O
EMB Report No. 78-NMN-6
AIR POLLUTION
MISSION TEST
SOURCE EMISSIONS TEST REPORT
EN6LEHARD MINERALS & CHEMICALS CORPORATION
Attapulgus, Georgia
July 1978
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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SOURCE EMISSIONS TEST REPORT
ENGELHARD MINERALS & CHEMICALS CORPORATION
Attapulgus, Georgia
#2 Raymond Mill
and
#2 Fluid Energy Mill
7/78
ROY F. WESTON, INC.
Barry L. Jacks
Supervisor Air Testing
Peter J. Marks
Department Manager
Laboratory Services
RFW Report No. 0300-81-02
Contract No. 68-02-2816
Work Assignment No. 1
Prepared by:
ROY F. WESTON, INC.
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 '•' n
Summary
Introduction J
Description of Processes 5
No. 2 Raymond Mill J!
No. 2 Fluid Energy Mill 5
o
Description of Test Locations
o
No. 2 Raymond Mill Baghouse Exhaust Stack °
No. 2 Raymond Mill Baghouse In let Duct !?
No. 2 Fluid Energy Mill Baghouse Exhaust Stack ;
No. 2 Fluid Energy Mill Baghouse Inlet Duct
Description of Sampling Trains 15
Particulate Sampling Trains 15
Particle Sizing Train 16
Test Procedures 19
Preliminary Tests 19
No. 2 Raymond Mill Baghouse Exhaust Stack 19
No. 2 Raymond Mill Baghouse Inlet Duct 20
No. 2 Fluid Energy Mill Baghouse Exhaust Stack 20
No. 2 Fluid Energy Mill Baghouse Inlet Duct 21
Analytical Procedures 22
Particulate Sample Recovery 22
Particulate Analyses 22
Particle Size Sample Recovery and Analyses 23
Discussion of Test Results 2k
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.
1
5
6
7
8
TITLE
#2 Raymond Mill Baghouse Exhaust
Summary of Test Data
#2 Raymond Mill Baghouse Inlet
Summary of Test Data
#2 Fluid Energy Mill Baghouse Exhaust
Summary of Test Data
#2 Fluid Energy Mill Baghouse Inlet
Summary of Test Data
#2 Raymond Mill Baghouse Exhaust
Summary of Test Results
#2 Raymond Mill Baghouse Inlet
Summary of Test Results
#2 Fluid Energy Mill Baghouse Exhaust
Summary of Test Results
#2 Fluid Energy Mill Baghouse Inlet
Summary of Test Results
PAGE
25
26
27
28
29
30
31
32
FIGURE
NO.
1
5
6
TITLE
Raymond High Side Roller Mill,
Cyclone Bag Collector
Fluid Energy Mill #2
Schematic Diagram
#2 Raymond Mill Baghouse Exhaust Stack
Port and Sampling Point Locations
#2 Raymond Mill Baghouse Inlet Duct
Port and Sampling Point Locations
#2 Fluid Energy Mill Baghouse Exhaust Stack
Port and Sampling Point Locations
#2 Fluid Energy Mill Baghouse Inlet Duct
Test Port Locations
PAGE
6
7
9
10
12
13
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FIGURE
NO. TITLE PAGE
7 #2 Fluid Energy Mill Baghouse Inlet Duct 1*»
Sampling Point Locations
8 Particulate Sampling Train 17
EPA Method 5
9 Particulate Sampling Train 18
EPA Method 17
In-Stack Filtration Method
10 #2 Raymond Mill Baghouse Inlet 33
Particle Size Distribution
11 #2 Fluid Energy Mill Baghouse Inlet 3k
Particle Size Distribution
i i
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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 Engelhard Minerals and Chemicals Corporation's, Attapulgus, Georgia clay
processing facility.
The primary objective of the testing program was to quantify the particulate
emissions to the atmosphere from two baghouse-controlled sources at the plant
(No. 2 Raymond Mill and No. 2 Fluid Energy Mill). This objective was achieved
by performing a series of three particulate tests utilizing EPA Method 17 pro-
cedures at each baghouse exhaust stack location. In addition, visual determina-
tions of plume opacities were made simultaneously with each particulate test at
(2)
both source discharge points according to EPA Method 9 protocol. Also,
singular EPA Method 5 particulate and Anderson cascade impactor tests were
executed at both baghouse inlet sites to measure the potential uncontrolled
emissions and the particle size distribution at the entering particulate matter
respectively.
The particulate matter emission results are summarized below:
No. 2 Raymond Mill Baqhouse Exhaust Stack
Test
Number Date
1 6-14-78
2 6-15-78
3 6-15-78
Series Average
Particulate Concentration,
Grains/DSCF
0.002
0.002
0.001
Particulate Emission Rate,
Pounds/Hour
0.03
0.04
0.02
0.03
(D
(2)
(3)
Federal Register, Vol. 41, No. 187, September 2k, 1976.
Federal Register, Vol. 39, No. 219, November 12, 1974.
