AN AIR POLLUTION CONTROL
EQUIPMENT INVENTORY OF THE
AMERICAN STEEL INDUSTRY
Volume 2
Draft Final Report
GCA
GCA CORPORATION
Technology Division
213 Burlington Road
Bedford, Mass. 01730
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CCA-TR-82-11-G
U.S. ENVIRONMENTAL PROTECTION AGENCY
Division of Stationary Source Enforcement
Washington, D.C.
Contract No. 68-01-6316
Technical Service Area 1
Work Assignment No. 28
EPA Project Officer
John R. Busik
EPA Task Manager
Bernard Bloom
EPA Assignment Manager
Laxmi Kesari
AN AIR POLLUTION CONTROL
EQUIPMENT INVENTORY OF THE
AMERICAN STEEL INDUSTRY
Volume 2
Draft Final Report
February 1982
Prepared by:
Michael Jasinski
Peter Spawn
Sandra Beaton
Eugene Bergson
William Farino
GCA CORPORATION
GCA/TECHNOLOGY DIVISION
Bedford, Massachusetts
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DISCLAIMER
This Draft Final Report was furnished to the Environmental Protection
Agency by GCA Corporation, GCA/Technology Division, Burlington Road, Bedford,
Massachusetts 01730, in partial fulfillment of Contract No. 68-01-6136,
Technical Service Area 1, Work Assignment No. 28. The opinions, findings, and
conclusions expressed are those of the authors and not necessarily those of
the Environmental Protection Agency. Mention of company or product names is
not to be considered as an endorsement by the Environmental Protection Agency.
SPECIAL NOTE
The inventory reported in this document was initiated in October 1980
under EPA Contract No. 68-01-4143, Technical Service Area 1, Task No. 94.
Additional data compilation and investigation were performed in January 1981
under EPA Contract No. 68-01-6316, Technical Service Area 1, Task No. 6
(Phase II), and in March 1981 under EPA Contract No. 68-01-6316, Technical
Service Area 1, Work Assignment No. 6 (Amendment 1 - Phase III). Mr. Bernard
Bloom and Mr. Laxmi Kesari served as EPA Task Directors/Assignment Managers
for this program.
All material presented in this document is subject to a confidentiality
review, and is not releasable as of February 1, 1982. For further
information, contact Mr. Laxmi Kesari, United States Environmental Protection
Agency, Division of Stationary Source Enforcement, Washington, D.C.
ii
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TABLES
(Volume 2)
Numbers Page
1-16 Coke Oven Gas Desulfurizatlon (Furnace Coke Producers) . . 354
1- 3 Coke Oven Gas Desulfurization (Foundry Coke Producers) • . 380
References 383
1-26 Sintering Machines 388
References 430
1-43 Blast Furnaces 439
References • 489
1-11 External Iron Desulfurization Stations 494
References 505
1-35 Basic Oxygen Converters 507
References 558
1-33 Electric Arc Furnaces 568
References 607
1-7 Open Hearth Furnaces 615
References 623
1-25 Scarfing Machines (automatic) 626
References 655
iii
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o
o
MATERIAL IN THIS SECTION SUBJECT TO CONFIDENTIALITY Q gj
REVIEW AND IS NOT RELEASABLE AS OF FEBRUARY 1, 1982. So
FOR INFORMATION, CONTACT L. KESARI, U.S. ENVIRONMENTAL p|
PROTECTION AGENCY, DIVISION OF STATIONARY SOURCE ENFORCEMENT. £ ^
o
o >
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TABLE 1. ARMCO INC./MIDDLETOWN WORKS IN MIDDLETOWN, OH
COKE PLANT NOS. 2a AND 3b COKE OVEN GAS DESULFURIZATION
PROCESS AND EMISSION CONTROL DATA
BATTERY DESIGNATION: No. I1 No. I1 No. 21
MANUFACTURER: Wilputte1 Dravo-Still (both batteries)1
STARTUP DATE: 19532>3 19761 19771
RECENT REHABILITATION DATE:
SCHEDULED SHUTDOWN DATE:
NO. OF OVENS: 761 571 571
OVEN HEIGHT (ft-in.): 13-61 19-81 19-81
OVEN LENGTH (ft-in.): 43-91 52-61 52-61
COKE PRODUCTION:
RATED TONS/DAY: 5,150 (all three batteries combined)4
TYPICAL TONS/DAY: 4,890 (all three batteries combined)4
PERCENT SULFUR OF COAL (BY WEIGHT): 0.6 (for all three batteries)2
QUANTITY OF COG PRODUCED (ft3/day): 77 x 106 (all three batteries
combined) •*
TYPE OF DESULFURIZATION PROCESS: Carl Still (serves all three batteries)6.7
MANUFACTURER: Dravo8
DATE INSTALLED: 19767
SYSTEM DESCRIPTION: • Carl Still process uses liquid oxidation
for sulfur removal8
• Process handles 60 x 106 scfd of COG,
and uses sulfuric acid production for
sulfur recovery8
• NH3 used as an absorbent in sulfur
removal process8
ADDITIONAL COMMENTS:
aBattery No. 1 (Wilputte).2
bBattery Nos. 1 and 2 (Dravo-Still).2
354
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TABLE 2. BETHLEHEM STEEL CORP./BETHLEHEM PLANT IN BETHLEHEM, PA
COKE OVEN GAS DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
BATTERY DESIGNATION:
MANUFACTURER:
STARTUP DATE:
RECENT REHABILITATION DATE:
SCHEDULED SHUTDOWN DATE:
NO. OF OVENS:
OVEN HEIGHT (m):
OVEN LENGTH (ft-ln.):
COKE PRODUCTION:
RATED TONS/DAY:
TYPICAL TONS/DAY:
PERCENT SULFUR OF COAL (BY WEIGHT);
QUANTITY OF COG PRODUCED (ft3/day):
TYPE OF DESULFURIZATION PROCESS:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
2A2
2B2
3A2
3B2
Koppers-Becker (batteries 2A through 3B)2
19412 19412 19422 19422
32
32
32
102C»10
32
5,840 (all six batteries combined)4
5,058 (all six batteries combined)4
1.0 (for all six batteries)2
100 x 106 (all six batteries
combined) H
Sulfiban (2 plants-serve all six
batteries)6»&
Bethlehem Steel/Applied Technology8
1975d,8,12
• Liquid absorption for sulfur removal**
• Amine solution (approximately 15%
monoethanol amine "MEA") as absorbent**
• Claus plant for sulfur recovery**
• Each sulfiban plant handles approximately
60 x 106 cu ft COG per day8
(continued)
355
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TABLE 2 (continued)
COKE OVEN GAS DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
BATTERY DESIGNATION:
MANUFACTURER:
STARTUP DATE:
RECENT REHABILITATION DATE:
SCHEDULED SHUTDOWN DATE:
NO. OF OVENS:
OVEN HEIGHT (m):
OVEN LENGTH (ft-in.):
COKE PRODUCTION:
RATED TONS/DAY:
TYPICAL TONS/DAY:
PERCENT SULFUR OF COAL (BY WEIGHT):
QUANTITY OF COG PRODUCED (ft3/day):
TYPE OF DESULFURIZATION PROCESS:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Koppers-Becker2
1953a,2
802
42
See previous page^
See previous page2
A2
McKee-Otto2
19762
802
62
11
See previous page
Sulfiban (2 plants—serve all six
batteries)6**5
See previous page for description.^
ADDITIONAL COMMENTS:
aBattery 5 rebuilt in 1977.9
bBattery 2A and 2B combined.1*10
cBattery 3A and 3B combined.1*10
dSulfiban plants rebuilt in 1976.8»12
356
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TABLE 3. BETHLEHEM STEEL CORP./BURNS HARBOR PLANT IN CHESTERTON, IN
COKE OVEN GAS DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
BATTERY DESIGNATION:
MANUFACTURER:
STARTUP DATE:
RECENT REHABILITATION DATE:
SCHEDULED SHUTDOWN DATE:
NO. OF OVENS:
OVEN HEIGHT (ft-in. ):
OVEN LENGTH (ft-in.):
No. I1
Wilputte1
196913
1980a,14
1982b>16
821
20-514' •
50-714
No. 21
Koppers1
1972^3
821
20-514
50-7*4
COKE PRODUCTION:
RATED TONS/DAY: 6,670 (both batteries combined)4
TYPICAL TONS/DAY: 5,179 (both batteries combined)4
PERCENT SULFUR OF COAL (BY WEIGHT): 0.89 (for both batteries)14
QUANTITY OF COG PRODUCED (ft3/day): 120 x 106 (both batteries combined)11
TYPE OF DESULFURIZATION PROCESS: Vacuum Carbonate (serves both batteries)6
MANUFACTURER: Koppers9
DATE INSTALLED: 19726>15
SYSTEM DESCRIPTION: • Process uses liquid absorption for sulfur
removal"
• Glaus plant used for sulfur recovery (HCN
destruct)®
• Sodium carbonate solution used for
absorption"
ADDITIONAL COMMENTS:
alnvolved changing steam nozzles, i.e., increasing aspiration and rebuilding
battery top.*4
^Scheduled shutdown for rebuild, i.e., double collector mains to be
installed.16
357
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TABLE 4. BETHLEHEM STEEL CORP./LACKAWANNA PLANT IN LACKAWANNA, NY
COKE OVEN GAS DESOLFURIZATION PROCESS AND EMISSION CONTROL DATA
r
BATTERY DESIGNATION:8 No. 72 No. 82 No. 92
MANUFACTURER: Wilputte2 Wilputte2 Wilputte2
STARTUP DATE: 19522 19612 19692
RECENT REHABILITATION DATE: 1980b>17
SCHEDULED SHUTDOWN DATE: 1982C»18
NO. OF OVENS: 762 762 762
OVEN HEIGHT (ft-in.): 12-219 12-219 20-419
OVEN LENGTH (ft-in.): 40-719 40-7*9 48-319
COKE PRODUCTION;d
RATED TONS/DAY: 8,140 (for seven battery operation)4
TYPICAL TONS/DAY: 6,908 (for seven battery operation)4
PERCENT SULFUR OF COAL (BY WEIGHT): 1.1 (for all three batteries)2
QUANTITY OF COG PRODUCED (ft3/day): 50-60 x 10& (all three batteries
combined)8*18
TYPE OF DESULFURIZATION PROCESS: Vacuum Carbonate (serves all three
batteries)6
MANUFACTURER: Koppers8
DATE INSTALLED:6 197618
SYSTEM DESCRIPTION: • Uses liquid absorption for sulfur
removal8
• Sulfuric acid production for sulfur
recovery8
• Sodium carbonate solution used for
absorption8
ADDITIONAL COMMENTS:
^Batteries No. 3, 4, 5 and 6 were shut down in 1977.18
^Battery was completely rebuilt.1?
cScheduled shutdown for rebuild.*8
^Production data appears to be prior to 1977 battery shut downs.4
eSystem was rebuilt in 1979.18
358
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TABLE 5. BETHLEHEM STEEL CORP./SPARROWS POINT PLANT IN SPARROWS POINT, MD
COKE OVEN GAS DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
BATTERY DESIGNATION:0
MANUFACTURER:
STARTUP DATE:
RECENT REHABILITATION DATE:
SCHEDULED SHUTDOWN DATE:
NO. OF OVENS:
OVEN HEIGHT (m):
OVEN LENGTH (ft-in.):
COKE PRODUCTION:
RATED TONS/DAY:
TYPICAL TONS/DAY:
PERCENT SULFUR OF COAL (BY WEIGHT);
QUANTITY OF COG PRODUCED (ft3/day):
TYPE OF DESULFURIZATION PROCESS:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No. I2
No. 22 No. 32
Koppers (all four batteries)2
I9602 19612 19512
1985b,20 I985b>20 1982C,2!
632 602 632
3 (each, all six batteries)2
43-0 (each, all six batteries)1
No. 42
19782
II*5 '"
5,500 (all eight batteries combined)21
l.l;2 0.74-avg. in 197422 (for all
eight batteries)
100 x 106;11 131.9 x 106—avg. in
197422 (all eight batteries combined)
Vacuum Carbonate (serves all eight
batteries)6*20
Koppers^
• Liquid absorption for sulfur removal"
• Sodium carbonate solution (approximately
2 percent) used as absorbent"*22
(continued)
359
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TABLE 5 (continued)
COKE OVEN GAS DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
BATTERY DESIGNATION:8 No. 52 No. 62 No. II2 No. 122
MANUFACTURER: Koppers2 Koppers2 Koppers- Koppers-
Becker2 Becker2
STARTUP DATE: 19782 19532 19552 19572
RECENT REHABILITATION DATE:
SCHEDULED SHUTDOWN DATE: 1985b>20 1982C>21
NO. OF OVENS: 632 632 652 652
OVEN HEIGHT (m): 32 32 42 42
OVEN LENGTH (ft-in.): 43-01 43-01 43-01 43-0*
COKE PRODUCTION:
RATED TONS/DAY: See previous page21
TYPICAL TONS/DAY:
PERCENT SULFUR OF COAL (BY WEIGHT): See previous page2>22
QUANTITY OF COG PRODUCED (ft3/day): See previous page11*22
TYPE OF DESULFURIZATION PROCESS: Vacuum Carbonate (serves all eight
batteries)6*20
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION: See previous page for description8>22
ADDITIONAL COMMENTS:
aBattery NOB. 9 and 10 were shut down in early 1981.21
bNew Battery "A" to start-up In December 1981; new Battery "B" scheduled to
start-up in December 1985 will replace Battery Nos. 1, 2, 4, and 5.21
cPlant has the option to either shut down Battery Nos. 3 and 6 in 1982, or
continue their operation until 1985.21
360
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TABLE 6. INLAND STEEL CORP./INDIANA HARBOR WORKS IN E. CHICAGO, IN
COKE PLANT NO. 2 COKE OVEN GAS DESULFURIZATION PROCESS
AND EMISSION CONTROL DATA
BATTERY DESIGNATION:
MANUFACTURER:
STARTUP DATE:
RECENT REHABILITATION DATE:
SCHEDULED SHUTDOWN DATE:
NO. OF OVENS:
OVEN HEIGHT (ft-in.):
OVEN LENGTH (ft-in.):
COKE PRODUCTION:
RATED TONS/DAY:
TYPICAL TONS/DAY:
PERCENT SULFUR OF COAL (BY WEIGHT):
QUANTITY OF COG PRODUCED (ft3/day);
TYPE OF DESULFURIZATION PROCESS:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No. 61
No. 71
No. 81
Koppers-Becker (all three batteries)1
19501 19561 19581
1971a,2 I974a>2
651
12-01
37-71
871
12-01
37-71
871
12-01
37-71
6170 (all five batteries combined)^
5640 (all five batteries combined)^
0.8 (for all five batteries)2
50 x 106 (all five batteries
combined)°
Vacuum Carbonate (serves all five
batteries)**
Koppers^
19746
• Vacuum carbonate process uses liquid
absorption for sulfur removal.**
• Glaus plant, with water wash of HCN, for
sulfur recovery."
• Sodium carbonate solution used for
absorption.8
(continued)
361
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TABLE 6 (continued)
COKE PLANT NO. 2 COKE OVEN GAS DESULFURIZATION PROCESS
AND EMISSION CONTROL DATA
BATTERY DESIGNATION: No. 91 No. 101
MANUFACTURER: Koppers-Becker (both batteries)1
STARTUP DATE: 19591 19701
RECENT REHABILITATION DATE:
SCHEDULED SHUTDOWN DATE:
NO. OF OVENS: 871 . , 511
OVEN HEIGHT (ft-in.): 12-01 20-01
OVEN LENGTH (ft-in.): 37-71 37-41
COKE PRODUCTION:
RATED TONS/DAY: See previou8 page4
TYPICAL TONS/DAY:
PERCENT SULFUR OF COAL (BY WEIGHT): See previous page2
QUANTITY OF COG PRODUCED (ft3/day): See previous page8
TYPE OF DESULFURIZATION PROCESS: Vacuum Carbonate (serves all five
batteries)6
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION: See previous page for description6*8
ADDITIONAL COMMENTS:
alnvolved end-flue rehabilitation2
362
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TABLE NO. 7. INLAND STEEL CORP./INDIANA HARBOR WORKS IN E. CHICAGO, IN
COKE PLANTS NO. 3a AND 4b COKE OVEN GAS DESULFURIZATION PROCESS
AND EMISSION CONTROL DATA
BATTERY DESIGNATION: C1 II1
MANUFACTURER: Koppers1 Koppers1
STARTUP DATE: 19741 19781
RECENT REHABILITATION DATE: 1979C»23
SCHEDULED SHUTDOWN DATE:
NO. OF OVENS: 561 • 691
OVEN HEIGHT (ft-in.): 20-21 20-21
OVEN LENGTH (ft-in.): 47-111 471
COKE PRODUCTION:
RATED TONS/DAY: 3014 (battery C)4 2500 (battery No. II)4
TYPICAL TONS/DAY: 2740 (battery C)4 1562 (battery No. II)4
PERCENT SULFUR OF COAL (BY WEIGHT): 1.1 (for both batteries)2
QUANTITY OF COG PRODUCED (ft3/day):
TYPE OF DESULFURIZATION PROCESS: Vacuum Carbonate Vacuum Carbonate
(serves battery C)23 (serves battery No.
MANUFACTURER: Koppers23 Koppers8
DATE INSTALLED: 197423 19786
SYSTEM DESCRIPTION: • Vacuum carbonate processes use liquid
absorption for sulfur removal.8
• Glaus plant, with water wash of HCN, for
sulfur recovery.8
• Sodium carbonate solution used for
absorption.8
ADDITIONAL COMMENTS:
aBattery C
bBattery No. 11
clnvolved end-flue rehabilitation23
363
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TABLE 8. JONES & LAUGLIN STEEL CORP./ALIQUIPPA WORKS IN ALIQUIPPA, PA
COKE OVEN GAS DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
BATTERY DESIGNATION:8
MANUFACTURER:
STARTUP DATE:
RECENT REHABILITATION DATE:
SCHEDULED SHUTDOWN DATE:
NO. OF OVENS:
OVEN HEIGHT (ft-ln.):
OVEN LENGTH (ft-in. ):
A-ll
Koppers-Becker2
19451
197824
1061
13-01
40-51
A-5b,l
Koppers^
197613
561
20-61
50-?1
COKE PRODUCTION:0
RATED TONS/DAY: 4,308 (both batteries combined)25
TYPICAL TONS/DAY: 3,500 (both batteries combined)26
PERCENT SULFUR OF COAL (BY WEIGHT): 1.0 (for both batteries)2'26
QUANTITY OF COG PRODUCED (ft3/day): 64.6 x 106 (both batteries
combined)25
TYPE OF DESULFURIZATION PROCESS: Carl Still (serves both batteries)6'25
MANUFACTURER: Dravo8
DATE INSTALLED: 198124»25
SYSTEM DESCRIPTION: • Liquid absorption used for sulfur
removal8
ADDITIONAL COMMENTS:
aBatteries A-3 and A-4 were shut down in I960.24
lattery A-5 replaced battery A-2 in 1975-1976.26
cProduction data for a 4-battery operation (A-l, A-3, A-4, and A-5) = 6,946
(rated tons/day); 4,506 (typical tons/day).4
364
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TABLE 9. JONES & LAUGHLIN STEEL CORP./PITTSBURGH WORKS IN PITTSBURGH, PA
COKE OVEN GAS DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
BATTKRY DESIGNATION:
MANUFACTURER:
STARTUP DATE:
RECENT REHABILITATION DATE:
SCHEDULED SHUTDOWN DATE:
NO. OF OVENS:
OVEN HEIGHT (ft-in.):
OVEN LENGTH (ft-in.):
COKE PRODUCTION:
RATED TONS/DAY:
TYPICAL TONS/DAY:
PERCENT SULFUR OF COAL (BY WEIGHT);
QUANTITY OF COG PRODUCED (ft3/day):
PI*
Wilputte1
I9601
197927
P21
Wilputte1
19611
1977*.2
P3N1
Wilputte1
19611
I96027
59 (each, batteries PI through P3N)1
13-0 (each, batteries PI through P3N)1
40-9 (each, batteries PI through P3N)1
5,300 (all five batteries combined)4
5,230 (all five batteries combined)4
1.2;2 0.9-1.227 (for all five
batteries)
80 x 106;11 90 x 106 (all five
batteries combined)27
TYPE OF DESULFURIZATION PROCESS: Sulfiban (serves all five batteries)6
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Bethlehem Steel/Applied Technology®
1975b»8
• Process uses liquid absorption for sulfur
removal®
• Amine solution (~15% monoethanol amine)
used as absorbent®
• Sulfuric acid production used for sulfur
recovery0»®
(continued)
365
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TABLE 9 (continued)
COKE OVEN GAS DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
BATTERY DESIGNATION:
MANUFACTURER:
STARTUP DATE:
RECENT REHABILITATION DATE:
SCHEDULED SHUTDOWN DATE:
NO. OF OVENS:
OVEN HEIGHT (ft-in. ):
OVEN LENGTH (ft-in.):
P3S1
Wilputte1
19611
1978a»2
591
13-Ql .
40-9 1
P4l
Koppers-Becker^
19531
19793.2
791
13-01
40-61
COKE PRODUCTION:
RATED TONS/DAY:
TYPICAL TONS/DAY:
PERCENT SULFUR OF COAL (BY WEIGHT):
QUANTITY OF COG PRODUCED (ft3/day):
TYPE OF DESULFURIZATION PROCESS:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
See previous page^
See previous page^»27
See previous page^'^'
Sulfiban (serves all five batteries)^
See previous page for description^
ADDITIONAL COMMENTS:
alnvolved end-flue rehabilitation.2
bRelined in 1977.8
cSulfuric acid plant has not operated since Dec. 1976.
366
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TABLE 10. KAISER STEEL CORP. IN FONTANA, CA
COKE OVEN GAS DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
BATTERY DESIGNATION:
MANUFACTURER:
STARTUP DATE:
RECENT REHABILITATION DATE:a
SCHEDULED SHUTDOWN DATE:
NO. OF OVENS:
OVEN HEIGHT (ft-in.):
OVEN LENGTH (ft-in.):
COKE PRODUCTION:
RATED TONS/DAY:
TYPICAL TONS/DAY:
PERCENT SULFUR OF COAL (BY WEIGHT);
QUANTITY OF COG PRODUCED (ft3/day):
TYPE OF DESULFURIZATION PROCESS:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Koppers-Becker2
194228
197328
4528
13-028 ,
40-528
Koppers-Becker2
194228
197328
4528
13-028
40-528
4.250;1 4,100^ (all seven batteries
combined)
3,800 (all seven batteries combined)^
0.75 (avg.);28 Q.92 (for all seven
batteries)
Takahax-A (serves all seven batteries)**
Nippon/Chemico8
1981^,29
• Process uses liquid oxidation for sulfur
removal
• NH3 absorption together with wet
oxidation removes sulfur8
(continued)
367
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TABLE 10 (continued)
COKE OVEN GAS DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
BATTERY DESIGNATION:
MANUFACTURER:
STARTUP DATE:
RECENT REHABILITATION DATE:
SCHEDULED SHUTDOWN DATE:
NO. OF OVENS:
OVEN HEIGHT (ft-in.):
OVEN LENGTH (ft-in.):
COKE PRODUCTION:
RATED TONS/DAY:
TYPICAL TONS/DAY:
PERCENT SULFUR OF COAL (BY WEIGHT):
QUANTITY OF COG PRODUCED (ft3/day)i
TYPE OF DESULFURIZATION PROCESS:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Koppers-Becker2
194928
1976a>28
Koppers-Becker2
195228
1979-80b>28
4528
13-028 .
40-528
4528
13-028
40-528
See previous
See previous page2»28
Takahax-A (serves all seven batteries)"
See previous page for description8>29
(continued)
368
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TABLE 10 (continued)
COKE OVEN GAS DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
BATTERY DESIGNATION: E1 F1 G1
MANUFACTURER: Koppers- Koppers- Koppers-
Becker2 Becker2 Becker2
STARTUP DATE: 195228 195828 195828
RECENT REHABILITATION DATE: 1978b>28
SCHEDULED SHUTDOWN DATE:
NO. OF OVENS: 4528 , . 4528 4528
OVEN HEIGHT (ft-in.): 13-028 13-028 13-028
OVEN LENGTH (ft-in.): 40-528 40-528 40-528
COKE PRODUCTION:
RATED TONS/DAY: See previous pages1*4
TYPICAL TONS/DAY:
PERCENT SULFUR OF COAL (BY WEIGHT): See previous pages2*28
QUANTITY OF COG PRODUCED (ft3/day):
TYPE OF DESULFURIZATION PROCESS: Takahax-A (serves all seven batteries)6
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION: See previous pages for description8*29
ADDITIONAL COMMENTS:
alnvolved trimwork.28
blnvolved end-flue rehabilitation.28
cFacility shut down in March 1981 due to corrosion problems.2'
369
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TABLE 11. NATIONAL STEEL CORP./WEIRTON STEEL DIVISION IN WEIRTON, WV
COKE OVEN GAS DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
BATTERY DESIGNATION:
MANUFACTURER:
STARTUP DATE:
RECENT REHABILITATION DATE:
SCHEDULED SHUTDOWN DATE:
NO. OF OVENS:
OVEN HEIGHT (ft-in.):
OVEN LENGTH (ft-in.):
COKE PRODUCTION:
RATED TONS/DAY:
TYPICAL TONS/DAY:
PERCENT SULFUR OF COAL (BY WEIGHT);
1.22
QUANTITY OF COG PRODUCED (ft3/day)j
TYPE OF DESULFURIZATION PROCESS:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
I-ll
Koppersl
19731.30
1979a»2
87l
20-431
47-331
3,600 (battery I-l)4
3,000 (battery I-l)4
1.03 (avg. in 1974) ;
35 x 106 (avg. in
1974); 34 70 x 10&
Vacuum Carbonate (serves
battery 1-1)6,30
Koppers^
197330
• Liquid absorption for
sulfur removal**
• Glaus plant, with water
wash of HCN, for sulfur
recovery^
• Sodium carbonate solution
used for absorption."
ADDITIONAL COMMENTS:
alnvolved end-wall rehabilitation.31
370
-------
TABLE 12. REPUBLIC STEEL CORP./CHICAGO DISTRICT IN CHICAGO, IL
COKE OVEN GAS DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
BATTERY DESIGNATION: No. I1
MANUFACTURER: Wilputte1
STARTUP DATE: 194 31
RECENT REHABILITATION DATE:
SCHEDULED SHUTDOWN DATE: 1981a>33
NO. OF OVENS: 751
OVEN HEIGHT (ft-in.): . 13-01
OVEN LENGTH (ft-in.): 42-733
COKE PRODUCTION:
RATED TONS/DAY: 1,369:4 1.2001
TYPICAL TONS/DAY: 1,300*
PERCENT SULFUR OF COAL (BY WEIGHT):
QUANTITY OF COG PRODUCED (ft3/day):
TYPE OF DESULFURIZATION PROCESS:b
ADDITIONAL COMMENTS:
aBattery No. 1 to be replaced by a Battery No. 2 with 60 ovens, 6 m high,
double collector mains, 4 charge holes, automatic lid lifters using stage
charging and rated at 1,800 tons of coke per day.33
bThe new battery will include a Takahax (Nippon/Chemico) coke oven gas
desulfurization process upon initial battery start up. Takahax process uses
liquid oxidation for sulfur removal.33
371
-------
TABLE 13. REPUBLIC STEEL CORP./CLEVELAND DISTRICT IN CLEVELAND, OH
COKE OVEN GAS DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
BATTERY DESIGNATION:* No. I1 No. 21 No. 31 No. 41
MANUFACTURER: Koppers (all four batteries)1
STARTUP DATE: . 19769 19582 19582 19582
RECENT REHABILITATION DATE: 19722 19722 19722
SCHEDULED SHUTDOWN DATE:
NO. OF OVENS: 511 , 511 511 511
OVEN HEIGHT (ft-in.): 13-2 (each; all four batteries)1
OVEN LENGTH (ft-in.): 41-0 (each; all four batteries)1
COKE PRODUCTION:
RATED TONS/DAY: 2,782 (all four batteries combined)4
TYPICAL TONS/DAY: 2,049 (all four batteries (combined)4
PERCENT SULFUR OF COAL (BY WEIGHT):
QUANTITY OF COG PRODUCED (ft3/day): 64 x 106 (all four batteries combined)34
TYPE OF DESULFURIZATION PROCESS: Sulfiban (serves all six batteries)6
MANUFACTURER: Bethlehem Steel/Applied Tech.8
DATE INSTALLED:
SYSTEM DESCRIPTION: • Sulfiban process uses liquid absorption
for sulfur removal"
• Araine absorber solution (~15% monoethanol
amine, "MEA") used for sulfur removal8
(continued)
372
-------
TABLE 13 (continued)
COKE OVEN GAS DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
BATTERY DESIGNATION:
MANUFACTURER:
STARTUP DATE:
RECENT REHABILITATION DATE:
SCHEDULED SHUTDOWN DATE:
NO. OF OVENS:
OVEN HEIGHT (ft-in.):
OVEN LENGTH (ft-in.):
COKE PRODUCTION:
RATED TONS/DAY:
TYPICAL TONS/DAY:
PERCENT SULFUR OF COAL (BY WEIGHT):
QUANTITY OF COG PRODUCED (ft3/day):
TYPE OF DESULFURIZATION PROCESS:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No. 61
Koppers-Beckerl
195213
19792
631
13-21
41-O1
No. 7l
Koppers-Beckerl
195213
19792
631
13-21
41-Ql
1,954 (both batteries combined)*
1,286 (both batteries combined)4
55 x 106 (both batteries combined)34
Sulfiban (serves all six batteries)6
See previous page for description"
ADDITIONAL COMMENTS:
aBattery No. 5 was shut down in 1975.
^Involved end-flue rehabilitation.2
373
-------
TABLE 14. REPUBLIC STEEL CORP./MAHONING VALLEY DISTRICT IN WARREN, OH
COKE OVEN GAS DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
BATTERY DESIGNATION:
MANUFACTURER:
STARTUP DATE:
RECENT REHABILITATION DATE:
SCHEDULED SHUTDOWN DATE:
NO. OF OVENS:
OVEN HEIGHT (ft-in.):
OVEN LENGTH (ft-in.):
COKE PRODUCTION:
RATED TONS/DAY:
TYPICAL TONS/DAY:
PERCENT SULFUR OF COAL (BY WEIGHT):
QUANTITY OF COG PRODUCED (ft3/day):
TYPE OF DESULFURIZATION PROCESS:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No. 42
Koppers2
19792
13-03&
41-1137
1.8524
1.2794
1.02
29.1 x 10637
Sulfiban6»36>37
Beth.,Steel/Applied Tech8*37
198036,37
• Sulfiban process uses
liquid absorption for
sulfur removal"
• Amine absorber solution
(~15% monoethanol amine,
"MEA") used for sulfur
removal"
ADDITIONAL COMMENTS:
aBatteries No. 1 and 2 were shut down in March 1979.36
374
-------
TABLE 15. UNITED STATES STEEL CORP./CLAIRTON WORKS IN CLAIRTON, PA
COKE OVEN GAS DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
BATTERY DESIGNATION:
MANUFACTURER:
STARTUP DATE:
RECENT REHABI
SCHEDULED SHU
NO. OF OVENS:
OVEN HEIGHT (ft-in.):
OVEN LENGTH (ft-in.):
COKE PRODUCTION:
RATED TONS/DAY:
TYPICAL TONS/DAY:
PERCENT SULFUR OF COAL (BY WEIGHT):
QUANTITY OF COG PRODUCED (ft3/day):
TYPE OF DESULFURIZATION PROCESS:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
IN:
: AT ION DATE:
IWN DATE:
•in.):
•in.):
No. I38 No. 238 No. 338
Wilputte38 Wilputte38 Wilputte38
195538 195538 195538
197938 197938 197938
6438 6438 6438
13-038 13-038 13-038
37-038 37-038 37-038
20,780 (entire coke plant)4
16,342 (entire coke plant)*1
0.9 (average for all batteries)2
300 x 106 (all batteries combined)27
Vacuum Carbonate (two systems serve
all batteries)6
Koppers8
First unit—19688
• Process uses liquid absorption for
sulfur removal8
• Sodium carbonate solution used as
absorbent8
• "Keystone" unit services 90 x 106
scfd of COG and has a Claus plant
(with HCN water wash) for sulfur
recovery8
• "No. 1" unit services 60 x 106 scfd
of COG and has a Claus plant (with
HCN water wash) for sulfur recovery8
(continued)
375
-------
TABLE 15 (continued)
COKE OVEN GAS DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
BATTERY DESIGNATION:
MANUFACTURER:
STARTUP DATE:
RECENT REHABILITATION DATE:
SCHEDULED SHUTDOWN DATE:
NO. OF OVENS:
OVEN HEIGHT (m) :
OVEN LENGTH (ft-In.):
No. ?38
19543"
1984*2
6439
42 •
No. 838
Koppers38
1954*°
1984*2
64*0
42
No. 938
Koppers38
1954*1
1984*2
64*1
42
COKE PRODUCTION:
RATED TONS/DAY:
TYPICAL TONS/DAY:
PERCENT SULFUR OF COAL (BY WEIGHT);
QUANTITY OF COG PRODUCED (ft3/day):
TYPE OF DESULFURIZATION PROCESS:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
See previous page*
See previous page2
See previous page27
Vacuum Carbonate (two systems serve all
batteries)6
See previous page for description8
(continued)
376
-------
TABLE 15 (continued)
COKE OVEN GAS DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
BATTERY DESIGNATION:
MANUFACTURER:
STARTUP DATE:
RECENT REHABILITATION DATE:
SCHEDULED SHUTDOWN DATE:
NO. OF OVENS:
OVEN HEIGHT (m):
OVEN LENGTH (ft-In.):
COKE PRODUCTION:
RATED TONS/DAY:
TYPICAL TONS/DAY:
PERCENT SULFUR OF COAL (BY WEIGHT):
QUANTITY OF COG PRODUCED (ft3/day):
TYPE OF DESULFURIZATION PROCESS:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No. 15 38
Koppers*3
1953a,43
7 •
61*3
42 .
No. 1638 No. 1738
Wilputte** Wilputte*5
195044 1950*5
198242 198242
6138 6138
42 42
See previous pages*
See previous pages2
See previous pages2'
Vacuum Carbonate (two systems serve all
batteries)6
See previous pages for description"
(continued)
377
-------
TABLE 15 (continued)
COKE OVEN GAS DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
BATTERY DESIGNATION:
MANUFACTURER:
STARTUP DATE:
RECENT REHABILITATION DATE:
SCHEDULED SHUTDOWN DATE:
NO. OF OVENS:
OVEN HEIGHT (m) :
OVEN LENGTH (ft-in.):
COKE PRODUCTION:
RATED TONS/DAY:
TYPICAL TONS/DAY:
PERCENT SULFUR OF COAL (BY WEIGHT);
QUANTITY OF COG PRODUCED (ft3/day):
TYPE OF DESULFURIZATION PROCESS:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No. 1938 No. 2038 No. 2138 No. 2238
Koppers-Becker (all four batteries)38
195146 I947b>47 194748 194649
197738 1972C,38 1973d,38
8738
52
8738
52
8738
52
8738
52
See previous pages4
See previous pages2
See previous pages27
Vacuum Carbonate (two systems serve all
batteries)6
See previous pages for description8
ADDITIONAL COMMENTS:
aBattery No. 15 was rebuilt in 1979.2
bBattery No. 20 was rebuilt in 1978.38
clnvolved end-flue rehabilitation.38
^Involved rehabilitation from bench-up.38
378
-------
TABLE 16. WHEELING-PITTSBURGH STEEL CORP./STEUBENVILLE PLANT IN
EAST STEUBENVILLE, WV
COKE OVEN GAS DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
BATTERY DESIGNATIONS
MANUFACTURER:
STARTUP DATE:
RECENT REHABILITATION DATE:
SCHEDULED SHUTDOWN DATE:
NO. OF OVENS:
OVEN HEIGHT (m) :
OVEN LENGTH (ft-in. ):
No. I2
Koppers2
1917b,50
1978e>2
4?2
350
37-550
No. 22
Koppers2
1917C.50
1978e»2
472
350
37-550
No. 32
Koppers-
Becker2
1917d,50
1978e, 2
512
350
38-550
No. 82
Koppers2
197650
792
650
47-1150
COKE PRODUCTION:
RATED TONS/DAY:
TYPICAL TONS/DAY:
PERCENT SULFUR OF COAL (BY WEIGHT);
QUANTITY OF COG PRODUCED (ft3/day);
4,400;! 5.2054 (all four batteries
combined)
4,310 (all four batteries combined)4
1.0 (for all four batteries)2
9 x 106 scfd (all four batteries
combined)6,8
TYPE OF DESULFURIZATION PROCESS: Carl Still (serves all four batteries)6
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Dravo8
197850
• Carl Still process uses liquid absorption
for sulfur removal8
• NH3 used as absorbent8
• Sulfuric acid production used for
sulfur recovery8
ADDITIONAL COMMENTS:
aPlant shut down Battery No. 4 (53 ovens) in 1977, Battery No. 5 (53 ovens)
in 1976, and Battery No. 6 (63 ovens) in 1977.50
bBattery No. 1 rebuilt in 1955.50
cBattery No. 2 rebuilt in 1953.50
dBattery No. 3 rebuilt in 1964.50
elnvolved end-flue rehabilitation.2
379
-------
MATERIAL IN THIS SECTION SUBJECT TO CONFIDENTIALITY
REVIEW AND IS NOT RELEASABLE AS OF FEBRUARY 1, 1982.
FOR INFORMATION, CONTACT L. KESARI, U.S. ENVIRONMENTAL
PROTECTION AGENCY, DIVISION OF STATIONARY SOURCE ENFORCEMENT.
n
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TABLE 1. ALLIED CHEMICAL CORP./ASHLAND PLANT IN ASHLAND, KY
COKE OVEN GAS DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
BATTERY DESIGNATION:
MANUFACTURER:
STARTUP DATE:
RECENT REHABILITAT:
SCHEDULED SHUTDOWN DATE:
NO. OF OVENS:
OVEN HEIGHT (m):
OVEN LENGTH (ft-in.):
COKE PRODUCTION:
RATED TONS/DAY:
TYPICAL TONS/DAY:
PERCENT SULFUR OF COAL (BY WEIGHT):
QUANTITY OF COG PRODUCED (ft3/day):
No. 32
Wilputte2
19532
IN DATE: 1973C>2
)ATE:
762
4.52
1 : 40-853
No. 4a>2
Wilputte2
b
702
4.5;2 552
46-1053
TYPE OF DESULFURIZATION PROCESS:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
3,480 (both batteries combined)^
2,100 (both batteries combined)^
0.8 (for both batteries)2
45 x 106 (normal; both batteries
combined),
53 x 106 (maximum; both batteries
combined)53
Sulfiban (serves both batteries)6'51
Bethlehem Steel/Applied Technology8
1978^1
• Process uses liquid absorption for
sulfur removal"
• Amine solution as absorber;
approximately 15% monoethanolamine
(MEA) solution8
ADDITIONAL COMMENTS:
aBattery No. 4 was shut down in December 1980 due to low coke demand.51
^Battery No. 4 was rebuilt in 1978.2
clnvolved end-flue rehabilitation.2
380
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TABLE 2. DONNER-HANNA COKE CORP IN BUFFALO, NY
COKE OVEN GAS DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
BATTERY DESIGNATION:
MANUFACTURER:
STARTUP DATE:
RECENT REHABILITATION DATE:
SCHEDULED SHUTDOWN DATE:
NO. OF OVENS:
OVEN HEIGHT (m):
OVEN LENGTH (ft-in.):
COKE PRODUCTION:
RATED TONS/DAY:
TYPICAL TONS/DAY:
PERCENT SULFUR OF COAL (BY WEIGHT);
QUANTITY OF COG PRODUCED (ft3/day);
TYPE OF DESULFURIZATION PROCESS:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
AB2
Koppers2
19512
512
4; 2 219
No. 32
Koppers2
19642
502
42,19
No. 42
Koppers2
19672
502
4-2,19
3,004 (all three batteries combined)4
3,004 (all three batteries combined)4
1.1 (for all three batteries)2
30 x 106 (all three batteries
combined)34
Vacuum Carbonate (serves all three
batteries)6
Koppers^
1978 (approximately)19
• Sulfur removal via liquid absorption
(sodium carbonate solution)"
ADDITIONAL COMMENTS:
381
-------
TABLE 3. KOPPERS CO., INC./INDUSTRIAL PRODUCTS DIVISION,
ERIE PLANT IN ERIE, PA
COKE OVEN GAS DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
BATTERY DESIGNATION: a
MANUFACTURER:
STARTUP DATE:
RECENT REHABILITATION DATE:
SCHEDULED SHUTDOWN DATE:
NO. OF OVENS:
OVEN HEIGHT (ft-in. ):
OVEN LENGTH (ft-in.):
A2
f\
Koppers^
1943b«54
23.2 ,
12-055
43-055
B2
Koppers2
1943b>2
352
12-055
42-055
COKE PRODUCTION:
RATED TONS/DAY:
TYPICAL TONS/DAY:
PERCENT SULFUR OF COAL (BY WEIGHT):
QUANTITY OF COG PRODUCED (ft3/day):
TYPE OF DESULFURIZATION PROCESS:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
730;1 6254 (both batteries
combined)
600 (both batteries combined)4
0.7 (for both batteries)2
6.5 x 106 fboth batteries
combined)5°
Hydro-Quinone (serves both batteries)56
ADDITIONAL COMMENTS:
aFacility previously owned and operated by Interlake, Inc.^
bBoth batteries rebuilt in 1971.2
382
-------
MATERIAL IN THIS SECTION SUBJECT TO CONFIDENTIALITY
REVIEW AND IS NOT RELEASABLE AS OF FEBRUARY 1, 1982.
FOR INFORMATION, CONTACT L. KESARI, U.S. ENVIRONMENTAL
PROTECTION AGENCY, DIVISION OF STATIONARY SOURCE ENFORCEMENT.
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REFERENCES
COKE OVEN GAS DESULFURIZATION
1. World Steel Industry Data Handbook: -Volume 1, The United States.
McGraw-Hill Magazine. 1978. p. 40. (Reliability No. 4.)
2. Technical Approach for a Coke Production Cost Model. PEDCo
Environmental, Inc. EPA Contract No. 68-02-3071. p. 47. (Reliability
No. 4.)
3. EPA Region V Files. (Renewal Permit Applications dated January 26, 1979.)
4. Development Document for Effluent Limitations Guidelines and Standards
for the Iron and Steel Manufacturing Point Source Category, Vol. II*
Draft Report. EPA-440/l-70-024a. October 1979. pp. 18-19.
(Reliability No. 4.)
5. ARMCO's Coke Batteries Scheduled for Mid-1976 Start-Up. Iron & Steel
Engineer. September 1975. pp. 61-62. (Reliability No. 4.)
6. COG Desulfurization: The Standard Tightens. Thirty-Three Metal
Producing Magazine. November 1980. Vol. 11. McGraw-Hill Publications.
pp. 44-45. (Reliability No. 4.)
7. EPA Region V Files. (Permit Application for Coke By-Product Plant, dated
August 3, 1978 by B. Steiner of ARMCO, Inc.)
8. Technical Support Document for the Recommended Lowest Achievable Emission
Rate for S02 Emissions from Coke-Oven Gas Combustion. U.S.
Environmental Protection Agency, Division of Stationary Source
Enforcement. January 1977. (Reliability No. 2.)
9. Telephone conversations. Bernard Bloom, U.S. Environmental Protection
Agency, Division of Stationary Source Enforcement to Michael Jasinski,
GCA/Technology Division. December 1980. (Reliability No. 2.)
10. Telephone conversation and letter response. Bill Nuver, Pennsylvania
Department of Environmental Resources to Sandy Beaton, GCA/Technology
Division. November 1981.
