United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EMB Report 80-MET-9
May 1980
Air
Metallic Minerals
Emission Test Report
Reynolds Metals
Company
Corpus Christi, Texas
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SOURCE EMISSIONS TEST REPORT
Reynolds Metals Company
Sherwin Plant
Corpus Christ!, Texas
Sources Tested:
• Ship Unloading Process
• Fine Ore Storage Area
August 1980
a. "R
David A. Ralston
Assistant Project Scientist
Barry I^ JacksTo
ProjectMan
Air Testing
RFW Report No. 0300-81-16
Contract No. 68-02-2816
Work Assignment No. 14
Prepared by
Roy F. Weston, Inc.
Designers - Consultants
Weston Way
West Chester, Pennsylvania
(215) 692-3030
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TABLE OF CONTENTS
Section Page
SUMMARY 1
INTRODUCTION 3
PROCESS DESCRIPTION 5
DESCRIPTION OF TEST LOCATIONS 8
Ship Unloading Scrubber Inlet Duct 8
Ship Unloading Scrubber Discharge Duct 8
No. 1 and No. 2 Fine Ore Storage Bins
Exhaust Stack 8
No. 2 Fine Ore Storage Bin Baghouse
Exhaust Duct 8
DESCRIPTION OF SAMPLING TRAINS 13
Particulate Sampling Trains 13
Particle Size Distribution Sampling
Apparatus 13
TEST PROCEDURES 16
Preliminary Tests 16
Formal Tests 16
Ship Unloading Scrubber Inlet Duct 16
Ship Unloading Scrubber Discharge
Duct 17
No. 2 Fine Ore Storage Bin Baghouse
Exhaust Duct 17
No. 1 and No. 2 Fine Ore Storage Bins
Exhaust Stack 18
Ship Unloading Platform 18
Ship Unloading Conveyor Belt 18
Tailings Pond No. 2 Bed 18
ANALYTICAL PROCEDURES 19
Particulate Sample Recovery 19
Particulate Analyses 19
Particle Size Sample Recovery and
Analyses 20
TEST RESULTS AND DISCUSSION 21
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TABLE OF CONTENTS
(continued)
Section Page
APPENDIX A - RAW TEST DATA A-l
APPENDIX B - LABORATORY REPORTS B-l
APPENDIX C - SAMPLE CALCULATIONS C-l
APPENDIX D - EQUIPMENT CALIBRATION RECORDS D-l
APPENDIX E - PROJECT PARTICIPANTS E-l
111
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LIST OF TABLES
Table No. Title Page
1 Ship Unloading Area Scrubber
Summary of Test Data 22
2 Ship Unloading Area Scrubber
Summary of Particulate Test Results
(English Units) 23
3 Ship Unloading Area Scrubber
Summary of Particulate Test Results
(Metric Units) 24
4 No. 2 Fine Ore Storage Bin Baghouse
Exhaust Duct
Summary of Test Data 25
5 No. 1 and No. 2 Fine Ore Storage Bins
Exhaust Stack
Summary of Test Data 26
6 No. 2 Fine Ore Storage Bin Baghouse
Exhaust Duct
Summary of Particulate Test Results
(English Units) 27
7 No. 2 Fine Ore Storage Bin Baghouse
Exhaust Duct
Summary of Particulate Test Results
(Metric Units) 28
8 No. 1 and No. 2 Fine Ore Storage Bins
Exhaust Stack
Summary of Particulate Test Results
(English Units) 29
9 No. 1 and No. 2 Fine Ore Storage Bins
Exhaust Stack
Summary of Particulate Test Results
(Metric Units) 30
10 Ship Unloading Scrubber Outlet
Particle Size Distribution 31
IV
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LIST OF TABLES
(continued)
Table No. Title Page
11 No. 1 and No. 2 Fine Ore Storage Bins
Exhaust Stack Run No. 1
Particle Size Distribution 33
12 . No. 1 and No. 2 Fine Ore Storage Bins
Exhaust Stack Run No. 2
Particle Size Distribution 35
13 Ship Unloading Outlet
Summary of Visible Emissions 37
14 Fine Ore Bin
Summary of Visible Emissions 38
15 Fine Ore Bin Exhaust Stack
Summary of Visible Emissions 39
16 Ship Unloading Platform
Summary of Visible Emissions 41
17 Ship Unloading Conveyor
Summary of Visible Emissions 42
18 Tailing Pond No. 2 Bed
Summary of Visible Emissions 43
19 Mean Fugitive Emission Values
(% frequency of emission) 44
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LIST OF FIGURES
Figure No. Title Page
1 Ship Unloading Scrubber Inlet Duct
Port and Sampling Point Locations 9
2 Ship Unloading Scrubber Discharge Duct
Port and Sampling Point Locations 10
3 No. 1 and No. 2 Fine Ore Storage Bins
Exhaust Stack
Port and Sampling Point Locations 11
4 No. 2 Fine Ore Storage Bin Baghouse
Exhaust Duct
Port and Sampling Point Locations 12
5 Particulate Sampling Train - EPA Method 5 14
6 Particle Size Distribution Sampling
Apparatus - Andersen 2000, Inc. 15
7 Ship Unloading Scrubber Outlet
Run No. 1
Particle Size Distribution Results 32
8 No. 1 and No. 2 Fine Ore Bins Exhaust
Stack Run No. 1
Particle Size Distribution Results 34
9 No. 1 and No. 2 Fine Ore Bins Exhaust
Stack Run No. 2
Particle Size Distribution Results 36
VI
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SUMMARY
The Emission Measurement Branch of the U. S. Environmental Pro-
tection Agency, contracted Roy F. Weston, Inc. (Weston) to con-
duct a source testing and analysis program at Reynolds Metals
Company's Sherwin Plant in Corpus Christi, Texas.
The objectives of the program were to collect representative
samples and make supplementary measurements necessary to deter-
mine the quantity of particulate emissions released to the envi-
ronment from each process discharge stream. Source emission
samples were procured by Weston test personnel during the period
23 to 26 June 1980, and analyzed gravimetrically at Weston1s
West Chester, Pennsylvania laboratories.
The test points sampled during the survey and the numbers and
types of tests conducted at each source are listed below.
Number of Test Repetitions by Type
Source Description
Ship Unloading Scrubber
Inlet Duct
Ship Unloading Scrubber
Discharge Duct
No. 2 Fine Ore Storage Bin
Baghouse Exhaust Duct
No. 1 and No. 2 Fine Ore
Storage Bins Exhaust Stack
Ship Unloading
Conveyor Belt
Ship Unloading Platform
Tailings Pond No. 2 Bed
Particu-
late1
Parti-
cle
Size2
3
3
Visi-
ble
Emis-
sions"
1
3
3
1
1
1
Fugi-
tive
Emis-
t
sions
1
1
"Standards of Performance for New Stationary Sources," Code of
Federal Regulations, Title 40, Part 60, Appendix A, 18 August 1977.
2
Operating Manual for Andersen 2000, Inc., "Mark III Particle Sizing
Stack Samplers," Andersen 2000, Inc., P.O. Box 20769, Atlanta, GA.
3Federal Register, Vol. 39, No. 219, 12 November 1974.
4Draft Method, Revised 28 July 1978.
-1-
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The particulate matter concentration and mass rate results are
summarized below for each test point:
Ship Unloading Scrubber Inlet Duct
Test Particulate Concentration
Number Date grains/DSCF
1 6-24-80 1.14
Particulate Mass Rate
pounds/hour
806.
Ship Unloading Scrubber Discharge Duct
Test Particulate Concentration
Number Date grains/DSCF
1 6-24-80 0.017
Particulate Mass Rate
pounds/hour
12.6
No. 1 and No. 2 Fine Ore Storage Bins Exhaust Stack
Test
Number
1
2
3
Avg.