Code of Federal Regulations, Title 40, Part 60, Appendix A, "Standards of
Performance for New Stationary Sources", August 18, 1977.
-1-
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No. 2 Raymond Mill Baghouse Inlet Duct
(4)
Test Participate Concentration,
Number Date Grains/DSCF
1 6-15-78 5.2k
Particulate Emission Rate,
Pounds/Hour
97.4
No. 2 Fluid Energy Mill Baqhouse Exhaust Stack
Test Particulate Concentration,
Number Date Grains/DSCF
1 .6-14-78 0.002
2 6-15-78 0.002
3 6-15-78 0.001
Series Average
Particulate Emission Rate,
Pounds/Hour
0.02
0.04
0.03
0.03
No. 2 Fluid Energy Mill Baghouse Inlet Duct
(5)
Test
Number
1
Date
6-15-78
Particulate Concentration^ Particulate Emission Rate,
Gra ins/DSCF Pounds/Hour
1.04
15.6
The particulate removal efficiency of No. 2 Raymond Mill Baghouse was measured
at 99.98%; that of No. 2 Fluid Energy Mill .was 99.87%. Both efficiencies were
calculated-based on one simultaneous inlet/outlet test only.
No visible emissions were observed emanating from either stack during the test
program by the certified observer.
Figures JO. and 11 illustrate the particle size distribution of the particulate
matter at the baghouse inlet locations.
Detailed summaries of test data and test results are presented in Tables 1
through 8 of this report.
(4)
(5)
Run performed simultaneously with Test Number 3 at exhaust stack.
Run performed simultaneously with Test Number 2 at exhaust stack.
-2-
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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 Engelhard Minerals and Chemicals Corporation's Attapulgus, Georgia clay
processing facility. The objective of the testing program was to measure vari-
ous emission parameters from two selected milling operations at the plant.
The locations tested, plus the number and types of tests performed at each site,
are 1 isted below:
1. No. 2 Raymond Mill Baghouse Exhaust Stack
a. 3 particulate tests by EPA Method 17
b. 3 opacity tests by EPA Method 9 simultaneous with each particulate
test.
2. No. 2 Raymond Mill Baghouse Inlet Duct
a. 1 particulate test by EPA Method 5 simultaneous with one of
the exhaust stack tests.
b. 1 particle size distribution test by cascade impaction.
(Anderson ) .
3. No. 2 Fluid Energy Mill Baghouse Exhaust Stack
a. 3 particulate tests by EPA Method 17
b. 3 opacity tests by EPA Method 9 simultaneous with each
particulate test.
k. No. 2 Fluid Energy Mill Baghouse Inlet Duct
a. 1 particulate test by EPA Method 5 simultaneous with one of
the exhaust stack tests.
b. 1 particle size distribution test by cascade impaction
(Anderson ).
A.11 tests were conducted during the period 14-15 June 1978 by Weston personnel
and were observed by Mr. Dennis P. Holzschuh, EPA Technical Manager.
-3-
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Test data and test result summaries are presented in Tables 1 through 8
of this report. Particle size distribution results are shown in
Figures 10 and 11. Also incorporated herein is a description of
the test locations, 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.
-4-
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DESCRIPTION OF PROCESSES
No. 2 Raymond Mi 11
Figure 1 illustrates the process flow diagram for No. 2 Raymond Mill. Also
shown are the baghouse inlet and outlet test locations. Note that a cyclone
collector prior to the baghouse is used to capture most of the product.
The raw materials feed rate to the mill was approximately 3 tons/hour during
each testing period. Raw materials feed rates and product production rates
were monitored by Engelhard personnel during each test but that information was
not supplied to Weston for inclusion in this report.
No. 2 Fluid Energy Mi 11
The process schematic of No. 2 Fluid Energy Mill is presented in Figure 2. Also
included in the diagram are the baghouse inlet and outlet test locations. Note
that product recovery is effected primarily by two cyclones in series prror to
final stage capture by the bag collector.
The mill feed rate was approximately 840 pounds/hour during the testing periods.
The exact raw material feed rates and product production rates were monitored
by Engelhard personnel but was not supplied to Weston for inclusion in this
report.
-5-
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FIGURE 1
/I/a.
&S
-6-
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1
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DESCRIPTION OF TEST LOCATIONS
No. 2 Raymond Mill Baghouse Exhaust Stack
Two 4" I.D. test ports, 90° apart, were installed on a straight section of the
10 1/V I.D. metal stack at a location which was 9.^ stack diameters (96")
downstream and 1.7 diameters (17") upstream from the nearest gas stream flow
disturbances. EPA Method 1 criteria for this test location required a
minimum of 16 traverse points to aid in the representative measurement of pollu-
tant emissions and total volumetric flow. A total of 20 traverse points were
chosen for sampling since this number conveniently related to the desired test
period length. See Figure 3 for port and sampling point locations.
No. 2 Raymond Mill Baghouse Inlet Duct
Two 4" I.D. test ports were placed at right angles on a straight section of the
12" I.D. duct work leading to the inlet of the baghouse at a position greater
than eight stack diameters downstream, and greater than two diameters upstream
from the nearest gas stream 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 k illustrates duct geometry plus port and sampling
point locations.
