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 ------- 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 ------- 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 ------- 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 ------- 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 > ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 o O (/> ------- 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 ------- 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. o o O < W O 2! > O W M (/I G ------- 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. 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(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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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) M co IX H H fa o o a 2: CO ------- 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 ------- 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 ------- a td H & ya MTJ o w ^ ye w a 2J w o w PI 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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. ^ " o w W 21 S3 C~3 w n en i ------- 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.) 12. Testing Data from Bethlehem Steel Corp./Bethlehem, Pennsylvania BOF 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 No. 4468-L(23). (Reliability No. 2.) 16. L-D Process Newsletter, L-D Capacity 1979. June 1979. News Letter No. 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 ------- 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 t-1 > M O O M n ------- 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 ------- 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 t-1 w > M 7* 7* n w 53 ^ o w en ------- REFERENCES ELECTRIC ARC FURNACES 1. World Steel Industry Data Handbook: Vol.. I. The United States. McGraw-Hill Magazine. 1978. pp. 80-89. (Reliability No. 4.) 2. Telephone conversation. Ralph Hall, Maryland State Department of Health and Mental Hygiene to Michael Jasinski, GCA/Technology Division. October 29, 1981. (Reliability No. 2.) 3. Telephone conversation. Mark Sylvester, Maryland State Department of Health and Mental Hygiene to Michael Jasinski, GCA/Technology Division. February 13, 1981. (Reliability No. 2.) 4. Development Document for Proposed Effluent Limitations Guidelines and Standards for the Iron and Steel Manufacturing Point Source Category. EPA-440/l-79-024a, Volume V. Draft Report, U.S. Environmental Protection Agency, Effluent Guidelines Division Office of Water and Waste Management. October 1979. (Reliability No. 4.) 5. American Iron and Steel Institute. Directory of Iron and Steel Works in the U.S. and Canada. Thirty-fourth Edition. 1977. (Reliability No. 4.) 6. McKewer, P. L. Unique Features of ARMCO-Butler1s Electric Furnace Melt Shop. Iron and Steel Engineer. 49(6):75-86, June 1972. (Reliability No. 3.) 7. Telephone conversation. Ken Bowman, Pennsylvania Department of Environmental Resources, Pittsburgh, PA to Michael Jasinski, GCA/Technology Division. February 18, 1981. (Reliability No. 2.) 8. JACA Steel Library. Summary Sheets Submitted by Thomas Maslany compiled by JACA from stack tests contained in Environmental Protection Agency Regional Offices. (Reliability No. 1.) 9. Telephone conversation. Arthur Witt, Pennsylvania Department of Environmental Resources, Pittsburgh, Pa. to Sandy Beaton, GCA/Technology Division. November 17, 1981. (Reliability No. 2.) 10. Lakee, C. J. Steel in Texas. Iron and Steel Engineer. 48(4):T-3 through T-14, April 1971. (Reliability No. 3.) 607 ------- 11. Allen, R.R. ARMCO Scrubs up for Clean Air. Iron and Steel Engineer. 48(9):113-116. September 1971. (Reliability No. 3.) 12. Iron and Steel Engineer. Industry News. 55(2):88,91. February 1978. (Reliability No. 3.) 13. Telephone conversation. Lawrence Pewitt, Texas Air Pollution Control Board to William Farino, GCA/Technology Division. October 16, 1980. (Reliability No. 2.) 14. Nunno, T. Assessment of Air Emissions from Steel Plant Operations. GCA/Technology Division Report No. 1061, Pretest Survey Report for ARMCO Steel, Kansas City, Missouri. Prepared for U.S. EPA. April 9, 1980. (Reliability No. 1.) 15. Brown, D. I. Mini and Medium Steel Plants of North America. Iron and Steel Engineer. 52(11):MM-1, MM-38. November 1975. (Reliability No. 4.) 16. Letter from Larry Cole, City of Kansas City Health Department (Air Quality Section) to Gene Bergson, GCA/Technology Division. March 6, 1981. (Reliability No. 1.) 17. Telephone conversation. Don Steele, Kansas City Health Department (Air Quality Section) to Michael Jasinski, GCA/Technology Division. October 22, 1981. (Reliability No. 2.) 18. Telephone conversation. Joe Morehart, Ohio Northwest District Air Pollution Control Board to Gene Bergson, GCA/Technology Division. March 6, 1981. (Reliability No. 2.) 