AN AIR POLLUTION CONTROL
       EQUIPMENT INVENTORY OF THE
        AMERICAN STEEL  INDUSTRY

               Volume 2

          Draft Final Report
GCA
GCA CORPORATION
Technology Division
213 Burlington Road
Bedford, Mass. 01730

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                                              CCA-TR-82-11-G
  U.S. ENVIRONMENTAL PROTECTION AGENCY
Division of Stationary  Source Enforcement
            Washington, D.C.
         Contract No. 68-01-6316
        Technical Service Area  1
         Work Assignment No.  28
EPA Project Officer

   John R. Busik
EPA Task Manager

  Bernard Bloom
                                     EPA Assignment Manager

                                           Laxmi Kesari
         AN AIR  POLLUTION CONTROL
        EQUIPMENT INVENTORY OF THE
         AMERICAN STEEL INDUSTRY

                 Volume  2

           Draft Final  Report
              February 1982
               Prepared  by:

            Michael  Jasinski
               Peter Spawn
              Sandra Beaton
             Eugene  Bergson
             William Farino
             GCA CORPORATION
         GCA/TECHNOLOGY DIVISION
         Bedford,  Massachusetts

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                                   DISCLAIMER
     This Draft Final Report was furnished to the Environmental Protection
Agency by GCA Corporation, GCA/Technology Division, Burlington Road, Bedford,
Massachusetts 01730, in partial fulfillment of Contract No. 68-01-6136,
Technical Service Area 1, Work Assignment No. 28.  The opinions, findings, and
conclusions expressed are those of the authors and not necessarily those of
the Environmental Protection Agency.  Mention of company or product names is
not to be considered as an endorsement by the Environmental Protection Agency.
SPECIAL NOTE
     The inventory reported in this document was initiated in October 1980
under EPA Contract No. 68-01-4143, Technical Service Area 1, Task No. 94.
Additional data compilation and investigation were performed in January 1981
under EPA Contract No. 68-01-6316, Technical Service Area 1, Task No. 6
(Phase II), and in March 1981 under EPA Contract No. 68-01-6316, Technical
Service Area 1, Work Assignment No. 6 (Amendment 1 - Phase III).  Mr. Bernard
Bloom and Mr. Laxmi Kesari served as EPA Task Directors/Assignment Managers
for this program.

     All material presented in this document is subject to a confidentiality
review, and is not releasable as of February 1, 1982.  For further
information, contact Mr. Laxmi Kesari, United States Environmental Protection
Agency, Division of Stationary Source Enforcement, Washington, D.C.
                                  ii

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                                     TABLES
                                   (Volume 2)
Numbers                                                                  Page

 1-16       Coke Oven Gas Desulfurizatlon (Furnace Coke Producers) . .   354
 1- 3       Coke Oven Gas Desulfurization (Foundry Coke Producers) • .   380
            References	   383

 1-26       Sintering Machines	   388
            References	   430

 1-43       Blast Furnaces	   439
            References	•	   489

 1-11       External Iron Desulfurization Stations 	   494
            References	   505

 1-35       Basic Oxygen Converters	   507
            References	   558

 1-33       Electric Arc Furnaces	   568
            References	   607

 1-7        Open Hearth Furnaces	   615
            References	   623

 1-25       Scarfing Machines (automatic)	   626
            References	   655
                                       iii

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                                                                                     o
                                                                                     o
     MATERIAL IN THIS SECTION SUBJECT TO CONFIDENTIALITY                           Q gj
    REVIEW AND IS NOT RELEASABLE AS OF FEBRUARY 1, 1982.                           So
   FOR INFORMATION, CONTACT L. KESARI, U.S. ENVIRONMENTAL                          p|
PROTECTION AGENCY, DIVISION OF STATIONARY SOURCE ENFORCEMENT.                      £ ^
                                                                                     o
                                                                                   o >

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             TABLE  1.   ARMCO  INC./MIDDLETOWN WORKS  IN MIDDLETOWN,  OH

            COKE PLANT NOS. 2a AND 3b COKE OVEN GAS DESULFURIZATION
                        PROCESS  AND  EMISSION CONTROL  DATA


BATTERY DESIGNATION:                No. I1      No. I1     No. 21

  MANUFACTURER:                     Wilputte1   Dravo-Still (both batteries)1
  STARTUP DATE:                     19532>3     19761      19771
  RECENT REHABILITATION DATE:
  SCHEDULED SHUTDOWN DATE:
  NO. OF OVENS:                     761         571        571
  OVEN HEIGHT (ft-in.):             13-61       19-81      19-81
  OVEN LENGTH (ft-in.):             43-91       52-61      52-61

COKE PRODUCTION:

  RATED TONS/DAY:                   5,150 (all three batteries combined)4
  TYPICAL TONS/DAY:                 4,890 (all three batteries combined)4

PERCENT SULFUR OF COAL (BY WEIGHT):  0.6 (for all three batteries)2

QUANTITY OF COG PRODUCED (ft3/day):  77 x 106 (all three batteries
                                    combined) •*

TYPE OF DESULFURIZATION PROCESS:    Carl Still (serves all three batteries)6.7

  MANUFACTURER:                     Dravo8
  DATE INSTALLED:                   19767
  SYSTEM DESCRIPTION:                • Carl Still process uses liquid oxidation
                                      for sulfur removal8
                                    • Process handles 60 x 106 scfd of COG,
                                      and uses sulfuric acid production for
                                      sulfur recovery8
                                    • NH3 used as an absorbent in sulfur
                                      removal process8
ADDITIONAL COMMENTS:

aBattery No. 1 (Wilputte).2

bBattery Nos. 1 and 2 (Dravo-Still).2
                                    354

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        TABLE 2.  BETHLEHEM STEEL CORP./BETHLEHEM PLANT IN BETHLEHEM, PA

         COKE  OVEN GAS  DESULFURIZATION  PROCESS  AND  EMISSION  CONTROL  DATA
BATTERY DESIGNATION:

  MANUFACTURER:
  STARTUP DATE:
  RECENT REHABILITATION DATE:
  SCHEDULED SHUTDOWN DATE:
  NO. OF OVENS:
  OVEN HEIGHT (m):
  OVEN LENGTH (ft-ln.):

COKE PRODUCTION:

  RATED TONS/DAY:
  TYPICAL TONS/DAY:

PERCENT SULFUR OF COAL (BY WEIGHT);

QUANTITY OF COG PRODUCED (ft3/day):


TYPE OF DESULFURIZATION PROCESS:
  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:
2A2
          2B2
3A2
    3B2
Koppers-Becker (batteries 2A through 3B)2
19412     19412     19422     19422
32
          32
32
102C»10
    32
5,840 (all six batteries combined)4
5,058 (all six batteries combined)4

1.0 (for all six batteries)2

100 x 106 (all six batteries
combined) H

Sulfiban (2 plants-serve all six
batteries)6»&

Bethlehem Steel/Applied Technology8
1975d,8,12
• Liquid absorption for sulfur removal**
• Amine solution (approximately 15%
  monoethanol amine "MEA") as absorbent**
• Claus plant for sulfur recovery**
• Each sulfiban plant handles approximately
  60 x 106 cu ft COG per day8
                                   (continued)
                                     355

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                               TABLE  2  (continued)

         COKE  OVEN GAS  DESULFURIZATION  PROCESS  AND  EMISSION  CONTROL  DATA
BATTERY DESIGNATION:

  MANUFACTURER:
  STARTUP DATE:
  RECENT REHABILITATION DATE:
  SCHEDULED SHUTDOWN DATE:
  NO. OF OVENS:
  OVEN HEIGHT (m):
  OVEN LENGTH (ft-in.):

COKE PRODUCTION:

  RATED TONS/DAY:
  TYPICAL TONS/DAY:

PERCENT SULFUR OF COAL (BY WEIGHT):

QUANTITY OF COG PRODUCED (ft3/day):

TYPE OF DESULFURIZATION PROCESS:
  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:
Koppers-Becker2
1953a,2
802
42
See previous page^


See previous page2
A2

McKee-Otto2
19762
802
62
                 11
See previous page
Sulfiban (2 plants—serve all six
batteries)6**5
See previous page for description.^
ADDITIONAL COMMENTS:

aBattery 5 rebuilt in 1977.9

bBattery 2A and 2B combined.1*10

cBattery 3A and 3B combined.1*10

dSulfiban plants rebuilt in 1976.8»12
                                    356

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       TABLE  3.  BETHLEHEM  STEEL CORP./BURNS  HARBOR  PLANT  IN  CHESTERTON,  IN

         COKE OVEN GAS DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
BATTERY DESIGNATION:
MANUFACTURER:
STARTUP DATE:
RECENT REHABILITATION DATE:
SCHEDULED SHUTDOWN DATE:
NO. OF OVENS:
OVEN HEIGHT (ft-in. ):
OVEN LENGTH (ft-in.):
No. I1
Wilputte1
196913
1980a,14
1982b>16
821
20-514' •
50-714
No. 21
Koppers1
1972^3


821
20-514
50-7*4
COKE PRODUCTION:

  RATED TONS/DAY:                   6,670 (both batteries combined)4
  TYPICAL TONS/DAY:                 5,179 (both batteries combined)4

PERCENT SULFUR OF COAL (BY WEIGHT): 0.89 (for both batteries)14

QUANTITY OF COG PRODUCED (ft3/day): 120 x 106 (both batteries combined)11

TYPE OF DESULFURIZATION PROCESS:    Vacuum Carbonate (serves both batteries)6

  MANUFACTURER:                     Koppers9
  DATE INSTALLED:                   19726>15
  SYSTEM DESCRIPTION:               • Process uses liquid absorption for sulfur
                                      removal"
                                    • Glaus plant used for sulfur recovery (HCN
                                      destruct)®
                                    • Sodium carbonate solution used for
                                      absorption"


ADDITIONAL COMMENTS:

alnvolved changing steam nozzles, i.e., increasing aspiration and rebuilding
 battery top.*4

^Scheduled shutdown for rebuild, i.e., double collector mains to be
 installed.16
                                    357

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        TABLE 4.   BETHLEHEM STEEL CORP./LACKAWANNA PLANT IN LACKAWANNA,  NY

         COKE OVEN GAS DESOLFURIZATION PROCESS AND EMISSION CONTROL DATA
r

 BATTERY DESIGNATION:8                No.  72       No.  82      No.  92

   MANUFACTURER:                      Wilputte2    Wilputte2   Wilputte2
   STARTUP  DATE:                      19522        19612       19692
   RECENT REHABILITATION DATE:                    1980b>17
   SCHEDULED SHUTDOWN DATE:                                  1982C»18
   NO.  OF OVENS:                      762          762         762
   OVEN HEIGHT (ft-in.):              12-219       12-219      20-419
   OVEN LENGTH (ft-in.):              40-719       40-7*9      48-319

 COKE PRODUCTION;d

   RATED TONS/DAY:                    8,140 (for  seven battery  operation)4
   TYPICAL  TONS/DAY:                  6,908 (for  seven battery  operation)4

 PERCENT SULFUR OF COAL (BY WEIGHT):  1.1  (for all three  batteries)2

 QUANTITY OF COG  PRODUCED (ft3/day):  50-60 x 10& (all three batteries
                                     combined)8*18

 TYPE OF DESULFURIZATION PROCESS:     Vacuum Carbonate (serves  all three
                                     batteries)6

   MANUFACTURER:                      Koppers8
   DATE INSTALLED:6                  197618
   SYSTEM DESCRIPTION:                •  Uses liquid absorption  for sulfur
                                       removal8
                                     •  Sulfuric  acid  production for  sulfur
                                       recovery8
                                     •  Sodium carbonate  solution  used for
                                       absorption8
 ADDITIONAL COMMENTS:

 ^Batteries No.  3,  4,  5 and  6 were  shut  down  in 1977.18

 ^Battery  was  completely  rebuilt.1?

 cScheduled shutdown for  rebuild.*8

 ^Production data appears to be  prior  to 1977 battery  shut  downs.4

 eSystem was rebuilt in 1979.18
                                    358

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   TABLE 5.  BETHLEHEM STEEL CORP./SPARROWS POINT PLANT IN SPARROWS POINT, MD

         COKE  OVEN GAS  DESULFURIZATION  PROCESS  AND  EMISSION  CONTROL DATA
BATTERY DESIGNATION:0

  MANUFACTURER:
  STARTUP DATE:
  RECENT REHABILITATION DATE:
  SCHEDULED SHUTDOWN DATE:
  NO. OF OVENS:
  OVEN HEIGHT (m):
  OVEN LENGTH (ft-in.):

COKE PRODUCTION:

  RATED TONS/DAY:
  TYPICAL TONS/DAY:

PERCENT SULFUR OF COAL (BY WEIGHT);
QUANTITY OF COG PRODUCED (ft3/day):
TYPE OF DESULFURIZATION PROCESS:
  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:
No. I2
No. 22     No. 32
Koppers (all four batteries)2
I9602      19612      19512
1985b,20   I985b>20   1982C,2!
632        602        632
3 (each, all six batteries)2
43-0 (each, all six batteries)1
No. 42


19782


II*5 '"
5,500 (all eight batteries combined)21


l.l;2 0.74-avg. in 197422 (for all
eight batteries)

100 x 106;11 131.9 x 106—avg. in
197422 (all eight batteries combined)

Vacuum Carbonate (serves all eight
batteries)6*20

Koppers^

• Liquid absorption for sulfur removal"
• Sodium carbonate solution (approximately
  2 percent) used as absorbent"*22
                                   (continued)
                                    359

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                              TABLE  5  (continued)