383
-------
11. Mossey, Michael J., and Robert W. Dunlap. Economics and Alternatives for
Sulfur Removal from Coke Oven Gas. JAPCA. 25(10):1019-1027. October
1975. (Reliability No. 4.)
12. Telephone conversation. Bernard Bloom, U.S. Environmental Protection
Agency, to Michael Jasinski, GCA/Technology Division. February 1981.
(Reliability No. 2.)
13. Cost Effectiveness Model for Pollution Control of Coke Facilities.
EPA-600/2-79-185. August 1979. Table 8. (Reliability No. 4.)
14. Petroccia, M., et al. Field Inspection Report. Bethlehem Steel
Corporation, Burns Harbor, Coke Batteries 1 and 2, Chesterton, Indiana.
GCA/Technology Division Draft Final Report No. TR-80-56-G. Prepared for
U.S. Environmental Protection Agency. July 1980. (Reliability No. 1.)
15. Hombeig, Otto A., and Alan H. Singleton. Claus Plant Performance and
Problems. Preprint of Paper No. 74-186 for presentation at the Air
Pollution Control Association 1974 Annual Meeting. (Reliability No. 4.)
16. Telephone conversation. Andy Sutherland, State of Indiana, Air Pollution
Control to Sandy Beaton, GCA/Technology Division. February 1981.
(Reliability No. 2.)
17. Telephone conversation. Henry Sandoto, New York State Department of
Environmental Conservation to William Farino, GCA/Technology Division.
February 1981. (Reliability No. 2.)
18. Telephone conversation. Jack Hausrath, Erie County Department of Health
to Gene Bergson, GCA/Technology Division. February 17, 1981.
(Reliability No. 2.)
19. Letter response. Richard Craig, U.S. Environmental Protection Agency,
Region II to William Farino, GCA/Technology Division. December 1981.
(Reliability No. 1.)
20. Telephone conversation. Mark Sylvester, Maryland Department of Health
and Mental Hygiene to Michael Jasinski, GCA/Technology Division.
February 13, 1981. (Reliability No. 2.)
21. Telephone conversation. Ralph Hall, State of Maryland, Department of
Health and Mental Hygiene to Michael Jasinski, GCA/Technology Division.
October 1981. (Reliability No. 2.)
22. Letter from J. W. Colberg, General Manager of BSC/Sparrows Point Plant,
Sparrows Point, Maryland to Stephen Wassersug, Director of Enforcement
Division, U.S. Environmental Protection Agency, Region III. Re:
Information Request subsequent to EPA inspection of Sparrows Point's Air
Pollution Control Systems on March 17, 18, and 27, 1975. Letter dated
April 11, 1975. JACA Inc. Files. (Reliability No. 3.)
384
-------
23. EPA Region V Files (August 1981 letter from Inland to EPA).
24. Telephone conversation. Ken Bowman, Pennsylvania Department of
Environmental Resources to Gene Bergson, GCA/Technology Division.
February 18, 1981. (Reliability No. 2.)
25. Telephone conversation. Arthur Witt, Pennsylvania Department of
Environmental Resources to Sandy Beaton, GCA/Technology Division.
November 17, 1981. (Reliability No. 2.)
26. Petroccia, M., et al. Field Inspection Report. J&L Steel Corporation/
Aliquippa Works, May 1981. GCA Final Report TR-81-57-G. Prepared for
U.S. Environmental Protection Agency. .July 1981. (Reliability No. 1.)
27. Telephone conversation. S. Banninthaya, Allegheny County Health
Department to Gene Bergson, GCA/Technology Division. February 12, 1981.
(Reliability No. 2.)
28. Spawn, P. and Ramon Li. Field Inspection Report. Kaiser Steel
Corporation, Fontana Works Coke Plant, Fontana, California.
GCA/Technology Division Draft Final Report No. TR-79-53-G. Prepared for
U.S. Environmental Protection Agency. February 1980. (Reliability
No. 1.)
29. Telephone conversation. Lois Green, U.S. Environmental Protection
Agency, Region IX to Michael Jasinski, GCA/Technology Division. November
1981. (Reliability No. 2.)
30. Telephone conversation. John Raggi, West Virginia Air Pollution Control
to Gene Bergson, GCA/Technology Division. February 17, 1981.
(Reliability No. 2.)
31. Spawn, P., et al. National Steel Corporation, Weirton Steel Division
Plant Inspection, August 1981. GCA/Technology Division Draft Final
Report No. TR-81-118-G. Prepared for U.S. Environmental Protection
Agency. November 1981. (Reliability No. 1.)
32. Summary Sheets compiled by PEDCo from stack tests at regional EPA
offices. Provided to JACA, Inc. for Steel Library by Tom Maslany, EPA
Region III. (Reliability No. 1.)
33. EPA Region V Files. (Report on RSC/Chicago new coke battery, 1978.)
34. Hall, Robert R., et al. Evaluations of the Technological Feasibility and
Cost of Selected Control Alternatives Necessary to Meet the Ohio SO
Regulations. Republic Steel Corporation/Cleveland District Plant.
Volume III. GCA/Technology Division Final Report. Prepared for U.S.
Environmental Protection Agency. April 1977. (Reliability No. 2.)
35. Telephone conversation. Mr. Habib, City of Cleveland Air Pollution
Control to Sandy Beaton, GCA/Technology Division. October 1981.
(Reliability No. 2.)
385
-------
36. EPA Region V Files. (Trip report dated February 20, 1980.)
37. Telephone conversation. Ted Davis, Northeast District Ohio EPA to Gene
Bergson, GCA/Technology Division. February 27, 1981. (Reliability
No. 2.)
38. Spawn, P., et al. Field Inspection Report. USSC Clairton Works Coke
Plant, Clairton, Pennsylvania. GCA/Technology Division, Draft Final
Report No. TR-80-30-G. Prepared for U.S. Environmental Protection
Agency. April 1980. (Reliability No. 1.)
39. Source Sheet on USSC Clairton Coke Battery #7. RACT-500478.
(Reliability No. 1.)
40. Source Sheet on USSC Clairton Coke Battery #8. RACT-500484.
(Reliability No. 1.)
41. Source Sheet on USSC Clairton Coke Battery #9. RACT-500490.
(Reliability No. 1.)
42. Computer Printout. Prepared by PEDCo Environmental Inc., for U.S.
Environmental Protection Agency, Washington, D.C. Coke Battery data
compilation of the United States. 1979. (Reliability No. 4.)
43. Source Sheet on USSC Clairton Coke Battery No. 15. RACT-500526.
(Reliability No. 1.)
44. Source Sheet on USSC Clairton Coke Battery No. 16. RACT-500528.
(Reliability No. 1.)
45. Source Sheet on USSC Clairton Coke Battery No. 17. RACT-500541.
(Reliability No. 1.)
46. Source Sheet on USSC Clairton Coke Battery No. 19. RACT-500553.
(Reliability No. 1.)
47. Source Sheet on USSC Clairton Coke Battery No. 20. RACT-500562.
(Reliability No. 1.)
48. Source Sheet on USSC Clairton Coke Battery No. 21. RACT-500569.
(Reliability No. 1.)
49. Source Sheet on USSC Clairton Coke Battery No. 22. RACT-500581.
(Reliability No. 1.)
50. Telephone conversation and letter from John Raggi, West Virginia APC to
Michael Jasinski, GCA/Technology Division. November 1981. (Reliability
No. 2.)
51. Letter from Jim Dills, Kentucky State to Michael Jasinski, GCA/Technology
Division. November 19, 1981. (Reliability No. 1.)
386
-------
52. Emissions Test Report Submitted to Allied Chemical Company, Semet-Solvay
Division, Ashland, Kentucky, for the Minister Stein System. York
Research Corp. Report No. 1-9868-04. June 7, 1979. (Reliability No. 1.)
53. Letter from James W. Dills, Department for Natural Resources and
Environmental Protection to Michael Jasinski, GCA/Technology Division.
February 26, 1981. (Reliability No. 2.)
54. RACT Box No. 503715-503716. (Reliability No. 1.)
55. RACT No. 503715-503716. (Reliability No. 2.)
56. Telephone conversation. Larry Wonders, Pennsylvania Department of
Environmental Resources to Gene Bergson, GCA/Technology Division.
February 17, 1981. (Reliability No.'2.)
387
-------
co
H
a
o
n
PC
M
25
W
MATERIAL IN THIS SECTION SUBJECT TO CONFIDENTIALITY
REVIEW AND IS NOT RELEASABLE AS OF FEBRUARY 1, 1982.
FOR INFORMATION, CONTACT L. KESARI, U.S. ENVIRONMENTAL
PROTECTION AGENCY, DIVISION OF STATIONARY SOURCE ENFORCEMENT.
-------
TABLE 1. ARMCO INC./ASHLAND WORKS IN ASHLAND, KY
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
STRAND DESIGNATION:
STARTUP DATE:
STRAND WIDTH (in.):
GRATE AREA (ft2):
NO. OF WINDBOXES:
TYPE OF IGNITION FUEL:
SINTER PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
WINDBOX EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No. I1
19582
961
807;2 8241
151
Natural Gas2
2.640:1 2.4003
1.6473
Flooded disc scrubber1'4
Research-Cottrell1
1972;4 19751
• Exhaust flow rate = 150,000 dscfm _+
5,000 (nominal)1
• Ap (scrubber) = 48 in. W.C. (design)1
• Test Data (1975):5
Flow = 216,700 acfm at 130°F
Ap = 40-50 in.
ADDITIONAL COMMENTS:
388
-------
TABLE 2. ARMCO INC./HOUSTON WORKS IN HOUSTON, TX
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
STRAND DESIGNATION: No. I2
STARTUP DATE: 19572
STRAND WIDTH (In.): 722
GRATE AREA (ft2): 5362
NO. OF WINDBOXES: 146
TYPE OF IGNITION FUEL: Natural Gas;7 COG2
SINTER PRODUCTION:
RATED TONS/DAY: 1.3603
AVERAGE TONS/DAY (1976): 1,0783
WINDBOX EMISSION CONTROL SYSTEM: Steam-Hydro Scrubber System8
MANUFACTURER: Hydrosonics/Lone Star9
DATE INSTALLED: 19757>9
SYSTEM DESCRIPTION:
• System consists of six parallel units (two stacks per unit); of which
five operate at one time7>9
• Each unit consists of, (1) combination steam-waste nozzle, (2) mixing
tube, and (3) twin cyclonic separators'*9
• System fan capacity » 135,000 acfm at 300°F7»9
• Design L/G ratio = 2.74:1 (at 370 gpm-scrubber water) and Ap = 30 in.
H202»6
• Test Data (1976-inlet)i11
162,700-170,900 acfm (range)
155-193°F (range)
• Test Data (1975-inlet);10
181,300-195,400 acfm (range)
191-230°F (range)
DISCHARGE END EMISSION CONTROL SYSTEM:3 Baghouse controls discharge end and
breaker12'13
(continued)
389
-------
TABLE 2 (continued)
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION: • Test Data (1975):14
124,000-136,800 acfm (range)
300-363°F (range)
ADDITIONAL COMMENTS:
aA new baghouse will replace the existing baghouse in 1982. New baghouse
will control similar emission points plus additional pick-up points. ^
390
-------
TABLE 3. ARMCO INC./MIDDLETOWN WORKS IN MIDDLETOWN, OH
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
STRAND DESIGNATION:
STARTUP DATE:
STRAND WIDTH (in.):
GRATE AREA (ft2):
NO. OF WINDBOXES:
TYPE OF IGNITION FUEL:
SINTER PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
WINDBOX EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
197A2
962,15
7682,15
1215
Natural Gasl5
2.6403
1,8753
High-energy variable throat venturi
scrubber, with adjustable plugl^,!7
Koch18
197616>17
• In series:15,17
Primary and secondary cyclones, two
I.D. fans, scrubbers, cyclonic mist
eliminator, stub stack3
• 304,500 acftn at 150°F17
• Ap of venturi = 45 in. W.C.I7
• L/G = 5.91 gpm/1,000 acfm17
• Test Data (1976):15
Flow = 194,400-209,300 dscfm
Temperature = 129-133°F
DISCHARGE END EMISSION CONTROL SYSTEM:b Baghouse19
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Buell18
197418
ADDITIONAL COMMENTS:
a325 gpm (mist eliminator blow-down) sent to blast furnace sludge ponds;
400 gpm used for mist eliminator makeup water.I7
l>Cold screens controlled by AAF baghouse installed in 1975; mixing drum
and pellet screens controlled by individual "Environeering" scrubbers
Installed in 1974; and bin building controlled by Flex Klean baghouse
Installed in 1975.18
391
-------
TABLE 4. BETHLEHEM STEEL CORP./BETHLEHEM PLANT IN BETHLEHEM, PA
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
STRAND DESIGNATION:
STARTUP DATE:
STRAND WIDTH (in.):
GRATE AREA (ft2):
NO. OF WINDBOXES:
TYPE OF IGNITION FUEL:
SINTER PRODUCTION:
RATED TONS/DAY:
TYPICAL TONS/DAY:
WINDBOX EMISSION CONTROL SYSTEM:3
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No. I20 No. 220 No. 320 No. 420
19302 19302 19422 19502
722,21 722,21 722,21 722,2!
4972 4972 4972 4972
1320 1320 1320
Natural Gas;22 COG20
(all four strands)
6,145 (all four strands combined)^
Strand Nos. 1
and 2 controlled
by cyclones
and No. 1-WET
ESpb,20,23
Buell
(cyclones);20
Research Cottrell
(ESP)20
197024
• Each windbox
drawn to two
parallel sets of
3 cyclones in
series with one
ID fan, common
manifold to ESP
No. 12°
• ID fan rated at
385,000 acfm @
245°F20,21
Strand Nos. 3
and 4 controlled
by cyclones
and No. 2-WET
ESpC,20,23
Buell and Sirrocco
(cyclones);20
Research Cottrell
(ESP)21
197024
• No. 3 strand
discharges to 2
Sirrocco cyclones
in series, ID fan,
common duct to ESP
No. 220
• No. 4 strand same
cyclone arrange-
ment as Nos. 1 &
2 strands but
shares ID fan
with No. 320
(continued)
392
-------
TABLE 4 (continued)
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
• Each set of
cyclones rated
at 150,000 acfm
@ 250°F21
• Water sprays
to ESP = 7.5-27
gpm20
• Test data
238,000 acfm @
190°F
* Test data
(1979);2Cf
195,000 dscfm
• ESP contains 3
sections, total
of 1,600 wires;
600 wires in each
first 2 sections,
400 wires in last
section2"
• Water sprays
to ESP =• 0-30
gpm20
• Test data
(1979);^
221,000 acfm @
182°F
• Test data
(1977);^
269,000-320,000
acfm @ 223-259°F
DISCHARGE END EMISSION CONTROL SYSTEM: Baghouse21*27
Wheelabrator21
196124
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
• Baghouse controls hopper, sinter breaker, and hot screens from all four
strands; all emission points ducted to an ID fan, baghouse, and twin
exhaust stacks.21*27
• 16 compartments, 72 bags per compartment21
• 240,000 acfm @ 350°F (design)21
• A/C = 2.44 ft/min21
• Reverse air cleaning @ 20 minute cycles.21
COLD SCREENS EMISSION CONTROL SYSTEM: Baghouse21
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Wheelabrator 2°
• Baghouse controls cold screens from
all four strands.21
ADDITIONAL COMMENTS:
aEffluent from cyclones is preconditioned with water to a temperature of
210°F.20
^No. 1 ESP upgraded in 1979 by replacing 600 plain wires (center section)
and adding three additional transformer rectifier units.2^
cNo. 2 ESP upgraded in 1977 (similar to upgrading of NO. 1 ESP).26
393
-------
TABLE 5. BETHLEHEM STEEL CORP./BURNS HARBOR PLANT IN CHESTERTON, IN
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
STRAND DESIGNATION:
STARTUP DATE: 19752
STRAND WIDTH (in.): 157.52>29
GRATE AREA (ft2): 2,494;29 2,0202
NO. OF WINDBOXES: 12 (two collector mains)29'30
TYPE OF IGNITION FUEL: Gas2
SINTER PRODUCTION:
RATED TONS/DAY: 6,070;3 6.00031
AVERAGE TONS/DAY (1976): 5.1003
WINDBOX EMISSION CONTROL SYSTEM: Venturi Scrubber3'30
MANUFACTURER: B. B. Barefoot Co.31
DATE INSTALLED:
SYSTEM DESCRIPTION:
• In Series: multiclones, two ID fans, scrubber30
• Design flow rate = 561,000 acfm at 425°F (inlet); 380,000 scfra
(outlet)31.32
• Ap = 65 in. W.C. (max.)- 60 in. ^0 (normal)31.32
• Fans = 9,000 hp (each)3*
• Scrubber water flow (design) = 4,400 gpm31
• Test data (1976);31
267,222-289,694 dscfm
DISCHARGE END EMISSION CONTROL SYSTEM: Baghouseb»30>33
MANUFACTURER: Industrial Clean Air Corp.33
DATE INSTALLED:
SYSTEM DESCRIPTION:
• Design flow rate = 193, 750 scfm33
• Ap = 8.7-9.5 in H?0 (during tests)33
• Net A/C = 2.67:130
• Fan rated at 900-hp33
(continued)
394
-------
TABLE 5 (continued)
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
• Negative pressure—8 compartments, 512 graphite impregnated silicone
bags (total)33
• Reverse air or shaker cleaning (75-hp reverse air fan)33
ADDITIONAL COMMENTS:
aReplaced adjustable disc throat and elbow mist eliminator with stainless
steel in I960.30
"Total of 65 collection points including discharge end, screens, cooler and
pickup points.29
395
-------
TABLE 6. BETHLEHEM STEEL CORP./LACKAWANNA PLANT IN LACKAWANNA, NY
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
STRAND DESIGNATION:
STARTUP DATE:
STRAND WIDTH (in.):
GRATE AREA (ft2):
NO. OF WINDBOXES:
TYPE OF IGNITION FUEL:
SINTER PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
WINDBOX EMISSION CONTROL SYSTEM:3
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
34
East
19502
612;2
West3^
19502
722
612;2 69635
COG
22
COG
22
4,000 (both strands combined)3
3,779 (both strands combined)3
Separate, but identical wet ESP's
serve each strand54,35
Koppers (both ESP's)35
196835
• Design flow rate = 130,000 scfm
(each)35
• Exit temperature = 250°F35
• Horsepower = 1,500 (each system)35
DISCHARGE END EMISSION CONTROL SYSTEM:
ADDITIONAL COMMENTS:
aTwo wet scrubbers, manufactured by AAF, for windbox emission control (Type F
high energy venturi's) being installed (1981) following existing ESP's on each
sinter strand. Each scrubber will handle 137,000 dscfm of preconditioned
gases.35»3°
b"East" and "West" transfer points controlled by individual Ducon scrubbers.
Sinter cooler transfer points and screening operation controlled by individual
Ducon scrubbers.35
396
-------
TABLE 7. BETHLEHEM STEEL CORP./SPARROWS POINT PLANT IN SPARROWS POINT, MD
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
STRAND DESIGNATION: No. 737
STARTUP DATE: 19752
STRAND WIDTH (in.): 1332
GRATE AREA (ft2): 3.8002
NO. OF WINDBOXES: 2237
TYPE OF IGNITION FUEL: COG37
SINTER PRODUCTION:
RATED TONS/DAY: 12,2003»37
AVERAGE TONS/DAY (1976): 8.2603
WINDBOX EMISSION CONTROL SYSTEM: 2 cyclone-venturi scrubber systems37
MANUFACTURER: Koch (scrubbers);a>37 Buell
(cyclones)37
DATE INSTALLED: 197537
SYSTEM DESCRIPTION:
• Two systems In parallel identified North and South;37 Each with 30
cyclones, 1 I.D. fan, 1 F.D. fan, venturi throat scrubber, mist
eliminator, and wastewater treatment system
Scrubber capacity = 456,163-547,677 acfm (each)37
Inlet temperature = 350-450°F (design)3^
Ap - 30-60 in. W.G. (design)37
L/G - 4.57-7.67 (design)37
Scrubber water pH = 4.5 (design)37
Scrubber water temperature = 55-72°F (design)37
Test Data (1979);b«37
North Scrubber— South Scrubber—
Inlet temperature = 410-455°F Inlet temperature = 370-418°F
Ap - 34-35.5 in. H20 Ap = 35-37 in. H20
Water flow » 2,600-2,750 gpm Water flow = 3,400-3,500 gpm
L/G - 4.75-6.03 L/G =• 6.21-7.67
• Test Data (1976);37
272,200 dscfm
Ap (throat) = 31 in. W.G.
Water flow (throat) = 3,250 gpm (average)
(continued)
397
-------
TABLE 7 (continued)
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
DISCHARGE END EMISSION CONTROL SYSTEM: Baghouse for discharge end and transfer
points" >39
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Indus. Clean Air Corp.37*39
197540
• Baghouse controls sinter breaker,
raw burden feeder, hot screen, and
primary and secondary cold screens-*'
• 14 compartments; 2 modules per
compartment; 64 fiberglass cloth
bags per module-' 7»39
• Baghouse has a total of 65 to 70
inlet locations*!
• Flow = 400,000 acfm at 550°F;
Ap - 25 in. W.G.37»39
• A/C = 30:1 (maximum)37*39
• Negative pressure design; reverse
air cleaning at 26,000 acfm and
Ap - 20 in. W.G.3»»39
SINTER COOLER EMISSION CONTROL SYSTEM: Multiclones37'39
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Zurn Industries38'39
1975*0
• One I.D. fan with inlet capacity
640,000 acfm @ 600°F37»39
• Ap m 7 in. W.G.37'39
ADDITIONAL COMMENTS:
aHigh-energy venturi scrubbers with adjustable plugs.
^Actual production rate during 1979 test was 10,200 tons/day.
398
-------
TABLE 8. CF&I STEEL CORP./PUEBLO PLANT IN PUEBLO, CO
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
STRAND DESIGNATION:
STARTUP DATE:8
STRAND WIDTH (in.):
GRATE AREA (ft2):
NO. OF WINDBOXES:
TYPE OF IGNITION FUEL:
SINTER PRODUCTION:
RATED TONS/DAY:
TYPICAL TONS/DAY:
WINDBOX EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
<: No. I42
19432
): 722
6122
164'3 '
FUEL: coo2'44
No. 242
19432
722
6122
1643
COG2'44
3,300 (both strands combined)43
Common ESP serves both strands43'44
1968
• Each strand ducted to separate multi-
clones, then combined into common
ESP and two outlet stacks45
• Multiclones each consist of 299
tubes, designed at 180,000 acfm at
250°F per strand43
• ESP rated at 420,000 acfm at 320°F45
• System uses two fans operated in
parallel with 1250-hp each43
• Test Data (1975) :45
North stack—194,401 acfm
South stack—186,084 acfm
DISCHARGE END EMISSION CONTROL SYSTEM: Baghouse46
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
197442
• Rated at 200,000 acfm47
ADDITIONAL COMMENTS:
aThis facility was shut down in mid-June 1981; not scheduled to operate
unless new controls are installed.
399
-------
TABLE 9. INLAND STEEL CO./INDIANA HARBOR WORKS IN E. CHICAGO, IN
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
STRAND DESIGNATION:
STARTUP DATE:
STRAND WIDTH (in.):
GRATE AREA (ft2):
NO. OF WINDBOXES:
TYPE OF IGNITION FUEL:
SINTER PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
WINDBOX EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No.
19592,48
962
1,3442,48
2151 '
COG48
4.00048
4.0003
Multiclones, dry ESP and baghouse48
Western Pre- McDowell,
cipitator48 Inc.48
(tnulticlones) (ESP)
195948 ,„ 195948
Carborundum48
(baghouse)
197548
• In Series;^0 Multiclones, ESP,
1 F.D. fan, baghouse, 1 I.D. fan,
stack
• Multiclones:48
Design flow rate = 440,000 cfm at
140-180°F
Ap = 2.4 in. H20
840-9 in. diameter tubes
• ESP:48
Design flow rate - 440,000 cfm at
140-180°F
Consists of 2 sides, West No. 1
outlet and East No. 2a inlet
(operating in series)
136 plates; plate size = 7.5 ft x
24 ft (includes openings of
unknown size) spaced at 8.5 in. apart
Rapper frequency = every 2 seconds
(continued)
400
-------
TABLE 9 (continued)
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
Baghouse.
Design flow rate = 440,000 cfm at
100-300°F
Ap = 2 in. H20 (after cleaning)
and 7 in. 1^0 (before cleaning)—
across each compartment
Reverse air cleaning; 2 of 20 compart-
ments cleaned at once
A/C = 1.5:1
7,040 woven acrylic homopolymer bags
total
2,000 hp windbox F.D. fan—negative
pressure
Test Data (1976):49
Flow rate = 491,500-506,500 acfm
Outlet temperature = 214-240°F
DISCHARGE END EMISSION CONTROL SYSTEM: Baghouseb»48
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
AAF48
197648
• 146,000 cfm at 100 to 300°F48
• Ap = 1.8-2.0 in. 1^0 (across
baghouse)48
• A/C = 1.99:I48
• Five compartments—2,080 acrylic
bags (total)48
• One, 150-hp I.D. fan48
• Shaker cleaning
• Test Data (1975);50
145,500-148,800 acfm
Outlet temperature = 167-170°F
ADDITIONAL COMMENTS:
aESP, East No. 2 contained plates that were worn out; were to be fixed by
9/79.48
bBaghouse controls: sinter breaker, vibrating conveyor, hot fines conveyor,
rotary sinter cooler, dust surge bin, and transfer points along burden
conveyor.48
401
-------
TABLE 10. JONES & LAUGHLIN STEEL CORP./INDIANA HARBOR WORKS IN E. CHICAGO, IN
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
STRAND DESIGNATION:
STARTUP DATE:
STRAND WIDTH (in.):
GRATE AREA (ft2):
NO. OF WINDBOXES:
TYPE OF IGNITION FUEL:
SINTER PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
WINDBOX EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
19592
962
1,3442
51
Gas
4.0003
3.2043
Multiclones, dry ESP and venturi
S9 S^
scrubber in series-^ >->J
AAF (scrubber)52'54
197953
• 375,000 cfra (rated)52
• Ap = 50 in. H205^
• Test Data (1981):55
377,000-404,000 acfm (range)
Temperature = 109-119°F (range)
DISCHARGE END EMISSION CONTROL SYSTEM: Venturi scrubber53>56
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Rated at 66,670 scfra56
ADDITIONAL COMMENTS:
402
-------
TABLE 11. KAISER STEEL CORP. IN FONTANA, CA
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
STRAND DESIGNATION:
STARTUP DATE:
STRAND WIDTH (in.):
GRATE AREA (ft2):
NO. OF WINDBOXES:
TYPE OF IGNITION FUEL:
SINTER PRODUCTION:
No. I57
19432
722,51
6122«51
i
COG2'51
No. 258
19532
722,51
6122>51
1658
COG2'51
RATED TONS/DAY:
TYPICAL TONS/DAY:
WINDBOX EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Baghouse5'
Baghouse57>58
Carborundum58 Carborundum5°
197159 197159
• Rated at 180,000 • Rated at 180,000
acfm using acfin at 275°F5°
1,100-hp F.D. • 7 compartments—
fan and 900-hp 1,288 (total)
I.D. fan5' silicone, graphite,
• 7 compartments— teflon-coated,
1,288 (total) fiberglass bags5?
• A/C (design) =
1.47:l58
• Test Data (1974-
Inlet):60
silicone,
graphite,
teflon-coated,
fiberglass
bags5/
Reverse air
cleaning with
150-hp fan and
24,900 cfm57
Test Data.(1974-
Inlet):60,161
138,500 scfm at
170°F
149,000 scfm (wet)
at 233°F
132,000 scfm at
270°F
(continued)
403
-------
TABLE 11 (continued)
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
• Both baghouses ducted to common
exhaust stack""
• Test Data (1975-Outlet):58
205,170-222,392 acfm (range)
285-320°F (range)
DISCHARGE END EMISSION CONTROL SYSTEM: • No. 2 strand
. . discharge-breaker
end ducted to
windbox control
system baghouse
(see above
description)^' 58
ADDITIONAL COMMENTS:
404
-------
TABLE 12. LONE STAR STEEL IN LONE STAR, TX
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
STRAND DESIGNATION:3
STARTUP DATE:
STRAND WIDTH (in.):
GRATE AREA (ft2):
NO. OF WINDBOXES:
TYPE OF IGNITION FUEL:
SINTER PRODUCTION:
RATED TONS/DAY:
TYPICAL TONS/DAY:
WINDBOX EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
DISCHARGE END EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
ADDITIONAL COMMENTS:
aOriginal sinter plant (rated at 1,900 tons/day) was shut down in
1977-1978.12
405
-------
TABLE 13. NATIONAL STEEL CORP./GREAT LAKES STEEL DIVISION IN ECORSE, MI
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
STRAND DESIGNATION:
STARTUP DATE:
STRAND WIDTH (in.):
GRATE AREA (ft2):
NO. OF WINDBOXES:
TYPE OF IGNITION FUEL:
SINTER PRODUCTION:
RATED TONS/DAY:
TYPICAL TONS/DAY:
WINDBOX EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No. 262
19582
1442,51
2,4002»51
COG
22
4.850;2 4.600;3 5,50062
Gas recycle gravel bed filter2'"3
Combustion Power Co.°^
197863
• Total inlet maximum flow rate =
780,000 acfm at 180°F27
• System Ap = 7-10 in. ^O27
• Two waste gas fans rated at
340,000 and 344,000 cfm2
• Gravel bed system is essentially
a dry scrubber unit filled with a
9 7
filter mediaz/
DISCHARGE END EMISSION CONTROL SYSTEM:3 Multiclones62
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Zurn65
197665
• Total of four multiclones^2
• Breaker and hot screens ducted
to two multiclones each°2
• Exhaust gases from multiclones
recycled back into sinter
machine^2
ADDITIONAL COMMENTS:
alncludes breaker and hot screens.
406
-------
TABLE 14. NATIONAL STEEL CORP./GRANITE CITY STEEL DIVISION
IN GRANITE CITY, IL
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
STRAND DESIGNATION:
STARTUP DATE:
STRAND WIDTH (in.):
GRATE AREA (ft2):
NO. OF WINDBOXES:
TYPE OF IGNITION FUEL:
SINTER PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
WINDBOX EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No. 1
19582»27
762,51
1,,0242»51
COG,and Natural gas;2>51 Gas or
oil6"5
2,500:2 3.8003
2.48631
Cyclones and high-energy venturi
scrubber""
Buell:66 AAF66'67
19736°
• In series;°" Cyclones (4 in
parallel), main windbox fan, venturi
scrubber, scrubber fan
• Fan capacity = 240,000-280,000 cfm2
• Inlet scrubber design flow rate =
180,000 dscfm at 300°F66
• Outlet mist eliminator flow rate =
289,700 acfm at 118°F66
• Design Ap = 55 in. W.G. (across
venturi throat)^
• Test Data (1975) ;66
Outlet flow rate = 199,000 dscfm
(avg)
Gas temperature at outlet = 149°F
(avg)
Ap (actual) = 51 in. W.G.
(continued)
407
-------
TABLE 14 (continued)
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
DISCHARGE END EMISSION CONTROL SYSTEM:3 Baghouseb»68.69
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Carborundum^8
198168
• Rated at 90,000 cfra
• Test Data (1981):68
69
111,600-114,600 acfra (range)
110-145°F (range)
ADDITIONAL COMMENTS:
Discharge end; including sinter breaker, hot fines screen and transfer
points."8
^Baghouse replaced an existing fabric filter (and cyclones) in 1981, which
exhausted~40,000 cfm.69
408
-------
TABLE 15. NATIONAL STEEL CORP./WEIRTON STEEL DIVISION IN WEIRTON, WV
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
STRAND DESIGNATION:3 No. 270
STARTUP DATE: 19582
STRAND WIDTH (in.): 1442>70
GRATE AREA (ft2): 1,7642»70
NO. OF WINDBOXES: 14 (dual arrangement)70
TYPE OF IGNITION FUEL: COG71
SINTER PRODUCTION:
RATED TONS/DAY: 5,200:71 4.8502
AVERAGE TONS/DAY (1976): 4,7503
WINDBOX EMISSION CONTROL SYSTEM:b Gas recycle, gravel bed filter70'71
MANUFACTURER: Weirton Steel Division73
DATE INSTALLED: 197670»73
SYSTEM DESCRIPTION:
• Two parallel waste gas mains (east and west) transport 50% of windbox
effluent to series of four cyclones, effluent recombines in plenum to
two I.D. fans (each rated at 393,000 acfm at 382°F, 50.8 in. W.C., and
4,500 bhp), waste gas fan handles 50% of total volume for the gravel
bed filter, recycle fan is designed to recirculate 39% of total gas
volume back to machine via six distribution ducts, remaining flow from
recirc. fan goes to bed filter.70
• Gravel Bed Filter Consists of:70 20 filter modules, assembled in
groups of four, modules have upper and lower filter bed, each bed
includes 22 ft of garnet or steel grit filter media at depth of
3.5-4 in., 22 modules operate at one time, system designed to handle a
flux rate of 120 cfm/ft2 of bed area at a Ap 13 in. W.C. (flange
to flange).
• Backflushing of the two down modules is done with externally preheated
air (using COG) of 300°F.70
• Rated at 600,000-700,000 scfm.72
ADDITIONAL COMMENTS:
aStrand No. 1 (installed in 1955) was shut down in 1975.71>73
"Control system was originally designed for the smaller No. 1 sinter strand;
at present control system is not operating.73
409
-------
TABLE 16. REPUBLIC STEEL CORP./SOUTHERN DISTRICT, GULFSTEEL WORKS
IN GADSDEN, AL
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
STRAND DESIGNATION:
STARTUP DATE: 19362
STRAND WIDTH (in.): 722»31
GRATE AREA (ft2): 5692>51
NO. OF WINDBOXES:
TYPE OF IGNITION FUEL: COG, Natural Gas, and oil2'51
SINTER PRODUCTION:
RATED TONS/DAY: 1,800;74 1,5003
TYPICAL TONS/DAY:
WINDBOX EMISSION CONTROL SYSTEM: Cyclones and baghouse (in series)74'75
MANUFACTURER: Fly Ash Arrester Corp. and Wheelabrator-
Frye. respectively74
DATE INSTALLED: 19767^
SYSTEM DESCRIPTION:
• Cyclones:74 • Baghouse;a»74
345 collector tubes 14 compartments with a total of
Design flow rate = 219,870 acfm 2,520 felted Dacron bags (sized
at 260°F finish)
Ap (design) = 2.95 in. W.G. A/C = 5.95:1 (design)
Ap = 5 in. W.G. (normal-design)
Negative pressure baghouse with
pulse jet cleaning
Fan (design) = radial blade;
1,800-hp; 210,000 acfm at 250°F
and 36.2 in. W.G.
DISCHARGE END EMISSION CONTROL SYSTEM: Cyclones and baghouse (in
series)74
MANUFACTURER: Fly Ash Arrestor Corp. and
Wheelabrator-Frye, respectively74
DATE INSTALLED: 197676
(continued)
410
-------
TABLE 16 (continued)
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
SYSTEM DESCRIPTION:
• Hoods from the four sinter screens, a discharge end hood, and hoods over
the feed and discharge end of pug mills are ducted to a common flue,
cyclones, and baghouse'^
• Cyclones :^
2 collectors with
154 tubes per
collector
Design flow = 92,700 acfm at 195°F
and Ap = 2.4 in. W.G.
Baghouse:^
14 compartments with a total of
2,520 Nomex felt bags
A/C = 7.37:1 (design)
Ap = 5 in. W.G. (normal-design)
Positive pressure baghouse with
pulse jet cleaning
Fan (design) = radial blade,
1,200-hp; 260,000 acfm at 275°F
and 18 in. W.G.
ADDITIONAL COMMENTS:
aMarch 1977—All compartments rebagged with felted Dacron bags having a
smoother or singed finish; October 1978—baghouse rebagged; 12 compartments
with Dacron bags and 2 compartments with Teflon and Nomex bags (experimental
testing).'^
411
-------
TABLE 17. REPUBLIC STEEL CORP./MAHONING VALLEY DISTRICT IN WARREN, OH
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
STRAND DESIGNATION:
STARTUP DATE:8
STRAND WIDTH (in.):
GRATE AREA (ft2):
NO. OF WINDBOXES/STRAND
TYPE OF IGNITION FUEL:
SINTER PRODUCTION:
RATED TONS/DAY:
TYPICAL TONS/DAY:
WINDBOX EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
DISCHARGE END EMISSION CONTROL SYSTEM:
No. I77
19432
722,51
4322,51
6003
Multiclone77
197977
• Single centrifugal dust
collector2»5l
ADDITIONAL COMMENTS:
aPlant will shutdown on December 31, 1981.77
412
-------
TABLE 18. REPUBLIC STEEL CORP./MAHONING VALLEY DISTRICT IN YOUNGSTOWN, OHa
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
STRAND DESIGNATION:
STARTUP DATE:
STRAND WIDTH (in.):
GRATE AREA (ft2):
NO. OF WINDBOXES:
TYPE OF IGNITION FUEL:
SINTER PRODUCTION:
RATED TONS/DAY:
TYPICAL TONS/DAY:
WINDBOX EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No. 278
19582
962
1,3442
Gas2
5,00078
ESP78
Koppers
195878
• Design flow rate = 345,000 scfm and
maximum gas temperature =
• Two cells—three fields79
78
• One fan
78
DISCHARGE END EMISSION CONTROL SYSTEM: Cyclones79
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Western Precipitator''
• 4 cyclones total7'
• 70,000 acfm79
ADDITIONAL COMMENTS:
aSinter plant sold by U.S. Steel Corp. to Republic Steel Corp. in 1980.80
413
-------
TABLE 19. UNITED STATES STEEL CORP./SOUTH WORKS IN CHICAGO, IL
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
STRAND DESIGNATION: No. 281
STARTUP DATE: 19582
STRAND WIDTH (in.): 962>51
GRATE AREA (ft2): 1,3442>51
NO. OF WINDBOXES: 2181
TYPE OF IGNITION FUEL: Natural Gas;2*51 (COG)81
SINTER PRODUCTION:
RATED TONS/DAY: 5.0003
TYPICAL TONS/DAY:
W1NDBOX EMISSION CONTROL SYSTEM: Cyclones, ESP's, Electro-Dynamics (EDV)
Scrubbers (in series)81
MANUFACTURER: Cheraico (EDV)81
DATE INSTALLED: i960 (EDV)SI
SYSTEM DESCRIPTION:
1 fan rated at 375.000 scfm located between the ESP and EDV81
Cyclones** and ESPs2 (original control system) reduce loading to
EDVs(2)81
Cyclone catch is recycled81
2 EDVs operate in parallel; each has 16 Venturis and 16 electrodes81
System handles approximately 420,000 acfm (total for both EDVs)82
Water flow (each EDV) = 880 gpm; 55 gpm per nozzle delivered at
53 psig81
• Test Data (1981):83,84,85
EDV inlet flow (avg.) = 360,909 acfm; temperature = 197°F (avg.)
EDV outlet flow (avg.) = 336,213 acfm; temperature = 108°F (avg.)
Water flow = 835 gpm (per EDV)
DISCHARGE END EMISSION CONTROL SYSTEM: Baghouse30'86
MANUFACTURER:
DATE INSTALLED:
(continued)
414
-------
TABLE 19 (continued)
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
SYSTEM DESCRIPTION:
• Controls emissions from discharge end, hot screens, sinter breaker, and
surge bins""
• 10 module baghouse"^-
• Baghouse exhaust gases are partially recycled back to strand (via
east and west return ducts) to provide preheated combustion air to the
windboxes°l
• Common outlet (4 ft x 14 ft); east and west duct—5 ft diameter each-*"
• Test Data (1981):50
East duct flow = 20,377 acfm (avg.); temperature = 134°F (avg.)
West duct flow = 53,896 acfm (avg.); temperature = 133°F (avg.)
Baghouse outlet = 148,800 acfm (avg.); temperature = 135°F (avg.)
ADDITIONAL COMMENTS:
415
-------
TABLE 20. UNITED STATES STEEL CORP./FAIRFIELD WORKS IN FAIRFIELD, AL
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
STRAND DESIGNATION:8
STARTUP DATE:
STRAND WIDTH (in.):
GRATE AREA (ft2):
NO. OF WINDBOXES:
TYPE OF IGNITION FUEL:
SINTER PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
WINDBOX EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No. I87 No. 287 No. 387 No. A87
194087 194087 194087 196187
722,51 722,51 722,51 962,51
1,760 (total for Nos. 1, 2, 1,3442»51
and 3 combined)2>51
Natural gas (all four strands)2>51
7,783 (all 4 strands combined)3
6,306 (all 4 strands combined)3
ESP88 ESP88
ESP88
ESP
(dry)63,88
197963
ADDITIONAL COMMENTS:
aStrand Nos. 1, 2 and 3 in one shop; Strand No. 4 in another shop.87
416
-------
NO. I89
19562
%2,90
1,47289,90
No. 289
196090
962,90
1,34490,91
TABLE 21. UNITED STATES STEEL CORP./FAIRLESS WORKS IN FAIRLESS HILLS, PA
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
STRAND DESIGNATION:
STARTUP DATE:
STRAND WIDTH (in.):
GRATE AREA (ft2):
NO. OF WINDBOXES:
TYPE OF IGNITION FUEL:
SINTER PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
WINDBOX EMISSION CONTROL SYSTEM:3
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
DISCHARGE END EMISSION CONTROL SYSTEM:
Mixed or Natural Mixed, or COG and
Gas2»90 Natural Gas2,90
7,400;90 7,2003 (both strands
combined)
6,7113 (both strands combined)
Cyclones92
Buell92
Cyclones89,92
Buell89.92
• Fan rated at • Fan rated at
440,000 acfm at 440,000 acfm at
300°F90 300°F90
Rotoclone Rotoclone
No. 589 (Type N) No. 392
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
AAF92
• Controls
discharge end
and sinter
breaker89
• Hood covers
approximately
last 15 ft of
sinter line
and sinter
breaker89
AAF
92
Controls dis-
charge end,
transfer points
after rotary
cooler, and a
belt transfer
Q1
7i
• Exhaust fan rated
at 40,000 cfm91
(continued)
417
-------
TABLE 21 (continued)
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
ADDITIONAL CONTROL SYSTEMS:
MANUFACTURER:
DATA INSTALLED:
SYSTEM DESCRIPTION:
ADDITIONAL CONTROL SYSTEMS:
MANUFACTURER:
DATE INSTALLED:
• Rotoclone Is a
low draft loss
scrubber with
fan rate at
40,000 cfm89
• Test Data
(1977);g9~
12,300-12,600
scfm
Temperature •»
92-100°F (avg.)
Rotoclone
No. 689 (Type N)
Rotoclone
No. 491>92
Controls hot • Controls sinter
sources and breaker9^
screen discharge • Exhaust fan rated
to cooler89 at 400,000 cfm91
Hoods ducted to
rotoclone by a
fan rated
at 38,000 cfm89
Test Data
(1977);°*
Flow (range) =
12,300-13,000
scfm
Temp, (range) a
94-96°F (avg.)
Multiclone89*92
Bueii89,92
Rotoclone Nos.
and
(continued)
418
-------
TABLE 21 (continued)
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
SYSTEM DESCRIPTION:
• Controls two
transfer points-
cooler discharge
and hot fumes
surge bin
QQ
discharge0*
• Emission from
both transfer
points are
ducted together
and exhausted
through control
by a fan rated
at 75,000 cfm9
• Test Data
(1974);9:3~
46,100 dscfm;
temp. = 152°F
(avg.)
