Report No. 78-GLS-2 POLLU SSION TE O CLASS CCNEAINERS CORPORATION VERNON? CALIFORNIA. 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 ------- STACK EMISSION SAMPLING AT GLASS CONTAINERS CORPORATION, VERNON, CALIFORNIA December 5, 6, 1978 TO ENVIRONMENTAL PROTECTION AGENCY (Contract No. 68-02-2812 Work Assignment No. 3) Project No. 78-GLS-2 BY DELBERT J. POWELL JANUARY 3, 1978 TRW ENVIRONMENTAL ENGINEERING DIVISION ONE SPACE PARK REDONDO BEACH, CALIFORNIA 90278 ------- TABLE OF CONTENTS Page 1. Introduction 1 2. Summary and Discussion of Results 2 3. Process Description (by EPA) 9 4. Sampling and Analytical Procedures 11 Appendices A. Field and Laboratory Data Nomograph Data Sheets A-l Field Data Sheets A-4 Preliminary Velocity Data Sheets A-8 Traverse Point Locations . . . A-10 Opacity Data Sheets A-l2 Orsat Data Sheets A-28 Analytical Data Sheets A-32 Daily Test Log A-36 EPA Sample Numbers for Samples A-38 B. Calibration Data and Calculations Example Calculations B-2 Dry Gas Meter and Orifice Calibration Data Sheets B-9 Computer Printout of Results B-ll ------- FIGURES Number _ Page 1 Side View of Stack 11 2 Plan View of Sampling Point 12 3 EPA Method 5 Particulate Sampling Train 13 TABLES 1 Summary of Results (Engltsh Units) 3 2 Summary of Results (Metric Units) . 5 3 Summary of Visible Emissions 6 4 Summary of Visible Emissions 7 5 Scrubber Liquor pH 8 iv ------- SECTION 1 INTRODUCTION On December 5 and 6, 1977, a test crew from TRW Environmental Engineering Division performed participate emission tests at the Glass Container Corpora^ tion in Vernon, California. The emission testing was done on the flue gas from a regenerative glass furnace, producing container glass. The sampling point was on the stack, downstream from the control devices, which consisted of a packed tower followed by a venturi scrubber and demister. The purpose of the tests was to determine the average particulate emission concentration while the furnace was operating at its capacity production rate, providing EPA with data relevant to the establishment of source performance standards for glass manufacturers. Plume opacities were observed and samples were taken of scrubber liquor for pH measurement during each sampling period. Dave Powell of Pacific Environmental Services, Inc. recorded the process information during each sampling period. ------- SECTION 2 SUMMARY AND DISCUSSION OF RESULTS The particulate sampling data and results for the three test runs are summarized tn Tables 1 and 2. The total particulate emission rate ranged from 4.65 to 6.49 pounds per hour with an average value of 5.52 pounds per hour. The filterable particulate (probe, cyclone and filter catch) ranged from 2.79 to 3.80 pounds per hour with an average value of 3.27 pounds per hour. Tables 1 and 2 present the corresponding emission rates in English and metric untts, respectively. The Summary sheets for visible emissions (Tables 3 and 4) are given on pages 3-5, pH measurements (Table 5) during each test run are given on page 8 . There was a large amount of high frequency vibration at the sampling platform during the testing which affected some of the sampling equipment. One problem which occurred was the loosening of the tightening nuts of the 4" filter holders. This appears to have been caused by the combination of the vibration and heating of the filter holders. Several methods were tried to keep the nuts tight, but the most successful was to heat the filter holder up to stack temperature in an oven and tighten the nuts while hot. A second problem caused by the vibration was a malfunction of the meter box vacuum gauge. The vibration caused the internal gears of the gauge to be- come disengaged so that no vacuum readings could be taken. All leak checks were consequently done at full vacuum (~ 24 inches of mercury) to assure enough vacuum was applied to meet the test specifications. The presence of an attached steam plume made opacity reading of the stack emissions very difficult. The