United States
            Environmental Protection
            Agency
            Office of Air Quality
            Planning and Standards
            Research Triangle Park NC 27711
EMB Report 78-NHF-2a
March 1979
            Air
v>EPA
Ammonium Sulfate

Emission  Test Report
• if^f^ i/"• £it*iTU I •  1*^^i*in i^"*^ I
V-JOLrHJ'    LCI  V^I      IOO
Company
Houston,  Texas

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                      SOURCE EMISSIONS TEST REPORT

                       OCCIDENTAL CHEMICAL COMPANY
                             Houston, Texas
            AMMONIUM  SULFATE  DRYER  BAGHOUSE  EXHAUST  STACK
\P
                                                             .  \je»
                                              Barry L. Jackson
                                              Supervi sor
                                              Air Testing
RFW W.O. #0300-81-0*t
Contract No. 68-02-2816
Work Assignment No. 3
                                              Peter J. >1arks~
                                              Department Manager
                                              Laboratory Services

                                              for:  ROY F. WESTON
                              Prepared by:

                             ROY F. WESTON
                   ENVIRONMENTAL CONSULTANTS-DESIGNERS
                               Weston Way
                    West Chester, Pennsylvania 19380
                             (215) 692-3030

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                                                     TABLE OF CONTENTS
                                                                  PAGE
LIST OF TABLES AND FIGURES                                          j

SUMMARY                                                             1

INTRODUCTION                                                        2

DESCRIPTION OF PROCESS                                              *»

DESCRIPTION OF TEST LOCATION                                        6

   Ammonium Sulfate Dryer Baghouse Exhaust Stack                    &

DESCRIPTION OF SAMPLING TRAIN                                       8

   Particulate Sampling Train                                       °

TEST PROCEDURES                                                    10

   Preliminary Tests                                               10
   Ammonium Sulfate Dryer Baghouse Exhaust Stack                   10

ANALYTICAL PROCEDURES                                              12

   Particulate Sample Recovery                                     12
   Particulate Analyses                                            13

DISCUSSION OF TEST RESULTS                                         1^

APPENDIX A - Raw Test Data

APPENDIX B - Laboratory Reports

APPENDIX C - Sample Calculations

APPENDIX D - Equipment Calibration Data

APPENDIX E - Detailed Baghouse Information

APPENDIX F - Project Participants

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                                            LIST OF TABLES  AND FIGURES
TABLE
NO.
               TITLE

Ammonium Sulfate Dryer Exhaust Stack
Summary of Test Data

Ammonium Sulfate Dryer Exhaust Stack
Summary of Test Results
PAGE
NO.

 15
                                                                  16
FIGURE
NO.

  1

  2
               TITLE

Ammonium Sulfate Dryer and Baghouse

Ammonium Sulfate Dryer Baghouse Exhaust Stack
Port and Sampling Point Locations

Particulate Sampling Train
EPA Method 5
Baghouse Exhaust Stack
PAGE
NO.

  5

  7

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                                                                SUMMARY

The Emission Measurement Branch of the U.S.  Environmental  Protection
Agency contracted Roy F. Weston, Inc. to conduct a source testing and
analysis program at Occidental Chemical  Company's Houston, Texas
Ammonium Sulfate Plant.

The primary objective of the testing program was to quantify the par-
ticulate emissions to the atmosphere from the Ammonium Sulfate Dryer
Baghouse Stack.   This objective was achieved by performing a series of
three particulate tests  utilizing EPA Method 5    procedures at the
baghouse exhaust stack location.  In addition, visual  determinations of
plume opacities  were made simultaneously with each particulate test at
                                                    (2)
the source discharge point according to  EPA  Method 9    protocol.
The particulate matter emission results are summarized below:

                    Ammonium Sulfate Dryer Baghouse

Test               Test            Particulate          Concentration
No.              Location          Grai ns/DSCF           Pounds/Hour
  1              Exhaust Stack        0.016                  0. 16
  2              Exhaust Stack        0.023                  0.23
  3              Exhaust Stack        0.026                  0.25

No visible emissions were observed emanating from the baghouse exhaust
stack during the test program by the certified observer.

Detailed summaries of test data and test results are presented in Tables
1 and 2 of this report,  respectively.
        of Federal Regulations, Title kQ , Part 60, Appendix A, "Standards
   of Performance for New Stationary Sources," August 18, 1977-
   Federal Register, Vol. 39, No. 219, November 12, 197^-

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                                                         INTRODUCTION
The Emission Measurement Branch of the U.S. Environmental Protection
Agency contracted Roy F. Weston, Inc. to conduct a source testing and
analysis program at Occidental Chemical'Company1s Houston, Texas
Ammonium Sulfate Plant.  The objective of the testing program was to
measure various emission parameters from Oxychem's Ammonium Sulfate
Dryer Baghouse.

The location tested, plus the number and types of tests performed at
the site are listed below:

     1.  Ammonium Sulfate Dryer Baghouse Exhaust Stack.
         a.  Three one-hour particulate tests by EPA Method 5-
         b.  Three opacity tests by EPA Method 9.   Visual
             determinations of plume opacities were determined
             simultaneously with the particulate tests.

These tests were conducted on 26 October 1978 by Weston personnel.  Tests
performed previously at the exhaust stack indicated emissions greater than
might be expected from a bag collector used in this application and were
attributed to leaking bag(s).

The baghouse inlet duct location was not tested during this period since most
of the internal area of the duct was filled with an irregular buildup of product
solids (which prevented representative sampling) as shown below:
                               Port Y
        Port X
Blockage
                           Baghouse Inlet
                      Duct Cross-Sectional  View
                                - 2 -

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A decision was made not to test the inlet duct since the entire unit would
have been required  to shut down  to enable the duct to be cleaned.

