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
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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
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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
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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
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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.
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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.
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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
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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
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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
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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
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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
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TABLE 5. SCRUBBER LIQUOR pH
TEST
1
2
3
PH
8.3
3.3
3.2
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SECTION 3
PROCESS DESCRIPTION AND OPERATION
(To be supplied by EPA.)
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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
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2*^5" -J
20'
34'
FIGURE 1. SIDE VIEW OF STACK
11
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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
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FIGURE 3 EPA METHOD 5 PARTICULATE SAMPLING TRAIN
13
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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
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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
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