        COKE OVEN GAS DESULFURIZATION  PROCESS AND EMISSION CONTROL DATA


BATTERY DESIGNATION:8               No. 52     No.  62     No. II2    No.  122

  MANUFACTURER:                     Koppers2   Koppers2   Koppers-   Koppers-
                                                           Becker2    Becker2
  STARTUP DATE:                     19782      19532      19552      19572
  RECENT REHABILITATION DATE:
  SCHEDULED SHUTDOWN DATE:          1985b>20   1982C>21
  NO. OF OVENS:                     632        632        652        652
  OVEN HEIGHT (m):                   32         32         42         42
  OVEN LENGTH (ft-in.):              43-01      43-01      43-01      43-0*

COKE PRODUCTION:

  RATED TONS/DAY:                   See previous page21
  TYPICAL TONS/DAY:

PERCENT SULFUR OF COAL (BY WEIGHT): See previous page2>22

QUANTITY OF COG PRODUCED (ft3/day): See previous page11*22

TYPE OF DESULFURIZATION PROCESS:    Vacuum Carbonate (serves all eight
                                    batteries)6*20

  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:               See previous page for description8>22


ADDITIONAL COMMENTS:

aBattery NOB.  9 and 10 were shut down in early 1981.21

bNew Battery "A" to start-up In December 1981; new Battery "B" scheduled to
 start-up in December 1985 will replace Battery Nos. 1, 2, 4, and 5.21

cPlant has the option to either shut down Battery Nos. 3 and 6 in 1982, or
 continue their operation until 1985.21
                                    360

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       TABLE  6.   INLAND  STEEL  CORP./INDIANA HARBOR WORKS IN E.  CHICAGO,  IN

             COKE PLANT NO. 2 COKE OVEN GAS DESULFURIZATION PROCESS
                            AND EMISSION CONTROL DATA
BATTERY DESIGNATION:

  MANUFACTURER:
  STARTUP DATE:
  RECENT REHABILITATION DATE:
  SCHEDULED SHUTDOWN DATE:
  NO. OF OVENS:
  OVEN HEIGHT (ft-in.):
  OVEN LENGTH (ft-in.):

COKE PRODUCTION:

  RATED TONS/DAY:
  TYPICAL TONS/DAY:

PERCENT SULFUR OF COAL (BY WEIGHT):

QUANTITY OF COG PRODUCED (ft3/day);


TYPE OF DESULFURIZATION PROCESS:
  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:
No. 61
No. 71
No. 81
Koppers-Becker (all three batteries)1
19501       19561       19581
1971a,2     I974a>2
651
12-01
37-71
871
12-01
37-71
871
12-01
37-71
6170 (all five batteries combined)^
5640 (all five batteries combined)^

0.8 (for all five batteries)2

50 x 106 (all five batteries
combined)°

Vacuum Carbonate (serves all five
batteries)**

Koppers^
19746
• Vacuum carbonate process uses liquid
  absorption for sulfur removal.**
• Glaus plant, with water wash of HCN, for
  sulfur recovery."
• Sodium carbonate solution used for
  absorption.8
                                   (continued)
                                    361

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                               TABLE  6  (continued)

             COKE PLANT NO. 2 COKE OVEN GAS DESULFURIZATION PROCESS
                            AND EMISSION  CONTROL DATA
BATTERY DESIGNATION:                No. 91      No. 101

  MANUFACTURER:                     Koppers-Becker (both batteries)1
  STARTUP DATE:                     19591       19701
  RECENT REHABILITATION DATE:
  SCHEDULED SHUTDOWN DATE:
  NO. OF OVENS:                     871   .  ,    511
  OVEN HEIGHT (ft-in.):             12-01       20-01
  OVEN LENGTH (ft-in.):             37-71       37-41

COKE PRODUCTION:

  RATED TONS/DAY:                   See previou8 page4
  TYPICAL TONS/DAY:

PERCENT SULFUR OF COAL (BY WEIGHT): See previous page2

QUANTITY OF COG PRODUCED (ft3/day): See previous page8

TYPE OF DESULFURIZATION PROCESS:    Vacuum Carbonate (serves all five
                                    batteries)6

  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:               See previous page for description6*8
ADDITIONAL COMMENTS:

alnvolved end-flue rehabilitation2
                                    362

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       TABLE  NO.  7.   INLAND  STEEL  CORP./INDIANA HARBOR WORKS  IN E.  CHICAGO,  IN

           COKE PLANTS  NO. 3a  AND  4b  COKE OVEN GAS  DESULFURIZATION  PROCESS
                              AND EMISSION CONTROL DATA


BATTERY DESIGNATION:              C1                     II1

  MANUFACTURER:                    Koppers1               Koppers1
  STARTUP DATE:                    19741                  19781
  RECENT REHABILITATION DATE:      1979C»23
  SCHEDULED SHUTDOWN DATE:
  NO. OF OVENS:                    561       •             691
  OVEN HEIGHT (ft-in.):           20-21                  20-21
  OVEN LENGTH (ft-in.):           47-111                 471

COKE PRODUCTION:

  RATED TONS/DAY:                 3014 (battery C)4      2500 (battery No. II)4
  TYPICAL TONS/DAY:                2740 (battery C)4      1562 (battery No. II)4

PERCENT SULFUR OF COAL (BY WEIGHT):  1.1 (for both batteries)2

QUANTITY OF COG PRODUCED (ft3/day):

TYPE OF DESULFURIZATION PROCESS:  Vacuum Carbonate       Vacuum Carbonate
                                  (serves battery C)23   (serves battery No.

  MANUFACTURER:                    Koppers23              Koppers8
  DATE INSTALLED:                 197423                 19786
  SYSTEM DESCRIPTION:             • Vacuum carbonate processes use liquid
                                    absorption for sulfur removal.8
                                  • Glaus plant, with water wash of HCN, for
                                    sulfur recovery.8
                                  • Sodium carbonate solution used for
                                    absorption.8
ADDITIONAL COMMENTS:

aBattery C

bBattery No. 11

clnvolved end-flue rehabilitation23
                                    363

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     TABLE 8.  JONES & LAUGLIN STEEL CORP./ALIQUIPPA WORKS IN ALIQUIPPA, PA

         COKE OVEN GAS  DESULFURIZATION PROCESS AND EMISSION  CONTROL DATA
BATTERY DESIGNATION:8
MANUFACTURER:
STARTUP DATE:
RECENT REHABILITATION DATE:
SCHEDULED SHUTDOWN DATE:
NO. OF OVENS:
OVEN HEIGHT (ft-ln.):
OVEN LENGTH (ft-in. ):
A-ll
Koppers-Becker2
19451
197824
1061
13-01
40-51
A-5b,l
Koppers^
197613
561
20-61
50-?1
COKE PRODUCTION:0

  RATED TONS/DAY:                    4,308 (both batteries combined)25
  TYPICAL TONS/DAY:                   3,500 (both batteries combined)26

PERCENT SULFUR OF COAL (BY WEIGHT):  1.0 (for both batteries)2'26

QUANTITY OF COG PRODUCED (ft3/day):  64.6 x 106 (both batteries
                                     combined)25

TYPE OF DESULFURIZATION PROCESS:     Carl Still (serves both batteries)6'25

  MANUFACTURER:                      Dravo8
  DATE INSTALLED:                    198124»25
  SYSTEM DESCRIPTION:                 • Liquid absorption used for sulfur
                                       removal8
ADDITIONAL COMMENTS:

aBatteries A-3 and A-4 were shut down in I960.24

lattery A-5 replaced battery A-2 in 1975-1976.26

cProduction data for a 4-battery operation (A-l, A-3,  A-4, and A-5) = 6,946
 (rated tons/day); 4,506 (typical tons/day).4
                                    364

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    TABLE  9.  JONES & LAUGHLIN  STEEL  CORP./PITTSBURGH WORKS  IN  PITTSBURGH, PA

        COKE OVEN GAS DESULFURIZATION  PROCESS  AND EMISSION  CONTROL DATA
BATTKRY DESIGNATION:

  MANUFACTURER:
  STARTUP DATE:
  RECENT REHABILITATION DATE:
  SCHEDULED SHUTDOWN DATE:
  NO. OF OVENS:
  OVEN HEIGHT (ft-in.):
  OVEN LENGTH (ft-in.):

COKE PRODUCTION:

  RATED TONS/DAY:
  TYPICAL TONS/DAY:

PERCENT SULFUR OF COAL (BY WEIGHT);
QUANTITY OF COG PRODUCED (ft3/day):
PI*

Wilputte1
I9601
197927
P21

Wilputte1
19611
1977*.2
P3N1

Wilputte1
19611
I96027
59 (each, batteries PI through P3N)1
13-0 (each, batteries PI through P3N)1
40-9 (each, batteries PI through P3N)1
5,300 (all five batteries combined)4
5,230 (all five batteries combined)4

1.2;2 0.9-1.227 (for all five
batteries)

80 x 106;11 90 x 106 (all five
batteries combined)27
TYPE OF DESULFURIZATION PROCESS:     Sulfiban (serves all five batteries)6
  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:
Bethlehem Steel/Applied Technology®
1975b»8
• Process uses liquid absorption for sulfur
  removal®
• Amine solution (~15% monoethanol amine)
  used as absorbent®
• Sulfuric acid production used for sulfur
  recovery0»®
                                    (continued)
                                    365

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                               TABLE  9  (continued)

         COKE  OVEN GAS  DESULFURIZATION  PROCESS  AND  EMISSION  CONTROL DATA
BATTERY DESIGNATION:
MANUFACTURER:
STARTUP DATE:
RECENT REHABILITATION DATE:
SCHEDULED SHUTDOWN DATE:
NO. OF OVENS:
OVEN HEIGHT (ft-in. ):
OVEN LENGTH (ft-in.):
P3S1
Wilputte1
19611
1978a»2
591
13-Ql .
40-9 1
P4l
Koppers-Becker^
19531
19793.2
791
13-01
40-61
COKE PRODUCTION:

  RATED TONS/DAY:
  TYPICAL TONS/DAY:

PERCENT SULFUR OF COAL (BY WEIGHT):

QUANTITY OF COG PRODUCED (ft3/day):

TYPE OF DESULFURIZATION PROCESS:

  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:
See previous page^


See previous page^»27

See previous page^'^'

Sulfiban (serves all five batteries)^



See previous page for description^
ADDITIONAL COMMENTS:

alnvolved end-flue rehabilitation.2

bRelined in 1977.8

cSulfuric acid plant has not operated since Dec. 1976.
                                    366

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                  TABLE 10.  KAISER STEEL CORP. IN FONTANA, CA

         COKE  OVEN GAS  DESULFURIZATION  PROCESS  AND  EMISSION CONTROL DATA
BATTERY DESIGNATION:

  MANUFACTURER:
  STARTUP DATE:
  RECENT REHABILITATION DATE:a
  SCHEDULED SHUTDOWN DATE:
  NO. OF OVENS:
  OVEN HEIGHT (ft-in.):
  OVEN LENGTH (ft-in.):

COKE PRODUCTION:

  RATED TONS/DAY:

  TYPICAL TONS/DAY:

PERCENT SULFUR OF COAL (BY WEIGHT);


QUANTITY OF COG PRODUCED (ft3/day):

TYPE OF DESULFURIZATION PROCESS:

  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:
Koppers-Becker2
194228
197328

4528
13-028  ,
40-528
Koppers-Becker2
194228
197328

4528
13-028
40-528
4.250;1 4,100^ (all seven batteries
  combined)
3,800 (all seven batteries combined)^

0.75 (avg.);28 Q.92 (for all seven
  batteries)
Takahax-A (serves all seven batteries)**

Nippon/Chemico8
1981^,29
• Process uses liquid oxidation for sulfur
  removal
• NH3 absorption together with wet
  oxidation removes sulfur8
                                   (continued)
                                    367

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                              TABLE 10 (continued)

         COKE  OVEN GAS  DESULFURIZATION  PROCESS  AND EMISSION  CONTROL DATA
BATTERY DESIGNATION:

  MANUFACTURER:
  STARTUP DATE:
  RECENT REHABILITATION DATE:
  SCHEDULED SHUTDOWN DATE:
  NO. OF OVENS:
  OVEN HEIGHT (ft-in.):
  OVEN LENGTH (ft-in.):

COKE PRODUCTION:

  RATED TONS/DAY:
  TYPICAL TONS/DAY:

PERCENT SULFUR OF COAL (BY WEIGHT):

QUANTITY OF COG PRODUCED (ft3/day)i

TYPE OF DESULFURIZATION PROCESS:

  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:
Koppers-Becker2
194928
1976a>28
Koppers-Becker2
195228
1979-80b>28
4528
13-028 .
40-528
4528
13-028
40-528
    See previous
    See previous page2»28
Takahax-A (serves all seven batteries)"
See previous page for description8>29
                                   (continued)
                                    368

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                              TABLE 10 (continued)

         COKE OVEN GAS DESULFURIZATION PROCESS AND EMISSION  CONTROL DATA
BATTERY DESIGNATION:                E1             F1             G1

  MANUFACTURER:                    Koppers-       Koppers-       Koppers-
                                    Becker2        Becker2        Becker2
  STARTUP DATE:                    195228         195828         195828
  RECENT REHABILITATION DATE:       1978b>28
  SCHEDULED SHUTDOWN DATE:
  NO. OF OVENS:                    4528   ,  .      4528           4528
  OVEN HEIGHT (ft-in.):            13-028         13-028         13-028
  OVEN LENGTH (ft-in.):            40-528         40-528         40-528

COKE PRODUCTION:

  RATED TONS/DAY:                          See previous pages1*4
  TYPICAL TONS/DAY:

PERCENT SULFUR OF COAL (BY WEIGHT):        See previous pages2*28

QUANTITY OF COG PRODUCED (ft3/day):

TYPE OF DESULFURIZATION PROCESS:   Takahax-A (serves all seven batteries)6

  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:              See previous pages for description8*29


ADDITIONAL COMMENTS:

alnvolved trimwork.28

blnvolved end-flue rehabilitation.28

cFacility shut down in March 1981 due to corrosion problems.2'
                                    369

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      TABLE  11.  NATIONAL  STEEL  CORP./WEIRTON  STEEL DIVISION IN WEIRTON,  WV

         COKE  OVEN GAS  DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
BATTERY DESIGNATION:

  MANUFACTURER:
  STARTUP DATE:
  RECENT REHABILITATION DATE:
  SCHEDULED SHUTDOWN DATE:
  NO. OF OVENS:
  OVEN HEIGHT (ft-in.):
  OVEN LENGTH (ft-in.):

COKE PRODUCTION:

  RATED TONS/DAY:
  TYPICAL TONS/DAY:

PERCENT SULFUR OF COAL (BY WEIGHT);
1.22

QUANTITY OF COG PRODUCED (ft3/day)j
TYPE OF DESULFURIZATION PROCESS:
  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:
I-ll

Koppersl
19731.30
1979a»2

87l
20-431
47-331
3,600 (battery I-l)4
3,000 (battery I-l)4

1.03 (avg. in 1974) ;
35 x 106 (avg. in
1974); 34 70 x 10&

Vacuum Carbonate (serves
battery 1-1)6,30

Koppers^
197330
• Liquid absorption for
  sulfur removal**
• Glaus plant, with water
  wash of HCN, for sulfur
  recovery^
• Sodium carbonate solution
  used for absorption."
ADDITIONAL COMMENTS:

alnvolved end-wall rehabilitation.31
                                     370

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           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

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        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

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     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

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       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 (/>

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          TABLE 1.  ALLIED CHEMICAL CORP./ASHLAND PLANT IN ASHLAND, KY

         COKE  OVEN GAS  DESULFURIZATION  PROCESS  AND  EMISSION CONTROL DATA
BATTERY DESIGNATION:

  MANUFACTURER:
  STARTUP DATE:
  RECENT REHABILITAT:
  SCHEDULED SHUTDOWN DATE:
  NO. OF OVENS:
  OVEN HEIGHT (m):
  OVEN LENGTH (ft-in.):

COKE PRODUCTION:

  RATED TONS/DAY:
  TYPICAL TONS/DAY:

PERCENT SULFUR OF COAL (BY WEIGHT):

QUANTITY OF COG PRODUCED (ft3/day):
No. 32
Wilputte2
19532
IN DATE: 1973C>2
)ATE:
762
4.52
1 : 40-853
No. 4a>2
Wilputte2
b
702
4.5;2 552
46-1053
TYPE OF DESULFURIZATION PROCESS:

  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:
3,480 (both batteries combined)^
2,100 (both batteries combined)^

0.8 (for both batteries)2

45 x 106 (normal; both batteries
 combined),
53 x 106 (maximum; both batteries
 combined)53

Sulfiban (serves both batteries)6'51

Bethlehem Steel/Applied Technology8
1978^1
• Process uses liquid absorption for
  sulfur removal"
• Amine solution as absorber;
  approximately 15% monoethanolamine
  (MEA) solution8
ADDITIONAL COMMENTS:

aBattery No. 4 was shut down in December 1980 due to low coke demand.51

^Battery No. 4 was rebuilt in 1978.2

clnvolved end-flue rehabilitation.2
                                    380

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                 TABLE 2.   DONNER-HANNA COKE CORP  IN BUFFALO,  NY

         COKE OVEN GAS DESULFURIZATION PROCESS  AND EMISSION CONTROL DATA
BATTERY DESIGNATION:

  MANUFACTURER:
  STARTUP DATE:
  RECENT REHABILITATION DATE:
  SCHEDULED SHUTDOWN DATE:
  NO. OF OVENS:
  OVEN HEIGHT (m):
  OVEN LENGTH (ft-in.):

COKE PRODUCTION:

  RATED TONS/DAY:
  TYPICAL TONS/DAY:

PERCENT SULFUR OF COAL (BY WEIGHT);

QUANTITY OF COG PRODUCED (ft3/day);


TYPE OF DESULFURIZATION PROCESS:
  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:
AB2
Koppers2
19512
512
4; 2 219
No. 32
Koppers2
19642
502
42,19
No. 42
Koppers2
19672
502
4-2,19
3,004 (all three batteries combined)4
3,004 (all three batteries combined)4

1.1 (for all three batteries)2

30 x 106 (all three batteries
combined)34

Vacuum Carbonate (serves all three
batteries)6

Koppers^
1978 (approximately)19
• Sulfur removal via liquid absorption
  (sodium carbonate solution)"
ADDITIONAL COMMENTS:
                                    381

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           TABLE 3.  KOPPERS CO., INC./INDUSTRIAL PRODUCTS DIVISION,
                     ERIE PLANT IN ERIE, PA

         COKE OVEN  GAS  DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
BATTERY DESIGNATION: a
MANUFACTURER:
STARTUP DATE:
RECENT REHABILITATION DATE:
SCHEDULED SHUTDOWN DATE:
NO. OF OVENS:
OVEN HEIGHT (ft-in. ):
OVEN LENGTH (ft-in.):
A2
f\
Koppers^
1943b«54

23.2 ,
12-055
43-055
B2
Koppers2
1943b>2

352
12-055
42-055
COKE PRODUCTION:

  RATED TONS/DAY:

  TYPICAL TONS/DAY:

PERCENT SULFUR OF COAL (BY WEIGHT):

QUANTITY OF COG PRODUCED (ft3/day):


TYPE OF DESULFURIZATION PROCESS:

  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:
730;1 6254 (both batteries
 combined)
600 (both batteries combined)4

0.7 (for both batteries)2

6.5 x 106 fboth batteries
combined)5°

Hydro-Quinone (serves both batteries)56
ADDITIONAL COMMENTS:

aFacility previously owned and operated by Interlake, Inc.^

bBoth batteries rebuilt in 1971.2
                                    382

-------
     MATERIAL IN THIS SECTION SUBJECT TO CONFIDENTIALITY
    REVIEW AND IS NOT RELEASABLE AS OF FEBRUARY 1, 1982.
   FOR INFORMATION, CONTACT L. KESARI, U.S. ENVIRONMENTAL
PROTECTION AGENCY, DIVISION OF STATIONARY SOURCE ENFORCEMENT.
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-------
                                   REFERENCES

                          COKE  OVEN GAS  DESULFURIZATION
1.   World Steel Industry Data Handbook:  -Volume 1, The United States.
     McGraw-Hill Magazine.  1978.  p. 40.  (Reliability No. 4.)

2.   Technical Approach for a Coke Production Cost Model.  PEDCo
     Environmental, Inc.  EPA Contract No. 68-02-3071.  p. 47.  (Reliability
     No. 4.)

3.   EPA Region V Files.  (Renewal Permit Applications dated January 26, 1979.)

4.   Development Document for Effluent Limitations Guidelines and Standards
     for the Iron and Steel Manufacturing Point Source Category, Vol. II*
     Draft Report.  EPA-440/l-70-024a.  October 1979.  pp. 18-19.
     (Reliability No. 4.)

5.   ARMCO's Coke Batteries Scheduled for Mid-1976 Start-Up.  Iron & Steel
     Engineer.  September 1975.  pp. 61-62.  (Reliability No. 4.)

6.   COG Desulfurization:  The Standard Tightens.  Thirty-Three Metal
     Producing Magazine.  November 1980.  Vol. 11.  McGraw-Hill Publications.
     pp. 44-45.  (Reliability No. 4.)

7.   EPA Region V Files.  (Permit Application for Coke By-Product Plant, dated
     August 3, 1978 by B. Steiner of ARMCO, Inc.)

8.   Technical Support Document for the Recommended Lowest Achievable Emission
     Rate for S02 Emissions from Coke-Oven Gas Combustion.  U.S.
     Environmental Protection Agency, Division of Stationary Source
     Enforcement.  January 1977.  (Reliability No. 2.)

9.   Telephone conversations.  Bernard Bloom, U.S. Environmental Protection
     Agency, Division of Stationary Source Enforcement to Michael Jasinski,
     GCA/Technology Division.  December 1980.  (Reliability No. 2.)

10.  Telephone conversation and letter response.  Bill Nuver, Pennsylvania
     Department of Environmental Resources to Sandy Beaton, GCA/Technology
     Division.  November 1981.
                                   383

-------
11.  Mossey, Michael J., and Robert W. Dunlap.  Economics and Alternatives for
     Sulfur Removal from Coke Oven Gas.  JAPCA.  25(10):1019-1027.  October
     1975.  (Reliability No. 4.)

12.  Telephone conversation.  Bernard Bloom, U.S. Environmental Protection
     Agency, to Michael Jasinski, GCA/Technology Division.  February 1981.
     (Reliability No. 2.)

13.  Cost Effectiveness Model for Pollution Control of Coke Facilities.
     EPA-600/2-79-185.  August 1979.  Table 8.  (Reliability No. 4.)

14.  Petroccia, M., et al.  Field Inspection Report.  Bethlehem Steel
     Corporation, Burns Harbor, Coke Batteries 1 and 2, Chesterton, Indiana.
     GCA/Technology Division Draft Final Report No. TR-80-56-G.  Prepared for
     U.S. Environmental Protection Agency.  July 1980.  (Reliability No. 1.)

15.  Hombeig, Otto A., and Alan H. Singleton.  Claus Plant Performance and
     Problems.  Preprint of Paper No. 74-186 for presentation at the Air
     Pollution Control Association 1974 Annual Meeting.  (Reliability No. 4.)

16.  Telephone conversation.  Andy Sutherland, State of Indiana, Air Pollution
     Control to Sandy Beaton, GCA/Technology Division.  February 1981.
     (Reliability No. 2.)

17.  Telephone conversation.  Henry Sandoto, New York State Department of
     Environmental Conservation to William Farino, GCA/Technology Division.
     February 1981.  (Reliability No. 2.)

18.  Telephone conversation.  Jack Hausrath, Erie County Department of Health
     to Gene Bergson, GCA/Technology Division.  February 17, 1981.
     (Reliability No. 2.)

19.  Letter response.  Richard Craig, U.S. Environmental Protection Agency,
     Region II to William Farino, GCA/Technology Division.  December 1981.
     (Reliability No. 1.)

20.  Telephone conversation.  Mark Sylvester, Maryland Department of Health
     and Mental Hygiene to Michael Jasinski, GCA/Technology Division.
     February 13, 1981.  (Reliability No. 2.)

21.  Telephone conversation.  Ralph Hall, State of Maryland, Department of
     Health and Mental Hygiene to Michael Jasinski, GCA/Technology Division.
     October 1981.  (Reliability No. 2.)

22.  Letter from J. W. Colberg, General Manager of BSC/Sparrows Point Plant,
     Sparrows Point, Maryland to Stephen Wassersug, Director of Enforcement
     Division, U.S. Environmental Protection Agency, Region III.  Re:
     Information Request subsequent to EPA inspection of Sparrows Point's Air
     Pollution Control Systems on March 17, 18, and 27, 1975.  Letter dated
     April 11, 1975.  JACA Inc. Files.  (Reliability No. 3.)
                                   384

-------
23.  EPA Region V Files (August 1981 letter from Inland to EPA).

24.  Telephone conversation.  Ken Bowman, Pennsylvania Department of
     Environmental Resources to Gene Bergson, GCA/Technology Division.
     February 18, 1981.  (Reliability No. 2.)

25.  Telephone conversation.  Arthur Witt, Pennsylvania Department of
     Environmental Resources to Sandy Beaton, GCA/Technology Division.
     November 17, 1981.  (Reliability No. 2.)

26.  Petroccia, M., et al.  Field Inspection Report.  J&L Steel Corporation/
     Aliquippa Works, May 1981.  GCA Final Report TR-81-57-G.  Prepared for
     U.S. Environmental Protection Agency. .July 1981.  (Reliability No. 1.)

27.  Telephone conversation.  S. Banninthaya, Allegheny County Health
     Department to Gene Bergson, GCA/Technology Division.  February 12, 1981.
     (Reliability No. 2.)

28.  Spawn, P. and Ramon Li.  Field Inspection Report.  Kaiser Steel
     Corporation, Fontana Works Coke Plant, Fontana, California.
     GCA/Technology Division Draft Final Report No. TR-79-53-G.  Prepared for
     U.S. Environmental Protection Agency.  February 1980.  (Reliability
     No. 1.)

29.  Telephone conversation.  Lois Green, U.S. Environmental Protection
     Agency, Region IX to Michael Jasinski, GCA/Technology Division.  November
     1981.  (Reliability No. 2.)

30.  Telephone conversation.  John Raggi, West Virginia Air Pollution Control
     to Gene Bergson, GCA/Technology Division.  February 17, 1981.
     (Reliability No. 2.)

31.  Spawn, P., et al.  National Steel Corporation, Weirton Steel Division
     Plant Inspection, August 1981.  GCA/Technology Division Draft Final
     Report No. TR-81-118-G.  Prepared for U.S. Environmental Protection
     Agency.  November 1981.  (Reliability No. 1.)

32.  Summary Sheets compiled by PEDCo from stack tests at regional EPA
     offices.  Provided to JACA, Inc. for Steel Library by Tom Maslany, EPA
     Region III.  (Reliability No. 1.)