Test data and test results of the outlet testing program are presented in
Tables 1  and 2 of this report, respectively.   Also, incorporated herein is
a description of the test location, test equipment, test procedures, sample
recovery, and analytical  methods used during  the test program.   Raw test
data, laboratory reports, sample calculations, equipment calibration data,
baghouse details, and a list of project participants are provided in
Appendices A through F, respectively.
                                  -  3  -

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                                               DESCRIPTION OF PROCESS

Ammonium Sulfate Dryer

Anhydrous ammonia and sulfuric acid are combined to yield granular ammonium
sulfate at a rate of 1^ to 18 tons/hour.  The heat of reaction causes
the desired moisture loss in the dryer to produce the final  product.  The
final product drops from the dryer and is then conveyed to storage.  The
moist hot air from the dryer, which contains ammonium sulfate fines, is
drawn through a baghouse to effect additional product recovery while re-
ducing particulate emissions.

A schematic diagram of the Ammonium Sulfate Dryer and Baghouse is presented
in Figure 1.

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      OCCIDENTAL CHEMICAL COMPANY
          Houston, Texas

             FIGURE 1

AMMONIUM SULFATE DRYER AND BAGHOUSE
                               Gas Flow to Atmosphere
                                          1
                                       ^    z
                       Exhaust Stack—rj
                       Test Site
                                              i
           Inlet Duct
           Test Site
  Ammonium
   Sul.fate
    Dryer
t
                                                         Baghouse
                                                    I.D.  Fan
                                                       Product
               - 5 -

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                                            DESCRIPTION OF TEST LOCATION

Ammonium Sulfate Dryer Baghouse Exhause Stack

Two 3" I.D.  test ports were placed on one side of the 7-1/2" x 8-5/8"
rectangular exhaust stack serving the baghouse.   The ports were located
15 diameters downstream and 10 diameters upstream from the nearest flow
disturbances.   Since the eight and two diameter  criterion were met,  a
minimum of eight traverse points were required by EPA Method 1 regulations,
Figure 2 illustrates duct geometry plus port and sampling point locations.
                                  -  6 -

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                OCCIDENTAL CHEMICAL COMPANY

                      Houston, Texas


                         FIGURE 2


       AMMONIUM SULFATE DRYER BAGHOUSE  EXHAUST  STACK
       — 8-5/8"  I.D.-
                           7-1/2" I.D.
                             _L
                              »
                           3-1/8"
                    3"
Duct Cross-Sectional View
Traverse
Point
Number
1
2
3
4
Distance From
Inside Near
Wall , 1 nches
1
2-3/4
4-5/8
6-1/2
             11 '
'00   -f
                                                                       7.5'
                           -  7 -
                                                               FAN
                                                   METAL  STACK

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                                         DESCRIPTION OF SAMPLING TRAIN

Particulate Sampling Train

The test train utilized for particulate sampling at the baghouse exhaust
duct location was the standard EPA Method Five Train (see Figure 3)•

A stainless steel nozzle was attached to a heated (r\j250°F) 3' borosilicate
glass  probe which was connected directly to a borosilicate filter holder
containing a V Reeve Angel 900 AF glass fiber filter.   The filter holder
was maintained at approximately 250 F in a heated chamber, and was connected
by a section of borosilicate tubing to the first of four Greenburg-Smith
impingers which were included in the train to condense the moisture in the
gas stream.  Each of the first two impingers contained 100 ml of distilled
water,  the third was dry and the final impinger contained 200 grams of dry
pre-weighed silica gel.  The first, third, and fourth impingers were modi-
fied Greenburg-Smith type; the second was a standard Greenburg-Smith  impinger.
All impingers were maintained in a crushed ice bath.  A RAC control console
with vacuum pump, dry gas meter, a calibrated orifice, and inclined manometers
completed the sampling train.

Flue gas temperature was measured by means of a Type K thermocouple which
was connected to a direct readout pyrometer.  The thermocouple sensor was
positioned adjacent to the sampling nozzle.

Gas velocity was measured using a calibrated "S" type pitot tube provided with
extensions and fastened alongside the sampling probe.  Gas stream composition
(carbon dioxide, oxygen, and carbon monoxide content) was determined utilizing
Orsat apparatus to analyze stack gas samples.  Gas stream composition proved
to be ambient air since no combustion products were found in any of the stack
gas effluent samples.
                                  - 8 -

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        JEMPERATURE
          SENSOR
                                                              THERMOMETER
                                                               CHECK VALVE

                                                                VACUUM  LINE

                                                                  VACUUM GUAGE
                                                                                THERMOMETERS
REVERSE TYPE
 PITOTTUBE
                                                                                        ORIFICE
                                                                                        AND
                                                                                        MANOMETER
           PITOT MANOMETER
                                                         ICE BATH

                                               DISTILLED WATER
               FIGURE $ PARTICULATE SAMPLING TRAIN-ERA METHOD 5
                                    BAGHOUSE  EXHAUST STACK

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                                                       TEST PROCEDURES
Preliminary Tests

Preliminary test data was obtained at the sampling location.   Stack geometry
measurements were recorded and sampling point distances calculated.  A pre-
liminary velocity traverse was performed utilizing a calibrated "S" type pitot
tube and a Dwyer inclined manometer to determine velocity profiles.  Stack
gas temperatures were observed with a direct read-out pyrometer equipped with
a chromel-alumel thermocouple.  Gas stream composition and moisture content
values were estimated from previous stack testing reports.

Preliminary test data was used for nozzle sizing and nomagraph set-up for
isokinetic sampling procedures.

Calibration of the probe nozzles,  pitot tubes,  metering systems,  probe heaters,
temperature gauges and barometer were performed as specified  in Section 5 of
EPA Method 5 test procedures (see Appendix E for calibration  data).

Ammonium Sulfate Dryer Baghouse Exhaust Stack
A series of three EPA Method 5 tests were performed at the Ammonium Sulfate
Dryer Baghouse exhaust stack.  Twelve points were traversed, six per port axis
for five minutes each yielding a test period 60 minutes in length.

During particulate sampling, gas stream velocities  were measured by inserting
a calibrated "S" type pitot tube into the stream adjacent to the sampling
nozzle.   The velocity pressure differential  was observed immediately after
positioning the nozzle at each point, and sampling  rates were adjusted to
maintain isokinetic sampling.  Stack gas temperatures  were also monitored at
each point with the pyrometer and thermocouple.  Additional  temperature
measurements were made at the final  impinger and at the inlet and outlet of
the dry gas meter.
                                 - 10 -

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Test data was recorded every five minutes during all  test periods.   Table
I  presents a summary of test data for each of the three runs.   Test result
summarization appears on Table 2.

