE 2-17
SUMMARY OF VISIBLE EMISSIONS OBSERVATIONS
GRIZZLY SCREEN AREA
HOMESTAKE GOLD MINE
LEAD, SOUTH DAKOTA
DATE
TIMEa
TEST NO.
Six Minute
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
1/15/80
1151-1517
1
Interval
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1/16/80
1018-1237
2
Averaqe Opacity, %
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
-
-
-
1/16/80
1435-1612
3
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
-
-
-
See Field Data Sheet for plant shutdown intervals.
-28-
-------
TABLE 2-18
SUMMARY OF VISIBLE EMISSIONS OBSERVATIONS
BAGHOUSE OUTLET
HOMESTAKE GOLD MINE
LEAD, SOUTH DAKOTA
Date
Time
Test No.
Six Minute
Intervals
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
1/15/80
1155-1350
1455-1523
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1/16/80
1015-1036
1121-1247
2
Average Opacity, %
" *
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
oa
-
-
-
-
-
1/16/80
1413-1617
3
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
ob
-
-
-
-
-
Based on 1 min. observation interval.
Based on 2 min. observation interval.
-------
TABLE 2-19
SUMMARY OF VISIBLE EMISSIONS OBSERVATIONS
CRUSHER BUILDING
HOMESTAKE GOLD MINE
LEAD, SOUTH DAKOTA
DATE
TIMEa
TEST NO.
Six Minute
Interval.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
1/15/80
1154-1409
1
0
0
0
0
. o
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1/16/80
1025-1232
2
Average Opacity, %
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1/16/80
1444-1620 .
3
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
See field data sheets for plant shutdown intervals.
-30-
-------
TABLE 2-20
SUMMARY OF FUGITIVE EMISSIONS OBSERVATIONS
HOMESTAKE GOLD MINE
LEAD, SOUTH DAKOTA
LOCATION
Primary Crusher
Inlet
Conveyor Transfer
Inlet
Grizzly Screen
Area
Crusher
Building
DATE
1/15/80
1/16/80
1/16/80
1/15/80
1/16/80
1/16/80
1/15/80
1/16/80
1/16/80
1/15/80
1/16/80
1/16/80
TIME3
1155-1523
1020-1236
1435-1603
1151-1516
1020-1236
1435-1612
1155-1517
1018-1237
1435-1612
1154-1409
1025-1232
1444-1544
a See Field Data Sheets for plant shutdown
Emission Frequency = emission time
ACCUMULATED
OBSERVATION
TIME (SEC)
7200
5460
5220
7200
5460
5820
7200
7560
5820
7200
7200
7200
intervals ,
i nn
ACCUMULATED
EMISSION
TIME (SEC) EMISSION FREQUENCY, %
806 11.2
393 7.2
633 12.7
0 0
0 0
0 0
16 <1
4 <1
1 <1
0 0
15 <1
0 0
observation time
-------
TABLE 2-21
SUMMARY OF LABORATORY ANALYSIS
ON PROCESS SAMPLES
HOMESTAKE GOLD MINE
LEAD, SOUTH DAKOTA
Location
% Moisture
Conveyor Outlet from
Primary Crusher
Conveyors preceeding
Grizzly Screens
(composite sample)
Beneath GrizzTy Screen
(North)
Beneath Grizzly Screen
(South)
Test!
4.5
1.4
1.4
5.2
Test 2
4.3
0.9
0.4
4.8
Test 3
2.2
3.1
1.4
6.8
-32-
-------
TABLE 2-22
TRACE ELEMENT CONCENTRATIONS
HOMESTAKE GOLD MINE
LEAD, SOUTH DAKOTA
Element
Concentration in
Particulate Sample* (ppm)
ZINC M
COPPER 10.
NICKEL 100.
COBALT ; 2.
IRON M
MANGANESE M
CHROMIUM 5.
VANADIUM 20.
TITANIUM 500.
SCANDIUM 2.
CALCIUM M
POTASSIUM M
CHLORINE 10.
SULFUR 1000.
PHOSPHORUS 100.
SILICON M
ALUMINIUM M
MAGNESIUM A
SODIUM M
FLUORINE 2.
CARBON
BORON 2.
BERYLLIUM A
LITHIUM 5.
URANIUM < 1.
THORIUM < 1.
BISMUTH < 1.
LEAD 50.