19. Telephone conversation. Glen Castleberry, Tulsa City-County Health Department to Gene Bergson, GCA/Technology Division. February 25, 1981. (Reliability No. 2.) 20. Kofsch, J. A. Iron and Steel Engineer. Editor's Notes. 52(9):23. August 1975. (Reliability No. 3.) 21. Telephone conversation. Glen Castleberry, Tulsa City-County Health Department to Michael Jasinski, GCA/Technology Division. October 22, 1981. (Reliability No. 2.) 22. Letter from Joseph Tramma, South Coast Air Quality Management District to Gene Bergson, GCA/Technology Division. March 10, 1981. (Reliability No. 1.) 23. Fennelly, P. F., and P. D. Spawn. Air Pollutant Control Techniques for Electric Arc Furnaces in the Iron and Steel Foundry Industry. EPA-450/2-78-024, OAQPS No. 1.2-099. U.S. Environmental Protection Agency, Office of Air Quality and Pollution Standards, Research Triangle Park, North Carolina. June 1978. pp. 3-19 through 3-27. (Reliability No. 3.) 608 ------- 24. Telephone conversation. Ted Polychronis, South Coast Air Quality Management District to Michael Jasinski, GCA/Technology Division. October 21, 1981. (Reliability No. 2.) 25. Gronberg, S. Assessment of Air Emissions from Steel Plant Sources. GCA/Technology Division Pretest Survey Report for Bethlehem Steel Corp., Bethlehem, Pennsylvania. Prepared for U.S. Environmental Protection Agency. June 13, 1979. (Reliability No. 1.) 26. Telephone conversation. Mr. DiLazaro, District Supervisor, Pennsylvania Department of Environmental Resources, Bethlehem, Pennsylvania to Eugene Bergson, GCA/Technology Division. October 22, 1980. (Reliability No. 2.) 27. Iron and Steel Engineer. Equipment News. 48(5):92. May 1971. (Reliability No. 3.) 28. Telephone conversation. Richard Maxwell, Pennsylvania Department of Environmental Resources, Williamsport, PA to Michael Jasinski, GCA/Technology Division. October 29, 1981. (Reliability No. 2.) 29. Venturini, J. L. 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.) 30. Telephone conversation. John Roberts, Puget Sound Air Quality Board to Michael Jasinski, GCA/Technology Division. October 21, 1981. (Reliability No. 2.) 31. Telephone conversation. Puget Sound Air Quality Board to Gene Bergson, GCA/Technology Division. February 24, 1981. (Reliability No. 2.) 32. Telephone conversation. John Buckley, Pennsylvania Department of Environmental Resources to Gene Bergson, GCA/Technology Division. February 13, 1981. (Reliability No. 2.) 33. Telephone conversation. Ron Davis, Pennsylvania Department of Environmental Resources to Sandy Beaton, GCA/Technology Division. November 4, 1981. (Reliability No. 2.) 34. Iron and Steel Engineer. Equipment News. 55(5):73. May 1978. (Reliability No. 3.) 35. Johnson, E. R., and J. Simmons. CF&I Replaces 73 Year Old Open Hearth Shop with UHP Electric Arc Furnaces. Iron and Steel Engineer. 55(l):46-54. January 1978. (Reliability No. 3.) 36. Telephone conversation. Dennis Myers, Colorado State Department of 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 Corporation. (Reliability No. 4.) 38. Jasinski, M. Trip Report-Pretest Survey, Crucible Stainless Steel Div., Midland, Pennsylvania, Electric Arc Shop. GCA/Technology Division. Prepared for U.S. Environmental Protection Agency. April 9, 1980. (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.) 40. Draft Report. Prepared by Pacific Environmental Services. Data Compilation of Electric Arc Furnaces in the United States. December 1981. (Reliability No. 2.) 41. Telephone conversation. Mr. Burdick and Mr. Abbott, Onondaga County Department of Health to Gene Bergson, GCA/Technology Division. February 1981. (Reliability No. 2.) 42. Region V files. (Ford response to EPA questionnaire - 2/21/78). 43. Letter from Michael Maillard, Wayne County Department of Health, to the Technical Service Files. RE: Source Testing Conducted at the Electric Arc Furnace Baghouse at the Ford Motor Company Rogue Complex. October 20, 1977. JACA Steel Library. (Reliability No. 2.) 44. Letter from Robert Bower, Assistant of Technical Services in Wayne County 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, Electric Arc Facility. October 26, 1975. JACA Steel Library. (Reliability No. 2.) 45. Telephone conversation. Bernard Bloom, U.S. Environmental Protection Agency, Division of Stationary Source Enforcement to Michael Jasinski, GCA/Technology Division. (Reliability No. 2.) 46. Region V files (1974 letter from Ford). 47. Telephone conversation. Michael Maillard, Wayne County Department of 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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 ------- 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.) 656 ------- 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.) 657 ------- |