Visible emissions observations were recorded concurrently with each par-
ticulate test repetition by a certified observer according to EPA Method 9
procedures.   See Table 2 for result summary.
                                 - 11  -

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                                                  ANALYTICAL PROCEDURES

Particulate Sample Recovery

At the conclusion of each test, the sampling train was dismantled, openings
sealed, and the components transported to the field laboratory.  Sample
integrity was assured by maintaining chain of custody records which will
be supplied upon request.

A consistent procedure was employed for sample recovery:

     9  The glass fiber filter(s)  was removed from its holder with
        tweezers and placed in its original container (petri dish),
        along with any loose particulate and filter fragments  (Sample
        1).

     •  The probe, and nozzle were separated and the internal par-
        ticulate rinsed with distilled water into a borosi1icate-
        container while brusting a minimum of three times until no •
        visible particles remained.  Particulate adhering to the
        brush was rinsed with distilled water into the same container.
        The front half of the filter holder was rinsed with distilled
        water while brushing a minimum of three times.  The rinses
        were combined (Sample 2) and the container sealed with a
        Teflon lined closure.

     •  The total liquid  in impingers one, two and three was measured,
        the value recorded, and the liquid discarded.

     •  The silica gel was removed from the last impinger and  immediately
        wei ghed.

     •  A  distilled water sample was retained for blank analysis.
                                 -  12  -

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Particulate Analyses

The filters (Sample 1) and any loose fragments were desiccated for 2A hours
and weighed to the nearest 0.1 milligram to a constant weight.

The distilled water wash samples (Sample 2) were evaporated at 105 C and
ambient pressure in tared beakers,  and desiccated to constant weight.  All
sample residue weights were adjusted by the water blank value.

The weight of the material collected on the glass fiber filter(s) plus the
weight of the residue of the nozzle/probe/front-half filter holder washes
represents the "total" EPA Method 5 catch.   Complete laboratory results are
presented in Appendix B of this report.
                                  - 13 -

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                                             DISCUSSION OF TEST RESULTS

Particulate test data and test result summaries are presented in Tables 1
and 2 of this report.

No unusual  process operating conditions were encountered during any of the
test periods.

The amount  of particulate matter discharged to the atmosphere from the
baghouse was low (£ 0.026 grains/dscf and * 0.25 pounds/hour).   The certi-
fied observer further corroborated the particulate test findings since no
visible emissions were recorded emanating from the stack during the test
program.

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                                    OCCIDENTAL CHEMICAL COMPANY

                                          Houston, Texas

                                             TABLE I

                          AMMONIUM 5ULFATE DRYER BAGHOUSE EXHAUST STACK


                                       Summary of Test Data



Test Data

   Test Number                                                       1                 2                 3
   Test Date                                                      10-26-78         10-26-78           10-26-78
   Test Period                                                   0850  -  0953       1044 -  1146       1222 - 1325

Samp I ing Data

   Sampling Duration, minutes                                       60.0             60.0              60.0
   Nozzle Diameter, inches                                            0.250            0.250             0.250
   Barometric Pressure, inches mercury                              29.91             29-91              29.91
   Average Orifice Pressure Differential,  inches water                2.54             2.77               2.74
   Average Dry Gas Temperature at Meter,  °F                         96.               99.                98.
   Sample Volume at Meter Conditions,  cubic feet                    54.43            54.15              54.08
   Sample Volume at Standard Condicions,  '  cubic feet               50.55            50.09              50.04

Gas Stream Moisture Content
   Total Water Collected by Train, ml                                 84.              139.               113.5
   Standard Volume of Water Collected,  cubic feet                     3.95             6.54              5.34
   Moisture in Gas Stream,  percent by  volume                          7.3              11.6               9.6
   Mole Fraction of Dry Gas                                           0.927            0.884             0.904

Gas Stream Composition

   C02, percent by volume                                             0.0               0.0               0.0
   02, percent by volume                                             20.9              20.9              20.9
   CO, percent by volume                                              0.0               0.0               0.0
   N2, percent by volume                                             79.1              79.1              79.1
   Molecular Weight of Wet  Gas                                       28.17            27-70             27.91
   Molecular Weight of Dry  Gas                                       28.97            28.97             28.97

Gas Stream Veloci ty

   Static Pressure, inches  water                                      4.2               4.2               4.1
   Absolute Pressure, inches mercury                                 30.22            30.22             30.21
   Average Temperature, °F                                           114.              114.               121.
   Pitot Tube Calibration Coefficient                                  0.843            0.843             0.843
   Total Number of Sampling Points                                   12.0              12.0              12.0
   Velocity at Actual Conditions, feet/second                        51.4              50.1              50.8

Gas Stream Volumetric Flow

   Stack Cross-Sectional Area, square feet                             0.45             0.45              0.45
   Volumetric Flow at Actual Conditions, cubic feet/minute        1,390.            1,380.             1,370.
   Volumetric Flow at Standard Conditions,  cubic feet/minute      1,200.            1,130.             1,140.

Percent Isokinetie                                                   93.0              97.5              96.9


Process Operations Data

   Product Production Rate, Tons/hour                                 17.               17.                17.
  Standard Conditions = 68°F,  29-92 inches mercury,  dry basis.

                                                  -  15  -

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                                     OCCIDENTAL CHEMICAL COMPANY

                                           Houston, Texas

                                              TABLE 2

                           AMMONIUM SULFATE DRYER 3AGHOUSE EXHAUST STACK

                                     Summary of Test Results


Test Data

   Test Number                                                        I                 2                 3
   Test Date                                                       10-26-78         10-26-78          10-26-78
   Test Time                                                      0850 - 0953      IOW - Il 5 percent opacity, minutes observed                                0.               0.                0.
   0 percent opacity, minutes observed                                0.               0.                0.
   No visible emission, minutes observed                             60.              60.               60.
 Based on Total  Particulates captured by train.