Particulate Concentration
Date grains/DSCF
6-25-80
6-25-80
6-25-80
0.003
0.003
0.004
0.003
Particulate Mass Rate
pounds/hour
0.388
0.392
0.482
0.421
No. 2 Fine Ore Storage Bin Baghouse Exhaust Duct
Test Particulate Concentration
Number Date grains/DSCF
1 6-25-80 0.004
2 6-25-80 0.002
3 6-25-80 0.002
Avg. 0.003
Particulate Mass Rate
pounds/hour
0.218
0.135
0.113
0.155
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INTRODUCTION
The Emission Measurement Branch of the U. S. Environmental Pro-
tection Agency/ contracted Roy F. Weston, Inc. to conduct a
source testing and analysis program at the Reynolds Metals
Company's Sherwin Plant in Corpus Christi, Texas. The objec-
tives of the testing program were to measure the quantity of
particulate emissions released to the environment from each pro-
cess discharge stream and to determine collector performance.
The locations tested, plus the number and types of tests per-
formed at each site, are as follows:
1. Ship Unloading Scrubber Inlet Duct
a. One particulate test by EPA Method 5.
2. Ship Unloading Scrubber Discharge Duct
a. One particulate test by EPA Method 5.
b. One particle size distribution test by
cascade impaction (Andersen).
c. One opacity test by EPA Method 9 simul-
taneous with the particulate test.
3. No. 1 and No. 2 Fine Ore Storage Bins Exhaust Stack
a. Three particulate tests by EPA Method 5.
b. Two particle size distribution tests by
cascade impaction (Andersen).
c. Three opacity tests by EPA Method 9 simul-
taneous with the three particulate tests.
4. No. 2 Fine Ore Storage Bin Baghouse Exhaust Duct
a. Three particulate tests by EPA Method 5.
b. Three opacity tests by EPA Method 9 simul-
taneous with the three particulate tests.
c. Three fugitive emission tests by EPA Method 22.
5. Ship Unloading Conveyor Belt
a. One opacity test by EPA method 9.
b. One fugitive emission test by EPA Method 22.
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6. Ship Unloading Platform
a. One opacity test by EPA Method 9.
b. One fugitive emission test by EPA Method 22.
7. Tailings Pond No. 2 Bed
a. One opacity test by EPA Method 9.
b. One fugitive emission test by EPA Method 22.
All testing was conducted during the period 23 to 26 June 1980
by Weston Air Measurement Services personnel.
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PROCESS DESCRIPTION
The Sherwin facility is located approximately 15 miles north of
Corpus Christi on the Gulf Coast of Texas. This facility proc-
esses bauxite imported from Caribbean and South American coun-
tries. Bauxite is transported to the facility in ships carrying
from 15,000 to 50,000 tons.
Bauxite is unloaded from the ships by one of two mechanisms.
Most ships are designated as "self-unloading." As such, they
have a self-contained extendable boom conveyor that interfaces
with a dockside conveyor belt via an accordian chute. Smaller
ships require the services of a dockside extendable boom convey-
or that is inserted into the side of the ship. Only a self-
unloading ship was tested during the test sequence reported
here.
From the dock, bauxite is conveyed to a covered "live" ore stor-
age area. Bauxite is then reclaimed from the storage area and
conveyed to one of four storage bins. Each storage bin feeds a
rod mill, although not all rod mills are operated simultane-
ously. Product from the rod mill is processed through a modi-
fied Bayer refining system. All processes from the rod mill up
to, but not including, the final calcination of alumina are wet
processes and do not emit particulate matter. After calcination
of alumina the product is transferred by railcar to the dock
area where the alumina is dumped from the bottom of railcar hop-
pers onto a tunnel conveyor. From the railcar dump alumina can
be conveyed either directly to a ship-loading tower or to one of
three temporary storage bins. From the ship-loading tower alu-
mina is dumped through an accordian chute into the hold of a
ship or barge for shipment to reduction plants in various parts
of the country.
SHIP UNLOADING
Emission Control
From the standpoint of particulate-emission control, the ship
unloading facility is simply a conveyor transfer point with a
fairly long free-fall zone (20 to 30 feet between conveyor belts
via an accordian chute).
Both the extendable boom conveyor from the ship and the dockside
conveyor are enclosed. Emission control is primarily affected
by ducting air from the base of the accordian chute and from
-5-
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the impact zone on the dockside conveyor belt. Approximately
20rOOO cubic feet per minute (cfm) are ducted to a dry cyclone
and then to a venturi scrubber. An additional 70,000 cfm are
ducted directly from the transfer point to the venturi scrubber.
Design pressure drop across the scrubber is 15 inches (water);
the system manometer was not functioning during the test.
Ship Unloading Test Points
The following points were tested at the ship unloading facility.
At the combined inlet duct for the venturi scrubber Method 5
(one test) measurements were taken. At the outlet of the
venturi scrubber Method 5 (one test), Method 9 (one test), and
particle size distribution measurements were taken. Visible
emission measurements were also made at points which were
indicative of the capture efficiency of the emission control
system. Accordingly, Method 9 and draft Method 22 readings
were taken at the interface of the accordian chute and the top
of the dockside conveyor shed, and at an open doorway in the
dockside conveyor shed. This doorway was located approximately
10 feet from the duct pickup points at the impact zone on the
dock conveyor belt. Visible emissions measurements at this
point measured the amount of emissions which escaped through
the doorway into the open environment.
Test Conditions
During the test period ore was unloaded at a rate of 1,500 to
1,700 tons per hour (normal rate). Actual measurements were not
possible due to a malfunction of the strip chart recording the
unloading rate. Plant personnel verified that the unloading
operation proceeded normally.
ORE STORAGE BIN
Emission Control
Particulate emissions from ore bins No. 1 and No. 2 (preceding
the rod mills) are ducted separately to individual baghouses.
Both baghouse outlets are combined in a common stack. Typically
only one bin is filled at a time, although both baghouses run
continuously. The baghouses are located directly over the fine
ore bins; therefore, no measurements could be taken of the inlet
loadings to these baghouses. Each baghouse is designed for a
flow rate of 7,000 cfm and an air-to-cloth ratio of 8 to 1.
-6-
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Test Points
Method 5 readings were taken at the outlet of the baghouse on
the No. 2 ore bin. Method 5f Method 9, and particle size dis-
tribution tests were taken at the combined outlet of the No. 1
and No. 2 baghouses. In addition, Method 9 and Method 22
readings were taken in the area of the baghouses at the top of
the ore bins.
Test Conditions
Because ore bin No. 2 was filled with a type of ore that is less
dusty than the normal mill feed, it was decided to test during
the filling of ore bin No. 1 only. Tests were conducted during
a continuous draw and fill of ore bin No. 1 in order to maximize
emissions during the test period. Fill rate varied between 425
and 475 tons per hour, which is the normal range.
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DESCRIPTION OF TEST LOCATIONS
SHIP UNLOADING SCRUBBER INLET DUCT
Two 3-inch I.D. test ports, 90° apart, were placed on a
straight section of the 54-inch I.D. metal duct at a location
approximately 72 inches downstream and 14 inches upstream from
the nearest flow disturbances. EPA Method 1 criteria for this
test location required a minimum of 48 traverse points (24 per
port). See Figure 1 for port and sampling point locations.
SHIP UNLOADING SCRUBBER DISCHARGE DUCT
Two 3-inch I.D. test ports, 90° apart, were placed on a
straight section of the 72-inch I.D. metal duct at a location
approximately 132 inches downstream and 42 inches upstream from
the nearest flow disturbances. Forty-eight sampling points (24
per port) were required for testing. See Figure 2 for port and
sampling point locations.