steam plume extended 20 - 30 feet from the top of the stack. By the time the steam plume had dissipated, the stack gas had undergone mixing and diffusion with the ambient air, and extrapolation of opacity back to the point of emission at the exit from the stack was not possible. ------- TABLE 1: SUMMARY OF RESULTS (ENGLISH UNITS) FURNACE #2 - SCRUBBER OUTLET RUN NUMBER Date Volume of Gas Sampled - DSCFa Percent Moisture by Volume Average Stack Temperature - °F Stack Volumetric Flow Rate - DSCFMb Stack Volumetric Flow Rate - ACFMC Percent Isokinetic Percent Excess Atr Feed Rate - ton/hr Pull Rate - ton/hr PARTICULATES - PROBE, CYCLONE, AND FILTER CATCH mg gr/DSCF gr/ACF Ib/hr Ib/ton feed Ib/ton pull PARTICULATES - (TOTAL CATCH) & PROBE, CYCLONE, FILTER, AND IMPINGERS mg gr/DSCF gr/ACF Ib/hr Ib/ton feed Ib/ton pull Percent Impinger catch TEST CONDITIONS 0 - Sampling Nozzle Diameter, in. T» - Net Tine of Test, Min. Pb - Barometric Pressure, In. He Absolute P^ - Average Orifice Pressure Drop, ir. H-0 Vm - Volune of Dry Gas Sampled at Meter Conditions, DCF Tm - Average Gas Meter Temperature, °F V - Volume of Dry Gas Sanpled at Standard Conditions, DSCF Std V^ - Total H20 Collected in Impingers S Silica Gel, H Vw - Volune of Water Vapor Collected at Standard Condi - - tions SCF" %H - i Moisture in Stack Gas, by Volune 1 12/05/77 56.09 24.3 150.4 14229. 21538.8 91.5 4.48 198.8 179.2 83.2 0.02284 0.01512 2.79 0.014 0.016 138.9 0.03814 0.02524 4.65 0.023 0.026 40.1 0.248 60 - 29.86 3.34 58.345 94.4 56.09 382.5 18.0 24.3 2 12/06/77 34.16 15.8 153.5 15503. 21163.3 90.5 4.48 198.8 179.2 63.4 0.02858 0.02097 3.80 0.019 0.021 108.3 0.04882 0.03583 6.49 0.033 0.036 41.5 0.185 61 29.92 1.22 34.552 • 77.1 34.16 136.2 6.41 15.8 3 12/06/77 34.53 15.5 152.0 16039. 21807.3 90.8 4.53 198.8 179.2 52.6 0.02346 0.01729 3.22 0.016 0.018 88.6 0.03951 0.02912 5.43 0.027 0.030 40.6 0.184 60 29.86 1.22 35.892 91.0 34.53 134.5 6.33 15.5 AVEMGE 41.59 18.53 152.0 15257. 21563.1 90.9 4.50 198.8 179.2 66.4 0.02496 0.0178 3.27 0.018 0.018 111.9 0.0422 0.0301 5.52 0.028 0.031 40.7 0.206 60.3 29.88 1.93 42.930 87.5 41.59 217.7 10.25 18.5 aOry standard cubic feet at 68°F, 29.92 in. Hg. Dry standard cubic feet per minute at 68°F, 29.92 in. Hg. cActual cubic feet per minute ------- TABLE 1: (CONTINUED) RUN NUMBER H,j - Mole Fraction of Dry Gas XC02 - Volume X Dry *02 - Volume % Dry ' SCO - Volume % Dry XN2 - Volume I Dry IEA - Percent Excess Air MWd - Molecular Weight of Stack Gas, Dry Basis MW - Molecular Weight of Stack Gas, Wet Basis Cp - P1tot Tube Coefficient Ts - Average Stack Temperature °F N - Net Sampling Points Pst - Static Pressure of Stack Gas, 1n. !ig . PS - Stack Gas Pressure, 1n. Ho Absolute Vs - Stack Gas Velocity at Stack Conditions, fpm As - Stack Area, 1n.2 0. - Dry Stack Gas Volumetrfc Flow Rate at Standard Condi - tlonsc, DSCFM Qa - Stack Gas Volumetric Flow Rate at Stack Conditions, ACFM XI - Percent Isoklnetic mf - Partlculate - Probe, Cyclone, and Filter, nq nt - Partlculate - total, ng Ic - % Impfnger Catch Can - Partlculate - Probe, Cyclone, and Filter, nr/SCF Can - Partlculate - Total, gr/SCF Cat - Partlculate - Probe, Cyclone, Filter, nr./ACF Cau - Partlculate - Total, cr/ACF Caw - Participate - Probe, Cyclone, and Filter, Ib/hr Clv - Partlculate - T-?tal, Ib/hr • ax Ptf - Particulate - Pr^be, Cyclone, and Filter, Ib/ton feed Pjf - Partlculate - Probe, Cyclone, and Filter Ib/ton pull Ptt - Particulate - Total, Ib/'tor. feed PttD - Partlculate - Total, Ib/ton, pull 1 0.757 3 10.9 1.5 84.6 4.48 28.92 26.26 0.84 150.4 12 0.29 30.15 4617.6 671.96 14229. 21538.8 91.5 83.2 138.9 40.1 0.02284 0.03814 0.01512 -0.02524 2.79 4.65 0.014 0.016 0.023 0;026 2 0.842 3.7 11.0 0.7 84.6 4.48 29.03 27.29 0.84 153.5 12 0.29 30.21 4537.2 671.96 15503. 21163.3 90.5 63.4 108.3 41.5 0.02858 0.04882 0.02097 0.03 583 3.8C 6.49 0.019 0.021 0.033 0.036 3 O.S45 4.3 11.4 0.6 83.7 4.53 29.14 27.42 0.84 152.0 12 0.29 30.15 4674.6 671.96 16039. 