 Standard Conditions « 63°F and 29.92 inches mercury.
                                                    - 16 -

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 APPENDIX A





RAW TEST DATA

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TRAVERSE POINT LOCATION FOR  CIRCULAR DUCTS
PLANT _
DATE                  	
SAMPLING LOCATION ___llllLL__
INSIDE OF FAR WALL TO
   OUTSIDE  OF PORT. (DISTANCE A) _.
INSIDE OF NEAR WALL TO
   OUTSIDE  OF PORT. (DISTANCES!-
STACK I.D.. (DISTANCE A - DISTANCE Bi.
NEAREST UPSTREAM DISTURBANCE	
NEAREST DOWNSTREAM DISTURBANCE _
CALCULATOR
                 8
                                             SCHEMATIC OF SAMPLING LOCATION
TRAVERSE
POINT
NUMBER
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DATE	\-/	/
LOCATION    >' "''•'' ' *~
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                      NOMOGRAPH DATA
PLANT
DATE..
SAMPLING LOCATION
CONTROL BOX NO.
CALIBRATED PRESSURE DIFFERENTIAL ACROSS
ORIFICE, in. H20
AVERAGE METER TEMPERATURE (AMBIENT + 20 °F),°F
PERCENT MOISTURE IN GAS STREAM BY VOLUME
BAROMETRIC PRESSURE AT METER, in Hg
STATIC PRESSURE IN STACK, in. Hg
(Pm±0.073 x STACK GAUGE PRESSURE in in. H20)
RATIO OF STATIC PRESSURE TO METER PRESSURE
AVERAGE STACK TEMPERATURE, °F
AVERAGE VELOCITY HEAD. in. H20
MAXIMUM VELOCITY HEAD. in. H20
C FACTOR
CALCULATED NOZZLE DIAMETER, in.
ACTUAL NOZZLE DIAMETER, in.
REFERENCE Ap. in. H20
±HC*
Tmavg.
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-------
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          FILTER NUMBER (si
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 PROBf LENGTH AND TYPE	
 NOZZLE ID..   «,P>3C'
 ASSUMED MOISTURE. "../• i .
 SAMPLE BOX NUMBER _ /.„  _ ^
 METER BOX NUMBER __<_"\. ! •''_•-'•
.METER AHM    /. -'J -•*-
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 PITOT  TUBE  FACTOR __•„'-. '
 REFERENCE Ap   f0 -1>  (•	
 NOTE   £-O-r  :-•	.  '> O /
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-------

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NUMBER
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PLANT (ff*
DATE
SAMPLING L(
SAMPLE TYP
RUN NUMBER
OPERATOR
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-------
PLANT
DATE
SAMPLING LOCATIOI
SAMPLE TYPE
RUN NUMBER
OPERATOR
                                     PROBE LtNGTH AND TYPE
                                     NOZZLE ID..   _.   .
                                     ASSUMED MOISTURE.".	
                                     SAMPLE BOX NUMBER
                                     METER BOX NUMBER
                                    •METER
                                     C FACTOR
AMBIENT TEMPERATURE
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                                     REFERENCE
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STATIC PRESSURE. IP |
FILTER NUMBER Is)
                                    READ AND RECORD ALL DATA EVERY
   CO
co
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                                                                                       ::ii: re ==r ••••'. CD -c.
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-------
                                SUMMARY
                      RECORD OF VISIBLE EMISSIONS
Type oT Plant 	
Company flame 	•
Plant Address 	
Type of Discharge  (STACK  :   OTHER
                                                  Date
                                                  Hours of Observation
                                                  Observer   _x  • \ '   -.'
Discharge Location \\'-s "
Height of Point of Discharge 	
Observer's Location:
    Distance to Discharge Point
    Height of Observation Point
    Direction from Discharge Point
Background Description  .S ft \\ c
Weather:  Clear
                                      &.VT.
                                           t *.,
                                                 ft T
d
                   Overcast '-.(partly Cloudy^ Other
          Wind Direction 	  Wind Velocity
Plume Description:
    Detached:  Yes    No
    Color:  Black    White    Other
                                                            ,  Sky Color
                                                                        mi/hr
    Plume Dispersion Boh?vior:  Looping    Coning    Fanning
                                Lofting    Fumigating    Othe/
    Estimated Distance Pluns Visible     —-

-------
                      RECORD OK VISIBLE EMISSIONS
Cotnoanv Name O A v
	 . . y. M
Plant Address nCUi
Stack Location t, -. •
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r )
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TIME
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30
31
32
33
34
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36
37
38
39
40
41
42
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44
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50
51
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53
54
55
56
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53
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31
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33
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52
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-------
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-------
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-------
                            RECORD OF VISIBLE  EMISSIONS
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                                                  Date
                                                  Observer
Stack Location
Weather Conditions
                                                  Observer's
                                                   Location
TIME
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00
01
02
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04
05
06
07
08
09
10
11
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                    >x   (~ A c j/i^            Date
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                                                       T.
Weather Conditions
                                               Observer's
                                                Location
TIME
                                              COMMENTS

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31
32
33
34
35
36
37
38
39
40
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42
43
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51
52
53
54
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58
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-------
Company flame   f> Y \j
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                            RECORD OF VISIBLE  EMISSIONS



                             V\P »Vv	    Date
                                                 Observer
Stack Location  !'  ' ••
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fN.-*"%"^
                                                 Observer's
                                                             N
                                                  Location    j•/  '—
TIME
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01
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03
04
05
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07
08
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11
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19
20
21
22
23
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25
26
27
28
29
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-------
    APPENDIX B




LABORATORY REPORTS

-------
                                    ANALYTICAL DATA
PL ANT _  Vj.JfJ;

DATE __./O..-.._. ..

SAMPLING LOCATION .

