United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EMB Report 80-WFB- 8
November 1980
Air
S-EPA Nonfossil Fueled Boilers
Emission Test Report
Owens-Illinois
Forest Products Division
Big Island, Virginia
-------
NONFOSSIL FUELED BOILERS
Emission Test Report
Owens-Illinois
Forest Products Division
Big Island, Virginia
22-26 September 1980
by
James A. Peters and Jesse R. McKendree
MONSANTO RESEARCH CORPORATION
Dayton Laboratory
Dayton, Ohio 45407
Contract No. 68-02-2818
ESED 78/31
Work Assignment No. 31
Project No. 80-WFB-8
November 1980
Prepared for
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF AIR QUALITY PLANNING AND STANDARDS
EMISSION MEASUREMENT BRANCH
RESEARCH TRIANGLE PARK, NC 27711
-------
CONTENTS
Figures iv
Tables v
1. Introduction 1
2. Summary of Results 2
3. Process Description 16
4. Location of Sampling Points 18
5. Sampling and Analytical Methods 23
Appendices
A. Complete Emission Results A-l
B. Field Data Sheets B-l
C. Visible Emission Field Data Sheets C-l
D. Analytical Data Sheets D-l
E. Boiler Operating Data E-l
F. Quality Assurance/Quality Control and
Equipment Calibration Sheets F-l
G. Project Participants G-l
AML5/D iii
-------
FIGURES
Figure Page
1 Schematic diagram of boilers at Owens-Illinois,
Forest Product Division, Big, Island, Virginia. ... 17
2 Inlet to boiler #4 multicyclones, Owens-Illinois,
Big Island, Virginia 19
3 Inlet to boiler #5 multicyclones, East view,
Owens-Illinois, Big Island, Virginia 20
4 Side view of ESP outlet sampling location,
Owens-Illinois, Big Island, Virginia 21
5 Top view of ESP outlet sampling location,
Owens-Illinois, Big Island, Virginia 22
IV
-------
TABLES
Table Page
1 Particulate Emission Data and Stack Gas Param-
eters, Owens-Illinois, Big Island, Virginia,
September 24-25, 1980 (English Units) 4
2 Particulate Emission Data and Stack Gas Parameters,
Owens-Illinois, Big Island, Virginia,
September 24-25, 1980 (Metric Units) 5
3 Summary of Visible Emissions, Owens-Illinois,
Big Island, Virginia, September 24-25, 1980 6
4 Summary of Integrated Gas Analyses, Owens-Illinois,
Big Island, Virginia, September 24-25, 1980 12
5 Summary of Andersen Particle Sizing Results,
Owens-Illinois, Big Island, Virginia,
September 24-25, 13
6 Summary of Fuel Ultimate Analyses, Owens-Illinois,
Big Island, Virginia, September 24-25, 1980 15
7 Average Boiler Operating Parameters During Testing,
Owens-Illinois, Big Island, Virginia,
September 24-25, 1980 15
-------
SECTION 1
INTRODUCTION
The Big Island Paper Mill of Owens-Illinois, Inc., Forest Products
Division, in Big Island, Virginia was emission tested by Monsanto
Research Corporation (MRC) for the U.S. Environmental Protection
Agency (EPA) under Contract No. 68-02-2818, Work Assignment
No. 31. The purpose of testing the Big Island Mill was to gather
data that could possibly be used to support the setting of stand-
ards of performance for the nonfossil fuel boiler industry; in
this case, the production of process steam from firing wood bark
in conjunction with coal. Particulate matter emissions were
determined by simultaneous sampling of four points: inlets and
outlets of control devices at two parallel boilers. The two
boiler units sampled consisted of one firing 100% wood waste and
another firing 100% coal. Each boiler is equipped with a multi-
cyclone, the outlets of which feed a common exhaust duct. This
exhaust duct is split into two equal streams, each equipped with
a five-stage electrostatic precipitator (ESP).
The field test work was monitored by Dan Bivins, Field Testing
Section, Emission Measurement Branch, EPA. The sampling performed
by MRC was directed by Jesse R. McKendree as team leader. The Big
Island Mill was sampled by MRC during the week of September 22-26,
1980. The sample collection methods employed were EPA Methods 1
through 5, and 9, and particulate sizing by Andersen cascade
impactor.
Quality assurance/quality control in the sampling area covered
such activities as instrument calibration, using standard or
approved sampling methods, chain-of-custody procedures, and pro-
tocols for the recording and calculation of data. QA/QC in the
analysis area involved using only validated analysis methods,
periodic operator QC checking and training, sample QC by the use
of splits, reference standards, and spikes, and interlaboratory
audits.
-------
SECTION 2
SUMMARY OF RESULTS
During this emission test, a total of three particulate matter
emission runs were conducted simultaneously at four locations with
two smoke readers taking opacity readings at each of the two elec-
trostatic precipitator outlet stacks. The cyclone inlet and ESP
outlet of boiler #4 are designated as the Trackside locations
(because of their physical proximity to the railroad tracks at
the plant), and the cyclone inlet and ESP outlet of boiler #5 are
designated as the Riverside locations. The stack sampling proce-
dure consisted of extracting four samples simultaneously for each
test run, one from each multiclone inlet duct and one from each ESP
outlet stack.
