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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