SAMPLE TYPE 	JL^

RUN NUMBLR	!•_

SAMPLE BOX NUMBER
COMMENTS:
CLEAN UP MAN	L_,
FRONT HALF

  ACETONE WASH OF NOZZLE. PROBE. CYCLONE (BYPASS).
    FLASK. FRONT HALF OF FILTER HOLDER

  FILTER NUMBER	  	
                           LABORATORY RESULTS
CONTAINER O C 0 " ! £
CONTAINER CC Q -  ! p
.mg
                                               FRONT HALF SUBTOTAL
                                    .4
                                         . mg
BACK HALF

  IMPINGER CONTENTS AND WATER WASH OF
    IMPINGERS. CONNECTORS. AND BACK
    HALF OF FILTER HOLDER

ACETONE WASH OF IMPINGERS, CONNECTORS,
    AND BACK HALF OF FILTER HOLDER
ETHER-CHLOROFORM
EXTRACTION
CriNTAiNER
BACK HALF SUBTOTAL
mg
mg
mg

TOTAI M/FIGHT

mg

MOISTURE
IMPINGERS „.,
FINAI VOLUME (X :^_^
INITIAI VOLUME 2Z®
NET Vm IIMF ' S
SILICA GEL ^ ,„
FINfll WFIf.HT - "r>
INITIAI WFIKHT -- -?__
NFT WFIGHT '"<-
ml
ml
ml
g

g
                                                           TOTAL MOISTURE
                             SUBTOTAL

-------
                                    ANALYTICAL DATA
PLANT _~?'•?>  	      CONTAINER
                                                                          LABORATORY RESULTS
                                                                   /-'
                                               FRONT HALF SUBTOTAL
BACK HALF
  IMPINGER CONTENTS AND WATER WASH OF
    IMPINGERS. CONNECTORS, AND BACK
    HALF OF FILTER HOLDER
ACETONE WASH OF IMPINGERS. CONNECTORS,
    AND BACK HALF OF FILTER HOLDER
ETHER-CHLOROFORM
EXTRACTION
CONTAINER
BACK HALF SUBTOTAL
mg
mg
mg

TQT/M WFIRHT

mg

MOISTURE
IMPINGERS
FINAL VOLUME
INITIAL VOLUME <
NET VOLUME
SILICA GEL
FINAL WEIGHT
INITIAL WEIGHT
NET WEIGHT

-^i''s ml
$& m|
1 *& V Im
v^> 'I p
;2-£fd 9
m .

g
E
g
SUBTOTAL
/zr
/J,
73^
p.
                                                           TOTAL MOISTURE

-------
                                   ANALYTICAL DATA
PLANT _  _--.:'..„
DATE...    	r.
SAMPLING LOCATION .
SAMPLE TYPE 	
RUN NUMBER	
SAMPLE BOX NUMBER
CLEAN UP MAN
                                            COMMENTS:
FRONT HALF
  ACETONE WASH OF NOZZLE. PROBE. CYCLONE (BYPASS).
    FLASK. FRONT HALF OF FILTER HOLDER
FILTER NUMBER    rr^- - -
                          D-
                                                                      LABORATORY RESULTS
                                            CONTAINER.
                                              CONTAINER
                                              FRONT HALF SUBTOTAL
                                                                                   .rag
BACK HALF
IMPINGER CONTENTS AND WATER WASH OF
IMPINGERS. CONNECTORS, AND BACK
HALF OF FILTER HOLDER
ACETONE WASH OF IMPINGERS. CONNECTORS,
AND BACK HALF OF FILTER HOLDER
MOISTURE
IMPINGERS -
FINAL VOLUME ^ .nil
INITIAL vmilMF -2^2 m|
NET VOLUME /^ ml
SILICA GEL
FINAL WEIGHT 2-l1',<* g g
INITIAL WEIGHT 2^ , g E
NCT u/rinHT /-• ^ ? e
SHRTflTII
mNTAINFR
ETHER-CHLOROFORM
CONTAINER
BACK HALF SUBTOTAL

TQTAi WFir,HT

/0/.0
I2J2— '
-T^
TOTAL MOISTURE /'/^ . 5
. . e
mg
mg
mg
mg

mg

g


-------
TITLE  J.
          G-"—

 .	. __,_	
                                                    Project No.


                                                   _  Book No.
                                                                                ..0^01
                                            35
OCQr3,P
:su;
                                                       ^.1755!.
                                                                       i  i
                                                                                       —t
                                                                            I   !
                                                           TTT
                                                                            To Page No.
 Witnessed & Understood by me.
    T.D.O.
                             Dale
                                        Invented by
                                        Recorded by
                                                                    Date

-------
I  I
TITLE.
                                                 Project No..
                                                  Bock No..
V
 From P-gs No	

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                                                                 13
                                                              ,yo7s
                                                              .WS"/
                                                              .^756'
                                                              .3782-
                                                              ,/f«6
                                                              .^f/^-
                                                              J5^7
                                                              .3821
   0,0^
   o,O c"
                                                                                 4.0
                                                                         . 375?
                                                                        .5823
Wilnesjed i Understood by me
                            Dote
                            it-1-7 V
                                      Invented by
                                      Recorded by
                                                                  Dale

-------
    APPENDIX C




SAMPLE CALCULATIONS

-------
                                SAMPLE CALCULATIONS
Test Run 1  - Ammonium Sulfate Dryer Baghouse Exhaust Stack
1.  Volume of dry gas sampled at standard conditions (68°F, 29-92
    in. Hg), dscf.

                         17.64?  x  Y  x  V    x
    v                                          A   v 'b  '    13.6  i
    Vm(std)          =   -
                                       T    +   460 i
                                      '
    V
    vm(std)
                                        m

                         17-647  x  0.973   *  54.43 x f  29-91   •*•   iV%  i     ~ 50.55
                                        96.2 +  460
    Where:

    V /   ,*          =   Volume of gas sample measured by the dry gas meter,
                         corrected to standard conditions, dscf.

    V                =   Volume of gas sample measured by the dry gas meter at
                         meter conditions, dcf.

    P.                =   Barometric pressure,  in. Hg.

   AH               =   Average pressure drop across the orifice meter,
                         in. H20.

    T                =   Average dry gas meter temperature, °F.

    17.647           =   Factor that includes  ratio of standard temperature
                         (528°R) to standard pressure (29-92 in. Hg).°R/in. Hg.

    Y                =   Dry gas meter calibration factor.


2.  Volume of water vapor in the gas sample corrected to standard conditions, scf.

    V , .  .x          =  (:).04707 x  V  ) +  0.04715  x  W    ,
     w(std)             v            we'                 wsg

    V , ,. ..          =  (0.04707  x  72   ) +  (0.04715 x  12    )      3-95
     wlstd;
    Where:

    V /   ,\          =   Volume of water vapor in the gas sample corrected to
                         standard conditions, scf.