Boiler #4 (Trackside) was 100% coal-fired and boiler #5 (River-
side) was 100% wood-fired. Sootblowing is performed on both
boilers at the beginning of each plant shift, at 7:00 a.m.,
3:00 p.m., and 11:00 p.m. During this emission test, no soot-
blows were made during any of the three runs.
The normal operating mode of the two boilers sampled is to
operate the Trackside (coal-fired) boiler at a constant loading,
and to vary the Riverside (wood-fired) boiler loading with demand.
This operating mode was continued during all three sampling runs.
The output loading of the Riverside boiler varied from 140,000 to
210,000 Ib steam/hr, while the Trackside boiler load varied from
55,000 to 75,000 Ib steam/hr.
Emissions of particulate matter and stack gas parameters are sum-
marized in Tables 1 and 2. All test runs were conducted within
isokinetic variation limits. Post-test calibration of the con-
sole meters used at the ESP outlet locations indicated that gas
volume measurement was out of calibration (change greater than
5%). The pre-test calibration gave the lower value of total
sample volume; hence, it was used in the emission calculations,
as described in Section 5.3 of the Federal Reference Method 5.
Simultaneous opacity readings were taken with particulate testing
by a certified observer for each ESP outlet stack during each
emission test. Summarized results of opacity readings are given
in Table 3. Plume readings remained at 0% opacity for all runs
with occasional periods of 1-5% opacity. Complete opacity
results are furnished in Appendix C.
-------
Integrated gas analysis results are given in Table 4; small
amounts of CO (less than 0.1%) were detected at both inlet and
outlet locations. A gas chromatograph with thermal conductivity
detector was used for the analysis rather than an Orsat analyzer.
Complete analytical results are given in Appendix D, with GC
calibration results presented in Appendix F.
Particulate sizing by Andersen cascade impactor was done at the
inlet and outlet of the Riverside emission control unit (wood-
fired) and the outlet only of the Trackside (coal-fired) since
uncontrolled emissions from coal-fired boilers have been well
characterized. Results are presented in Table 5; at the Riverside
inlet only two particle sizing runs are presented. The first two
runs were well over isokinetic variation limits due to pressure
head reading outside the magnehelic gage range; the last two runs
are presented. Complete particle sizing results are given in
Appendix B.
Samples of fuel were collected during each emission test run for
ultimate analysis. Table 6 presents a summary of analysis results
of the bark and coal fuels.
Plant operating data for each of three emission tests is sum-
marized in Table 7. Complete operating data taken during testing
is contained in Appendix E. The coal and bark feed rates given
in Table 7 were not directly measured since the plant measures
only daily use rates; the rates given were based on historical
usage data as determined by plant operating personnel.
-------
TABLE 1. PARTICIPATE EMISSION DATA AND STACK GAS PARAMETERS, OWENS-ILLINOIS,
BIG ISLAND, VIRGINIA, SEPTEMBER 24-25, 1980 (ENGLISH UNITS)
Run
number
Riverside iniet
boiler *5
1
2
3
Average
Tracks ide inlet
boiler #4
1
2
3
Average
Riverside outlet
1
2
3
Average
Trackside outlet
1
2
3
Average
Date
9/24/80
9/24/80
9/25/80
9/24/80
9/24/80
9/25/80
9/24/80
9/24/80
9/25/80
9/24/80
9/24/80
9/25/80
Time,
min
98
98
98
98
90
90
90
90
96
96
96
96
96
96
96
96
Temperature, Flow,
°F dscfm
324
333
328
328
401
413
406
407
260
339
330
310
267
347
339
318
80,824
79,848
75,399
78,690
36,315
35,679
35,584
35,859
85,051
84,481
84,205
84,579
72,079
75,509
71,226
72,938
H2O,
percent
12.19
15.63
13.04
13.62
4.84
5.31
5.48
5.21
11.77
12.70
11.43
11.97
12.07
9.27
12.21
11.18
Isokinetic,
percent
96.
101.
95.
103.
100.
101.
104.
106.
99.
107.
103.
107.
3
0
0
9
9
3
7
5
a
7
9
9
gr/dscf
2.2344
1.2146
1.2282
1.5590
1.3823
1.7583
1.2250
1.4552
0.0366
0.0147
0.0208
0.0240
0.0244
0.0111
0.0056
0.0137
Actual
Ib/hr
1,547.7
831.1
793.7
1,057.5
430.2
537.7
373.6
447.2
26.7
10.7
15.0
17.5
15.1
7.2
3.4
8.6
Emissions
Ib/mm Btua
6.7695
4.3159
3.4320
4.8391
6.0281
8.0329
4.7011
6.2540
0.1672
0.0486
0.0624
0.0927
0.0826
0.0355
0.0199
0.0460
Corrected to
12 percent CO2
qr/dscf
2.5536
1.6948
1.4887
2.1476
2.7193
3.7017
2.0137
2.8116
0.0699
0.0213
0.0430
0.0447
0.0327
0.0203
0.0091
0.0207
Calculated using F-factor method with F = 9,640 dscf/mm Btu for wood bark.