33.  EPA Region V Files.  (Report on RSC/Chicago new coke battery, 1978.)

34.  Hall, Robert R., et al.  Evaluations of the Technological Feasibility and
     Cost of Selected Control Alternatives Necessary to Meet the Ohio SO
     Regulations.  Republic Steel Corporation/Cleveland District Plant.
     Volume III.  GCA/Technology Division Final Report.  Prepared for U.S.
     Environmental Protection Agency.  April 1977.  (Reliability No. 2.)

35.  Telephone conversation.  Mr. Habib, City of Cleveland Air Pollution
     Control to Sandy Beaton, GCA/Technology Division.  October 1981.
     (Reliability No. 2.)


                                  385

-------
36.  EPA Region V Files.  (Trip report dated February 20, 1980.)

37.  Telephone conversation.  Ted Davis, Northeast District Ohio EPA to Gene
     Bergson, GCA/Technology Division.  February 27, 1981.  (Reliability
     No. 2.)

38.  Spawn, P., et al.  Field Inspection Report.  USSC Clairton Works Coke
     Plant, Clairton, Pennsylvania.  GCA/Technology Division, Draft Final
     Report No. TR-80-30-G.   Prepared for U.S. Environmental Protection
     Agency.  April 1980.  (Reliability No. 1.)

39.  Source Sheet on USSC Clairton Coke Battery #7.  RACT-500478.
     (Reliability No. 1.)

40.  Source Sheet on USSC Clairton Coke Battery #8.  RACT-500484.
     (Reliability No. 1.)

41.  Source Sheet on USSC Clairton Coke Battery #9.  RACT-500490.
     (Reliability No. 1.)

42.  Computer Printout.  Prepared by PEDCo Environmental Inc., for U.S.
     Environmental Protection Agency, Washington, D.C.  Coke Battery data
     compilation of the United States.  1979.  (Reliability No. 4.)

43.  Source Sheet on USSC Clairton Coke Battery No. 15.  RACT-500526.
     (Reliability No. 1.)

44.  Source Sheet on USSC Clairton Coke Battery No. 16.  RACT-500528.
     (Reliability No. 1.)

45.  Source Sheet on USSC Clairton Coke Battery No. 17.  RACT-500541.
     (Reliability No. 1.)

46.  Source Sheet on USSC Clairton Coke Battery No. 19.  RACT-500553.
     (Reliability No. 1.)

47.  Source Sheet on USSC Clairton Coke Battery No. 20.  RACT-500562.
     (Reliability No. 1.)

48.  Source Sheet on USSC Clairton Coke Battery No. 21.  RACT-500569.
     (Reliability No. 1.)

49.  Source Sheet on USSC Clairton Coke Battery No. 22.  RACT-500581.
     (Reliability No. 1.)

50.  Telephone conversation and letter from John Raggi, West Virginia APC to
     Michael Jasinski, GCA/Technology Division.  November 1981.  (Reliability
     No. 2.)

51.  Letter from Jim Dills,  Kentucky State to Michael Jasinski, GCA/Technology
     Division.  November 19, 1981.  (Reliability No. 1.)

                                   386

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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

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                                                                                    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.

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               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

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                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

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                               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

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             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

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         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

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                               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

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      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

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                               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

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       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

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   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

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                               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

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             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

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       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

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                              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

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 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

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                  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

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                              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

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                   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

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    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

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          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

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                              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

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     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

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       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

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     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

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  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

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        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

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      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

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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

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                              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

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                              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

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           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

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                              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

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         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

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     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

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                                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

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                               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

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                                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

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  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

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         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

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                              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

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                                                                                  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.

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                                   REFERENCES

                                  SINTER  PLANTS
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 2.   World Steel Industry Data Handbook:  Volume I.  The United States.
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                                  430

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11.  Southwestern Labs.  Sampling and Analysis of Particulate Emissions from
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24.  Letter response.  J. McGrogan, PADER—Reading, PA to Sandy Beaton,
     GCA/Technology Division.  November 1981.  (Reliability No. 1.)
                                  431

-------
38.  Bethlehem Steel Corporation, Sparrows Pt., Maryland, No. 7 Sinter Strand
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39.  Letter to Robert McCrillis, U.S. Environmental Protection Agency, from
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40.  Telephone conversation.  Mark Sylvester.  Maryland State Department of
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41.  Gronberg, S.  Pretest Survey of Bethlehem Steel Corporation/Sparrows
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43.  Egley, B. D., Selection of Gas Cleaning Equipment for an Ore Preparation
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44.  Electrostatic Precipitator Manual.  The Mcllvaine Company.  1977.
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45.  CF&I, Pueblo, Colorado, Air Pollution Emissions Test, June 1975.  U.S.
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50.  Report of Emissions Test for Inland Steel Company at the No. 3 Sinter
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                                 433

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51.  American Iron and Steel Institute.  Directory of  Iron and Steel Works of
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54.  Telephone conversation.  Bernard Bloom.  U.S. Environmental Protection
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56.  Region V files.  (J&L letter to EPA, 1976.)

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65.  EPA Region V files.  (June 1977 Permit  Application to Wayne County by
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                                 434

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66.  Loch, T. A. Air Pollution Test, Sinter Plant, Granite City Steel
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68.  EPA Region V files.  (Stack Test Report on NSC/G.C. Sinter Plant, 1981.)

69.  EPA Region V files.  (Memo from EPA V to Illinois EPA, 1979.)

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73.  Letter response from John Raggi, Regional Engineer in West Virginia to
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75.  Schiff, H. F.  RSC/Gadsden Plant:  Windbox Exhaust System Particulate
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76.  Telephone conversation.  Sue Robertson, State of Alabama Air Pollution
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77.  Telephone conversation.  Ted Davis, Ohio Northeast District Air Pollution
     Control to Gene Bergson, GCA/Technology Division.  February 27, 1981.
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78.  EPA Region V files.  (Permits—U.S. Youngstown.)
                                  435

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79.  EPA Region V files.  (NEIC Report dated January 1979. U.S./Youngstown
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80.  Telephone conversation.  Dennis Bush, NE District—Ohio Environmental
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81 .  Nunno, T. J.  Letter Report to EPA Region V regarding process
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82.  The Wet Scrubber Newsletter.  The Mcllvaine Co.  49:1,2.  July 31, 1978.
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84.  Kaufman, Peter W. and Virginia A. Barkus.  Particulate Emission Test, Wet
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85.  Kaufman, Peter W., and Virginia A. Barkus.  Particulate Emission Tests
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86.  Telephone conversation.  J. Solkorowski, City of Chicago Department of
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87.  Letter response.  Paul Pate, Director of Jefferson County Department of
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88.  Telephone conversation.  J. Carroll, Jefferson County Department of
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89.  PADER, Inc.  Stack Test Report on Sinter Plant at U.S. Steel Corporation,
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     Plant.  July 29-30, 1974.  JACA Library.  (Reliability No. 1.)
                                 436

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  92.   Telephone  conversation and  letter response.   Tom McGinley,  PADER—
       Morristown,  PA to  Sandy Beaton,  GCA/Technology Division.   November 1981.
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  93.   Stack Test Report  on  U.S. Steel  Corporation,  Fairless  Works Sinter
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   ^4.  Telephone  conversation.  Roland  Elrambuena,  City of Gary  Air Pollution
       Control  Division to Gene Bergson,  GCA/Technology Division.   March 4,
       1981.   (Reliability No.  2.)
V
   95.  EPA Region files.   (May 1979 Gary response to EPA interogatory.)

   96.  Gary Steel Works Experience with TT  Type  Dust Collectors  at No.  3 Sinter
       Plant.   Paper presented at  the Eastern States Blast Furnace and  Coke  Oven
       Association,  Pittsburgh, PA. February 4,  1977.   RACT  Box No.
       401427-401440.  (Reliability No.  2-3.)

   97.  Westbrook, C. W.   Level 1 Assessment of Uncontrolled Sinter Plant
       Emissions.   EPA-600/2-79-112.  U.S.  Environmental Protection Agency,
       Research Triangle  Park,  NC.  May 1979. pp.  7-10.   (Reliability  No. 3.)

   98.  Report of  Stack Test  at U.S. Steel,  Geneva Works Sinter  Plant.
       RTI/1371/13-035.   Septembers, 1978.  JACA Library.  (Reliability No.  1.)

   99.  Telephone  conversation.  Dave Kopta, Utah State  Division  of Environmental
       Health to  Michael  Jasinski, GCA/Technology Division.  November 1981.
       (Reliability No. 2.)

  100.  Impact of  Particulate Matter Emissions on Ambient Air  Quality U.S. Steel
       Corporation—Geneva Works.   Appendix II—Source  Identification.
       EPA-330/2-77-005b.  February 1977.   pp. 53,  56.   (Reliability No.  4.)

  101.  Ten Eyck,  P.  U.S. Steel Corporation Saxonburg Sintering  Operation Line
       No.  1.   Stack Tests by Apollo Chemical, Inc.   July 13, 1978 through
       August 2,  1978.  JACA Library.   (Reliability  No.  1.)

  102.  Letter from  J.  G.  Donelson, U.S.  Steel Corporation/Director—Research,  to
       S.  P.  Curtis, USS/V.P.  of Design and Construction, Re:  Gas sampling  and
       testing, Saxonburg Sintering Plant.  April 27,  1972.  JACA Library.
       (Reliability No. 1.)

  103.  Stack Test Report  on  U.S. Steel  Corporation/Saxonburg, PA Sinter Plant.
       Test No. 3376.  October  14, 1976.  JACA Library.   (Reliability No. 1.)

  104.  Letter response.   Arthur Witt, PADER—Pittsburg,  PA to Sandy Beaton,
       GCA/Technology  Division.  November 1981.   (Reliability No.  1.)

  105.  PADER, Inc.   Stack Test  Report on U.S. Steel  Corporation/Saxonburg, PA
       Plant.   Test  Nos.  2376 A and B.   August 3, 1976.   JACA Library.
       (Reliability No. 1.)

                                   437

-------
106. Stack Test Report at U.S. Steel Corporation/Saxonburg, PA Sinter Plant.
     PADER Test No. 3476.  October 15, 1976.  JACA Library.  (Reliability
     No. 1.)

107. Telephone conversation.  Ken Bowman, Pennsylvania Department of
     Environmental Resources to Michael Jasinski, GCA/Technology Division.
     February 18, 1981.  (Reliability No. 2.)

108. Electrostatic Precipitator Newsletter.  Mcllvaine, Inc.  July 20, 1981.
     (Reliability No. 3.)

109. Letter from B. J. Dunsmore, Director—Environmental Control for U.S.
     Steel Corporation to Nicholas Pazuchanics, Air Pollution Control Engineer
     for PADER.  Re:  USSC/Saxonburg Sintering Plant.  Letter dated September
     1971.  JACA Library.  (Reliability No. 1.)

110. Black, A. W.  Stack Emissions from ESP No. 1, USSC/Saxonburg, PA Sinter
     Plant.  Testing by Henen Associates.  March 28, 1979.  JACA Library.
     (Reliability No. 1.)

111. Stack Test Report at USSC/Saxonburg, PA Sinter Plant.  Test No. 171.
     January 21, 1971.  JACA Library.  (Reliability No. 1.)

112. Letter response.  Richard Thomas, PADER—Greensburg, PA to Sandy Beaton,
     GCA/Technology Division.  December 1981.  (Reliability No. 1.)

113. RACT Box No. 401141-401170.  (Reliability No. 1.)

114. Telephone conversation.  Tony Johnson, Pennsylvania Department of
     Environmental Conservation to Gene Bergson, GCA/Technology Division.
     February 26, 1981.  (Reliability No. 2.)