' 'Code of Federal Regulations, Title kO, Part 60, Appendix A, "Standards of
Performance for New Stationary Sources," August 18, 1977.
-8-
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ENGELHARD MINERALS & CHEMICALS CORPORATION
Attapulgus, Georgia
FIGURE 3
#2 RAYMOND MILL BAGHOUSE EXHAUST STACK
PORT AND SAMPLING POINT LOCATIONS
DISCHARGE TO ATMOSPHERE
o
DUCT CROSS-SECTIONAL VIEW
Traverse Point
Number
1
2
3
k
5
6
7
8
9
10
Distance From Inside
Near Wai 1 , Inches
1/2 Adj.
7/8
1-1/2
2-1 A
3-1/2
6-3A
7-7/8
8-3A
9-3/8
9-3 A Adj.
Metal Stack
-9-
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ENGELHARD MINERALS & CHEMICALS CORPORATION
Attapulgus, Georgia
Figure 4
#2 RAYMOND MILL BAGHOUSE INLET DUCT
PORT AND SAMPLING POINT LOCATIONS
12" I.D.
TRAVERSE DISTANCE FROM
POINT
NUMBER
1
" " 2
.3
k
INSIDE NEAR
WALL, INCHES
3A
2
9
11-1/4
DUCT CROSS-SECTIONAL VIEW
TOP OF RAILING
AS FLOW
FROM
CYCLONE
BAGHOUSE
GRATING
-10-
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No. 2 Fluid Energy Mill Baghouse Exhaust Stack
Two 4" I.D. test ports at 90°, were placed on the 12" I.D. metal stack
8 diameters downstream and 1.3 diameters upstream from the nearest flow
disturbances. EPA Method 1 protocol required the traversing of a
minimum of 20 sampling points, 10 per axis, which was the number selected
for testing. See Figure 5 for further details.
No. 2 Fluid Energy Mill Baghouse Inlet Duct
Two V I.D. test ports, 90° apart, were installed in a straight section
of the metal stack at a location which was 5- ^ duct diameters downstream and
1.4 diameters upstream from the nearest flow disturbances. EPA Method 1 criteria
for this test location required a minimum of 20 traverse points for representative
sampling. A total of 36 points were selected for test purposes, 18 per port axis.
Figure 6 illustrates stack geometry measurements while Figure 7 presents traverse
point distances.
-11-
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ENGELHARD MINERALS & CHEMICALS CORPORATION
Attapulgus, Georgia
FIGURE 5
#2 FLUID ENERGY MILL BAGHOUSE EXHAUST STACK
PORT AND SAMPLING POINT LOCATIONS
DISCHARGE TC
ATMOSPHERE
16"
96"
DUCT CROSS SECTIONAL VIEW
TRAVERSE
POINT
NUMBER
1
2
3
4
5
6
7
8
9
10
DISTANCE FROM
INSIDE NEAR
WALL, INCHES
1/2 Adj
1
1-3/4
2-3/4
4-1/8
7-7/8
9-1 A
10-1/4
11
11-1/2 Adj
O
X
I.D. FAN
FROM OUTLET OF BAGHOUSE
METAL STACK
-12-
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to Fan
ENGELHARD MINERALS & CHEMICALS CORPORATION
Attapulgus, Georgia
FIGURE 6
#2 FLUID ENERGY MILL BAGHOUSE INLET DUCT
TEST PORT LOCATIONS
Product
Return
DILUTION AIR
Gas Flow From Cyclone
METAL STACK
Mixing Area
Grating
Level
-13-
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ENGELHARD MINERALS & CHEMICALS CORPORATION
Attapulgus, Georgia
FIGURE 7
#2 FLUID ENERGY MILL BAGHOUSE INLET DUCT
SAMPLING POINT LOCATIONS
10-1/2"I.D4-
DUCT CROSS-SECTIONAL VIEW
TRAVERSE POINT
NUMBER
DISTANCE FROM INSIDE
NEAR WALL, INCHES
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1/2 Adj.
1/2
3/4
1-1/8
1-1/2
1-7/8
2-1/2
3-1/8
4
6-1/2
7-3/8
8
8-1/2
9
9-3/8
9-3/4
10
10 Adi,
-14-
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DESCRIPTION OF SAMPLING TRAINS
Particulate Sampling Trains
The test train utilized for particulate sampling at both baghouse inlet duct
locations was the standard EPA Method Five Train (see Figure 8).
A stainless steel nozzle was attached to a heated (^250 F) 3" borosilicate glass
probe which was connected directly to a borosilicate filter holder containing a
4" Reeve Angel 900 AF glass fiber filter. The filter holder was maintained at
rt R
approximately 250 F in a heated chamber, and was connected by Tygon vacuum
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-weighted silica gel. The first, third,
and fourth impingers were modified 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.
The test train used for particulate sampling at both baghouse exhaust stack
locations was the EPA Method 1? Train (In-Stack Filtration Method). See Figure
9 for train schematic.