THALLIUM < 1.
MERCURY < 2.
GOLD < 1.
PLATINUM < 2.
IRIDIUM < 1.
OSMIUM < 2.
* Primary Crusher Inlet Filter Sample from Test 1.
A Matrix Interference
M Signifies Major Constituent of Sample
-33-
-------
TABLE 2-22 (Con't)
Element
Concentration in
Particulate Sample* (ppm)
REHENIUM < 2.
TUNGSTEN < 2.
TANTALUM < 1.
HAFNIUM < 2.
LUTETIUM < 0.2
YTTERBIUM < 1.
THULIUM < 0.2
ERBIUM < 1.
HOLMIUM < 0.2
DYSPROSIUM < 1.
TERBIUM < 0.2
GADOLINIUM < 1.
EUROPIUM < 1.
SAMARIUM < 1.
NEODYMIUM 10.
PRASEODYMIUM 5.
CERIUM 10.
LANTHANUM 5.
BARIUM 500.
CESIUM < 1.
IODINE < 1.
TELLURIUM < 1.
ANTIMONY 10.
TIN < 1.
INDIUM < 2.
CADMIUM < 2.
SILVER < 1.
PALLADIUM < 2.
RHODIUM < 1.
RUTHENIUM < 2.
MOLYBDENUM < 2.
NIOBIUM 2.
ZIRCONIUM 20.
YTTRIUM 10.
STRONTIUM 1000.
RUBIDIUM 100.
BROMINE < 0.5
SELENIUM < 0.5
ARSENIC 1000.
GERMANIUM < 2.
GALLIUM i.
-34-
-------
3.0 PROCESS DESCRIPTION
3.1 Process Description
.A schematic flow diagram for the processing of gold ore at
Homestake mine is shown in Figure 3-1. Gold ore, which is
mined underground, is loaded into nine 10-ton capacity
rectangular ore skips and hoisted to the surface where the
dry crushing operation takes place. Ore is mined from two
shafts (the Yates and the Ross), each of which is equipped
with its own surface primary, secondary, and tertiary
crushing operation. The two operations at these shafts
are nearly identical in that they both have one primary
gyratory crusher, one 7-foot standard Symons secondary
cone crusher, one 7-foot shorthead Symons tertiary cone
crusher and nearly identical enclosing structures. Ore is
transported to the mill from both shafts by trains through
enclosed passageways.
Emission measurements were made only at the Ross shaft
operations. The emissions are controlled by a baghouse.
The Yates shaft is controlled by a low energy dry cyclone
(4-6 inch pressure drop). The baghouse at the Ross shaft
controls emission from the secondary and teriary crusher,
conveyor transfer, and ore storage operations. The
primary crusher is a 30-inch gyratory crusher, fed by a
chain feeder directly from the ore skips, reducing the ore
to <6-inch size. The ore travels by an open conveyor to
the secondary crusher and then is conveyed to and passed
over a vibrating screen set to allow <3/8-inch size so it
can pass through the vibrating screen and into the ore
storage area. From the storage bins, the ore is
transported by an enclosed conveyor to the mill where wet
processing begins.
-35-
-------
LEGEND
"> -Ore Row
> - Dust Emissions
TP -Test Points
1-4:Method 5
5-7,9:Methods 9422
SrMethod 9
/^TAND
/ SYMONS
\SECOND
TP-9 (V.E. outside crusher building)
FLOW DIAGRAM
Homestake Mining Co., Lead, South Dakota
figure 3-1
-36-
-------
Water content of the ore remains at 1.5 to 2 percent
throughout the crushing operation because no water is added
during this process.
The preceeding description includes all steps leading up to
the wet processing which includes milling, recovery, and
refining. There are no drying operations.
Milling is performed by four rod mills and four ball mills
with full load capacity of 5400 tons per day. This process
mills and separates the ore into two fractions:
Sand - 54% + 200 mesh 59% of ore
46% - 200 mesh
Slime - 95% - 325 mesh 41% or ore
5% - 200 to 325 mesh
Gold is recovered from the sand and slime fractions by
gravity concentration and cyanidation. There are 35
cyanidation vats, each holding 750 to 780 tons of material.