115. Bareford, P., et al.  Wheeling-Pittsburgh Steel Corporation Follansbee,
     West Virginia Sinter Plant, Particulate Emission Quantification.  GCA
     Draft Final Report No. TR-79-47-G.  Prepared for U.S. EPA.  September
     1979.  (Reliability No. 1.)
                                 438

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     MATERIAL IN THIS SECTION SUBJECT TO CONFIDENTIALITY                            H
    REVIEW AND IS NOT RELEASABLE AS OF FEBRUARY 1, 1982.                            w
   FOR INFORMATION, CONTACT L. KESARI, U.S. ENVIRONMENTAL                           ^
PROTECTION AGENCY, DIVISION OF STATIONARY SOURCE ENFORCEMENT.                       S
                                                                                    CO

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               TABLE  1.   ARMCO  INC./ASHLAND WORKS IN ASHLAND,  KY




           BLAST FURNACE—CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION :
STARTUP DATE:
RECENT REL1NE (REBUILD) DATE:
HEARTH DIAMETER (ft-in.):
WORKING VOLUME (ft3):
NO. OF TAPHOLES /FURNACE:
NO. OF CASTHOUSES/FURNACE:
IRON PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
CASTHOUSE EMISSION CONTROL SYSTEM:8
Amanda^
19631

33-51
72.0001
21


3.6002
3.5612

Bellefonte*
19421

28-9 *
52.4381
I1


2.0002
2.1882

ADDITIONAL COMMENTS:




aNo commitment to install controls as of February 1981.
                                    439

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              TABLE  2.  ARMCO  INC./HAMILTON  PLANT  IN  HAMILTON,  OH




           BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in.):
WORKING VOLUME (ft3):
NO. OF TAPHOLES/FURNACE:
NO. OF CASTHOUSES /FURNACE:
IRON PRODUCTION:
RATED TONS/DAY:
AVERAGE TONS/DAY (1976):
CASTHOUSE EMISSION CONTROL SYSTEM:3
No. 1 l
19282
19751
18-6 l
22',8391
I1
!4

1.1602
1.2202

No. 2 L
19282
19762
19-61
27.5151
I1
1*

1.4002
8172

ADDITIONAL COMMENTS:




aNo commitment to install controls as of February 1981.
                                      440

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                TABLE  3.   ARMCO  INC./HOUSTON WORKS  IN HOUSTON,  TX

           BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA


FURNACE DESIGNATION:                                    No. 1 l

STARTUP DATE:                                           19442

RECENT RELINE (REBUILD) DATE:                           19761

HEARTH DIAMETER (ft-in.):                               27-31

WORKING VOLUME (ft3):                                   52.3011

NO. OF TAPHOLES/FURNACE:                                I1

NO. OF CASTHOUSES/FURNACE:                              I5

IRON PRODUCTION:

  RATED TONS/DAY:                                       2.2002
  AVERAGE TONS/DAY (1976):                              1.6652

CASTHOUSE EMISSION CONTROL SYSTEM:3


ADDITIONAL COMMENTS:

aNo commitment to install controls as of February 1981.3
                                      441

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             TABLE  4.   ARMCO  INC./MIDDLETOWN  WORKS  IN  MIDDLETOWN,  OH

           BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA


FURNACE DESIGNATION:                   No. 31

STARTUP DATE:                          19532

RECENT RELINE (REBUILD) DATE:          19761

HEARTH DIAMETER (ft-in.):              29-61

WORKING VOLUME (ft3):                  55.3241

NO. OF TAPHOLES/FURNACE:               21

NO. OF CASTHOUSES/FURNACE:             24

IRON PRODUCTION:

  RATED TONS/DAY:                      4.7302
  AVERAGE TONS/DAY (1976):             3,5982

CASTHOUSE EMISSION CONTROL SYSTEM:3


ADDITIONAL COMMENTS:

aNo controls scheduled for installation; facility under "Bubble"
 regulation.^
                                      442

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        TABLE 5.   BETHLEHEM STEEL CORP./BETHLEHEM PLANT IN BETHLEHEM, PA

           BLAST FURNACE—CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
RECENT RELINE (REBUILD) DATE:
HEARTH DIAMETER (ft-in. ):
WORKING VOLUME (ft3):
NO. OF TAPHOLES/FURNACE:
NO. OF CASTHOUSES/FURNACE:
IRON PRODUCTION:
B1
19552
19732
30-0 l
54.4311
if
1?

ci
19432
19722
27-111
49.7481
17
17

Dl
19532
19752
30-0 !
54.8341
17
17

El
I9602
19762
24-0 1
41.2541
17
17

  RATED TONS/DAY:
  AVERAGE TONS/DAY (1976):

CASTHOUSE EMISSION CONTROL SYSTEM:
  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:
3.0002     2.6002     3.0002     2.0002
2,7902                2,4362     1.6962

Partial evacuation system via canopy hood
for each casthouse ducted to common
baghouse7

Mikropul8
19807
• System can control 2 of 4 casthouses
  simultaneously7 > 8
• Flow capacity = 660,000 acfm @ <150°F;
  flow per casthouse = 330,000 acfm7*8
• A/C = 4.9:1 (minimum for 1 casthouse);
  9.7:1 (maximum for 2 casthouses)7»8
• Felted polyester bags7>°
ADDITIONAL COMMENTS:
                                       443

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      TABLE 6.  BETHLEHEM STEEL CORP./BURNS HARBOR PLANT IN CHESTERTON, IN

           BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:                C1                   D1

STARTUP DATE:                       19722                19692

RECENT RELINE (REBUILD) DATE:

HEARTH DIAMETER (ft-in.):           38-31                35-01

WORKING VOLUME (ft3):               89,423;9 89.2041     86.646;10 85.75010

NO. OF TAPHOLES/FURNACE:            211                  211

NO. OF CASTHOUSES/FURNACE:                               210

IRON PRODUCTION:

  RATED TONS/DAY:                   5.5002               5.0002
  AVERAGE TONS/DAY  (1976):          4,9432               5,465;2 4,650
                                                         (1971 avg.)9

CASTHOUSE EMISSION CONTROL SYSTEM:3


ADDITIONAL COMMENTS:

aNo commitment to install controls as of February 1981.3
                                      444

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       TABLE 7.  BETHLEHEM STEEL CORP./LACKAWANNA PLANT IN LACKAWANNA, NY

           BLAST FURNACE—CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:8

STARTUP DATE:

RECENT RELINE (REBUILD) DATE:

HEARTH DIAMETER (ft-in.):

WORKING VOLUME (ft3):

NO. OF TAPHOLES/FURNACE:

NO. OF CASTHOUSES/FURNACE:

IRON PRODUCTION:

  RATED TONS/DAY:
  AVERAGE TONS/DAY (1976):
H1

190512

197912

29-01

51.009;1 51.88612
2.5002
2.2112
Jl

195312

197712

29-111

55.107;1 55.11212
2.7502
2,6572
CASTHOUSE EMISSION CONTROL SYSTEM:
                                  .b
ADDITIONAL COMMENTS:

aBlast furnace designation
               A
               B
               C
               F
               G
  Date shutdown

 prior to 1973 - (dismantled)
          1973
          1979
          1981
          1977
''Local hooding committed by State Order for  1982.
                                      445

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   TABLE 8.  BETHLEHEM STEEL CORP./SPARROWS POINT PLANT IN SPARROWS POINT, MD

           BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA


FURNACE DESIGNATION:3                 G1             H1             J1

STARTUP DATE:

RECENT RELINE (REBUILD) DATE:

HEARTH DIAMETER (ft-in.):           28-01          30-01          30-01

WORKING VOLUME (ft3):               47.1561'       54,792[        54.5051

NO. OF TAPHOLES/FURNACE:

NO. OF CASTHOUSES/FURNACE:

IRON PRODUCTION:

  RATED TONS/DAY:
  AVERAGE TONS/DAY (    ):

CASTHOUSE EMISSION CONTROL SYSTEM:b


                                   (continued)
                                      446

-------
                               TABLE 8 (continued)

           BLAST FURNACE--CASTHOUSE PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:3

STARTUP DATE:

RECENT RELINE (REBUILD) DATE:

HEARTH DIAMETER (ft-in.):

WORKING VOLUME (ft3):

NO. OF TAPHOLES/FURNACE:

NO. OF CASTHOUSES/FURNACE:

IRON PRODUCTION:

  RATED TONS/DAY:
  AVERAGE TONS/DAY (    ):

CASTHOUSE EMISSION CONTROL SYSTEM:

  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:
K1
30-01

54.6101
197813



44-6 L

130,3991

41

213



8.00013


Local hoods ducted to baghouse13

Wheelabrator-Frye13
19783
• Local hoods located on each
  taphole, iron pool, tilting
  iron runner, and slag spoon.'-3
  312,000 acfm @ 140°F13
  5 cell baghouse; one cell in
  cleaning mode*-3
  A/C = 2.5:1 (4 cells operating)13
  Shaker cleaning mechanism13
  Test Data (1981);7
  320,000 acfm <§ 184°F (avg.)
ADDITIONAL COMMENTS:

aBlast furnaces A,B,C,D,E, and F were shut down in 1979 by state
 order. "-1*13

^Partial casthouse evacuation control system for blast furnaces G,H,J, and K
 or shutdown committed for 1982 by state order.11
                                      447

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              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

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           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

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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

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            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

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    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

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   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

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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

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            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

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                   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

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           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

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   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

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      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

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                              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

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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

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     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

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        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

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     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

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         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

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     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

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       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

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    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

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   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

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           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

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 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

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         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

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  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

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      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

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       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

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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

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                              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

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                              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

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   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

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 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

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         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

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       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

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   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

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         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

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  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

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     MATERIAL IN THIS SECTION SUBJECT TO CONFIDENTIALITY

    REVIEW AND IS NOT RELEASABLE AS OF FEBRUARY 1,  1982.

   FOR INFORMATION, CONTACT L. KESARI, U.S. ENVIRONMENTAL

PROTECTION AGENCY, DIVISION OF STATIONARY SOURCE ENFORCEMENT.
                                                                                   >
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                                   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

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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

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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

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 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

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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

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     MATERIAL IN THIS SECTION SUBJECT TO CONFIDENTIALITY

    REVIEW AND IS NOT RELEASABLE AS OF FEBRUARY  1,  1982.

   FOR INFORMATION, CONTACT L. KESARI, U.S. ENVIRONMENTAL

PROTECTION AGENCY, DIVISION OF STATIONARY SOURCE ENFORCEMENT.
                                                                                   d)
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               TABLE 1.  ARMCO INC./ASHLAND WORKS IN ASHLAND, KY

           EXTERNAL DESULFURIZATION PROCESS AND EMISSION CONTROL DATA


STARTUP DATE:          ,                           19781

TYPE OF DESULFURIZATION PROCESS:                  Lance  injection3'3*4

TYPE OF DESULFURIZATION COMPOUND(S) USED:        Magnesium/lime mixture3*4

TYPE OF CARRIER GAS USED:                        Nitrogen2

NO. OF TORPEDO CARS DESULFURIZED AT ONCE:b       24;12

TYPE OF EMISSION CONTROL SYSTEM:                  Hood ducted to a baghouse2'4

  MANUFACTURER:
  DATE INSTALLED:                                19781
  SYSTEM DESCRIPTION:                             • Rated capacity = 40,000 acfm
                                                   @ uo^1
                                                 • A/C  (design) = 6:!1
                                                 • Test Data (1980);2
                                                   20,400-24,200 scfm @
                                                   101-154°F


ADDITIONAL COMMENTS:
                                                             •y
aDesnlfurization station contains 2 units designated A and B.

"Each torpedo car contains 200 tons of hot metal.4
                                 494

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            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

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             TABLE 3.  CF&I STEEL CORP./PUEBLO PLANT IN PUEBLO, CO

           EXTERNAL DESULFURIZATION PROCESS AND EMISSION CONTROL DATA


STARTUP DATE:                                    19817

TYPE OF DESULFURIZATION PROCESS:                 Lancing7

TYPE OF DESULFURIZATION COMPOUND(S) USED:

TYPE OF CARRIER GAS USED:

NO. OF TORPEDO CARS DESULFURIZKD AT ONCE:

TYPE OF EMISSION CONTROL SYSTEM:3                Baghouse7

  MANUFACTURER:
  DATE INSTALLED:                                19817
  SYSTEM DESCRIPTION:
ADDITIONAL COMMENTS:

aPrior to the baghouse installation, an unevacuated enclosure was used to
 contain emissions.8
                                  496

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     TABLE 4.  JONES &  LAUGHLIN  STEEL  CORP./ALIQUIPPA WORKS  IN  ALIQUIPPA,  PA

           EXTERNAL DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
STARTUP DATE:

TYPE OF DESULFURIZATION PROCESS:

TYPE OF DESULFURIZATION COMPOUND(S) USED:

TYPE OF CARRIER GAS USED:

NO. OF TORPEDO CARS DESULFURIZKD AT ONCE:

TYPE OF EMISSION CONTROL SYSTEM:

  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:
19759

Injection10

Magnesium carbide1
Baghouse13'10*11

Buell. Inc.10'11
• 100,000 acfm (rated)11
• A/C • 3:1 (design)11
• 7 compartments; 120 bags
  per compartment11
ADDITIONAL COMMENTS:

aStation can handle 8,000-9,000 tons/day of hot metal.9

^house replaced Dueon scrubber, originally used, in 1981.
                                  497

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     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

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                      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

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   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

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         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

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                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

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     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

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          TABLE 11.  UNITED STATES STEEL CORP./NATIONAL-DUQUESNE WORKS
                     IN DUQUESNE, PA

           EXTERNAL DESULFURIZATION PROCESS AND EMISSION CONTROL DATA
STARTUI' DATE:

TYPE OI-" DESULFURIZATION PROCESS:

TYPE OP DESULFURIZATION COMPOUND(S) USED:

TYPE OK CARRIER GAS USED:

NO. OF TORPEDO CARS DESULFURIZED AT ONCE:

TYPE OF EMISSION CONTROL SYSTEM:

  MANUFACTURER:
  DATE INSTALLED:
  SYSTiiM DESCRIPTION:
19809

ATH3

Calcium carbide3

Nitrogen2^



Baghouse^l


198021
• 4 compartments2^
• Flow rate = 40,000 cfm21
ADDITIONAL COMMENTS:
                                   504

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     MATERIAL IN THIS SECTION SUBJECT TO CONFIDENTIALITY

    REVIEW AND IS NOT RELEASABLE AS OF FEBRUARY  1,  1982.

   FOR INFORMATION, CONTACT L. KESARI, U.S. ENVIRONMENTAL

PROTECTION AGENCY, DIVISION OF STATIONARY  SOURCE ENFORCEMENT.

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                                   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

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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

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                                                                                   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.