-15-
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The configuration and operation of the train is similar to the Method 5 train
except that the filter was placed immediately after the nozzle and prior to
the probe in the Method 17 train. Also, the glass probe and filter heating
systems were eliminated, and the sample was collected at or below stack temper-
ature. It should be noted that elbow nozzles with extra long shafts were
utilized with the Method 17 trains to enable sampling the small stacks without
exceeding the cross sectional area blockage limit of 3% as specified in the
regulations.
Particle Size Distribution Sampling Apparatus
p
A stainless steel nozzle was connected directly to an 8-stage Anderson cascade
impaction device which separated the particles according to their effective
aerodynamic particle diameters. A glass fiber filter was used to capture any
particles that passed through the impactor substrates to permit the measurement
of total particulate. The filter holder was maintained at stack temperature
ft
and was connected by Tygon vacuum tubing to the first of four Greenburg-Smith
impingers which were included in the train to condense the moisture in the gas
stream. 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.
-16-
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0.75 TO! in.
I TEMf
- * '^^^
TEMPERATURE SENSOR
3 __PROBE
T
TEMPERATURE CONTROLLED
HEATED AREA
> 0.75 in. PITOTTUBE
TEMPERATURE SENSOR
PROBE \
V—*
FILTER HOLDER
VACUUM
TUBING
• STACK WALL
~
REVERSE-TYPE
PITOTTUBE
PITOT MANOMETER
ORIFACE
THERMOMETER
CHECK VALVE
U,J \ -I \-rr-l A-rJ
^
L
—
V
1 — \
v t
c
r-
"_/
]
^^
1 — \
>*
I
, 1
±±!
V
-
-J
BYPASS VALVE
X,
IMPINGERS
ICE BATH
X
VACUUM GAUGE
THERMOMETERS
\
DRY GAS METER
AIR TIGHT PUMP
VACUUM
LINE
FIGURE 8 PARTICULATE SAMPLING TRAIN
EPA METHOD 5
-------
0.75 TO 1 in.
1
TEMPERATURE SENSOR
_ PROBE
20.75m.
t
PITOTTUBE
TEMPERATURE SENSOR
IN-;STACK' FILTER
_\
NOZZLE
• STACK WALL
PROBE-
REVERSE-TYPE
PITOTTUBE
THERMOMETER
VACUUM
TUBING
CHECK VALVE
3
1-1
/
J
~x *
i
c
1
3
1 •(
\
i
i
'
-*
n:
L
-*
-
' ^^' V
PITOT MANOMETER
ORIFICE;
BYPASS VALVE
X,
IMPINGERS
\
ICE BATH
VACUUM
LINE
\
VACUUM GAUGE
THERMOMETERS
\
DRY GAS METER
MAIN VALVE
AIR TIGHT PUMP
FIGURE 9 PARTICULATE SAMPLING TRAIN
EPA METHOD 1?
IN-STACK FILTRATION METHOD
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TEST PROCEDURES
Preliminary Tests
Preliminary test data was obtained at each sampling location. Stack geometry
measurements were recorded and sampling point distances calculated. A pre-
liminary velocity traverse was performed at each test location utilizing a
calibrated "S" type pi tot tube and a Owyer inclined manometer to determine
velocity profiles. A check for the presence or absence of cyclonic flow was
conducted at each test location prior to formal testing. The cyclonic flow
check proved negative at all locations verifying the suitability of these
locations for representative sampling. Stack gas temperatures were observed
with a direct read-out pyrometer equipped with a chrome1-a 1ume1 thermocouple.
Gas stream composition and moisture content values were estimated from informa-
tion supplied by Englehard.
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).
No. 2 Raymond Mill Baqhouse Exhaust Stack
A series of three tests were conducted at No. 2 Raymond Mill Baghouse Exhaust
Stack to measure the concentration and mass rate of particulate matter emissions.
Twenty traverse points, 10 per;port axis, were sampled for six minutes each
resulting in a total test time of 120 minutes.
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.
-19-
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Test data was recorded every three minutes at each point during all test periods.
Leak checks were performed according to EPA Method 17 instructions prior to and
after each run and/or component change. Table 1 presents a summary of test data
for each of the three runs. Test result summarization appears on Table 5.
Visible emissions observations were recorded concurrently with each particulate
test repetition by a certified observer according to EPA Method 9 procedures.
See Table 5 for result summary.
No. 2 Raymond Mill Baqhouse Inlet Duct
One EPA Method 5 test was performed at the inlet simultaneous with particulate
Test Run 3 at the outlet. Eight points were traversed, k per port axis, for
15 minutes, each yielding a test period 120 minutes in length.
Procedures for isokinetic sampling were identical for those described for the
outlet location except that test data was recorded every 5 minutes and the filter
holder temperatures were monitored. Test data and test result summaries are
provided in Tables 2 and 6 respectively.