Gold, as free gold, precipitates and the steel wool gold
sponge are sent to the refinery where they are mixed with
suitable fluxes and smelted to remove iron, zinc, and copper
impurities. The resulting crude bullion is further refined
to separate silver and the last races of impurities. The
final product is 250 troy ounce bars representing the
mining, hoisting, crushing, grinding, and cyanidation of
2,170,000 pound of ore. Again, the milling, recovery, and
refining are wet processes not included in the scope of
work.
Two thousand nine hundred ton/day of mine tailings not
backfilled are collected and pumped 16,000 feet (487 feet in
-37-
-------
elevation) to the Grizzly Gulch Impoundment. Impoundment
water is recycled to the mine.
The baghouse that was tested is a Sky-Kleen "HT" Continuous
Duty Bag Collector controlling dust generated from the
crushing, transferring, and storing of ore. The baghouse
has a design capacity of 24,000 cfm at 708F. The baghouse
uses 210 16 oz. dacron felt filter bags each 6-inch in
diameter and 96 inches long. The filtering area is 2,625
square feet and the air to cloth ratio is 9.14:1. Bag
cleaning is accomplished by sequential air pulsing of the
filter bags, automatically controlled by a solidstate timer.
The baghouse has a maximum pressure drop of 6 inches W.G.
which is measured by a manometer. If the manometer reading
gets much higher than the maximum level, the bags are
cleaned by manual air lancing. The pressure drop of the
baghouse was checked at 1/2 hour intervals. Table 3-1 shows
the readings for the three test runs.
3.2 Process Operation
The production rates for the crushing, screening, transfer,
and storage operations for the Ross shaft processing stream
did not vary over the length of the tests on January 15 and
16. Their production rates for these two days were 2699
Mg/day (2971.5 tons/day) and 2654 Mg/day (2992.5 tons/day),
respectively.
-38-
-------
TABLE 3-1
MANOMETER READINGS OF BAGHOUSE
January
January
January
Time
15, 1980 - Test #1
11:57
12:19
12:40
12:59
13:15
13:28
14:05
14:25
14:33
14:56
15:10
15:27
15:36
16, 1980 - Test #2
09:35
10:03
10:17
10:30
10:50
11:05
11:25
11:42
12:02
12:24
12:40
16, 1980 - Test #3
14:34
14:45
15:05
15:20
15:40
15:56
16:10
16:25
16:45
18:00
18:33
Pressure Differential
(inches of water)
4.7
5.1
5.5
5.7
5.9
6.0
6.2
6.4
6.6
6.8
7.0
7.2
7.4
2.2
2.9
3.2
3.3
3.5
3.9
4.3
4.5
4.7
4.9
5.1
3.6
3.8
4.1
4.2
4.3
4.5
4.6
4.7
4.8
5.3
5.5
-39-
-------
4.0 SAMPLING LOCATIONS AND EMISSIONS OBSERVATION LOCATIONS
4.1 Introduction
Emission sampling was conducted on the primary crusher,
conveyor transfer and ore storage reclaim operations of
the Homestake Gold Mine in Lead, South Dakota. The emis-
sions produced by these operations are vented to a bag-
house. The baghouse outlet duct was also tested so that a
collection efficiency for the baghouse could ultimately be
calculated.
The locations of the particulate test ports and the sam-
pling points at each test site were determined in accor-
dance with guidelines outlined in EPA Method 1 (Sample and
Velocity Traverses for Stationary Sources)-*-. This section
also presents detailed descriptions of the particle size
sampling locations and opacity observation and fugitive
emissions observation location. It should be noted that
the sampling procedure of the particulate tests was modi-
fied in order to avoid testing delays and incompletion of
the program. The sampling times per traverse point were
reduced by two minutes for the inlet locations and one
minute for the outlet location during the second test.
4.2 Particulate Sampling Locations
Primary Crusher Inlet
The sampling ports for the primary crusher inlet are
located in the duct which vents particulate emissions
from the crusher outlet to the baghouse. The inner
diameter of the duct at this location is 13.5
inches. The ports are perpendicular to each other,
-'All test methods cited in this report are from "Standards
of Performance for New Stationary Sources, Appendix A",
Federal Register, Volume 42 No. 160, August 13, 1977.
-41-
-------
and are located 21 inches from a downstream disturb-
ance and 45 inches upstream from a bend in the duct
(see Figures 4-1 and 4-2).
Twenty-eight traverse points, 14 in each port, were
sampjLed for five minutes each during the first test.