NO. 1 AND NO. 2 FINE ORE STORAGE BINS EXHAUST STACK
Two 3-inch I.D. test ports, 90° apart, were placed on a
straight section of the 29-1/2-inch I.D. metal stack at a loca-
tion approximately 30 feet downstream and 60 inches upstream
from the nearest flow disturbances. Test site geometry required
a minimum of 12 traverse points (6 per port axis). Figure 3
illustrates port and sampling point locations.
NO. 2 FINE ORE STORAGE BIN BAGHOUSE EXHAUST DUCT
Two 3-inch I.D. test ports, 90° apart, were located on a
straight section of the 18-inch. I.D. metal duct at a location
approximately 12 inches downstream and 48 inches upstream from
the nearest flow disturbances. EPA Method 1 protocol required a
minimum of 32 traverse points (16 per port). Figure 4 illus-
trates port and sampling point locations.
-8-
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Traverse
Point
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Distance From
Inside Near Wall
Inches
5/8
1 3/4
3
4 1/4
55/8
71/8
83/4
101/2
123/8
143/4
171/2
21 1/2
32 1/2
36 1/2
393/8
41 5/8
43 1/2
45 1/4
467/8
483/8
493/4
51
521/4
533/8
Flow
O
CM
JT
X *
JL
\
Scrubber
Test Point Elevation
Duct Cross-Sectional Plan
FIGURE 1 SHIP UNLOADING SCRUBBER INLET DUCT
PORT AND SAMPLING POINT LOCATIONS
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Scrubber1
Test Point Elevation
Traverse
Point
Location
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
Inside Near Wall
Inches
3/4
2 1/4
4
53/4
7 1/2
91/2
11 5/8
14
161/2
195/8
231/4
285/8
433/8
483/4
523/8
551/2
58
603/8
62 1/2
641/2
66 1/4
68
693/4
71 1/4
Duct Cross-Sectional Plan
FIGURE 2 SHIP UNLOADING SCRUBBER DISCHARGE DUCT
PORT AND SAMPLING POINT LOCATIONS
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T
5'
-• c
X
30'
o
Y
t
Row
Test Point Elevation
29 1/2" I.D.
From No. 1
Fine Ore Bin
Baghouse
From No. 2
Fine Ore Bin
Baghouse
Traverse
Point
Location
1
2
3
4
5
6
Distance From-
Inside Near Wall
Inches ;:.
1 1/4
4 1/4
83/4
203/4
25 1/4
28 1/4
Duct Cross-Sectional Plan
FIGURE 3 NO. 1 AND NO. 2 FINE ORE STORAGE BINS EXHAUST
STACK - PORT AND SAMPLING POINT LOCATIONS
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Row
Floor Level
12"
Baghouse
Test Point Elevation
Duct Cross-Sectional Plan
Traverse
Point
Location
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Distance From
Inside Near Wall
Inches .
1/2
7/8
1 1/2
21/4
3
4
5 1/8
63/4
11 1/4
127/8
14
15
153/4
161/2
17 1/8
171/2.
FIGURE 4 NO. 2 FINE ORE STORAGE BIN BAGHOUSE EXHAUST
DUCT - PORT AND SAMPLING POINT LOCATIONS
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' DESCRIPTION OF SAMPLING TRAINS
PARTICULATE SAMPLING TRAINS
The test train utilized for particulate sampling of all test
locations was the standard EPA Method 5 train (see Figure 5).
A stainless steel nozzle was attached to a heated (— 250°F)
borosilicate probe which was connected directly to a borosili-
cate filter holder containing a 9-cm Reeve Angel 900 AF glass
fiber filter. The filter holder was maintained at approximately
250°F in a heated chamber, and was connected by vacuum tubing
to the first of four Greenburg-Smith impingers which were
included in the train to condense the moisture in the gas
stream. Each of the first two impingers contained 100 ml of
distilled water, the third was dry, and the final impinger
contained 200 grams of dry preweighed silica gel. The first,
third, and fourth impingers were modified Greenburg-Smith types;
the second was a standard Greenburg-Smith impinger. All
impingers were maintained in a crushed ice bath. A Nutech con-
trol console with vacuum pump, dry gas meter, a calibrated ori-
fice, and inclined manometers completed the sampling train.
Flue gas temperature was measured by means of a calibrated Type
K thermocouple which was connected to a direct readout pyrom-
eter. The thermocouple sensor was positioned adjacent to the
sampling nozzle.
Gas velocity was measured using a calibrated S-type pitot tube
provided with extensions and fastened alongside the sampling
probe. Gas stream composition (carbon dioxide, oxygen, and car-
bon monoxide content) was determined utilizing an Orsat appara-
tus.
PARTICLE SIZE DISTRIBUTION SAMPLING APPARATUS
A stainless steel nozzle was connected directly to an 8-stage
Andersen cascade impaction device which separated the particles
according to their effective aerodynamic particle diameters. A
solid glass fiber filter was used to capture any particles that
passed through the impactor substrates to permit the measurement
of total particulate. The filter holder was maintained at stack
temperature, and was connected by vacuum tubing to the first of
four Greenburg-Smith impingers which were included in the train
to condense the moisture in the gas stream. All impingers were
maintained in a crushed ice bath. An RAC control console with
vacuum pump, dry gas meter, a calibrated orifice, and inclined
manometers completed the sampling train. See Figure 6 for a
schematic of the particle sizing apparatus.
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.TEMPERATURE
SENSOR
THERMOMETER
CHECK VALVE
VACUUM LINE
'ACUUM GUAGE
THERMOMETERS
HEATED AREA
FILTER HOLDER
NOZZLE/HEATED -
PROBE
REVERSE TYPE
PITOT TUBE
PITOT MANOMETER
ORIFICE
AND
MANOMETER
IMPINGERS
ICE BATH
FIGURE 5 PARTICULATE SAMPLING TRAIN-EPA METHOD 5
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Thermometer
Nozzle
I
M
Ul
Reverse-Type
Pilot Tube
Pilot Manomeler
Orifice
hermometers
Bypass Valve lingers
\
Ice Balh
Vacuum Gauge
Air Tighl Pump
Check Valve
Vacuum
Line
FIGURE 6 PARTICLE SIZE DISTRIBUTION SAMPLING
APPARATUS - ANDERSEN 2000, INC.
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TEST PROCEDURES
PRELIMINARY TESTS
Preliminary test data were obtained at each sampling location.
Stack geometry measurements were recorded and sampling point
distances calculated. A preliminary velocity traverse was per-
formed at each test location utilizing a calibrated S-type
pitot tube and a Dwyer inclined manometer to determine velocity
profiles. A check for the presence or absence of cyclonic flow
was conducted at each test location prior to formal testing.
Stack gas temperatures were observed with a direct readout
pyrometer equipped with a chromel-alumel thermocouple.
Preliminary test data were used for nozzle sizing and nomagraph
set-up for isokinetic sampling procedures.
Calibration of the probe nozzles, pitot tubes, metering systems,
probe heaters, temperature gauges, and barometer were performed
as specified in Section 5 of EPA Method 5 test procedures (see
Appendix D for calibration data).
FORMAL TESTS
Ship Unloading Scrubber Inlet Duct
A single test was conducted at the Ship Unloading Scrubber Inlet
Duct to measure the concentration and mass rate of particulate
matter emissions. Forty-eight traverse points (24 per axis)
were sampled for two minutes each, resulting in a total test
time of 96 minutes.
During particulate sampling, gas stream velocities were measured
by inserting a calibrated S-type pitot tube into the stream
adjacent to the sampling nozzle. The velocity pressure
differential was observed immediately after positioning the noz-
zle at each point, and sampling rates were adjusted to maintain
isokinetic sampling. Stack gas temperatures were also monitored
at each point with the pyrometer and thermocouple. Additional
temperature measurements were made at the final impinger, and at
the inlet and outlet of the dry gas meter.