    V                =   Volume of liquid condensed in impingers, ml.
     we

-------
                                       - 2 -
    W
     wsg
=   Weight of water vapor collected in silica gel, g.

-   Factor which includes the density of water
    (0.002201'.-Vml) ,  the molecular weight of water
    (18.0 1b/Ib-mole),  the ideal gas constant
    121.85  (In.  Hg)' (ft3)/(Jb-nole)(°R)]  ; absolute
    temperature at standard  conditions  (528°R), absolute
    pressure  at standard conditions (29-92  in. Hg) ,  ffVml
                         Factor which includes the molecular weight of water
                         (18.0 Ib/lb-mole), the ideal gas constant
                         [21.85 (in.  Hg)(ft3)/(lb-mo1e)(°R)j .  absolute
                         temperature at standard conditions (528°R), absolute
                         pressure at standard conditions (29-92 in. Hg), and
                         1*53.6 g/lb,  ft3/g.
3.   Moisture content.
     ws
                                 w
             (std)
     w(std)
                                       V
                                        m(std)
    B
     ws

    Where:

    B
     ws
          3.95 + 50.55
                              = 0.073
    Proportion of water vapor, by volume, in the gas
    stream, dimensionless.
k.   Mole fraction of dry gas.
    M
    1 - B
                              ws
    M
    1 - 0.073  =  0.927
    Where:

    M.
    Mole fraction of dry gas, dimensionless
5-  Dry molecular weight of gas stream, Ib/lb-mole.
    MW,
    O.MfO(*C02)   +  0.320 (*02)  + 0.280
+  % CO)

-------
                                       - 3 -






    MWd              =   (O.MtO x      )+ (0.320 x      )  +[0.280 (      +       )]






                         28.97 (Ambient ai r)






    Where:




    MW,              =   Dry molecular weight, Ib/lb-mole.





    |C02             =   Percent carbon dixoide by volume, dry basis.






    %0«              =   Percent oxygen by volume, dry basis.






    %N.              =   Percent nitrogen by volume, dry basis.




    %CO              =   Percent carbon monoxide by volume, dry basis.




    O.AAO            =   Molecular weight of carbon dioxide, divided by 100.




    0.320            =   Molecular weight of oxygen, divided by 100.




    0.280            =   Molecular weight of nitrogen or carbon monoxide,

                         divided by 100.






6.   Actual molecular weight of gas stream (wet basis), Ib/lb-mole.




    MWs              =    'MWd  x  M^)   +    [18  (1 - M j]





    MW               =    (28.97x0.927)    + [18  (1 -0.927;]




                          28.17






    Where:




    MW               =   Molecular weight of wet gas, Ib/lb-mole.




    18               =   Molecular weight of water, Ib/lb-mole.






7.   Average velocity of gas stream at actual conditions, ft/sec.



                                                            T    Ts  (avg)   ]

                          85.^9 x C   x  ( /' :.p)
    •s                             p          H' avg.  x      -=	^—j

                                                            us        s  J

-------
                          flc JQ                        r (1]3-9  + 460
  TS                =    85.49   xo.843  X0.869  x
                                                       •_  30.22  X28.17



    Where:

   ,p/.                =   Average gas stream velocity, ft/sec.

    85.49            ~   Pitot tube constant, ft/sec  X

                         (Ib/lb-mole) (in.Hg)'j
                         T°P) (in.' H26T ' "__  '

    C                =   Pitot tube coefficient, dimensionless.

   ^ p               ==   Velocity head of stack gas, in HLO.

    T                =   Absolute  gas stream temperature,  R.

    P                =   Absolute gas stack pressure, in. Hg.


8.  Average gas stream dry volumetric flow rates, dscf/min.

    .                    1058.8  x  v   x  A   x  M ,  x  P
    Qs(std)          -   	!	_J	d	s
                                           s

    n                -   1058.8  x 51  ^ xQ./tg  x 28.97 x 30.22
    ys(std)          "               (i+  460)

                         1,200.

    Where:

    Q /   .\          -   Volumetric flow rate of dry stack gas, corrected  to
                         standard conditions, dscf/min.
                                                          2
    A                =   Cross-sectional area of stack, ft .

    1058.8           =   Factor which includes standard temperature  (528°R),
                         standard pressure (29-92 in. Hg), and 60 sec/min,
                         (°R) (sec)
                        (in. Hg)(min)


9-  Isokinetic variation calculated from intermediate values, percent.

-------
                                       - 5 -

                         17-316  x  T    x  V
                                             m(std)
                                                        2
                         V   x9xP   x  M,  x  (D )


    I                 -   17.316 x 573.9 x 50.55

                         51.4x 60x 30.22 x 0.927 x(0.250J2

                         93-0

    Where:

    I                 =   Percent of isokinetic sampling.

    6                 =   Total  sampling time, minutes.

    D                 =   Diameter of nozzle,  inches.

    17.316           =   Factor which includes standard temperature (528°R) ,
                         standard pressure (29-92 in.  Hg) ,  the formula for
                         calculating area of  circle Trt^   >  conversion of

                         square feet to square inches  (  144), conversion of
                         seconds to minutes  (60), and conversion to
                         percent (100), (in.  Hg)  (in2) (min)  .
                                        (°R)  (ft2) (sec)

10.   Particulate concentration, gr/dscf.

    C]                =   0.015432 x M
                                    Vm(std)

    C.                =   0.015432  x   -51^	    " °'016
                                       50.55
    Where:

    C,                =   Particulate concentration,  gr/dscf.

    M                =   Total  weight of particulate caught by train, mg.

    0.015432         =   Conversion factor of gr/mg.
11.   Particulate mass emission rate,  Ib/hr.

    PMR              =   0.0085714  x  C.   x  Q ,
       t                                I       s (s

                     =   0.0085714  x 0.016  x  1,196   = 0.16

-------
                                   - 6 -
Where:

PMR              =   Particulate mass emission  rate,  Ib/hr.

0.00857lJt        =   Conversion factor  relating minutes  to  hours  (60),  and
                     grains to pounds  (7,000),(lb)  (min)/(gr)  (hr).