During the second test, the sampling time was reduced
to three minutes per point. The entire third run was
also based on three minutes per point of sampling.
The resulting times of the three tests were 140 min-
utes, 92 minutes and 84 minutes, respectively.
Conveyor Transfer Inlet
Following the secondary and tertiary crushing pro-
cesses, conveyors transfer ore to separation
screens. The sampling ports for the conveyor trans-
fer inlet are located in the duct which vents from
the collection hoods of the transfer drops to the
baghouse. Two ports, separated by approximately 90
degrees, are located 25 inches from an upstream dis-
turbance and 46 inches from a downstream disturb-
ance. At this location, the inner diameter of the
duct is 19.5 inches (see Figures 4-3 and 4-4).
Sixteen traverse points were sampled in each port.
The sampling time for the first test was five minutes
per point. This time was changed to three minutes
per point during the second test, remaining at three
minutes per point throughout the third test. The
total sampling time for tests one, two and three was
140 minutes, 89 minutes and 84 minutes, respec-
tively.
-42-
-------
SAMPLING POINT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
DISTANCE FROM DUCT WALL (INCHES)
1,
1,
1
00
14
,69
2.28
2.97
3.82
5.06
8.44
9.68
10.53
11.22
11.81
12.35
12.50
FIGURE 4-1
SAMPLING POINT LOCATION
PRIMARY CRUSHER INLET
-43-
-------
13.5
i
Port B
Flow
To Baghouse
a
Port A
21
45
FIGURE 4-2
ILLUSTRATIONS OF PRIMARY CRUSHER INLET
SAMPLING LOCATION
-44-
-------
SAMPLING POINT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
DISTANCE FROM DUCT WALL (INCHES)
0
0
1
2
3
4
5
7
12
13
15
16
17
17
18
19
.31
.95
.66
.44
.30
.29
.52
.31
.19
.98
.21
.20
.06
.84
.54
.19
FIGURE 4-3
SAMPLING POINT LOCATION
CONVEYOR TRANSFER INLET
-45-
-------
Port B
From
collection
hoods
FIGURE 4-4
ILLUSTRATIONS OF CONVEYOR TRANSFER INLET
SAMPLING LOCATION
-46-
-------
Ore Storage Reclaim Inlet
The ore storage reclaim inlet is a bin which retains
processed ore prior to further refining. Sampling
ports for this operation are situated 90 degrees to
each other, in a duct venting emissions from the bin
to the baghouse. At this location the inner duct
s
diameter is 16.5 inches. The upstream and downstream
disturbances from the ports are 98 inches and 34
inches, respectively (see Figures 4-5 and 4-6).
Fourteen traverse points were sampled in each port
for five minutes per point during the first test and
for three minutes per point during the second and
third tests. These sampling times resulted in total
test times of 140 minutes for the first test and 84
minutes for the second and third tests.
Baghouse Outlet
The baghouse outlet duct vents controlled emissions
from the baghouse to the atmosphere. The rectangular
duct has inner dimensions of 65.5 inches in width and
17.5 inches in height. The upstream disturbance from
the two sampling ports is approximately 58 inches
(see Figures 4-7 and 4-8). Forty-eight traverse
points were sampled for three minutes per point for
the first test, resulting in a total test time of 144
minutes. During the second test, the sampling time
was reduced to two minutes per point; the total sam-
pling time was 103 minutes. The sampling time re-
mained at two minutes per point throughout the third
test, resulting- in a total sampling time of 96 minu-
tes.
-47-
-------
SAMPLING POINT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
DISTANCE FROM DUCT WALL (INCHES)
0.
1.
2.
2.
3.
4.
6.
10.
11.
12.
13.
14.
15.
15.
81
40
06
79
63
67
19
31
83
87
71
44
10
69
FIGURE 4-5
SAMPLING POINT LOCATION
ORE STORAGE RECLAIM INLET
-48-
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/\
98"
s
16.5"
Port A
34"
Port B
FIGURE 4-6
ILLUSTRATIONS OF ORE STORAGE RECLAIM INLET SAMPLING LOCATION
-------
Two four inch
diameter ports
SAMPLING POINT
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 FROM DUCT WALL
(INCHES)
FIGURE 4-7
1
4.