Test data were recorded at each traverse point during all test
periods. Leak checks were performed according to EPA Method 5
instructions prior to and after each run and/or component
change. Table 1 presents a summary of test data and test result
summarization appears in Tables 2 and 3.
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Ship Unloading Scrubber Discharge Duct
One Method 5 test was conducted at the Ship Unloading Scrubber
Discharge Duct simultaneous with the inlet testing. Forty-eight
points were traversed (24 per axis) for two minutes each,
yielding a test period of 96 minutes. Procedures for isokinetic
sampling were identical to those described in the Ship Unloading
Scrubber Inlet Duct section.
See Tables 1, 2, and 3 for test data and test result summaries,
respectively.
One sampling point located at a site of average velocity was
selected from particulate traverse data for one particle size
distribution test. During this test the gas stream was sampled
isokinetically at that point for 95 minutes, which permitted
collection of sufficient sample for analysis without overloading
the filter substrates. See Table 10 for data and results, and
Figure 7 for the distribution plot.
Visual determinations of plume opacity were performed by a cer-
tified observer according to Method 9 procedures. A summary of
results is presented in Table 13.
No. 2 Fine Ore Storage Bin Baghouse Exhaust Duct
Three Method 5 tests were performed on the No. 2 Fine Ore
Storage Bin Baghouse Exhaust Duct. A total of 32 points were
sampled (16 per port) for three minutes each, yielding a test
period of 96 minutes.
Isokinetic sampling procedures were identical to those previous-
ly described. Table 4 shows test data summarization and Tables
6 and 7 present test results.
Visual determinations of plume opacity were performed in accord-
ance with EPA Method 9 procedures. Table 14 presents a summary
of results.
Fugitive emissions determinations were also conducted at this
location according to EPA Method 22 procedures. A summary of
results is presented in Table 19.
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No. 1 and No. 2 Fine Ore Storage Bins Exhaust Stack
Three Method 5 tests were performed on the No. 1 and No. 2 Fine
Ore Storage Bins Exhaust Stack. Twelve points were traversed
(six per axis) for eight minutes each, resulting in a test
period of 96 minutes. Samples were collected concurrently with
those at No. 2 Fine Ore Storage Bin Baghouse Exhaust Duct.
Isokinetic sampling procedures were identical to those previous-
ly described. Table 5 shows test data summarization and Tables
8 and 9 present test results.
Two particle size distribution tests were conducted at a point
of average velocity. The first particle size distribution test
was 90 minutes in length and the second test was 180 minutes in
duration. Sample volume, temperature, and pressure data were
recorded at five-minute intervals. See Tables 11 and 12 for
test data and test result summaries, and Figures 8 and 9 for
distribution plots.
Visual determinations of plume opacity were performed by a cer-
tified observer according to Method 9 procedures. Result sum-
maries are presented in Table 15.
Ship Unloading Platform
Ship Unloading ConveyoF Belt
Tailings Pond No. 2 Bed
Plume opacities were recorded at these locations in accordance
with EPA Method 9 procedures. See Tables 16, 17 and 18 respec-
tively for a summary of results.
Fugitive emission frequencies were also recorded at these loca-
tions according to EPA Method 22 procedures. Table 19 presents
a summary of these results.
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ANALYTICAL PROCEDURES
PARTICIPATE SAMPLE RECOVERY
At the conclusion of each test, the sampling trains were disman-
tled, openings sealed, and the components transported to the
field laboratory. Sample integrity was assured by maintaining
chain-of-custody records, which will be supplied on request.
A consistent procedure was employed for sample recovery.
1. The glass fiber filter(s) was removed from its
holder with tweezers and placed in its original
container (petri dish), along with any loose
particulate and filter fragments (sample type 1).
2. The probe and nozzle were separated, and the
internal particulate rinsed with acetone into
a borosilicate container while brushing a mini-
mum of three times until no visible particles
remained. Particulate adhering to the brush
was rinsed with acetone into the same contain-
er. The front half of the filter holder was
rinsed with acetone while brushing a minimum
of three times. The rinses were combined (sam-
ple type 2) and the container sealed with a
Teflon-lined closure.
3. The total liquid in impingers 1, 2, and 3 was
measured, the value recorded, and the liquid
discarded.
4. The silica gel was removed from the last
impinger and immediately weighed.
5. An acetone sample was retained for blank
analysis.
PARTICIPATE ANALYSIS
The filters (sample type 1) and any loose fragments were oven
dried at 105QC for two to three hours, cooled in a desiccator,
and weighed to the nearest 0.1 milligram to constant weight.
The acetone wash samples (sample type 2) were evaporated at
ambient temperature in tared beakers, and desiccated at ambient
temperature and pressure to a constant weight. All sample resi-
due weights were adjusted by the acetone blank value.
-19-
-------
The weight of the material collected on the glass fiber
filter(s) plus the weight of the residue of the acetone nozzle/
probe/front-half filter holder washes represents the total EPA
Method 5 catch. Complete laboratory results are presented in
Appendix B of this report.
PARTICLE SIZE SAMPLE RECOVERY AND ANALYSES
The cascade impactor substrates and any loose fragments were
carefully removed from their support plates with tweezers and
placed in individual containers (petri dishes) for shipment to
Weston's laboratory.
Each cascade impactor filter was fired at 525°C and pre-
weighed to the nearest 0.1 milligram to constant weight at
Weston's laboratory prior to on-site application. Subsequent to
emissions exposure, the cascade impactor substrates, back-up
filters, and any loose fragments were oven dried at 105°C for
two to three hours, cooled in a desiccator, and weighed to the
nearest 0.1 milligram to constant weight.
-20-
-------
TEST RESULTS AND DISCUSSION
Particulate test data and test result summaries are presented
in Tables 1 through 9 of this section. Tables 10 through 12
contain data and results of the particle size distribution
tests; Figures 7 through 9 show the distribution plots. Tables
13 through 18 present plume opacity determination results and
Table 19 shows fugitive emission test results summaries.
The quantity of particulate matter measured during the one test
at the Ship Unloading Scrubber Inlet Duct was 1.14 grains/DSCF
and 806 pounds/hour. The particulate matter discharged to the
atmosphere from the Ship Unloading Scrubber Discharge Duct was
0.017 grains/DSCF and 12.6 pounds/hour. The Ship Unloading
Scrubber particulate removal efficiency was 98.4 percent.
The particulate matter discharged from the No. 2 Fine Ore
Storage Bin Baghouse Exhaust Duct was <0.004 grains/DSCF and
< 0.218 pounds/hour. The particulate matter discharged from
the No. 1 and No. 2 Fine Ore Storage Bins Exhaust Stack was
< 0.004 grains/DSCF and <0.482 pounds/hour.
It should be noted that only one test set was run at the Ship
Unloading Scrubber. Weston test personnel were directed by the
EPA Administrator not to conduct further testing at this site
due to high plume opacities recorded at the Scrubber Discharge
Stack by the Weston certified observer.
As per instructions by Mr. Dennis P. Holzschuh, EPA Task
Manager, certain samples obtained by Weston test personnel were
released to York Research Corporation for trace metals
analysis. See Appendix B for the trace metals analysis results.