• Test Data
(1977):89
53,300-54,100
scfm
Temp. = 136-144°]
n93
Controls hot
sinter screen and
discharge points
between screens
and cooler'^
Common manifold
ducted to both
rotoclones'l
Exhaust fan for
each collector
rated at 38,000
ADDITIONAL COMMENTS:
aWindbox emissions (No. 1 and No. 2) will be controlled by an ESP for each
strand by December 1982.^2
419
-------
TABLE 22. UNITED STATES STEEL CORP./GARY WORKS IN GARY, IN
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
STRAND DESIGNATION:3
STARTUP DATE:
STRAND WIDTH (in.):
GRATE AREA (ft2):
NO. OF WINDBOXES:
TYPE OF IGNITION FUEL:
SINTER PRODUCTION:
RATED TONS/DAY:
NORMAL TONS/DAY:
No. 194
19582.95
992,95
1,29395,96
Natural
Gas:2»51
COG95
5,00097
4,00097
No. 294
1958:2
195995
992,95
1,29395,96
Natural
Gas-2. 51
COG95
5,00097
4,00097
No. 39*
1958:2
195995
992>95
1,29395,96
Natural
Gas:2»51
COG95
5,00097
4.00097
WINDBOX EMISSION CONTROL SYSTEM:b»c ESP94
ESP
,94
ESP
94
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Western Precipitator (all 3 ESPs)82
Before 1972 (all 3 ESPs)94
DISCHARGE END EMISSION CONTROL SYSTEM: 3 baghouses (one for each strand)95,96
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
U.S. Steel/Gary (all three
baghouses)9'
No. 1—1966;95,96 No. 2~1968;95,96
No. 3—1968;96 196995
(All three baghouses are similar, except
where noted)
• Controls emissions from the discharge end, hot sinter conveyor, hot
screens, and sinter cooler inlet (controls 21 pickup points)95,96
• 10 compartments; 880 silicone treated fiberglass bags (total)96>97
(continued)
420
-------
TABLE 22 (continued)
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
• Design flow rate = 171,550 scfm at 260°F97
• I.D. fan (design) = 162,000 cfm at 225°F96
• A/C (normal) = 2.17:1- A/C (during cleaning cycle) =
• Reverse air cleaning''
ADDITIONAL COMMENTS:
aAll strands located at the No. 3 sinter
^An electro-dynamic venturi (EDV) scrubber system is presently being
installed.'^
CEDV system will handle a total flow of 1,260,800 acfm.
82
421
-------
TABLE 23. UNITED STATES STEEL CORP./GENEVA WORKS IN PROVO, UT
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
STRAND DESIGNATION:
STARTUP DATE:
STRAND WIDTH (in.):
GRATE AREA (ft2):
NO. OF WINDBOXES:
TYPE OF IGNITION FUEL:
SINTER PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
WINDBOX EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:3
SYSTEM DESCRIPTION:
DISCHARGE END EMISSION CONTROL SYSTEM:b
North98
19442
722,51
6122,51
1099
South98
19442
722,51
6122,51
1099
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Natural Gas and/or mixed gas
(both strands)2*51
3,000;100 2.9103 (both strands
combined)
1,3733 (both strands combined)
Separate identical partial-orifice
plate type wet scrubber per
strand100
U.S. Steel100
1962 (upgraded-1975)100
• Each scrubber designed for 180,000
scfm, 200°F, Ap = 2-3 in. W.G., and
700 gpm of scrubber water (L/G
approximately 3.1:1)100
• Separate exhaust stack per strand°°
• Test Data • Test Data
(1978);*c (1978);*°
249,210-278,600 246,460-250,665
acfm (range) acfm (range)
97-107°F (range) 102-109°F (range)
Rotoclones per strand control
discharge end, and conveying
systems'9
198199
ADDITIONAL COMMENTS:
aBoth scrubbers were modified in 1975 by relocating the internal sprays.10°
^Rotoclones replaced a common ring-orifice scrubber (installed approximately
1962) which controlled only the discharge end of both strands.99
422
-------
TABLE 24. UNITED STATES STEEL CORP./HOMESTEAD WORKS IN SAXONBURG, PA
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
STRAND DESIGNATION:
STARTUP DATE:
STRAND WIDTH (in.):
GRATE AREA (ft2):
NO. OF WINDBOXES:
TYPE OF IGNITION FUEL:
SINTER PRODUCTION:
RATED TONS/DAY:
No. llOl
1958a,32
98103,104
1,29351,104
24103,107
Natural
Gas44*51
15.000;3 12
No. 2102
1958^,32
98104
No. 3102
I959b,32
98104,105
1>29351,104 1>29351,104
24106,107
Natural
Gas44, 51
,900104 (all
24105,107
Natural
Gas44, 51
three
strands combined)
TYPICAL TONS/DAY:
WINDBOX EMISSION CONTROL SYSTEM:
Dry ESP per
strand0 >1°4
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Koppers (all 3 ESPs)
No. 1—1958;d»32 No. 2—1958;3»32
No. 3—1959e»32
(All ESPs are similar, except where
noted)
• 4 compartment ESpl°3
• Design Data;32
234,000-284,000 scfm at 70°F
Collection area = 41,500 sq ft
• SCA (calculated) = 138 sq ft/
1000 cfm104
• I.D. fan rated at 300,000 acfm at
275oF104
• A gas recycle system (exhausting
from windbox Nos. 16-21) using
cyclones and a fan rated at
110,000 acfm at 350°F has been
installed recentlyl°4»l08
• Test Data (1979) A10
Flow (range) » 294,000-338,500 dscfm
Temperature (range) = 166-194°F
• Test Data (1976);103,105,106
ESP No. 1—223,600 dscfm
ESP No. 2—231,700 dscfm
ESP No. 3—287,000 dscfm
(continued)
423
-------
TABLE 24 (continued)
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
• Test Data (1972);102,105
ESP No. 1—Flow (range) - 265,000-
267,000 scfm
Temperature (range) = 239-278°F
ESP No. 2—Flow (range) - 243,000-
270,000 scfm
Temperature (range) = 269-277°F
• Test Data (1971);109
ESP No. 3—377,000 scfm at 244°F
DISCHARGE END EMISSION CONTROL SYSTEM: Baghouse per strand111
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
ADDITIONAL CONTROL SYSTEM:
No. 1—1969;32 No. 2—1969;32
No. 3—197032
(All baghouses are similar, except
where noted)
• Controls emissions from discharge
end, transfer of sinter at breaker,
hot screens, and other sinter
transfer points111
• 168,000 scfm at 70°F, 29.92 in. Hg32
• Ap = 6 in. W.C.32
• A/C - 1.94:132
Baghouse for cold
screen Nos. 3 and
4 on sinter line
No. I111
Baghouse for
cold screen Nos. 1 and
2 on sinter line
Nos. 2 and 3111
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
197232
• Combined effluent
from screen Nos.
3 and 4 pass
through multi-
clone111
197232
• Combined effluent
from screen Nos.
1 and 2 pass
through multi-
clone111
(continued)
424
-------
TABLE 24 (continued)
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
00
• Design Data:J^
70,000 scfm fan
at 100°F
Ap = 5.25 in. W.C.
A/C = 2.0:1
• I.D. fan rated
at 60,000 cfm
'discharges to
stack No. 2—
South32
• Test Data
(1971):f»lu
09
• Design Data. ^
(similar to
baghouse on strand
No. 1)
• I.D. fan rated
at 60,000 cfm
discharges to
stack No. 1 —
North32
46,100 cfm
ADDITIONAL CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
ADDITIONAL CONTROL SYSTEM:
MANJFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
ADDITIONAL CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
Baghouse per strand controlling sinter
feed ends32
1967 (all three baghouses)32
(All baghouses are similar, except
where noted)
• 12,400 acfm at ambient32
• Ap = 16 in. W.C.32
A/C = 2.01:1
32
Baghouse for bin building32
• 24,400 scfm at ambient32
• Ap = 16 in. W.C.32
• A/C = 1.78:132
Baghouse for sinter sizing operation32
(continued)
425
-------
TABLE 24 (continued)
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
SYSTEM DESCRIPTION: • 110,000 scfm at 180°F32
• Ap = 12.4 in. W.C.32
« A/C = 1.97:132
ADDITIONAL COMMENTS:
aStrand No. 1 remodeled in 1972.32
bStrand Nos. 2 and 3 remodeled in 197232
CA second ESP will be installed by the end of 1981 at the outlet of the
existing No. 1 windbox ESP and will have the following specifications:
flow = 310,000 acfm at 225°F; SCA = 451 sq ft/1,000 cfm; 3 fields and 40 gas
passages (12-in. wide). Similar systems will be installed on the Nos. 2 and
3 strands in the future.108
dESP rehabilitated in 1972.32
eESP rehabilitated in 1971.32
^Only cold screen No. 3 was operating during 1971 stack tests.111
426
-------
TABLE 25. WHEELING-PITTSBURGH STEEL CORP./MON VALLEY PLANT IN MONESSEN, PA
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
STRAND DESIGNATION:
STARTUP DATE:
STRAND WIDTH (in.):
GRATE AREA (ft2):
NO. OF WINDBOXES:
TYPE OF IGNITION FUEL:
SINTER PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
WINDBOX EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
DISCHARGE END EMISSION CONTROL SYSTEM:b
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
1966112
722,51
6122>51
COG
113
1,0003
8693
Wet Espa,H2,114
114
Western Precipitator
1981112,114
• Design flow rate = 190,000 acfm
at 155'F112.11^
• System uses 3 F.D.
Hooded area ducted to a scrubber113
Ducon113
196611*
• In Series: hood, I.D. fan,
scrubber, demister, and stack113
• Design flow = 38,000 scfm11^
• Wet I.D. fan rated at 41,000 acfm
at 110°F113
• Water supply to fan/scrubber =
85-100 gpm113
• Test Data (1977):113
24,500 dscfm with temperature =
107°F (avg.)
34,700 dscfm with temperature =
106°F (avg.)
ADDITIONAL COMMENTS:
aThis new ESP replaced the original ESP which was installed in 1966.112,H4
Contrr's emissions from discharge end, crusher and hot screens.113
427
-------
TABLE 26. WHEELING-PITTSBURGH STEEL CORP./STEUBENVILLE PLANT
IN EAST STEUBENVILLE, WV
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
STRAND DESIGNATION:
STARTUP DATE:
STRAND WIDTH (in.):
GRATE AREA (ft2):
NO. OF WINDBOXES:
TYPE OF IGNITION FUEL:
SINTER PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
WINDBOX EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
DISCHARGE END EMISSION CONTROL SYSTEM:b
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No. I73
19442
722,51
.535;2 54051
COG;115 Gas2»51
1,5003
1,130
High-efficiency venturi scrubber 15
AAF72>73
1973a,115
• In Series :
2 cyclones, 2 fans
(one fan for windbox draft, one
fan for venturi pressure control),
venturi scrubber, cyclone
separator, stack11-*
• Scrubber rated at 135,000 scftn115
• Ap = 42 in. H20 (operation)115
• 2,000 gpm scrubber water used115
• Test Data (1978) :115
Ap = 38-44 in. H20
Baghouse73
Bauraco73
198173
• 2 units rated at 40,000 acfm at
200°F (total)73
(continued)
428
-------
TABLE 26 (continued)
SINTER PLANT PROCESS AND EMISSION CONTROL DATA
• Total cloth area = 8,900 sq ft73
• A/C = 4.5:173
• Nomex bags, with pulse-jet
cleaning'3
ADDITIONAL COMMENTS:
aScrubber rebuilt in 1975.73
"Discharge end previously controlled by a venturi scrubber prior to 1976;
was uncontrolled from 1976 to 1981. ^
429
-------
CO
ftl
a
o
o n
K M
CO
MATERIAL IN THIS SECTION SUBJECT TO CONFIDENTIALITY
REVIEW AND IS NOT RELEASABLE AS OF FEBRUARY 1, 1982.
FOR INFORMATION, CONTACT L. KESARI, U.S. ENVIRONMENTAL
PROTECTION AGENCY, DIVISION OF STATIONARY SOURCE ENFORCEMENT.
-------
REFERENCES
SINTER PLANTS
1. Letter response. James Dills, Commonwealth of Kentucky Department for
Natural Resources and Environmental Protection to Michael Jasinski,
GCA/Teclmology Division. November 19, 1981. (Reliability No. 1.)
2. World Steel Industry Data Handbook: Volume I. The United States.
McGraw Hill Magazine. 1978. pp. 12 and 13. (Reliability No. A.)
3. Development Document for Proposed Effluent Limitations Guidelines and
Standards for the Iron and Steel Manufacturing Point Source Category,
Volume III. EPA-440/l-79-024a. Draft Report. U.S. Environmental
Protection Agency, Research Triangle Park, NC. October 1979. pp. 8-9.
(Reliability No. 4.)
4. The Wet Scrubber Newsletter. Mcllvaine Co. March 31, 1978. Volume No.
45, pp. 1. (Reliability No. 4.)
5. Telephone conversation. Gerald Shicker, Kentucky Air Pollution Control
Division to Michael Jasinski, GCA/Technology Division. February 23,
19.81. (Reliability No. 2.)
6. Steel in Texas. Iron & Steel Engineer. 48(4): T-3 through T-14. April
1971. (Reliability No. 3.)
7. Steiner, B. A., and R. J. Thompson. Wet Scrubbing Experience for Steel
Mill Applications. ARMCO Steel Corp. in Middletown, Ohio. JAPCA.
27(11):1071. (Reliability No. 3.)
8. Iron & Steel Engineer. Industry News. May 1979. p. 91. (Reliability
No. 4.)
9. Carpenter, B. H., et al. Pollution Effects of Abnormal Operations in
Iron & Steel Making—Volume II, Sintering, Manual of Practice. EPA
600/2-78-118b. U.S. Environmental Protection Agency, Research Triangle
Park, NC. June 1978. pp. 33, 35. (Reliability No. 3.)
10. Letter report from Southwestern Laboratories Testing Engineers to C.
Wright, Lone Star Steel Co./Lone Star, Texas. Stack sampling of Lone
Star Steel's Steam—Hydro units. RACT Box No. 400541-400584.
(Reliability No. 1.)
430
-------
11. Southwestern Labs. Sampling and Analysis of Particulate Emissions from
the ARMCO Steel, Sintering Plant Steam—Hydro Cleaning System at Houston,
Texas. February 24-26, 1976. JACA Inc. Library. (Reliability No. 1.)
12. Telephone conversation. John Hepola, U.S. Environmental Protection
Agency Region VI to Michael Jasinski, GCA/Technology Division. November
1981. (Reliability No. 2.)
13. Telephone conversation. Lawrence Pewitt, Texas Air Control Board to
Sandy Beaton, CCA/Technology Division. November 1981. (Reliability
No. 2.)
14. Sampling and Analysis of Particulate Emissions from the Sintering Plant
Cooler Stack at ARMCO Steel Corporation/Houston, Texas. January 9-11,
1975. JACA Inc. Library. (Reliability No. 1.)
15. Letter report from T. E. Power, Senior Research Chemist, Environmental
Research & Technology, Inc., Inc., to Mr. B. A. Steiner, ARMCO Steel
Inc. RACT Box No. 400635-400658. (Reliability No. 2.)
16. Steiner, B. A., and R. J. Thompson. Metallurgical Applications. JAPCA.
27(11): 1074. November 1977. (Reliability No. 3.)
17. Carpenter, B. H., et al. Pollution Effects of Abnormal Operations in
Iron and Steelmaking—Vol. II. Sintering, Manual of Practice.
lilPA-600/2-78-1186. June 1978. p. 34. (Reliability No. 3.)
18. Telephone conversation. Ed Luebering, SW District Ohio EPA to Gene
Bergson, GCA/Technology Division. March 9, 1981. (Reliability No. 2.)
19. Telephone conversation. Mr. Lemkuhl, Southwest Ohio APC Agency to Gene
Bergson, GCA/Technology Division. October 27, 1980. (Reliability No. 2.)
20. RACT Box No. 400709-400728. (Reliability No. 1.)
21. Air Pollution Emission Test at Bethlehem Steel, Bethlehem, Pennsylvania
Sinter Plant. York Research Corp. Final Report No. 75-SIN-l. December
22, 1975. RACT Box No. 400763. (Reliability No. 1.)
22. U.S. Steel Industry APC Equipment Manual. The Mcllvaine Co. July 1980.
p. ST-28. (Reliability No. 4.)
23. Test Plan for Sampling and Analysis of Total Particulates and S02 from
the Sinter Plant at Bethlehem Steel Corp./Sparrows Point Works.
GCA/Technology Division, Bedford, Massachusetts. September 1979.
(Reliability No. 1.)
24. Letter response. J. McGrogan, PADER—Reading, PA to Sandy Beaton,
GCA/Technology Division. November 1981. (Reliability No. 1.)
431
-------
38. Bethlehem Steel Corporation, Sparrows Pt., Maryland, No. 7 Sinter Strand
Scrubber Outlet Tests performed by BSC. Letter to L. Kertcher, Bureau of
Air Quality and Noise Contro.l in Baltimore, Maryland. July 14, 1976.
RACT Box No. 400389-400392. (Reliability No. 1.)
39. Letter to Robert McCrillis, U.S. Environmental Protection Agency, from
CCA/Technology Division, Bedford, Massachusetts. (Reliability No. 3.)
40. Telephone conversation. Mark Sylvester. Maryland State Department of
Health and Mental Hygiene to Michael Jasinski, GCA/Technology Division.
February 13, 1981. (Reliability No. 2.)
41. Gronberg, S. Pretest Survey of Bethlehem Steel Corporation/Sparrows
Point Plant. GCA/Technology Division, January 1979. (Reliability No. 1.)
42. Telephone conversation. Dennis Myers, Colorado State Department of
Health to Stephen Piper, GCA/Technology Division. February 1981.
(Reliability No. 2.)
43. Egley, B. D., Selection of Gas Cleaning Equipment for an Ore Preparation
Plant. Iron & Steel Engineer. 47(11):111-113. November 1970.
(Reliability No. 3.)
44. Electrostatic Precipitator Manual. The Mcllvaine Company. 1977.
(Reliability No. 4.)
45. CF&I, Pueblo, Colorado, Air Pollution Emissions Test, June 1975. U.S.
Environmental Protection Agency, Emissions Measurements Branch, OAQPS
Report No. 75-SIN-5. February 1976. JACA Library. (Reliability No. 1.)
46. The Fabric Filter Manual. The Mcllvaine Co. p. 165.7. (Reliability
No. 4.)
47. Telephone conversation. Dennis Myers, Colorado State Department of
Health to Michael Jasinski, GCA/Technology Division. November 1981.
(Reliability No. 2.)
48. Nunno, T., et al. Assessment of Air Emissions from Steel Plant
Operations. Inland Steel Corp./Indiana Harbor Works, No. 3 Sinter
Plant. GCA/Technology Division Final Report No. TR-79-65-G. Prepared
for U.S. EPA. March 1980. (Reliability No. 3.)
49. Report of Emission Tests for Inland Steel Co. at the Sinter Plant Main
Stack Baghouse. Clean Air Engineering, Inc. February 27, 1976. RACT
Box No. 400423-400456. (Reliability No. 1.)
50. Report of Emissions Test for Inland Steel Company at the No. 3 Sinter
Plant. Clean Air Engineering, Inc. July 30, 1975. JACA Library.
(Reliability No. 1.)
433
-------
51. American Iron and Steel Institute. Directory of Iron and Steel Works of
the U.S. and Canada. Thirty-fourth edition. 1977. (Reliability No. 4.)
52. Iron and Steel Engineer. Editor's Notes. December 1978. p. 13.
(Reliability No. 3.)
53. Telephone conversation. Ed Wojciechowski, U.S. Environmental Protection
Agency Region V to Gene Bergson, GCA/Technology Division. February 4,
1981. (Reliability No. 2.)
54. Telephone conversation. Bernard Bloom. U.S. Environmental Protection
Agency, Washington, DC to Michael Jas.inski, GCA/Technology Division.
November 1980. (Reliability No. 2.) .
55. Region V files. (J&L letter to EPA, 1981.)
56. Region V files. (J&L letter to EPA, 1976.)
57. Carpenter, B. H., et al. Pollution Effects of Abnormal Operations in
Iron and Steelmaking—Volume II; Sintering Manual of Practice.
EPA-600/2-78-118b, U.S. Environmental Protection Agency, Research
Triangle Park, NC. pp. 28-31. (Reliability No. 4.)
58. Bryan, R. J. Emissions Source Test from a Baghouse Serving an Iron and
Steel Sintering Plant at Kaiser Steel Corp., Fontana, CA. Project No.
75-SIN-3. Pacific Environmental Services, Inc. November 19, 1975. RACT
Box No. 400659-400690. (Reliability No. 1.)
59. Letter from R. J. Hilovsky, Senior Engineer, San Bernadino County APC
District to J. Kunz, U.S. Environmental Protection Agency Region III,
Philadelphia, PA. May 12, 1976. RACT Box No. 400415-400422.
(Reliability No. 1.)
60. Schneider, R. C., Jr. Report of Source Test Conducted at Kaiser Steel
Corp. Sinter Plant. March 11, 1974. Report No. 74-16. RACT Box No.
400409-400414. (Reliability No. 1.)
61. Report of Source Test Conducted at Kaiser Steel Corp., Fontana, CA.
January 25, 1974. JACA Steel Library. (Reliability No. 1.)
62. EPA Region V files. (March 1979 Litigation Report NSC/GLS).
63. Telephone conversation. Bernard Bloom, U.S. Environmental Protection
Agency, Washington, DC to Michael Jasinski, GCA/Technology Division.
February 1981. (Reliability No. 2.)
64. EPA Region V files. (November 1975 Permit Application to Wayne County by
NSC).
65. EPA Region V files. (June 1977 Permit Application to Wayne County by
NSC).
434
-------
66. Loch, T. A. Air Pollution Test, Sinter Plant, Granite City Steel
Division, National Steel Division, Granite City, IL. EMB No. 75-S1N-4.
KACT Box No. 400243-400340. (Reliability No. 1.)
67. Telephone conversation. Anton Telford. Illinois State Environmental
Protection Agency to Sandy Beaton, GCA/Technology Division. October
1981. (Reliability No. 2.)
68. EPA Region V files. (Stack Test Report on NSC/G.C. Sinter Plant, 1981.)
69. EPA Region V files. (Memo from EPA V to Illinois EPA, 1979.)
70. Current, G.P. Sinter Plant Windbox Recirculation and Gravel Bed Filter
Demonstration: Phase 2; Construction, Operation, and Evaluation.
EPA-600/2-79-203, U.S. Environmental Protection Agency, Research Triangle
Park, NC. November 1979. pp. 7, 9-11, 13-18. (Reliability No. 3.)
71. Spawn, P. D., et al. National Steel Corporation/Weirton Steel Division
Plant Inspection, August 1981. GCA/Technology Division Draft Final
Report No. TR-81-118-G. Prepared for U.S. EPA. November 1981.
(Reliability No. 1.)
72. Telephone conversation. John Raggi, West Virginia Air Pollution Control
Commission to Gene Bergson, GCA/Technology Division. February 17, 1981.
(Reliability No. 2.)
73. Letter response from John Raggi, Regional Engineer in West Virginia to
Michael Jasinski, GCA/Technology Division. November 1981. (Reliability
No. 1.)
74. Coy, D. M. Report of Process Observations on Sinter Plant/Windbox
Baghouse at RSC, Gadsden Plant. RT1/1371/09-045. Research Triangle
Institute, Research Triangle Park, NC. January 4, 1979. RACT Box No.
400187-400242. (Reliability No. 1.)
75. Schiff, H. F. RSC/Gadsden Plant: Windbox Exhaust System Particulate
Emission Quantification and Baghouse Efficiency Determination.
GCA/Technology Division Draft Final Report GCA-TR-79-20-G. July 1979.
Prepared for U.S. EPA. Appendix D. RACT Box No. 400115-400186a.
(Reliability No. 1.)
76. Telephone conversation. Sue Robertson, State of Alabama Air Pollution
Control Commission to Gene Bergson, GCA/Technology Division. February
25, 1981. (Reliability No. 2.)
77. Telephone conversation. Ted Davis, Ohio Northeast District Air Pollution
Control to Gene Bergson, GCA/Technology Division. February 27, 1981.
(Reliability No. 2.)
78. EPA Region V files. (Permits—U.S. Youngstown.)
435
-------
79. EPA Region V files. (NEIC Report dated January 1979. U.S./Youngstown
Sinter Plant.)
80. Telephone conversation. Dennis Bush, NE District—Ohio Environmental
Protection Agency to Sandy Beaton, GCA/Technology Division. January
1982. (Reliability No. 2.)
81 . Nunno, T. J. Letter Report to EPA Region V regarding process
observations of the U.S. Steel/South Works Sinter Plant EDV tests.
GCA/Technology Division. January 1982. (Reliability No. 1.)
82. The Wet Scrubber Newsletter. The Mcllvaine Co. 49:1,2. July 31, 1978.
(Reliability No. 3.)
83. Particulate Emision Test on EDV at U.S. Steel's South Works, Chicago,
IL. CH2M Hill. June 1981. (Reliability No. 1.)
84. Kaufman, Peter W. and Virginia A. Barkus. Particulate Emission Test, Wet
Electrostatic Precipitator Inlet. U.S. Steel Corporation/South Works
Sinter Plant. Source Evaluation and Analyses, Inc. (SEA). SEA/HH
Technical Report TR-81-66. May 1981. (Reliability No. 1.)
85. Kaufman, Peter W., and Virginia A. Barkus. Particulate Emission Tests
Baghouse-Breaker End of Sinter Plant. U.S. Steel Corporation, South
Works. Source Evaluation and Analyses, Inc. (SEA). SEA/HH Technical
Report TR-81-72. June 1981. (Reliability No. 1.)
86. Telephone conversation. J. Solkorowski, City of Chicago Department of
Inspectional Services to Marc Grant, GCA/Technology Division. March 5,
1981. (Reliability No. 2.)
87. Letter response. Paul Pate, Director of Jefferson County Department of
Health to Michael Jasinski, GCA/Technology Division. December 1981.
(Reliability No. 1.)
88. Telephone conversation. J. Carroll, Jefferson County Department of
Health to Gene Bergson, GCA/Technology Division. February 1980.
(Reliability No. 2.)
89. PADER, Inc. Stack Test Report on Sinter Plant at U.S. Steel Corporation,
Fairless Hills Works, Fairless Hills, PA. November 1 and 2, 1977. JACA
Library. (Reliability No. 1.)
90. Samways, N. L. Fairless Works Faces the 1980's—A Look at the Plant
Today. Iron & Steel Engineer. April 1980. p. F-l. (Reliability No. 4.)
91. Stack Test Report on U.S. Steel Corporation, Fairless Works Sinter
Plant. July 29-30, 1974. JACA Library. (Reliability No. 1.)
436
-------
92. Telephone conversation and letter response. Tom McGinley, PADER—
Morristown, PA to Sandy Beaton, GCA/Technology Division. November 1981.
(Reliability No. 2.)
93. Stack Test Report on U.S. Steel Corporation, Fairless Works Sinter
Plant. July 23, 1974. JACA Library. (Reliability No. 1.)
^4. Telephone conversation. Roland Elrambuena, City of Gary Air Pollution
Control Division to Gene Bergson, GCA/Technology Division. March 4,
1981. (Reliability No. 2.)
V
95. EPA Region files. (May 1979 Gary response to EPA interogatory.)
96. Gary Steel Works Experience with TT Type Dust Collectors at No. 3 Sinter
Plant. Paper presented at the Eastern States Blast Furnace and Coke Oven
Association, Pittsburgh, PA. February 4, 1977. RACT Box No.
401427-401440. (Reliability No. 2-3.)
97. Westbrook, C. W. Level 1 Assessment of Uncontrolled Sinter Plant
Emissions. EPA-600/2-79-112. U.S. Environmental Protection Agency,
Research Triangle Park, NC. May 1979. pp. 7-10. (Reliability No. 3.)
98. Report of Stack Test at U.S. Steel, Geneva Works Sinter Plant.
RTI/1371/13-035. Septembers, 1978. JACA Library. (Reliability No. 1.)
99. Telephone conversation. Dave Kopta, Utah State Division of Environmental
Health to Michael Jasinski, GCA/Technology Division. November 1981.
(Reliability No. 2.)
100. Impact of Particulate Matter Emissions on Ambient Air Quality U.S. Steel
Corporation—Geneva Works. Appendix II—Source Identification.
EPA-330/2-77-005b. February 1977. pp. 53, 56. (Reliability No. 4.)
101. Ten Eyck, P. U.S. Steel Corporation Saxonburg Sintering Operation Line
No. 1. Stack Tests by Apollo Chemical, Inc. July 13, 1978 through
August 2, 1978. JACA Library. (Reliability No. 1.)
102. Letter from J. G. Donelson, U.S. Steel Corporation/Director—Research, to
S. P. Curtis, USS/V.P. of Design and Construction, Re: Gas sampling and
testing, Saxonburg Sintering Plant. April 27, 1972. JACA Library.
(Reliability No. 1.)
103. Stack Test Report on U.S. Steel Corporation/Saxonburg, PA Sinter Plant.
Test No. 3376. October 14, 1976. JACA Library. (Reliability No. 1.)
104. Letter response. Arthur Witt, PADER—Pittsburg, PA to Sandy Beaton,
GCA/Technology Division. November 1981. (Reliability No. 1.)
105. PADER, Inc. Stack Test Report on U.S. Steel Corporation/Saxonburg, PA
Plant. Test Nos. 2376 A and B. August 3, 1976. JACA Library.
(Reliability No. 1.)
437
-------
106. Stack Test Report at U.S. Steel Corporation/Saxonburg, PA Sinter Plant.
PADER Test No. 3476. October 15, 1976. JACA Library. (Reliability
No. 1.)
107. Telephone conversation. Ken Bowman, Pennsylvania Department of
Environmental Resources to Michael Jasinski, GCA/Technology Division.
February 18, 1981. (Reliability No. 2.)
108. Electrostatic Precipitator Newsletter. Mcllvaine, Inc. July 20, 1981.
(Reliability No. 3.)
109. Letter from B. J. Dunsmore, Director—Environmental Control for U.S.
Steel Corporation to Nicholas Pazuchanics, Air Pollution Control Engineer
for PADER. Re: USSC/Saxonburg Sintering Plant. Letter dated September
1971. JACA Library. (Reliability No. 1.)
110. Black, A. W. Stack Emissions from ESP No. 1, USSC/Saxonburg, PA Sinter
Plant. Testing by Henen Associates. March 28, 1979. JACA Library.
(Reliability No. 1.)
111. Stack Test Report at USSC/Saxonburg, PA Sinter Plant. Test No. 171.
January 21, 1971. JACA Library. (Reliability No. 1.)
112. Letter response. Richard Thomas, PADER—Greensburg, PA to Sandy Beaton,
GCA/Technology Division. December 1981. (Reliability No. 1.)
113. RACT Box No. 401141-401170. (Reliability No. 1.)
114. Telephone conversation. Tony Johnson, Pennsylvania Department of
Environmental Conservation to Gene Bergson, GCA/Technology Division.
February 26, 1981. (Reliability No. 2.)
115. Bareford, P., et al. Wheeling-Pittsburgh Steel Corporation Follansbee,
West Virginia Sinter Plant, Particulate Emission Quantification. GCA
Draft Final Report No. TR-79-47-G. Prepared for U.S. EPA. September
1979. (Reliability No. 1.)
438
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MATERIAL IN THIS SECTION SUBJECT TO CONFIDENTIALITY H
REVIEW AND IS NOT RELEASABLE AS OF FEBRUARY 1, 1982. w
FOR INFORMATION, CONTACT L. KESARI, U.S. ENVIRONMENTAL ^
PROTECTION AGENCY, DIVISION OF STATIONARY SOURCE ENFORCEMENT. S
CO
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TABLE 1. ARMCO INC./ASHLAND WORKS IN ASHLAND, KY
BLAST FURNACE—CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION :
STARTUP DATE:
RECENT REL1NE (REBUILD) DATE:
HEARTH DIAMETER (ft-in.):
WORKING VOLUME (ft3):
NO. OF TAPHOLES /FURNACE:
NO. OF CASTHOUSES/FURNACE:
IRON PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
CASTHOUSE EMISSION CONTROL SYSTEM:8
Amanda^
19631
33-51
72.0001
21
3.6002
3.5612
Bellefonte*
19421
28-9 *
52.4381
I1
2.0002
2.1882
ADDITIONAL COMMENTS:
aNo commitment to install controls as of February 1981.
439
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TABLE 2. ARMCO INC./HAMILTON PLANT IN HAMILTON, OH
BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in.):
WORKING VOLUME (ft3):
NO. OF TAPHOLES/FURNACE:
NO. OF CASTHOUSES /FURNACE:
IRON PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
CASTHOUSE EMISSION CONTROL SYSTEM:3
No. 1 l
19282
19751
18-6 l
22',8391
I1
!4
1.1602
1.2202
No. 2 L
19282
19762
19-61
27.5151
I1
1*
1.4002
8172
ADDITIONAL COMMENTS:
aNo commitment to install controls as of February 1981.
440
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TABLE 3. ARMCO INC./HOUSTON WORKS IN HOUSTON, TX
BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION: No. 1 l
STARTUP DATE: 19442
RECENT RELINE (REBUILD) DATE: 19761
HEARTH DIAMETER (ft-in.): 27-31
WORKING VOLUME (ft3): 52.3011
NO. OF TAPHOLES/FURNACE: I1
NO. OF CASTHOUSES/FURNACE: I5
IRON PRODUCTION:
RATED TONS/DAY: 2.2002
AVERAGE TONS/DAY (1976): 1.6652
CASTHOUSE EMISSION CONTROL SYSTEM:3
ADDITIONAL COMMENTS:
aNo commitment to install controls as of February 1981.3
441
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TABLE 4. ARMCO INC./MIDDLETOWN WORKS IN MIDDLETOWN, OH
BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION: No. 31
STARTUP DATE: 19532
RECENT RELINE (REBUILD) DATE: 19761
HEARTH DIAMETER (ft-in.): 29-61
WORKING VOLUME (ft3): 55.3241
NO. OF TAPHOLES/FURNACE: 21
NO. OF CASTHOUSES/FURNACE: 24
IRON PRODUCTION:
RATED TONS/DAY: 4.7302
AVERAGE TONS/DAY (1976): 3,5982
CASTHOUSE EMISSION CONTROL SYSTEM:3
ADDITIONAL COMMENTS:
aNo controls scheduled for installation; facility under "Bubble"
regulation.^
442
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TABLE 5. BETHLEHEM STEEL CORP./BETHLEHEM PLANT IN BETHLEHEM, PA
BLAST FURNACE—CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in. ):
WORKING VOLUME (ft3):
NO. OF TAPHOLES/FURNACE:
NO. OF CASTHOUSES/FURNACE:
IRON PRODUCTION:
B1
19552
19732
30-0 l
54.4311
if
1?
ci
19432
19722
27-111
49.7481
17
17
Dl
19532
19752
30-0 !
54.8341
17
17
El
I9602
19762
24-0 1
41.2541
17
17
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
CASTHOUSE EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
3.0002 2.6002 3.0002 2.0002
2,7902 2,4362 1.6962
Partial evacuation system via canopy hood
for each casthouse ducted to common
baghouse7
Mikropul8
19807
• System can control 2 of 4 casthouses
simultaneously7 > 8
• Flow capacity = 660,000 acfm @ <150°F;
flow per casthouse = 330,000 acfm7*8
• A/C = 4.9:1 (minimum for 1 casthouse);
9.7:1 (maximum for 2 casthouses)7»8
• Felted polyester bags7>°
ADDITIONAL COMMENTS:
443
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TABLE 6. BETHLEHEM STEEL CORP./BURNS HARBOR PLANT IN CHESTERTON, IN
BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION: C1 D1
STARTUP DATE: 19722 19692
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in.): 38-31 35-01
WORKING VOLUME (ft3): 89,423;9 89.2041 86.646;10 85.75010
NO. OF TAPHOLES/FURNACE: 211 211
NO. OF CASTHOUSES/FURNACE: 210
IRON PRODUCTION:
RATED TONS/DAY: 5.5002 5.0002
AVERAGE TONS/DAY (1976): 4,9432 5,465;2 4,650
(1971 avg.)9
CASTHOUSE EMISSION CONTROL SYSTEM:3
ADDITIONAL COMMENTS:
aNo commitment to install controls as of February 1981.3
444
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TABLE 7. BETHLEHEM STEEL CORP./LACKAWANNA PLANT IN LACKAWANNA, NY
BLAST FURNACE—CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:8
STARTUP DATE:
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in.):
WORKING VOLUME (ft3):
NO. OF TAPHOLES/FURNACE:
NO. OF CASTHOUSES/FURNACE:
IRON PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
H1
190512
197912
29-01
51.009;1 51.88612
2.5002
2.2112
Jl
195312
197712
29-111
55.107;1 55.11212
2.7502
2,6572
CASTHOUSE EMISSION CONTROL SYSTEM:
.b
ADDITIONAL COMMENTS:
aBlast furnace designation
A
B
C
F
G
Date shutdown
prior to 1973 - (dismantled)
1973
1979
1981
1977
''Local hooding committed by State Order for 1982.
445
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TABLE 8. BETHLEHEM STEEL CORP./SPARROWS POINT PLANT IN SPARROWS POINT, MD
BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:3 G1 H1 J1
STARTUP DATE:
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in.): 28-01 30-01 30-01
WORKING VOLUME (ft3): 47.1561' 54,792[ 54.5051
NO. OF TAPHOLES/FURNACE:
NO. OF CASTHOUSES/FURNACE:
IRON PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
CASTHOUSE EMISSION CONTROL SYSTEM:b
(continued)
446
-------
TABLE 8 (continued)
BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:3
STARTUP DATE:
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in.):
WORKING VOLUME (ft3):
NO. OF TAPHOLES/FURNACE:
NO. OF CASTHOUSES/FURNACE:
IRON PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
CASTHOUSE EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
K1
30-01
54.6101
197813
44-6 L
130,3991
41
213
8.00013
Local hoods ducted to baghouse13
Wheelabrator-Frye13
19783
• Local hoods located on each
taphole, iron pool, tilting
iron runner, and slag spoon.'-3
312,000 acfm @ 140°F13
5 cell baghouse; one cell in
cleaning mode*-3
A/C = 2.5:1 (4 cells operating)13
Shaker cleaning mechanism13
Test Data (1981);7
320,000 acfm <§ 184°F (avg.)
ADDITIONAL COMMENTS:
aBlast furnaces A,B,C,D,E, and F were shut down in 1979 by state
order. "-1*13
^Partial casthouse evacuation control system for blast furnaces G,H,J, and K
or shutdown committed for 1982 by state order.11
447
-------
TABLE 9. CF&I STEEL CORP./PUEBLO PLANT IN PUEBLO, CO
BLAST FUKNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION: A1 D1 E1 F1
STARTUP DATE: 195014 190314 190414 194014
RECENT RELINE (REBUILD) DATE: 198014 197414 197414 197114
HEARTH DIAMETER (ft-in.): 22-91 21-01 21-61 21-91
WORKING VOLUME (ft3): 32.0001 30.7001 24.6561 31.3101
NO. OF TAPHOLES/FURNACE: i14 i14 i14 i14
NO. OF CASTHOUSES/FURNACE: I14 I14 I14 I14
IRON PRODUCTION:
RATED TONS/DAY: 90014 90014 90014 90014
AVERAGE TONS/DAY ( ):
CASTHOUSE EMISSION CONTROL SYSTEM:3
ADDITIONAL COMMENTS:
aNo commitment to install controls of Feb. 1981.3
448
-------
TABLE 10. FORD MOTOR CO./RIVER ROUGE PLANT IN DEARBORN, MI
BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION: AL fil Cl
STARTUP DATE: 192Q1 19221 19481
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in.): 20-fll 20-Ql 20-Ql
WORKING VOLUME (ft3): 28,0581 27,5091 54,9871
NO. OF TAPHOLES/FURNACE: I1 I1 I1
NO. OF CASTHOUSES/FURNACE: I6 I6 I6
IRON PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
CASTHOUSE EMISSION CONTROL
1,69915 1,69915
1.6252 1.6382
SYSTEM:3
3.15Q15
3.0072
ADDITIONAL COMMENTS:
Stretchout Act application for blast furnaces A and B, with conversion
to noncapture control technology by 1985; local hoods were completed in
Oct. 1981 for Furnace B but the baghouse was still under construction.i
449
-------
TABLE 11. INLAND STEEL CO./INDIANA HARBOR WORKS IN E. CHICAGO, IN
BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in. ):
WORKING VOLUME (ft3):
NO. OF TAPHOLES/FURNACE:
NO. OF CASTHOUSES/FURNACE:
IRON PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
CASTHOUSE EMISSION CONTROL SYSTEM:3
No. I1
19072
19751
21-61
32.1791'
ll
l"
2, ISO2
1.6132
No. 21
19092
19751
29-101
25,6891
ll
l"
2.1002
1.6552
No. 31
19172
19781
21-61
30,7931
ll
l"
2.3002
1.7672
(continued)
450
-------
TABLE 11 (continued)
BLAST FURNACE—CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in. ):
WORKING VOLUME (ft3):
NO. OF TAPHOLES/FURNACE:
NO. OF CASTHOUSES/FURNACE:
IRON PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
CASTHOUSE EMISSION CONTROL SYSTEM:3
No. 41
19262
19771
20-101
29.5851
ll
l"
2.3502
1.6892
No. 5l
19392
19741
26-61
48,2181
ll
I17
3.2502
2.4612
No. 61
19422
19761
26-61
48.0971
ll
ll7
3.2502
2.3192
(continued)
451
-------
TABLE 11 (continued)
BLAST FURNACE—CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in. ):
WORKING VOLUME (ft3):
NO. OF TAPHOLES/FURNACE:
NO. OF CASTHOUSES/FURNACE:
IRON PRODUCTION:
No. 71
198018
45-01
123, 8971
41
219
A1
19472
19771
26-61
48.0421
I1
I17
B1
19432
19751
26-6 *
48.1821
I1
I*7
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
CASTHOUSE EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
7.00018
3,400
2,374
3,400
2,477
Local hoods a a
to common
baghouse*8
Cadre & Koppers8
198018
• Local hoods at tapholes and tilting
iron runners. *
• 300,000 acfra at 140°F8«18
• A/C = 1.95:18
• 9 chambers; 1,729 Dacron polyester
bags.8
• Test Data (1981);19
225,000 acfm at 115°F (avg.)
ADDITIONAL COMMENTS:
aNo commitment to install controls as of February 1981.3
452
-------
TABLE 12. INTERLAKE INC./RIVERDALE PLANT IN CHICAGO, IL
BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION: A1 B8*1
STARTUP DATE: 19072 19092
RECENT RELINE (REBUILD) DATE: 19632 19652
HEARTH DIAMETER (ft-in.): 25-31 19-81
WORKING VOLUME (ft3): 41.4481 27.0271
NO. OF TAPHOLES/FURNACE: I6 I6
NO. OF CASTHOUSES/FURNACE: I6 I6
IRON PRODUCTION:
RATED TONS/DAY: 2.1002 1.3002
AVERAGE TONS/DAY (1976): 1.8522 1.0052
CASTHOUSE EMISSION CONTROL SYSTEM:b
ADDITIONAL COMMENTS:
aBlast furnace "B" was shut down hot in 1980.20
"No commitment to install controls as of Feb. 1981.3
453
-------
TABLE 13. JONES & LAUGHLIN STEEL CORP./ALIQUIPPA WORKS IN ALIQUIPPA, PA
BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION: A-I1 A-21 A-4l
STARTUP DATE: 19091 191Q1 19121
RECENT RELINE (REBUILD) DATE: 19692 19702 19662
HEARTH DIAMETER (ft-in.): 28-61 29-Ql 29-fll
WORKING VOLUME (ft3): 43,892V 54,OOQl 54.4001
NO. OF TAPHOLES/FURNACE: I1 I1 I1
NO. OF CASTHOUSES/FURNACE: I21 ln I2i
IRON PRODUCTION:
RATED TONS/DAY: 2.000;2 3.500;2 2.500;2
2.2001 3.2001 2.4001
AVERAGE TONS/DAY (1976): 3.0572
CASTHOUSE EMISSION CONTROL SYSTEM:b«c
ADDITIONAL COMMENTS:
aBlast furnaces A-3 (1,600 tons/day) and A-5 (1,500 tons/day) are shut
down.2!
