United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EMB Report 78-ISC-2
April 1979
Air
Industrial Surface
Coating:
Cord Coating
Emission Test Report
The Gates Rubber
Company
Denver, Colorado
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VOLATILE ORGANIC CARBON EMISSION TESTING
AT
GATES RUBBER COMPANY.
DENVER, COLORADO
JULY, 1979
,TO
Environmental Protection Agency
Research Triangle Park, NC 27711
ENVIRONMENTAL ENGINEERING DIVISION
One Space Park
Redondo Beach, California 90278
by
.Tom Hurst
Robert F. Jongleux
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TABLE OF CONTENTS
Page
I. Introduction and Summary 1
II. Process Description 3
III. Discussion of Results 4
IV. Sampling Procedure 8
V. Appendix 17
© Test Data Sheets
® Velocity Traverse Data Sheets
6) Gas Flow Calculations
f> Truesdail Laboratory Report
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LIST OF TABLES AND FIGURES
TABLES PAGE
TABLE 1 - SUMMARY OF TEST RESULTS 2
TABLE 2 - ANALYTICAL RESULTS . . . 7
TABLE 3 - SUMMARY OF VOLUMETRIC FLOWRATE 16
FIGURES
FIGURE 1 - TOTAL GASEOUS NON-METHANE ORGANIC SAMPLING TRAIN . 9
FIGURE 2 -.CORD COATER OVEN INCINERATOR SCHEMATIC '. 11
FIGURE 3 - BANBURY FUME EXHAUST HOOD SCHEMATIC 12
FIGURE 4 - BAGHOLISE OUTLET 13
FIGURE 5 - BANBURY MILL EXHAUST 14
FIGURE 6 - SHEET MILL SCHEMATIC 15
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INTRODUCTION
From 12 June to 20 June, 1978 a two person test crew from the
Environmental Engineering Division at TRW, Inc. performed volatile organic
carbon (VOC) emission tests at Gates Rubber Company in Denver, Colorado.
The total gaseous non-methane organic (TGNMO) sampling method was utilized at
the following six locations:
1. Cord Coater Incinerator inlet
2. Cord Coater Incinerator outlet
3. Banbury exhaust hood
4. Baghouse Outlet of the banbury exhaust system
5. Banbury Mill exhaust hood
6. Sheet Mill.
The purpose of the tests was to obtain for the Environmental Protection
Agency volatile organic carbon emissions data from these processes in the rubber
industry.
Table 1 summarizes the results of the volatile organic carbon tests.
Results are reported as total gaseous non-methane organics as carbon. The
average total gaseous non-methane organic concentration from the incinerator
inlet was 1637 parts per million (ppm) while the incinerator outlet was 1311
parts per million (ppm). The results obtained at the incinerator are inconsistent
with the results that would be expected. No explanation for the erratic results
is available. Due to the nature of the results, a retest of this incinerator should
be conducted. The banbury fume exhaust hood had an average concentration of 194
ppm reported as TGNMO. Test results for the banbury mill fume exhaust hood
averaged 239 ppm. The baghouse outlet emitted an average concentration of 946
ppm. The sheet mill average concentration of VOC reported as TGNMO was 631 ppm.
(1)
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DATE
6-13
6-13
6-15
— .
;3
6-15
6-16
6-19
TEST LOCATION
Incinerator Inlet
Incinerator Outlet
Banbury
Banbury Baghouse Outlet
Banbury Mill
Sheet Mill
SAMPLING TIME
(MINUTES)
60
60
60
60
60
60
60
60
60
60
60
40
60
70
50
40
50
75.5
79.75
60
70
70
TOTAL GASEOUS NON-METHANE ORGAN I CS
(PP. Cl}
136
3390
2220
801
1580
1490
2100
75
158
224
190
205
1130
148
2180
326
154
269
295
145
148
1600
f
AVERAGE
(ppm C-|)
1637
1311
194
946
239
631
VOLUMETRIC FLOW RATE
DSCF/hr
_
-
99.4
218.9
195.1
87.7
DSCM/hr
2.82
6.20
5.52
2.48
TABLE 1. SUMMARY OF TEST RESULTS
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II. PROCESS DESCRIPTION
(to be prepared as an addendum to this report by the Chemical and Petroleum
Branch, Environmental Protection Agency (EPA) }.