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               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

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            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

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                               TABLE 2 (continued)


           BASIC  OXYGEN  FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
  SYSTIM DESCRIPTION:                  » Rated at 95,000 acfm at 275°F
                                       • A/C = 2.6:!11
                                       • Ap = 4-6 in H201:1
ADDITIONAL COMMENTS:


aMembrane tube hood with double walled water cooling; gas cooling by water
 quenehing.2>8


^Tests were performed for 6 consecutive heats from end of charging to
 beginning of tap.**


cTests were performed during two oxygen blow periods.^


dHMT area was controlled by AAF multiclones from 1969 to 1975.8>1]-
                                      509

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         TABLE  3.   BETHLEHEM  STEEL CORP./BETHLEHEM PLANT IN BETHLEHEM,  PA

           BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:

STARTUP DATE:

TYPE OF BLOWING MECHANISM:

TYPE OF COMBUSTION HOOD:a»b

STEEL PRODUCTION:

  RATED TONS/DAY:
  AVERAGE TONS/DAY (    ):

PRIMARY EMISSION CONTROL SYSTEM:

  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:
No. 7012

19681

Top2

Full2
No. 8012

19681

Top2

Full2
SECONDARY EMISSION CONTROL SYSTEM:
Common dry ESP serves both furnaces2 »

Research Cottrell12
197014
• Exhaust from each furnace to common
  header, ESP, outlet header, 3 I.D.
  fans, and one outlet stack-*-2
• Six section ESP with four cells per
  section*2
• 750,000 acfm at 420°F (design flow
  during 02 blow)^
• Test Data (1977);d»]-2
  Avg. inlet—850,000 acfm at 400°F
   (02 blow)
   650,000 acfm at 175°F (charging and
   tapping)
  Avg. outlet—900,000 acfm at 260°F
   (02 blow)
   840,000 acfm at 175°F (charging and
   tapping)
• Test Data (1976);c>12
  442,400 dscfm (avg.); temperature -
  207°F (avg.)
• Test Data (1972);15
  493,500 dscfm at 200°F (avg.)

Permanent enclosures and awning on
tapside of each furnace-emissions
serviced by primary
                                   (continued)
                                       510

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                               TABLE 3 (continued)

           BASIC OXYGEN FURNACE SHOP PROCESS AND EMISSION CONTROL DATA
  MANUFACTURER:
  DATK INSTALLED:                      197612
  SYSTEM DESCRIPTION:                  • Evacuation rate during hot metal
                                         charging, turndowns, tapping,
                                         slagging, etc. = 500,000 acfm at
                                         180°F13
ADDITIONAL COMMENTS:

aFinned tube hood with steam generation cooling.2

^Gas cooling by water sprays.2

cBoth furnaces operating; testing only during 02 blow periods.12

dFan dampers set at 40 to 48 percent during normal full exhaust flow rate.12
                                      511

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      TABLE 4.  BETHLEHEM STEEL CORP./BURNS HARBOR PLANT IN CHESTERTON, IN

           BASIC  OXYGEN FURNACE  SHOP  PROCESS  AND  EMISSION  CONTROL  DATA


FURNACE DESIGNATION:

STARTIP DATE:

TYPE OF BLOWING MECHANISM:8

TYPE OF COMBUSTION HOOD:b

STEEL PRODUCTION:

  RATED TONS/DAY:
  AVEFAGE TONS/DAY (1976):

PRIMARY EMISSION CONTROL SYSTEM:
No. I1
196916
Top2
Full2
No. 21
196916
Top2
Full2
  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:
12,050 (all three furnaces combined)?
10,520 (all three furnaces combined)?

Variable throat venturi scrubbers serve
both furnaces1^1**

Cheraico10
196910
• Three scrubbers in parallel with
  individual stacks1'
• 2,570,000 acfm at 180°F (design)10
• Three I.D. fans rated at 1500-hp18
• 5,700 gpm (water flow design)10
• L/G =2.2 gpm/1,000 acfm
  (calculated)10
• Test Data (1974);15
  Ap - 55 in. H20
SECONDARY EMISSION CONTROL SYSTEM:
                                   (continued)
                                       512

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                              TABLE  4  (continued)

           BASIC  OXYGEN FURNACE  SHOP  PROCESS  AND EMISSION CONTROL  DATA
FURNACE DESIGNATION:

STARTUP DATE:

TYPE OF BLOWING MECHANISM:

TYPE OF COMBUSTION HOOD:

STEEL PRODUCTION:

  RATED TONS/DAY:
  AVEFAGE TONS/DAY (    ):

PRIMARY EMISSION CONTROL SYSTEM:
                                       No.  31

                                       19782

                                       Top2

                                       Partial2



                                       See previous page'
  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:
                                       High-energy variable throat venturi
                                       scrubber1' >^

                                       Chemico10
                                       197810
                                       • 280,000 acfm at 165°F (design)10
                                       • One I.D. fan rated at 7,000-hp1^>20
                                       • 2,800 gpm (water flow design)10
                                       • L/G = 10 gpm/1,000 acfm (design-
                                         calculated)10

SECONDARY EMISSION CONTROL SYSTEMS    Hot metal transfer area to baghouse18
  MANUFACTURER:
  DATE INSTALLED:
  SYST1M DESCRIPTION:
                                       • 100,000 cfm18
                                       • Test Data (1978);17
                                         Avg. flow = 139,400 dscfm
                                         Avg. temp. = 138°F
ADDITIONAL COMMENTS:

aCan only blow one vessel at a time.1'

^Tube hood with steam generation cooling; gas cooling by water quenching.2

cSecondary emissions controlled by hood located inside furnace enclosure
 drafted to primary scrubber.17'1'
                                      513

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       TAIVLIi 5.  BETHLEHEM STEEL CORP./LACK AW ANNA PLANT IN LACKAWANNA, NY

           BASIC  OXYGEN  FURNACE  SHOP  PROCESS  AND EMISSION  CONTROL DATA


FURNACE DESIGNATION:

STARTUP DATE:

TYPE OF BLOWING MECHANISM:

TYPE OF COMBUSTION HOOD:3

STEEL PRODUCTION:
No. 1621
196422,23
Top2
Full2
No. 17 21
196422, 23
Top2
Full2
No. 1821
196622.23
Top2
Full2
  RATED TONS/DAY:
  AVERAGE TONS/DAY (1976):
                                    14,400 (all three furnaces combined)'
                                     9,397 (all three furnaces combined)7
PRIMARY EMISSION CONTROL SYSTEM:    Separate, identical scrubbers per furnace23
  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:
                                    Buell (all three scrubbers)10
                                    196423        196423          196623
                                    • Separate, identical scrubber units;
                                      common manifold — single exhaust stack21
                                    • Each unit contains 384 multi-venturi
                                      tubes, assembled side by side (spray
                                      nozzles located above tubes)23
                                    • Design Ap = 50 in. ^0
                                    • Entire system requires three I.D. fans;
                                      each rated at 327,000 cfra (fourth fan on
                                      standby)23
                                    • Each fan normally operates at 980-1,100
SECONDARY EMISSION CONTROL SYSTEM: b
                                    • Approx. inlet gas flow rate — 650,000 scfm
                                      at 215 °F (during oxygen blow)23

                                    Hot metal transfer area ducted to
                                    baghouse.24
  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:
                                    Pangborn24
                                    196924
                                    • Design flow rate
                                    • Exit temperature
                                    • Ap - 6 in. H2024
100,000 scfm24
90°F24
ADDITIONAL COMMENTS:

aPlate and tube hood with steam condensed cooling; gas cooling by water
 sprays.2
^Tapside onclosures installed on each furnace to control tapping emissions.
                                      514

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   TABLE 6.  BETHLEHEM STEEL CORP./SPARROWS POINT PLANT IN SPARROWS POINT, MD

           BASIC OXYGEN FURNACE  SHOP PROCESS  AND  EMISSION  CONTROL  DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:a»b
STEEL PRODUCTION:
No. 125
19661
Top2
Full2

No. 2"
19661
Top2
Full2

  RATED TONS/DAY:
  AVERAGE TONS/DAY (1976):
PRIMARY EMISSION CONTROL SYSTEM:
  MANUFACTURER:
  DATE INSTALLED:

  SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
9,167 (both furnaces combined)'
8,903;' 15,457—avg. In 197425
  .  (both furnaces combined)

Four venturi scrubbers serve both
furnaces.25,26

Chemico (all four scrubbers)2**
Original 3 scrubbers—1966;25
 4th scrubber—1975C»25
• All scrubbers arranged in, parallel2^
• Design Data (3 original
  scrubbers);iy»"
  81,069 dscfm per scrubber; 700,000
   acfm (design-total)
  Water flow - 7,000 gpm
  Ap = 50 in. W.G.
  L/G - 10 (based on design)
• Design Data (4th scrubber);2^
  150,000 acfm at 150°F
  Water flow - 1,400 gpm
  Ap = 50 in. H20
  L/G =9.3 (based on design)

Baghouse for hot metal transfer
                                   (continued)
                                  515

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                               TABLE  6  (continued)
           BASIC  OXYGEN  FURNACE  SHOP  PROCESS  AND EMISSION CONTROL DATA
  MANUFACTURER:                        Buell26
  DATE INSTALLED:                      198126
  SYSTEM DESCRIPTION:                  • Exhaust flow - 100,000 acfm at 170°F
                                         (rated)26
ADDITIONAL COMMENTS:

Membrane tube hood with steam generation cooling; gas cooling by water
 sprays2

bwaste heat boilers, quenchers, isolation dampers, and emergency stacks
 follow each combustion hood.2^

cFourth scrubber installed to increase hood draft and thereby collect
 charging and tapping emissions."

       baghouse replaced original Carborundum baghouse installed in 1971.26
                                  516

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             TABLE  7.   CF&I  STEEL  CORP./PUEBLO  PLANT  IN  PUEBLO,  CO

          BASIC OXYGEN  FURNACE  SHOP  PROCESS  AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
TYPE OF BLOWING MECHANISM:
TYPE OF COMBUSTION HOOD:a
North1
19611
Top2
Full2
South1
19611
Top2
Full2
STEEL PRODUCTION:

  RATED TONS/DAY:
  AVERAGE TONS/DAY (    ):

PRIMARY EMISSION CONTROL SYSTEM:

  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:b
  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:
Common ESP serves both furnaces27*28

United McGill27
1961 ;27 (Refurbished—1978)29
• ESP contains four units with a design
  flow rate - 300,000 acfm at 350°F29
• Test Data (1978);15
  Inlet—90,600-104,000 dscfm (range)
       —458-515°F (range)
  Outlet—151,000-169,000 dscfm (range)
        —207-289°F (range)

Three-sided evacuated enclosure per
furnace, six roof canopy hoods, and hot
metal transfer station ducted to common
baghouse.29»30

Wheelabrator-Frye29
197828
• Total system flow rate
  acfm29
                           540,000

• Baghouse contains five compartments
  with 600 Nomex bags per compartment
• Positive pressure; requires three
  fans28,30
• Test Data (1975);31
  Inlet—606,000 acfm at 80°F (avg.)
                                                                            29
ADDITIONAL COMMENTS:

aPaneled plate hoods with gas cooling by water sprays.2

bThe damper located on the reladling station opens only when hot metal is
 transferred.28
                                   517

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           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

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                               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

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       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

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                               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

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       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

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            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

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    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

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           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

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               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

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    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

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    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

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     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

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         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

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        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

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     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

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                              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

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       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

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     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

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          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

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       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

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         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

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       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

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     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

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                              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

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           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

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          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

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    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

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   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

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         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

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     MATERIAL IN THIS SECTION SUBJECT TO CONFIDENTIALITY                           >

    REVIEW AND IS NOT RELEASABLE AS OF FEBRUARY  1,  1982.                           £ ^

   FOR INFORMATION, CONTACT L. KESARI, U.S. ENVIRONMENTAL                          o "

PROTECTION AGENCY, DIVISION OF STATIONARY SOURCE ENFORCEMENT.                      ^ "

                                                                                   o w
                                                                                   W 21
                                                                                   S3 C~3
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                                                                                   i

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                                   REFERENCES

                             BASIC  OXYGEN CONVERTERS
1.   World Steel Industry Data Handbook:  Volume I.  The United States.
     McGraw-Hill Magazine.  1978.  (Reliability No. 4.)

2.   Caine, K. E., Jr.  Development of Technology For Controlling BOP Charging
     Emissions.  EPA-600/2-77-218.  October 1977.  (Reliability No. 3.)

3.   Letter response.  James Dills, Commonwealth of Kentucky Department of
     Natural Resources and Environmental Protection to Michael Jasinski,
     GCA/Technology Division.  November 19, 1981.  (Reliability No. 1.)

4.   Letter to Barry Gilbert, Air Programs Branch of U.S. Environmental
     Protection Agency, Atlanta, Georgia from John E. Barker, Director of
     Environmental Engineering, ARMCO, Middletown, Ohio.  December 12, 1979.
     (Reliability No. 1.)

5.   Bergson, Eu.gene, et al.  Assessment of Air Emissions from Steel Plant
     Operations-ARMCO Steel, Ashland, Kentucky.  GCA/Technology Division Draft
     Final Report No. TR-81-95-G.  Prepared for U.S. Environmental Protection
     Agency.  September 1981.  (Reliability No. 1.)

6.   Cowherd, C., Jr.  Source Testing—EPA Task No. 2, ARMCO Steel
     Corporation, Middletown, Ohio, BOF Shop.  RACT #202185-202275.
     (Reliability No. 1.)

7.   Development Document for Proposed Effluent Limitations Guidelines and
     Standards for the Iron and Steel Manufacturing Point Source Category,
     Vol. IV.  Draft Report.  EPA-440/l-79-024a.  October 1979.  pp. 15-17.
     (Reliability No. 4.)

8.   Kashay, A. M.  ARMCO's Middletown Works - A Blend of In-House Knowledge
     and Supplier Competence.  Iron & Steel Engineer.  September 1974.  p.
     M-47.  (Reliability No. 4.)