One sampling point located at a site of average velocity was selected from parti-
culate traverse data for particle size distribution testing. The gas stream was
sampled isokinetically at that point for 30 seconds which permitted collection of
sufficient sample for analysis without overloading the filter substrates. Sample
volume, temperature, and pressure data was recorded before and after the test.
See Figure 10 for a distribution plot.
No. 2 Fluid Energy Mill Baqhouse Exhaust Stack
Three 120 minute Method 17 test runs were performed at the baghouse outlet. A
total of 20 points were sampled for 6 minutes each per test.
Procedures for isokinetic sampling were identical to those described in No. 2
Raymond Mill Baghouse Exhaust Stack Section.
See Tables 3 and 7 for test data and test result summaries respectively.
-20-
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Visual determinations of plume opacity were performed by a certified observer
according to Method 9 Procedures. A summary of results is presented in Table 7.
No. 2 Fluid Energy Mill Baghouse Inlet Duct
One Method 5 test was performed at the inlet simultaneous with particulate Test
Run 2 at the outlet. Thirty-six points were traversed, 18 per port axis, for
3.5 minutes each yielding a test period of 126 minutes.
Isokinetic sampling procedures were identical to those previously described
except that test data was recorded every 3.5 minutes. Table k shows test data
summarization and Table 8 presents test results.
One particle size distribution sample was collected isokinetically at a point
of average velocity over a 1.5 minute period. Sample volume, temperature, and
pressure data was recorded before and after the test. See Figure 11 for distri-
bution results.
-21-
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ANALYTICAL PROCEDURES
Participate Sample Recovery
At the conclusion of each test, the sampling trains were dismantled, openings
sealed, and the components transported to the field laboratory. Sample inte-
grity was assured by maintaining chain of custody records which will be supplied
upon request.
A consistent procedure was employed for sample recovery:
• 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 (EPA 5) and nozzle were separated and the internal
particulate rinsed with acetone into a borosilicate container
while brushing a minimum of three times until no visible
particles remained. Particulate adhering to the brush was
rinsed with acetone into the same container. The front half
of the filter holder was rinsed with acetone 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 immed-
iately weighed.
• An acetone sample was retained for blank analysis.
Particulate Analyses
The filters (Sample 1) and any loose fragments were desiccated for 2k hours and
weighed to the nearest 0.1 milligram to a constant weight.
The acetone wash samples (Sample 2) were evaporated at ambient temperature and
pressure in tared beakers, and desiccated to constant weight. All sample resi-
due weights were adjusted by the acetone blank value.
-22-
-------
The weight of the material collected on the glass fiber filter(s) plus the
weight of the residue of the acetone 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.
Particle Size Sample Recovery and Analyses
The cascade impactor substrates and any loose fragments were carefully removed
from their support plates with tweezers and placed in individual containers
(petri dishes) for shipment to Weston Laboratory.
Each cascade impactor filter was fired at 525°C and pre-weighed to the nearest
0.1 milligram to constant weight at Weston1s Laboratory prior to on-site applica-
tion. Subsequent to emissions exposure, the cascade impactor substrates, back-up
filters and any loose fragments (Sample k) were desiccated for 2k hours in the
Laboratory, and weighed to the nearest 0.1 milligram to constant weight.
-23-
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DISCUSSION OF TEST RESULTS
Particulate test data and test result summaries are presented in Tables 1 through
8 of this report. Figures 10 and 11 illustrate the particle size distribution
of the particulate matter at the baghouse inlet locations.
No unusual sampling difficulties or process operating problems were encountered
during any of the test periods.
The amount of particulate matter discharged to the atmosphere from both
baghouse sources was low (£0.007 grains/dscf and £0.08 pounds/hour), which
indicates the effectiveness of bag collectors in this application when they
are properly maintained. The certified observer further corroborated the
particulate test findings sfnce no visible emissions were recorded emanating
from either stack during the test program. For the record, almost no visible
emissions were detected from similar adjacent sources by the smoke reader.
The particulate removal efficiency of No. 2 Raymond Mill Baghouse was measured
at 99.98%; that of No. 2 Fluid Energy Mill was 99-87?. Both efficiencies were
calculated based on one simultaneous inlet/outlet test only.
Results of the Anderson ^ cascade impaction particle size distribution test
conducted at No. 2 Raymond Mill Baghouse Inlet showed a preponderance of
relatively large particles entering the collector (3k% of the particles,
by weight, were >_ A.OM in diameter). The large particles were easily
captured in the bag collector. At No. 2 Fluid Energy Mill Inlet, the
particles were distributed normally across the particle size range. The
higher percentage of small particles quantified at this location may
explain the slightly lower collection efficiency of No. 2 Fluid Energy
Mill Baghouse compared to No. 2 Raymond Mill Baghouse assuming identical
bag specifications, collector operating conditions, etc.