(3)
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III. DISCUSSION OF RESULTS
Table 2 is a tabulation of the analytical results obtained for all test
runs. In all cases, the methane and volatile non-methane organics (non-methane
organics not captured in the trap but carried over to the evacuated tank)
concentrations were less than the sensitivity of the analytical method (10 and
20 ppm for methane and non-methane organics, respectively). Consequently, the
organics captured in the condensate trap fraction of the sampling train consti-
tute the total gaseous non-methane organic emissions.
Sampling at the incinerator inlet and outlet were conducted simultaneously.
Nonetheless, the results obtained are so erratic that it is not useful to calculate
an incinerator efficiency either on a per run or on an average basis. No expla-
nation for the erratic results is available. During the day of testing, some
problems were encountered with the cord oven operation (shut-off due to electrical
problems). However, this would not seem to have any effect on the test results
since'the process was operating normally during the actual testing.
Continuous samples were taken at all test locations except for the
banbury mill(in some cases at other locations the sampling trains were stopped
and restarted during process breaks—see test logs in appendix). Sampling of
the banbury mill was conducted only when material was being processed which was
approximately a three to five minute period every ten minutes. Material was
not continuously being worked on the mill because the banbury takes longer than
the mill to completely process a batch. During the first test run a three (3)
minute sampling period was conducted for each process batch. The sampling began
when the banbury skip entered the mill hood. At the end of the three minute
period, the train was shut off and the probe tip was moved to a new traverse
point in the duct; sampling resumed with the processing of the next batch.
However, during this run it became apparent that the period of time during
(4)
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which material was on the mill varied considerably. Therefore, for the next
two runs the sampling trains were not abitrarily stopped at the end of a
three minute period but instead were left operating until the mill was completely
clear of material. During each of the three test runs, twenty batches"were
sampled.
The banbury exhaust system and the banbury exhaust baghouse outlet stack
were sampled simultaneously. In general, the results obtained at the baghouse
outlet were higher than the results obtained at the banbury; this requires some
explanation. The purpose of the baghouse is to control fugitive carbon black
and other dry chemical compound emissions generated at the banbury j
(refer to Figure 5). The testing at the banbury was being conducted in order
to determine VOC emissions, and not particulate emissions, from the banbury. It
was believed that all the banbury VOC emissions would be coming from the banbury
door area and not from the carbon black feeder; therefore, a test location
upstream of the point where the carbon black exhaust stream feeds into the
system was chosen (see Figure 5). Hence, two possible explanations for the
higher concentrations at the baghouse outlet are:
1. VOC emissions were emitted from the carbon black feeder and
these emissions were entering the exhaust system downstream of the
test location.
2. Carbon black in the baghouse outlet stream passed the filter
of the sampling train and caused a positive interference during analysis.
Upon further investigation.subsequent to the testing, plant personnel
confirmed1 that emissions from a defective banbury bearing seal were being fed
into the exhaust system downstream of the banbury sampling location.
Personal conversation between Roy Neulicht (EPA) and Ernest Karger
(Gates Rubber), January 19, 1979
(5)
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Two other points about testing at these locations are worthy of
notation. First, the last test run was stopped prematurely because the process
operator began feeding scrap material to the banbury. Second, during the third
test at the banbury baghouse outlet a loose fitting (connecting the probe to
the filter inlet) was found. What effect, if any, this had on the test results
is not discernable.
During the three sheet mill tests, no process or sampling problems were
encountered. The value reported for condensable hydrocarbon for one test is
exceedingly high relative to the other two. No reason is evident for this
high value.