9.   Determination of BOF and Kish Collector Emissions at ARMCO Steel
     Corporation, Middletown, Ohio.  Roy F. Weston, Environmental Scientists
     and Engineers.  November 14, 1969.  RACT Box #202611-202636.
     (Reliability No. 1.).
                                   558

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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

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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

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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

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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

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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

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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

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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

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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

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123. Stack Emission Tests Results-No. 2 Q-BOP, Gary Works.  Report No.
     18-E-005(003).  RACT No. 201929-201950.  (Reliability No. 1.)

.124. EPA Test Number 72-MM-02, Basic Oxygen Furnace, USSC, Lorain, Ohio.
     Engineering Science, Inc.  June 27, 1972.  RACT No. 201281-201360.
     (Reliability No. 1.)

125. U.S. Steel Corp./Lorain, Ohio BOF Tests.  Engineering Science Inc.
     December 21, 1971 publication.  RACT No. 201361-201436.  (Reliability
     No. 1.)

126. Process Description of Wheeling-Pittsburgh Steel Corporation, Monessan,
     Pennsylvania.  RACT No. 202637-202640.  (Reliability No. 1.)

127. Telephone conversation.  Tony Johnson, Pennsylvania Department of
     Environmental Resources to Gene Bergson, GCA/Technology Division.
     February 26, 1981.  (Reliability No. 2.)

128. Letter in EPA Region V files.

129. Telephone conversation.  Harold Strohmeyer, North Ohio Air Quality
     Authority to Sandy Beaton, GCA/Technology Division.  November 1981.
     (Reliability No. 2.)

130. EPA Region V files.  (Stack Test Report by Clean Air Engineering, Inc.)

131. EPA Region V files.  (Reladling Baghouse Blueprints.)
                                  567

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     MATERIAL IN THIS SECTION SUBJECT TO CONFIDENTIALITY
    REVIEW AND IS NOT RELEASABLE AS OF FEBRUARY 1, 1982.
   FOR INFORMATION, CONTACT L. KESARI, U.S. ENVIRONMENTAL
PROTECTION AGENCY, DIVISION OF STATIONARY SOURCE ENFORCEMENT.
                                                                                     w
                                                                                     t-1
                                                                                   > M
                                                                                   O O
                                                                                   M
                                                                                     n

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              TABLE  1.   ARMCO  INC./BALTIMORE WORKS  IN BALTIMORE,  MD

               ELECTRIC  ARC  SHOP  PROCESS  AND EMISSION CONTROL DATA
FURNACE DESIGNATIONS

STARTUP DATE:

SHELL DIAMETER (ft-in.):

STEEL PRODUCTION:

  RATED TONS/DAY:
  AVERAGE TONS/DAY (    ):

TYPE(S) OF STEEL PRODUCED:

PRIMARY EMISSION CONTROL SYSTEM:
  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:
SECONDARY EMISSION CONTROL SYSTEM:
No. 3b>!

19371

1A-31
»A"c,2

I9602
Stainless and super alloyl

Direct shell evacuation per furnace,
ducted to common baghouse2»3

Fuller2
19682
• 292,000 acfm at 270°F (rated)2
• A/C - 2.54:1 (design)2
• Positive pressure^
• Baghouse also controls AOD vessel via
  local hood capture system-*

Canopy hood above "A" furnace, ducted to
primary control system baghouse2 (see
above system description)
ADDITIONAL COMMENTS:

aShop presently operates "A" furnace only; furnace No. 3 used as back-up.

^Furnace No. 3 to be shut down in December 1981.2

C"A" furnace replaced furnace Nos. 5 and 6 in December I960.2
                                    568

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                 TABLE  2.   ARMCO  INC./BUTLER WORKS  IN BUTLER,  PA

               ELECTRIC ARC SHOP  PROCESS  AND EMISSION CONTROL  DATA
FURNACE DESIGNATION:

STARTUP DATE:

SHELL DIAMETER (ft-ln.):

STEEL PRODUCTION:

  RATED TONS/DAY:
  AVERAGE TONS/DAY (1976):

TYPE(S) OF STEEL PRODUCED:

PRIMARY EMISSION CONTROL SYSTEM:
  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:
No. 2*
19691
22-01
No. 31
19691
22-Ql
No. 41
1969^
22-01
SECONDARY EMISSION CONTROL SYSTEM:
  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:
2,500 (all three furnaces combined)^
2,502 (all three furnaces combined)^

  Carbon, alloy, stainless^^

Direct shell evacuation per furnace,
ducted to individual scrubbers6

Pease-Anthony (all three scrubbers)7
1969 (all three scrubbers)7
• Each scrubber system similar, unless
  noted;
  Scrubber design » 30,000 dscfm at Ap=
   50 in. H20 (Nos. 2 and 3)7
  Fan rated capacity • 112,000 cfm;
   1750-hp motor6
• Test Data (1972);8
  No. 2 furnace:  54,140 dscfm
                  Ap = 48 in. H20
                  Water flow - 970 gpm
  No. 4 furnace:  53,183 dscfm
                  Ap - 45 in. H£0
                  Water flow •» 970 gpm

Hot metal transfer area, charging and
tapping control by canopy hood over each
furnace, ducted to common baghouse7'^

Wheelabrator-Frye7»'
19757
• Design flow rate = 350,000 acfm at
  275°F7»9
• 8 compartments; total of 1536 woven
  Dacron bags^
• A/C varies with each furnace—No. 2 =
  2.53:1: No. 3 - 2.89:1; No. 4 -
  3.05:1*
• Reverse air cleaning'
ADDITIONAL COMMENTS:
                                     569

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                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

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                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

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            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

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                               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

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            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

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                 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

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           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

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               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

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          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

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       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

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      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

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          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

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        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

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             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

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       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

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                              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

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       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

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           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

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       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

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           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

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   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

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       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

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                              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

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                 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

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           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

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    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

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     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

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     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

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         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

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           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

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         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

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         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

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         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

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                              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

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                              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

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     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

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     MATERIAL IN THIS SECTION SUBJECT TO CONFIDENTIALITY

    REVIEW AND IS NOT RELEASABLE AS OF FEBRUARY  1,  1982.

   FOR INFORMATION, CONTACT L. KESARI, U.S. ENVIRONMENTAL

PROTECTION AGENCY, DIVISION OF STATIONARY SOURCE ENFORCEMENT.
                                                                                   w
                                                                                   t-1
                                                                                   w
                                                                                   > M
                                                                                   7* 7*
                                                                                   n w
                                                                                     53
                                                                                   ^ o
                                                                                   w
                                                                                   en

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                                   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

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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

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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

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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

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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

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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

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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

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                                                                                  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.

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             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

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              TABLE 2.  BETHLEHEM STEEL CORP./SPARROWS POINT PLANT
                        IN SPARROWS POINT, MD

            NO. 4 OPEN HEARTH SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:
STARTUP DATE:
STEEL PRODUCTION:
  RATED TONS/DAY:
  AVERAGE TONS/DAY  (1976):
TYPE OF EMISSION CONTROL SYSTEM:
  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:
   Nos.  90 through 961

   4 furnaces in 1957; 3 furnaces in 1958-*
   10,822 (all 7 furnaces combined)^
   6,304 (all 7 furnaces combined)-*
   6 dry ESPs (designated C, D, E, F, G, H)
   2 venturi scrubbers (designated A and B)
   serve all 7 furnaces'
                    and
   Koppers (ESPs)8
        19617
Chemico (scrubbers)7
         19727
    • Common manifold connects
    • Each ESP discharges to an
      common stack'
    • ESP Design Data:7
      - 57,200. dscfm per ESP
      - Inlet temp = 503°F
      - Outlet temp = 467°F
     . - 34,700 sq ft collection
        area per ESP
      - 50 sparks/min (rated)
    • Test Data (1976):a»9
scrubbers and ESPs which operate in parallel'
 individual stack; scrubbers discharge to a

           • Scrubber Design Data;7
             - 99,300 dscfm per scrubber
             - Inlet temp = 503°F
             - Outlet temp = 141°F
             - Ap = 55 in. W.C. per scrubber
- Scrubbers "A" and "B": 192,206 dscfm (avg.),
- ESP "C"
- ESP "D"
- ESP "E"
- ESP "F"
- ESP "G"
- ESP "H"
52,640 dscfm (avg.), 428°F (avg.)
56,1.65 dscfm (avg.), 434°F (avg.)
58,618 dscfm (avg.), 449°F (avg.)
62,988 dscfm (avg.), 434°F (avg.)
59,782 dscfm (avg.), 446°F (avg.)
64,300 dscfm (avg.), 410°F (avg.)
• Control System Operating Data (1976) :a>y
- Scrubber A: Ap = 54-57 in. H20; water flow =
- Scrubber B: Ap = 54-55 in. H20; water flow =
143°F (avg.)







930-1,200 gpm
1,070-1,140 gpm
                                   (continued)
                                       616

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                              TABLE 2 (continued)

            NO. A OPEN HEARTH SHOP PROCESS AND EMISSION CONTROL DATA


SECONDARY EMISSION CONTROL SYSTEM:     Hot metal transfer area to baghouse7*10

  MANUFACTURER:                        Buell10
  DATE INSTALLED:                      1975;8 197710
  SYSTEM DESCRIPTION:                  • Conventional hood system with a
                                         spark box'
                                       • 150,000 scfm and 200°F (design)7.10
                                       • Positive pressure design'


ADDITIONAL COMMENTS:

aSix of seven furnaces operating during 1976 testing; i.e., Nos. 90, 91, 92,
 93, 95, and 96.9
                                      617

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        TABLE  3.   INLAND STEEL  CO./INDIANA HARBOR WORKS  IN E.  CHICAGO,  IN

            NO. 3 OPEN HKARTH SHOP PROCESS AND EMISSION CONTROL DATA


FURNACE DESIGNATION:a»b           Nos. 1 through 71

STARTUP DATE:                      Nos. 1 through 4 in 1951t1
                                  Nos. 5 through 7 in 19531

STEEL PRODUCTION:0

  RATED TONS/DAY:                 8,136 (all 7 furnaces combined)11
  AVERAGE TONS/DAY:

TYPE OF EMISSION CONTROL SYSTEM:  All 7 furnaces manifold to common, dry
                                  ESPsl,13

  MANUFACTURER:                   Western Precipitator14
  DATE INSTALLED:                 196815
  SYSTEM DESCRIPTION:d

    • Five ESPs each divided into two chambers; system designed for 9 out of 10
      to be in use14
    • Five I.D. fans rated at 400,000 cfm each14
    • 1.6 x 10& acfm (avg.)13
    • 130 flat collection plates spaced 10 in. apart13
    • Surface area - 490,000 sq ft (total)13
    • 304 ft2/I,000 acfm13
    • Test Data (1981);16
      5-furnace operation, exhaust flow rate = 1,288,000 acfm at 419°F
    • Test Data (1974);13
      Flow rate - 1,590,000-1,630,000 (range)
      Temperature » 435-460°F (range)


ADDITIONAL COMMENTS:

aReversing recuperator,  overfired type furnaces*1

bsix furnaces operate at any one time.12

C1977 yearly production (total shop) = 1,910,000 tons.12

^Manifold collects gases from all seven furnaces to 18 x 20 x 32 ft mixing
 chamber which provides a homogeneous mixture of particulate at ESP inlet;
 ten 8 x 7 ft rectangular ducts carry gases to the ESP.13
                                      618

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                 TABLE 4.  LONE STAR STEEL CO. IN LONE STAR, TX

               OPEN HEARTH SHOP PROCESS AND EMISSION CONTROL DATA
FURNACE DESIGNATION:a'b           No. I1   No. 21   No. 31   No. 41   No. 51

STARTUP DATE:                     4 units in 1953; 5th unit added in 195617

STEEL PRODUCTION:

  RATED TONS/DAY:                 3,835 (all 5 furnaces combined)3
  AVERAGE TONS/DAY (I'i76):        3,048 (all 5 furnaces combined)3

TYPE OF EMISSION CONTROL SYSTEM:  3 steam-hydro scrubber units in parallel
                                  serve all 5 furnaces18
  MANUFACTURER:                   Hydro-Sonics/Lone Star18
  DATE INSTALLED:
  SYSTEM DESCRIPTION:
DATE INSTALLED:                 197218
    • Common manifold from all furnaces to 3 waste-heat boilers18
    • Design flow rate = 105,000-160,000 acfm (total)18
    • Gas temp (inlet) = 1,200-1,700°F18
    • Each steam-hydro unit consists of steam nozzle-water injector which
      induces flow (no fan needed)18
ADDITIONAL COMMENTS:

aMaximum of 4 furnaces operate at any one time.18

^Natural gas and oil used as fuel; gas/oil ratio = 80/20 during
 meltdown and 50/50 during refining.17
                                       619

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    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

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      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

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          TABLE  7.   UNITED STATES  STEEL CORP./GENEVA WORKS IN PROVO,  UT

               OPEN HEARTH SHOP PROCESS AND EMISSION CONTROL DATA


FURNACE DESIGNATION:8             Nos. 90 through 991

STARTUP DATK:                     1944 (all 10 furnaces)3

STEEL PRODUCTION:

  RATED TONS/DAY:                 6,550;3 6,85027 (all 10 furnaces combined)
  AVERAGE TONS/DAY  (1976):        5,867 (all,10 furnaces combined)3

TYPE OF EMISSION CONTROL SYSTEM:  8 ESP-scrubber units serve all 10  furnaces27

  MANUFACTURER:                   ESPs, Research Cottrell;27
                                  Scrubbers, U.S. Steel27
  DATE INSTALLED:b"e              ESPs, 1955;27 Scrubbers,  196227
  SYSTEM DESCRIPTION:             • Each unit contains an ESP and scrubber  in
                                    series; all 8 units operate in parallel27>2°
                                  • Design flow rate per unit = 66,400 dscfra2°
                                  • ESP Specifications;27
                                    - Plate-type, each with  three fields
                                      and two sections per  field
                                    - Collection area per unit:
                                        Field 1 = 6,043.5 sq ft
                                        Field 2 = 6,043.5 sq ft
                                        Field 3 = 12,087 sq  ft
                                    - SCA per unit  = 180 sq  ft/1,000 acfm
                                  • Scrubber Specifications;27
                                    - Partial-orifice type wet scrubbers
                                    - Ap = 4 in. W.C. (per unit)
                                    - Scrubber water = 650 gpm (per  unit)
                                    - L/G = 5.9:1 (per unit)


ADDITIONAL COMMENTS:

aFour furnaces operate at  any one time  (1981).29

bAll ESPs upgraded  in 1968 to increase voltage.2**

cEach ESP unit was  modified  in  1972 by  increasing the number of transformer-
 rectifier sets  from two  to  three.27
     scrubbers were modified  in  1972 by relocating  the  internal  sprays.27

eFour of eight ESP-scrubber units were upgraded  in  1981.29
                                      622

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                                                                                      w
                                                                                    K-j CO
     MATERIAL IN THIS SECTION SUBJECT TO CONFIDENTIALITY

    REVIEW AND IS NOT RELEASABLE AS OF FEBRUARY 1,  1982.