21807.3 90.8 52.6 88.6 40.6 0.02346 0.03951 0.02346 0.03951 3.22 5.43 0.016 0.018 0.027 0.030 AVEJMfiC 0.815 3.7 11.1 0.9 84.3 4.50 29.03 26.99 0.84 152.0 12 0.29 30.17 4609.8 671.96 15257. 21503.1 90.9 66.4 111.9 40.7 0.02496 0.04216 0.01985 0.03353 3.27 5.52 0.016 0.01S 0.028 0.031 *Dry standard cubic feet at 68°F, 29.92 1n. Hp. bDry standard cubic feet per minute at 68°F, 29.92 1n. Hg. cActual cubic feet per minute ------- TABLE 2: SUMMARY OF RESULTS (METRIC UNITS) FURNACE #2 - SCRUBBER OUTLET •m nan Bate Volume of Gas Sampled - Nra3'*1 Percent Moisture by Volume Average Stack Temperature - °C Stack Voluntetrtc Flow Rate - Nm3/m1nb Stack Volumetric Flo* Rate - m3/m1nc Percent Isoklnetlc Percent Excess A1r Fedd Rate - m ton/hr Pull Rate - m ton/hr PARTICULATES - PROBE. CYCLONE, AND FILTER CATCH mg mg/Hm mg/m3 kg/hr kg/M ton feed kg/H ton pull PARTICULATES - (TOTAL MTeM). PftWE, CYCLONE, FILTER. & IMPINGERS mg mg/Nm3 mg/m3 kg/hr kg/M ton feed kg/M ton pull Percent Implnger catch 1 12/05/77 1.59 24.3 65.8 402.9 609.8 91.5 4.477 180.3 162.5 83.2 52.27? 34.598 1.26 0.007 0.008 138.9 87.275 57.760 2.11 0.012 0.013 40.1 2 12/06/77 ».9T 15.8 67.5 439.0 646.1 90.5 4.526 180.3 162.5 63.4 65,396 47.993 1.72 0.009 0.011 108.3 111.710 81.981 2.94 0.016 0.018 41.5 3 12/06/77 0.98 15.5 66.7 454.2 617.5 90.8 4.477 180.3 162.5 52.6 53,680 39.556 1.46 0.008 0.009 88.6 90.420 66.629 2.46 0.014 0.015 40.6 jnSMK 1.18 18.53 66.7 , 432.0 624.5 90.9 4.49 180.3 162.5 66.4 57,kk8 40.716 1.48 0.008 0.009 111.9 96.468 68.790 2.50 0.014 0.015 40.7 aOry normal cubic meters at 20°C, 760mm Hg. Dry normal cubic meters per minute at 20°C, 760mm Hg. cActual cubic meters per minute ------- TABLE 3. SUMMARY OF VISIBLE EMISSIONS Date: 12/6/77 Glass Containers Corporation Vernon, California Type of Plant: Glass Factory Type of Discharge: Stack Location of Discharge: Furnace #2 Stack Height of Point of Discharge: 55' Description of Sky: Clear Wind Direction: _ Color of Plume: __ Observer No.: South White Wind Velocity: Detached Plume: 10 mph No 1 Duration of Observation: Distance from Observer to Discharge Point: 110' Direction of Observer from Discharge Point: Height of Observation Point: Description of Background,: SE Ground Level Superstructure 2.5 hours SUMMARY OF AVERAGE OPACITY SET # 1 2 3 4 5 6 7 8 TIME START 13:10 13:15 13:20 13:25 13:30 13:45 13:50 13:55 END 13:15 13:20 13:25 13:30 13:35 13:50 13:55 14:00 OPACITY SUM 0 i 0 0 0 0 0 0 0 AVERAGE 0 0 0- 0 0 0 0 0 ------- TABLE 4. SUMMARY OF VISIBLE EMISSIONS Glass Containers Corporation Vernon, California Date: 12/5/77 Type of Discharge: Stack Height of Point of Discharge: Wind Direction: _ South Color of Plume: Observer No.: 55' White Type of Plant: Glass Factory Location of Discharge: Furnace #2 Stack Description of Sky: Hazy Wind Velocity: 5 mph Detached Plume: No 1 Duration of Observation: Distance from Observer to Discharge Point: 110' Direction of Observer from Discharge Point: Height of Observation Point: Description of Background: 2 hrs, 50 min. SE Ground Level Superstructure SUMMARY OF AVERAGE OPACITY SET # 1 2 3 4 5 6 7 3 9 10 TIME START 11:40 11:50 12:00 12:15 12:30 13:00 13:15 13:25 13:35 13:40 END 11:45 11:55 12:05 12:20 12:35 13:05 13:20 13:30 13:40 13:45 OPACITY SUM 0 0 0 0 0 0 0 0 0 0 AVERAGE 0 0 0 0 0 0 0 0 0 0 ------- TABLE 5. SCRUBBER LIQUOR pH TEST 1 2 3 PH 8.3 3.3 3.2 ------- SECTION 3 PROCESS DESCRIPTION AND OPERATION (To be supplied by EPA.) ------- LOCATION OF SAMPLING POINTS The particulate samples were drawn from the glass oven stack downstream from the control devices and induced draft fan. The sampling location was 34 feet downstream from the induced draft fan. Since the stack diameter is 29.25 inches, the location was 14 duct diameters from the nearest upstream distur- bance (the I.D. fan) and 8 duct diameters from the nearest downstream flow disturbance (the top of the stack). This relatively large distance from flow distrubances allowed the use of the minimum of twelve traverse points during the tests. Figures 1 and 2 