(6)
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Date
6-13
6-13
6-15
6-15
6-16
6-19
Test
Location
01 -A
Incinerator
Inlet
01 -B
Incinerator
Outlet
02
Banbury
03
Banbury
Baghouse
Outlet
04
Banbury
Mill
05
Sheet Mill
Sample
Sequence
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
1
2
3
Concentrations- (ppm as C"])
Volatile Condensable
arbon Monoxide Methane Carbon Dioxide ORGANIC ORGANIC
<10
103
65
5
11
19
19
19
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IV. SAMPLING PROCEDURES
A schematic of the sampling apparatus is provided in Figure 1. The
sampling and analytical procedures used during these tests are essentially
the same as the Total Combustion Analysis procedures established by The
Southern California Air Pollution Control District. One difference in
technique is that a heated filter was used in the sampling train during
these tests. The sample was drawn from the duct by an one-eighth outside
diameter (OD) stainless steel probe through a heated (250°F) glass fiber
filter and through a chilled stainless steel condensate trap into a six (6)
liter evacuated alumninum gas collection tank. A capillary orifice was
installed between the condensate trap and the evacuated tank to provide a
constant sample rate (80 cc/min, nominal). The condensate trap was partially
submerged in crushed dry ice during the test and was kept packed in dry ice
until analysis.
The analytical work was performed by Truesdail Laboratories, Inc. The
laboratory report is included in the appendix. Total gaseous non-methane
organics (TGNMO) were determined by combining the analytical results obtained
from independent analyses of the condensate trap and the evacuated tank sample
fractions. The organic contents of the condensate trap were oxidized to carbon
dioxide (C02) which was quantitatively collected and then measured by a non-
dispersive infrared (NDIR) analyzer. A fraction of the sample collected in
the evacuated tank was injected into a gas chromatograph in order to achieve
separation of the non-methane organics from carbon monoxide, carbon dioxide,
and methane. Once separated, the four fractions were oxidized to carbon dioxide
and separately measured with the NDIR. The volume of sample collected was
1"Total Combustion Analysis: A Test Method for Measuring Organic
Carbon; "Salo, Albert E., Oaks, William L., MacPhee, Robert D., Air Pollution
Control District - County of Los Angeles; August, 1974.
(8)
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POTENTIOMETER
THERMOCOUPLE
CAPILLARY ORIFICE
FILTER HOLDER .
\
/
PROBE '
X.
HM
M
^
'
'
COND
r
ENSA
TETRAP
I
— -H
V
1
SHUTOF
^A
HEATED BOX
( , I
CRUSHED DRY ICE
VACUUM-PRESSUR,
•GAUGE
6-LITER GAS
COLLECTION
TANK
Figure 1
• ^^l;-:^.:l:i. •^•1 TOTAL GASEOUS NON-METHANE ORGANIC (TGNMO) SAMPLING TRAINv:
-------
calculated from vacuum and pressure readings of the evacuated sample tank
before and after sampling. The measured C02 concentrations and the sample
volume collected were used to calculate the total gaseous non-methane organic
concentration in the source as parts per million carbon.
Four samples were consecutively taken at each location except for the
sheet mill and banbury mill where only three samples were taken. Incinerator
inlet and outlet samples were taken from single sampling points; however, each
of the process ducts were subdivided into sections and traversed within the duct
during sampling. Figures 2 through 6 are schematics of the sampling locations
and the traverse points. Velocity measurements were taken before and after
each test series at each location (except at the cord coater incinerator)
according to standard procedures. Gas flow data were calculated based on these
velocity measurements. Due to the large amount of ambient air being drawn into
the process exhaust system, ambient conditions (moisture, temperature, and
composition) were assumed and a molecular weight of 28.80 was used in the
flowrate calculations. At the incinerator only efficiency data were of
interest and no volumetric flow rate measurements were taken. Table 3 summarizes
the volumetric flow rate data (gas velocity calculation sheets are included in
the appendix).
(10)
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NOTE:
e No Velocity Measurements
Were Taken at This
Location.