-------
TABLE 2.
PARTICULATE
BIG ISLAND,
EMISSION DATA AND STACK GAS PARAMETERS, OWENS-ILLINOIS,
VIRGINIA, SEPTEMBER 24-25, 1980 (METRIC UNITS)
Emissions
Run
number
Riverside inlet
boiler #5
1
2
3
Average
Trackside inlet
boiler #4
1
2
3
Average
Riverside outlet
1
2
3
Average
Trackside outlet
1
2
3
Average
Date
9/24/80
9/24/80
9/25/80
9/24/80
9/24/80
9/25/80
9/24/80
9/24/80
9/25/80
9/24/80
9/24/80
9/25/80
Time,
min
98
98
98
98
90
90
90
90
96
96
96
96
96
96
96
96
Temperature, Flow,
°C dncmpm
162
167
164
164
205
211
208
208
127
170
165
154
130
175
171
159
2,
2,
2,
2,
1,
1,
Ij,
2,
2,
2j_
2,
2,
2,
289
261
135
228
028
010
008
015
409
393
385
396
041
138
017
065
H2O,
percent
12
15
13
13
4
5
5
5
11
12
11
11
12
9
12
11
.19
.63
.04
.62
.84
.31
.48
.21
.77
.70
.43
.97
.07
.27
.21
.18
Isokinetic,
percent
96
101
95
103
100
101
104
106
99
107
103
107
.3
.0
.0
.9
.9
.3
.7
.5
.8
.7
.9
.9
gr/dncm
5
2
2
3
3
4
2
3
0
0
0
0
0
0
0
0
.1143
.7800
.8113
.5685
.1640
.0247
.8040
.3309
.0838
.0338
.0475
.0550
.0559
.0253
.0129
.0314
Actual
kg/hr
702.0
377.0
360.0
479.7
195.1
243.9
169.5
202.8
12.1
4.8
6.8
7.9
6.8
3.2
1.6
3.9
Corrected to .
12 percent CO2
kg/GJ
2.911
1.856
1.476
2.081
2.592
3.454
2.021
2.689
0.0719
0.0209
0.0268
0.0399
0.0355
0.0153
0.0086
0.0198
gr/dncm
5.8449
3.8791
3.4076
4.3772
6.2243
8.4731
4.6093
6.4356
0.1596
0.0488
0.0983
0.1022
0.0762
0.0349
0.0770
0.0627
Calculated using F-factor method with F = 263.3 dncm/GJ for wood bark.
-------
TABLE 3. SUMMARY OF VISIBLE EMISSIONS, OWENS-ILLINOIS,
BIG ISLAND, VIRGINIA, SEPTEMBER 24-25, 1980
Date: 9-24-80
Type of Discharge:Stack
Height of Point of Discharge:190 ft~
wind Direction: North
Color of Plume: Black
Observer Name: J. Hoeflein
Owens-Illinois, Run R-l
Type of Plant:
Distance from Observer to Discharge Point:
Direction of Observer from Discharge Point:
Height of Observation Point: Ground level
Location of Discharge:
Description of Sky:
Wind Velocity:
Detached Plume:
Paper Mill
Riverside stack
Overcast
5-10 mph
No
Duration of Observation:
500 yds
South
145 rain
Summary of
Set
number
Test began
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Test ended
Average,
all sets
avaraqe opacity
Time
Start
12
12
12
12
12
12
12
12
12
13
13
13
13
13
13
13
13
13
13
14
14
14
:06
:12
-.18
:24
:35
:41
:47
:53
:S9
:05
:11
:17
:13
:29
:35
:41
:47
:53
:59
:05
:11
:17
End
12
12
12
12
12
12
12
12
13
13
13
13
13
13
13
13
13
13
14
14
14
14
11
17
73
29
40
46
52
58
04
40
16
22
28
34
40
46
52
58
04
10
16
22
Opacity
Sum
0
0
0
0
10
0
0
0
0
0
0
0
0
35
0
0
0
0
0
0
0
0
0
0
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
1
0
0
0
0
0
0
0
0
0
0
0
0
0
4
0
0
0
0
0
0
0
0
6
0
0
0
0
0
0
0
0
08%
* 2
>-"
t—
o
o 1
A
1
RUN R-l
1 2
TIME, hours
(continued)
-------
TABLE 3 (continued)
Date:
Type
Ke:gh
Wind
Coic
Obser
Tista
Di rec
Keigl-.