-21-
-------
Table 1
Ship Unloading Area Scrubber
Summary of Test Data
Reynolds Metals Company, Sherwin Plant
Corpus Christi, Texas
Test Data
Test Run Number
Test Location
Test Date
Test Period
Sampling Data
Sampling Duration, minutes
Nozzle Diameter, inches
Barometric Pressure, inches mercury
Average Orifice Pressure Differential, inches water
Average Dry Gas Temperature at Meter, °F
Total Water Collected by Train, ml
Standard Volume of Water Vapor Collected, cubic feet
Dry Gas Meter Calibration Factor, dimensionless
Sample Volume at Meter Conditions, cubic feet
Sample Volume at Standard Conditions, cubic feet1
Gas Stream Composition
COj, percent by volume
02, percent by volume
CO, percent by volume
N2, percent by volume
Moisture in Gas Stream, percent by volume
Mole Fraction of Dry Gas
Molecular Weight of Dry Gas
Molecular Weight of Wet Gas
Gas Stream Velocity and Volumetric Flow
Static Pressure, inches water
Absolute Pressure, inches mercury
Average Temperature, °F
Pitot Tube Calibration Coefficient, dimensionless
Total Number of Traverse Points
Velocity at Actual Conditions, feet/second
Stack/Duct Cross-Sectional Area, square feet
Volumetric Flow, wet actual cubic feet/minute
Volumetric Flow, dry standard cubic feet/minute
Percent Isokinetic
Unit/Process Operations Data
1
Inlet
6-24-80
0807-1000
96.0
0.135
29.94
0.88
87
41.6
96
00
52.3
50.7
0.9
20.0
0.0
79.1
3.7
0.963
28.95
28.5
102.3
1
Outlet
6-24-80
0800-0952
96.0
0.188
29.94
1.42
95
43.
2.
1.
03
00
58.5
55.9
0.9
20.0
0.0
79.1
3.5
0.965
28.95
28.6
-6.1
29.49
85.
0.84
48.0
94.2
15.9
89,800.
82,600.
-15.0
28.84
77.
0.84
48.0
54.4
28.3
92,300.
84,400.
101.2
!standard Conditions = 68°F (20°C) and 29.92 inches (760 mm) mercury, dry basis.
-22-
-------
Table 2
Ship Unloading Area Scrubber
Summary of Particulate Test Results
Reynolds Metals Company, Sherwin Plant
Corpus Christi, Texas
(English Units)
Test Data
u>
i
Test Number
Test Location
Test Date
Test Time
Gas Flow
Standard Cubic Feet/Minute, dry
Actual Cubic Feet/Minute, wet
Particulates
Front-Half Wash Residue Catch Fraction, g
Filter Catch Fraction, g
Total Particulates, g
Particulate Emissions^-
Grains/Dry Standard Cubic Foot2
Pounds/Hour
Scrubber Particulate Removal, percent
1
Inlet
6-24-80
0807-1000
82,600.
89,800.
2.2573
1.4825
3.7398
1.14
806.
Discharge
6-24-80
0800-0952
84,400.
92,300
0.0186
0.0443
0.0629
0.017
12.6
98.4
^Based on Total Particulates captured by train.
2Standard Conditions = 68°F and 29.92 inches Hg.
-------
Table 3
Ship Unloading Area Scrubber
Summary of Particulate Test Results
Reynolds Metals Company, Sherwin Plant
Corpus Christi, Texas
(Metric Units)
Test Data
i
NJ
Test Number
Test Location
Test Date
Test Time
Gas Flow
Standard Cubic Meters/Minute, dry
Actual Cubic Meters/Minute, wet
Particulates
Front-Half Wash Residue Catch Fraction,g
Filter Catch Fraction, g
Total Particulates, g
Particulate Emissions^
Grams/Dry Standard Cubic Meter2
Kilograms/Hour
Scrubber Particulate Removal, percent
1
Inlet
6-24-80
0807-1000
2,340.
2,540.
2.2573
1.4825
3.7398
2.61
365.6
Discharge
6-24-80
0800-0952
2,390.
2,610.
0.0186
0.0443
0.0629
0.039
5.7
98.4
^Based on Total Particulates captured by train.
2Standard Conditions = 68°F and 29.92 inches Hg.
-------
Table 4
No. 2 Fine Ore Storage Bin Baghouse Exhaust Duct
Summary of Test Data
Reynolds Metals Company, Sherwin Plant
Corpus Christi, Texas
Test Data
Test Run Number
Test Location
Test Date
Test Period
Sampling Data
Sampling Duration, minutes
Nozzle Diameter, inches
Barometric Pressure, inches mercury
Average Orifice Pressure Differential, inches water
Average Dry Gas Temperature at Meter, °P
Total Water Collected by Train, ml
Standard Volume of Water Vapor Collected, cubic feet
Dry Gas Meter Calibration Factor, dimensionless
Sample Volume at Meter Conditions, cubic feet
Sample Volume at Standard Conditions, cubic feet1
Gas Stream Composition
CO2, percent by volume
02, percent by volume
CO, percent by volume
N2» percent by volume
Moisture in Gas Stream, percent by volume
Mole Fraction of Dry Gas
Molecular Weight of Dry Gas
Molecular Weight of Wet Gas
Gas Stream Velocity and Volumetric Flow
Static Pressure, inches water
Absolute Pressure, inches mercury
Average Temperature, °F
Pitot Tube Calibration Coefficient, dimensionless
Total Number of Traverse Points
Velocity at Actual Conditions, feet/second
Stack/Duct Cross-Sectional Area, square feet
Volumetric Flow, wet actual cubic feet/minute
Volumetric Flow, dry standard cubic feet/minute
Percent Isokinetic
Discharge Duct
6-25-80
0915-1100
96.0
0.180
30.00
1.83
110.
34.6
1.63
1.00
69.4
64.9
0.9
20.0
0.0
79.1
2.5
0.975
28.95
28.7
-7.1
29.48
88.
0.84
32.0
67.9
1.77
7,200.
6,670.
Discharge Duct
6-25-80
1215-1415
96.0
0.180
29.99
2.59
108.
38.8
1.83
1.00
84.2
79.0
0.9
20.0
0.0
79.1
2.3
0.977
28.95
28.7
-7.1
29.47
88.
0.84
32.0
79.6
1.77
8,440.
7,820.
Discharge Duct
6-25-80
1450-1650
96.0
0.180
29.96
2.50
Average
112.
38.
1
1
83
80
,00
.5
77.7
0.9
20.0
0.0
79.1
2.3
0.977
28.95
28.7
-7.1
29.44
88.
0.84
32.0
79.2
1.77
8,400.
7,780.
96.0
0.180
29.98
2.31
110.
37.2
1.75
1.00
79.0
73.9
0.9
20.0
0.0
79.1
2.4
0.976
28.95
28.7
-7.1
29.46
88.
0.84
32.0
75.6
1.77
8,010.
7,420.
Unit/Process Operations Data
101.3
105.2
104.0
103.5
*Standard Conditions = 68°F (20°C) and 29.92 inches (760 mm) mercury, dry basis.
-------
Table 5
No. 1 and No. 2 Fine Ore Storage Bins Exhaust Stack
Summary of Test Data
Reynolds Metals Company, Sherwin Plant
Corpus Christi, Texas
Test Data
Test Run Number
Test Location
Test Date
Test Period
Sampling Data
Sampling Duration, minutes
Nozzle Diameter, inches
Barometric Pressure, inches mercury
Average Orifice Pressure Differential, inches water
Average Dry Gas Temperature at Meter, °F
Total Water Collected by Train, ml
Standard Volume of Water Vapor Collected, cubic feet
Dry Gas Meter Calibration Factor, dimensionless
Sample Volume at Meter Conditions, cubic feet
Sample Volume at Standard Conditions, cubic feetl
Gas Stream Composition
C02, percent by volume
02, percent by volume
CO, percent by volume
N2, percent by volume
Moisture in Gas Stream, percent by volume
Mole Fraction of Dry Gas
Molecular Weight of Dry Gas
Molecular Weight of Wet Gas
Gas Stream Velocity and Volumetric Flow
Static Pressure, inches water
Absolute Pressure, inches mercury
Average Temperature, °F
Pitot Tube Calibration Coefficient, dimensionless
Total Number of Traverse Points
Velocity at Actual Conditions, feet/second
Stack/Duct Cross-Sectional Area, square feet
Volumetric Flow, wet actual cubic feet/minute
Volumetric Flow, dry standard cubic feet/minute
Percent Isokinetic
Discharge Stack
6-25-80
0915-1050
96.0
0.188
30.00
1.25
95.