   FOR INFORMATION, CONTACT L. KESARI, U.S. ENVIRONMENTAL

PROTECTION AGENCY, DIVISION OF STATIONARY SOURCE ENFORCEMENT.

-------
                                   REFERENCES

                                OPEN HEARTH SHOP
 1.  World Steel Industry Data Handbook:  Volume No. 1.  The United States.
     McGraw-Hill Magazine.  1978.  (Reliability No. 4.)

 2.  Data collected by GCA from EPA Region V files.  (Renewal Permit
     Applications No. 1809010006P028-33, dated September 1976.)

 3.  Development Document for Proposed Effluent Limitations Guidelines and
     Standards for the Iron and Steel Manufacturing Point Source Category.
     Draft Report.  Vol.  IV.  EPA 440/l-79-024a.  October 1979.  pp. 275.
     (Reliability No. 4.)

 4.  Metallurgical Applications.   JAPCA.  27(11):  1072-1074.  November 1977.
     (Reliability No. 4.)

 5.  Telephone conversation.  Ed  Luebering, SW District-Ohio EPA to Gene
     Bergson, GCA/Technology Division.  March 9, 1981.  (Reliability No. 2.)

 6.  Telephone conversation.  Steve Samorgin, SW District-Ohio Environmental
     Protection Agency to Sandy Beaton, GCA/Technology Division.  October
    . 1981.  (Reliability No. 2.)

 7.  Correspondence to Robert McCrillis, U.S. EPA, Research Triangle Park, NC
     from Peter Spawn, GCA/Technology Division.  May 5, 1980.  (Reliability
     No. 3.)

 8.  Telephone conversation.  Mark Sylvester, Maryland State Department of
     Health and Mental Hygiene to Michael Jasinski, GCA/Technology Division.
     February 13, 1981.  (Reliability No. 2.)

 9.  Stack Test Report No. 76-19.  Bethlehem Steel Corp./Sparrows Point,
     Maryland.  No. 4 Open Hearth Shop.  Testing by Maryland Department of
     Health and Mental Hygiene.  July 1976.  (Reliability No. 1.)

10.  Telephone conversation.  Ralph Hall, State of Maryland to M. Jasinski,
     GCA/Technology Division.  October 29, 1981.  (Reliability No. 2.)

11.  Telephone conversation.  Phil Pekron, U.S. EPA Region V to S. Beaton,
     GCA/Technology Division.  October 1981.  (Reliability No. 2.)
                                   623

-------
12.  Spawn, P.  Collection of Samples for Radioassay at Integrated Steel
     Mills.  CCA/Technology Division.  Draft Final Report No. TR-80-7-G.
     February 1980.  (Reliability No. 2.)

13.  Jacko, R. B., et al.  Fractional Collection Efficiency of Electrostatic
     Precipitation for Open Hearth Furnace Metal Emissions.  Environmental
     Science and Technology.  10(10):  1002-1005.  October 1976.

14.  Stewart, J. Jr.  Centralized Control Guides Efficient Operation of Inland
     Precipitators.  Iron and Steel Engineer.  February 1971.  (Reliability
     No. A.)

15.  Air, Water, and Inland Steel.  Environmental Quality Control at Inland
     Steel Company's/Indiana Harbor Works.  2nd Edition.  Inland Steel
     Publication,  pp. 28.  (Reliability No. 4.)

16.  Data collected by GCA from EPA Region V files.  (Inland Steel Open Hearth
     Shop Stack Tests in July 1981.)

17.  Steel in Texas.  Iron and Steel Engineer.  48(4):  T-14 through T-21.
     April 1971.  (Reliability No. 3.)

18.  Blair, T. R. and W. L. Martin.  Air Pollution Control System at Lone Star
     Steel's Open Hearth Shop.  Iron and Steel Engineer, April 1976.  pp.
     83-88.  (Reliability No. 4.)

19.  Telephone conversation.  Tom McGinley, PADER, Morristown, PA to Sandy
     Beaton, GCA/Technology Division.  October 1981.  (Reliability No. 2.)

20.  Report of an Emission Test at the Common Stack of 9 Open Hearth Furnaces.
     U.S. Steel Corp./Fairless Works in Fairless Hills, PA.  JACA Corp.
     testing for U.S. EPA, Region III.  August 1977.  JACA Library.
     (Reliability No. 1.)

21.  Samways, N. L.  Fairless Works Faces the 1980's—A Look at the Plant
     Today.  Iron and Steel Engineer.  April 1980.  pp. F-l.  (Reliability
     No. 4.)

22.  Stack Test Report.  USSC/Fairless Works Open Hearth Shop in Fairless
     Hills, PA.  PADER testing.  September 16, 1974.  JACA Library.
     (Reliability No. 1.)

23.  Telephone conversation.  Robert Felt, Allegheny County Department of
     Health to Sandy Beaton, GCA/Technology Division.  November 1981.
     (Reliability No. 2.)

24.  Bradway, R. M. and H. F. Schiff.  USSC Homestead Open Hearth Furnace Shop
     No. 5 Particulate Emission Quantification.  GCA Report No. TR-77-44-G.
     Final Report.  May 1978.  (Reliability No. 1.)
                                   624

-------
25.  Telephone conversation.  Bob Felt, Allegheny County Health Department to
     Gene Bergson, GCA/Technology Division.  February 12, 1981.  (Reliability
     No. 2.)

26.  Telephone conversation.  Bernard Bloom, U.S. EPA, Division of Stationary
     Source Enforcement to Michael Jasinski, GCA/Technology Division.
     December 1980 through February 1981.  (Reliability No. 2.)

27.  Impact of Particulate Matter Emissions on Ambient Air Quality.
     USSC-Geneva Works.  EPA-300/2-77-005b.  Appendix Il-Source
     Identification.   February 1977.  pp. 84, 90.  (Reliability No. 4.)

28.  Telephone conversation.  Mr. Kopta, Utah State Division of Environmental
     Health to Gene Bergson, GCA/Technology Division.  February 27, 1981.
     (Reliability No. 2.)

29.  Telephone conversation.  Dave Kopta, Utah State Division of Environmental
     Health to Michael Jasinski, GCA/Technology Division.  October 1981.
     (Reliability No. 2.)
                                   625

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     MATERIAL IN THIS SECTION SUBJECT TO CONFIDENTIALITY                             9
    REVIEW AND IS NOT RELEASABLE AS OF FEBRUARY 1, 1982.                           9 gj
   FOR INFORMATION, CONTACT L. KESARI, U.S. ENVIRONMENTAL                          gg
PROTECTION AGENCY, DIVISION OF STATIONARY SOURCE ENFORCEMENT.                      Q°
                                                                                   H !>
                                                                                   H n
                                                                                   o tfi

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                TABLE  1.   ARMCO  INC./HOUSTON WORKS IN HOUSTON,  TX

              SCARFING MACHINE(S)  PROCESS  AND EMISSION CONTROL  DATA
MILL DESIGNATION:


STARTUP DATE:

STEEL PROCESSED:

  RATED TONS/DAY:
  AVERAGE TONS/DAY:

AMOUNT OF OXYGEN USED (ft3/min):

SCARFING EMISSION CONTROL SYSTEM:
  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:
35-inch1
Blooming
1.7811
High-energy
scrubber1
• Rated at
  141,000 acfra1
Slabbing1
High-energy
scrubber1
• Rated at
  100,000 acfm1
ADDITIONAL COMMENTS:
                                     626

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            TABLE  2.   ARMCO  INC./KANSAS CITY WORKS IN KANSAS CITY,  MO

              SCARFING MACHINE(S)  PROCESS AND EMISSION CONTROL DATA
MILL DESIGNATION:

STARTlj? DATE:

STEEL PROCESSED:

  RATED TONS/DAY:
  AVERAGE TONS/DAY:

AMOUNT OF OXYGEN USED (ft3/min):

SCARFING EMISSION CONTROL SYSTEM:

  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:
BlDoming1

19632



2.2741




High-energy scrubber^-

Koch2
19742
• Design flow rate = 46,000
  acfm* (50,000 acfm
  @ 60°F—inlet)2
• Scrubber water flow rate
  (design) = 400 gpm2
• L/G =8:1 (calculated-
  design)2
ADDITIONAL COMMENTS:
                                     627

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             TABLE  3.   ARMCO INC./MIDDLETOWN WORKS IN MIDDLETOWN, OH

              SCARFING  MACHINE(S)  PROCESS AND EMISSION CONTROL DATA
MILL DESIGNATION:


STARTUP DATE:

STEEL PROCESSED:

  RATED TONS/DAY:
  AVERAGE TONS/DAY:

AMOUNT OF OXYGEN USED (ft3/rain):

SCARFING EMISSION CONTROL SYSTEM:

  MANUFACTURER:
  DATE INSTALLED:
  SYSTEM DESCRIPTION:
Slabbing1 (48 x 96 in. 2-h
universal mill)3
1967-
7.1231
High-energy scrubber1*3

AAF3
19673
• 100,000 scfm scarfing fume
  exhaust system.3
• System includes a gas
  scrubber and fume eliminator3
• Scarfing occurs on all four
  sides of slab simultaneously3
ADDITIONAL COMMENTS:
                                    628

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      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

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        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

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         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

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      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

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              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

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            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

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        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

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    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

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    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

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         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

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          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

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                     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

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           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

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          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

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       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

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        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

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         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

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              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

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           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

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                              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

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              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

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         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

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     MATERIAL IN THIS SECTION SUBJECT TO CONFIDENTIALITY
    REVIEW AND IS NOT RELEASABLE AS OF FEBRUARY  1,  1982.
   FOR INFORMATION, CONTACT L. KESARI, U.S. ENVIRONMENTAL
PROTECTION AGENCY, DIVISION OF STATIONARY SOURCE ENFORCEMENT.
                                                                                   *J W
                                                                                   M Tl
                                                                                   2! W
                                                                                   O PS
                                                                                   w W
                                                                                   5> o
                                                                                   n M

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                                   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

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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

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24.  Correspondence from Allegheny County Health Department to J&L Steel
     Corp./Pittsburgh Works regarding compliance tests on the wet
     electrostatic precipitator at the 46 inch primary mill hot scarfer.
     December 12, 1971.  RACT No. 600087.  (Reliability No. 1.)

25.  Telephone conversation.  Robert Felt, Allegheny County Department of
     Health to Sandy Beaton.  GCA/Technology Division.  November 3, 1981.
     (Reliability No. 2.)

26.  Telephone conversation.  Bob Felt, Allegheny County Department of Health
     to Gene Bergson, GCA/Technology Division.  February 12, 1981.
     (Reliability No. 2.)

27.  Anderson, P. A.  GCA Compliance Inspection Report for EPA Region V at
     McLouth Steel/Trenton, MI.  1979.  (Reliability No. 2.)

28.  Summary sheets compiled by JACA Corp. from stack tests in regional EPA
     offices.  Provided to JACA, Inc. for Steel Library by Tom Maslany, EPA
     Region III.  (Reliability No. 1.)

29.  Telephone conversation.  Al Carlacci, New York State Department of
     Environmental Coservation to William Farino, GCA/Technology Division.
     October 1981.  (Reliability No. 2.)

30.  Current Domestic Expansion and Modernization Programs.  Iron & Steel
     Engineer.  February 1980.  (Reliability No. 4.)

31.  EPA Region V files.  (RSC/Cleveland 1978 Publication.)

32.  Iron & Steel Engineer.  Equipment News.  52(9):95.  September 1975.
     (Reliability No. 3.)

33.  The Precipitator Newsletter.  Mcllvaine, Inc.  June 20, 1980.  No. 53, p.
     54.  (Reliability No. 4.)

34.  Telephone conversation and letter response.  Tom McGinley, FADER,
     Morristown, PA to Sandy Beaton, GCA/Technology Division.  November 1981.
     (Reliability No. 1.)

35.  Telephone conversation.  Roland Elvambuena, City of Gary Health
     Department to Gene Bergson, GCA/Technology Division.  March 4, 1981.
     (Reliability No. 2.)

36.  Telephone conversation.  Harold Strohmeyer, North Ohio Valley Air
     Authority to Sandy Beaton, GCA/Technology Division.  October 1981.
     (Reliability No. 2.)

37.  EPA Region V files.  (Litigation Report.)
                                   657

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