are diagrams of the sampling location and cross section of the stack at the sampling point. SAMPLING AND ANALYTICAL PROCEDURE The procedures described in EPA Methods 1, 2, 3, and 5, Vol. 42, No. 160, Aug. 18, 1977, were followed in performing the sampling and analysis. A Research Appliance Corporation Method 5 sampling train was used for the par- ticulate sampling. Figure 3 is a diagram of the sampling train. Stack gas, filter holder, and sample box temperatures were monitored with a potentiometer and thermocouple. Before each test a velocity traverse of the stack was done to determine the average stack temperature and velocity pressure. The velocity traverse was done according to EPA Methods 1 and 2. An integrated bag sample of the stack gas was taken before each test as well. This sample was immediately analyzed for Op, COp, and CO with an orsat analyzer. The particulate samples were taken at 12 traverse points at the centers of equal areas within the stack (6 traverse points on each of 2 traverses at an angle of,90° to one another). Sampling was done for 5 minutes at each traverse point. The sampling rate was adjusted to isokinetic conditions using a nomograph which had been set based on the preliminary velocity data. Leak checks of the sampling system were done at the beginning of each test, at each sampling port change, and at the end of the test. The filter holder was kept at 250°F. At the end of the test the sampling train was inspected for cracked or broken glassware, and to assure that the filter was intact. 10 ------- 2*^5" -J 20' 34' FIGURE 1. SIDE VIEW OF STACK 11 ------- 1 4" O.D. Sampling Ports •29.25- Dlstance of Sampling Point From Wall Point Distance, inches % of Diam. 1 7 1.3 4.4 2 8 4.3 14.6 3 9 8.7 29.6 4 10 20.6 70.4 5 11 25.0 85.4 6 12 28.0 95.6 FIGURE 2. PLAN VIEW OF SAMPLING POINT 12 ------- FIGURE 3 EPA METHOD 5 PARTICULATE SAMPLING TRAIN 13 ------- LEGEND EPA METHOD 5 SAMPLING TRAIN 1. Sampling Nozzle 2. Sampling probe sheath 3. Heated sample probe liner 4. Cyclone assembly 5. Out of stack filter assembly 6. Heated filter compartment maintained at 248 ± 25°F. 7. Impinger case 8. First impinger filled with H20 (100 ml) 9. Greenburg-Smith (or modified Greenburg-Smith) impinger filled with H20 (100 ml) 10. Third impinger - Dry 11. Fourth impinger - filled with H20 absorption media (200-300 gm) 12. Impinger exit gas thermometer 13. Check valve to prevent back pressure 14. Umbilical cord - vacuum line 15. Pressure gauge 16. Coarse adjustment valve 17. Leak free pump 18. By-pass valve 19. Dry gas meter with inlet and outlet dry gas meter thermometer 20. Orifice meter with manometer 21. "S" type pit»t tube with manometer 22. Stack temperature sensor 23. Thermocouple 14 ------- After completing the particulate test the sampling probe was removed from the sampling train, the nozzle wiped off and capped and the ball joint wiped off and capped. The filter holder ball socket was wiped free of sili- cone grease and was capped, and the filter oven and impinger box were discon- nected from the umbilical and removed to the laboratory for sample recovery. The collected sample was recovered and placed in four containers. The particulate filter was placed in the first container. The particulate matter from the nozzle, probe fitting, probe liner, and front half of the filter holder were recovered quantitatively to the second container. The silica gel from ,the fourth impinger was weighed and placed in the third container. The contents of the first two impingers were measured and placed in the fourth container. The front half acetone rinse, back half acetone rinse, and back half water were placed in tared glass beakers and evaporated. The impinger solu- tions were extracted with ether and chloroform, and the organic and inorganic fractions placed in tared beakers and evaporated. The filter and tared beak- ers were then placed in a dessicator until they reached a constant weight and weighed to a tenth of a milligram. 15 ------- |