35.6
1.68
1.00
59.6
57.1
0.9
20.0
0.0
79.1
2.9
0.971
28.95
28.6
0.40
30.03
91.
0.84
12.0
53.8
4.75
15,300.
14,300.
Discharge Stack
6-25-80
1208-1340
96.0
0.188
29.99
1.32
96.
42.4
00
00
62.9
60.1
0.9
20.0
0.0
79.1
3.2
0.968
28.95
28.6
0.40
30.02
93.
0.84
12.0
54.9
4.75
15,600.
14,500.
Discharge Stack
6-25-80
1442-1620
96.0
0.188
29.96
1.33
Average
89.
49.
2.
1.
61.
34
00
0
59.0
0.9
20.0
0.0
79.1
3.8
0.962
28.95
28.5
0.40
29.99
94.
0.84
12.0
53.7
4.75
15,300.
14,000.
96.0
0.188
29.98
1.30
93.
42.6
2.01
1.00
61.2
58.7
0.9
20.0
0.0
79.1
3.3
0.967
28.95
28.6
0.40
30.01
93.
0.84
12.0
54.1
4.75
15,400.
14,300.
Unit/Process Operations Data
102.3
106.4
107.7
105.5
^Standard Conditions = 68°F (20°C) and 29.92 inches (760 mm) mercury, dry basis.
-------
Table 6
No. 2 Pine Ore Storage Bin Baghouse Exhaust Duct
Summary of Particulate Test Results
Reynolds Metals Company, Sherwin Plant
Corpus Christi, Texas
(English Units)
Test Data
Test Number
Test Location
Test Date
Test Time
Gas Flow
Standard Cubic Feet/Minute, dry
Actual Cubic Feet/Minute, wet
Part iculates
Front-Half Wash Residue Catch Fraction,g
Filter Catch Fraction,g
Total Particulates, g
Particulate Emissions1
Grains/Dry Standard Cubic Foot^
Pounds/Hour
Discharge Duct
6-25-80
0915-1100
6,670.
7,200.
Discharge Duct
6-25-80
1215-1415
7,820.
8,440
Discharge Duct
6-25-80
1450-1650
7,780.
8,400.
Average
7,420.
8,010.
0.0013
0.0147
0.0160
0.004
0.218
0.0020
0.0083
0.0103
0.002
0.135
0.0013
0.0072
0.0085
0.002
0.113
0.0015
0.0101
0.0116
0.003
0.155
Ifiased on Total Particulates captured by train.
2Standard Conditions = 68°F and 29.92 inches Hg.
-------
Table 7
No. 2 Fine Ore Storage Bin Baghouse Exhaust Duct
Summary of Particulate Test Results
Reynolds Metals Company, Sherwin Plant
Corpus Christi, Texas
(Metric Units)
Test Data
Test Number
Test Location
Test Date
Test Time
Gas Plow
Standard Cubic Meters/Minute, dry
Actual Cubic Meters/Minute, wet
Particulates
Front-Half Wash Residue Catch Fraction,g
Filter Catch Fraction, g
Total Particulates, g
Particulate Emissions^
Grams/Dry Standard Cubic Meter^
Kilograms/Hour
Discharge Duct
6-25-80
0915-1100
188.9
203.9
0.0013
0.0147
0.0160
0.009
0.099
Discharge Duct
6-25-80
1215-1415
221.4
239.0
0.0020
0.0083
0.0103
0.005
0.061
Discharge Duct
6-25-80
1450-1650
220.3
237.9
0.0013
0.0072
0.0085
0,005
0.051
Average
210.2
226.9
0.0015
0.0101
0.0116
0,006
0.070
iBased on Total Particulates captured by train.
2Standard Conditions = 68°F and 29.92 inches Hg.
-------
Table 8
No. 1 and No. 2 Fine Ore Storage Bins Exhaust stack
Summary of Particulate Test Results
Reynolds Metals Company, Sherwin Plant
Corpus Christi, Texas
(English Units)
Test Data
Test Number
Test Location
Test Date
Test Time
Gas Flow
Standard Cubic Feet/Minute, dry
Actual Cubic Feet/Minute, wet
Particulates
Front-Half Wash Residue Catch Fraction, g
Filter Catch Fraction, g
Total Particulates, g
Particulate Emissions^
Grains/Dry Standard Cubic Foot2
Pounds/Hour
Fine Ore Bin
Discharge Stack
6-25-80
0915-1050
14,300.
15,300.
Fine Ore Bin
Discharge Stack
6-25-80
1208-1340
14,500.
15,600.
Fine Ore Bin
Discharge Stack
6-25-80
1442-1620
14,000.
15,300.
Average
14,300.
15,400.
0.0055
0.0062
0.0117
0.388
0.0076
0.0047
0.0123
0.392
0.0077
0.0076
0.0153
0.482
0.0069
0.0062
0.0131
0.421
^Based on Total Particulates captured by train.
2Standard Conditions = 68°F and 29.92 inches Hg.
-------
Table 9
No. 1 and No. 2 Fine Ore Storage Bins Exhaust Stack
Summary of Particulate Test Results
Reynolds Metals Company, Sherwin Plant
Corpus Christi, Texas
(Metric Units)
Test Data
Test Number
Test Location
Test Date
Test Time
Gas Flow
Dry Standard Cubic Meters/Minute
Wet Actual Cubic Meters/Minute
Particulates
Front-Half Wash Residue Catch Fraction, g
Filter Catch Fraction, g
Total Particulates, g
Particulate Emissions1
Grams/Dry Standard Cubic Meter2
Kilograms/Hour
Fine Ore Bin
Discharge Stack
6-25-80
0915-1050
404.9
433.3
0.0055
0.0062
0.0117
0.007
0.176
Fine Ore Bin
Discharge Stack
6-25-80
1208-1340
410.6
441.7
0.0076
0.0047
0.0123
0.007
0.178
Fine Ore Bin
Discharge Stack
6-25-80
1442-1620
396.4
433.3
0.0077
0.0076
0.0153
0.009
0.219
Average
404.0
436.1
0.0069
0.0062
0.0131
0.008
0.191
Iflased on Total Particulates captured by train.
2Standard Conditions = 68°F and 29.92 inches Hg.