^Noncapture controls or local hooding committed for 1982.1
cBlast furnace A-4 will have a permanent noncapture control system in
the near future.''
454
-------
TABLE 14. JONES AND LAUGHLIN STEEL CORP./CLEVELAND WORKS IN CLEVELAND, OH
BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACK DESIGNATION: C-ll C-31
STARTUP DATE: 19522 1963;2 196922
RECENT RELINE (REBUILD) DATE: 19722 197822
HEARTH DIAMETER (ft-in.): 27-61 30-6 *
WORKING VOLUME (ft3): 46.6471 57.2341
NO. OF TAPHOLES/FURNACE: I1 ' 21
NO. OF CASTHOUSES/FURNACE: I23 I22
IRON PRODUCTION:
RATED TONS/DAY: 2,2272 3.140:2 3.85022
AVERAGE TONS/DAY (1976): 2,3742 2,7322
CASTHOUSE EMISSION CONTROL SYSTEM:a»b
ADDITIONAL COMMENTS:
aNoncapture techniques or local hooding committed in negotiations for
''Blast furnace C-3—currently installing permanent noncapture casthouse
controls.^
455
-------
TABLE 15. JONES & LAUGHLIN STEEL CORP./INDIANA HARBOR WORKS IN E. CHICAGO, IN
BLAST FURNACE—CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in.):
WORKING VOLUME (ft3):
NO. OF TAPHOLES/ FURNACE:
NO. OF CASTHOUSES/FURNACE:
IRON PRODUCTION:
No. I;1 H-l25
19171
19482
27-61
48, 1911
16
126
No. 2;1 H-225>a
19251
22-01
28.5321
16
126
RATED TONS/DAY: 2,5002 1.4002
AVERAGE TONS/DAY ( ):
CASTHOUSE EMISSION CONTROL SYSTEM:b
(continued)
456
-------
TABLE 15 (continued)
BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in.):
WORKING VOLUME (ft3):
NO. OF TAPHOLES/FURNACE:
NO. OF CASTHOUSES/FURNACE:
IRON PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
CASTHOUSE EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No. 3;1 H-325
19532
Ellen;1 H-425
19672
29-61
52.0001
1«
32-01
64.2301
26
26
2,8002
2,5262
Noncapture
technique2^
4.0002
4.1082
Jones & Laughlin Steel Corp.
198125
• System uses no fans or gas cleaning
equipment.2-*
ADDITIONAL COMMENTS:
aBlast furnace No. 2 to be shut down permanently in future.2^
^Noncapture controls (by Consent Decree) to be installed by 1985.
°Noncapture controls (by Consent Decree) to be installed by 1984.
457
-------
TABLE 16. KAISER STEEL CORP./FONTANA WORKS IN FONTANA, CA
BLAST FURNACE—CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in. ):
WORKING VOLUME (ft3):
NO. OF TAPHOLES/FURNACE:
NO. OF CASTHOUSES/FURNACE:
IRON PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
CASTHOUSE EMISSION CONTROL SYSTEM:3
No. I1
19422
27-01
40, 531 l
129
129
2.220;30
1.6752
1.5752
No. 21
19492
197927
27-01
40.0861
L29
l29
2.370;30
1.6752
1.6612
No. 31
19532
27-01
40.5311
X29
!29
2.130;30
1.6752
1,3892
No. 41
19592
198128
29-61
50.9161
X29
!29
2.980;30
2.1752
2.0852
ADDITIONAL COMMENTS:
aNo commitment to install controls as of Feb. 1981.
458
-------
TABLE 17. LONE STAR STEEL IN LONE STAR, TX
BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION: No. I1 (Flossie Belle)1
STARTUP DATE: 19472
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in.): 27-01
WORKING VOLUME (ft3): 44.4031
NO. OF TAPHOLES/FURNACE: I5
NO. OF CASTHOUSES/FURNACE: I5
IRON PRODUCTION:
RATED TONS/DAY: 1.2002
AVERAGE TONS/DAY (1976): 1.5402
CASTHOUSE EMISSION CONTROL SYSTEM:8
ADDITIONAL COMMENTS:
aNo commitment to install controls as of Feb. 1981.3
459
-------
TABLE 18. MCLOUTH STEEL CORP./TRENTON WORKS IN TRENTON, MI
BLAST FUKNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in. ):
WORKING VOLUME (ft3):
NO. OF TAPHOLES/FURNACE:
NO. OF CASTHOUSES /FURNACE:
IRON PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
CASTHOUSE EMISSION CONTROL SYSTEM:8
No. I1
19542
30-0 l
57.2381
16
131
2,5002»31
2,4572
No. 21
19582
30-0 l
57.2381
16
131
2,5002>31
2,5462
ADDITIONAL COMMENTS:
aNo commitment to install controls as of Feb. 1981.
460
-------
TABLE 19. HANNA FURNACE CORP./SUBSIDIARY OF NATIONAL STEEL IN BUFFALO, NY
BLAST FURNACE—CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:3 No. 41
STARTUP DATE: 1911;2 19121
RECENT RELINE (REBUILD) DATE: 198032
HEARTH DIAMETER (ft-in.): 19-111
WORKING VOLUME (ft3): 29.9181
NO. OF TAPHOLES/FURNACE: I1
NO. OF CASTHOUSES/FURNACE: I32
IRON PRODUCTION:
RATED TONS/DAY: 9802
AVERAGE TONS/DAY (1976): 9982
CASTHOUSE EMISSION CONTROL SYSTEM:b
ADDITIONAL COMMENTS:
aBlast furnace No. 1 shut down in July 1977; blast furnace No..3 shut down
in summer of 1979.32
"Local hoods committed by state order for 1982.3
461
-------
TABLE 20. NATIONAL STEEL CORP./GREAT LAKES STEEL DIV. IN ECORSE, MI
BLAST FURNACE—CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION: . A;1 A-l33 B;1 A-233
STARTUP DATE: 1954;1 19552 1941;2 19511
RECENT RFLINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in.): 30-61 29-01
WORKING VOLUME (ft3): 62.4341 55.4681
NO. OF TAPHOLES/FURNACE: i1 i1
NO. OF CASTHOUSES/FURNACE: I33 I33
IRON PRODUCTION:
RATED TONS/DAY: 3.12033 2.76033
AVERAGE TONS/DAY (1976): 2,9542 2,6052
CASTHOUSE EMISSION CONTROL SYSTEM:3
(continued)
462
-------
TABLE 20 (continued)
BLAST FURNACE—CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION: C;1 C-333 D;1 D-433
STARTUP DATE: 19381'2 19521*2
RECENT REFINE (REBUILD) DATE: 1978-7933
HEARTH DIAMETER (ft-in.): 28-31 28-0
WORKING VOLUME (ft3): 50,66s1 53.2521
NO. OF TAPHOLES/FURNACE: I1 I1
NO. OF CASTHOUSES/FURNACE: I33 I33
IRON PRODUCTION:
RATED TONS/DAY: 2,76033 2.88033
AVERAGE TONS/DAY (1976): 2,4872 2.6202
CASTHOUSE EMISSION CONTROL SYSTEM:a
ADDITIONAL COMMENTS:
^National Steel is negotiating to regulate the blast furnaces under the
"Bubble" concept and install no controls.^
463
-------
TABLE 21. NATIONAL STEEL CORP./GRANITE CITY STEEL DIVISION IN GRANITE CITY, IL
BLAST FURNACE—CASTHOUSE PROCESS AND MISSION CONTROL DATA
FURNACE DESIGNATION: A1 s1
STARTUP DATE: 19561 1961l
RECENT RELINE (REBUILD) DATE: 198034
HEARTH DIAMETER (ft-in.): 27-31 27-31
WORKING VOLUME (ft3): 50,6591 50.64634
NO. OF TAPHOLES/FURNACE: I1 I1
NO. OF CASTHOUSES/FURNACE: Shared casthouse35
IRON PRODUCTION:
RATED TONS/DAY: 2.6002 2.6002
AVERAGE TONS/DAY (1976): 2.0992 2,2882
CASTHOUSE EMISSION CONTROL SYSTEM:
.a
ADDITIONAL COMMENTS:
aLocal hooding by Consent Decree to be installed by 1982; National Steel is
proposing to regulate the casthouses under the "Bubble" concept.3*^
464
-------
TABLE 22. NATIONAL STEEL CORP./WEIRTON STEEL DIVISION IN WEIRTON, WV
BLAST FURNACE—CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:3
STARTUP DATE:
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in. ):
WORKING VOLUME (ft3):
NO. OF TAPHOLES/FURNACE:
NO. OF CASTHOUSES/FURNACE:
IRON PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
CASTHOUSE EMISSION CONTROL SYSTEM:0
No. I1
19171
19712
27-01
54.0481
ll
I36
2.7001
2.7152
No. 21
19281
19762
27-01
45.9601
I1
136
2.3001
1.8542
No. 41
19521
19772
26-3 l
46.6701
I1
!36
2.3501
1.9482
ADDITIONAL COMMENTS:
aBlast furnace No. 3 (originally installed 1941, rated at 2,350 tons/day)
shut down indefinitely in Oct. 1981.37
^Casthouses for blast furnace Nos. 2 and 3 are structurally joined,
essentially forming one casthouse.3^
cLocal hooding committed for 1982 by Federal Consent Decree.11
465
-------
TABLE 23. REPUBLIC STEEL CORP./BUFFALO DISTRICT IN BUFFALO, NY
BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION: No. 21
STARTUP DATE: 19062
RECENT RELINE (REBUILD) DATE: 198138
HEARTH DIAMETER (ft-in.): 23-638
WORKING VOLUME (ft3):b 35.21338
NO. OF TAPHOLES/FURNACE: I38
NO. OF CASTHOUSES/FURNACE: I38
IRON PRODUCTION:
RATED TONS/DAY:b 2,00038
AVERAGE TONS/DAY (1976): 1.7542
CASTHOUSE EMISSION CONTROL SYSTEM:c
ADDITIONAL COMMENTS:
aBlast furnace No. 1 was shut down in 1976.^
bAfter 1981 reline.38
cLocal hood control system committed for 1982 by state order.38
466
-------
TABLE 24. REPUBLIC STEEL CORP./CENTRAL ALLOY DISTRICT IN CANTON, OH
BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION: NO. i1
STARTUP DATE:
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in.): 18-4 *
WORKING VOLUME (ft3): 21.6001
NO. OF TAPHOLES/FURNACE:
NO. OF CASTHOUSES/FURNACE:
IRON PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
CASTHOUSE EMISSION CONTROL SYSTEM:-
ADDITIONAL COMMENTS:
467
-------
TABLE 25. REPUBLIC STEEL CORP./CHICAGO DISTRICT IN CHICAGO, IL
BLAST FURNACE—CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION: No. I1
STARTUP DATE: 19432
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in.): 28-01
WORKING VOLUME (ft3): 54.4001
NO. OF TAPHOLES/FURNACE: I39
NO. OF CASTHOUSES/FURNACE: I39
IRON PRODUCTION:
RATED TONS/DAY: 2.8702
AVERAGE TONS/DAY (1976): 2,5322
CASTHOUSE EMISSION CONTROL SYSTEM:8
ADDITIONAL COMMENTS:
aLocal hood control by Federal Consent Decree to be installed by 1981.3
468
-------
TABLE 26. REPUBLIC STEEL CORP./CLEVELAND DISTRICT IN CLEVELAND, OH
BLAST FURNACE—CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:8
STARTUP DATE:
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in. ):
WORKING VOLUME (ft3):
NO. OF TAPHOLES/FURNACE:
NO. OF CASTHOUSES/FURNACE:
IRON PRODUCTION:
No. I1 No. 41 No. 51 No. 6*
194040 193740 195340 195240
27-01 27-01 29-61 29-61
44,900* 43,300* 56,100* 56,100*
*41 I41 I41 I41
*41 *41 *41 *41
RATED TONS/DAY:
AVERAGE TONS/YEAR (1977): 646,20040 588,30040 783,60040 782,30040
CASTHOUSE EMISSION CONTROL SYSTEM:b
ADDITIONAL COMMENTS:
aBlast furnace No. 3 was shut down between 1969-1970.
"No commitments to install casthouse controls as of February 1981.
469
-------
TABLE 27. REPUBLIC STEEL CORP./SOUTHERN DISTRICT, GULFSTEEL WORKS
IN GADSDEN, AL
BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION: No. I1 No. 21
STARTUP DATE: 19182 19422
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in.): 17-01 26-01
WORKING VOLUME (ft3): 19.7001 45.6001
NO. OF TAPHOLES/FURNACE: lA2 I42
NO. OF CASTHOUSES/FURNACE: i42 i42
IRON PRODUCTION:
RATED TONS/DAY: 8002 1.5002
AVERAGE TONS/DAY (1976): 9162 1,7842
CASTHOUSE EMISSION CONTROL SYSTEM:3
ADDITIONAL COMMENTS:
aNo commitment to install controls as of Feb. 1981.3
470
-------
TABLE 28. REPUBLIC STEEL CORP./MAHONING VALLEY DISTRICT IN WARREN, OH
BLAST FURNACE—CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION: NO. i1
STARTUP DATE: 19212
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in.): . 28-01
WORKING VOLUME (ft3): 53.2001
NO. OF TAPHOLES/FURNACE: ia>4
NO. OF CASTHOUSES/FURNACE: ia>4
IRON PRODUCTION:
RATED TONS/DAY: 2.8002
AVERAGE TONS/DAY (1976): 2,5652
CASTHOUSE EMISSION CONTROL SYSTEM:b
ADDITIONAL COMMENTS:
aBy December 1981 the No. 1 blast furnace will contain two tapholes and two
casthouses.4
"A casthouse emission control system will be installed in December 1981
including a baghouse with the following specifications.
A/C » 2.56-2.98:1
Total cloth area = 125,44p ft2
Flow rate = 320,000-375,000 cfra
Seven compartments
Shaker cleaning mechanism
471
-------
TABLE 29. REPUBLIC STEEL CORP./MAHONING VALLEY DISTRICT IN YOUNGSTOWN, OH
BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in. ):
WORKING VOLUME (ft3):
NO. OF TAPHOLES/FURNACE:
NO. OF CASTHOUSES/FURNACE:
IRON PRODUCTION:
No. I1
194243,44
198044
26-31
42.7001
I43
143
No. 2a»! No. 31
192643»44 193843»44
25-3 1 26-3 1
35.2001 46.5001
l43 X43
I43 1«
RATED TONS/DAY:
AVERAGE TONS/DAY: 1.59443 1.42843 1,55843
CASTHOUSE EMISSION CONTROL SYSTEM:b
ADDITIONAL COMMENTS:
aBlast furnace No. 2 has not operated for several years.44
bShutdown scheduled by Federal Consent Decree by 1982; Republic currently
wants to operate blast furnaces past 1982 shutdown date and install
controls.3»44
472
-------
TABLE 30. SHARON STEEL CORP./STEEL DIVISION IN FARRELL, PA
BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION: NO. 21 NO. 31
STARTUP DATE: 19022 19022
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in.): 23-11 23-11
WORKING VOLUME (ft3): 30.8501 31.5501
NO. OF TAPHOLES/FURNACE: I1 I1
NO. OF CASTHOUSES/FURNACE: Both furnace*, share a common
casthouse.4-5
IRON PRODUCTION:
RATED TONS/DAY: 1.4002 1.4002
AVERAGE TONS/DAY (1976): 1,1772 1,4332
CASTHOUSE EMISSION CONTROL SYSTEM:*,b
ADDITIONAL COMMENTS:
aPartial evacuation or local hooding committed by negotiations for 1982.3
bA local hood system with a Fuller baghouse (300,000 acfm) to be completed
by Dec. 1982.45
473
-------
TABLE 31. UNITED STATES STEEL CORP./EDGAR THOMSON-IRVIN WORKS IN BRADDOCK, PA
BLAST FURNACE—CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:8
STARTUP DATE:
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in.):
WORKING VOLUME (ft3):
NO. OF TAPHOLES/ FURNACE:
NO. OF CASTHOUSES/FURNACE:
IRON PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
No. I1
19432
19772
28-101
57.2181
17
17
2.5002
1,5112
No. 21
19432
28-lQl
48.0941
17
17
2,3002
2.0162
No. 3l
18832
198146
26-01
38.8371
!46
].46
1,8002
1.7292
CASTHOUSE EMISSION CONTROL SYSTEM:
Noncapture
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Local hoods
ducted to a
baghouse with
noncapture
controls7»46
Wheelabrator-Frye8>46
19817,46
• Iron trough • Entire cast-
hood—16 ft house floor
long covers is fitted
60% of with noncapti
trough area7 controls7>45
• 4 compartment
baghouse4&
• 140,000 acfm
(rated)7,4&
• Pulse-jet
cleaning46
b,c
ADDITIONAL COMMENTS:
aBlast furnace No. 6 shut down in 1979;3 blast furnace No. 5 is
presently not operating, and will shut down in 1982.H>46
bLocal hoods and noncapture controls by Federal Consent Decree committed
for 1982.n
cBlast furnace No. 3 scheduled for local hoods and noncapture controls and
will share baghouse with furnace No. 1 (nonsimultaneous casting)46
474
-------
TABLE 32. UNITED STATES STEEL CORP./SOUTH WORKS IN CHICAGO, IL
BLAST FURNACE—CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:3
STARTUP DATE:
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in.):
WORKING VOLUME (ft3):
NO. OF TAPHOLES/FURNACE:
NO. OF CASTHOUSES/FURNACE:
IRON PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS /DAY:
CASTHOUSE EMISSION CONTROL SYSTEM
No. 81
197047
32-01
63.3701
26,48
16
4,00048«49
3,044
(1980 avg.)49
.c
•
No. llb
194847
29-01
51.0041
l6, 48
I6
2,400*8.49
1,431
(1977 avg.)*9
No. 121
194847
29-0 l
51.0041
16,48
16
2.400;48
2.20049
898
(1980 avg.)49
ADDITIONAL COMMENTS:
aBlast furnace No. 10 (blown-in 1906) has been permanently dismantled.
bBlast furnace No. 11 did not operate in 1980.49
cNo commitment to install controls as of Feb. 1981.3
475
-------
TABLE 33. UNITED STATES STEEL CORP./NATIONAL-DUQUESNE WORKS IN DUQUESNE, PA
BLAST FURNACE—-CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
RECENT REHNE (REBUILD) DATE:
HEARTH DIAMETER (ft-in. ):
WORKING VOLUME (ft3):
NO. OF TAPHOLES/FURNACE:
NO. OF CASTHOUSES/ FURNACE:
IRON PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
CASTHOUSE EMISSION CONTROL SYSTEM:
No. I13'1
18962
20-01
25,909*
146
146
1,0002
c
No. 2b»1
189 7 2
23-01
32,7131
146
i46
1,2502
1.1002
c
No. 61
19632
28-Ql
58.0451
211
l46
3.0002
2,8432
d,e
ADDITIONAL COMMENTS:
aBlast furnace No. 4 shut down in 1979 by Federal Consent Decree.^
bfilast furnace Nos. 1 and 2 used only as a backup to blast furnace No. 6.^6
cFurnace Nos. 1 and 2 are to shut down or install local hood control system
in 1982 by Federal Consent Decree.3»^6
^Total evacuation, local hooding, or noncapture technique committed for 1982
by Federal Consent Decree.3.
eNoncapture controls to be installed by 1982, but company has applied for a
stretch-out to 1985.*6
476
-------
TABLE 34. UNITED STATES STEEL CORP./FAIRFIELD WORKS IN FAIRFIELD, AL
BLAST FURNACE—CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:8 No. 71
STARTUP DATE: 1941b»2
RECENT RELINE (REBUILD) DATE:
HEARTH DI4METER (ft-in.): 28-91
WORKING VOLUME (ft3) : 52.0701
NO. OF TAPHDLES/FURNACE: 251
NO. OF CASTHOUSES/FURNACE: 251
IRON PRODUCTION:
RATED TONS/DAY: 2,3002
AVERAGE TONS/DAY (1976): 1,7282
CASTHOUSE EMISSION CONTROL SYSTEM: c
No.
198151
32-050
77,52051
250,51
251
ADDITIONAL COMMENTS:
aBlast furnace Nos. 1,2,3, and 4 were shut down between Nov. 1978 and Jan.
1979; blast furnace Nos. 5 and 6 are also shut down.51
ABlast furnace No. 7 was shut down from 1978-1980; back on-line
Nov. 1981.51
cNo commitment to install controls as of Feb. 1981.3
dAAF has received a turnkey order for casthouse emissions control on furnace
No. 8. Control system design includes localized hoods and runner covers,
XLC FABRI-pulse fabric collector system with 2,400 polyester felt bags
handling 300,000 cfm.52
477
-------
TABLE 35. UNITED STATES STEEL CORP./FAIRLESS WORKS IN FAIRLESS, PA
BLAST FURNACE—-CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in. ):
WORKING VOLUME (ft3):
NO. OF TAPHOLES/FURNACE:
NO. OF CASTHOUSES/FURNACE:
IRON PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
CASTHOUSE EMISSION CONTROL SYSTEM:3
No. I1
19522
29-6 j1
(30-0)50
55.6511
!50,53
1*3
2,6072
2.7002
No. 21
19532
30-101
58.9401
153
153
2.8202
2,7762
No. 31
19572
30- 101
58.9401
153
I53
2,7792
2,8722
ADDITIONAL COMMENTS:
aLocal hoods or noncapture technique committed by negotiations for 1983
(No. 1), 1984 (No. 2), and 1985 (No. 3).11
478
-------
TABLE 36. UNITED STATES STEEL CORP./GARY WORKS IN GARY, IN
BLAST FURNACE—CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:3
STARTUP DATE:
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in.):
WORKING VOLUME (ft3):
NO. OF TAPHOLES/ FURNACE:
NO. OF CASTHOUSE S/ FURNACE:
IRON PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
CASTHOUSE EMISSION CONTROL SYSTEM: b
No. 41
19172
28-3 1
47.5631
154
L54
1.9592
2,3372
No. 61
19102
28-0 l
47.5501
^54
^54
1,9802
1.4852
No. 71
19092
28-0 l
42.1061
154
X54
1.9812
1,7082
(continued)
479
-------
TABLE 36 (continued)
BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:3 No. 81 No. 91 No. 101
STARTUP DATE: 19092 19092 19092
REtfENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in.): 26-61 23-01 27-01
WORKING VOLUME (ft3): 41.0171 28.8271 42.6801
NO. OF TAPHOLES/FURNACE:
NO. OF CASTHOUSES/FURNACE:
IRON PRODUCTION:
RATED TONS/DAY: 1.7212 9802 1.8182
AVERAGE TONS/DAY (1976): 1.9102 5642 1.9032
CASTHOUSE EMISSION CONTROL SYSTEM:b
(continued)
480
-------
TABLE 36 (continued)
BLAST FURNACE—-CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:*
STARTUP DATE:
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in. ):
WORKING VOLUME (ft3):
NO. OF TAPHOLES/FURNACE:
NO. OF CASTHOUSES/FURNACE:
IRON PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
CASTHOUSE EMISSION CONTROL SYSTEM:
No. II1
19082
25-0 !
39.2561
1.54
^54
1.1052
1.2472
c
No. 121
19082
25-0 *
39.2561
15*
L54
1,1372
1,3602
c
No. 131
19742
40-01
100, 1001
6.1482
5,0222
b
ADDITIONAL COMMENTS:
aFurnace Nos. 1 and 2 shut down in 1975, No. 3 shut down in 1979, No. 5
shut down in 1977.2»3
^Noncapture controls—commitment in negotiations*3
cShutdown scheduled—commitment in negotiation.3
481
-------
TABLE 37. UNITED STATES STEEL CORP./LORAIN--CUYAHOGA WORKS IN LORAIN, OH
BLAST FURNACE—CASTIIOUSE PROCESS AND KMISSTON CONTROL DATA
FURNACE DESIGNATION:3
STARTUP DATE:
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in. ):
WORKING VOLUME (ft3):
NO. OF TAPHOLES/FURNACE:
NO. OF CASTHOUSES/ FURNACE:
IRON PRODUCTION:
No. I1
18982
192655
23-01
28.6281
1*3
1*3
No. 21
18992
193755
23-3 *
28.9731
1«
1*3
No. 31
194155
28-6 !
48.5051
1*3
1*3
No. 41
194255
29-01
49.1961
1*3
1*3
RATED TONS/DAY: 1.39956 1.41256 2.18456 2,22256
AVERAGE TONS/DAY (1976): 1.3462 2,7182 2,3262
CASTHOUSE EMISSION CONTROL SYSTEM:5
ADDITIONAL COMMENTS:
aBlast furnace No. 5 (built in 1907) dismantled in 1979.55
bNoncapture controls to be installed by 1982,*3 1985.6
482
-------
TABLE 38. UNITED STATES STEEL CORP./NATIONAL-DUQUESNE WORKS IN McKEESPORT, PA
BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION: No. I1
STARTUP DATE:
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in.): 24-01
WORKING VOLUME (ft3): 30.6131
NO. OF TAPHOLES/FURNACE: I46
NO. OF CASTHOUSES/FURNACE: I46
IRON PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
CASTHOUSE EMISSION CONTROL SYSTEM:
ADDITIONAL COMMENTS:
aBlast furnace Nos. 2 and 3 were shut down in 1979.3
483
-------
TABLE 39. UNITED STATES STEEL CORP./GENEVA WORKS IN PROVO, UT
BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:8
STARTUP DATE:
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in. ):
WORKING VOLUME (ft3):
NO. OF TAPHOLES/FURNACE:
NO. OF CASTHOUSES/FURNACE:
No. I1
19442
198156
26-61
43.8971
157
158
No. 21
19442
26-6 l
43.8971
157
Furnace Nos.
No. 31
19442
26-6 1
43.8971
157
2 and 3
share common casthouse"
IRON PRODUCTION:
RATED TONS/DAY:b 1,900:2 , 1.80059 (for each furnace)
AVERAGE TONS/DAY (1976): 1,3442 (for each furnace)
CASTHOUSE EMISSION CONTROL SYSTEM:0»d
ADDITIONAL COMMENTS:
aCurrently, two out of three furnaces operate at any one time.57
"Furnace production capacities can be increased to 2,200-2,400 tons per day
when feed material is predominantly ore, and no sinter is used.-*9
cLocal hooding or noncapture controls committed for 1982 by Federal Consent
Decree.3
^Experimentation with noncapture suppression techniques that differ from the
J&L technology underway in 1981 on blast furnace No. 2.
484
-------
TABLE 40. UNITED STATES STEEL CORP./HOMESTEAD WORKS IN RANKIN, PA
BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:8 No. 31 No. 41
STARTUP DATE:
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in.): 29-61 29-61
WORKING VOLUME (ft3): 51.2811 51.2811
NO. OF TAPHOLES/FURNACE:
NO. OF CASTHOUSES/FURNACE:
IRON PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
CASTHOUSE EMISSION CONTROL SYSTEM:
.b
ADDITIONAL COMMENTS:
aBlast furnace Nos. 6 and 7 are permanently shut
"Total evacuation, local hoods, or noncapture controls committed for
1982 by Federal Consent Decree.11
485
-------
TABLE 41. WHEELING-PITTSBURGH STEEL CORP./MON VALLEY PLANT IN MONESSEN, PA
BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:8 No. I1
STARTUP DATE: 19132
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in.): 19-01
WORKING VOLUME (ft3): 24,6611
NO. OF TAPHOLES/FURNACE: i60
NO. OF CASTHOUSES/FURNACE: I60
IRON PRODUCTION:
RATED TONS/DAY: 1,0002
AVERAGE TONS/DAY (1976): 9732
CASTHOUSE EMISSION CONTROL SYSTEM: b
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No. 37'60 ("Jane")1
19482
28-01
46.5961
2.4002
2.1922
Local hoods over
taphole and three hot
metal cars ducted to a
baghouse60
I96060
• Design flow rate =
130,000 acfm60
• 10 modules, positive
pressure design"0
• Pulse-jet cleaning,
A/C = 6:I39
• Trough hood -27 ft
long extending 4 ft
, QQ °
past dam.J7
ADDITIONAL COMMENTS:
aBlast furnace No. 2 permanently shut down in Jan. 1980.60
bLocal hood controls on blast furnace No. 1 committed for 1982 by Federal
Consent Decree.11'60
486
-------
TABLE 42. WHEELING-PITTSBURGH STEEL CORP./STEUBENVILLE PLANT
IN STEUBENVILLE, OH
BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:8
STARTUP DATE:
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in.):
WORKING VOLUME (ft3):
NO. OF TAPHOLES/FURNACE:
NO. OF CASTHOUSES /FURNACE:
IRON PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
CASTHOUSE EMISSION CONTROL SYSTEM:b»
No. I1
19032
19762
25-01
37.1611
1*1
Share common
1.5502
1.4822
c
No. 21
19042
19692
23-101
35.4151
L61
casthouse61
1.5502
1,2792
ADDITIONAL COMMENTS:
aBlast furnace Nos. 1 and 2 are located in the North Plant.6
^Local hood with baghouse for all furnaces to be installed in 1982 by
Federal Consent Decree.6*11
cCompany applied for Stretch-out until Dec. 1985 for furnace Nos. 1
and 2.6
487
-------
TABLE 43. WHEELING-PITTSBURGH STEEL CORP./STEUBENVILLE IN MINGO JUNCTION, OH
BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:3
STARTUP DATE:
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in. ):
WORKING VOLUME (ft3):
NO. OF TAPHOLES/FURNACE:
NO. OF CASTHOUSES /FURNACE:
IRON PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
CASTHOUSE EMISSION CONTROL SYSTEM:5
No. 31
19482
•*
24-0 !
33.7711
1«
l"
1.5002
1.5022
No. 41
19502
21-51
27.6391
I61
1*1
9002
No. 51
19482
197762
24-9 l
40.5361
1"
l"
1.8002
1.8502
ADDITIONAL COMMENTS:
aBlast furnace Nos. 3, 4, and 5 are located in the South Plant.*
"Local hood-baghouse control on all furnaces to be installed in 1982 by
Federal Consent Decree. »*•*•
488
-------
MATERIAL IN THIS SECTION SUBJECT TO CONFIDENTIALITY
REVIEW AND IS NOT RELEASABLE AS OF FEBRUARY 1, 1982.
FOR INFORMATION, CONTACT L. KESARI, U.S. ENVIRONMENTAL
PROTECTION AGENCY, DIVISION OF STATIONARY SOURCE ENFORCEMENT.
>
CO
H
> M
o co
w
CO
-------
REFERENCES
BLAST FURNACE CASTHOUSE
1. World Steel Industry Data Handbook. Volume I. The United States.
McGraw-Hill Magazine. 1978. pp. 40. (Reliability No. 4.)
2. Development Document for Proposed Effluent Limitations Guidelines and
Standards for the Iron and Steel Manufacturing Point Source Category.
Vol. III. Draft Report. EPA 440/l-79-024a. October 1979. pp. 151.
(Reliability No. 4.)
3. Maslany, T. U.S. EPA, Region III. Memo on Blast Furnace Casthouse
Controls and Commitments. February 1981. (Reliability No. 1.)
4. Telephone conversation. Steve Samorgin, SW District-Ohio Environmental
Protection Agency to Sandy Beaton, GCA/Technology Division. October
1981. (Reliability No. 2.)
5. Telephone conversation. John Hepola, U.S. EPA Region VI to Michael
Jasinski, GCA/Technology Division. November 1981. (Reliability No. 2.)
6. EPA Region V Engineers comments to GCA questionnaire. December 1981.
7. Spawn, P. D. and T. J. Maslany. Blast Furnace Casthouse Control
Technology and Recent Emissions Test Data. JACA. 31(10): 1060.
October 1981. (Reliability No. 1.)
8. Estimation of Particulate Emission Concentrations from Blast Furnace
Casthouse Fabric Filters. Midwest Research Institute. Draft Final
Report. Project No. 4310-L, Task 18. July 1980. RACT Box No.
100507-100564. (Reliability No. 1.)
9. Franch, G. L. At Burns Harbor: Operating Experience with Large Blast
Furnaces. Iron and Steel Engineer. 49(9): 57-63. September 1972.
(Reliability No. 3.)
10. Greenwald, R. A. Burns Harbor "D" - Lady on Lake Michigan. Iron and
Steel Engineer. 48(11): 24-78. November 1971. (Reliability No. 3.)
11. Information supplied to P. Spawn, GCA/Technology Division by T. Maslany,
U.S. EPA Region III. (Reliability No. 2.)
489
-------
12. Farino W., P. Spawn, and M. Jasinski. Analysis of Control Options for
Blast Furnace in EPA Region II. Bethlehem Steel Corporation/Lackawanna
Plant. GCA/Technology Division. Draft Final Report No. TR-81-120-G.
Prepared for U.S. EPA. December 1981. (Reliability No. 2.)
13. Letter report. Bethlehem Steel Corp./Sparrows Point L Blast Furnace
Inspection. . GCA/Technology Division to U.S. EPA. April 1981.
(Reliability No. 2.)
14. Spawn, P. D. and S. G. Piper. Evaluation of Control Options and Costs
for CF&I Steel Corporation Blast Furnace Casthouse. GCA/Technology
Division. Final Report No. TR-80-104-G. Prepared for U.S. EPA. June
1981. (Reliability No. 1.)
15. EPA Region V files. (Ford response to EPA questionnaire dated February
2, 1978.)
16. EPA Region V files. (Ford 3rd qt. progress report to EPA dated October
16, 1981.)
17. Telephone conversation. Phil Pekron, U.S. EPA Region V to Sandy Beaton,
GCA/Technology Division. October 1981. (Reliability No. 2.)
18. Samivays, N. L. No. 7 Blast Furnace Completes Inland's $1 Billion
Expansion. Iron and Steel Engineer. December 1980. pp. 64-68.
(Reliability No. 4.)
19. GCA/Technology Division letter report to U.S. EPA Region III on testing
at Inland Steel's No. 7 Blast Furnace Casthouse, February 1981.
(Reliability No. 1.)
20. EPA Region V files. (Trip report at Interlake dated June 1980.)
21. Telephone conversation. Arthur Witt, Pennsylvania Department of
Environmental Resources to Sandy Beaton, GCA/Technology Division.
November 17, 1981. (Reliability No. 2.)
22. Spawn, P. D., et al. Assessment of Air Emissions from Steel Plant
Sources. J&L Steel Corp./Cleveland Works Blast Furnace. GCA Draft Final
Report No. TR-81-75-G. Prepared for U.S. EPA. July 1981. (Reliability
No. 1.)
23. Telephone conversation. Greg Trovasso, City of Cleveland Air Pollution
Control to Sandy Beaton, GCA/Technology Division. October 1981.
(Reliability No. 2.)
24. EPA Region V files. (J&L letter.)
25. EPA Region V files. (Letter from J&L to EPA, 1981.)
26. Telephone conversation. Don Kuh, State of Indiana Air Pollution Control
to Sandy Beaton, GCA/Technology Division. October 1981. (Reliability
No. 2.)
490
-------
27. Iron and Steel Engineer. Editor's Note. 56(11): November 1979.
(Reliability No. 4.)
28. Telephone conversation. Robert Bean, South Coast Air Quality Management
District to Michael Jasinski, GCA/Technology Division. November 1981.
(Reliability No. 2.)
29. Telephone conversation. Lois Green, U.S. EPA Region IX to Michael
Jasinski, GCA/Technology Division. October 1981. (Reliability No. 2.)
30. Cost Estimates and Construction Schedules for the Control of Visible
Emissions from the Blast Furnace Casthouse at Kaiser Steel Corporation,
Fontana, California. PCM Report. August 1980. (Reliability No. 1.)
31. EPA Region V files. (March 14, 1981, EPA Inspection at McLouth.)
32. Farino, W. F., et al. Analysis of Control Options for Blast Furnaces in
EPA Region II. Hanna Furnace Corporation, Buffalo, NY. GCA/Technology
Division Report No. TR-81-84-G. Prepared for U.S. Environmental
Protection Agency. August 1981. (Reliability No. 1.)
33. EPA Region V files. (March 1979 Litigation Report on NSC/GLS.)
34. Fornadley, R. J. Granite City—Bold Modernization of an Integrated Steel
Plant. Iron & Steel Engineer. August 1980. pp. SL-67 through SL-80.
(Reliability No. 3.)
35. Telephone conversation. Anton Telford, State of Illinois Environmental
Protection Agency to Sandy Beaton, GCA/Technology Division. October
1981. (Reliability No. 2.)
36. Spawn, P. D., et al. National Steel Corporation/Weirton Steel Division
Plant Inspection in August 1981. GCA/Technology Division Draft Final
Report No. TR-81-118-G. Prepared for U.S. Environmental Protection
Agency. November 1981. (Reliability No. 1.)
37. Iron & Steel Engineer. Industry News. November 1981. (Reliability
No. 4.)
38. Farino, W., et al. Analysis of Control Options for Blast Furnaces in EPA
Region II. Republic Steel Corporation/Buffalo, NY. GCA/Technology
Division Draft Final Report No. TR-81-93-G. Prepared for U.S.
Environmental Protection Agency. October 1981. (Reliability No. 1.)
39. EPA Region V files. (Acurex Report on RSC/Chicago Blast Furnace dated
1980.)
40. EPA Region V files. (RSC/Cleveland A.P. Emission Report dated 1978.)
41. Telephone conversation. Ike Habib, City of Cleveland Air Pollution
Control to Sandy Beaton, GCA/Technology Division. October 1981.
(Reliability No. 2.)
491
-------
42. Telephone conversation. Sue Robertson. Alabama State Air Pollution
Control Agency to Michael Jasinski, GCA/Technology Division. October
1981. (Reliability No. 2.)
A3. Letter response. Dennis Buuh, Ohio Environmental Protection Agency to
Sandy Beaton, GCA/Technology Division. November 1981. (Reliability
No. 2.)
44. EPA Region V files. (1974 permits.)
45. Telephone conversation. Bill Charleton, PADER—Meadsville, PA to Sandy
Beaton, GCA/Technology Division. October 11, 1981. (Reliability No. 2.)
46. Telephone conversation. Bob Felt, Allegheny County Department of Health
to Sandy Beaton, GCA/Technology Division. November 3, 1981.
(Reliability No. 2.)
47. EPA Region V files. (Air Pollution Emission Inventory prepared in 1977
regarding U.S. Steel Corp./Chicago Works.)
48. Memo regarding, Casthouse Emission Control Facilities for U.S. Steel
Corp./South Works. June 23, 1980. RACT No. 101293. (Reliability No. 2.)
49. EPA Region V files. (Letter from U.S. Steel/South Works to EPA Region V
dated January 1981.)
50. U.S. Steel Corporation. Memorandum from D. G. Wilson in reference to
Blast Furnace Casthouse Emission Control Facilities. RACT No. 101298.
(Reliability No. 2.)
51. Letter response. Paul Pate, Director of Jefferson County Department of
Health to Michael Jasinski, GCA/Technology Division. December 1981.
(Reliability No. 1.)
52. Iron & Steel Engineer. 57(11):90. November 1980. (Reliability No. 3.)
53. Telephone conversation and letter response. Tom McGinley, PADER—
Morristown, PA to Sandy Beaton, GCA/Technology Division. November 1981.
(Reliability No. 1.)
54. Telephone conversation. Roland Elrambuena, City of Gary Air Pollution
Control Division to Eugene Bergson, GCA/Technology Division. March 4,
1981. (Reliability No. 2.)
55. EPA Region V files. (1974 permits.)
56. EPA Region V files. (1972 permits.)
57. Telephone conversation. Dave Kopta, Utah State Department of Health to
Michael Jasinski, GCA/Technology Division. November 1981. (Reliability
No. 2.)
492
-------
58. USS Memorandum: Geneva Blast Furnaces Casthouse Emission Control
Facilities. Notes of Meeting. RACT No. 101413-101417. (Reliability
No. 2.)
59. National Enforcement Investigation Center. Report on Plant Inspection at
U.S. Steel Corp./Geneva Works. 1977. (Reliability No. 2.)
60. Letter response. Richard Thomas, FADER—Greensburg, PA to Sandy Beaton,
GCA/Technology Division. October 1981. (Reliability No. 2.)
61. Letter response. Harold Strohmeyer, North Ohio Valley Air Authority to
Sandy Beaton, GCA/Technology Division. October 1981. (Reliability
No. 2.)
62. EPA Region V files. (Blueprints.)
493
-------
MATERIAL IN THIS SECTION SUBJECT TO CONFIDENTIALITY
REVIEW AND IS NOT RELEASABLE AS OF FEBRUARY 1, 1982.
FOR INFORMATION, CONTACT L. KESARI, U.S. ENVIRONMENTAL
PROTECTION AGENCY, DIVISION OF STATIONARY SOURCE ENFORCEMENT.
d)
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IX
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TABLE 1. ARMCO INC./ASHLAND WORKS IN ASHLAND, KY
EXTERNAL DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
STARTUP DATE: , 19781
TYPE OF DESULFURIZATION PROCESS: Lance injection3'3*4
TYPE OF DESULFURIZATION COMPOUND(S) USED: Magnesium/lime mixture3*4
TYPE OF CARRIER GAS USED: Nitrogen2
NO. OF TORPEDO CARS DESULFURIZED AT ONCE:b 24;12
TYPE OF EMISSION CONTROL SYSTEM: Hood ducted to a baghouse2'4
MANUFACTURER:
DATE INSTALLED: 19781
SYSTEM DESCRIPTION: • Rated capacity = 40,000 acfm
@ uo^1
• A/C (design) = 6:!1
• Test Data (1980);2
20,400-24,200 scfm @
101-154°F
ADDITIONAL COMMENTS:
•y
aDesnlfurization station contains 2 units designated A and B.
"Each torpedo car contains 200 tons of hot metal.4
494
-------
TABLE 2. ARMCO INC./MIDDLETOWN WORKS IN MIDDLETOWN, OH
EXTERNAL DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
STARTUP DATE: 19795
TYPE OF DESULFURIZATION PROCESS: Injection3
TYPE OF DESULFURIZATION COMPOUND(S) USED:
TYPE OF CARRIER GAS USED:
NO. OF TORPEDO CARS DESULFURIZED AT ONCE: 25
TYPE OF EMISSION CONTROL SYSTEM: Baghouse6
MANUFACTURER: Standard Havens6
DATE INSTALLED: 1978;6 19795
SYSTEM DESCRIPTION:
ADDITIONAL COMMENTS:
495
-------
TABLE 3. CF&I STEEL CORP./PUEBLO PLANT IN PUEBLO, CO
EXTERNAL DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
STARTUP DATE: 19817
TYPE OF DESULFURIZATION PROCESS: Lancing7
TYPE OF DESULFURIZATION COMPOUND(S) USED:
TYPE OF CARRIER GAS USED:
NO. OF TORPEDO CARS DESULFURIZKD AT ONCE:
TYPE OF EMISSION CONTROL SYSTEM:3 Baghouse7
MANUFACTURER:
DATE INSTALLED: 19817
SYSTEM DESCRIPTION:
ADDITIONAL COMMENTS:
aPrior to the baghouse installation, an unevacuated enclosure was used to
contain emissions.8
496
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TABLE 4. JONES & LAUGHLIN STEEL CORP./ALIQUIPPA WORKS IN ALIQUIPPA, PA
EXTERNAL DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
STARTUP DATE:
TYPE OF DESULFURIZATION PROCESS:
TYPE OF DESULFURIZATION COMPOUND(S) USED:
TYPE OF CARRIER GAS USED:
NO. OF TORPEDO CARS DESULFURIZKD AT ONCE:
TYPE OF EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
19759
Injection10
Magnesium carbide1
Baghouse13'10*11
Buell. Inc.10'11
• 100,000 acfm (rated)11
• A/C • 3:1 (design)11
• 7 compartments; 120 bags
per compartment11
ADDITIONAL COMMENTS:
aStation can handle 8,000-9,000 tons/day of hot metal.9
^house replaced Dueon scrubber, originally used, in 1981.