-------
       APPENDIX D




EQUIPMENT CALIBRATION DATA

-------
                                                                   r 2F
     Date
     Barometric  pressure,
          Box flo..

Dry gas meter llo.
                                                                     Cf<'(•>{''• ~l...
Or i f ice
manometer
setting ,
AH,
in. H20
0.5
1.0
2.0
•S" jLrfr
.5 >rfT
8.0
Gas vplunie
wet test
meter
Vw
5. esc
5.c:-i
>«-7.?.7
10.OCO
Gas volume
dry gas
meter
5T/SZ
fj^?;'5l 5" 5£o
10 |
Temperature
Wet test
Meter
°F
6?
f.1
%\
9: 7
££
.t!

D
Inlet
(J 1 *
°F
rc°.
?r
?A
fi~r/
/os?
/jt

ry gas
Outlet
°F
7£T
7?
r'z
£-j

meter
Average
°F
?y.zo
%•:,-<:£'
&1,6V
5'C2r"
f/.Tf^

Time
0.
mi n
12 .733
£30
&.&
//. 7 fa
7. 5£3

Average
Y
,^
97^
.
Calculations



AH
0.5
l.O
2.0
4.0
6.0
8.0


AM
llTi
0.0360
0.0737
0.147
0.294
0.431
0.588
Y
Vw Pb (td + "60)

Vd(pb + f3 e) (tw + 46°)






All|_3
0.0317 AH f(tw + 460) el 2
w
Pb (td + 460) |_ Vw






      =  Ratio  of  accuracy  of wet  test  meter  to  dry  test  meter.   Tolerance  =  i  O.Ol
  AH@  =  Orifice  pressure  differential  that  gives  0.75  cfm  of  air  at  70°  F  and  29.92
        inches of  mercury,  in.  f^O.   Tolerance  -  -  0.15

-------
                                                                /.C. ' .
Da te
                /Q-30-7P
          Box  No.
Barometric pressure,
                                  in. Hg
Dry gas meter ilo.
Or i f ice
manometer
setting ,
All,
in. H20
0.5
1.0
2.0
.O^tr
.r '>#-
8.0
Ga s vo 1 ume
wet test
meter
vw.
S.oof
S.co/
I0,00i
J&5.KS.
das volume
dry gas
meter
V
ft3
£.&S
-S-./0-?
/O. 2.ff
3.7-Zf
-wrV.-.-Jz ^,z?s
10 I
Temperature
Wet test
Meter
°F
65°
$t
?3
%3
bl'

D
Inlet
°F
P^
?l
?OI
%?
90

ry gas
Outlet
°F
76/
'7-7
?^
77
meter
Average
"F
7f.s
$(*.$o

T ime
0,
min
/7.?o
?,-?£"
/3r/€5
7.6?o
7^/t

Average
Y
,ff£
/.OCX?
/.OO-J
,^2
.^?3

•W

f /77/
// s"^-^
ASY5
- A ?/?
/.201

'- A?/?
Calculations



AH
0.5
1.0
2.0
4.0
6.0
8.0


All
1576
0.0368
0.0737
0.147
0.294
0.431
0.508
Y
Vw PD Ud * 460>

Vd(Pb * f3-6) (tw + 460)






All(3
0.0317 All f(tw + 46°) el 2
w
Pb (td + 460) L Vw






      -  Ratio  of  accuracy of wet test meter to dry test meter.  Tolerance = ± 0.01
  AH@  =  Orifice  pressure differential that gives 0.75 cfm of air at 70° F and  29.92
        inches of mercury, in. I^O.  Tolerance - - 0.15

-------
                                                     SHEET.
                                                                   OF.
CHKD BY
 ROJECT	.	
S U B J E C T _J_li<3
                                              W.O.  NO..
                       Ip-g.    C-aAS
                Q ,"50
                                                   n
,  o.^o  o.
                                                             Q,
A.VJ
U
r
T
Y
2:
                         -Vbo
                          .si's
                                                            .S32.
                                                                    21,1
                                                                                   .s'ss

-------
            THE  PENNSYLVANIA STATE  UNIVERSITY
                                2Zt> FENSKE LAHORATORV
                            UNIVERSITY PARK. PENNSYLVANIA ih»o:
Center for Air Environment Studies
Area Code 3U
  865-1415
                                            June 5,  1978
           Mr. Jeffrey D. O'Neill
           Roy F.  Western, Incorporated
           Weston Way                                 .  •
           West Chester, Pennsylvania  19380

           Dear Mr.  O'Neill:

                Please be advised that  you successfully completed the
           "Visible Emissions" course given June 1,  1978.  You are
           certified to  evaluate visible emissions since you met the
           standards described as Method 9 in the Federal Register of
           November 12,  1974.  These standards are:

                1)  To maintain an average deviation of less than
                    7.5% for a set of 25 white smoke plumes and a
                    set  of 25 black smoke plumes.

                2)  To have no single reading of the 50 plumes to
                    be in error by more than 15%.

                                            Sincerely,
                                            Robert  Jennings Heinsohn
                                            Professor of Mechanical Engineering
                                            Project Director
           RJH/cb

           Enclosure

-------
                        CONTINUING
                                        EDUCATION
                                               certified  In at

                                      JEFFREY D,  O'NEILL
It
                                 leted
                                           t a A comp

                                 VISIBLE EMISSIONS EVALUATION SEMINAR
Recertified:
Oiti:
                                                                     R»c«filllod:
                                                                      Don:
                                       Car 11 Hod
                                      Duta:
    PROJECT OIHECTOB OF VISIBLE EMISSIONS
          TRAINING PROGRAM
    CENTER FOR AIR ENVIRONMENT STUDIES
                                                          VICE PRESIDENT FOR
                                                         CONTINUING EDUCATION

-------
         APPENDIX E




DETAILED BAGHOUSE INFORMATION

-------
                                                                                                C-40
                                              atic
Efficient,  low-maintenance  filters for any  air volume.
       Carter-Day

   type "CS"  filter

Exclusive combined shock design.
Efficiency up to 99.99+%.'