CATALYST BED
INLET -' ' OUTLET
3/4" SAMPLING PORTS
SIDE VIEW
FIGURE 2. CORD COATER OVEN INCINERATOR SCHEMATIC
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SAMPLE PORTS
\ •
BANBURY
CARBON
BLACK
FEED
SIDE VIEW
HOOD
\
CARBON
BLACK —
FEED
SAMPLE PORT
\
NOTE:
// TOP VIEW
Sampled 12 points vertical and
horizontal for the TGNMO Test.
, Twenty four points vertical and
'.horizontal for post Velocity Test,
FIGURE 3. BANBURY FUME EXHAUST HOOD SCHEMATIC
-------
OUTLET BAGHOUSE
*
WL
\
FAN
ROOF
SIDE .VIEW
co
OUTLET
1
__.....
L_
INLET
\
>y
A
INLET
i
o
28'
<3-
2i".
^
8 j 16 j 24 1 32 !
40
39
6 | 14 I 22 30
5 JT3 I 21 [29
I i ^_\m
\ 38
}~37
3 j 11 1 19 27 | 35
" ~" ~
9 1 17 1 35
'l
t ' I t t
TRAVERSE POINTS
Ports
TOP VIEW
NOTE: Points 1-8, 17-24 and 33-40
were used for initial velocity
test and all volatile hydrocarbon
tests. Points 1-40 were used for
the post-test velocity measuring.
Sampled Gas 40" after fan
FIGURE 4. BAGHOUSE OUTLET
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MILL HOOD
(
— _ ,.
ILL
OOR -"
" J HUR1/UNIAL
1 DUCT.,. ^-^ pni?T# PORT* PORT*
v^ *•• •» -i o c
—£> *F 1 0 0
Si-y/' ^
V.
t
\
I
{
1
/
f /
/
/
u
t
Ports
SIDE VIEW :
i
-JoJi-1 15
4 1 9 114
I
3 | 8 | 13 I 3C
2 | 7 i 12
«. j
1 1 6 | 11
i i
r
>"
y
^*#i « .. V>^
^^ • °° ^
8 1 16 1 24 1 32 1 40
riljnB_UU_JMMnM0M_JMM.,»f«*..*MM_i'HM M
7 1 15TZ3T31jL_30_
6= _[ J4 ' ZZJ_3_0_ 1 38_
5 ^LJ^.121 j~29 "^"37
11 1 19 I 27 | 35
2 "£l
-------
SIDE
TOP VIEW
DUCT
Sample
ports
MILL
MILL
Sample
ports.
00
28"
t
3 11 J19
118
j
17
TRAVERSE POINTS
FIGURES. SHEET MILL SCHEMATIC
-------
Date
6-14-78
6-15-78
6=16-78
6-16-78
6-14-78
6-15-78
6-19-78
6-19-78
Location
Banbury
Banbury
Banbury Mill
Banbury Mill
Baghouse Outlet
Baghouse Outlet
Sheet Mill
Sheet Mill
Gas Flow Rate
M/Sec. Ft/Sec. M /Win. CFM :DSCM/HR DSCF/HR
12.22
12.92
11.27
11.03
18.77
19.29
8.33
7.25
40.1
42.4
37.0
36.2
61.6
63.3
27.0
23.8
188.02
198.73
392.65
384.35
427.58
439.01
178.47
157.31
6638.9
7017.2
13864.6
13571.4
15097.8
15501.4
6301.8
5554.9
2. J5
2.88
. 5. -47
5.-571-
5.61
. 6. .28.
2.6.6
2.31
••97.1
101.7
193.3'.
.196.8:
215.9.
221.9. .
93._8//
81.7
AVERAGE
DSCM/HR D'SCF/HR
2.82
5.52
•6. -20
2.48
99.4
195.1
218.9
87.7
Note: Molecular weight assumed at 28.80, traverses conducted before and after volatile emission test.
TABLE 3._SJJMMARY OF VOLUMETRIC FLOWRATE
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