of Di
t of
Direc
Of F
ver N
e f
tion
of
scharge: Stack
Point of Discharge:
11 on: NE
iun-.e: Reddish
ane:
Owens-Illinois, Run R-2
Type of Plant:
190 ft
J. Hoeflein
rom Observer to Discharge Point:
of Observer from Discharge Point:
Observation Point: Ground level
Paper Mill
Location of Discharge: Riverside stack
Description of Sky: Overcast
wind Velocity:
Detached Plume:
5-12 mph
No
Duration of Observation:
150 yds
90 min
s-w
Summary of
Set
nu.T.ber
1
2
3
4
5
average opacity
Time
Start
17
17
17
17
17
01
07
13
19
25
End
17
17
17
17
17
06
12
16
24
30
Opacity
Sum
40
25
0
0
0
0
0
0
0
0
Average
1
1
0
0
0
7
0
0
0
0
Test began
6
7
6
9
10
11
12
13
14
15
17
17
17
17
17
16
16
16
18
16
31
37
43
49
5S
01
07
13
19
25
17
17
17
17
18
18
16
18
16
18
36
42
46
54
00
06
12
18
24
30
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Reading
stopped
Average,
all sets
0
18%
t—
D-
O
3
2
1
n
RUN R-2
-
\ , ,
1 2
TIME, hours
(continued)
-------
TABLE 3 (continued)
9/25/80
Stack
Date:
Type of Discharge:
Height of Point of Discharge:
wind Direction: _ _S W
Color of Plume:
Observer Name:
Owens-Illinois, Run R-3
Type of Plant:
190 ft
Black
J. Hoeflein
Distance from Observer to Discharge Point:
Direction of Observer from Discharge Point:
Height of Observation Point: Ground level
Location of Discharge:
Description of Sky:
Wind Velocity:
Detached Plume:
Paper Mill
Riverside stack
Overcast
5-10 mph
No
Duration of Observation:
500 yds
South
175 mm
Summary of
Set
number
1
2
3
4
5
Test began
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Test ended
Average,
all sets
avarage opacity
Time
Start
11
11
11
11
11
12
12
12
12
12
12
12
12
12
13
13
13
13
13
13
13
13
13
13
14
14
14
14
14
:30
:36
:42
:48
:S4
:06
:12
:18
:24
:30
:36
:42
:48
:54
:00
:06
:12
:18
:24
:30
:36
:42
:48
:54
:00
:06
:12
:18
:24
End
11
11
11
11
11
12
12
12
12
12
12
12
12
12
13
13
13
13
13
13
13
13
13
13
14
14
14
14
14
35
41
47
53
59
11
17
23
29
35
41
47
53
59
05
11
17
23
29
35
41
47
53
59
05
11
17
23
29
Opacity
Sum
0
0
0
0
0
0
0
0
0
0
0
25
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.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
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
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
03%
o
I 1
RUN R-3
2 3
TIME, hours
(continued)
8
-------
TABLE 3 (continued)
9/24/80
Owens-Illinois, Run T-l
Type of Discharc
Height of Point
wind Direction:
Color of Plume:
Observer Name:
je: Stack
of Discharge:
N
Black
C. Clark
190 ft
Distance from Observer to Discharge Point:
Direction of Observer from Discharge Point:
Height of Observation Point: Ground level
Type of Plant: Paper Mill
Location of Discharge: Trackside stack
Description of Sky: Scattered clouds
Wind Velocity: 0-5 mph
Detached Plume:
No
Duration of Observation:
500 yds
South
120 mm
Summary of
Set
number
Test began
1
2
3
4
5
6
7
S
9
10
11
12
13
14
15
16
17
18
19
20
Test ended
Average,
all sets
avarage opacity
Time
Start
12
12
12
12
12
12
12
12
12
12
13
13
13
13
13
13
13
13
13
13
05
11
17
23
29
35
41
47
53
59
05
11
17
23
29
35
41
47
53
59
End
12
12
12
12
12
12
12
12
12
13
13
13
13
13
13
13
13
13
13
14
10
16
22
28
34
40
46
52
58
04
10
16
22
28
34
40
46
52
58
04
Opacity
Sum
0
0
0
0
0
0
0
35
0
5
0
0
0
0
0
0
0
0
0
0
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
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
5
0
2
0
0
0
0
0
0
0
0
0
0
09%
RUN T-l
1 2
TIME, hours
(continued)
-------
TABLE 3 (continued)
9/24/80
Stack
Date: ^
Type of Discharge: _|
Height of Point of Discharge:
Wind Direction: NE
Color of Plume: Reddish
Observer Name: C. Clark
Owens-Illinois, Run T-2
Type of Plant:
190 ft
Distance from Observer to Discharge Point:
Direction of Observer from Discharge Point:
Height of Observation Point: Ground level
Location of Discharge:
Description of Sky:
Wind Velocity:
Detached Plume:
Paper Mill
Trackside stack
Overcast
5-10 mph
No
Duration of Observation:
150 yds
90 mm
South-West
Summary of
Set
number
Test began
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Reading
stopped
Average,
all sets
avarage opacity
Time
Start
17
17
17
17
17
17
17
17
17
17
18
18
18
18
18
:01
:07
:13
:19
:25
:31
:37
:43
:49
:55
:01
:07
:13
:19
:25
End
17
17
17
17
17
17
17
17
17
18
18
18
18
18
18
06
12
18
24
30
36
42
48
54
00
06
12
18
24
30
Opacity
Sum
110
5
0
0
0
0
0
0
0
0
0
0
0
0
0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
Average
4
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
6
2
0
0
0
0
0
0
0
0
0
0
0
0
0
3%
\
1
RUN T-2
1 2
TIME, hours
(continued)
10
-------
TABLE 3 (continued)
9/25/80
Stack
Date:
Type of Discharge:
Height of Point of Discharge:"
Wind Direction: NV
Color of Plume:
Observer Name:
Owens-Illinois, Run T-3
Type of Plant:
190 ft
Black
Distance from Observer to Discharge Point:
Direction of Observer from Discharge Point:
Height of Observation Point: Ground level
Location of Discharge:
Description of Sky:
Wind Velocity:
Detached Plume:
Paper Mill
Trackside stack
Overcast
5-10 mph
No
Duration of Observation:
500 yds
South
175 min
Summary of
Set
number
1
2
3
4
5
Test began
6
7
e
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Test ended
Average,
all sets
avarage opacity
Time
Start
11
11
11
11
11
12
12
12
12
12
12
12
12
12
13
13
13
13
13
13
13
13
13
13
14
14
14
14
14
30
36
42
48
54
06
12
18
24
30
36
42
4E
54
00
06
12
18
24
30
36
42
48
54
00
06
12
18
24
End
11
11
11
11
11
12
12
12
12
12
12
12
12
12
13
13
13
13
13
13
13
13
13
13
14
14
14
14
14
35
41
47
53
59
11
17
23
29
35
41
47
53
59
05
11
17
23
29
35
41
47
53
59
05
11
17
23
29
Opacity
Sum
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
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
o
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
.0%
RUN T-3
1 2
TIME, hours
11
-------
TABLE 4. SUMMARY OF INTEGRATED GAS ANALYSES, OWENS-ILLINOIS,
BIG ISLAND, VIRGINIA, SEPTEMBER 24-25, 1980
Run
number
Date
C02,
percent
02,
percent
CO,
percent
N2,
percent
MW,
Ib/lb mole
Riverside inlet
boiler #5
1 9/24/80
2 9/24/80
3 9/25/80
Average
Trackside inlet
boiler #4
1 9/24/80
2 9/24/80
3 9/25/80
Average
Riverside outlet
1 9/24/80
2 9/24/80
3 9/25/80
Average
Trackside outler
1 9/24/80
2 9/24/80
3 9/25/80
Average
6.1
5.7
7.3
6.4
6.3
8.3
5.8
6.8
8.8
8.7
7.4
8.3
11.4
12.8
10.6
11.6
14.6
12.2
11.3
12.7
12.4
11.9
12.8
12.4
0.04
0.0
0.0
0.01
0.04
0.04
0.03
0.04
0.04
0.04
0.03
0.04
78.0
78.5
79.4
78.6
79.5
79.7
79.4
79.5
79.1
79.4
82.9
80.5
78.7
79.4
79.8
79.3
30.39
29.89
30.00
30.09
29.55
29.48
29.69
29.57
29.54
29.82
29.62
29.66
29.91
29.86
29.70
29.82
-------
TABLE 5. SUMMARY OF ANDERSEN PARTICLE SIZING RESULTS, OWENS-ILLINOIS,
BIG ISLAND, VIRGINIA, SEPTEMBER 24-25, 1980
Riverside ESP
Flow
Run RO-1
rate (ACFM)
Percent ISO:
Percent
in size
range
88.6
2.4
1.9
1.9
1.2
1.0
0.5
0.9
1.8
Cumulative
percent
less than
size range
11.4
9.1
7.2
5.3
4.2
3.1
2.6
1.8
0
: 0.32
106.0
Size
range ,
Flow
Run RO-2
rate (ACFM)
Percent ISO:
Percent
microns
>19.0
11.8 - 19.0
8.1 - 11
5.3 - 8.
3.55 - 5.
1.75 - 3.
1.1 - 1.
0.76 - 1.
0-0.
.8
1
3
55
75
1
76
in
size
range
12
6
1
2
0
2
10
40
23
.0
.3
.9
.5
.0
.5
.7
.9
.3
Cumulative
percent
less than
size range
88.0
82.8
79.9
77.4
77.4
74.8
64.2
23.3
0
Trackside ESP
Flow
Run TO-1
rate (ACFM)
Percent ISO:
Percent
in size
range
25.7
2.8
1.7
1.7
6.2
5.6
15.1
24.6
16.8
Cumulative
percent
less than
size range
74.3
71.5
69.8
68.2
62.0
56.4
41.3
16.8
0
: 0.26
107.5
Size
range ,
microns
>21.3
13.3 - 21
9.1 - 13
6.2 - 9.
3.95 - 6.
2.0 - 3.
1.25 - 2.
0.85 - 1.
0-0.