497
-------
TABLE 5. JONES & LAUGHLIN STEEL CORP./CLEVELAND WORKS IN CLEVELAND, OH
EXTERNAL DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
STARTUP DATE:8
TYPE OF DESULFURIZATION PROCESS:
TYPE OF DESULFURIZATION COMPOUND(S) USED:
TYPE OF CARRIER GAS USED:
NO. 01- TORPEDO CARS DESULFURIZED AT ONCE:
TYPE OF EMISSION CONTROL SYSTEM:*5
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Lancing"' *•*
Lime-magnesium mixture^
ADDITIONAL COMMENTS:
aProC'!S8 is located in the abandoned open hearth shop.12
bSingLe-unit, experimental treatment station desulfurizing 50 to 60 percent
of hot metal produced. No emissions controls are used.9>12
498
-------
TABLE 6. KAISER STEEL IN FONTANA, CA
EXTERNAL DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
STARTUP DATE:
TYPE OF DESULFURIZATION PROCESS:
TYPE OF DESULFURIZATION COMPOUND(S) USED:
TYPE OF CARRIER GAS USED:
NO. OF TORPEDO CARS DESULFURIZED AT ONCE:
TYPE OF EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
197813
1i
Injection1-*
Calcium carbide and calcium
carbonate13
Nitrogen (200 cfm at 30-40 psi)13
Up to three13
Baghouse14
Wheelabrator-Frye13
197914
• 100,000 scfm, positive pressure13
• 6 compartments - 1728 total
Dacron bags - 6 exhaust stacks13
• A/C = 3:1 at AP = 7-8 in. W.G.13
• Mechanical shakers13
ADDITIONAL COMMENTS:
499
-------
TABLE 7. NATIONAL STEEL CORP./GRANITE CITY STEEL DIV. IN GRANITE CITY, IL
EXTERNAL DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
STARTUP DATE:
TYPE OF DESULFURIZATION PROCESS:
TYPE OF DESULFURIZATION COMPOUND(S) USED:
TYPE OF CARRIER GAS USED:
NO. OF TORPEDO CARS DESULFURIZED AT ONCE:
TYPE OF EMISSION CONTROL SYSTEM:0
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
19805
Injection15'16
Calcium carbide3>15>16
Nitrogen5*16
lb,5
Baghouse5»15»16
Carborundum16
197815
• 100,000 acfm16
• 8 compartments, Noraex bags
and a total cloth area of
93,356 sq. ft.16
ADDITIONAL COMMENTS:
aReplaced the soda-ash desulfurization process.16
bStation capacity is 5,500 tons/day;15 (300 tons/day).16
Emissions collected by a 9 x 11 ft hood, located 2 ft above hot metal car.
Emissions ducted to same baghouse used for controlling the hot metal transfer
station.5,15,16
500
-------
TABLE 8. REPUBLIC STEEL CORP./CHICAGO DISTRICT IN CHICAGO, IL
EXTERNAL DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
STARTUP DATE:
TYPE OF DESULFURIZATION PROCESS:1
TYPE OF DESULFURIZATION COMPOUND(S) USED:
TYPE OF CARRIER GAS USED:
NO. OF TORPEDO CARS DESULFURIZED AT ONCE:
TYPE OF EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
ADDITIONAL COMMENTS:
Scheduled startup in Spring of 1981 of a Takahax desulfurization process
supplied by Envirotech/Chemico Corp.17
501
-------
TABLE 9. REPUBLIC STEEL CORP./SOUTHERN DISTRICT,
GULFSTEEL WORKS IN GADSDEN, AL
EXTERNAL DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
STARTUI' DATE:8
TYPE OF DESULFURIZATION PROCESS:
TYPE OF DESULFURIZATION COMPOUND(S) USED:
TYPE OF CARRIER GAS USED:
NO. OF TORPEDO CARS DESULFURIZED AT ONCE:b
TYPE OF EMISSION CONTROL SYSTEM:0
MANUFACTURER:
DATE INSTALLED:
SYSTJ:M DESCRIPTION:
ADDITIONAL COMMENTS:
aStaticn not completed as of Oct. 1981.18
"Two tcrpedo-ladle stations to be built.9»19
cDesulfurization will be within EOF Shop, with a baghouse for control.
502
-------
TABLE 10. REPUBLIC STEEL CORP./MAHONING VALLEY DISTRICT IN WARREN, OH
EXTERNAL DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
STARTUP DATE:
TYPE 01' DESULFURIZATION PROCESS:
TYPE OF DESULFURIZATION COMPOUND(S) USED:
TYPE OF CARRIER GAS USED:
NO. OF TORPEDO CARS DESULFURIZED AT ONCE:
TYPE OF EMISSION CONTROL SYSTEM:3
MANUFACTURER:
DATE INSTALLED:
SYSTF.M DESCRIPTION:
ADDITIONAL COMMENTS:
aNo controls are presently used.
503
-------
TABLE 11. UNITED STATES STEEL CORP./NATIONAL-DUQUESNE WORKS
IN DUQUESNE, PA
EXTERNAL DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
STARTUI' DATE:
TYPE OI-" DESULFURIZATION PROCESS:
TYPE OP DESULFURIZATION COMPOUND(S) USED:
TYPE OK CARRIER GAS USED:
NO. OF TORPEDO CARS DESULFURIZED AT ONCE:
TYPE OF EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTiiM DESCRIPTION:
19809
ATH3
Calcium carbide3
Nitrogen2^
Baghouse^l
198021
• 4 compartments2^
• Flow rate = 40,000 cfm21
ADDITIONAL COMMENTS:
504
-------
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MATERIAL IN THIS SECTION SUBJECT TO CONFIDENTIALITY
REVIEW AND IS NOT RELEASABLE AS OF FEBRUARY 1, 1982.
FOR INFORMATION, CONTACT L. KESARI, U.S. ENVIRONMENTAL
PROTECTION AGENCY, DIVISION OF STATIONARY SOURCE ENFORCEMENT.
-------
REFERENCES
EXTERNAL IRON DESULFURIZATION STATIONS
1. Letter response. Jim Dills, State of Kentucky to Michael Jasinski,
GCA/Technology Division. November 19, 1981. (Reliability No. 1.)
2. Steel Processing Fugitive Emissions; Emission Test Report, ARMCO Steel,
Ashland, Kentucky. Clayton Environmental Consultants* EMB Report No.
HO-BOF-4. August 1980. (Reliability No. 4.)
3. Iron & Steel Engineer. Developments in the Iron & Steel Industry—U.S.
and Canada. February 1980. p. 220. (Reliability No. 4.)
4. New ARMCO Facilities Reduce Sulfur Level. Iron & Steel Engineer.
'56(1):63. January 1979. (Reliability No. 3.)
5. EPA Region V engineer's comments to GCA questionnaire, December 1981.
6. Telephone conversation. Ed Luebering, SW District Ohio EPA to Gene
Bergson, GCA/Technology Division. Marcy 9, 1981. (Reliability No. 2.)
7. Telephone conversation. Dennis Myers. Colorado State Department of
Health to Michael Jasinski, GCA/Technology Division. October 1981.
(Reliability No. 2.)
8. Telephone conversation. Dennis Myers, Colorado State Department of
Health to Stephen Piper, GCA/Technology Division. February 1981.
(Reliability No. 2.)
9. Desulfurization '80: Heavy booking on a bandwagon promising quality. 33
Metal Producing Magazine. November 1980. pp. 43-48. (Reliability
No. 4.)
10. Telephone conversation. Arthur Witt, PADER—Pittsburgh, PA to Sandy
Iteaton, GCA/Technology Division. November 17, 1981. (Reliability No. 2.)
11. Telephone conversation. Ken Bowman, Pennsylvania Department of
Environmental Resources to Mike Jasinski, GCA/Technology Division.
I'ebruary 18, 1981. (Reliability No. 2.)
12. Telephone conversation. Edward Wojciechowski, U.S. Environmental
Protection Agency Region V to Gene Bergson, GCA/Technology Division.
February 4, 1981. (Reliability No. 2.)
505
-------
13. Steiner, J. and B. J. Bodnaruk. Particulate and 862 Emission Factors
for Hot Metal Desulfurization, Kaiser Steel, Fontana Works. Paper
presented at EPA's Symposium on Iron and Steel Pollution Abatement
Technology. Philadelphia, PA. November 18-20, 1980. (Reliability
No. 2.)
14. Telephone conversation. Norm Ernstein, South Coast Air Quality
Management District to Gene Bergson, GCA/Technology Division. February
]981. (Reliability No. 2.)
15. Formadley, R. J. Granite City: Bold Modernization of an Integrated
Steel Plant. Iron and Steel Engineer. August 1980. pp. SL-67—SL-80.
(Reliability No. 3.)
16. KPA Region V files (permit application to construct dated May 29, 1979).
17. Iron & Steel Engineer. Industry News. 57(2):100. February 1980.
(Reliability No. 3.)
18. Telephone conversation. Sue Robertson, Alabama State Air Pollution
Control to Michael Jasinski, GCA/Technology Division. October 27, 1981.
(Reliability No. 2.)
19. Telephone conversation. Sue Robertson, Alabama State Air Pollution
Control to Gene Bergson, GCA/Technology Division. February 25, 1981.
(Reliability No. 2.)
20. Telephone conversation. Ted Davis. SW District Ohio EPA to Gene
Bergson, GCA/Technology Division. February 27, 1981. (Reliability
Mo. 2.)
21. Telephone conversation. Bob Felt, Allegheny County Department of Health
to Gene Bergson, GCA/Technology Division. February 12, 1981.
(Reliability No. 2.)
506
-------
O >
pa o
ri ><
W HJ
!*J O
W td
MATERIAL IN THIS SECTION SUBJECT TO CONFIDENTIALITY
REVIEW AND IS NOT RELEASABLE AS OF FEBRUARY 1, 1982.
FOR INFORMATION, CONTACT L. KESARI, U.S. ENVIRONMENTAL
PROTECTION AGENCY, DIVISION OF STATIONARY SOURCE ENFORCEMENT.
-------
TABLE 1. ARMCO INC./ASHLAND WORKS IN ASHLAND, KY
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:a
No. I1
19631
Top2
Full2
No. 21
19631
Top2
Full2
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:b
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:c
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
5,640 (both furnaces combined)^
Common dry ESP serves both furnaces2*^
Western Precipitator1
19634
• Four chambered ESP; four fields per
chamber5
• Total plate area = 117,054 sq ft5
• 4 I.D. fans with maximum rated
capacity = 350,000 scfm (total)5
Hot metal transfer area ducted to
baghouse5
Carborundum5
19755
• Design specifications;5
Flow rate = 90,000 acfm at 250°F
8 compartments; 2,304 total bags
(Nomex)
Total cloth area = 39,600 sq ft
A/C - 2.27:1
Shaker cleaning mechanism
ADDITIONAL COMMENTS:
aMembrane tube hood with steam condensed cooling and water sprays.2
bSeven ESP units were originally installed in 1963; eighth unit added in
1969.4
cTapping enclosure on each furnace directs tapping emissions into primary
exhaust hood and ESP.2
507
-------
TABLE 2. ARMCO INC./MIDDLETOWN WORKS IN MIDDLETOWN, OH
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
:E DESIGNATION:
IP DATE:
)F BLOWING MECHANISM:
)F COMBUSTION HOOD:8
No. 151
19691*6
Top2
Partial2
No. 161
1969L6
Top2
Partial2
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
7,599 (both furnaces combined)'
5,795 (both furnaces combined)''
Individual scrubber system per
furnace6*8'9
Chemico10
19696
• Separate but similar scrubber systems
consisting of a venturi scrubber
first and then a high-energy variable
throat scrubber®
* Scrubber Design Data (Single
System);g»lu
water now = 2,000 gpm in primary
venturi scrubber system
Ap • 45 in. H20 (primary venturi)
£p •= 45 in. H20 (variable throat)
One I.D. fan rated at 100,000 acfm
825 gpm of recirculated water used
55,000 dscfm of gas leaves primary
scrubber and enters variable throat
scrubber
Test Data
(1971);p»°
43,793-63,491
acfm
• Test Data
(1969);C7B
49,100-57,100
scfm
Hot metal transfer area ducted to
baghouse^*11
Industrial Clean Air11
197511
(continued)
508
-------
TABLE 2 (continued)
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
SYSTIM DESCRIPTION: » Rated at 95,000 acfm at 275°F
• A/C = 2.6:!11
• Ap = 4-6 in H201:1
ADDITIONAL COMMENTS:
aMembrane tube hood with double walled water cooling; gas cooling by water
quenehing.2>8
^Tests were performed for 6 consecutive heats from end of charging to
beginning of tap.**
cTests were performed during two oxygen blow periods.^
dHMT area was controlled by AAF multiclones from 1969 to 1975.8>1]-
509
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TABLE 3. BETHLEHEM STEEL CORP./BETHLEHEM PLANT IN BETHLEHEM, PA
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:a»b
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No. 7012
19681
Top2
Full2
No. 8012
19681
Top2
Full2
SECONDARY EMISSION CONTROL SYSTEM:
Common dry ESP serves both furnaces2 »
Research Cottrell12
197014
• Exhaust from each furnace to common
header, ESP, outlet header, 3 I.D.
fans, and one outlet stack-*-2
• Six section ESP with four cells per
section*2
• 750,000 acfm at 420°F (design flow
during 02 blow)^
• Test Data (1977);d»]-2
Avg. inlet—850,000 acfm at 400°F
(02 blow)
650,000 acfm at 175°F (charging and
tapping)
Avg. outlet—900,000 acfm at 260°F
(02 blow)
840,000 acfm at 175°F (charging and
tapping)
• Test Data (1976);c>12
442,400 dscfm (avg.); temperature -
207°F (avg.)
• Test Data (1972);15
493,500 dscfm at 200°F (avg.)
Permanent enclosures and awning on
tapside of each furnace-emissions
serviced by primary
(continued)
510
-------
TABLE 3 (continued)
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
MANUFACTURER:
DATK INSTALLED: 197612
SYSTEM DESCRIPTION: • Evacuation rate during hot metal
charging, turndowns, tapping,
slagging, etc. = 500,000 acfm at
180°F13
ADDITIONAL COMMENTS:
aFinned tube hood with steam generation cooling.2
^Gas cooling by water sprays.2
cBoth furnaces operating; testing only during 02 blow periods.12
dFan dampers set at 40 to 48 percent during normal full exhaust flow rate.12
511
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TABLE 4. BETHLEHEM STEEL CORP./BURNS HARBOR PLANT IN CHESTERTON, IN
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTIP DATE:
TYPE OF BLOWING MECHANISM:8
TYPE OF COMBUSTION HOOD:b
STEEL PRODUCTION:
RATED TONS/DAY:
AVEFAGE TONS/DAY (1976):
PRIMARY EMISSION CONTROL SYSTEM:
No. I1
196916
Top2
Full2
No. 21
196916
Top2
Full2
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
12,050 (all three furnaces combined)?
10,520 (all three furnaces combined)?
Variable throat venturi scrubbers serve
both furnaces1^1**
Cheraico10
196910
• Three scrubbers in parallel with
individual stacks1'
• 2,570,000 acfm at 180°F (design)10
• Three I.D. fans rated at 1500-hp18
• 5,700 gpm (water flow design)10
• L/G =2.2 gpm/1,000 acfm
(calculated)10
• Test Data (1974);15
Ap - 55 in. H20
SECONDARY EMISSION CONTROL SYSTEM:
(continued)
512
-------
TABLE 4 (continued)
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:
STEEL PRODUCTION:
RATED TONS/DAY:
AVEFAGE TONS/DAY ( ):
PRIMARY EMISSION CONTROL SYSTEM:
No. 31
19782
Top2
Partial2
See previous page'
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
High-energy variable throat venturi
scrubber1' >^
Chemico10
197810
• 280,000 acfm at 165°F (design)10
• One I.D. fan rated at 7,000-hp1^>20
• 2,800 gpm (water flow design)10
• L/G = 10 gpm/1,000 acfm (design-
calculated)10
SECONDARY EMISSION CONTROL SYSTEMS Hot metal transfer area to baghouse18
MANUFACTURER:
DATE INSTALLED:
SYST1M DESCRIPTION:
• 100,000 cfm18
• Test Data (1978);17
Avg. flow = 139,400 dscfm
Avg. temp. = 138°F
ADDITIONAL COMMENTS:
aCan only blow one vessel at a time.1'
^Tube hood with steam generation cooling; gas cooling by water quenching.2
cSecondary emissions controlled by hood located inside furnace enclosure
drafted to primary scrubber.17'1'
513
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TAIVLIi 5. BETHLEHEM STEEL CORP./LACK AW ANNA PLANT IN LACKAWANNA, NY
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:3
STEEL PRODUCTION:
No. 1621
196422,23
Top2
Full2
No. 17 21
196422, 23
Top2
Full2
No. 1821
196622.23
Top2
Full2
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
14,400 (all three furnaces combined)'
9,397 (all three furnaces combined)7
PRIMARY EMISSION CONTROL SYSTEM: Separate, identical scrubbers per furnace23
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Buell (all three scrubbers)10
196423 196423 196623
• Separate, identical scrubber units;
common manifold — single exhaust stack21
• Each unit contains 384 multi-venturi
tubes, assembled side by side (spray
nozzles located above tubes)23
• Design Ap = 50 in. ^0
• Entire system requires three I.D. fans;
each rated at 327,000 cfra (fourth fan on
standby)23
• Each fan normally operates at 980-1,100
SECONDARY EMISSION CONTROL SYSTEM: b
• Approx. inlet gas flow rate — 650,000 scfm
at 215 °F (during oxygen blow)23
Hot metal transfer area ducted to
baghouse.24
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Pangborn24
196924
• Design flow rate
• Exit temperature
• Ap - 6 in. H2024
100,000 scfm24
90°F24
ADDITIONAL COMMENTS:
aPlate and tube hood with steam condensed cooling; gas cooling by water
sprays.2
^Tapside onclosures installed on each furnace to control tapping emissions.
514
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TABLE 6. BETHLEHEM STEEL CORP./SPARROWS POINT PLANT IN SPARROWS POINT, MD
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:a»b
STEEL PRODUCTION:
No. 125
19661
Top2
Full2
No. 2"
19661
Top2
Full2
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
9,167 (both furnaces combined)'
8,903;' 15,457—avg. In 197425
. (both furnaces combined)
Four venturi scrubbers serve both
furnaces.25,26
Chemico (all four scrubbers)2**
Original 3 scrubbers—1966;25
4th scrubber—1975C»25
• All scrubbers arranged in, parallel2^
• Design Data (3 original
scrubbers);iy»"
81,069 dscfm per scrubber; 700,000
acfm (design-total)
Water flow - 7,000 gpm
Ap = 50 in. W.G.
L/G - 10 (based on design)
• Design Data (4th scrubber);2^
150,000 acfm at 150°F
Water flow - 1,400 gpm
Ap = 50 in. H20
L/G =9.3 (based on design)
Baghouse for hot metal transfer
(continued)
515
-------
TABLE 6 (continued)
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
MANUFACTURER: Buell26
DATE INSTALLED: 198126
SYSTEM DESCRIPTION: • Exhaust flow - 100,000 acfm at 170°F
(rated)26
ADDITIONAL COMMENTS:
Membrane tube hood with steam generation cooling; gas cooling by water
sprays2
bwaste heat boilers, quenchers, isolation dampers, and emergency stacks
follow each combustion hood.2^
cFourth scrubber installed to increase hood draft and thereby collect
charging and tapping emissions."
baghouse replaced original Carborundum baghouse installed in 1971.26
516
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TABLE 7. CF&I STEEL CORP./PUEBLO PLANT IN PUEBLO, CO
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:a
North1
19611
Top2
Full2
South1
19611
Top2
Full2
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:b
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Common ESP serves both furnaces27*28
United McGill27
1961 ;27 (Refurbished—1978)29
• ESP contains four units with a design
flow rate - 300,000 acfm at 350°F29
• Test Data (1978);15
Inlet—90,600-104,000 dscfm (range)
—458-515°F (range)
Outlet—151,000-169,000 dscfm (range)
—207-289°F (range)
Three-sided evacuated enclosure per
furnace, six roof canopy hoods, and hot
metal transfer station ducted to common
baghouse.29»30
Wheelabrator-Frye29
197828
• Total system flow rate
acfm29
540,000
• Baghouse contains five compartments
with 600 Nomex bags per compartment
• Positive pressure; requires three
fans28,30
• Test Data (1975);31
Inlet—606,000 acfm at 80°F (avg.)
29
ADDITIONAL COMMENTS:
aPaneled plate hoods with gas cooling by water sprays.2
bThe damper located on the reladling station opens only when hot metal is
transferred.28
517
-------
TABLE 8. FORD MOTOR CO./RIVER ROUGE WORKS IN DEARBORN, MI
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:a
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1977):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM :
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No. I;1 A32
196433
Top2
Full2
No. 2;1 B32
196433
Top2
Full2
8,380 (one vessel operation)3^
7,350 (one vessel operation)3^
Common dry ESP serves both furnaces32*35
Western Precipitator (Type R)36
1964;35 upgraded I96037
• 1,500,000 acfm (rated)2
• Ap » 3 in. W.C. (across entire unit)36
• 4 ESP units in parallel35*36
• 8 chambers, 4 fields per chamber35*36
• Test Data (1977);38
780,514 acfm (avg.); gas temp. = 300°F
(avg.)
• Test Data (1971);36
Inlet—863,000 acfm at 492°F
Outlet—810,900 acfm at 284°F
Hot metal transfer and hot metal skimming
station to spark arrester and common
baghouse36*39
Flex Clean39
197839
• 130,000 acfm at 175°F39
OQ
• Ap M 15 in. H20 across baghouse-5"
• I.D. fan rated at 457-hp39
• 9 compartments—2»592 acrylic polymer
fiber bags total39
• Cloth area—38,052 sq. ft.39
• Manual shaker cleaning39
(continued)
518
-------
TABLE 8 (continued)
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
Test Data (1981);32
784,000 acfm at 281°F
(Vessel A operating only, during oxygen
blow period)
ADDITIONAL COMMENTS:
aMembrane tube hood with steam generated cooling; gas cooling by water
sprays.^
t>Gaw dampers, installed in 1973, were replaced by the three-sided "doghouse"
and charge side local hoods in 1981; charge side hood ducted to primary ESP.
519
-------
TABLE 9. INLAND STEEL CO./INDIANA HARBOR WORKS IN E. CHICAGO, IN
NO. 2 BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:a
STEEL PRODUCTION:
No. 101
19741
Top2
Partial2
No. 201
19741
Top2
Partial2
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTKM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
6,000 (both furnaces combined)^
5,424 (both furnaces combined)^
Individual high-energy fixed throat
venturi scrubbers per furnace1^
Chemico10
197A40
• Separate but identical high-energy,
fixed throat venturi scrubbers1-'
Overall system Ap = 51 in. W.G.1^
One I.D. fan rated at 127,500 acfm at
170°F40
Ap •» 67 in. W.G.40
Scrubber water flow rate » 825 gpm10
L/G = 6.5 gpm/1,000 acfm (design)10*40
Test Data • Test Data
(1975);»
Without preheating
= 59,073 acfm at
118°F
With preheating
= 63,251 acfm
at 183°F
(1975);p»*1
Without preheating
= 60,801 acfm at
127 °F
With preheating
= 69,057 acfm
at 142°F
Local hoods within "doghouse" enclosure
drafted to primary scrubbers—(See above
description)1^
(continued)
520
-------
TABLE 9 (continued)
NO. 2 BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION: • Local hoods include a charging hood,
a tapping hood and a wrap-around hood
(at side of furnace)c»^^
• Design flow rate for enclosure »
131,000 acfm at 70°F13
ADDITIONAL COMMENTS:
aGas cooling by water quencher; quencher is a manually adjustable throat
venturi (design Ap = 6 in. W.C.)2»^°
^Testing from beginning of Q£ blow to start of tap without preheating,
and testing from start of preheating to start of tap (including HMC) with
preheating.^1
cDuring charging, only charging hood is drafted; during tapping the tapping
hood and wrap-around hoods are drafted. During 02 blows, all three hoods
are drafted."
521
-------
TABLE 10. INLAND STEEL CO./INDIANA HARBOR WORKS IN E. CHICAGO, IN
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:8
TYPE OF COMBUSTION HOOD:b
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No. 501
19661
Top2
Full2
No. 601
19661
Top2
Full2
11,200 (both furnaces combined)^
10,174 (both furnaces combined) ^
Four venturi scrubbers serve both
furnaces. 3-*
Buell35
196642
• Four venturi scrubbers in parallel
42
500,000 acfm;42 484,500 acfm at
128°F35
• L/G - 10 gpm/1,000 acfm (calculated)10
• Test Data (1974) ;43
474,000 acfm at 122°F (cooling water
on)
• 495,000 acfm at 135°F (cooling water
off)
Hot metal transfer station (including
desulfurization) drafted to
baghouse.13'40
Peabody44
197440
• 400,000 acfm at 275°F (rated)13*40
• Available system An = 15 in. W.G.13
• Test Data (1979) ;44
188,000 acfm at 187 °F
ADDITIONAL COMMENTS:
aSteam rings on lance hole help contain 03 blow emissions3^
^Paneled plate hoods with water cooling; gas cooling by water quenching.2
522
-------
TABLE 11. INTERLAKE INC./RIVERDALE PLANT IN CHICAGO, IL
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:a
STEEL PRODUCTION:
No. I1
195916
Top2
Full2
No. 21
195916
Top2
Full2
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
2,400 (both furnaces combined)7
2,A51 (both furnaces combined)'
Common ESP serves both furnaces45
Western Precipitatcr***45
I96046
• ESP is divided into three sections.
each section rated at 100,000 scfm45
• One section of ESP handles emissions
captured by "scavenger hood" directed
to single stack45
• Remaining two sections of ESP handle
primary furnace emissions and are
ducted to a separate stack45
• Test Data (I960);47
Main stack—185,916 acfm at 198°F
(avg.)
Secondary stack—71,729 acfm at 127°F
(avg.)
Scavenger hood on tap side of each
vessel ducted to primary ESP45
(see above description)
ADDITIONAL COMMENTS:
aPaneled plate hood with water cooling; gas cooling by water sprays prior
to ESP.2»48
Existing Western Precipitator ESP replaced a Research Cottrell ESP in
1980.45,46
523
-------
TABLE 12. JONES & LAUGHLIN STEEL CORP./ALIQUIPPA WORKS IN ALIQUIPPA, PA
NO. 2 BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
3IGNATION:a
IE:
OWING MECHANISM:
ylBUSTION HOOD:b
No. 1*9
196833
Top2
Full2
No. 2*9
196833
Top2
Full2
No. 3*9
196833
Top2
Full2
STARTUP DATE:
TYPE OF BLOWI
TYPE OF COMBt!
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
9,600 (all three furnaces combined)?
6,700 (all three furnaces combined)7
Common dry ESPs serve all three
furnaces*9>50
Research Cottrell and Western
Precipitator*9
1975 and 1968, respectively51
• Western Precipitator ESP consists of
8 units; units 1 through 6 control
furnace Nos. 2 and 3 while the
remaining 2 units are combined with
the 6 unit Research Cottrell ESP to
control furnace Nos. 2 and 1*9
• Maximum flow rate = 1,500,000 acfm at
500°F50
• Three I.D. fans per ESP discharge to
No. 1 (North) stack or No. 2 (South)
stack*9
• Test Data (1976);*9
No. 1 stack—388,000 dscfm; temp. »
311°F (avg.)
No. 2 stack—334,000 dscfm; temp. =
274°F (avg.)
Hot metal transfer area ducted to
primary control system ESPs (see
above description)^5^
ADDITIONAL COMMENTS:
aFurnaces are located in the No. 2 BOF shop which replaced the No. 1 BOF
shop in 1968.
^Paneled plate hood with gas cooling by water sprays; 11 water spray
banks.2>*9
cThe Research Cottrell ESP units were added in 1975 to increase system
capacity to enable handling of reladling emissions.50
524
-------
TABLE 13. JONES AND LAUGHLIN STEEL CORP./CLEVELAND WORKS
IN CLEVELAND, OH
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:a
STEEL PRODUCTION:
No. 9452
19611
Top2
Full2
No. 9552
19611
Top2
Full2
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
6,585;7 5,52052 (entire shop)
6,271 (entire shop)7
Common dry ESPs serve both furnaces3
Western Precipitator^2
1961;53 reconditioned-197552
• Two ESPs operate in parallel:->3
North ESP rated at 114,000 dscfm
South ESP rated at 225,000 dscfm
• Test data (1977);52
Avg. flow rate • 564,000 acfm at
265°F
SECONDARY EMISSION CONTROL SYSTEM:
ADDITIONAL COMMENTS:
aPaneled plate hood with gas cooling by water sprays.2
525
-------
TABLE 14. JONES & LAUGHLIN STEEL CORP./INDIANA HARBOR WORKS
IN E. CHICAGO, IN
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:3
No. I54
19701,55
Top2
Full2
No. 254
1970L55
Top2
Full2
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
9,985 (both furnaces combined)55
Common dry ESP serves both
f urnaces5-*»56
Western Precipitator55*56
1970b»53
• 1,285,000 cfm at 600°F (design);56
878,261 cfm at 550°F55
• Ap (design) = 25 in. H20;
• Ap (operational) = 6-12 in^
• 8 chambers (7 operate normally) 5
fields/chamber designated as A, B,
C, D and E56
• Fields A and B—barbed wire; fields
C, D and E—0.1055 shrouded plow
steel56
• Fields A and B—30 gas passages,
Fields C, D and E—39 gas passages56
• Test Data (I960);54
Hot metal charge: 308,000-344,000
scfm (avg.)
Oxygen blow: 380,000 scfm (avg.)
Tapping: 160,000 scfm (avg.)
Hot metal transfer and ladle
desulfurization drafted to common
baghousec>5'
(continued)
526
-------
TABLE 14 (continued)
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
MANUFACTURER:
DATE INSTALLED: 198157
SYSTEM DESCRIPTION:
ADDITIONAL COMMENTS:
aMembrane tube hood with high pressure water cooling; gas cooling by water
sprays from 11 banks.2>56
bESP revamped—1980.46
cPrior to baghouse installation, HMT area was controlled by multiclones.13,55
527
-------
TABLE 15. KAISER STEEL/FONTANA WORKS IN FONTANA, CA
NO. 2 BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:8
No. 51
19 7 81
Top2
Partial2
No. 61
19781
Top2
Partial2
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTHM DESCRIPTION:
Separate, identical high-energy venturi
scrubbers per furnace^®
197858
• Two stage venturi scrubbers ;59
First stage (quencher) with fixed
throat area measuring 20,900 sq cm
Second stage (scrubber) with variable
throat area measuring 8,750 sq cm
• Each scrubber rated at 200,000 cfm
using a 5,000-hp fan6(i
• Test Data
(1978);30
Scrubber water
flow rate =
2,400-2,500 gpm
Ap - 65-73 in.
H20
Test Data
(1978P0
Scrubber water
flow rate = 2,400
gpm
Ap - 87-89 in.
H20
Evacuated "doghouse" enclosure per
furnace ducted to common
1978.52,59 197946
• 600,500 cfm capacity with 2 fans each
rated at 315,000 acfm and 450°F13
• 12 compartments (2 cells each);
positive pressure; with gross cloth
area - 360,058 sq ft13
(continued)
528
-------
TABLE 15 (continued)
NO. 2 BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
• Gross A/C = 1.75:1; net A/C - 2:1,
with 3 cells offline13
• 7 fiberglass bags treated with
silicon, graphite and Teflon13
• Reverse air cleaning mechanism13
ADDITIONAL COMMENTS:
aMembrane water cooled hoods.°0
metal transfer (HMT) and skimming operations are ducted to the
secondary control baghouse.13
cThe secondary baghouse does not permit oxygen blowing, turndowns, tapping,
or slagging on one vessel while the second vessel is charged, and does not
permit HMT, skimming, or hot metal charging on one vessel while the
second vessel is being charged.13
529
-------
TABLE 16. McLOUTH STEEL CORP./TRENTON WORKS IN TRENTON, MI
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:3
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:b»c
STEEL PRODUCTION:
No. I1
19 581
(I960)61
Top2
Full2
No. 21
19581,61
Top2
Full2
No. 31
195861
Top2
Full2
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTI2M DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
6,000 (all five furnaces combined)7
5,502 (all five furnaces combined)7
High efficiency wet scrubber—
disintegrator per furnace62*63
Thiessen (all 5 systems)63*64
No. 1—1960;61 Nos. 2 and 3—1958;61
Nos. 4 and 5--196961
• Each control system includes a
settling chamber, wet centrifugal
separator, and high efficiency wet
scrubber, mist eliminator, and an
I.D. fan rated at 60,000 scfm68
• I.D. fans for systems on furnace Nos.
2 and 3 were installed in 1960; no
induced draft was used on these
systems prior to I96061
• Nos. 1, 2 and 3 control systems
exhaust via a common stack; Nos. 4
and 5 control systems exhaust via a
common stack61
• Test Data (1981);63
Outlet stack for Nos. 1, 2 and 3:
Avg. flow = 134,525 acfm
Avg. temp. = 112°F
"Mark Hoods" on all five furnaces63*65
(continued)
530
-------
TABLE 16 (continued)
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
SYSTEM DESCRIPTION:
ADDITIONAL CONTROL SYSTEMS:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
• Movable hoods on furnace charge
side61
• No tapping control; roof is completely
sealed61
Two hot metal transfer areas ducted to
common baghouse62
• Spark arrestor prior to baghouse
inlet62
• Baghouse exhausts within BOF shop62
(continued)
531
-------
TABLE 16 (continued)
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:3
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:b»c
No. 41
19691'61
Top2
Full2
No. 51
19691,61
Top2
Full2
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM.DESCRIPTION:
ADDITIONAL CONTROL SYSTEMS:
MANUFACTURER:
DATA INSTALLED:
SYSTEM DESCRIPTION:
See previous pages^
See previous
See previous
See previous pages"2
ADDITIONAL COMMENTS:
aAll five EOF vessels and two EAF vessels are located in the same melt
shop.62
^Hoods are water cooled.6^
cPrimary exhaust hoods are movable.62
532
-------
TAWLE 17. NATIONAL STEEL CORP./GREAT LAKES STEEL DIVISION IN ECORSE, MI
NO. 1 BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA3
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:b
No. 2166
19621
Top2
Full2
No. 2266
19 6 21
Top2
Full2
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
9,390 (both furnaces combined)0»66
Canopy hoods per furnace, ducted to
common dry ESP2
Koppers67
• 1,260,000 acfm2
• 3,000-hp fan2
Canopy hoods at hot metal transfer area
to multiclonesd>68
AAF68
• Flow rate (design) = 106,000 acfm
at 88°F69
• Treadwell HMT operation68
• Test Data (1976);68
71,879-74,122 acfm, 134-138°F (avg.)
ADDITIONAL COMMENTS:
aShop presently idle unless No. 2 shop is down for an extended period
of time.70
^Paneled plate hoods with steam generation cooling; gas cooling by water
sprays.2
cEstimated production figure.66
^Planning to duct multiclone outlet into primary ESP inlet rather than ESP
outlet; as previously planned.6^
533
-------
TABLE 18. NATIONAL STEEL CORP./GREAT LAKES STEEL DIVISION IN ECORSE, MI
NO. 2 BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:a
No. 2566
19 701
Top2
Full2
No. 2666
19701
Top2
Full2
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:0
7,050 (both furnaces combined)*5*66
Canopy hoods per furnace, ducted to
common dry ESP2
Hoppers-*6
197071
• 650,000 acfm2
• 60,000 scfm of dilution air added
approximately 10 ft above vessel
mouth during oxygen blow period71
Fan hp - 1,6002
6 chambers, 4 fields per chamber-*6
Ap - 2.34 in H20 (design)71
Ap » 2.4-2.5 in. HoO (actual)71
Test Data (1980);72
649,000 acfm at 260°F
661,000 acfm at 260°F
607,000 acfm at 288°F
Test Data (1973);36
746,000 acfm at 505°F (inlet)
746,000 acfm at 325°F (outlet)
Hot metal transfer and skimmer
station to common baghouse71
ADDITIONAL COMMENTS:
^Membrane tube hood with water cooling; gas cooling by water sprays (series
of five banks).2«71
^Estimated production figure.66
c"Garage door devices" retain tapping emissions for capture by the primary
hood.'
534
-------
TABLE 19. NATIONAL STEEL CORP./GRANITE CITY STEEL DIVISION
IN GRANITE CITY, IL
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
DESIGNATION:
DATE:
BLOWING MECHANISM:
COMBUSTION HOOD:C
No. I1
19671>2
Topa»2
Full2
No. 21
1967L 2
KMSb»2
Full2
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1978):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSThM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:d
MANUl'ACTURER:
DATE INSTALLED:
6,900 (both furnaces combined)73.74
5,048 (both furnaces combined)74
Common dry ESP serves both
furnaces >7-*
Koppers75'76
196875
• Rated at 800,000-810,000 acfm74'75
• Control system consists of three
double-chamber ESP's75*77
• Each ESP contains the following:77
68 gas channels
4 electrical fields
2 rows per field of 18 gauge mild
steel flat plates
• Each field has effective collection
area of 78,336 sq ft
• Three I.D. fans operate in parallel,
each with 1,000-hp motor rated at
360,000 cfm'7
• Test Data (1981);78
392,854-472,681 acfm (range)
237-273°F (range)
Hot metal transfer and external
desulfurization7^.7^
Carborundum7^»
197875
197375
(continued)
535
-------
TABLE 19 (continued)
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
SYSTEM DESCRIPTION: • Rated at 100,000 • 300,000 acfm75
acfm80 • 93 kW power
• 8 compart- requirement'^
ments80
• A/C = l.lrl80
• Nomex bags with
93,356 sq ft of
filter area
ADDITIONAL COMMENTS:
aFurnace No. 1 will be converted to KMS (Klockner-Maxhutte-Scrap) steelmaking
process when furnace No. 2 becomes operational.79
^Furnace No. 2 converted to KMS but not operational yet.79
cWater cooled combustion hood.75
^Secondary emissions will be controlled by "doghouse" enclosures per
furnace ducted to primary ESP; secondary emissions are currently ducted to
primary ESP.73»75
536
-------
TABLE 20. NATIONAL STEEL CORP./WEIRTON STEEL DIVISION IN WEIRTON, WV
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
]E DESIGNATION:
JP DATE:
)F BLOWING MECHANISM:
)F COMBUSTION HOOD:a»b
No. 681
19 6 71
Top2
Full2
No. 781
19671
Top2
Full2
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
11.690;7 13.57082 (both furnaces
combined)
9,892 (both furnaces combined)7
Common high-energy variable throat
venturi scrubber serves both
SECONDARY EMISSION CONTROL SYSTEM:
Chemico81
196781
• Dual scrubber system — common header
after waste heat boiler (for each
furnace) to crossover pipe; flow
split into 2 sections to separate
Venturis, and common exhaust stack"!
• Scrubber Design Data; 36
Flow - 225,000 scfm with Ap - 32 in.
W.C.
Inlet temperature = 850°F (prior to
quencher); outlet temperature = 140 °F
• 420,000 acfm at 140°F or 369,000 scfm
(design for entire system)8^
• Water flow = 4,200 gpm81
• L/G •= 10 gpm/acfm (calculated)8^
• Ap = 44 in. H20 (design)81
• Test Data (1979) ;81
Exhaust flow = 388,609-401,845 acfm
at 127. 5-150. 8 °F
Hot metal transfer area to
baghousec»36»82
(continued)
537
-------
TABLE 20 (continued)
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
MANUFACTURER: Amerclone36
DATIJ INSTALLED: 196783
SYSTEM DESCRIPTION: • Flow - 83,000 scfm (est.)36
• Temperature = I80°F (inlet est.);
140°F (outlet est.)3°
• A/C = 3.9:136
• Ap = 8 in. W.C.
ADDITIONAL COMMENTS:
aMembrane tube hood with steam generation.
heat boilers (for each furnace) generate steam during the Q£ blow
period. 81
cBaghouse reportedly is inoperable most of the time; new consent order
requires new control device for hot metal transfer area. 83
538
-------
TABLE 21. REPUBLIC STF.EL CORP./BUFFALO DISTRICT IN BUFFALO, NY
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:a
STEEL PRODUCTION:
No. I1
19701
Top2
Full2
No. 21
19 701
Top2
Full2
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:b
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
4,356 (both furnaces combined)'
2,680 (both furnaces combined)7
Common dry ESP serves both furnaces84
Western-Precipitator21 (Wheelabrator
Corp.)22*
197084
• Design flow rate = 475,000 scfm84
• Total plate area = 130,000 sq ft84
• 4 identical, parallel compartments
with 2 fields per compartment84
• Each compartment contains 32 frames
with 60 discharge wires per furnace84
• Two fans at 700-hp each84
• Single stack exhaust84
• Test Data (1975);84
245,450 scfm at 260°F
Hot metal transfer station ducted to
baghouse2
Pangborn24
197024
• Design flow rate = 81,000 scfm24
• Ap = 6 in. H2024
• Total fan hp = 40024
ADDITIONAL COMMENTS:
^ater cooled combustion hood; gas cooling by water sprays.2
^Tapside enclosures installed on both vessels (1980) for tapping emissions
control. Drafted to primary control system ESP.24
539
-------
TABLE 22. REPUBLIC STEEL CORP./CHICAGO DISTRICT IN CHICAGO, IL
NO. 2 BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:a
No. I1
19771,85
Bottom2
Partial2
No. 21
1977L85
Bottom2
Partial2
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATi: INSTALLED:
SYSTEM DESCRIPTION:
Separate, identical high-energy venturi
scrubber per furnace8^
Baumco^"
197785
• 424,000 acfm (total exhaust rate of
two systems)86
• Ap = 60 in. H20 (each scrubber)86
• One 6,000-hp I.D. fan; Ap = 76-86 in.
W.C. (each scrubber)86
• 2,500 gpm water (inlet)86
• Test Data (1977);87
101,903-106,085 acfm at 139-184°F
Evacuated "doghouse" enclosure drafted
by both primary scrubber systems8^
(see above description)
• Local hood on charge side of
vessel8 ^
• Design evacuation rate - 370,000
• Quenchers bypassed during charging
and tapping8*
• Test Data (1977) ;87
197,508-205,895 acfm at 118-125°F
(continued)
540
-------
TABLE 22 (continued)
NO. 2 BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
• Test Data (1978);88
Charging—268,000-463,000 dscfm
Temp.—16 8-2 43° F
Tapping—106,000-196,500 dscfm
Temp.—173-313 °F
ADDITIONAL COMMENTS:
aGas cooling by two venturi quenchers operated in parallel; three section
combustion hood.°6
541
-------
TABLE 23. REPUBLIC STEEL CORP./CLEVELAND DISTRICT IN CLEVELAND, OH
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:
STEEL PRODUCTION:
No. I1
196636,89
Top2
Partial2
No. 21
196636,89
Top2
Partial2
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
9.800;7 9.40089 (entire shop)
7,840 (entire shop)7
Separate, identical IRSID-CAFL
scrubber system per furnace""
American Air Filter91
197791
• Test Data (1977- • Test Data (1977-
1978);92
70,076-89,088
acfm
• Test Data
(1977);*u
79,076 acfm at
146.1°F
1978)7^
66,653-84,722
acfm
• Test Data
(1977) !*P"
78,521 acfm at
130 °F
SECONDARY EMISSION CONTROL SYSTEM:a>b Furnace enclosure—hoods on each
vessel and hot metal transfer area,
ducted to common dry ESP91»93
MANUFACTURER:
DATK INSTALLED:
SYSTEM DESCRIPTION:
Koppers (original 3 units), and Western
Precipitator (additonal 1 unit)93
1966—Koppers units93
1974—Western Precipitator unit93
• Series of hoods located within the furnace enclosure, and scavenger
hoods in the building trusses collect secondary emissions91'93
• Design evacuation rate (enclosure hoods) = 300,000 acfm at 100°F13
• Charging aisle scavenger hoods designed for 100,000 acfm at 100°F13
(continued)
542
-------
TABLE 23 (continued)
• Design Data (Western Precipltator Unit);93
375,500 acfm at 550°F,
Ap - 10 in. WC (negative)
2 chamber, 5 field ESP unit
Fields identified: "A", "B", "C", "D", and "E"
Discharge electrodes: 560 barbed wires for field "A"; 2,496 round wires
for fields "B" through "E."