-------
Table 10
PARTICLE SIZE DISTRIBUTION
Date: 6-24-80 P. (in. Hg.) 29.94
bar
Location: Reynolds Metals Company Stack Temp ( F) 76
Sampling Location: Shtp Unloading Scb.Outls.amP1e Time (Min.) 95.0
Traverse Point No. Sampled: X-15 Sample Volume (cf) 59.3
Run No. 1 Molsture <* ^20) 3'5
Meter Temp ( F) 1QO
Flow Setting, ^H 1.2
(in. H20)
Nozzle Diameter (in.) 0.188
Sample Flow Rate (at stack conditions);0.6l cfm
Net Wt. % Cumulative EAD
(mg) % (Microns)
1 18.9 32.7 100.0 12.5
2 0.5 0.8 67.3 7.8
3 0.9 1.6 66.5 5.2
4 1.8 3.1 64.9 3.6
5 4.5 7.8 61.8 2.7
6 15.4 26.6 54.0 1.2
7 8.7 15.1 27.4 0.71
8 4.8 8.3 12.3 0.48
Backup
Filter 2.3 4.0
TOTAL 57.8
-31-
-------
Figure 7
I/I
o
u
i
co
o
oc
o
I
o
an
UJ
<
tu
>
o
LU
10.0
9.0
8.0
7.0
6.0
5.0
k.O
3.0
2.0
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
Ship Unloading Scrubber Outlet
Run No. 1 Particle Size Distribution
z
0.01 0.05 O.I 0.2 0.5 I
10 20 30 40 50 80 70 BO 90
CUMULATIVE PERCENTAGE
By Weight Less Than Diameter
95
98 99
9.1 99.9
99.99
-------
Table 11
PARTICLE SIZE DISTRIBUTION
Date: 6-25-80 Pbar (in. Hg.) 30.00
Location: Reynolds Metals Company Stack Temp ( F) 9°
Sampling Location: No. t & No. 2 Fine Ore. Sample Time (Min.)90.0
Bins Exhaust Stack . . c-. c
Traverse Point No. Sampled: X-3 Sample Volume (cf) ;>/•:>
Run No. 1 Moisture (% H20) 2-°
Meter Temp (°F)
Flow Setting, O H1-35
(in. H20)
Nozzle Diameter (in.)o.l85
Sample Flow Rate (at stack conditions):0.63 cfm
Net Wt. % Cumulative EAD
(mg) % (Microns)
1 2.A 17.8 100 12.2
2 1.0 7.A 82.2 7.6
3 1.1 8.2 7^.8 5.2
* 0.8 5.9 66.6 3.6
5 1.5 11.1 60.7 2.A
6 1.6 11.9 A9.6 1.2
7 1.3 9.6 37.7 0.71
8 1.5 11.1 28.1 O.A7
Backup
Filter 2-3 17.0 17.0
TOTAL
13.5
-33-
-------
Figure 8
No. 1 and No. 2 Fine Ore Bins Exhaust Stack
Run No. 1 Particle Size Distribution
EFFECTIVE AERODYNAMIC PARTICLE DIAMETER, microns
O O OOOOOOO— 10 VA> .p- Ui ON >J OOVOC
— N» U) .p- Ul ON vj OOVOO O O O OOOOOC
/
i
/
/
t
I
I
1
/
1
1
1
•f
, 1
/
1
1
1
•j
/
0.01 0.05 O.I 0.2 0.5 1
10 20 30 40 50 60 70 80
CUMULATIVE PERCENTAGE
By Weight Less Than Diameter
90
95
-------
Table 12
PARTICLE SIZE DISTRIBUTION
Date: 6-25-80 p (in. Hg.) 29-99
Location: Reynolds Metals Stack Temp ( F) 90
Sampling Location: No. 1 & No. 2 Fine Ore Sample Time (Min.)l80
Bins Exhaust Stack „ , , /,»..,..-.
Traverse Point No. Sampled: X-3 Sample Volume (cf) 113.152
n „ 0 Moisture (% H,0) 2.0
Run No. 2 2
Meter Temp (°F) 95
Flow Setting, AH 1.35
(in. H20)
Nozzle Diameter (in.)°-l85
Sample Flow Rate (at stack conditions):0.62 cfm
Plate
No.
1
2
3
*
5
6
7
8
Net Wt.
(mg)
12.2
1.5
1.3
0.5
1.2
0.8
.1.1
1.0
*
55.5
6.8
5.9
2.3
5.5
3.6
5.0
4.5
Cumulative EAD
% (Microns)
100 12.2
Mt.5 7.6
37,7 5.2
31.8 3.6
29.5 2.4
24.0 1.2
20.4 0.71
15.A 0.47
Backup 2.1* 10.9 10.9
Filter
TOTAL 22.0
-35-
-------
Figure 9
i
u>
V)
O
U
1
UJ
O
O
£
O
O
oc
LLI
<
UJ
10.0
9.0
8.0
7.0
6.0
5.0
k.O
3.0
2.0
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
No. 1 and No. 2 Fine Ore Bins Exhaust Stack
Run No. 2 Particle Size Distribution
0.01 0.05 O.I 0.2 0.5 I
10 20 30 40 50 60 70 BO
CUMULATIVE PERCENTAGE
90
95
99
99.99
-------
Date:
2k June 1980
Table 13
SUMMARY OF VISIBLE EMISSIONS
Type of Plant:
oT Discharge:
Stack
of Point of Discharge: 5 Feet
Wind Direction: Out of Southwest
|plor of Plume:
fcserver No.:
Rust
Distance from Observer to Discharge Point:
irection of Observer from Discharge Point:
bight of Observation Point;
escriptfon of 'Background:
Bauxite Processing
Location of Discharge:.Ship Unloading Outlet
Description of Sky; Clear blue sky
Wind Velocity:
Detached Plume:
10-30 mph
Duration of Observation:
40 Feet
Southeast
heet
Blue sky and hill
97 minutes
SUMMARY OF-AVERAGE OPACITY
Set
Number
1
2
3
k
s
6
7
/
8
9
10
11
12
13
1 ^
14
i ~
15
» J>
16
17
18
19
20
Time Opacity
Start
0808
0814
0820
0826
0832
0838
0844
0850
0856
0902
0908
0914
0920
0926
0932
0938
End
081 4
.0820
0826
0832
0838
0844
0850
0856
0902
0908
0914
0920
0926
0932
0938
0945
Sum
420
465
485
455
470
455
440
450
440
430
455
445
460
465
460
555
Average
17.5
19.4
20.2
18.9
19.6
18.9
18.3
18.7
18.3
17-9
18.9
. 18.5
19.1
19.4
19.1
19.8
Set
Number
21
22
23
24
25
26
27
28
29
30
^ **
31
^ *
32
33
34
J •
35
«/ «*
36
37
38
39
40
T
Start
me
End
Opa
Sum
pity
Average
Sketch Showing How.Opacity Varied with Time:
Opacity
20
15
10
5
4-
1/2 hr- Time, Hours ] nr-
1 1/2 hr.
-37-
-------
Table 14
SUMMARY OF VISIBLE EMISSIONS
Date:
Type oT~Di sch'arge: Baghouse
25 June 1980
Height of Point of Discharge: 6 feet
Wind Direction: None
Color of Plume: Rust
Observer No.:
Distance from Observer to Discharge Point:
Direction of Observer from Discharge Point:
Height of Observation Point:
Description of Background:
Type of Plant: Bauxite Processing
Location of Discharge: Fine Ore Bin
Description of Sky: Inside BuiIding
Wind Velocity: None
Detached Plume:
Duration of Observation:
80 feet
3 runs @ 1 hour each
Gray Machinery
Set
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
SUMMARY OF AVERAGE OPACITY
Time
Start
0925
0931
0937
0943
0949
0955
1001
1007
1013
1019
1215
1221
1227
1233
1239
121*5
1251
1257
1303
1309
End
0930
0936
0942
0948
0954
1000
1006
1012
1018
1024
1220
1226
1232
1238
1244
1250
1256
1302
1308
1314
Opacity
Sum
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Average
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Set
Number
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
T
Start
1505
1511
1517
1523
1529
1535
1541
1547
1553
1559
me
End
1510
1516
1522
1528
1534
1540
1546
1552
1558
1604
Opac
Sum
0
0
0
0
0
0
0
0
0
0
;ity
Average
0
0
0
0
0
0
0
0
0
0
Sketch Showing How Opacity Varied with Time:
Opaci ty
(*)
1 hour
Time, Hours 2 hours
3 hours
-38-
-------
Table 15
SUMMARY OF VISIBLE EMISSIONS
25 June 1980
Date:
Type of Discharge: Stack
Type of Plant: Bauxite Processing
B'
Height of Point of Discharge: 125 feet
Wind Direction: Out of South
Color of Plume: None
Observer No. :
Distance from Observer to Discharge Point:
Direction of Observer from Discharge Point:
Height of Observation Point: '
Description of Background:
Location of Discharge: p;np
Description of Sky: Clear Blue Sk
Wind Velocity: 10-30 mph
Detached Plume:
Duration of Observation:
350 feet
4.8 hours
East
100 feet
Stacks, PTpes, Sky
Set
Number
1
2
3
4
5
s
6
7
8
9
10
11
12
13
1 *
14
15
16
17
18
19
20
SUMMARY OF AVERAGE OPACITY
Time
Start
0926
0932
0938
0949
0956
1002
1008
1014
1020
1026
1032
1038
1044
1050
1056
1102
1209
1215
1221
1227
End
0931
0937
0943
0955
1001
1007
1013
1019
1025
1031
1037
1043
1049
1055
1101
1107
1214
1220
1226
1232
Opacity
Sum
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Average
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Set
Number
21
22
23
24
25
*• «•' •
26
27
28
29
30
31
j '
32.