,36
,09
6.82
9.55
12.28
15.01
17.74
20.47
23.20
25.93
28.66
31.39
34.12
36.85
39.58
42.31
45.04
47.77
50.50
53.23
55.96
58.69
61.42
64.15
SAMPLING POINT LOCATION-BAGHOUSE OUTLET
-50-
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Duct exits the wall
FIGURE 4-8
ILLUSTRATIONS OF BAGHOUSE OUTLET SAMPLING LOCATION
-51-
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4.3 Particle Size Distribution
The sampling -point used for particle size distribution at
each test location was determined by selecting the tra-
verse point which represents the average velocity within
that duct.
o
4.4 Fugitive Emissions and Opacity Observation Locations
One fugitive emissions observer and one opacity observer
were positioned at each of the following locations:
Conveyor Transfer Inlet
Grizzly Screen Area
Primary Crusher Conveyor Area
Crusher Building (Overlook)
Only an opacity observer was evaluating emissions at the
baghouse outlet stack. The locations are shown in Figures
4-9 through 4-11. Observations at these locations were
performed concurrently with EPA Method 5 testing.
-52-
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FIGURE 4-9
VISIBLE AND FUGITIVE EMISSIONS OBSERVATION LOCATIONS
PRIMARY CRUSHER
Conveyor
Belt
Secondary
Crusher
r
Observers'
Location
Stairs
j
' :. Lower
; Floor"
--G-a-t-wa-ik-
-53-
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. FIGURE 4-10
VISIBLE AND FUGITIVE EiMISSIONS OBSERVATION LOCATIONS
CONEYOR TRANSFER INLET AND GRIZZLY SCREENS AREA
Garaae Door
Dust
Collection
Hoods
Conveyor
Transfer
Observers
Location
Grizzly
Screens
( .
tO\
o
r
Grizzly Screen Area
Observers' Location
-54- '
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FIGURE 4-11
VISIBLE AND FUGITIVE EMISSIONS OBSERVATION LOCATIONS
BAGHOUSE OUTLET STACK AND CRUSHER BUILDING (OVERLOOK).
CRUSHER BUTLDIJrfG OBSERVERS'
CAT/ON (2nd half)
Outlet Sta
Observer's
Location
o
o
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5.0 SAMPLING AND ANALYTICAL PROCEDURES
5.1 Introduction
This section describes the sampling and analytical pro-
cedures used by YRC at the Homestake Gold Mine in Lead,
South Dakota in January, 1980. Only brief descriptions
and modifications of standard test procedures will be pre-
sented here. Details are contained in Appendices 6.1
through 6.7.
5.2 Preliminary Measurements
Gas Velocity and Temperature
Gas velocity and temperature were measured at each
location in accordance with guidelines outlined in
EPA Method 2 (Determination of Stack Gas Velocity and
Volumetric Flow Rate).
A precalibrated type "S" pitot tube and a thermo-
couple were rigidly attached to each sampling probe.
The velocity pressure was measured on an inclined,
vertical, dual manometer, and the temperature on a
pyrometer. Measurements were recorded at each tra-
verse point.
Moisture Determination
The percent by volume of moisture of the stack gas at
each test location was determined in accordance with
guidelines outlined in EPA Method 4 (Determination of
Moisture Content in Stack Gases).
A sample of gas was extracted from each test location
at one traverse point for a period of thirty min-
-57-
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utes. Dry gas meter readings and inlet and outlet
temperature readings were recorded every five min-
utes. The moisture content of the stack gas was de-
termined from the volume of excess water in the im-
pingers and the temperature and meter readings.
5.3 Gas Composition
The gas composition at each test location was determined
in accordance with guidelines outlined in EPA Method 3
(Gas Analysis for Carbon Dioxide, Oxygen, Excess Air and
Dry Molecular Weight).
Since no combustion was involved in the process, the gas
composition at each test location was assumed to be air.
A Fyrite Analyzer, which determines carbon dioxide and
oxygen content, was used to verify this assumption.
5.4 Particulate
The particulate concentrations were determined at each
test location in accordance with guidelines outlined in
EPA Method 5 (Determination of Particulate Emissions from
Stationary Sources).
Sampling
The sampling train consisted of a nozzle, stainless
steel probe, heated sample box which contained the
filter, four impingers, vacuum pump, dry gas meter
and calibrated orifice (Figure 5-1).