Flow
Run TO- 2
rate (ACFM)
Percent ISO:
Percent
in
size
range
.3
.3
1
2
95
0
25
85
7
7
2
3
6
4
0
19
49
.2
.2
.4
.2
.4
.0
.8
.2
.6
Cumulative
percent
less than
size range
92.8
85.6
83.2
80.0
73.6
69.6
68.8
49.6
0
outlet
: 0.31
90.0
Size
range ,
microns
>19.5
12.1 - 19.5
8.2 - 12.1
5.6 - 8.2
3.6 - 5.6
1.8 - 3.6
1.1 - 1.8
0.78 - 1.10
0 - 0.78
outlet
: 0.30
107.3
Size
range ,
microns
>19.5
12.3 - 19.5
8.4 - 12.3
5.7 - 8.4
3.65 - 5.7
1.8 - 3.65
1.13 - 1.8
0.79 - 1.13
0 - 0.79
Flow
Run RO-3
rate (ACFM)
Percent ISO:
Percent
in size
range
14.2
1.8
1.8
5.1
3.7
21.6
26.6
8.3
17.0
Flow
Cumulative
percent
less than
size range
85.8
84.0
82.1
77.1
73.4
51.9
25.3
17.0
0
Run TO- 3
rate (ACFM)
Percent ISO:
Percent
in size
range
54.1
2.7
5.4
0.0
0.0
2.7
5.4
5.4
24.3
Cumulative
percent
less than
size range
45.9
43.2
37.8
37.8
37.8
35.1
29.7
24.3
0
: 0.32
96.4
Size
range ,
microns
>19.0
11.8 - 19
8.1 - 11
5.3 - 8.
3.55 - 5.
1.75 - 3.
1.1 - 1.
0.76 - 1.
0-0.
: 0 . 29
107.3
Size
range ,
microns
>19.9
12.5 - 19
8.5 - 12
5.8 - 8.
3.7 - 5.
1.85 - 3.
1.15 - 1.
0.80 - 1.
0-0.
.0
.8
1
3
55
75
1
76
.9
.5
5
8
7
85
15
80
-------
TABLE 5 (continued)
Riverside
ESP
inlet
Run RI-3
Flow
rate
Percent
(ACFM)
ISO:
: 0.18
80.9
Flow
Run
RI-4
rate (ACFM)
Percent
Cumulative
Percent
in
size
range
86
0
1
1
2
1
2
0
3
.7
.0
.0
.6
.4
.3
.1
.9
.9
percent
less
size
13
13
12
10
8
6
4
3
0
than
range
.3
.3
.2
.6
.2
.9
.8
.9
Size
range ,
microns
>23.0
15.9-23.0
10.8-15.9
7.3-10.8
4.8-7.3
2.4-4.8
1.48-2.4
1.05-1.48
0-1.05
Percent
in
size
range
69
1
2
2
2
5
4
3
7
.8
.7
.4
.2
.6
.3
.6
.7
.7
ISO:
: 0
85.
.20
9
Cumulative
percent
less
size
30
28
26
23
21
16
11
7
0
than
range
.2
.5
.1
.9
.3
.0
.4
.7
Size
range
,
microns
15
10
7
4
2.
1
0.
>22.0
.0-22
.3-15
.0-10
.5-7.
25-4.
.4-2.
97-1.
0-0.
.0
.0
.3
0
5
25
4
97
-------
TABLE 6. SUMMARY OF FUEL ULTIMATE ANALYSES, OWENS-ILLINOIS,
BIG ISLAND, VIRGINIA, SEPTEMBER 23-25, 19803
Sample
Carbon,
Hydrogen,
Trackside coal bin
boilei f4
Run 1
dry
Run 7
dry
Run 3
as
dry
basis
basis
received
basis
9/24/60
79.
9/24/60
77.
9/25/80
74.
78.
37
.38
.99
.56
4.
4
S
4
.81
.65
.07
.79
Nitrogen,
1.41
1.26
1.35
1.42
Sulfur.
o
0
0
0
58
.94
.57
.60
Ash
6.38
7.79
6.82
7.14
Oxygen ,
7.45
7.99
11.19
7.49
Fuel
value.
14,235
14,009
13,492
14,134
Riverside bark
•crew
feeder
boiler 15
Run 1
dry
Run 2
• s
dry
Run 3
dry
basis
received
basis
basis
9/24/80
45.
9/24/80
25
45.
9/25/80
46.
66
66
78
35
5
8
5
5
.56
.06
.68
.77
0.17
0.12
0.21
0.26
0
0
0
0
.02
.02
.03
.04
4.83
2.57
4.59
3.65
43.75
63.56
43.71
43.73
7,980
4.482
7,995
8,179
%umbers represent an average of samples taken at the start, niddle, and end of sampling runs.