Collecting surface is unitized modular finned plate
• Design Data (Koppers Precip. Units);93
Three, 4 field, double chamber units
Total collecting surface area = 139,536 ft2
Discharge electrodes: 4,752 barbed wires and 1,584 square wires
Total design flow rate = 1,000,000 acfm at 550°F
• Test Data (1979);94
Inlet—292,900-400,700 dscfm (during hot metal charging—HMC)
Outlet—410,000-788,800 dscfm (during HMC)
Inlet—290,200-410,700 dscfm (during tapping)
Outlet—450,900-815,000 dscfm (during tapping)
ADDITIONAL COMMENTS:
aThese ESP units were the original primary emission control system from
1966-1977.89,91
^Republic Steel is in the preliminary stages of removing these ESP units and
replacing them with a baghouse.95
543
-------
TABLE 24. REPUBLIC STEEL CORP./SOUTHERN DISTRICT, GULFSTEEL WORKS
IN GADSDEN, AL
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:a
STEEL PRODUCTION:
No. 196
19 651
Top2
Full2
No. 296
19651
Top2
Full2
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
4,500 (both furnaces combined)'
3,087 (both furnaces combined)'
PRIMARY EMISSION CONTROL SYSTEM:b Common dry ESP serves both furnaces13*96
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Koppers9'
196497
• Two double-chambered ESPs; four fields
per chamber96
• Flow rate = 700,000 acfm at 550°F
(design)96
• Three I.D. fans (with a fourth on
standby) required, each rated at
240,000 acfm at 500°F and 15 in.
W.G.96
• Evacuation rate during oxygen blow
period = 600,000 acfm at approximately
16 in. W.G. (normally)96
Gaw damper for hot metal charging (HMC)
and a fume canopy for tapping on each
furnace, drafted by primary control
system ESp96
Gaw damper and fume canopies installed
between 1977 and 197996»97
• Gaw damper closes off approximately
50% of primary hood face during HMC13
• Fume canopies contain tapping fumes to
allow evacuation through primary
exhaust hood13
(continued)
544
-------
TABLE 24 (continued)
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
• Evacuation rate during HMC = 600,000
acfm at approximately l70°F^-3
• Evacuation rate during tapping,
slagging and turndowns = 350,000 acfm
at 170°F13
ADDITIONAL COMMENTS:
aPaneled plate hood with gas cooling by water sprays.
one furnace operates at a
545
-------
TABLE 25. REPUBLIC STEEL CORP./MAHONING VALLEY DISTRICT IN WARREN, OH
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:a
STEEL PRODUCTION:
No. I1
19651
Top2
Full2
No. 21
19651
Top2
Full2
-
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:b
DATE INSTALLED:
7,120 (entire shop)7
5,493 (entire shop)7
Common dry ESP serves both
furnaces9°>99
Koppers and Wheelabrator-Frye98»100
1965;100 Upgraded-198098*100
• System upgraded 50% in I960100
• ESP contained 4 chambers prior to
upgrading — currently contains 6
chambers with steam accumulators for
improved efficiency. 98
• Design flow rate: 720,000 acfm with
three fans operating (fourth fan on
standby)101
• Test data (1981) ;102
587,100 acfm at 212 °F
Gaw damper98,99
1979"
197999
ADDITIONAL COMMENTS:
aPaneled plate hood with gas cooling by water sprays.2
^Installation of "baffle plates" for tapping control in future.101
546
-------
TABLE 26. SHARON STEEL CORP./STEEL DIVISION IN FARRELL, PA
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:a»b
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
PRIMARY EMISSION CONTROL SYSTEM:c
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No. 3103,104
19741,104
Top2
Full2
Variable throat venturi scrubber10^
Baumco10-'
1972103
• In series:
Water cooled exhaust
duct, quencher venturi, scrubber,
cyclone separator, I.D. fan, stack10^
I.D. fan rated at 300,000 cfm105
Ap (quencher venturi) - 7 in. W.G.105
Ap (venturi throat) » 55 in. W.G.105
110,000 acfm at Ap = 58 in. W.G.103
Water flow - 6,600
Test Data (1978);10*
172,105 acfm at 146°F (run No. 1)
• 169,851 acfm at 155°F (run No. 2)
Test Data (1976);105
209,600 scfm; temp. » 144°F (avg.)
Hot metal transfer area to baghouse10*
Pangborn10*
Baghouse rated at 90,800
ADDITIONAL COMMENTS:
aShop originally contained two "Kaldo" vessels (Nos. 1 and 2) which were
taken out of service in 1974 and 1980, respectively.10*
t>A new BOF vessel has been acquired to replace the No. 2 "Kaldo" and is
scheduled to be operational in 1981-1982.10*
cThe shop will operate one vessel at a time once second BOF is installed,
using existing scrubber control system.10*
^Control system was previously used at the Alan Wood Steel BOF shop.10*
547
-------
TABLE 27. UNITED STATES STEEL CORP./EDGAR THOMSON-IRVIN WORKS IN
BRADDOCK, PA
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:a
Rl
19 7 21
Top1
Full2
Ll
19721
Top1
Full2
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
7,750 (both furnaces combined)7
7,283 (both furnaces combined)7
Three common venturi scrubbers serve
both furnaces.107
AAj.107,108
197246,107
• Variable throat scrubbers operated in
parallel107
• Each furnace has a gas quencher107
• Design flow = 223,000 dscfm*6
• 2 I.D. fans (1 fan is a spare)107
• Fan hp - 4,600109
• Test Data (1974);109
Flow range = 176,500-248,500 scfm
• (wet)
Test Data (1972);107
Ap = 65-76 in. HZ0
SECONDARY EMISSION CONTROL SYSTEM:b Hot metal transfer to baghouse110
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
1975111
• Movable hood between pouring
spouts110
• 14 module baghouse110
• 150,100 scfm (avg. observed); 130,000
scfm (total)110
• Test Data (1978);110
151,000 acfm (avg.)
ADDITIONAL COMMENTS:
aPaneled plate hoods with water cooling; gas cooling by water spray.2
secondary emissions control by a Carborundum baghouse, planned for
Dec. 1982. i11
548
-------
TABLE 28. UNITED STATES STEEL CORP./SOUTH WORKS IN CHICAGO, IL
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:a
STEEL PRODUCTION:
Hi
196933
Top2
Full2
Jl
196933
Top2
Full2
Kl
196933
Top2
Full2
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:b
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
11,200 (all three furnaces combined)''
7,091 (all three furnaces combined)7
Common scrubber system serves three
furnaces^2
1969^9
• Exhaust hoods ducted to a manifold, to
a single pre-scrubber, then a single
duct from pre-scrubber branches to 3
separate, identical scrubbers operat-
ing in parallel.112
• Design flow rate = 500,000 acfm
(total)17
• Scrubbers designated as "A," "B" and
"C.-.112
• Test Data (1977) ;112
Total (average) flow of system =
425,000 acfm
Scrubber A — 138,500 acfm (avg.)
Scrubber B— 150,300 acfm (avg/)
Scrubber C — 135,900 acfm (avg.)
Hot metal transfer and mixing station
ducted to baghouse17
• Negative pressure, 12 compartments17
• One I.D. fan per compartment17
7Q
• Shaker type cleaning mechansim''
ADDITIONAL COMMENTS:
aPaneled plate hood with water cooling; gas cooling by water quencher.2
t>Gaw dampers and tapping deflectors have been installed. Gaw dampers are
not used; have met compliance by pouring hot metal at slow rate.17
549
-------
TABLE 29. UNITED STATES STEEL CORP./DUQUESNE WORKS IN DUQUESNE, PA
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:a
STEEL PRODUCTION:
No. I1
(A)"!
19 6 31
Top2
Full2
No. 21
(B)1H
19631
Top2
Full2
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
7,500 (both furnaces combined) ?
6,109 (both furnaces combined)?
Common venturi scrubber serves both
furnaces^-
1968b,lll
• Scrubber design data ;•
200,000 scfm; p = 57 in. H20
• Test Data (1978) ;113
Vessel No. 1: 105,100-113,400 dscfm;
Ap = 37.7-39.5 in. H20
Vessel No. 2: 78,900-82,200 dscfm;
Ap « 43.2-45.1 in H20
Unevacuated "doghouse" enclosures per
furnace, drafted to primary control
system scrubber "m
(See above system description)
ADDITIONAL COMMENTS:
aMembrane tube hood with water cooling.2
^Scrubber upgraded in 1975.11:L
550
-------
TABLE 30. UNITED STATES STEEL CORP./FAIRFIELD WORKS IN FAIRFIELD, AL
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
X9742.33
Bottom2
Partial2
19742,33
Bottom2
Partial2
7,400 (furnaces U and X combined)7
6,198 (furnaces U and X combined)7
Separate, identical scrubbers per
Baumco (both scrubbers)*"
1974;15 1976*6 (both scrubbers)
• Test Data (1974) ;15»115
67,900-69,200
scfm (range)
140-150°F (range)
p = 68-71 in. H20
(range)
220-225 gpm,
(scrubber
water)
Secondary emissions captured by hoods
within "doghouse" enclosures ducted to
primary scrubber system (see above
system description)a»k»ll*
(continued)
551
-------
TABLE 30 (continued)
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
19781]4
Bottom2
Partial2
Venturi scrubber46*116
Baumco46
197846
• Design Parametersi11'
Flow rate = 177,900 acfm at 160°F
Ap (quencher) = 10 in. H20
Ap (venturi) = 55 in. t^O
• Test Data (1978);15
76,300 dscfm at 163°F; 92,700 dscfm
at 158°F
Unevacuated "doghouse" and charge-side
canopy hood ducted to a baghouse118
Carborundum114
I960114
• Canopy hood—30 ft long x 3 ft wide114
• Baghouse design flow = 370,000 acfm at
200°F114
• Draft for canopy hood = 440,000 acfm118
• Baghouse also serves south hot metal
mixer area via a hood118
ADDITIONAL COMMENTS:
aEnclosure doors and secondary hoods for Furnace U, were originally installed
December 1978; doors replaced and hoods moved inside enclosure in January
1979.114
^Enclosure doors and secondary hoods for Furnace X, (located inside of
enclosure) installed in February 1974.114
552
-------
TABLE 31. UNITED STATES STEEL CORP./GARY WORKS IN GARY, IN
NO. 1 BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:
STEEL PRODUCTION:
Mary119
19651
Top2
Full2
Evelyn11-9
19651
Top2
Full2
Daisy119
19 651
Top2
Full2
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
12,400 (all three furnaces combined)7
10,762 (all three furnaces combined)7
Common venturi scrubber system serves all
three furnaces3"*119
Chemico36
1965b»36
* Two variable throat venturi scrubbers
operate in parallel119
• 1,161,000 dscfm at 2975°F (total
design)119
• Ap = 50-80 in. H20119
• 5,500-hp fan119
• Test Data (1981);120
208,000 dscfm at 73°F
• Test Data (1979);36
212,900 acfm (east inlet)
Ap - 62-68
186, 900 acfm (west inlet)
Ap - 62-64
Gaw damper and tapping enclosure per
furnace drafted to primary scrubber
110
system.-1-1-'
(See above description)
• Gaw damper for charging installed
1978/1979119
• Tapping enclosure installed 1977117
ADDITIONAL COMMENTS:
aWater cooled combustion hood; 1970—complete replacement of furnace hoods.119
t>New fans installed in 1978, replaced original 2,500-hp fans; new venturi's
installed in 1979.119
553
-------
TABLE 32. UNITED STATES STEEL CORP./GARY WORKS IN GARY, IN
NO. 2 BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:a
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
Tl
19731
Bottom2
Partial2
19731 19731
Bottom2 Bottom2
Partial2 Partial2
15,000 (all three furnaces combined) ^
11,875 (all three furnaces combined)''
PRIMARY EMISSION CONTROL SYSTEM:b Twin scrubber system serves all three
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
AAF*22
1973122
Entire system consists of:
• Two triple-throat venturi scrubbers each
with two I.D. fans designed for 202,000
dscfm121
• Test Data (1975) ;123
212,900 dscfm (east stack)
186,900 dscfm (west stack)
Unevacuated "doghouse" drafted by primary
scrubber system121
(See above description)
ADDITIONAL COMMENTS:
Conventional water cooled combustion hood; gas cooling by water sprays.2
cleaning system designed for two furnaces operating on 02 blow.121
554
-------
TABLE 33. UNITED STATES STEEL CORP./LORAIN—CUYAHOGA WORKS IN LORAIN, OH
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:a
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:b
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
East124 ("L")36
19711
Top2
Partial2
West124
19711
Top2
Partial2
7,700 (entire shop)7
3,086 (entire shop)7
Separate, identical twin stage
Venturi scrubber per furnace^-2 5
1971124,125
• Design flow rate (both systems •
combined) = 140,000 acfm at 168°F36
• Inlet design Ap - 65-70 in. H2036
• Test Data (1972) ;124
Avg. flow rate = 73,408 acfm
• Avg. temp. = 126 °F
Test Data (1971);3-25
Flow rate (range) = 56,619-57,800 dscfm
Local hood on charge side of each vessel
ducted to common venturi scrubber^24
Chemico3^
• Scrubber designed for 104,000 acfm at
98°F36
ADDITIONAL COMMENTS:
^Membrane combustion hood with gas cooling by water quenching*2
^Evacuated doghouse enclosure on each vessel ducted to a common baghouse
planned for December 1982.102
555
-------
TABLE 34. WHEELING-PITTSBURGH STEEL CORP./MON VALLEY PLANT IN MONESSEN, PA
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:
No. 1011
19 6 41
Top2
Full2
No. 10 21
19641
Top2
Full2
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
4,800 (both furnaces combined)7
3,776 (both furnaces combined)'
Common dry ESP serves both furnaces126
Western Precipitator126
1964b,127
• Six section ESP with five cells per
section126
• 3 I.D. fans rated at 300,000 cfm
(each)126
• 13 ft I.D. stack (outlet)126
• Test Data (1979);126
Flow = 356,500 scfm (avg. of 4 heats
during blow period)
SECONDARY EMISSION CONTROL SYSTEM:
ADDITIONAL COMMENTS:
Membrane tube hood with water cooling; gas cooling by water sprays
(7 banks)2'126
bESP rebuilt in 1981.127
556
-------
TABLE 35. WHEELING-PITTSBURGH STEEL CORP./STEUBENVILLE PLANT
IN MINGO JUNCTION, OH
BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:
STEEL PRODUCTION:
»A»128
19651
Top2
Full2
-B"128
19651
Top2
Full2
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
8,550 (both furnaces combined)''
7,707 (both furnaces combined)^
Common venturi scrubber serves both
furnaces2
Cheraico2
1965129
• 570,800 acfm (est.)10
• 57,000 gpm (water flow)10
• L/G = 10 gpm/1,000 acfm (calculated)10
Hot metal transfer area ducted to
baghouse130'131
I960130
• Eight modules130
• One I.D. fan rated at 175,000 cfm131
• Test Data (1980);130
24,278-25,090 acfm (range)
108-110°F (range)
ADDITIONAL COMMENTS:
aPaneled plate hoods with water cooling; gas cooling with water sprays.'
557
-------
MATERIAL IN THIS SECTION SUBJECT TO CONFIDENTIALITY >
REVIEW AND IS NOT RELEASABLE AS OF FEBRUARY 1, 1982. £ ^
FOR INFORMATION, CONTACT L. KESARI, U.S. ENVIRONMENTAL o "
PROTECTION AGENCY, DIVISION OF STATIONARY SOURCE ENFORCEMENT. ^ "
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S3 C~3
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i
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REFERENCES
BASIC OXYGEN CONVERTERS
1. World Steel Industry Data Handbook: Volume I. The United States.
McGraw-Hill Magazine. 1978. (Reliability No. 4.)
2. Caine, K. E., Jr. Development of Technology For Controlling BOP Charging
Emissions. EPA-600/2-77-218. October 1977. (Reliability No. 3.)
3. Letter response. James Dills, Commonwealth of Kentucky Department of
Natural Resources and Environmental Protection to Michael Jasinski,
GCA/Technology Division. November 19, 1981. (Reliability No. 1.)
4. Letter to Barry Gilbert, Air Programs Branch of U.S. Environmental
Protection Agency, Atlanta, Georgia from John E. Barker, Director of
Environmental Engineering, ARMCO, Middletown, Ohio. December 12, 1979.
(Reliability No. 1.)
5. Bergson, Eu.gene, et al. Assessment of Air Emissions from Steel Plant
Operations-ARMCO Steel, Ashland, Kentucky. GCA/Technology Division Draft
Final Report No. TR-81-95-G. Prepared for U.S. Environmental Protection
Agency. September 1981. (Reliability No. 1.)
6. Cowherd, C., Jr. Source Testing—EPA Task No. 2, ARMCO Steel
Corporation, Middletown, Ohio, BOF Shop. RACT #202185-202275.
(Reliability No. 1.)
7. Development Document for Proposed Effluent Limitations Guidelines and
Standards for the Iron and Steel Manufacturing Point Source Category,
Vol. IV. Draft Report. EPA-440/l-79-024a. October 1979. pp. 15-17.
(Reliability No. 4.)
8. Kashay, A. M. ARMCO's Middletown Works - A Blend of In-House Knowledge
and Supplier Competence. Iron & Steel Engineer. September 1974. p.
M-47. (Reliability No. 4.)
9. Determination of BOF and Kish Collector Emissions at ARMCO Steel
Corporation, Middletown, Ohio. Roy F. Weston, Environmental Scientists
and Engineers. November 14, 1969. RACT Box #202611-202636.
(Reliability No. 1.).
558
-------
10. U.S. Steel Industry Air Pollution Control Equipment Market. The
Mcllvaine Company. July 1980. Figure 8. (Reliability No. A.)
11. EPA Region V files. (Permit Applications dated December 5, 1980,
prepared by B. Steiner, ARMCO.)
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Shop. RACT Box #200903-300956. (Reliability No. 1.)
13. Letter from Don R. Goodwin, Director of Emission Standards and
Engineering Division, U.S. Environmental Protection Agency to Bernard
Bloom, Division of Stationary Source Enforcement, U.S. Environmental
Protection Agency. Re: Working Group Meeting - NSPS for Basic Oxygen
Process Furnace Secondary Emission Control. Attachments Nos. 1 and 2,
letter dated November 24, 1980. (Reliability Nos. 3 and 4.)
14. Letter response. J. McGrogan, PADER-Wernersville, Pennsylvania to Gene
Bergson, GCA/Technology Division. March 17, 1981. (Reliability No. 1.)
15. Castino, T. A., Jr. Particulate Emission Factors Applicable to the Iron
and Steel Industry. Final Report. Midwest Research Institute Project
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77. p. 2. (Reliability No. 2.)
17. Telephone conversation. Dan Bakk, U.S. Environmental Protection Agency,
Region V to Michael Jasinski, GCA/Technology Division. October 1980.
(Reliability Nos. 1 and 2.)
18. Labee, C. J. From Sand to Steel: The Burns Harbor Story. Iron & Steel
Engineer. 48(10):B-18 through B-48. October 1971. (Reliability No. 3.)
19. Performance Test of No. 3 BOF Gas Cleaning System at BSC/Burns Harbor,
Indiana. Prepared by Indiana State APC Board. 1978. RACT
#201612-201727. (Reliability No. 1.)
20. Burns Harbor Unveils New Facilities. Iron and Steel Engineer. September
1978. p. 69. (Reliability No. 4.)
21. Telephone conversation. Henry Sandonato, New York Department of
Environmental Conservation to Gene Bergson, GCA/Technology Division.
February 17, 1981. (Reliability No. 2.)
22. Labee, D. J. Lackawanna Plant: Bethlehem Steel Corporation. Iron &
Steel Engineer. 50(9):60-75. September 1973. (Reliability No. 3.)
23. Wilkinson, F. M. Wet Washing of BOF Gases-Lackawana. Iron & Steel
Engineer. September 1967. p. 142. (Reliability No. 3.)
559
-------
24. Letter response. Richard Craig, U.S. Environmental Protection Agency,
Region II to William Farino, GCA/Technology Division. December 1981.
(Reliability No. 1.)
25. Letter to Robert McCrillis, U.S. Environmental Protection Agency, from
Peter Spawn, GCA/Technology Division. May 5, 1980. (Reliability No. 2.)
26. Telephone conversation. Ralph Hall, Maryland State Department of Health
and Mental Hygiene to Michael Jasinski, GCA/Technology Division.
October 29, 1981. (Reliability No. 2.)
27. CF&I to Install Precipitator in BOF. Editor's Notes.Iron & Steel
Engineer. September 1976. (Reliability No. 4.)
28. Fugitive Visible Emission and Process Observation of CF&I BOP Secondary
Emission Control System. RACT Box #200971-200826. (Reliability No. 3.)
29. Telephone conversation. Dennis Myers, Colorado State Air Pollution
Control Division to Michael Jasinski, GCA/Technology Division. October
1981. (Reliability No. 2.).
30. Letter to Bernard Bloom, U.S. Environmental Protection Agency, Division
of Stationary Source Enforcement from Peter Spawn, GCA/Technology
Division.Preliminary Data Analysis of BOF Roof Monitor Emissions Data.
April 10, 1980. (Reliability No. 2.)
31. Investigation of Particulate Emissions—Basic Oxygen Furnace Roof
Monitor. CF&I Corporation, Pueblo, Colorado. Seton, Johnson and Odell,
Inc., Portland, Oregon. December 1975. (RACT Box #201437-201611.)
32. EPA Region V files. (Test Report at Ford Steel. May 1, 1981.)
33. Draft EIS for Revised Standards for Basic Oxygen Process Furnaces -
Background Information for Proposed Standards. Prepared by the Emission
Standards and Engineering Division of the U.S. Environmental Protection
Agency. November 1980. pp. 3-3. (Reliability Nos. 2-3)
34. EPA Region V files. (Ford response to EPA questionnaire, February 21,
1978).
35. Nunno, T. J., et al. Field Evaluation of Fugitive Emissions from BOF
Steelmaking Shops. Paper presented at EPA's Iron and Steel Symposium,
Philadelphia, PA. November 1980. (Reliability No. 2.)
36. Summary sheets compiled by PEDCo, from stack tests in regional EPA
offices. Provided to JACA for Steel Library by Tom Maslany,
U.S.Environmental Protection Agency, Region III. (Reliability No. 1.)
37. Telephone conversation. Mike Maillard, Wayne County Department of Health
to Gene Bergson, GCA/Technology Division. February 1980. (Reliability
No. 2.)
560
-------
38. EPA Region V files. (Stack Test Report by Wayne County at Ford, June
1977.)
39. Piper, S. Assessment of Air Emissions from Steel Plant Operations,
Pretest Survey Report, Ford Steel, Dearborn, Michigan. GCA/Technology
Division. Report No. 1061. Prepared for U.S. Environmental Protection
Agency. March 1980. (Reliability No. 1.)
40. McCluskey, E. J. Design Engineering of the OG Gas Cleaning System at
Inland's No. 2 EOF Shop. Iron & Steel Engineer. December 1976. p. 53.
(Reliability No. 4.)
41. Schmidt, J. H. Source Sampling Studies at Inland Steel Co., E. Chicago,
Indiana. No. 2 BOF APC System Emission Tests on OG Stacks No. 10 and
No. 20. Nalco Contract No. PCD-522. RACT #202337-202366. (Reliability
No. 1.)
42. Air, Water and Inland Steel. Inland Steel Publications, pp. 26-31.
(Reliability No. 4.)
43. EPA Region V files. (Test Report on Inland No. 4 BOF, June 1974.)
44. Baghouse Exhaust Particulates Emission Test, Fume Emission Control System
for the Hot Metal Transfer Station. No. 4 BOF Shop at Inland Steel
Company. Almega Corporation. July 3, 1979. (Reliability No. 1.)
45. EPA Region V files. (Letter to file from trip report at: Interlake, June
1980.)
46. Telephone conversation. Bernard Bloom, U.S. Environmental Protection
Agency, Washington, D.C. to Michael Jasinski, GCA/Technology Division.
November 1980-February 1981. (Reliability No. 2.)
47. EPA Region V files. (Interlake Tests at BOF, October 1980).
48. Stationary Source Testing, Interlake, Inc., Riverdale Plant—BOF.
August 18, 1976. RACT #202277-202308. (Reliability No. 2.)
49. J&L Steel Corporation, Aliquippa, Pennsylvania. Process Description.
RACT Box #200879-200902. (Reliability No. 1.)
50. Iron & Steel Engineer. Equipment News. 48(9):145-146. September 1971.
(Reliability No. 3.)
51. Telephone conversation. Ken Bowman, Pennsylvania Department of
Environmental Resources to Michael Jasinski, GCA/Technology Division.
February 18, 1981. (Reliability No. 2.)
52. Letter response. Gary Nied, Cleveland Division of Air Pollution to Gene
Bergson, GCA/Technology Division. March 9, 1981. (Reliability No. 1.)
561
-------
53. Telephone conversation. Edward Wojciechowski, U.S. Environmental
Protection Agency, Region V to Gene Bergson, GCA/Technology Division.
February 4, 1981. (Reliability No. 2.)
54. Bergson, G., et al. Assessment of Air Emissions from Steel Plant
Sources. J&L Steel Indiana Harbor Works BOF Shop. GCA/Technology
Division Final Report No. TR-80-84-G. Prepared for U.S. Environmental
Protection Agency. (Reliability No. 1.)
55. EPA Region V files. (J&L letter to EPA, April 1978.)
56. Steiner, J., and J. Knuck. Particulate Matter Emission Rates for BOF
Operations at Youngstown Sheet and Tube, East Chicago, Indiana. Acurex
Report TR-78-123, Vol. 1. pp. 2-5. August 1978. RACT Box
#201137-201244. (Reliability No. 1.)
57. EPA Region V files. (J&L letter to EPA, 1981.)
58. DeVorkin, H. Report on Source Test, Visible Emissions and Plant
Observations, Kaiser Steel Corporation/Fontana Works, Basic Oxygen
Furnace 5 and 6. Engineering-Science, Inc., February 1979. p. 5. RACT
Box //202391-202574A. (Reliability No. 1.)
59. Kaiser Steel Dedicates New Steelmaking Shop. Iron & Steel Engineer. May
1979. pp. 29-31. (Reliability No. 4.)
60. Letter to Bernard Bloom from Howard Lange, Chief Deputy Air Pollution
Control Officer, South Coast Mr Quality Management District, concerning
fugitive emission control system at new BOF at Kaiser Steel. June 7,
1977. RACT Box #201911-201928. (Reliability No. 1.)
61. EPA Region V files. (McLouth 1974 permits.)
62. Anderson, P. Compliance Monitoring Inspection Report, McLouth Steel
Corp./Trenton, Michigan. Prepared by GCA/Technology Division for U.S.
Environmental Protection Agency, Region V. 1979. (Reliability No. 2.)
63. EPA Region V files. (EPA inspection of McLouth, May 14, 1981.)
64. Bloomfield, Bernard. Air Pollution Control Installations. Industrial
Hygiene Quarterly. December 1956. (Reliability No. 4.)
65. Letter to John Heeney. U.S. Environmental Protection Agency, Region V,
from GCA/Technology Division. August 27, 1979. (Reliability No. 4.)
66. EPA Region V files. (March 1979 Litigation Report on NSC/Ecorse.)
67. Emission Study, BOP No. 1 Precipitator, Great Lakes Steel, Detroit,
Michigan. George D. Clayton Associates. March 1971. RACT Box
#202607-202716. (Reliability No. 1.)
562
-------
68. Memo from Mike Maillard of the Wayne County Department of Health to
Technical Services File, dated 1/19/77. Re: Source sampling performed
at Great Lakes Steel, Ecorse, Michigan on the No. 1 BOP Kish Collector.
JACA Library. (Reliability No. 1.)
69. EPA Region V files. (Permit Applications for HMT, November 1977,
NSC/GLS.)
70. Telephone conversation. Al Buck, Wayne County Department of Health—Down
River Office to Sandy Beaton, GCA/Technology Division. January 1982.
(Reliability No. 2.)
71. Piper, S.G. and T. J. Nunno. Assessment of Air Emissions from Steel
Plant Operations, National Steel Division Great Lakes Steel No. 2 BOF
Shop, Ecorse, Michigan. GCA/Technology Division Draft Final Report No.
TR-80-33-G. Prepared for the U.S. Environmental Protection Agency. June
1980. (Reliability No. 1.)
72. EPA Region V files. (Stack Test Report by GLS No. 2 BOP Shop.)
73. Telephone conversation. Anton Telford, Illinois Environmental Protection
Agency to Sandy Beaton, GCA/Technology Division. October 1981.
(Reliability No. 2.)
74. EPA Region V files. (Litigation Report on NSC/GC, December 12, 1978.)
75. Fornadley, R. J. Granite City: Bold Manufacturing of an Integrated
Steel Plant. Iron & Steel Engineer. August 1980. pp. SL-67 through
SL-80. (Reliability No. 3.)
76. EPA Region V files. (National Steel 114 letter response to EPA, 1974).
77. EPA Region V files. (Stack Tests at BOF, FSC/GC, December 1974).
78. EPA Region V files. (Stack Tests at BOF, NSC/GC, January 1981).
79. Region V Engineers response to GCA/Technology Division questionnaire,
December 1981.
80, EPA Region V files. (Permit Applications to construct dated May 1979).
81. Gronberg, S. and P. Bareford. National Steel, Weirton Division Basic
Oxygen Furnace BOF No. 6 and 7, Particulate Emission Testing Region III.
GCA/Technology Division, Draft Final Report No. TR-79-32-G. Prepared for
U.S. Environmental Protection Agency. RACT Box No. 200967-201136.
(Reliability No. 1.)
82. Telephone conversation. John Raggi, West Virginia Air Pollution Control
to Gene Bergson, GCA/Technology Division. February 1981. (Reliability
No. 2.)
563
-------
83. Letter response. John Raggi, West Virginia Regional Engineer to Michael
Jasinski, CCA/Technology Division. November 1981. (Reliability No. 1.)
8A. Letter report to Norman Surprenant from Peter Spawn, GCA/Technology
Division. Facility Inspection Report for BOFs at Republic Steel in
Buffalo, New York. December 1978. (Reliability No. 2.)
85. Anderson P. and P. Spawn. Assessment of Air Emissions from Steel
Operations, Republic Steel Corporation, Chicago District Q-BOP Shop,
Emission Evaluation, GCA/Technology Division, Draft Final Report No.
TR-79-64-G. Prepared for U.S. EPA. September 1979. pp. 33-37.
(Reliability No. 1.)
86. Williams, E., and W. Hayard. The Engineering and Installation of Two
225-ton Q-BOP Vessels in an Open Hearth Shop. Iron & Steel Engineer.
November 1978. pp. 33-37. (Reliability No. 4.)
87. Particulate Emission Test Data of Republic Steel Corporation Chicago
District No. 1 Q-BOP Shop. Mostardi Platt, Inc. Submitted to L.
Kertcher, U.S. EPA Region V. September 1977. RACT No. 202575-202604.
(Reliability No. 1.)
88. Steiner, J., and J. Knuch. Particulate Matter Emissions Factor Tests for
Q-BOP Hot Metal Addition and Tapping Operations at RSC, Chicago,
Illinois. Acurex Report No. TR-78-143, Vol. 1. November 1978. RACT Box
No. 201975-202080. (Reliability No. 1.)
89. EPA Region V files. (RSC/Cleveland, 1978 Publication).
90. Test Results of Basic Oxygen Furnace Suppressed Combustion Gas Cleaning
System, Republic Steel Corporation, Cleveland District, Cleveland, Ohio.
Submitted by Republic Steel. May 1978. RACT Box No. 201245-201254.
(Reliability No. 1.)
91. Brown, C.M. and R.W. Englebert. Control of Secondary Emissions of Basic
Oxygen Steelmaking Furnaces. Iron & Steel Engineer. June 1980. pp.
.39-45. (Reliability No. 4.)
92. Report on Stack Tests conducted on the Suppressed Combustion Gas Cleaning
System at Republic Steel Corporation, Cleveland District, Cleveland, Ohio
BOF. Submitted to U.S. EPA, Region V by RSC/Environmental Control
Department, General Office-Cleveland. May 1978. JACA Library.
(Reliability No. 2.)
93. Steiner, J. Steel Mill Enforcement Compliance Testing in Region V. Trip
Report Presurvey of BOF Shop Republic Steel, Cleveland, Ohio, July 27,
1978. RACT No. 201951-201974. (Reliability No. 1.)
94. Paper, R. and J. Steiner. Particulate Matter Emissions Factor Tests for
BOF Hot Metal Charging and Tapping at Republic Steel, Cleveland, Ohio.
Vol. 1, Acurex Final Report 80-62/EE. Acurex Project No. 280. June
1980. JACA Library. (Reliability No. 1.)
564
-------
95. Telephone conversation. Mr. Habib, City of Cleveland Air Pollution
Control to Sandy Beaton, GCA/Technology Division. October 1981.
(Reliability No. 2.)
96. Anderson, P., et al. Assessment of Air Emissions From Steel Plant
Operations, Republic Steel Corporation BOF Shop Gadsden, Alabama.
GCA/Technology Division Final Report No. TR-79-68-G. Prepared for U.S.
EPA. March 1980. RACT Box No. 200703-200790. (Reliability No. 1.)
97. .Telephone conversation. Sue Roberson, Alabama Air Pollution Control to
Gene Bergson, GCA/Technology Division. February 25, 1981. (Reliability
No. 2.)
98. EPA Region V file. Review by GCA December 1981.
99. EPA Region V files. (Letter by RSC, Progress Report, August 28, 1979).
100. Telephone conversation. Ted Davis, NE District Ohio EPA to Gene Bergson,
GCA/Technology Division. March 3, 1981. (Reliability No. 2.)
101. EPA Region V files. (Letter to EPA dated January 25, 1980).
102. Letter response. Dennis Bush, Ohio EPA-NE to GCA/Technology Division.
November 1981. (Reliability No. 1.)
103. Telephone conversation. Larry Wonders, Pennsylvania Department of
Environmental Conservation to Gene Bergson, GCA/Technology Division.
February 17, 1981. (Reliability No. 2.)
104. Telephone conversation. Bill Charleton, PADER-Meadsville, PA to
GCA/Technology Division. October and November 1981. (Reliability No. 2.)
105. Stack Tests at Sharon Steel Corporation, "L-D" Vessel BOF Stack.
December 9, 1976. Commonwealth of Pennsylvania, Department of
Environmental Resources. RACT No. 201847-201864. (Reliability No. 1.)
106. Testing of Sharon Steel BOF. Mogul Corporation. May 31, 1978. RACT No.
201863-201910. (Reliability No. 1.)
107. U.S. Steel Memo of Dust Emission and Efficiency Testing at Edgar Thompson
BOP Shop. June 1972. (Reliability No. 1.)
108. Telephone conversation. Bob Felt, Allegheny County Department of Health
to Sandy Beaton, GCA/Technology Division. November 1981. (Reliability
No. 2.)
109. Roof Monitor Emission Rates, U.S. Steel Corp./Braddock, Pennsylvania.
Vol. No. 1, Roof Monitor. April 15, 1974. JACA Library. (Reliability
No. 1.)
565
-------
110. U.S. Steel Memo of Stack Tests for Operating Permit at the EOF Shop Hot
Metal Transfer Facility - Edgar Thompson Plant. July 18, 1978. RACT No.
300131-300148. (Reliability No. 1.)
111. Telephone conversation. Bob Felt, Pennsylvania Department of
Environmental Resources to Gene Bergson, GCA/Technology Division.
February 12, 1981. (Reliability No. 2.)
112. Stack Test Particulates, EOF Scrubbers, U.S. Steel South Works, Chicago,
Illinois. Engineering Services Division, Department of Environmental
Control, City of Chicago. July 1977. RACT No. 202641-202696.
(Reliability No. 1.)
113. U.S. Steel Memo of Stack Testing at Duquesne BOF 1 and 2. October 25,
1978. RACT No. 201821-201846. (Reliability No. 1.)
114. Letter response from Jefferson County Department of Health to
GCA/Technology Division. December 1981. (Reliability No. 1.)
115. Letter from Jim Carroll, Jefferson County Department of Health Engineer
to Larry Ketcher, U.S. EPA Region V, concerning stack tests at
USS/Fairfield. RACT No. 202367-202389. (Reliability No. 1.)
116. Measurement of Fugitive Roof Emissions and Auxiliary Hood Capture at U.S.
Steel Corporation/Fairfield Q-BOP. April 2, 1975. JACA Library.
(Reliability No. 1.)
117. Kenher, W.F. and R.W. Mcllvaine. Review of Venturi Scrubber Performance
on Q-BOP Vessel C at the Fairfield Works of USSC. February 1979. JACA
Library. (Reliability No. 4.)
118. Spawn, P.O. and S. Beaton. U.S. Steel, Fairfield, AL. Q-BOP Fugitive
Emissions Evaluation in June 1981. GCA/Technology Division Draft
Report. December 1981. Prepared for U.S. EPA. (Reliability No. 1.)
119. Spawn, P., et al. Assessment of Air Emissions From Steel Plant
Operations.USSC No. 1 BOF Shop, Gary, Indiana. GCA/Technology Division*
Draft Final Report No. TR-79-68-G. March 1980. Prepared for U.S. EPA.
(Reliability No. 1.)
120. EPA Region V files. (Stack test at Gary BOF, May 1981).
121. Hubbard, H.N., and W.T. Lankford. Development and Operation of the Q-BOP
Process in the U.S. Steel Corporation. Iron & Steel Engineer.
50(10):37-43. October 1973. (Reliability No. 3.)
122. Markoya, R. Q-BOP Roof Monitor Emissions at U.S. Steel Gary Works, Gary,
Indiana, January 1980. Acurex Report No. TR-80-57/EE. (Reliability
. No. 1.)
566
-------
123. Stack Emission Tests Results-No. 2 Q-BOP, Gary Works. Report No.
18-E-005(003). RACT No. 201929-201950. (Reliability No. 1.)
.124. EPA Test Number 72-MM-02, Basic Oxygen Furnace, USSC, Lorain, Ohio.
Engineering Science, Inc. June 27, 1972. RACT No. 201281-201360.
(Reliability No. 1.)
125. U.S. Steel Corp./Lorain, Ohio BOF Tests. Engineering Science Inc.
December 21, 1971 publication. RACT No. 201361-201436. (Reliability
No. 1.)
126. Process Description of Wheeling-Pittsburgh Steel Corporation, Monessan,
Pennsylvania. RACT No. 202637-202640. (Reliability No. 1.)
127. Telephone conversation. Tony Johnson, Pennsylvania Department of
Environmental Resources to Gene Bergson, GCA/Technology Division.
February 26, 1981. (Reliability No. 2.)
128. Letter in EPA Region V files.
129. Telephone conversation. Harold Strohmeyer, North Ohio Air Quality
Authority to Sandy Beaton, GCA/Technology Division. November 1981.
(Reliability No. 2.)
130. EPA Region V files. (Stack Test Report by Clean Air Engineering, Inc.)
131. EPA Region V files. (Reladling Baghouse Blueprints.)
567
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MATERIAL IN THIS SECTION SUBJECT TO CONFIDENTIALITY
REVIEW AND IS NOT RELEASABLE AS OF FEBRUARY 1, 1982.
FOR INFORMATION, CONTACT L. KESARI, U.S. ENVIRONMENTAL
PROTECTION AGENCY, DIVISION OF STATIONARY SOURCE ENFORCEMENT.
w
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TABLE 1. ARMCO INC./BALTIMORE WORKS IN BALTIMORE, MD
ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATIONS
STARTUP DATE:
SHELL DIAMETER (ft-in.):
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
No. 3b>!
19371
1A-31
»A"c,2
I9602
Stainless and super alloyl
Direct shell evacuation per furnace,
ducted to common baghouse2»3
Fuller2
19682
• 292,000 acfm at 270°F (rated)2
• A/C - 2.54:1 (design)2
• Positive pressure^
• Baghouse also controls AOD vessel via
local hood capture system-*
Canopy hood above "A" furnace, ducted to
primary control system baghouse2 (see
above system description)
ADDITIONAL COMMENTS:
aShop presently operates "A" furnace only; furnace No. 3 used as back-up.
^Furnace No. 3 to be shut down in December 1981.2
C"A" furnace replaced furnace Nos. 5 and 6 in December I960.2
568
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TABLE 2. ARMCO INC./BUTLER WORKS IN BUTLER, PA
ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
SHELL DIAMETER (ft-ln.):
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No. 2*
19691
22-01
No. 31
19691
22-Ql
No. 41
1969^
22-01
SECONDARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
2,500 (all three furnaces combined)^
2,502 (all three furnaces combined)^
Carbon, alloy, stainless^^
Direct shell evacuation per furnace,
ducted to individual scrubbers6
Pease-Anthony (all three scrubbers)7
1969 (all three scrubbers)7
• Each scrubber system similar, unless
noted;
Scrubber design » 30,000 dscfm at Ap=
50 in. H20 (Nos. 2 and 3)7
Fan rated capacity • 112,000 cfm;
1750-hp motor6
• Test Data (1972);8
No. 2 furnace: 54,140 dscfm
Ap = 48 in. H20
Water flow - 970 gpm
No. 4 furnace: 53,183 dscfm
Ap - 45 in. H£0
Water flow •» 970 gpm
Hot metal transfer area, charging and
tapping control by canopy hood over each
furnace, ducted to common baghouse7'^
Wheelabrator-Frye7»'
19757
• Design flow rate = 350,000 acfm at
275°F7»9
• 8 compartments; total of 1536 woven
Dacron bags^
• A/C varies with each furnace—No. 2 =
2.53:1: No. 3 - 2.89:1; No. 4 -
3.05:1*
• Reverse air cleaning'
ADDITIONAL COMMENTS:
569
-------
TABLE 3. ARMCO INC./HOUSTON WORKS IN HOUSTON, TX
NO. 1 ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
SHELL DIAMETER (ft-in.):
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:3
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No. 41
19511
20-01
No. 51
1956;! 195710
20-01
1,100 (both furnaces combined)^
949 (both furnaces combined)^
Low carbon, alloy^
Direct shell evacuation per furnace,
ducted to individual scrubbers^-
196911
• Ap - 55 in. W.C.
(normal)*•*•
196911
• Ap = 55 in. W.C.