-2k-
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ENGELHARD MINERALS S CHEMICALS CORPORATION
Attapulgus, Georgia
TABLE 1
#2 Raymond Mill Baghouse Exhaust
Summary of Test Data
Test Data
Test Number
Test Date
Test Period
SamplIng Data
Sampling Duration, minutes
Nozzle Diameter, inches
Barometric Pressure, inches mercury
Average Orifice Pressure Differential, inches water
Average Dry Gas Temperature at Meter, F
Sample Volume at Meter Conditions, cubic feet
Sample Volume at Standard Conditions, ' cubic feet —
Gas Stream Moisture Content
Total Water Collected by Train, ml
Standard Volume of Water Collected, cubic feet
Moisture in Gas Stream, percent by volume
Mole Fraction of Dry Gas
Gas Stream Composition
C02, percent by volume
03, percent by volume
CO, percent by volume
N2, percent by volume
Molecular Weight of Wet Gas
Molecular Weight of Dry Gas
Gas Stream Velocity
Static Pressure, inches water
Absolute Pressure, inches mercury
Average Temperature, °F
Pitot Tube Calibration Coefficient
Total Number of Sampling Points
Velocity at Actual Conditions, feet/second
Gas Stream Volumetric Flow
Stack Cross-Sectional Area, square feet
Volumetric Flow at Actual Conditions, cubic feet/minute
Volumetric Flow at Standard Conditions, cubic feet/minute
Percent Isokinetic
6/14/78
1527-1735
24.6
1.16
1.-1
0.989
0.0
20.9
0.0
79.1
28.85
28.97
0.573
2,580.
2,100.
92.6
6/15/78
0851-1159
39-0
1.84
1.7
0.983
0.0
20.9
0.0
79.1
28.78
28.97
0.573
2,460.
2,090.
91.9
6/15/78
11*02-1620
120.0
0.218
30.12
3.2
130.
116. 48
105.66
120.0
0.218
30.08
3-2
111.
111.61
104.1(5
120.0
0.218
30.08
3.1
121.
113-51
104.39
35.7
1.68
1.6
0.984
0.0
20.9
0.0
79.1
28.80
28.97
- 0.42
30.09
183.
0.855
20.0
74.9
- 0.44
30.05
15' •
0.855
20.0
71.4
- 0.42
30.05
150.
0.855
20.0
71.4
0.573
2,450.
2,100.
91.5
Process Operations Data
Mill Feed Rate, pounds/hour
Baghouse Pressure Drop, inches
MONITORED BY ENGELHARD PERSONNEL
3.7 4.4 4.8
Standard Conditions = 68 F, 29-92 inches mercury, dry basis.
-25-
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ENGELHARD MINERALS 6 CHEMICALS CORPORATION
Attapulgus, Georgia
TABLE 2
#2 Raymond Mill Baghouse Inlet
Summary of Test Data
Test Data
Test Number •>
Test Date
Test Period
Samp I ing Data
Sampling Duration, minutes
Nozzle Diameter, inches
Barometric Pressure, inches mercury
Average Orifice Pressure Differential, inches water
Average Dry Gas Temperature at Meter, °F
Sample Volume at Meter Conditions, cubic feet
Sample Volume at Standard Conditions, ' cubic feet
Gas Stream Moisture Content
Total Water Collected by Train, ml
Standard Volume of Water Collected, cubic feet
Moisture in Gas Stream, percent by volume
Mole Fraction of Dry Gas
Gas Stream Composition
CC>2, percent by volume
02, percent by volume
CO, percent by volume
N2, percent by volume
Molecular Weight of Wet Gas
Molecular Weight of Dry Gas
Gas Stream Velocity
Static Pressure, inches water
Absolute Pressure, inches mercury
Average Temperature, °F
Pilot Tube Calibration Coefficient
Total Number of Sampling Points
Velocity at Actual Conditions, feet/second
Gas Stream Volumetric Flow
Stack Cross-Sectional Area, square feet
Volumetric Flow at Actual Conditions, cubic feet/minute
Volumetric Flow at Standard Conditions, cubic feet/minute
Percent Isokinetic
6/15/78
1400-1612
120.0
0.189
30,08
1.2
112.
72.83
67.67
26.0
1.22
1.8
0.982
0.0
20.9
0.0
79.1
28.77
28.97
- 2.1
29.93
153.
0.835
8.0
54.4
0.785
2,560.
2,170.
104.8
Process Operations Data
Mill Feed Rate, pounds/hour
Baghouse Pressure Drop, inches
H20
MONITORED BY ENGELHARD PERSONNEL
4.8
1Standard Conditions = 68°F, 29-92 inches mercury, dry basis.
