REPORT NO. 78-GLS-l
O
AIR POLLUTION
EMISSION TEST
CA-ENS-OORNING FIBERGIAS CORPORATION
KANSAS CriY, KANSAS
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Waste Management
Office of Air Quality Planning and Standards
Emission Measurement Branch
Research Triangle Park. North Carolina
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STATIONARY SOURCE TESTING OF A FIBERGLAS PLANT
AT THE OWENS-CORNING FIBERGLAS CORPORATION
KANSAS CITY, KANSAS
By
George R. Cobb
Midwest Research Institute
FINAL REPORT.
February 24, 1978
EPA Contract No. 68-02-2814, Work Assignment No. 2
EPA Project No. 78-GLS-l
MRI Project No. 4468-L(2)
For
Emission Measurement Branch
Field Testing Section
Environmental Protection Agency
Research Triangle Park, North Carolina 27711
Attn: Mr. J. E. McCarley, Jr.
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PREFACE
The work reported herein was conducted by Midwest Research Institute
(MRI) under Environmental Protection Agency (EPA) Contract No. 68-02-2814,
Work Assignment No. 2.
The project was under the supervision of Mr. Doug Fiscus, Head, Field
Programs Section, and Mr. William Maxwell, Program Manager. Mr. George
Cobb served as field team leader and was assisted by Messrs. Calvin Bolze,
Thurmon Oliver, and William Maxwell. The visual opacity observations were
done by Mr. Joe Arello, EPA Region VII Laboratory.
Approved for:
MIDWEST RESEARCH INSTITUTE
L. J. \hannon, Director
Environmental Materials and
Sciences Division
ii
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CONTENTS
Preface ii
1. Introduction 1
2. Summary and Discussion of Results ..... 2
3. Process Description and Operation .. . 8
4. Location of Sample Points 9
5. Sampling and Analytical Procedures 12
Particulate . 12
Baghouse Dust 12
Appendices
A. Computer Printout of Field Data and Reductions A-l
B. Sample Calculations B-l
C. Field Data C-l
D. Visual Emissions Certification D-l
111
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TABLES
Number . Page
1 Summary of Results - English 3
2 Summary of Results - Metric .. 4
3 Midwest Research Institute Summary of Visible Emissions,
Run No.l 5
4 Midwest Research Institute Summary of Visible Emissions,
Run No. 3 6
5 Midwest Research Institute Summary of Visible Emission,
Run No. 4 7
6 Sample Point Location .............. 11
FIGURES
Number Page
1 Owens-Corning sampling site 10
2 Sampling train for Owens-Corning . 13
iv
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SECTION 1
INTRODUCTION
During the period of December 12 to 16, 1977, stationary source testing
was conducted by Midwest Research Institute (MRI) at the Owens-Corning Fiber-
glas Plant at Sunshine and Fiberglas Roads in Kansas City, Kansas. While
these tests were being performed, the glass melting furnace was fired by
natural gas. The furnace could have been converted to oil if fuel availability
conditions had warranted such a change. The flue gases were controlled by a
baghouse prior to being exhausted through the exhaust duct and stack to the
atmosphere.
Particulate emissions samples were taken from the exhaust duct using EPA
Reference Method 17 in connection with modified EPA Reference Method 5 as a
backup. A multipoint and integrated sampling procedure was used for flue gas
molecular weight determination. Baghouse collected particulate was collected
from the screw conveyors at the bottom of the baghouse. EPA personnel col-
lected the process data and did the visual opacity measurements by EPA Reference
Method 9. The above information is to be used for developing and supporting
new national source performance standards.
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SECTION II
SUMMARY AND DISCUSSION OF RESULTS
Tables 1 and 2 present a summary of the particulate emissions measured
during the three tests. These data are presented as grains per dry standard
cubic foot (gr/dscf) and pounds per hour (Lb/hr) in Table 1, and as milligrams
per normal cubic meter (mg/ncm) and kilograms per hour (kg/hr) in Table 2.
Computer printouts of the field data and reductions are in Appendix A. Sample
calculatons are found in Appendix B. Copies of the raw data sheets are con-
tained in Appendix C.
A large weight gain was determined in the impinger contents. This may be
explained by the presence of volatile boron compounds which have condensed
in the impingers.