TABLE 7. AVERAGE BOILER OPERATING PARAMETERS DURING
TESTING, OWENS-ILLINOIS, BIG ISLAND,
VIRGINIA, SEPTEMBER 24-25, 1980
Boiler
Date
Boiler test time, min
Fuel oil feed rate, gal/hr
Boiler #4 (Trackside)
Steam production, 103 Ib/hr
Steam pressure, psig
Steam temperature
Coal feed rate, ton/hra
Boiler #5 (riverside)
Steam production, 103 Ib/hr
Steam pressure, psig
Steam temperature, °F
Bark feed rate, ton/hr
Test 1
9/24/80
1205-1630
5.2
67. g
b
5.7
174.0
583
708
28.2
Test 2
9/24/80
1700-1930
5.2
68. g
b
5.7
176.0
597
712
28.2
Test 3
9/25/80
1205-1530
2.3
67. g
b
5.4
176.0
597
708
21.9
Calculated by plant personnel based on 24-hour period;
estimated to be within ±1 ton/hr.
Data not taken.
15
-------
SECTION 3
PROCESS DESCRIPTION
The Big Island Mill manufactures paper products, and operates
three boilers for process steam, two of which are in operation
at all times. The third boiler is on secondary status. Boiler
#3 uses wood bark and sawdust as fuel, is normally on standby,
and has a design capacity of 60,000 Ib steam per hour. The
operating boilers are Boiler #4 (Trackside boiler) which is a
Combustion Engineering, Inc. pulverized coal dry bottom boiler
with a design capacity of 140,000 Ib steam per hour and Boiler #5
(Riverside boiler) which is a Foster Wheeler stoker-grate coal or
refuse boiler with a design capacity of 200,000 Ib steam per hour.
The Riverside boiler was historically fired with 80% coal, 20%
bark, but that ratio has been switched as the plant burns as much
bark as possible now—up to 100% bark in the Riverside boiler.
Each boiler is exhausted to Zurn multicyclone units (type MTSA),
installed in 1970 and 1971, then ducted to a common duct which
leads to a pair of United McGill electrostatic precipitators, as
shown in Figure 1. There is not complete mixing of exhaust gases
from the Trackside and Riverside boilers since the common duct is
very straight between the two exhaust path junction points. The
twin ESP's contain ten fields, five on each side, and are designed
to handle a flow of 300,000 acfm. Installed in 1978, the twin
ESP's exhaust to a pair of stacks which terminate 190 ft above
ground level.
The plant is located between railroad tracks and the James River;
hence, the two precipitators are designated the Riverside unit
and Trackside unit, respectively.
The plant operations are best termed as continuous. The schedule
is based on 24 hours a day operation, seven days a week.
16
-------
140,000 Ib STEAM CAPACTIY
100% PULVERIZED COAL
MULTICYCLONES
200.000 Ib STEAM CAPACITY
100% WOOD BARK
60,000 Ib STEAM CAPACITY
100% WOOD BARK
STANDBY
Figure 1. Schematic diagram of boilers at Owens-Illinois,
Forest Product Division, Big Island, Virginia.
17
-------
SECTION 4
LOCATION OF SAMPLING POINTS
As a result of the pretest survey, the sampling program included
the inlets to the multicyclone units of boilers #4 and #5 and
the outlets of the ESP units at the stack platform. Simultan-
eous sampling for particulates using EPA Method 5 was performed
at the four locations. The common duct leading to the ESP units
branched and had existing sampling ports but was eliminated from
consideration in this program due to the proximity of disturbances,
Sampling ports at the inlet of the cyclone on boiler #4 were
utilized as is. The duct leading to the multicyclones was
rectangular and measured 74 in. by 98 in. with five 4 in. capped
ports installed 81 inches above floor level in the 98 in. face.
The direction of flow when facing the port was upward. The
nearest upstream disturbance was approximately one duct diameter
away and the nearest downstream disturbance was also one duct
diameter away. Figure 2 illustrates the duct configuration of
the Trackside inlet sampling location.
Sampling ports for boiler #5 cyclone inlet were installed by a
local contractor prior to the test. This location had seven
4 in. flanged ports unevenly spaced in a 116 in. by 122 in.
rectangular duct. Figure 3 illustrates the duct configuration
of the Riverside inlet sampling location. The nearest disturb-
ances were two duct diameters upstream and one diameter down-
stream. The U-shaped ductwork resulted in a gas flow pattern
which was not cyclonic but tended to stay close to the outside
edge of the U-shape.
The twin ESP outlet locations were circular stacks, 84 in.
diameter, each with two 4 in. ports at 90° from each other. The
top of the stack was 2-1/2 diameters downstream and the nearest
upstream disturbance was an expansion one diameter away.
Figures 4 and 5 illustrate side and top views of the outlet loca-
tions, respectively.
18
-------
o o o o o
FLOW
* *~
n
a. SOUTH VIEW
©
\CYCLONE /
FLOW
©
b. WEST VIEW
Figure 2. Inlet to boiler #4 multicyclones, Owens-Illinois,
Big Island, Virginia.
19
-------
20'
MULTICYCLONES 130"X130" 0. D.
2-1/2 DUCTS
SAMPLING PORTS-
FLOOR LEVEL
-130"-
FROM
NO. 5
BOILER
Figure 3. Inlet to boiler #5 multicyclones, East view,
Owens-Illinois, Big Island, Virginia.