-26-
-------
ENGELHARD MINERALS & CHEMICALS CORPORATION
Attapulgus, Georgia
TABLE 3
#2 Fluid Energy Mill Baghouse Exhaust
Summary of Test Data
Test Data
Test Number
Test Date
Test Period
Samp I ing Data
Sampling Duration, minutes
Nozzle Diameter, inches
Barometric Pressure, inches mercury
Average Orifice Pressure Differential, inches water
Average Dry Gas Temperature at Meter, F
Sample Volume at Meter Conditions, cubic feet
Sample Volume at Standard Conditions, ' cubic feet
Gas Stream Moisture Content
Total Water Collected by Train, ml
Standard Volume of Water Collected, cubic feet
Moisture in Gas Stream, percent by volume
Mole Fraction of Dry Gas
Gas Stream Composition
C02, percent by volume
02, percent by volume
CO, percent by volume
N2, percent by volume
Molecular Weight of Wet Gas
Molecular Weight of Dry Gas
Gas Stream Velocity
Static Pressure, inches water
Absolute Pressure, inches mercury
Average Temperature, °F
Pitot Tube Calibration Coefficient
Total Number of Sampling Points
Velocity at Actual Conditions, feet/second
Gas Stream Volumetric Flow
Stack Cross-Sectional Area, square feet
Volumetric Flow at Actual Conditions, cubic feet/minute
Volumetric Flow at Standard Conditions, cubic feet/minute
Percent Isokinetic
6/14/78
151)3-1801
0,0
20.9
0.0
79.1
28.66
28.97
- 0.10
30.11
124.
0.843
20.0
39.0
0.785
,840.
,620.
96.6
2
6/15/78
0914-1151
0.0
20.9
0.0
79.1
28.52
28.97
- 0.25
30.06
121.
0.843
20.0
31.6
0.785
1,490.
1,300.
108.2
6/15/78
1333-1636
120.0
0.220
30.12
1.1
104.
65-76
63.31
120.0
0.220
30.08
0.77
102.
58.96
56.84
120.0
0.220
30.08
0.75
103.
56.99
54.80
39.0
1.84
2.8
0.972
52.0
2.45
4.1
0.959
51.0
2.40
4.2
0.958
0.0
20.9
0.0
79.1
28.51
28.97
- 0.21
30.06
124.
0.843
20.0
33.2
0.785
,560.
,360.
99-9
Process Operations Data
Mill Feed Rate, pounds/hour
Baghouse Pressure Drop, inches
MONITORED BY ENGELHARD PERSONNEL
2.2 2.4 2.0
Standard Conditions = 68?F, 29-92 inches mercury, dry basis.
-27-
-------
ENGELHARD MINERALS 6 CHEMICALS CORPORATION
Attapulgus, Georgia
TABLE ft
#2 Fluid Energy Mill Baghouse Inlet
Summary of Test Data
Test Data
Test Number
Test Date
Test Period
Samp I ing Data
Sampling Duration, minutes
Nozzle Diameter, inches
Barometric Pressure, inches mercury
Average Orifice Pressure Differential, inches water
Average Dry Gas Temperature at Meter, F
Sample Volume at Meter Conditions, cubic feet
Sample Volume at Standard Conditions, ' cubic feet
Gas Stream Moisture Content
Total Water Collected by Train, ml
Standard Volume of Water Collected, cubic feet
Moisture in Gas Stream, percent by volume
Mole Fraction of Dry Gas
Gas Stream Composition
C02, percent by volume
03, percent by volume
CO, percent by volume
Nj, percent by volume
Molecular Weight of Wet Gas
Molecular Weight of Dry Gas
Gas Stream Velocity
Static Pressure, inches water
Absolute Pressure, inches mercury
Average Temperature, °F
PItot Tube Calibration Coefficient
Total Number of Sampling Points
Velocity at Actual Conditions, feet/second
Gas Stream Volumetric Flow
Stack Cross-Sectional Area, square feet
Volumetric Flow at Actual Conditions, cubic feet/minute
Volumetric Flow at Standard Conditions, cubic feet/minute
Percent Isoklnetic
6/15/78
0916-1207
126.0
0.189
30.08
1.2
10ft.
7ft.38
70.05
73-0
3.ftft
*». 7
0.953
0.0
20.9
0.0
79.1
28.1*6
28.97
- 11.0
29.27
121.
0.835
36.0
57.0
0.601
2,060.
1,7ftO.
103.5
Process Operations Data
Mill Feed Rate, pounds/hour
Baghouse Pressure Drop, inches
MONITORED BY ENGELHARD PERSONNEL
2.ft
Standard Conditions = 68°F, 29-92 inches mercury, dry basis.
-28-
-------
ENGELHARD MINERALS & CHEMICALS CORPORATION
Attapulgus, Georgia
TABLE 5
#2 Raymond Mill Baghouse Exhuast
Summary of Test Results
Test Data
Test Number 1 2 3
Test Date 6/14/78 6/15/78 6/15/78
Test Time 1527-1735 0851-1159 1402-1620
Gas Flow
Standard Cubic Feet/minute, dry 2,100. 2,090. 2,100.
Actual Cubic Feet/minute, wet 2,580. 2,460. - 2,450.
Particulates
Nozzle and Front Half Filter Holder Catch Fraction, g 0.0089 0.0104 0.0075
Filter Catch Fraction, g 0.0039 0.0053 - 0.0004
Total Particulates, g 0.0128 0.0157 0.0075
Particulate Emissions
Grains/dry standard cubic foot 0,002 0.002 0.001
Pounds/hour 0.03 0.04 0.02
Baghouse Particulate Removal Efficiency, percent —* 99-98
Visible Emissions
>^ 5 percent opacity, mtnutes observed 0. 0. 0.