The results of the visual opacity observations are presented in Tables 3,
4, and 5. During parts of Test No. 1 the stack was obscured by steam plumes
from other sources. These are indicated by an "x" in the raw data forms in
Appendix C. Mr. Arello's visual emissions certification is in Appendix D.
Run No. 2 was aborted when the glass probe liner broke during insertion
of the probe into the port for the second traverse. When the probe liner
broke, the high negative pressure in the duct caused the particulate matter
collected up to that time to be lost into the duct.
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TABLE 1. SUMMARY OF RESULTS - ENGLISH
Run No.
Date
Gas flow
dscfm3-7
Particulates
Method 17
Probe
gr/dscf I/
Ib/hrl/
Filter
gr/dscf
Ib/hr
Total Method 17
gr/dscf
Ib/hr
Method 5k/
Probe
gr/dscf
Ib/hr
Filter
gr/dscf
Ib/hr
Total Method 5
gr/dscf
Ib/hr
Total Method 17 and 5,
Front half
gr/dscf
Ib/hr
Back half-£/
gr/dscf
Ib/hr
Total, front half, and
Back half
gr/dscf
Ib/hr
Method 17 and 5 removal
Method 17
Method 5 front halfb/
Method 5 back half£/
1
12-14-77
28,111
0.00089
0.21
0.00825
1.99
0.00914
2.20
0.00391
0.94
0.00279
0.68
0.00670
1.62
0.01584
3.82
0.6825
16.44
0.08409
20.26
efficiency
10.86
8.00
81.14
3
12-14-77
27,817
0.00078
0.19
0.02212
5.27
0.02290
5.46
0.00223
0.53
0.00194
0.46
0.00417
0.99
0.02707
6.45
0.07972
19.01
0.10679
25.46
(percent)
21.45
3.89
74.66
4
12-15-77
24,418
-0.00088
-0.18
0.00479
1.00
0.00391
0.82
0.00578
1.21
0.00399
0.83
0.00977
2.04
0.01368
2.86
0.12983
27.17
0.14351
30.03
2.73
6.79
90.48
Average
26,782
0.01198
2.83
0.00688
1.55
0.01886
4.38
0.09260
20.87
0.11146
25.25
11.21
6.14
82.65
aj dscfm = dry standard cubic feet per minute.
gr/dscf = grains per dry standard cubic foot.
Ib/hr = pounds per hour.
b/ Excludes Method 17.
£/ Includes ether/chloroform extraction and impinger rinse.
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TABLE 2. SUMMARY OF RESULTS - METRIC
Run No.
Date
Gas flow
nm3/minS/
Particulates
Method 17
Probe
/ a/'
mg/ncm— '
kg/hri/
Filter
mg/ncm
kg/hr
Total Method 17
mg/ncm
kg/hr
Method 55.'
Probe
mg/ncm
kg/hr
Filter
mg/ncm
kg/hr
Total Method 5
mg/ncm
kg/hr
Total Method 17 and 5
Front half
mg/ncra
kg/hr
Back half-5'
mg/ncm
kg/hr
Total front half and
Back half
mg/ncm
kg/hr
1
12-14-77
796.0
2.03
0.096
18.88
0.903
20.91
0.999
8.96
0.427
6.38
0.308
15.34
0.733
36.25
1.732
156.17
7.457
192.42
9.189
3
12-14-77
787.7
1.78
0.086
50.62
2.390
52.40
2.476
5.10
0.241
4.44
0.209
9.54
0.451
61.94
2.927
182.44
8.621
244.38
11.548
4
12-15-77
691.4
-2.01
-0.082
10.96
0.453
8.95
0.371
13.22
0.549
9.13
0.377
22.35
0.927
31.30
1.298
297.09
12.323
328.39
13.621
Average
758.4
27.18
1.282
15.75
0.704
42.93
1.986
222.53.
9.467
255.06
11.453
a_/ nnH/min = normal cubic meters per minute.
mg/ncm = milligrams per normal cubic meter.
kg/hr = kilograms per hour.
b/ Excludes Method 17.
c_/ Includes ether/chloroform extraction and probe rinse.