33
34
35
36
37
38
39
40
T
Start
1233
1239
1245
1251
1257
1303
1309
1315
1321
1327
1333
1339
1442
1448
1454
1500
1506
1512
1518
1524
me
End
1238
1244
1250
1256
1302
1308
1314
1320
1326
1332
1338
1344
1447
1453
1459
1505
1511
1517
1523
1529
Opa<
Sum
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
;ity
Average
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Sketch Showing How Opacity Varied with Time:
8
6
4
2
Opaci ty
hbur
2 hoursj hours
Time, Hours
4 hiurs
-39-
-------
Table 15 (continued)
SUMMARY OF VISIBLE EMISSIONS
25 June 1980
Date: _^_
Type of Discharge: Stack
Height of Point of Discharge: 125 feet
Wind Direction: Out of South
Color of Plume: None
Observer No. : _
Distance from Observer to Discharge Point:
Direction of Observer from Discharge Point:
Height of Observation Point: '
Description of Background:
Type of Plant: Bauxite Processing
Location of Discharge: Fine Ore Bin Exhaust Stack
Description of Sky: Clear Blue Sky
Wind Velocity: 10-30 mph
Detached Plume:
Duration of Observation:
350 feet
East
100 feet
Stacks, Pipes, Sky
Set
Number
1
2
3
k
5
6
7
8
9.
10
11
12
13
14
15
16
17
18
19
20
SUMMARY OF AVERAGE OPACITY
Time
Start
1530
1536
1542
1548
155k
1600
1606
1612
End
1535
1541
1547
1553
1559
1605
1611
1617
Opaci ty
Sum
0
0
0
0
0
0
0
0
Average
0
0
0
0
0
0
0
0
Set
Number
21
22
23
21*
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
T
Start
me
End
Opa<
Sum
pity
Average
Sketch Showing How Opacity Varied with Time:
Opaci ty
5 hours
Time, Hours
-40-
-------
2k June 1980
Table 16
SU:;.",ARY OF VISIBLE EMISSIC'.'S
Type of Plant:
Type ot Dischorgc: Conveyor
Height of Point of Discharge:
Ir/ind Direction: Northwest
Color of Plume,: Rust
Observer No.:
Roof Level
Distance from Observer to Discharge Point:
Direction of Observer from Discharge Point:
Height of Observation Point:
Description of Background:
Bauxite Processing
Location of Pischarge:Ship Unloading Platform
Description of Sky: Clear blue sky
Wind Veloci ty:
Detached Plume:
18 mph
Duration of Observation:
\5 feet
101 minutes
Southeast
Koor^eve I
Discharge Pipe
Set
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
\s
16
17
18
19
20
SUMMARY OF AVERAGE OPACITY
Time
Start
0800
0806
0812
0818
0824
0830
0836
0842
0848
0854
0900
0906
0912
0918
0924
0930
0936
End
0806
0812
0818
0824
0830
0836
0842
0848
0854
0900
0906
0912
0918
0924
0930
0936
0941
Opacity
Sum
85
120
120
155
165
215
165
195
40
135
260
5
0
0
0
0
0
Average
3-5
5.0
5.0
6.4
6.9
9-0
6.9
8.1
1.7
5.6
1.0.8
0.2
0
0
0
0
0
Set
Number
21
22
23
24
25
26
27
28 -
29
30
31
32
33
34
35
36
37
38
39
40
T
Start
me
End
Opa
Sum
pity
Average
i
Sketch Showing How Opacity Varied with Time:
1/2 hour Time, Hours 1 hour
1-1/2 hour
-41-
-------
2k June 1980
Conveyor
Date:
Type of Discharge:
Height of Point of Discharge: 4 Feet
Wind Direction: Northwest
Color of Plume:
Observer No.:
Table 17
SUMMARY OF VISIBLE EMISSIONS
Type of Plant:
Rust
Distance from Observer to Discharge Point:
Direction of Observer from Discharge Point:
Height of Observation Point;
Description of 'Background:
Bauxite Processing
Location of Discharge; . Ship Unloading Conveyor
Description of Sky; NA
Wind Velocity:
Detached Plume:
5 mi/hr.
Duration of Observation:
3-4 Feet
104 minutes
o feet north or doorway
ground level
doorway
Set
Number
1
2
3
k
5
6
7
/
8
9
10
11
12
13
1 J
11*
15
' S
16
l \J
17
18
19
20
SUMMARY OFAVERAGE OPACITY
Time Opacity
Start
0806
0812
0818
0824
0830
0836
0842
0848
0854
0900
0906
0912
0918
0924
0930
0936
0942
End
0812
.0818
0824
0830
0836
0842
0848
0854
0900
0906
0912
0918
0924
0930
0936
0942
0950
Sum
60
90
45
85
55
55
80
70
60
45
65
40
70
45
50
45
90
Average
2.5
3-7
1.9
3-5
2.3
2.3
3-3
2.9
2.5
1-9
2.7
1.7
2.9
1.9
2.1
1.9
3-7
Set
Number
21
22
23
2k
25
26
27
28
29
30
31
32
33
34
35
36
J**
37
38
39
40
T
Start
me
End
Opa
Sum
pity
Average
Sketch Showing How Opacity Varied with Time:
1/2 hr- Time, Hours ' nr-
1 1/2 hr.
-42-
-------
Table 18
SU.'-'.MARY OF VISIBLE EMISSIONS
25 June 1980
Date: ^
Type of Discharge: Tailing Pond
Type of Plant: Bauxite Processing
Height of Point of Discharge: 1 foot
Wind Direction: Southwest
Color of Plume: Rust
Observer No.:
Location of Discharge: Tailing Pond. Bed
Description of Sky: Clear B.lue Sky
Wind Velocity:
Detached Plume:
20 mph
Duration of Observation: 1 hour
Distance from Observer to Discharge Point: 2 ft. overlooking area of dry claylike bauxite
Direction of Observer from Discharge Point:Northeast corner looking south of Bed #2
Height of Observation Point: Ground Level
Description of Background:
Dry c1 ay 1 ike bauxite
Set
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
SUMMARY OF AVERAGE OPACITY
Time
Start
1435
1441
1447
1453
1459
1505
1511
1517
1523
1529
End
1440
1446
1452
1458
1504
1510
1516
1522
1528
1534
Opacity
Sum
0
0
0
0
0
0
0
0
0
0
Average
0
0
0
0
0
0
0
0
0
0
Set
Number
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
T
Start
me
End
Opaci ty
Sum
Average
Sketch Showing How Opacity Varied with Time:
Opaci ty
(*)
1 hour
Time, Hours
-43-
-------
Table 19
Mean Fugitive Emission Values (% frequency of emission)
Test
Test 1
Test 2
Test 3
Site Mean
Test
Test 1
Test
Test 1
Test
Test 1
FINE ORE BIN
TAILINGS POND NO. 2
SHIP UNLOADING CONVEYOR
SHIP UNLOADING PLATFORM
Test Mean
< 1.0
< 1.0
< 1.0
< 1.0
Test Mean
0.0
Test Mean
69.2
Test Mean
60.7
-44-
------- |