(normal)H
ADDITIONAL COMMENTS:
aPrimary control during 1962-1969 consisted of a direct shell evacuation-
baghouse which was subsequently replaced by scrubbers.H
570
-------
TABLE 4. ARMCO INC./HOUSTON WORKS IN HOUSTON, TX
NO. 2 ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
SHELL DIAMETER (ft-in.):
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:3
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
No. 61 No. 71 No. 81 No. 91
Two in 1966; one In 1970; and one in
197110
22-01
22-01 22-01
22-01
3,900 (all four furnaces combined)4
2,081 (all four furnaces combined)4
Low carbon, and ~35 percent alloys1
Direct shell evacuation per furnace,
ducted to common baghouse12
Fuller12
197810,12
• Baghouse rated at 2,000,000 cfm13
• 24-compartraents, and 6,912 polyester-
cloth bags (total)12
• A/C (design) - 3:112
• Five fans required, 12,500 hp (total)12
• Reverse air cleaning with 200 hp fan12
Canopy hoods per furnace, ducted to primary
control system baghouse12 (see above
system description)
ADDITIONAL COMMENTS:
aBaghouse appears to have replaced high-energy venturi scrubber in
1978.10.12
571
-------
TABLE 5. ARMCO INC./KANSAS CITY WORKS IN KANSAS CITY, MO
NO. 1 ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
No. I1*1
1952;1,14
No. 21*14
19561*14
SHELL DIAMETER (ft-in.):
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
20-2;1»14 20-016
62216
20-2;1»14 20-016
62216
Carbon;1 carbon, alloy^
Direct shell evacuation per furnace,
ducted to individual baghouse14*16
AAF16
197016
• 107,000 acfm at
400°F16
• A/C - 1.65:116
• 10 compartments—
720 bags (total)16
• Reverse air
cleaning16
Western
Precipitator16
• 177,000 acfm at
400°F16
• A/C - 1.9:116
• 16 compartments —
1,152 bags (total)16
• Reverse air
cleaning16
SECONDARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Canopy hoods per furnace, ducted to common
baghousea»14
AAF14
1977 (2 furnaces)16*17—1978 (for
remaining furnaces)17
• 900,000 acfm at 140°F14»16
• A/C - 2.7:1 (design)16
• Positive pressure with 12 compartments—
3,024 seamless polyester bags (total)14*16
• Ap - 5 in. H20 (design)14
• 4 fans—800 hp each14
• Reverse air cleaning14*16
(continued)
572
-------
TABLE 5 (continued)
NO. 1 ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
SHELL DIAMETER (ft-in.):
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
TYPE(S) OF STEEL PRODUCED-,
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No. 31'14
No. 4
19701 >
22-6;
1.02C16
22-016
1,02016
Carbon;1 carbon, alloy^
Direct shell evacuation per furnace,
ducted to individual baghousel^>16
AAF16
197016
• 70,000 acfm at
400°F16
• A/C - 1.47:116
• 6 compartments—
528 bags (total)16
• Reverse air
cleaning
16
AAF16
197016
• 140,000 acfm at
400°Fl6
• A/C - 1.76:116
• 10 compartments—
880 bags (total)16
• Reverse air
cleaningl6
SECONDARY EMISSION CONTROL SYSTEM:
Canopy hoods per furnace, ducted to common
baghousea»14 (see previous page system
description)
ADDITIONAL COMMENTS:
aEach furnace has charge side and tap side canopy hood ducted to a common
17-ft diameter duct and baghouse.l^
573
-------
TABLE 6. ARMCO INC./KANSAS CITY WORKS IN KANSAS CITY, MO
NO. 2 ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
SHELL DIAMETER (ft-in.):
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
No. 51*14
No. 6l»1A
1,02016
22-Ol,14
1, 02016
Carbon;! carbon, alloy^
Direct shell evacuation per furnace,
ducted to common baghousel»14»l"
197714,16
672,000 acfm at 270°Fl4,16
Positive pressure, 10 compartments
with 2,520 polyester bags (total)!4»l6
Ap = 7 in. H20l4,16
4 fans, (1 spare)14»16
A/C (design) - 3:116
Reverse air cleaning performed by one
250 hp fan14
Canopy hoods per furnace, ducted to
primary control system baghousel4 (see
above system description)
ADDITIONAL COMMENTS:
574
-------
TABLE 7. ARMCO INC./MARION WORKS IN MARION, OH
ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE: '
SHELL DIAMETER (ft-in.):
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
1968;1 196718
1975;1 197615»18
13-6^5
Carbon1
Canopy hood per furnace, ducted to common
baghousel8
Wheelabrator-Frye18
197618
• Rated at 225,000 acfm18
• Ap = 4-6 In. H2018
Total building evacuation, ducted to
primary control system baghousel8 (see
above system description)
ADDITIONAL COMMENTS:
575
-------
TABLE 8. ARMCO INC./SAND SPRINGS WORKS IN SAND SPRINGS, OK
ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
SHELL DIAMETER (ft-in.):
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
No. I1
1957a,l,19
18-01*5
No. 21
19701.^9
18-01*5
Carbonl » 5
Direct shell evacuation per furnace,
ducted to common baghousel9
AAp.19,20
197019
• Baghouse rated at 112,000 acfm at
• Baghouse contains 1,080 "silicone-
graphite" treated bags with an
effective cloth area = 100,300 sq ft19*21
• Design A/C = 1.12:121
ADDITIONAL COMMENTS:
aFurnace No. 1 revamped in 1969.
576
-------
TABLE 9. ARMCO INC./TORRANCE PLANT IN TORRANCE, CA
ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
SHELL DIAMETER (ft-in.):
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:3
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
No. 51
19411
12-O;1 17-022
No. 61
19491
10-0j1 14-022
Low carbon, alloy,
Canopy hoods per furnace, ducted to
common baghouse^-* 22,23
Fuller22
195622
• Exhaust flow rate = 60.000 cfm22
• A/C (design) - 1.96:12^
• Shaker type cleaning mechanism2^
Tap pit enclosure per furnace, ducted to
primary control system baghouse2-* (see
above system description)
ADDITIONAL COMMENTS:
aBaghouse also controls two jaw crushers and a chaser mill.22
577
-------
TABLE 10. BETHLEHEM STEEL CORP./BETHLEHEM PLANT IN BETHLEHEM, PA
ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
SHELL DIAMETER (ft-in.):
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No.2125 No.2225 No.2325 No.242^ No.2525
19381 19401 19401 19571 19571
15-Ql 18-Ql 18-01 18-Ql 18-Ql
SECONDARY EMISSION CONTROL SYSTEM:
Alloy1*5
Canopy hood per furnace, ducted to common
baghouse2^*26
Fuller8
1972a,26
• Each canopy hood (unbaffled) measures
1,296 sq ft located 30 ft above
furnaces26
• Hood draft controlled by five 900-hp,
600 rpm, F.D. fans26
• Total fan (5) capacity = 1,350,000 cfm27
• 5 section baghouse (one fan per
section); 10 compartments, 90 Dacron
bags per compartment"*2"
• Reverse air cleaning2-'
Total building evacuation, ducted to primary
control system baghouse2^*26 (see above
system description)
ADDITIONAL COMMENTS:
aAll bags replaced in 1976.
578
-------
TABLE 11. BETHLEHEM STEEL CORP./JOHNSTOWN PLANT IN JOHNSTOWN, PA
ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
SHELL DIAMETER (ft-in.):
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
19812»
198128
Direct shell evacuation per furnace,
ducted to common baghouse28
Baumco28
198128
• Design flow rate = 740,000 acfm28
• 20 compartments: 176 polyester bags
per compartment28
• A/C - 2.28:1 (design)28
• 4 fans—3 operate, 1 as spare28
• Positive pressure, reverse air
cleaning2"
Canopy hood and 3-sided (partial)
enclosure per furnace, ducted to primary
control system baghouse28 (see above
system description)
ADDITIONAL COMMENTS:
579
-------
TABLE 12. BETHLEHEM STEEL CORP./LOS ANGELES PLANT IN LOS ANGELES, CA
NO. 3 ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
SHELL DIAMETER (ft-in.):
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:3»
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No. I22
19481.22
17 -0*
No. 222
1950*»22
20-Ql
No. 322
1951;!
195222
20-Ql
Rimmed;^ carbon, alloy^
Direct shell evacuation per furnace,
ducted to common baghouse29
Fuller22
1965b,22,29
• Rated at 525,000 cfm with A/C =
1.95:1;22 1.80:129
• Two 250 hp exhaust fans29
• 26 compartments; total of 3,120
slllcone treated glass fiber bags29
• Reverse air cleaning using
29,750 cfm29
Canopy hoods per furnace, ducted to
primary control system baghouse29
(see above system description)
• Canopy hood dimensions—40 x 60 x
18-ft29
ADDITIONAL COMMENTS:
aBaghouse also controls the hot scarfer (located at blooming mill) and the
leaded steel preparation area.22>29
ABaghouse replaced an ESP previously used for primary emission control
between 1950 and 1965.29
580
-------
TABLE 13. BETHLEHEM STEEL CORP./SEATTLE PLANT IN SEATTLE, WA
ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
SHELL DIAMETER (ft-in.):
STEEL PRODUCTION:8
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No. 130
19581
20-Ql
No. 230
19581
20-Ql
Rimmed;^ carbon, alloy^
Direct shell evacuation per furnace,
ducted to common baghouse^l
Western Precipitator^l
195931
• Rated at 90,000 acfm at 350°F31
Total building evacuation, ducted to
baghouse31
Wheelabrator-Frye31
1972; 31 197330
• Rated at 900,000 acfm at 100°F31
• 14 compartments with design A/C -
3.17:1; using acrylic bags30
ADDITIONAL COMMENTS:
aActual yearly production figures from entire shop (tons);30
1975 - 357,400
1976 - 262,986
1978 - 373,400
1979 - 402,900
1980 - 316,246
581
-------
TABLE 14. BETHLEHEM STEEL CORP./STEELTON PLANT IN STEELTON, PA
ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
SHELL DIAMETER (ft-in. ):
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1979):
TYPE(S) OF STEEL PRODUCED:
No. 207 32
19681
22-01
1,17633
No. 20832
19681
22-01
1.22233
Carbon, alloy^>
No. 20932
19681
22-01
1.18333
5
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Direct shell evacuation per furnace,
ducted to common baghouse32*33
Wheelabrator-Frye32»33
1968;33 196932
• 253,000 acfm (rated)32
• 10 compartment baghouse32
Total building evacuation, ducted to
baghouse32*3^
AAF32.34
197632,33,34
• Design Data;32»3^
20 compartments with a total of 5,040
ringed Dacron filter tubes (12 in.
diameter x 34 ft long)
4 F.D. fans (400,000 cfm each)
Reverse air cleaning
ADDITIONAL COMMENTS:
582
-------
TABLE 15. CF&I STEEL CORP./PUEBLO PLANT IN PUEBLO, CO
ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
CE DESIGNATION:
UP DATE:
DIAMETER (
ft-in.):
No. 335
197335
22-035
No. 435
197635
22-035
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Carbon, alloy^>5
Direct shell evacuation per furnace,
ducted to common baghouse35»36
Cadre Corp.37
1974a»36
• Rated at 540,000 acfm, containing
32 compartments with 1,920 Dacron
bags (total)35,37
• Positive pressure using three
exhausters, and reverse air
cleaning35»37
SECONDARY EMISSION CONTROL SYSTEM: Canopy hoods per furnace, ducted to
primary control system baghouse35»36
(see above system description)
ADDITIONAL COMMENTS:
aBaghouse was upgraded in 1976 to accommodate startup of furnace No. 4.36
583
-------
TABLE 16. CRUCIBLE INC./A DIVISION OF COLT INDUSTRIES, STAINLESS
STEEL DIVISION IN MIDLAND, PA
ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:8
STARTUP DATE:
SHELL DIAMETER (ffin.):
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No. 138 NO. 238 NO. 338 No. 5™
193738 193738 193738 i93738
Stainless, specialty steels^>5»38,39
Canopy hood per furnace, ducted to common
baghouse7*38,39
AAF7»38
1973b»7
• Baghouse controls all 6 furnaces, and an AOD vessel (100-ton) tied into
the baghouse via a canopy hood and common duct work38»39
• Total system flow - 1,375,000 acfm at 2758F (during tap/melt phase)*0
• 1,504,000 acfm at 205°F (during charge/melt phase)40
• Canopy hoods (each) measure 48 ft x 43 ft40
• Cloth area - 23,867 sq ft per compartment (24 compartments)40
• A/C - 2.63:1 (24 compartments operating):
A/C - 2.86:1 (22 compartments operating)40
SECONDARY EMISSION CONTROL SYSTEM:
Canopy hoods (see above system
description)7*38,39
(continued)
584
-------
TABLE 16 (continued)
ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
SHELL DIAMETER (ft-in.):
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:
SECONDARY EMISSION CONTROL SYSTEM:
A38
198139
IJ38
198139
Carbon, alloy39
Direct shell evacuation per furnace,
ducted to common baghouse39>40 (see
previous page for system description)
3-section canopy hood over each furnace,
ducted to primary control system
baghousec>39,40 (see previous page for
system description)
ADDITIONAL COMMENTS:
aFurnace No. 4 has not operated since 1979.38
bBaghouse was upgraded in 1981.48,49
cCanopy hoods divided into charge, central, and tap sections.
585
-------
TABLE 17. CRUCIBLE INC./A DIVISION OF COLT INDUSTRIES, SPECIALTY
METALS DIVISION IN SYRACUSE, NY
ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:8
STARTUP DATE:
SHELL DIAMETER (ft-in. ):
STEEL PRODUCTION:
No. I41
19661
15-01
i
No. 241
19511
11-61
No. 341
19511
11-61
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
T-300, T-400, value, high speed and tool
steel;! Carbon, alloy, stainless.5
Direct shell evacuation per furnace,
ducted to common baghouse4!
AAF4!
19 7 341
• Design flow rate - 84,000 scfm41
• Positive pressure4^
• Reverse air cleaning41
ADDITIONAL COMMENTS:
aShop originally contained 5 furnaces; No. 4 has not been used in years;
No. 5 was dismantled.4*
586
-------
TABLE 18. FORD MOTOR CO./RIVER ROUGE WORKS IN DEARBORN, MI
ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DE SIGNATION:
STARTUP DATE:
SHELL DIAMETER (ft-in.):
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
19761
24-01
19 7 61
24-01
2,304 (both furnaces combined)42
Low carbon sheet, bar, AK & HSLA;1
Carbon, alloy^
Direct shell evacuation per furnace,
ducted to common baghouse8*42*43
AAF44
1976;46 1978*5
• 1,000,000 acfm (design)8*42*43
• 14 compartments;8*43 positive
pressure42*4'
• Three forced draft fans required42
Canopy hood and tapping-slagging fume
hoods per furnace, ducted to primary
control system baghouse8»42*43 (see
above system description)
ADDITIONAL COMMENTS:
587
-------
TABLE 19. INLAND STEEL CO./INDIANA HARBOR WORKS IN E. CHICAGO, IN
NO. 1 ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
SHELL DIAMETER (ft-in. ):
STEEL PRODUCTION:
No. 80*8
19701.*9
22-01
No. 90*8
19701,49
22-Ql
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
TYPE(S) OF STEEL PRODUCED:*1
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Carbon, low
Direct shell evacuation per furnace,
ducted to common baghouse*****9
AAF50
19 7051
• 615,000 cfm (capacity)*9
• 20 chambers — 2,400 Dacron bags (total)*9
• Three I.D. fans rated at 210,000 acfm
each-*!
• Reverse air cleaning*9
Canopy hoods per furnace, ducted to primary
control system baghouse*" (see above
system description)
• Each canopy hood measures 4,500 sq ft*9
• Hoods are divided into 3 sections:
1 section over charge side; 1 directly
over furnace, and 1 on tap side-'-'-
ADDITIONAL COMMENTS:
aAll heats are sent to continuous caster.
588
-------
TABLE 20. JONES & LAUGHLIN STEEL CORP./CLEVELAND WORKS
IN CLEVELAND, OH
ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
SHELL DIAMETER (
ft-in.):
No. 79 52
19591
22-01
No. 8052
19591
22-0*
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
2,280 (entire shop)4
2,081 (entire shop)4
Rimmed, semikilled, hot-topped steel;!
Carbon, high strength steel-5
Direct shell evacuation per furnace,
ducted to common dry ESP->2
Western Precipitator^2
197152
• Design flow rate: 140,000 acfm
at 170°F53
• Test data (1972);52
106,333 dscfm
SECONDARY EMISSION CONTROL SYSTEM:3
ADDITIONAL COMMENTS:
Secondary emission control via charging and tapping canopy hoods ducted to
a 1,075,000 acfm positive pressure baghouse with a gross air-to-cloth ratio
of 3.15:1 scheduled for November 1982 startup.52
589
-------
TABLE 21, JONES & LAUGHLIN STEEL CORP./PITTSBURGH WORKS IN PITTSBURGH, PA
ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
SHELL DIAMETER (ffin. ):
No. 915/>
19791,54
32-01
No. 9254
19791,54
32-Ql
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
Carbon^
Direct shell evacuation per furnace,
ducted to common baghouse-^
AAF55
197945,55
• Rated flow - 1,000,000 acfm at 200°F55
• 13 compartments; Dacron bags"
• Pressurized baghouse^4
• Three 2,000 hp fans required^
Canopy hood per furnace, ducted to
primary control system baghouse^*
(see above system description)
ADDITIONAL COMMENTS:
590
-------
TABLE 22. JONES & LAUGHLIN STEEL CORP./WARREN PLANT IN WARREN, MI
ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
SHELL DIAMETER (ft-ln.):
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION^
SECONDARY EMISSION CONTROL SYSTEM:
No. 11>56
19331*56
18-01
No. 21*56
19391,56
18-01
No. 31.56
19451,56
18-81
2,100 (all five furnaces combined)57
1,260 (with normal three furnace
operation)3*57
Stainless, alloy1*5
Canopy hood per furnace, ducted to common
baghouse56*5'
Wheelabrator56
196756
• 800,000 acfm (rated)56
• Four 700 hp forced draft fans operated
in parallel56*57
• Positive pressure—30 compartments56^7
• 5,760 bags (total)57
Total building evacuation, ducted to
primary control system baghouse56*57
(see above system description)
(continued)
591
-------
TABLE 22 (continued)
ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
SHELL DIAMETER (ft-in.):
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:b
SECONDARY EMISSION CONTROL SYSTEM:
No. 4l»5
19481,56
18-01
No. 51»56
19491*56
18-01
See previous pagea»"
Stainless, alloyl>5
Canopy hoods per furnace, ducted to
common baghouse56»57 (8ee previous page
for system description)
Total building evacuation, ducted to
primary control system baghouse56»57
(see previous page for system description)
ADDITIONAL COMMENTS:
three EAF's operate at one time, fourth furnace on standby, fifth
furnace being relined.56,57
and all five EAF's ducted to common baghouse. Curtain wall inside
shop on charge side of furnaces extends 10 to 15 ft down from roof to direct
emissions to each duct. 56
592
-------
TABLE 23. LONE STAR STEEL CO. IN LONE STAR, TX
ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
SHELL DIAMETER (
ft-in. ):
No. 651
197651
15-058
No. 751
197651
15-058
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
Carbon1' 5
Total enclosure on each furnace, ducted
to common steam-hydro scrubber system51
Hydro-sonlcs/Lone Star59,60
197651,60
• Enclosure volume * 114,000 cu ft per
furnace59,60
• 75,000-90,000 acfm exhausted from
each enclosure during all process
• Gas temperature (charging, melt,
refine) - 175°F6°
• Inlet Ap - 7.5 in. W.G.60
• Steam pressure per unit » 400 psig51
• Typical operating parameters (2 furnace
operation);-'1
175,000-200,000 acfm at 150°F
480 gpm H20 required
L/G - 2.4-2.7 gpm/ 1000 acfm
Tapping emissions collected by a local hood
inside each enclosure51 (see above
system description)
ADDITIONAL COMMENTS:
593
-------
TABLE 24. McLOUTH STEEL CORP./TRENTON WORKS IN TRENTON, MI
ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATIONS
STARTUP DATE:
SHELL DIAMETER (
ft-ln. ):
No. 661
19 541
27-61
No. 761
19541
24-61
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
TYPE(S) OF STEEL PRODUCED:b
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
1,150 (both furnaces combined)*
410 (both furnaces combined)*
Carbon1*5
Direct shell evacuation per furnace,
ducted to common scrubber-disintegrator
system62
Thiessen6-*
195463
• High efficiency wet scrubber-
disintegrator8*62
• 60,000 scfm induced draft fan62
• Test data (1956);8
50,000 acfm at 60°F (inlet)
ADDITIONAL COMMENTS:
aFurnaces are located in EOF shop.61
^Facility produced stainless steel prior to November 1977.62
594
-------
TABLE 25. NATIONAL STEEL CORP./GREAT LAKES STEEL DIVISION IN ECORSE, MI
ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
SHELL DIAMETER (ft-in.):
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:8
No. 3164 No.
1968;64 19701 19701
22-01 22-01
2,085 (both furnaces combined)65
1,903 (both furnaces combined)*
Low, medium carbon, low alloy1
Direct shell evacuation per furnace,
ducted to common baghouse64
• Flow rate » 75,300 scfm (each furnace)65
• 7 compartments—966 graphite coated
bags (total)64
• A/C - 1.67:1 (normal operation) one
compartment down for cleaning64
• Baghouse exhausts through 3 stacks65
ADDITIONAL COMMENTS:
aPlanning to install roof canopy hoods by December 1982.66
595
-------
TABLE 26. REPUBLIC STEEL CORP./CENTRAL ALLOY DISTRICT IN CANTON, OH
NO. 3 ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
»
STARTUP DATE:
SHELL DIAMETER (ft-in.):
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No. 267
No. 467
194268
No. 567
194268
SECONDARY EMISSION CONTROL SYSTEM:
Carbon, alloy,
Canopy hoods per furnace, ducted to common
baghouse^^
Wheelabrator68
197667,68
• Design flow rate - 1,400,000 acfm;
positive pressure baghouse67
• Baghouse also controls AOD vessel within
No. 3 shop67
Total building evacuation, ducted to
primary control system6^ (see above
system description)
ADDITIONAL COMMENTS:
596
-------
TABLE 27. REPUBLIC STEEL CORP./CENTRAL ALLOY DISTRICT IN CANTON, OH
NO. 4 ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
SHELL DIAMETER (ft-In. ):
No. 667
19681
26-01
No. 767
19681
26-01
No. 867
19681
26-Ql
No. 967
19681
26-01
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY:
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:b
SYSTEM DESCRIPTION:
3,776 (all four furnaces combined)7**
Carbon, alloy,
Direct shell evacuation per furnace,
ducted to common
AAj-68,71
1968&7
• Total flow rate - 450,000 acfm;67
112,000 acfm at 275°F from each
furnace7 0
• Positive pressure baghouse6^
• AMERtherm ringed-Dacron bag collector7^
SECONDARY EMISSION CONTROL SYSTEM:
ADDITIONAL COMMENTS:
aThe No. 4 shop will have a new 2.7 x 10& acfm baghouse by 1982 for primary
and secondary emission control.7^
bBaghouse upgraded in 1977.67
597
-------
TABLE 28. REPUBLIC STEEL CORP./CHICAGO DISTRICT IN CHICAGO, IL
ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
SHELL DIAMETER (ft-in. ):
STEEL PRODUCTION:
No. 572
19 701
24-01
No. 672
19701
24-Ql
No. 772
19701
24-01
RATED TONS/DAY:
AVERAGE TONS/DAY (1974):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
1,985 (all three furnaces combined)73
Carbon,
Direct shell evacuation per furnace,
ducted to common baghouse'^
1970a»73
Rated at 700,000 acfm7^
Canopy and scavenger hoods per furnace,
ducted to common ESp74
Research Cottrell and Western
Precipitator74
1977b,74
• System consists of three dry Research
Cottrell ESP units; each rated at
120,000 acfm at 500 °F and four dry
Western Precipitator units; each rated
at 176,000 acfm at 500°F7*
• ESP units are all operated in parallel
with an individual exhaust fan per ESP
unit7*
ADDITIONAL COMMENTS:
aPrimary system upgraded in 1977.7*
''The ESP1 s currently in use for secondary control of EAF shop were
originally installed between 1963 and 1971 for control at the dismantled
open hearth shop.^
598
-------
TABLE 29. SHARON STEEL CORP./STEEL DIVISION IN FARRELL, PA
ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
SHELL DIAMETER (ft-in.):
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:3
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
No. I75
19581
No.
19621
Carbon, alloy, stainless-^ ^
Side-draft hood per furnace, ducted to
common baghous e"»'"
198075,76
• Baghouse rated at 900,000 scfm75
• A/C =3:1 (design)76
Charge side canopy hood per furnace,
ducted to primary control system
baghouse75>76 (8ee above system
description)
ADDITIONAL COMMENTS:
^aghouse replaced original 300,000 scfm unit (installed in 1973) which
controlled by primary emissions.7^
599
-------
TABLE 30. UNITED STATES STEEL CORP./TEXAS WORKS IN BAYTOWN, TX
NO. 1 ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
SHELL DIAMETER (ft-ln.):
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No. I77
1970;1 197178
24-01
No. 277
19701*78
24-0*
1,560 (both furnaces combined)^
1,536 (both furnaces combined)^
Carbon, alloyl>5
Direct shell evacuation per furnace,
ducted to separate, identical scrubbers7**
AAF77
197177
• Each system consists of a quencher,
scrubber, cyclone separator and fan
ducted to a common stack7**
• Each scrubber rated at 42,000 scfm,
and using 950 gpm of scrubber water7^
ADDITIONAL COMMENTS:
600
-------
TABLE 31. UNITED STATES STEEL CORP./TEXAS WORKS IN BAYTOWN, TX
NO. 2 ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
SHELL DI/METER (ft-in. ):
No. 377
197778
24-078
No. 477
197778
24-078
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM;
Carbon,
Direct shell evacuation per furnace,
ducted to common baghouse78
Wheelabrator-Frye77
197777,78
• Baghouse rated at 1,750,000 acfm at
150°F (inlet)77
• Baghouse contains 20-compartments with
13,440 bags (total)77
• Design A/C = 2.75:1 with shaker type
cleaning77
Canopy hoods per furnace, ducted to
primary control system bghouse (see above
system description)78
ADDITIONAL COMMENTS:
601
-------
TABLE 32. UNITED STATES STEEL CORP./SOUTH WORKS IN CHICAGO, IL
NO. 4 ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION: No. 41180 No. 41280
STARTUP DATE: 197081 197081
SHELL DIAMETER (ft-in.): 24-01 24-0*
STEEL PRODUCTION:
RATED TONS/DAY: 1,985 (both furnaces combined)4
AVERAGE TONS/DAY (1976): 1,914 (both furnaces combined)4
TYPE(S) OF STEEL PRODUCED: Carbon, alloy, stainless1*5
PRIMARY EMISSION CONTROL SYSTEM: Direct shell evacuation per furnace,
ducted to individual scrubbers8^
MANUFACTURER: Research Cottrell81*83
DATE INSTALLED: 197181»83
SYSTEM DESCRIPTION: Both control systems similar, except
where noted;
• Each scrubber rated at 322,190 acfm at 400°F (inlet) and Ap » 2.17 psi81
• One I.D. fan80
• Exhaust discharge via dual stacks (denoted as east and west)8^
• Test Data (1978);84
Furnace No. 411: Ap (throat-DSE) = 60 in. ^0
Water flow = 1,274-1,547 gpm
East stack - 56,400 dscfm
West stack = 82,100 dscfm
Furnace No. 412: Ap (throat-DSE) - 61-62 in. ^0
Water flow = 1,691-1,700 gpm
East stack - 74,600-79,200 dscfm
West stack •= 62,300-63,400 dscfm
• Test Data (1977);80
Furnace No. 412: DSE inlet flow = 43,800 acfm (wet)
DSE inlet flow - 46,100 acfm (wet)
DSE outlet flow - 81,200 acfm (wet)
Ap (throat-DSE operation) » 60 in. 1^0
Water flow - 1,680 gpm
SECONDARY EMISSION CONTROL SYSTEM: Canopy hood per furnace, ducted to
individual scrubbers (one per furnace)8^
(continued)
602
-------
TABLE 32 (continued)
NO. A ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
MANUFACTURER: Research Cottrell81*83
DATE INSTALLED: 197l81,83
SYSTEM DESCRIPTION: Both control systems similar, except
where noted;
• Each scrubber rated at 230,000 acfm at 150°F (inlet) and Ap = 1.08 psi81
• A common I.D. fan and manifold exhausts from both primary and secondary
systems. (The dual exhaust stacks are also common for both systems.)"
• Test Data (1978);84
Ap (building evacuation) = 30 in. t^O (same for both furnaces)
• Test Data (1977);80
Furnace No. 412: Canopy inlet flow » 183,900 acfm (wet)
Canopy outlet flow = 36,800 acfm (wet)
(continued)
603
-------
TABLE 32 (continued)
NO. 4 ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
*
STARTUP DATE:
SHELL DIAMETER (ft-in.):
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No. 43581
197581
20-081
463*
544*
Stainless
Direct shell evacuation ducted to
Venturi Scrubber8
AAF81.85
197581
• Scrubber Design Data;8^>85
49,870 acfm at 156°F (inlet)
60,300 acfm (outlet)
Ap = 62 in. H20 (2.3 psi)
Water use rate = 54,100 gph
L/G = 18 gpm/1,000 acfm
• Test Data (1976);85
39,500-42,700 dscfm
Ap (Kinpactor) = 61.3-62.4 in. H20
Scrubber water flow = 300-320 gpm
Quencher water flow « 504-517 gpm
SECONDARY EMISSION CONTROL SYSTEM: Canopy hoods ducted to baghouse86*87
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Carborondum8* >
197581
Baghouse Design Data;8»8*
232,000 acfm (inlet) at 150°F
222,000 acfm (outlet)
54,000 sq ft (total cloth area)
Dacron bags
(continued)
604
-------
TABLE 32 (continued)
NO. 4 ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
• 10 compartment baghouse; each
compartment uses one fan rated at
23,000 cfm87
• Canopy hood dimensions are 70 ft x
100 ft87
ADDITIONAL COMMENTS:
605
-------
TABLE 33. UNITED STATES STEEL CORP./NATIONAL-DUQUESNE WORKS IN DUQUESNE, PA
ELECTRIC ARC SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION: '
STARTUP DATE:
SHELL DIAMETER (ft-in.):
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
TYPE(S) OF STEEL PRODUCED:
PRIMARY EMISSION CONTROL SYSTEM:3
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
No. 1«8 NO. 288 NO. 388 NO. 488 NO. 588
19421 19431 19431 19561 1956*
18-01 20-01 20-01 20-01 20-0*
SECONDARY. EMISSION CONTROL SYSTEM:
Alloy, stainless^-»5
Canopy hoods per furnace, ducted to
common baghouse89
AAF89.90
197189,90
Flow - 1,750,000 scfm (rated)88
3 compartment baghouse; 8 sections per
compartment8"
Ringed Dacron bags^l
3 fans used89
Positive pressure89
Reverse air cleaning^!
Total building evacuation, ducted to
primary control system baghouse89
(see above system description)
ADDITIONAL COMMENTS:
aCanopy hoods divided into 2 sections—over tapping operation and over
furnace directly^
606
-------
MATERIAL IN THIS SECTION SUBJECT TO CONFIDENTIALITY
REVIEW AND IS NOT RELEASABLE AS OF FEBRUARY 1, 1982.
FOR INFORMATION, CONTACT L. KESARI, U.S. ENVIRONMENTAL
PROTECTION AGENCY, DIVISION OF STATIONARY SOURCE ENFORCEMENT.
w
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7* 7*
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53
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en
-------
REFERENCES
ELECTRIC ARC FURNACES
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607
-------
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608
-------
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(Reliability No. 3.)
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Health to Steve Piper, GCA/Technology Division. February 1981.
(Reliability No. 2.)
609
-------
37. Advertisement by The Cadre Corporation, Environmental Services Group to
Michael Jasinski, GCA/Technology Division from Terry Bartlett, Cadre
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38. Jasinski, M. Trip Report-Pretest Survey, Crucible Stainless Steel Div.,
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(Reliability No. 2.)
39. Telephone conversation. Bill Baxter, Pennsylvania Department of
Environmental Resources, Pittsburgh, Pa. to Sandy Beaton, GCA/Technology
Division. January 1982. (Reliability No. 2.)
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41. Telephone conversation. Mr. Burdick and Mr. Abbott, Onondaga County
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Department of Health, to William Achinger, Assistant Director of Wayne
County Department of Health. RE; Comments on Proposed Method for
Particulate Emission Tests of Baghouse Collection - Ford Motor Company,
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(Reliability No. 2.)
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Health, Air Pollution Division to William Farino, GCA/Technology
Division. October 16, 1980. (Reliability No. 2.)
48. Pekron, P. Checklist Supporting Findings of Violation. U.S.
Environmental Protection Agency, Region V. November 25, 1979.
(Reliability No. 1.)
610
-------
49. Air, Water,, and Inland Steel. Environmental Quality Control at Inland
Steel Company's Indiana Harbor Works. 2nd Edition, Inland Steel
Publication. (Reliability No. 4.)
50. Brough, J. R., and W. A. Carter. Air Pollution Control of an Electric
Furnace Steelmaking Shop. Presented at the Sixty-fourth Annual Meeting
of the Air Pollution Control Association, Atlantic City, New Jersey.
June 27-July 2, 1971. (Reliability No. 4.)
51. Blair, T. R., and W. L. Martin. Electric Arc Furnace Fume Control at
Lone Star Steel Company. Presented at the Seventy-first Annual Meeting
of the Air Pollution Control Association, Houston, Texas. June 25-30,
1978. (Reliability No. 4.)
52. Telephone conversation. Ed Wojciechowski, U.S. EPA, Region V to Gene
Bergson, GCA/Technology Divsion. February 4, 1981. (Reliability No. 2.)
53. Letter from Gary Nied, Cleveland Division of Air Pollution Control to
Gene Bergson, GCA/Technology Division. March 9, 1981. (Reliability
No. 1.)
54. Grandy, P. J., and R. M. Vesokey. J&L Steel's Pittsburgh Works Electric
Furnace Shop. Iron and Steel Engineer. 57(10):25. October 1980.
(Reliability No. 4.)
55. Telephone conversation. S. Baninthaya, Allegheny County Health
Department to Gene Bergson, GCA/Technology Division. February 12, 1981.
(Reliability No.2.)
56. Spawn, P. Trip Report—Pretest Survey, J&L Steel Electric Arc Shop,
Warren, Michigan. GCA Technology Division. Prepared for U.S.
Environmental Protection Agency. February 12, 1980. (Reliability No. 2.)
57. EPA Region V Files (11-7-79 Trip Report at J&L/Warren).
58. Telephone conversation. Lawrence Pewitt, Texas Air Control Board to
Sandy Beaton, GCA/Technology Division. November 1981. (Reliability
No. 2.)
59. Review of Standards of Performance for Electric Arc Furnaces in the Steel
Industry. Emission Standards and Engineering Division, U.S.
Environmental Protection Agency, Research Triangle Park, North Carolina.
EPA-450/3-79-033. October 1979. pp. 4-8 through 4-15. (Reliability
No. 3.)
60. Fennelly, P. F., and P. D Spawn, op. cit., Reference 23. pp. 3-38
through 3-40. (Reliability No. 3.)
61. Anderson, P. Compliance Inspection of McLouth Steel. GCA/Technology
Division. Conducted for EPA Region V in 1978. (Reliability No. 2.)
611
-------
62. EPA Region V Files (EPA inspection on 3-14-81).
63. EPA Region V Files (1974 permits).
64. Miller, R. L. The Electric Furnace Shop at Great Lakes Steel. Iron and
Steel Engineer. 48(5):69-76. May 1971. (Reliability No. 3.)
65. EPA Region V Files (Litigation Report dated March 1979 w/NSC).
66. EPA Region V Files (March 1981 Memo from P. Kelly).
67. Telephone conversation. B. Blankinship, Canton City Health Department to
Gene Bergson, GCA/Technology Division. March 2, 1981. (Reliability
No. 2.)
68. Letter response. Andy Pasko, Canton City Health Department to Sandy
Beaton, GCA/Technology Division. November 2, 1981. (Reliability No. 1.)
69. Telephone conversation. Mr. Stromsky, Canton City Health Department, Air
Pollution Control Division to William Farino, GCA/Technology Division.
November 1980. (Reliability No. 2.)
70. EPA Region V Files review by GCA/Technology Division. December 1981.
71. Advertisement in Iron and Steel Engineer. 48(10):24,25. October 1971.
(Reliability No. 3)
72. Telephone conversation. J. Solkorowski, City of Chicago Department of
Inspectlonal Services to Marc Grant, GCA/Technology Division. March 5,
1981. (Reliability No. 2.)
73. EPA Region V Files (Region V 1974 Emission Inventory—RSC/Chicago).
74. EPA Region V Files (Trip Report by Edward Wojciechowski at RSC/Chicago—
6/79).
75. Telephone conversation. Larry Wonders, Pennsylvania Department of
Environmental Resources to Gene Bergson, GCA/Technology Division.
February 17, 1981. (Reliability No. 2.)
76. Telephone conversation. Bill Charleton, Pennsylvania Department of
Environmental Resources, Meadsville, PA to Sandy Beaton, GCA/Technology
Division. November 9, 1981 (Reliability No. 2.)
77. Telephone conversation. John Hepola, U.S. EPA Region VI to Michael
Jasinski, GCA/Technology Division. November 1981. (Reliability No. 2.)
78. Laber, C. J. Baytown Revisited—U.S. Steel Texas Works' Update. Iron
and Steel Engineer. 55(3):T-1 through T-12. March 1978. (Reliability
No. 3.)
612
-------
79. Richards, J. H. U.S. Steel Corporation's First Ingot-free Electric Arc
Furnace Steel Melting Shop. Iron and Steel Engineer. 48(8):41-52.
August 1971. (Reliability No. 3.)
80. Letter from D. R. Cronin, U.S. Steel Corporation/Manager of Environmental
Control-West, to Laxmi Kesari, U.S. Environmental Protection Agency,
Region V. RE: Stack Test Report Conducted at the No. 4 Electric Arc
Furnace Shop at U.S. Steel Corporation/South Works in August 1977. JACA
Steel Library. (Reliability No. 2.)
81. EPA Region V files. (Emission Inventory Data on USS/Chicago.)
82. Bergson, E. and T. Nunno. Assessment of Air Emissions from Iron and
Steelmaking Sources. U.S. Steel Corporation/South Works. No. 4 EAF
Shop—Scrubber stack Test Overview. GCA/Technology Division Draft Final
Report No. TR-81-80-G. Prepared for U.S. Environmental Protection
Agency. July 1981. (Reliability No. 1)
83. Telephone conversation. Phil Borowy, Environmental Engineer, U.S.
Steel/South Works in So. Chicago, Illinois to Tom Nunno, GCA/Technology
Division. September 21, 1981. (Reliability No. 2.)
84. Letter from J. H. Gross, U.S. Steel Corporation/Director-Research, to Dr.
P. X. Masciantonio, U.S. Steel Corporation/Director-Environmental
Control. RE; Particulate Emissions Tests, South Works Electric Arc
Furnace Gas Cleaning Systems No. 411 and 412 Furnaces. Performed by U.S.
Steel Corporation for Both Stacks. JACA Steel Library. June 1978.
(Reliability No. 2.)
85. Letter from J. H. Gross, U.S. Steel Corporation/Director-Research, to Mr.
S. P. Curtis, U.S. Steel Corporation/Vice President-Engineering. RE;
Compliance Test 100-ton Electric Furnace Facility, South Works, performed
by.U.S. Steel Corporation. JACA Steel Library. April 23-24.
(Reliability No. 2.)
86. Telephone conversation. Daniel Bakk, U.S. Environmental Protection
Agency, Region V to Michael Jasinski, GCA/Technology Division. October
1980. (Reliability No. 2.)
87. EPA Region V Files (Checklist prepared 1-22-81 by D. Bakk for
USS/Chicago).
88. Telephone conversation. Bob Felt, Allegheny County Health Department to
Gene Bergson, GCA/Technology Division. February 12, 1981. (Reliability
No. 2.)
89. Telephone conversations. Robert Felt, Allegheny County Health
Department to William Farino, GCA/Technology Division. October-November
1980. (Reliability No. 2.)
613
-------
90. Telephone conversation. Bob Felt, Allegheny County Health Department to
Sandy Beaton, GCA/Technology Division. November 3, 1981. (Reliability
No. 2.)
91. Advertisement in Iron and Steel Engineer. 49(9):140-141. September
1972. (Reliability No. 3.)
614
-------
O
MATERIAL IN THIS SECTION SUBJECT TO CONFIDENTIALITY
REVIEW AND IS NOT RELEASABLE AS OF FEBRUARY 1, 1982.
FOR INFORMATION, CONTACT L. KESARI, U.S. ENVIRONMENTAL
PROTECTION AGENCY, DIVISION OF STATIONARY SOURCE ENFORCEMENT.
-------
TABLE 1. ARMCO INC./MIDDLETOWN WORKS IN MIDDLETOWN, OH
OPEN HKARTH SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:3 Nos. 9 through 141
STARTUP DATE: 1950-1956;l 19562 (all 6 furnaces)
STEEL PRODUCTION:1*'0
RATED TONS/DAY: 5,507 (all 6 furnaces combined)3
AVERAGE TONS/DAY (1976): 2,754 (all 6 furnaces combined)3
TYPE OF EMISSION CONTROL SYSTEM: Venturi scrubber per furnace^
MANUFACTURER: Research Cottrell5
DATE INSTALLED: 1964 (Furnace No. 9)2,
1969 (Furnace Nos. 10-14)2
SYSTEM DESCRIPTION:
• In series;^
Venturi scrubber, flooded elbow, cyclonic separator, fan and a sound
attenuated stack
• Each scrubber designed for 117,000 acfm at 194°F; 225,000 acftn at 1350°F
(maximum at scrubber inlet)2
• Design scrubber Ap = 52 in. H202
• 1,500 gpm water flow^
• L/G = 6.7 gpm/1,000 acfm (based on 225,000 acfra)^
• Test Data (1971) :^
Ap = 47 in. W.C.
ADDITIONAL COMMENTS:
aAs of 1981, three furnaces operating due to low steel demand.6
bTotal tonnage in 1977 = 934,000.1
cFurnaces normally on 100 percent scrap charge; tap to tap time is 12 hours;
oxygen lancing @ 60,000 scf/hr, 100,000 scf/hr (max); checker blowing on a
4-hr cycle.^
615
-------
TABLE 2. BETHLEHEM STEEL CORP./SPARROWS POINT PLANT
IN SPARROWS POINT, MD
NO. 4 OPEN HEARTH SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
STEEL PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
TYPE OF EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Nos. 90 through 961
4 furnaces in 1957; 3 furnaces in 1958-*
10,822 (all 7 furnaces combined)^
6,304 (all 7 furnaces combined)-*
6 dry ESPs (designated C, D, E, F, G, H)
2 venturi scrubbers (designated A and B)
serve all 7 furnaces'
and
Koppers (ESPs)8
19617
Chemico (scrubbers)7
19727
• Common manifold connects
• Each ESP discharges to an
common stack'
• ESP Design Data:7
- 57,200. dscfm per ESP
- Inlet temp = 503°F
- Outlet temp = 467°F
. - 34,700 sq ft collection
area per ESP
- 50 sparks/min (rated)
• Test Data (1976):a»9
scrubbers and ESPs which operate in parallel'
individual stack; scrubbers discharge to a
• Scrubber Design Data;7
- 99,300 dscfm per scrubber
- Inlet temp = 503°F
- Outlet temp = 141°F
- Ap = 55 in. W.C. per scrubber
- Scrubbers "A" and "B": 192,206 dscfm (avg.),
- ESP "C"
- ESP "D"
- ESP "E"
- ESP "F"
- ESP "G"
- ESP "H"
52,640 dscfm (avg.), 428°F (avg.)
56,1.65 dscfm (avg.), 434°F (avg.)
58,618 dscfm (avg.), 449°F (avg.)
62,988 dscfm (avg.), 434°F (avg.)
59,782 dscfm (avg.), 446°F (avg.)
64,300 dscfm (avg.), 410°F (avg.)
• Control System Operating Data (1976) :a>y
- Scrubber A: Ap = 54-57 in. H20; water flow =
- Scrubber B: Ap = 54-55 in. H20; water flow =
143°F (avg.)