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TABLE 3. MIDWEST RESEARCH INSTITUTE SUMMARY OF VISIBLE EMISSIONS. RUN NO. 1
Type of plant: Fibers las
Date: 12-14-77
Type of discharge: Stack Height of point of discharge: 40 ft
Location of discharge: Stack exit Height of observation point: -— 40 ft
Distance from observer to discharge point: ~ 50 ftDuration: 2 hr. 40 min
Direction of observer from discharge point: Southeast to south
Descript. of background: Clear Wind direction: South Color of plume:Gray
Descript. of sky: Clear to cloudy Wind velocity: Detached plume: No
SUMMARY OF TIME AND AVERAGE OPACITY
Set No.
1
2
3
4
5
6*
7*
8*
9*
10
11
12
13
14
15
16*
17*
18*
19*
20*
Start
8:
8:
8:
8:
38
:44
:50
:56
9:02
9
9
9:
9:
9:
9
9:
9:
9:
10:
10
10
10:
10:
10
-.08
: 14
:21
:27
:33
:40
:46
:52
:57
:03
:09
:21
:27
:33
:39
End
8:43
8:49
8:55
9:01
9:07
. 9:13
9:19
9:26
9:32
9:37
9:45
9:51
9:54
10:02
10:08
10:11
10:26
10:32
10:38
10:44
Sum
15
190
120
195
340
170
75
125
135
175
180
80
25
250
175
85
125
160
10
75
Avg.
1
8
5
8
14
11
6
7
6
9
8
3
2
10
7
8
7
7
1
5
Set No.
21*
22*
23*
24
25
26*
27*
28*
29
30
31
32
33
34
35
36
37
38
39
40
Start
10:45
10:51
10:57
11:03
11:09
11: 15
11:21
11:27
11:33
End
10:
10:
11:
H:
11:
11:
11:
11:
11:
:50
:56
:02
:08
14
:20
:26
:32
:34
Sum
70
25
50
25
105
20
10
85
0
Avg.
4
1
2
I
4
1
0
4
0
Stack obscured by steam plumes.
Sketch Showing How Opacity Varied With Time:
* 15-
x
'u
5-
n
0
8:30 9:00
JkM.
10:00
11:00
Time, Hour
12:00
20
15
-10
-5
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TABLE 4. MIDWEST RESEARCH INSTITUTE SUMMARY OF VISIBLE EMISSIONS, RUN NO. 3
Type of plant: Fiberglas
Type of discharge: Stack
Location of discharge: Stack exit
Date: 12/14/77
Height of point of discharge: 40 ft
Height of observation point: — 40 ft
Distance from observer to discharge point:'" 50 ft Duration: 32 min
Direction of observer from discharge
point: West i on Baghouse
Descript. of background: Clear Wind direction: - Color of plume: Gray
Descript. of sky: Clear to cloudy Wind velocity: - Detached plume: No
SUMMARY OF TIME AND AVERAGE OPACITY
Set No. Start End Sum Avg.
1 15:22 15:27 55 3
2 15:28 15:33 200 8
3 15:34 15:34 25 6
4 16:34 16:39 40 2
5 16:40 16:45 30 1
6 16:46 16:51 95 4
7 16:52 16:52 15 4
8
9
10
11
12
13
14
15
16
17
18
19
20
Set No. Start End Sum Avg.
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
9-
8-
1 7-
if
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TABLE 5. MIDWEST RESEARCH INSTITUTE SUMMARY OF VISIBLE EMISSIONS. RUN NO. 4
Type of plant: Fiberslas
Type of discharge: Stack
Stack exit
Date: 12-15-77
Location of discharge:
Distance from observer to discharge point: ~
Height of point of discharge: 40 ft
Height of observation point: ~- 40 ft
Oft Duration: 2 hr. 6 min
Direction of observer from discharge point: West on baghouse
Descript. of background: Clear Wind direction:
Descript. of sky: Cloudy Wind velocity:
Color of plume:Grav
Detached plume: No
SUMMARY OF TIME AND AVERAGE OPACITY
Set No.
1
2
3
4
. 5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Start
14:17
14:23
14:29
14:35
14:41
14:47
14:53
14:59
15:02
15:08
15:15
15:21
15:27
15:33
15:38
16:14
16:20
16:26
16:32
16:38
End
14:22
14:28
14:34
14:40
14:46
14:52
14:58
14:59
15:07
15:13
15:20
15:26
15:32
15:38
15:38
16:19
16:25
16:31
16:37
16:43
Sum
100
125
95
225
235
175
50
20
140
85
325
235
180
235
55
290
210
325
150
175
Avg.