0 percent opacity, minutes observed ' 0. 0, 0.
No visible emission, minutes observed 120. 120. 120.
Based on Total Particulates captured by train.
Standard Conditions » 68°F and 29-92 Inches mercury.
Opacity results listed are in minutes of the observed reading during the 120 minute test period.
-29-
-------
ENGELHARD MINERALS S CHEMICALS CORPORATION
Attapulgus, Georgia
TABLE 6
#2 Raymond Mill Bag house Inlet
Summary of Test Results
Test Data
Test Number 1
Test Date 6/15/78
Test Time 1400-1610
Gas Flow
Standard Cubic Feet/minute, dry .. 2,170.
Actual Cubic Feet/minute, wet 2,560.
Particulates
Nozzle, Probe and Front Half Filter Holder Catch Fraction, g 0.9102
Filter Catch Fraction, g 22.0470
Total Particulates, g 22.9572
Participate Emissions
2
Grains/dry standard cubic foot 5.24
Pounds/hour 97.4
Based on Total Particulates captured by train.
Standard Conditions = 68°F and 29.92 inches mercury.
Test conducted simultaneously with Run 3, No. 2 Raymond Mill Baghouse.Exhaust.
-30-
-------
ENGELHARD MINERALS & CHEMICALS CORPORATION
Attapulgus, Georgia
TABLE 7
#2 Fluid Energy Mill Baghouse Exhaust
Summary of Test Results
Test Data
Test Number 123
Test Date 6/14/78 6/15/78 6/15/78
Test Time 1543-J801 0914-1151 1333-1636
Gas Flow
Standard Cubic Feet/minute, dry 1,620. 1,300. 1,360.
Actual Cubic Feet/minute, wet 1,840. 1,490. 1,560.
Participates
Nozzle and Front Half Filter Holder Catch Fraction, g 0.0016 0.0051 0.0099
Filter Catch Fraction, g 0.0017 -0.0004 0.0149
Total Particulates, g 0.0033 0,0051 0.0248
Particulate Emissions
Grains/dry standard cubic foot 0.001 0.001 0.007
Pounds/hour 0.01 0.02 0.08
Baghouse Particulate Removal Efficiency, percent 95,87
Visible Emissions
>_ 5 percent opacity, minutes observed 0. 0. 0.
0 percent opacity, minutes observed 0. 0. 0.
No visible emission, minutes observed 120. 120. 120.
Based on Total Particulates captured by train.
Standard Conditions = 68°F and 29.92 inches mercury.
* Opacity results listed are in minutes of the observed reading during the 120 minute test period.
-31-
-------
ENGELHARD MINERALS £ CHEMICAL CORPORATION
Attapulgus, Georgia
TABLE 8
#2 Fluid Energy Mill Baghouse Inlet^
Summary of Test Results
Test Data
Test Number 1
Test Date 6/15/78
Test Time 0916-1207
Gas Flow
Standard Cubic Feet/minute, dry 1,7^0.
Actual Cubic Feet/minute, wet 2,060.
Particulates
Nozzle, Probe and Front Half Filter Holder Fraction, g 0.2755
Filter Catch Fraction, g It. 1*616
Total Particulates, g ^.7371
Particulate Emissions
Grains/dry standard cubic foot 1.QA
Pounds/hour 15-6
Based on Total Particulates captured by tratn.
Standard Conditions = 68°F and 29-92 inches mercury.
Test conducted simultaneously with Run 2, No. 2 Fluid Energy Mill Baghouse Exhaust.
-32-
-------
#2 RAYMOND MILL BAGHOUSE INLET
PARTICLE SIZE DISTRIBUTION
c.
o
L-
O
o
LU
o
o
LU
O
LU
LL.
10.0
9.0
8.0
7.0
6.0
5.0
U.O
3.0
2.0
1.0
°-2
0.8
0.7
0.6
0.5
0.3
0.2
0.1
o
LU
0.01 0.05 0. I 0.2 0.5 I
10 20 30 40 50 60 70 BO
CUMULATIVE PERCENTAGE
90
95
M 99
9.1 99.9
99.99
-------
#2 FLUID ENERGY MILL BAGHOUSE INLET
PARTICLE SIZE DISTRIBUTION
10.0
9.0
8.0
7.0
6.0
§ 5.0
o
•i k.o
85 3.0
i-
UJ
<
5 2.0
UJ
_l
o
p
DC
2
s i:3°
i 0.8
1 °'7
o 0.6
1 0.5
% 0.**
f-
(_>
UJ Q 0
u. v. j
u.
UJ
0.2
0.1
/
X
}
/
f
/
/
/
/
7
'
/
x
/^
./
/
y
7
/
/
f
UJ
cc
o
U.
0.01 0.05 0. I 0.2 0.5 I 2
10 70 30 40 50 BO 70 BO
CUMULATIVE PERCENTAGE
(% WEIGHT LESS THAN DIAMETER)
BO
95
M 98
99.1 99.9
99.99
------- |