20
-------
to
GUARDRAIL
FLOOR
— c
60"
1
O 14"
22'-5"
Figure 4. Side view of ESP outlet sampling location,
Owens-Illinois, Big Island, Virginia.
-------
N
36"
NJ
NJ
TRACKSIDE
RIVERSIDE
42"
t
_• ^"v
=1=
30'
•v^<«_
Figure 5. Top view of ESP outlet sampling location,
Owens-Illinois, Big Island, Virginia.
-------
SECTION 5
SAMPLING AND ANALYTICAL PROCEDURES
The Owens-Illinois Big Island Mill was sampled for participate
matter, particle size, opacity, integrated gas analysis, and fuel
analysis.
The following describes the methods used.
Sampling Procedures
Particulate Matter—
Sampling for particulates was performed using the method outlined
in the Federal Register, Method 5, "Determination of Particulate
Emissions from Stationary Sources," modified so that the sample
box temperature was 325°F instead of 250°F. A glass-lined probe
was used at the Riverside inlet sampling location, and all other
locations used stainless steel probes. A six-step cleanup is
used on stainless steel probes and a three-step cleanup is used
on glass-lined probes. Pre-filter cyclones were also used on all
Method 5 trains at the inlet locations.
Particle Size—
Sampling for particle size was performed using an Andersen
cascade impactor with seven stages and a back-up filter.
The sampling train used consisted of the following equipment
listed in order of the flow: a 10-mm diameter probe tip; a curved
(90°C) probe tip to Andersen head connector; standard Andersen
heads; a stainless steel probe; a Smith-Greenburg impinger with
water, then one charged with color indicating silica gel; and an
EPA-5 console equipped with a dry gas meter, digital electronic
thermometer and an inclined manometer. Also, an S-type pitot
tube was connected to the probe so the stack pressure could be
continually monitored. A 10-ft glass-lined probe with pre-
separator was used at the Riverside inlet sampling location, and
5 ft stainless steel probes without preseparators were used at
the outlet locations.
23
-------
A total of 3 particle sizing runs were made simultaneously at the
Riverside inlet location and both outlet locations. Each run was
conducted for 5 minutes under isokinetic conditions at the River-
side inlet location and from 16 to 30 minutes at the stack out-
lets. At the completion of each run, the moisture collected was
measured and the Andersen heads were opened and oven-dried for
three hours. After drying, each stage was weighed, then the
filter was removed and the stage assemblies were cleaned, desic-
cated and reweighed to provide partial tare weights. The tare
weights of the filters were taken during the assembly of the
heads (after desiccation for 24 hours).
All weight measurements were made with a Mettler analytical
balance. The balance was calibrated daily and rezeroed before
each weight determination. Calculations were performed using
the methods and tables provided in the Andersen manual.
Opacity—
Visible emissions of each outlet stack were read during particu-
late sampling by a certified smoke reader who met the specifica-
tion of Federal Register, Method 9, "Visual Determination of the
Opacity of Emissions from Stationary Sources."
Integrated Gas Analysis—
Exhaust gas sampling was performed using the multi-point, inte-
grated sampling method outlined in the Federal Register, Method 3,
"Gas Analysis for Carbon Dioxide, Oxygen, Excess Air, and Dry
Molecular Weight."
Fuel —
Fuel samples were grabbed in 1-liter nalgene bottles from the coal
bins feeding boiler #4 and the bark screw feeder to boiler #5 just
prior, during, and just after each test run.
Analytical Procedures
Particulate Matter--
Analytical procedures were performed using the methods described
in EPA Method 5, previously mentioned in the sampling procedures
section.
Integrated Gas Analysis--
Samples collected using a Tedlar bag were analyzed on site using
direct injection into a gas chromatograph with a thermal conduc-
tivity detector (GC/TCE). The instrument was zeroed with prepuri-
fied nitrogen as a zero gas. Each gas analyzed (C02, 02, and CO)
had three calibration gas concentrations which spanned the probable
concentrations in the exhaust gas. For 02 calibration, NBS trace-
able cylinders containing 5% 02, 9.99% 02 and air (20.9% 02) were
used. For C02 calibration, NBS traceable cylinders containing
10.2% C02, 1.008% CO2, and zero gas (N2) were used. For CO cali-
bration, cylinders containing 9,600 ppm CO, 5,000 ppm CO, and zero
24
-------
gas (N2) were used. The instrument was calibrated immediately
before each sample run, and, in accordance with MRC's QA/QC manual,
triplicate sample injections were made for each run.
Fuel —
Analysis of the coal and bark feed was performed using ASTM D 3178
for carbon and hydrogen, ASTM D 3176 for oxygen, ASTM D 3179 for
nitrogen, ASTM D 3177 for sulfur, and ASTM D 3174 for ash. Fuel
value was determined using ASTM D 2015.
Quality Assurance/Quality Control—
Results of quality control tests are furnished with the analytical
data sheets provided in Appendix E, specifically calibration runs
for integrated gas analyses and equipment calibration sheets.
25
------- |