4
5
4
9
10
7
2
5
6
4
14 .
10
8
10
14
12
9
14
6
7
Set No.
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Start End Sum Avg.
.16:44 16:49 245 10
16:50 16:55 295 12
16:56 16:59 255 16
20
- 15-
10-
u
o
Q.
O
5-
Sketch Showing How Opacity Varied With Time:
~u
0
14:12 14:30
15:00
\
16:00
20
-15
-10
-5
17:00
Time, Hour
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SECTION III
PROCESS DESCRIPTION AND OPERATION
This section to be furnished by EPA.
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SECTION IV
LOCATION OF SAMPLE POINTS
The site is shown in Figure 1. The circular exhaust duct is made of
0.953 cm (0.375 in.) thick steel with an inside diameter of 1.206 m (47.5 in.).
The sampling ports are 10.15 cm (4 in.) Schedule 40 pipe. The ports are approxi-
mately six stack diameters downstream and 1.25 diameters upstream from obstruc-
tions in the duct. This made it necessary to have 16 sample points per traverse.
Table 6 presents the sampling point locations for the stack.
Two screw conveyors removed the collected particulate from the baghouse.
After each particulate run, a sample was taken from the outlets of these
screw conveyors.
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fl
Cat-Walk-,
Porthole **!;
Porthole^
I:;:;:!:;:;*
Probe::
t
90°
Probe
|L
J
:BAGHOUSE
;BLDG.
Cat-Walk
Pipe
Lamp Pole
TOP VIEW
Figure 1. Owens-Corning sampling site
10
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TABLE 6. SAMPLE POINT LOCATION
Radius
point
1
2
3
4
5
6
7
8
9
10
1.1
12
13
14
15
16
Fraction of
duct ID (%)
1.6
4.9
8.5
12.5
16.9
22.0
28.3
37.5
62.5
71.7
78.0
83.1
87.5
91.5
95.1
98.4
Distance from
inside wall
1.91 cm ((0.75 in.)
5.92 cm (2.33 in.)
10.26 cm (4.04 in.)
15.09 cm (5.94 in.)
20.37 cm (8.02 in.)
26.54 cm (10.45 in.)
34.14 cm (13.44 in.)
45.24 cm (17.81 in.)
75.41 cm (29.69 in.)
86.51 cm (34.06 in.)
94.11 cm (37.05 in.)
100.25 cm (39.47 in.)
105.56 cm (41.56 in.)
110.39 cm (43.46 in.)
114.73 cm (45.17 in.)
118.72 cm (46.74 in.)
11
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SECTION V
SAMPLING AND ANALYTICAL PROCEDURES
PARTICULATE
Particulate samples were taken with Research Appliance Company (RAG) Model
2243 "Stacksamplr" equipment, modified by MRI. A Gelman stainless steel 47 mm
in-line filter holder was used for the in-stack filter. Pyrex glass probe liners
were used for all tests.
The "S" type pitot was extended to allow for the in-stack filter length.
Due to the placement of the sampling ports and obstructions, the sample box
could not be attached directly to the probe. A special heated box was designed
so that the Method 5 filter holder could be attached directly to the probe. The
impingers were attached to the Method 5 filter holder by means of a flexible
teflon tube. Figure 2 shows the sampling train.
Sample times of 1 hr 36 min were used for each test, 3 min/point. Console
readings were taken every 3 min. The Method 5 filter compartment was heated to
approximately 121°C (25CfF) for the duration of the test.
Flue gas samples were obtained at each point, integrated over the length
of the run, and analyzed using Orsat apparatus.
BAGHOUSE DUST
The baghouse screw conveyors discharged the collected particulate into
large plastic bags. After each run a sample was removed from these plastic
bags. Analysis of the baghouse samples will be conducted by EPA.
12
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In-Stack Filter
Holder
• Stack Wall
•Heated Probe
Thermoncoup le
u>
Heated
'Filter Holder
Teflon
• Line
Heated
' Compartment
Air Tight
\ / Pump
_J
Figure 2. Sampling train for Owens-Corning.
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