The nozzle was rigidly connected to the probe, and
the probe consisted of a 5/8 inch O.D. tubing which
was wrapped with heater tape to prevent condensa-
tion. Attached to the probe was a precalibrated type
-58-
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PARTICULATE
FIGURE 5-1
SAMPLING TRAIN
Coarse
control
valve
The rmome ters
Stack
wall
i
S Pitot
1 . tube
Sampling
1 nozzle
Stack
thermocouple
Inclined manometer
(AP)
Air-tight
pump
Pyrometer
Impinger
train
Check
valve
Dry gas
meter
Inclined
manometer
(A h)
Vacuum gauge
Ice
bath
ES - 089
-------
"S" pitot tube and a thermocouple used to monitor the
velocity pressure and temperature.
The probe was connected to a heated sample box which
contained a tared fiberglass filter encased in a
coarse, fritted glass filter holder. The filter
holder was sealed with heat-resistant tape and
secured in the sample box with U-type clamps. The
ball joints of the filter holder were thoroughly
coated with silicone grease in order to insure the
presence of a vacuum. The temperature of the sample
box was maintained at 248°F + 25°F throughout the
test program.
The probe and heater box were connected to the impin-
ger assembly by means of a flexible sample line. The
four impingers were of the Greenburg-Smith design and
were connected in series. The first impinger was
initially filled with 100 milliliters of distilled
water. The second impinger was a standard Greenburg-
Smith impinger containing 100 ml of distilled water.
The third and fourth impingers were identical to the
first, the third being left dry while the fourth con-
tained 300 grams of dry indicating-type silica gel.
From the fourth impinger the effluent stream flowed
through a check valve, flexible rubber vacuum tubing,
a vacuum gauge, a needle valve, a leakless vacuum
pump and a dry gas meter. The impingers were ar-
ranged in an insulated box and surrounded by ice.
A calibrated orifice completed the train and was used
to measure instantaneous flow rates. The dual mano-
meter across the calibrated orifice was an inclined
vertical type, graduated in hundredths of an inch of
water from 0 to 0.1 inch and in tenths of an inch
from 1 to 10 inches.
60-
-------
During the test, the following data were recorded at
each traverse point:
Traverse point number
Sampling time (min.)
Clock time (24-hour clock)
Dry gas meter reading (Vm/ ft^)
Velocity pressure (APS/ in. H2°)
o Desired pressure drop across orifice (AH,
in. H2o)
Actual pressure drop across orifice (AH,
in. H20)
e Stack temperature (Ts / °F)
Dry gas meter temperature-inlet (Tm, °F)
and outlet (Tm, °F)
Pump Vacuum (in. Hg)
Sample box temperature (°F)
Impinger temperature (°F)
The relationship of the Ap reading with the £H read-
ing is a function of the following variables:
Orifice calibration factor
Gas meter temperature
Moisture content of flue gas
Ratio of flue gas pressure to barometric
pressure
Stack temperature
« Sampling nozzle diameter
A nomograph was used to correlate all of the above
variables such that a direct relationship between Ap
and AH could be determined by the test technician and
isokinetic conditions could be maintained. Initial
and final leak checks were performed on the sampling
train prior to sampling and upon completion of each
-61- -'
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test to confirm the presence of a vacuum. These
measurements were recorded on the data sheets.
Sample Recovery
Upon completion of the test, the samples were recov-
ered in the following manner:
Container #1 - The filter was removed from the filter
holder and placed in its original con-
tainer.
Container #2 - The nozzle, probe and front half fil-
ter holder were brushed and washed
with acetone three times. The wash
was collected in a grass jar.
Container #3 - The silica gel was returned to its
original container.
Container #4 - A blank sample of the acetone from the
field supply was collected in a glass
jar.
Each sample container was sealed and labeled with the
date, test location, test number and contents. All
glass sample jars had Teflon lined lids. The volume
of water in the first three impingers was measured
and recorded on the data sheets and the water was
discarded.
-62-
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Analysis
Each sample was analyzed in the following manner:
Container #1 - The filter was removed from its sealed
container and placed on a tared watch
glass. The filter and watch glass
were dessicated with anhydrous CaSC>4
and weighed to a constant weight. The
weight was recorded to the nearest
0.01 mg.
Container #2 - The acetone washings were transferred
to a tared beaker. The acetone was
evaporated at ambient temperature and
pressure, and then the beaker was des-
sicated and weighed to a constant
weight. The weight was recorded to
the nearest 0.01 mg.