930-1,200 gpm
1,070-1,140 gpm
(continued)
616
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TABLE 2 (continued)
NO. A OPEN HEARTH SHOP PROCESS AND EMISSION CONTROL DATA
SECONDARY EMISSION CONTROL SYSTEM: Hot metal transfer area to baghouse7*10
MANUFACTURER: Buell10
DATE INSTALLED: 1975;8 197710
SYSTEM DESCRIPTION: • Conventional hood system with a
spark box'
• 150,000 scfm and 200°F (design)7.10
• Positive pressure design'
ADDITIONAL COMMENTS:
aSix of seven furnaces operating during 1976 testing; i.e., Nos. 90, 91, 92,
93, 95, and 96.9
617
-------
TABLE 3. INLAND STEEL CO./INDIANA HARBOR WORKS IN E. CHICAGO, IN
NO. 3 OPEN HKARTH SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:a»b Nos. 1 through 71
STARTUP DATE: Nos. 1 through 4 in 1951t1
Nos. 5 through 7 in 19531
STEEL PRODUCTION:0
RATED TONS/DAY: 8,136 (all 7 furnaces combined)11
AVERAGE TONS/DAY:
TYPE OF EMISSION CONTROL SYSTEM: All 7 furnaces manifold to common, dry
ESPsl,13
MANUFACTURER: Western Precipitator14
DATE INSTALLED: 196815
SYSTEM DESCRIPTION:d
• Five ESPs each divided into two chambers; system designed for 9 out of 10
to be in use14
• Five I.D. fans rated at 400,000 cfm each14
• 1.6 x 10& acfm (avg.)13
• 130 flat collection plates spaced 10 in. apart13
• Surface area - 490,000 sq ft (total)13
• 304 ft2/I,000 acfm13
• Test Data (1981);16
5-furnace operation, exhaust flow rate = 1,288,000 acfm at 419°F
• Test Data (1974);13
Flow rate - 1,590,000-1,630,000 (range)
Temperature » 435-460°F (range)
ADDITIONAL COMMENTS:
aReversing recuperator, overfired type furnaces*1
bsix furnaces operate at any one time.12
C1977 yearly production (total shop) = 1,910,000 tons.12
^Manifold collects gases from all seven furnaces to 18 x 20 x 32 ft mixing
chamber which provides a homogeneous mixture of particulate at ESP inlet;
ten 8 x 7 ft rectangular ducts carry gases to the ESP.13
618
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TABLE 4. LONE STAR STEEL CO. IN LONE STAR, TX
OPEN HEARTH SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:a'b No. I1 No. 21 No. 31 No. 41 No. 51
STARTUP DATE: 4 units in 1953; 5th unit added in 195617
STEEL PRODUCTION:
RATED TONS/DAY: 3,835 (all 5 furnaces combined)3
AVERAGE TONS/DAY (I'i76): 3,048 (all 5 furnaces combined)3
TYPE OF EMISSION CONTROL SYSTEM: 3 steam-hydro scrubber units in parallel
serve all 5 furnaces18
MANUFACTURER: Hydro-Sonics/Lone Star18
DATE INSTALLED:
SYSTEM DESCRIPTION:
DATE INSTALLED: 197218
• Common manifold from all furnaces to 3 waste-heat boilers18
• Design flow rate = 105,000-160,000 acfm (total)18
• Gas temp (inlet) = 1,200-1,700°F18
• Each steam-hydro unit consists of steam nozzle-water injector which
induces flow (no fan needed)18
ADDITIONAL COMMENTS:
aMaximum of 4 furnaces operate at any one time.18
^Natural gas and oil used as fuel; gas/oil ratio = 80/20 during
meltdown and 50/50 during refining.17
619
-------
TABLE 5. UNITED STATES STEEL CORP./FAIRLESS WORKS IN FAIRLESS HILLS, PA
OPEN HEARTH SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION: NOS. 1 through 91
STARTUP DATE: From 1951-1953; rebuilt I96021
STEEL PRODUCTION:3
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
TYPE OF EMISSION CONTROL SYSTEM: 9 Dry ESPs 1 Dry ESP
(Primary)1^ (Secondary)^
MANUFACTURER: Koppers20 Research Cottrell20
DATE INSTALLED: 197021
SYSTEM DESCRIPTION:
• Waste heat boiler, ducted to a primary ESP per furnace, common manifold
to the secondary ESP which serves all 9 furnaces, discharging to a
common stack**
• 3 I.D. fans preceed stack (total rating = 1,023,000 scfm)20
• Koppers ESP—9 pairs of single- • Research Cottrell ESP—2 dual-celled
celled ESPs (1 per furnace) units operated in parallel2"
9O 91
operated in parallel^" • Design Data:^1
Plate area = 119,300 sq ft
3 I.D. fans @ 340,000 cfm each
• Test Data (1974):22
847,500 scfm
Temp = 414°F (avg.)
• Test Data (1977);b»20
1,059,9-14-1,202,511 acfm
Temp = 401-410°F
ADDITIONAL COMMENTS:
aPlant presently operating at 50 percent capacity.^
bAll furnaces, except No. 2, operated during 1977 stack tests.20
620
-------
TABLE 6. UNITED STATES STEEL CORP./HOMESTEAD WORKS IN HOMESTEAD, PA
OPEN HEARTH SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:3
STARTUP DATE:
STEEL PRODUCTION:b
RATED TONS/DAY:
AVERAGE TONS/DAY ( ):
TYPE OF EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Nos. 65 through 751
Approx. 1946 (all furnaces)2-^
5 dry ESPs24
4 ESPs—Research 1 ESP—Western
Cottrell25 Precipitator25
Pre-197026 197126
• Common manifold directs gases to 5 ESPs
operating in parallel24
• Total (combined) flow rate = 600,000 scfm2^
• Test Data (1977);24
ESP No. 1—318,281 acfm (avg.)
ESP No. 2—165,963 acfm (avg.)
ESP No. 3—156,322 acfm (avg.)
ESP No. 4—193,838 acfm (avg.)
ESP No. 5—282,755 acfm (avg.)
ADDITIONAL COMMENTS:
aOnly 10 furnaces can be operated at any one time; usually 6-8 furnaces are
in operation simultaneously.24
bOxygen lancing at 105,000-110,000 cfh during refining.24
621
-------
TABLE 7. UNITED STATES STEEL CORP./GENEVA WORKS IN PROVO, UT
OPEN HEARTH SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:8 Nos. 90 through 991
STARTUP DATK: 1944 (all 10 furnaces)3
STEEL PRODUCTION:
RATED TONS/DAY: 6,550;3 6,85027 (all 10 furnaces combined)
AVERAGE TONS/DAY (1976): 5,867 (all,10 furnaces combined)3
TYPE OF EMISSION CONTROL SYSTEM: 8 ESP-scrubber units serve all 10 furnaces27
MANUFACTURER: ESPs, Research Cottrell;27
Scrubbers, U.S. Steel27
DATE INSTALLED:b"e ESPs, 1955;27 Scrubbers, 196227
SYSTEM DESCRIPTION: • Each unit contains an ESP and scrubber in
series; all 8 units operate in parallel27>2°
• Design flow rate per unit = 66,400 dscfra2°
• ESP Specifications;27
- Plate-type, each with three fields
and two sections per field
- Collection area per unit:
Field 1 = 6,043.5 sq ft
Field 2 = 6,043.5 sq ft
Field 3 = 12,087 sq ft
- SCA per unit = 180 sq ft/1,000 acfm
• Scrubber Specifications;27
- Partial-orifice type wet scrubbers
- Ap = 4 in. W.C. (per unit)
- Scrubber water = 650 gpm (per unit)
- L/G = 5.9:1 (per unit)
ADDITIONAL COMMENTS:
aFour furnaces operate at any one time (1981).29
bAll ESPs upgraded in 1968 to increase voltage.2**
cEach ESP unit was modified in 1972 by increasing the number of transformer-
rectifier sets from two to three.27
scrubbers were modified in 1972 by relocating the internal sprays.27
eFour of eight ESP-scrubber units were upgraded in 1981.29
622
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W
a t*
w
Bj *J
H a
a n
w
K-j CO
MATERIAL IN THIS SECTION SUBJECT TO CONFIDENTIALITY
REVIEW AND IS NOT RELEASABLE AS OF FEBRUARY 1, 1982.
FOR INFORMATION, CONTACT L. KESARI, U.S. ENVIRONMENTAL
PROTECTION AGENCY, DIVISION OF STATIONARY SOURCE ENFORCEMENT.
-------
REFERENCES
OPEN HEARTH SHOP
1. World Steel Industry Data Handbook: Volume No. 1. The United States.
McGraw-Hill Magazine. 1978. (Reliability No. 4.)
2. Data collected by GCA from EPA Region V files. (Renewal Permit
Applications No. 1809010006P028-33, dated September 1976.)
3. Development Document for Proposed Effluent Limitations Guidelines and
Standards for the Iron and Steel Manufacturing Point Source Category.
Draft Report. Vol. IV. EPA 440/l-79-024a. October 1979. pp. 275.
(Reliability No. 4.)
4. Metallurgical Applications. JAPCA. 27(11): 1072-1074. November 1977.
(Reliability No. 4.)
5. Telephone conversation. Ed Luebering, SW District-Ohio EPA to Gene
Bergson, GCA/Technology Division. March 9, 1981. (Reliability No. 2.)
6. Telephone conversation. Steve Samorgin, SW District-Ohio Environmental
Protection Agency to Sandy Beaton, GCA/Technology Division. October
. 1981. (Reliability No. 2.)
7. Correspondence to Robert McCrillis, U.S. EPA, Research Triangle Park, NC
from Peter Spawn, GCA/Technology Division. May 5, 1980. (Reliability
No. 3.)
8. Telephone conversation. Mark Sylvester, Maryland State Department of
Health and Mental Hygiene to Michael Jasinski, GCA/Technology Division.
February 13, 1981. (Reliability No. 2.)
9. Stack Test Report No. 76-19. Bethlehem Steel Corp./Sparrows Point,
Maryland. No. 4 Open Hearth Shop. Testing by Maryland Department of
Health and Mental Hygiene. July 1976. (Reliability No. 1.)
10. Telephone conversation. Ralph Hall, State of Maryland to M. Jasinski,
GCA/Technology Division. October 29, 1981. (Reliability No. 2.)
11. Telephone conversation. Phil Pekron, U.S. EPA Region V to S. Beaton,
GCA/Technology Division. October 1981. (Reliability No. 2.)
623
-------
12. Spawn, P. Collection of Samples for Radioassay at Integrated Steel
Mills. CCA/Technology Division. Draft Final Report No. TR-80-7-G.
February 1980. (Reliability No. 2.)
13. Jacko, R. B., et al. Fractional Collection Efficiency of Electrostatic
Precipitation for Open Hearth Furnace Metal Emissions. Environmental
Science and Technology. 10(10): 1002-1005. October 1976.
14. Stewart, J. Jr. Centralized Control Guides Efficient Operation of Inland
Precipitators. Iron and Steel Engineer. February 1971. (Reliability
No. A.)
15. Air, Water, and Inland Steel. Environmental Quality Control at Inland
Steel Company's/Indiana Harbor Works. 2nd Edition. Inland Steel
Publication, pp. 28. (Reliability No. 4.)
16. Data collected by GCA from EPA Region V files. (Inland Steel Open Hearth
Shop Stack Tests in July 1981.)
17. Steel in Texas. Iron and Steel Engineer. 48(4): T-14 through T-21.
April 1971. (Reliability No. 3.)
18. Blair, T. R. and W. L. Martin. Air Pollution Control System at Lone Star
Steel's Open Hearth Shop. Iron and Steel Engineer, April 1976. pp.
83-88. (Reliability No. 4.)
19. Telephone conversation. Tom McGinley, PADER, Morristown, PA to Sandy
Beaton, GCA/Technology Division. October 1981. (Reliability No. 2.)
20. Report of an Emission Test at the Common Stack of 9 Open Hearth Furnaces.
U.S. Steel Corp./Fairless Works in Fairless Hills, PA. JACA Corp.
testing for U.S. EPA, Region III. August 1977. JACA Library.
(Reliability No. 1.)
21. Samways, N. L. Fairless Works Faces the 1980's—A Look at the Plant
Today. Iron and Steel Engineer. April 1980. pp. F-l. (Reliability
No. 4.)
22. Stack Test Report. USSC/Fairless Works Open Hearth Shop in Fairless
Hills, PA. PADER testing. September 16, 1974. JACA Library.
(Reliability No. 1.)
23. Telephone conversation. Robert Felt, Allegheny County Department of
Health to Sandy Beaton, GCA/Technology Division. November 1981.
(Reliability No. 2.)
24. Bradway, R. M. and H. F. Schiff. USSC Homestead Open Hearth Furnace Shop
No. 5 Particulate Emission Quantification. GCA Report No. TR-77-44-G.
Final Report. May 1978. (Reliability No. 1.)
624
-------
25. Telephone conversation. Bob Felt, Allegheny County Health Department to
Gene Bergson, GCA/Technology Division. February 12, 1981. (Reliability
No. 2.)
26. Telephone conversation. Bernard Bloom, U.S. EPA, Division of Stationary
Source Enforcement to Michael Jasinski, GCA/Technology Division.
December 1980 through February 1981. (Reliability No. 2.)
27. Impact of Particulate Matter Emissions on Ambient Air Quality.
USSC-Geneva Works. EPA-300/2-77-005b. Appendix Il-Source
Identification. February 1977. pp. 84, 90. (Reliability No. 4.)
28. Telephone conversation. Mr. Kopta, Utah State Division of Environmental
Health to Gene Bergson, GCA/Technology Division. February 27, 1981.
(Reliability No. 2.)
29. Telephone conversation. Dave Kopta, Utah State Division of Environmental
Health to Michael Jasinski, GCA/Technology Division. October 1981.
(Reliability No. 2.)
625
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MATERIAL IN THIS SECTION SUBJECT TO CONFIDENTIALITY 9
REVIEW AND IS NOT RELEASABLE AS OF FEBRUARY 1, 1982. 9 gj
FOR INFORMATION, CONTACT L. KESARI, U.S. ENVIRONMENTAL gg
PROTECTION AGENCY, DIVISION OF STATIONARY SOURCE ENFORCEMENT. Q°
H !>
H n
o tfi
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TABLE 1. ARMCO INC./HOUSTON WORKS IN HOUSTON, TX
SCARFING MACHINE(S) PROCESS AND EMISSION CONTROL DATA
MILL DESIGNATION:
STARTUP DATE:
STEEL PROCESSED:
RATED TONS/DAY:
AVERAGE TONS/DAY:
AMOUNT OF OXYGEN USED (ft3/min):
SCARFING EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
35-inch1
Blooming
1.7811
High-energy
scrubber1
• Rated at
141,000 acfra1
Slabbing1
High-energy
scrubber1
• Rated at
100,000 acfm1
ADDITIONAL COMMENTS:
626
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TABLE 2. ARMCO INC./KANSAS CITY WORKS IN KANSAS CITY, MO
SCARFING MACHINE(S) PROCESS AND EMISSION CONTROL DATA
MILL DESIGNATION:
STARTlj? DATE:
STEEL PROCESSED:
RATED TONS/DAY:
AVERAGE TONS/DAY:
AMOUNT OF OXYGEN USED (ft3/min):
SCARFING EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
BlDoming1
19632
2.2741
High-energy scrubber^-
Koch2
19742
• Design flow rate = 46,000
acfm* (50,000 acfm
@ 60°F—inlet)2
• Scrubber water flow rate
(design) = 400 gpm2
• L/G =8:1 (calculated-
design)2
ADDITIONAL COMMENTS:
627
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TABLE 3. ARMCO INC./MIDDLETOWN WORKS IN MIDDLETOWN, OH
SCARFING MACHINE(S) PROCESS AND EMISSION CONTROL DATA
MILL DESIGNATION:
STARTUP DATE:
STEEL PROCESSED:
RATED TONS/DAY:
AVERAGE TONS/DAY:
AMOUNT OF OXYGEN USED (ft3/rain):
SCARFING EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Slabbing1 (48 x 96 in. 2-h
universal mill)3
1967-
7.1231
High-energy scrubber1*3
AAF3
19673
• 100,000 scfm scarfing fume
exhaust system.3
• System includes a gas
scrubber and fume eliminator3
• Scarfing occurs on all four
sides of slab simultaneously3
ADDITIONAL COMMENTS:
628
-------
TABLE 4. BETHLEHEM STEEL CORP./BURNS HARBOR PLANT IN CHESTERTON, IN
SCARFING MACHINE(S) PROCESS AND EMISSION CONTROL DATA
MILL DESIGNATION: Slabbing (50 x 96 in.)4
STARTUP DATE: • 19694
STEEL PROCESSED:
RATED TONS/DAY: 9,31s1
AVERAGE TONS/DAY:
AMOUNT OF OXYGEN USED (ft3/min):
SCARFING EMISSION CONTROL SYSTEM: High-energy scrubber1*4
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION: • 110,000 acfm1'4
ADDITIONAL COMMENTS:
629
-------
TABLE 5. BETHLEHEM STEEL CORP./JOHNSTOWN PLANT IN JOHNSTOWN, PA
SCARFING MACHINE(S) PROCESS AND EMISSION CONTROL DATA
MILL DESIGNATION:
STARTUP DATE:
STEEL PROCESSED:
RATED TONS/DAY:
AVERAGE TONS/DAY:
AMOUNT OF OXYGEN USED (ft3/rain):
SCARFING EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Blooming*
(46-in. mill)5
19695
6,630]
High-energy
scrubber1
19695
• 100,000 acfm1
Billet1
(46-in. mill)5
19695
2.6711
Wet ESPJ
19715
• 26,000 acfm1'6
• Temp. - 50-150°F6
ADDITIONAL COMMENTS:
630
-------
TABLE 6. BETHLEHEM STEEL CORP./LACKAWANNA PLANT IN LACKAWANNA, NY
SCARFING MACHINE(S) PROCESS AND EMISSION CONTROL DATA
•^•^^••^^•••••^^•^••••MWMMBMHKSlMBMHM^niMHBMMMBIvaMMMeHnnaBKM^HM^nBaKWaMKanHiHMSKMSMii^a^MK
MILL DESIGNATION: 45 x 90 in.7 44 in.7
Slab mill Slab mill
STARTUP DATE:
STEEL PROCESSED:
RATED TONS/DAY: l.OOO.pOO lb/hr7 350,000 lb/hr7
AVERAGE TONS/DAY:
.AMOUNT OF OXYGEN USED (ft3/min):
SCARFING EMISSION CONTROL SYSTEM: Tunnel with water Tunnel with water
sprays7 sprays7
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
ADDITIONAL COMMENTS:
631
-------
TABLE 7. BETHLEHEM STEEL CORP./LOS ANGELES PLANT IN LOS ANGELES, CA
SCARFING MACHINE(S) PROCESS AND EMISSION CONTROL DATA
MILL DESIGNATION:
STARTUP DATE:
STEEL PROCESSED:
RATED TONS/DAY:
AVERAGE TONS/DAY:
AMOUNT OF OXYGEN USED (ft3/min):
SCARFING EMISSION CONTROL SYSTEM:3
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Blooming1
I9608
1.8491
2,3839
Baghouse1
Fuller9
19659
• Rated at 525,000 cfm9 with
A/C = 1.95:1;10 1.80:19
• 26 compartments; total of
3,120 silicone treated glass
filter bags10
• Reverse air cleaning using
29,750 cfm10
• Two 250-hp exhaust fans10
ADDITIONAL COMMENTS:
aBaghouse also controls the No. 3 Electric Arc Shop (primary and secondary
control system), two jaw crushers, and a chaser mill.9
632
-------
TABLE 8. BETHLEHEM STEEL CORP./SPARROWS POINT PLANT
IN SPARROWS POINT, MD
SCARFING MACHINE(S) PROCESS AND EMISSION CONTROL DATA
MILL DESIGNATION:
STARTUP DATE:
STEEL PROCESSED:
RATED TONS/DAY:
AVERAGE TONS/DAY:
AMOUNT OF OXYGEN USED (ft3/min):
SCARFING EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Slabbing
45 x 90 in.11
Blooming
40 in.1*
8.2191
9.47311
Wet ESP1'11
7.9731
1.45911
Wet ESP1'11
°6
Western Precip.11 Western Precip.11
197211 197211
• 6 section ESP; • 25,000 acfm;
each section with
a stack11
• F.D. fan11
• 150,000 acfm;
temp. = 100-
150°F6
• Spark rate
11
per **-
17
• Collection area =
18,462 sq. ft.11
• Test Data (1973) :n
94,300 dscfm
Temp. = 125 °F
temp. = 125°F
• Spark rate = 21
per sec^
• Collection area =
3,071 sq. ft.11
• Test Data (1975) :n
26,100 acfm
Temp. = 115°F
(continued)
633
-------
. TABLE 8 (continued)
SCARFING MACHINE(S) PROCESS AND EMISSION CONTROL DATA
MILL DESIGNATION:
STARTUP DATE:
STEEL PROCESSED:
RATED TONS/DAY:
AVERAGE TONS/DAY (1974):
AMOUNT OF OXYGEN USED (ft3/min):
SCARFING EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Slabbing
40 x 80 in.11
6.39811
High-energy venturi scrubber-
Koch (Flexi venturi)^
197011
• Test Data (1972) ;u
119,800 acfm @ stack conditions
Temp. = 130°F (avg.)
Ap = 60-66 in. ^0
Water flow = 600-660 gpra
L/G = 5-5.5 (actual)
ADDITIONAL COMMENTS:
634
-------
TABLE 9. CRUCIBLE, INC./A DIVISION OF COLT INDUSTRIES,
ALLOY DIVISION IN MIDLAND, PA
SCARFING MACHINE(S) PROCESS AND EMISSION CONTROL DATA
MILL DESIGNATION:
STARTUP DATE:
STEEL PROCESSED:
RATED TONS/DAY:
AVERAGE TONS/DAY:
AMOUNT OF OXYGEN USED (ft3/min):
SCARFING EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Blooming*-
1976"
3.0821
208.312
ESP13
Western Precip./Joy Mfg.*-3
197614
• Hood collection system with water
sprays^3
• 3 module ESP with water wash
cleaning: 1 module is cleaned
every 3 scarfs - scarfing is
often performed while a module
is in the washing mode.*-3
• Design flow rate = 90,000 acfm1^
• 1 I.D. fan13
• Test Data (1976);13
Outlet avg. = 86,525 acfm
Inlet avg. = 97,090 acfm
ADDITIONAL COMMENTS:
635
-------
TABLE 10. FORD MOTOR CO./RIVER ROUGE PLANT IN DEARBORN, MI
SCARFING MACHINE(S) PROCESS AND EMISSION CONTROL DATAa»b
MILL DESIGNATION:
STARTUP DATE:
STEEL PROCESSED:
RATED TONS/DAY:
AVERAGE TONS/DAY (1973):
AMOUNT OF OXYGEN USED (ft3/min):
SCARFING EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Slabbing1'15 (48 x 96 in.
universal)1**
10.9591
9.63215
Water flume and sprays1
95,000 acfm1
ADDITIONAL COMMENTS:
aScarfer has 22 continuous set burners.1**
used to have a bloom scarfer controlled by packed spray tower which
is currently shut down.15
636
-------
TABLE 11. INLAND STEEL CO./INDIANA HARBOR WORKS IN E. CHICAGO, IN
SCARFING MACHINE(S) PROCESS AND EMISSION CONTROL DATA
MILL DESIGNATION: Blooming1 Blooming1
(No. 2A)17 (No. 3)17
STARTUP DATE:
STEEL PROCESSED:
RATED TONS/DAY: 3.4251. , 4.9321
AVERAGE TONS/DAY:
AMOUNT OF OXYGEN USED (ft3/min):
SCARFING EMISSION CONTROL SYSTEM: Water flume and sprays (both mills)1
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION: • 90,000 acfm1 • 80.0001
• Test Data (1980):17 • Test Data (I960);17
38,448 acfm at 82°F 79,189 acfm at 60°F
(continued)
637
-------
TABLE 11 (continued)
SCARFING MACHINE(S) PROCESS AND EMISSION CONTROL DATA
MILL DESIGNATION:
STARTUP DATE:
STEEL PROCESSED:
RATED TONS/DAY:
AVERAGE TONS/DAY:
AMOUNT OF OXYGEN USED (ft3/min):
SCARFING EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Slabbing1
(No. 4)17
8,767
1
Water flume and sprays
• 100,OOO1
• Test Data (1980);17
132,395 acfm at 95°F
ADDITIONAL COMMENTS:
638
-------
TABLE 12. JONES & LAUGHLIN STEEL CORP./ALIQUIPPA WORKS IN ALIQUIPPA, PA
SCARFING MACHINE(S) PROCESS AND EMISSION CONTROL DATA
MILL DESIGNATION: Blooming Mill1 (45-in.)14>18
STARTUP DATE: 197712
STEEL PROCESSED:
RATED TONS/DAY: 5.7951
AVERAGE TONS/DAY:
AMOUNT OF OXYGEN USED (ft3/min): 10.83312
SCARFING EMISSION CONTROL SYSTEM: Wet ESP1
MANUFACTURER: Western Precipitator19
DATE INSTALLED: 197714
SYSTEM DESCRIPTION:
• 1 chamber ESP19
• 3 fields (A,B,C); each field 6 ft x 24 ft with 31 gas passages19
• Discharge electrodes—744 stainless steel 0.1055 in. dia. with stiff
electrode19
• 96 stainless steel collecting surfaces, each a unitized modular fin
plate19
• 1 I.D. fan18
• Design flow = 125,000 acfm at 125°F
• Negative operating pressure19
• Test Data (1977) ;l8
Inlet = 125,000-127,500 acfm (avg.)
Outlet = 151,000-153,600 acfm (avg.)
• Test Data (1972) :19
Inlet = 121,000 acfm (avg.)
Outlet = 97,550 acfm (avg.)
ADDITIONAL COMMENTS:
639
-------
TABLE 13. JONES & LAUGHLIN STEEL CORP./CLEVELAND WORKS IN CLEVELAND, OH
SCARFING MACHINE(S) PROCESS AND EMISSION CONTROL DATA
MILL DESIGNATION:
STARTUP DATE:
STEEL PROCESSED:
RATED TONS/DAY:
. AVERAGE TONS/DAY:
AMOUNT OF OXYGEN USED (ft3/min):
SCARFING EMISSION CONTROL SYSTEM:
MANUFACTURER:
• DATE INSTALLED:
SYSTEM DESCRIPTION:
Slabbing
7.20021; 7.3971
21,00021
Wet ESP1
Western Precipitator21
197521
• Design flow rate = 125,000 acfm
at 150°F21
ADDITIONAL COMMENTS:
640
-------
TABLE 14. JONES & LAUGHLIN STEEL CORP./INDIANA HARBOR WORKS
IN E. CHICAGO, IN
SCARFING MACHINE(S) PROCESS AND EMISSION CONTROL DATA
MILL DESIGNATION:
STARTUP DATE:
STEEL PROCESSED:
RATED TONS/DAY:
AVERAGE TONS/DAY:
AMOUNT OF OXYGEN USED (ft3/rain):
SCARFING EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Slabbing]
7.1341
High-energy scrubber1
• Actual flow rate = 85,667 scfra
with exit temp = 118°F22
• Design flow rate = 100,000 acfm
at 80°F (wet)1'23
• Ap = 50 in. H2023
ADDITIONAL COMMENTS:
641
-------
TABLE 15. JONES & LAUGHLIN STEEL CORP./PITTSBURGH WORKS IN
PITTSBURGH, PA
SCARFING MACHINE(S) PROCESS AND EMISSION CONTROL DATA
MILL DESIGNATION:
STARTUP DATE:
STEEL PROCESSED:
RATED TONS/DAY:
AVERAGE TONS/DAY:
AMOUNT OF OXYGEN USED (ft3/min):
SCARFING EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Blooming1
(46-in. primary mill)24
197925
4.9751
Wet ESP24
Western Precipitator2^
197925
• Flow = 125,000 acfm (original
design); lowered to 90,000 acfm in
late 197924
• Current flow rate = 91,000 scfm
(1980)26
• Test Data (1979):24
Exhaust flow (range) = 89,900-93,500
acfm
ADDITIONAL COMMENTS:
642
-------
TABLE 16. KAISER STEEL IN FONTANA, CA
SCARFING MACHINE(S) PROCESS AND EMISSION CONTROL DATA
MILL DESIGNATION:
STARTUP DATE:
STEEL PROCESSED:
RATED TONS/DAY:
AVERAGE TONS/DAY:
AMOUNT OF OXYGEN USED (ft3/rain):
SCARFING EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Slabbing^
8,548
1
Wet ESPJ
82,000 acfra (capacity)1
ADDITIONAL COMMENTS:
643
-------
TABLE 17. McLOUTH STEEL CORP./TRENTON WORKS IN TRENTON, MI
SCARFING MACHINE(S) PROCESS AND EMISSION CONTROL DATA
MILL DESIGNATION:
STARTUP DATE:
STEEL PROCESSED:
RATED TONS/DAY:
AVERAGE TONS/DAY:
AMOUNT OF OXYGEN USED (ft3/min):
SCARFING EMISSION CONTROL SYSTEM:3
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Slabbing27
Baghouse28
Sly Manufacturing Co.2°
• Collection area = 2,574 sq. ft28
• A/C = 2.92.-128
no
• Dacron bagszo
ADDITIONAL COMMENTS:
aFour roof mounted scrubbers, installed in 1954, were the original control
system.
644
-------
TABLE 18. REPUBLIC STEEL CORP./BUFFALO DISTRICT BUFFALO, NY
SCARFING MACHINE(S) PROCESS AND EMISSION CONTROL DATA
MILL DESIGNATION:3 Blooming1
STARTUP DATE: 19637
STEEL PROCESSED:
RATED TONS/DAY: 2.3591
AVERAGE TONS/DAY:
AMOUNT OF OXYGEN USED (ft3/min):
SCARFING EMISSION CONTROL SYSTEM: Dry ESP29
MANUFACTURER: Peabody29
DATE INSTALLED: 197429
SYSTEM DESCRIPTION: • Design flow rate = 42,000 scfm with
an exit temperature = 96°F7
ADDITIONAL COMMENTS:
aBlooming mill tables and manipular replacement scheduled for 1980.^
645
-------
TABLE 19. REPUBLIC STEEL CORP./CLEVELAND DISTRICT IN CLEVELAND, OH
SCARFING MACHINE(S) PROCESS AND EMISSION CONTROL DATA
MILL DESIGNATION:
STARTUP DATE:
STEEL PROCESSED:
RATED TONS/DAY:
AVERAGE TONS/DAY:
AMOUNT OF OXYGEN USED (ft3/mln):
SCARFING EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
44-in. bloom28.31
196131
2.7951
Wet ESP1*28
Western
Precipitator21
197321; 197431
• ESP Design Data:6
75,000 acfm at
40-150°F
3 modules with
1 field/module
96 discharge
electrodes per
module
Tube type collect-
ing surface
• Test Data (1973);21
60,050 acfm at 86°F
45-in. slab28.31
197031
7.7751
Wet ESP1*28
Western
Precipitator21
197721; 197831
• ESP rated at
100,000 acfm1
(continued)
646
-------
TABLE 19 (continued)
SCARFING MACHINE(S) PROCESS AND EMISSION CONTROL DATA
MILL DESIGNATION:
STARTUP DATE:
STEEL PROCESSED:
RATED TONS/DAY:
AVERAGE TONS/DAY:
AMOUNT OF OXYGEN USED (ft3/min):
SCARFING EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
18-in. billet28*31
195231
1.9181
Wet ESP1>28
Western Precipitator21
197321; 197231
• ESP Design Data:
45,000 acfm at 40-160°F
2 modules with 1 field/
module
96 discharge electrodes
per module
Tube type collecting surface
ADDITIONAL COMMENTS:
647
-------
TABLE 20. UNITED STATES STEEL CORP./EDGAR THOMSON-IRVIN WORKS
IN BRADDOCK, PA
SCARFING MACHINE(S) PROCESS AND EMISSION CONTROL DATA
MILL DESIGNATION:
STARTUP DATE:
STEEL PROCESSED:
RATED TONS/DAY:
AVERAGE TONS/DAY:
AMOUNT OF OXYGEN USED (ft3/min):
SCARFING EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Slabbing1
(44-in.)
6.8491
Scrubber1
Blooming2°
(46-in.)
Wet ESP25»26
Western Precipitator2^'2^
198125,26
• Exhaust flow rate =
100,000 acfm at 125°F26
ADDITIONAL COMMENTS:
648
-------
TABLE 21. UNITED STATES STEEL CORP./NATIONAL-DUQUESNE WORKS
IN DUQUESNE, PA
SCARFING MACHINE(S) PROCESS AND EMISSION CONTROL DATA
MILL DESIGNATION:
STARTUP DATE:
STEEL PROCESSED:
RATED TONS/DAY:
AVERAGE TONS/DAY:
AMOUNT OF OXYGEN USED (ft3/min):
SCARFING EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Slabbing1
(46-in. blooming mill)26
4.5211
Wet ESPa>1»32
Western
Precipitator26
197526
• Design Data;6
100,000 acfm
at 125°F
4 modules with
84 discharge
electrodes per
module
Tube-type
collecting
surface
• Particulate matter
is washed off
collection
surfaces
periodically32
Baghouse28
6 modules28
A/C - 3.6:128
Temps (design)-
200°F inlet; 125°F
outlet28
Test Data (1975);28
15,000 acfm
ADDITIONAL COMMENTS:
aReplaced dry ESP originally installed in 1959.32
649
-------
TABLE 22. UNITED STATES STEEL CORP./FAIRLESS WORKS
IN FAIRLESS HILLS, PA
SCARFING MACHINE(S) PROCESS AND EMISSION CONTROL DATA
MILL DESIGNATION:
STARTUP DATE:
STEEL PROCESSED:8
RATED TONS/DAY:
AVERAGE TONS/DAY:
AMOUNT OF OXYGEN USED (ft3/min):
SCARFING EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Blooming1 Slabbing*
(40-in. mill)33 (45-in. mill)33
195434
195534
64234 1,900 scfm34
Common Wet ESP1*34
Joy Manufacturing Co.3->
197633
• 4 rectangular module ESPs (one chamber per module), each containing
84 vertically mounted 10 in. I.D. x 15 ft pipes with discharge wires
inside35
• 1 I.D. fan rated at 75,000 acfm35
• Water spray flushing system activated after every fifth slab or
bloom is processed3*
• Test Data (1976);35
. 65,162 dscfm; temperature • 1128F (avg.)
ADDITIONAL COMMENTS:
a525 tons of blooms or slabs are scarfed per hour (maximum capacity).
650
-------
TABLE 23. UNITED STATES STEEL CORP./GARY WORKS IN GARY, IN
SCARFING MACHINE(S) PROCESS AND EMISSION CONTROL DATA
MILL DESIGNATION:
STARTUP DATE:
STEEL PROCESSED:
RATED TONS/DAY:
AVERAGE TONS/DAY:
AMOUNT OF OXYGEN USED (ft3/min):
SCARFING EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Slabbing1 Billet1
(46-in. mill)35 (24-in. mill)35
7.7261, ,
ESP1
3.2881
ESP1
197435 197435
• 95,000 acfm1 • 62,000 acfm1
(continued)
651
-------
TABLE 23 (continued)
SCARFING MACHINE(S) PROCESS AND EMISSION CONTROL DATA
MILL DESIGNATION:
STARTUP DATE:
STEEL PROCESSED:
RATED TONS/DAY:
AVERAGE TONS/DAY:
AMOUNT OF OXYGEN USED (ft3/min):
SCARFING EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Rail1 Bar1 Bar1
(18-in. billet (18-in. billet
mill)35 mill)35
1.8691 1.3701
ESP1
197435
• 31,000
acfm1
ESP1
197435
• 62,000
acfm1
5651
ESP1
197435
• 62,000
acfm1
ADDITIONAL COMMENTS:
652
-------
TABLE 24. UNITED STATES STEEL CORP./HOMESTEAD WORKS
IN HOMESTEAD, PA
SCARFING MACHINE(S) PROCESS AND EMISSION CONTROL DATA
MILL DESIGNATION:
STARTUP DATE:
STEEL PROCESSED:
RATED TONS/DAY:
AVERAGE TONS/DAY:
AMOUNT OF OXYGEN USED (ft3/min):b
SCARFING EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Slabbing3»1
(45-in. mill)26
8,433!
112,500 scfm26
Rotoclones26
Envirotech/Chemico26
197426
• Exhaust flow rate = 105,000 scfm26
(8,200 acfm)1
ADDITIONAL COMMENTS:
aFacility rarely operates at present.
^Conditioning of slabs by grinding.1
653
-------
TABLE 25. WHEELING-PITTSBURGH STEEL CORP./STEUBENVILLE PLANTS
IN STEUBENVILLE AND MINGO JUNCTION, OH
SCARFING MACHINE(S) PROCESS AND EMISSION CONTROL DATA
MILL DESIGNATION:
STARTUP DATE:
STEEL PROCESSED:
RATED TONS/DAY:
AVERAGE TONS/DAY:
AMOUNT OF OXYGEN USED (ft3/mln):
SCARFING EMISSION CONTROL SYSTEM:
MANUFACTURER:
DATE INSTALLED:
SYSTEM DESCRIPTION:
Slabbing41
(45-in.)1'37
195736
4,1841; (5,243)37
Low-pressure
scrubber1>36
195736
Slabbing15
(44-in.)37
196536
2.68037
Impingement
scrubber3^
ADDITIONAL COMMENTS:
aPlant is located in Steubenville, OH.36
bPlant is located in Mingo Junction, OH.36
654
-------
MATERIAL IN THIS SECTION SUBJECT TO CONFIDENTIALITY
REVIEW AND IS NOT RELEASABLE AS OF FEBRUARY 1, 1982.
FOR INFORMATION, CONTACT L. KESARI, U.S. ENVIRONMENTAL
PROTECTION AGENCY, DIVISION OF STATIONARY SOURCE ENFORCEMENT.
*J W
M Tl
2! W
O PS
w W
5> o
n M
-------
REFERENCES
SCARFING
1. U.S. Steel Industry Air Pollution Control Equipment Marketing Report.
The Mcllvaine Company. July 1980. Figure 12, p. ST-31. (Reliability
No. 4.)
2. Telephone conversation and letter response. Don Steele, Kansas City
Health Department, Mr Quality Section to Michael Jasinski,
CCA/Technology Division. October 22, 1981. (Reliability No. 1.)
3. Telephone conversation. Ed Luebering, SW District Ohio EPA to Gene
Bergson, GCA/Technology Division. March 9, 1981. (Reliability No. 2.)
4. Labee, Charles J. From Sand to Steel: The Burns Harbor Story. Iron &
Steel Engineer. 48(10): B-18 through B-48. October 1971. (Reliability
No. 3.)
5. Telephone conversation. Bob Clark, Pennsylvania Department of
Environmental Resources to Gene Bergson, GCA/Technology Division. March
2, 1981. (Reliability No. 2.)
6. Varga, John Jr. Control of Steel Plant Scarfing Emissions Using Wet
Electrostatic Precipitators. EPA-600/2-76-054. March 1976. RACT No.
600171-600206. (Reliability No. 3.)
7. Letter response. Richard Craig, U.S. Environmental Protection Agency
Region II to William Farino, GCA/Technology Division. December 1981.
(Reliability No. 1.)
8. Telephone conversation. Ted Polychronis, South Coast Air Quality
Management District to Michael Jasinski, GCA/Technology Division.
November 1981. (Reliability No. 2.)
9. Letter response, Joseph Tramtna, South Coast Air Quality Management
District to Gene Bergson, GCA/Technology Division. March 10, 1981.
(Reliability No. 1.)
10. Venturini, John. Operating Experience with a Large Baghouse in the
Electric Arc Furnace Steelmaking Shop at Bethlehem Steel Corporation's
Los Angeles Plant. Presented at the Sixty-third Annual Meeting of the
Air Pollution Control Association. St. Louis, Missouri. June 14-18,
1970. (Reliability No. 4.)
655
-------
11. Letter from J. W. Colbert, General Manager of BSC/Sparrows Pt. Plant,
Sparrows Pt., Maryland, to Stephen Wasserserg, Director of Enforcement
Division, U.S. Environmental Protection Agency Region III. Re:
Information Request subsequent to EPA inspection of Sparrows Point's air
control systems of March 17, 18, 27, 1975. Letter dated April 11, 1975.
JACA files. (Reliability No. 2.)
12. Telephone conversation. Arthur Witt, PADER, Pittsburgh, Pennsylvania to
Sandra Beaton, GCA/Technology Division. November 1981. (Reliability
No. 2.)
13. Compliance Test Report, Blooming Mill Scarfer Precipitator, Crucible
Steel Corp. in Midland, Pennsylvania. Western Precipitation Division Joy
Manufacturing Company. Project No. 55, 139. Test Date December 13-17,
1976. RACT No. 600093. (Reliability No. 1.)
14. Telephone conversation. Ken Bowman, Pennsylvania Department of
Environmental Resources to Michael Jasinski, GCA/Technology Division.
February 18, 1981. (Reliability No. 2.)
15. EPA Region V files. (Ford 1973 permits.)
16. Katofiasc, Thomas W. Launching of Ford's 48 x 96 inch Universal Slabbing
Mill. Iron & Steel Engineer. 48(6):49-55. 1971. (Reliability No. 3.)
17. EPA Region V files. (Data from Inland Tests in 1980.)
18. Test Report for J&L Steel Corp. 45 inch Blooming Mill Scarfer
Precipitator by Western Precipitation. Test date August-September 1977.
RACT No. 600027. (Reliability No. 1.)
19. Test Report for Jones & Laughlin Steel Corp./Aliquippa, Pennsylvania.
Blooming Mill Hot Scarfers. Western Precipitation Division of Joy
Manufacturing Company. May 1972. Job No. 781-138-01. RACT No. 600019.
(Reliability No. 1.)
20. EPA Region V file review by GCA in December 1981.
21. Letter response. Gary Nied, Cleveland Division of Air Pollution Control
to Gene Bergson, GCA/Technology Division. March 9, 1981. (Reliability
No. 1.)
22. Telephone conversation. Don Kuh, State of Indiana Air Pollution Control
to Sandy Beaton, GCA/Technology Division. October 1981. (Reliability
No. 2.)
23. Telephone conversation. Ed Wojcichowski, U.S. Environmental Protection
Agency Region V to Gene Bergson, GCA/Technology Division. February 4,
1981. (Reliability No. 2.)
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24. Correspondence from Allegheny County Health Department to J&L Steel
Corp./Pittsburgh Works regarding compliance tests on the wet
electrostatic precipitator at the 46 inch primary mill hot scarfer.
December 12, 1971. RACT No. 600087. (Reliability No. 1.)
25. Telephone conversation. Robert Felt, Allegheny County Department of
Health to Sandy Beaton. GCA/Technology Division. November 3, 1981.
(Reliability No. 2.)
26. Telephone conversation. Bob Felt, Allegheny County Department of Health
to Gene Bergson, GCA/Technology Division. February 12, 1981.
(Reliability No. 2.)
27. Anderson, P. A. GCA Compliance Inspection Report for EPA Region V at
McLouth Steel/Trenton, MI. 1979. (Reliability No. 2.)
28. Summary sheets compiled by JACA Corp. from stack tests in regional EPA
offices. Provided to JACA, Inc. for Steel Library by Tom Maslany, EPA
Region III. (Reliability No. 1.)
29. Telephone conversation. Al Carlacci, New York State Department of
Environmental Coservation to William Farino, GCA/Technology Division.
October 1981. (Reliability No. 2.)
30. Current Domestic Expansion and Modernization Programs. Iron & Steel
Engineer. February 1980. (Reliability No. 4.)
31. EPA Region V files. (RSC/Cleveland 1978 Publication.)
32. Iron & Steel Engineer. Equipment News. 52(9):95. September 1975.
(Reliability No. 3.)
33. The Precipitator Newsletter. Mcllvaine, Inc. June 20, 1980. No. 53, p.
54. (Reliability No. 4.)
34. Telephone conversation and letter response. Tom McGinley, FADER,
Morristown, PA to Sandy Beaton, GCA/Technology Division. November 1981.
(Reliability No. 1.)
35. Telephone conversation. Roland Elvambuena, City of Gary Health
Department to Gene Bergson, GCA/Technology Division. March 4, 1981.
(Reliability No. 2.)
36. Telephone conversation. Harold Strohmeyer, North Ohio Valley Air
Authority to Sandy Beaton, GCA/Technology Division. October 1981.
(Reliability No. 2.)
37. EPA Region V files. (Litigation Report.)
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