Designed to operate at  higher air-to-
cloth ratios  on difficult  applications.
Requires only 80 PSIG of compressed
air. Can be  supplied with individual
hoppers or  trough type hoppers  for
multiple installations. For complete
information,  ask for Bulletin No.  L-
1126R2.
  , Pressure  •»£*

   Blower


   Reverse Air
   Manifold


   Air Inlet


   Filter Tubes


  ' Pressure
   Release Control


   Air Outlet


   Drive Motor
These diagrams illustrate the unique Dual Re-
verse air cleaning system ol the "CS" filter.
       Carter-Day

    type "RJ" filter

Performance proven in hundreds of
installations.

Versatile — handles  air streams with
light, medium or heavy material con-
centrations. Efficient—up to 99.99-!-%.
Simple design. Automatic, continuous,
low-cost operation. Can be supplied
with  individual  hoppers  or trough
type  hoppers for  multiple installa-
tions. For  complete information, ask
for Bulletin No. G-464R.

CAPACITY TABLE - DAY "RJ" FILTERS
Filter
No.
12RJ26
12RJ36
12RJ48
12RJ60
18RJ36
18RJ48
18RJ60
24RJ37
24RJ48
. 24RJ60
24RJ72
24RJ84
72RJ37
72RJ48
72RJ60
72RJ72
72RJ84
72RJ96
Cloth
Area
Sq. Ft.
57.5
83.5
105
131
125
165
208
200
255
320
385
448
6OO
765
960
1155
1340
1530
Cubic Fe«t or Alr/Min. (CFM)
Air to Media Ratio
5
28S
418
525
655
625
825
1040
1000
130O
1600
1925
224O
3OOO
3825
480O
5775
6700
7650
10
570
835
1050
1310
1250
1650
2080 •
2000
260O
3200
3850
4480
6OOO
7650
96OO
11550
13400
15300
15
855
1252
1575
1965
1875
2475
312O
3000
3900
4800
5775
6720
90OO
1147S
14400
17325
2O1OO
22950
20
1140
1670
2100
2620
2500
3300
4160
4000
520O
6400
7700
8960
120OO
15300
19200
23100
26800
306OO
No.
Sleeves
12
12
12
12
18
18
18
24
24
24
24
24
72
72
72
72
72
72
Sleeve
Loth.
26
36
48
60
36
48
6O
37
48
60
72
84
36
48
6O
72
84
96
Blower
No.
3A1
3 A3
3A3
3A6
3A3
3A3
3A6
3A3
3A6
3A6
4A
4A
4A
4A
4A
4A
4B
48
Blower
H.P.
1
IV*
2
2
1V4
2
3
2
2
3
9
7Vi
5
7V4
7V4
10
IS
15
Drive
H.P.
•A
V*
%
• Vt
vt
v»
Vt
vt
Vi
14
'A
Vi
Vi
Vi
Vi
Vi
Vi
Vi
                                 Multiple grouping* can be furnished for greater capacities.
CAPACITY TABLE - DAY TYPE "CS" DUST FILTER
niter
No.
12CS26
12CS36
12CS48
12CS6O
18CS36
18CS48
18CS60
24CS37
24CS48
24CS60
24CS72
24CS84
72CS37
72CS48
72CS60
72CS72
72CS84
72CS96
Cloth
Area
Sq.ft.
57.5
83.6
105
131
125
167
208
2OO
255
32O
384
448
6OO
765
960
1150
1340
1530
Cubic Feet of Alr/Mln. (CFM)
Air to Media Ratla
1O
575
835
1050
1310
12SO
167O
2080
20OO
2550
32OO
384O
4480
6OOO
765O
9600
11SOO
13400
153OO.
IS
865
1250
1575
1965
1875
2500
3110
3000
3820
4800
5750
6700
9000
115OO
14400
1725O
20100
23000
20
1150
1670
2100
2620
2500
3340
4160
4000
5100
64OO
7680
896O
12000
153OO
192OO
23000
268OQ
306OO
25
1440
2080
2620
3280
3120
41 7O
5200'
5000
' 6370
800O
9600
11200
15000
191OO
24000
288OO
33500
383OO
No.
Sleeves
12
12
12
12
18
18
18
24
24
24
24
24
72
72
72
72
II
Sleeve
Loth.
26
36
48
60
36
48
60
37
48
60
72
84
37
48
60
72
84
96 .
Blower
No.
3A1
3A1
3A1
3A1
3A1
3A1
3A1
3A1
3A1
3A1
3A1
.3A3
3A3
3A3
3A3
3A6
3A6
3A6
Blower
H.P.
1*
f
2
2
3
3
3
3
5
5
7V4
7V1
Drive
H.P.
I*
U
Vi
I*
'4
Vi
'A
>A
Vt
V4
.'A
Vi
B
I
SCFM«:
Comp. <
Air 6
80 PSIG.
4.1 ,
4.1
tl!
s.6 ;
5.6
5.6
6.6 i
6.6 :
6.6
6.6
6.6
13.9
13.9
13.9
13.9
13.9
13.9
•Compressed air consumption may be reduced through use ol a timer, available when applicable at extra cost.
                                                                                       AIR MANIFOLD
                                                                                         BUTTERFLY VA1VE
                                                                                         TRIP MECHANISM
                                                                                       •AIR INLET
                                                                                        RJ" FILTER

-------
 MOTO/S../IC

 tazo

/•JO. f6 C  S?0£. A/0. VL YSf // 8 B -
                                                               i" i 4^ I  4-V  ! -*i>'J
                                                                 *T*~   *i* "  *T*   *~1
                                /.  STYLE :_££k

                                 "         A/O.  /0-5---


                                3.
                               4.M/=>XlMUM  ALLOVir/» QLf  Vif f E K E NTlflL-

                                  HOUS/MG ppfue?  is:'--'of !

-------
     APPENDIX F




PROJECT PARTICIPANTS

-------
                                                  PROJECT PARTICIPANTS
The following Weston employees participated in this project:
Peter J.  Marks
Laboratory Manager
econENVIRONomics Division
Barry L.  Jackson
Supervisor, Air Testing
econENVIRONomics Division
Jeffrey D. O'Nei11
Project Scientist Assistant
econENVIRONomics Division
Gregory Celiano
Assistant Project Scientist
econENVIRONomics Division
David D. Maloney
Laboratory Technician
econENVIRONomics Division

-------