Container #3 - The silica gel was weighed on a beam
balance and the weight was recorded to
the nearest 0.1 gram.
Container #4 - The acetone blank was transferred to a
tared beaker. The acetone was evap-
orated at ambient temperature and
pressure, and then the beaker was des-
sicated and weighed to a constant
weight. The weight was recorded to
the nearest 0.01 mg. This weight was
subtracted from the final weight of
the contents of container #2 to obtain
the net weight of particulate in the
acetone wash.
The filter from the Primary Crusher Inlet, Test 1 was then
analyzed for trace elements by SSMS.
-63-
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5.5 Particle Size Distribution
Sampling
Samples for particle size distribution analysis were
collected at each location using an Andersen Cascade
Impactor. The impactor consists of multiple stages
which collect different particle sizes, as shown in
Figure 5-2. Each stage consists of an orifice of
specific diameter above a collection plate. The ori-
fice sizes of each stage are different and are ar-
ranged in descending order, the largest being stage
one. A modified impinger of the Greenburg-Smith de-
sign filled with 300 grams of dry indicating-type
silica gel, was placed between the Andersen sampler
and the pump to dessicate the gas entering the pump.
The sampling system was set up as shown in Figure
5-3. The stack conditions were determined and the
sample was extracted isokinetically.
As the sample flows through each orifice, and is de-
flected off of a glass fiber substrate filter placed
on the collection plate, particles of a specific size
become impacted on the substrate while the remaining
particles entrained in the gas stream proceed to the
next collection stage. The range of particle sizes
retained on the substrate varies according to the
velocity of the gas (as determined by the sampling
rate and orifice diameter), the gas viscosity and the
particle density. Since the orifices are arranged in
descending diameters, the gas velocity increases and
the particle size collected on each stage decreases.
-64-
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FIGURE 5-2
ANDERSEN STACK SAMPLER
BACKUP
FILTER
PLATED,
HOLDER
JET STAGE (9 TOTAL)
SPACERS
GLASS FIBER
COLLECTION
SUBSTRATE
NOZZLE
INLET
CORE
ES-095
-65-
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FIGURE 5-3
ANDERSEN SAMPLING TRAIN
CTi
1
ANDERSEN
SAMPLER
STACK
'WALL
IMPINGER
PUMP
GAS METER
ORIFICE
MANOMETER
ES-094
-------
Sample Recovery
The fiberglass substrate filters were returned to
their original containers. Prior to sealing the con-
tainers with adhesive tape, the particulate matter on
the individual jet stages and spaces for each stage
was carefully brushed off into the corresponding
filter container.
Analysis
The fiberglass substrate filters were removed from
their sealed containers and placed individually on
tared watch glasses. The filters and watch glasses
were dessicated with anhydrous CaSC>4 and weighed to a
constant weight. The net weight gain was recorded to
the nearest 0,01 mg.
5.6 Process Samples
Sample Recovery
Grab samples of the ore were collected at four loca-
tions by TRW engineers during each of the three par-
ticulate tests. The samples were placed in sealed,
air-tight plastic bags, which were subsequently
placed in another sealed and labeled, air-tight,
plastic bag.
Analysis
A representative sample was weighed to the nearest
0.01 gram and transferred to a tared aluminum pan.
The sample was dried for 24 hours at 103°C. The
dried sample was dessicated and reweighed to the
nearest 0.01 gram. The weight loss was calculated
-67-
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and the percent moisture determined according to the
equation:
% Moisture = Weight Loss x 100
Initial Sample Weight
5. 7 Visible Emissions
The visible emissions were determined in accordance with
guidelines outlined in EPA Method 9 (Visual Determination
of the Opacity of Emissions from Stationary Sources).
5.8 Fugitive Emissions
The fugitive emission frequencies were determined in ac-
cordance with guidelines outlined in EPA Method 22 (Visual
Determination of Fugitive Emissions from Material Process-
ing Sources).
-68-
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PROJECT 01-9517-22
Prepared By:
Reveiwed By:
Martha M. Murray HI_/
Project Scientist
Emissions Measurement Department
Roge/ffA. Kniskern
Project Manager
Emissions Measurement ..Department
Approved By:
Approved By:
:T& ..
Jam.es W. Davison
President
technical Operations
Peter L. Cashman
Executive-Vice President
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