United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EMB Report 82-IBR-16
March, 1982
Air
&EPA
Industrial Boilers
Emission Test Report
General Motors Corporation
Hamilton, Ohio
-------
INDUSTRIAL BOILERS
FINAL REPORT
GENERAL MOTORS CORPORATION
FISHER BODY DIVISION
BOILER NO. 1
Hamilton, Ohio
March 1-4, 1982
Technical Directives 19 and 20
Prepared for
Environmental Protection Agency
Office of Air Quality Planning and Standards
Emission Measurement Branch
Research Triangle Park
North Carolina 27711
by
Duane R. Day and Carol S. Smith
Contract No. 68-02-3547, Work Assignment No. 2
(ESED 76/13)
EMB No. 82-IBR-16
November 1982
MONSANTO RESEARCH CORPORATION
DAYTON LABORATORY
Dayton, Ohio 45407
-------
CONTENTS
Page
Figures iv
Tables v
1. Introduction.
2. Summary of Results 3
Description of Monitoring 3
Test Results 5
3. Process Description 19
Boiler System Description 19
Side Stream Separator System Description . . 22
4. Location of Sampling Points 24
Stack 24
Coal Feed System 24
5. Sampling and Analysis Procedures 27
Summary 27
Stack Sampling 27
Stack Sample Analyses 29
Coal Sampling and Analyses 29
Sample Handling 29
Data Reduction 29
Quality Assurance 30
Appendices
A. Field Sampling Data Sheets and Computer
Coding Forms A-l
B. Printouts of Sampling Results and Emission
Calculations B-l
C. Boiler and Side Stream Separator Process
Monitoring Data C-l
D. Analytical Results, Quality Control, and
Coal Analyses Results D-l
E. Project Participas E-l
0146/C iii
-------
FIGURES
Nmber Page
1 Schematic diagram of General Motors Corporation,
Fisher Body Division boiler installation. ... 2
2 Boiler/side stream separator process diagram. . . 20
3 Fan, stack, and sample port dimensions for
General Motors Corporation, Fisher Body
Division, Boiler No. 1 at Hamilton, Ohio. ... 25
4 Traverse point location for General Motors
Corporation, Fisher Body Division, Boiler
No. 1 at Hamilton, Ohio 26
5 Dual-probe sampling train 28
IV
-------
TABLES
Nmber Page
1 Source Sampling and Analyses at General Motors
Corporation, Fisher Body Division in Hamilton,
Ohio 4
2 Emision Data for Gneral Motors Corporation,
Fisher Body Division, Boiler No. 1 in
Hamilton, Ohio (metric units, 3/1-4/82) . . .
3 Emision Data for Gneral Motors Corporation,
Fisher Body Division, Boiler No. I in
Hamilton, Ohio (English units, 3/1-4/82). . .
4 Summary of Duration of Sampling, Stack Tempera-
ture, Stack Flow Rate, Sample Volume, Sample
Water Content, and Statis Pressure at General
Motors Corporation, Fisher Body Division,
Boiler No. 1 in Hamilton, Ohio
5 Summary of Integrated Gas Analysis at General
Motors Corporation, Fisher Body Division,
Boiler No. 1 in Hamilton, Ohio (3/1-4/82) .
6 Summary of Coal Analysis at General Motors
Corporation, Fisher BOD Division, Boiler
No. 1 in Hamilton, Ohio (3/1-4/82)
7a Summary of Method 9 Visible Emission Observa-
tions at General Motors Corporation, Fisher
Body Division, Boiler No. 1 in Hamilton,
Ohio - Run 1 10
7b Summary of Method 9 Visible Emission Observa-
tions at General Motors Corporation, Fisher
Body Division, Boiler No. 1 in Hamilton,
Ohio - Run 2 11
7c Summary of Method 9 Visible Emission Observa-
tions at General Motors Corporation, Fisher
Body Division, Boiler No. 1 in Hamilton,
Ohio - Run 3 12
7d Summary of Method 9 Visible Emission Observa-
tions at General Motors Corporation, Fisher
Body Division, Boiler No. 1 in Hamilton,
Ohio - Run 4 13
-------
TABLES (continued)
Nmber Page
7e Summary of Method 9 Visible Emission Observa-
tions at General Motors Corporation, Fisher
Body Division, Boiler No. 1 in Hamilton,
Ohio - Run 5 14
7f Summary of Method 9 Visible Emission Observa-
tions at General Motors Corporation, Fisher
Body Division, Boiler No. 1 in Hamilton,
Ohio - Run 6 15
7g Summary of Method 9 Visible Emission Observa-
tions at General Motors Corporation, Fisher
Body Division, Boiler No. I in Hamilton,
Ohio - Run 7 16
7h Summary of Method 9 Visible Emission Observa-
tions at General Motors Corporation, Fisher
Body Division, Boiler No. 1 in Hamilton,
Ohio - Run 8 17
7i Summary of Method 9 Visible Emission Observa-
tions at General Motors Corporation, Fisher
Body Division, Boiler No. 1 in Hamilton,
Ohio - Run 9 18
8 Design Data for Boiler 1 21
9 Predicted Performance Data for Boiler No. 1
at Time of Installation 21
10 Baghouse Design Data 23
VI
-------
SECTION 1
INTRODUCTION
Emissions from Boiler No. 1 at the General Motors Corporation,
Fisher Body Division Plant in Hamilton, Ohio, were tested
March 1-4, 1982 by Monsanto Research Corporation (MRC). This
work was performed for the Emission Measurement Branch of the
U.S. Environmental Protection Agency (EPA) under Contract No.
68-02-3547, Work Assignment No. 2.
The boiler tested is a 20,430 kg steam/hr (45,000 Ib steam/hr)
capacity coal-fired boiler fed by two spreader stoker units. It
is equipped with multicyclone and baghouse pollution control
equipment. Figure 1 is a schematic diagram of the installation
showing the locations sampled.
The purpose of the sampling program was to provide background
information on well-controlled industrial boilers for the devel-
opmet of new source performance standards. Within this frame
work the objectives of sampling at General Motors Corporation in
Hamilton, Ohio was to determine the effect of raising the temper-
ature of the filter and probe on an EPA Method 5 train from 120°C
(248°F) to 160°C (320°F) on the amounts of particulate, sulfate,
and sulfuric acid emissions measured downstream of the multi-
cyclone and baghouse. Method 5 testing with the filter and probe
at 160°C ± 14°C (320°F ± 25°F) will be referred to as Method 5B
testing.
-------
BOILER
MULT)
[CYCLONE
\ /
.6
*\J
SAMPLING PORTS
ROOF
FAN
BAGHOUSE
Figure 1. Schematic diagram of General Motors Corporation,
Fisher Body Division boiler installation.
-------
SECTION 2
SUMMARY OF RESULTS
DESCRIPTION OF MONITORING
Table 1 summarizes the monitoring that was performed at this
plant, downstream of all pollution control equipment. Sampling
consisted of three simultaneous runs of Methods 5 and 5B at
approximately two-thirds boiler capacity (Runs 1, 2, and 3) and
three additional runs of Method 5B at approximately 50% reduced
boiler capacity (Runs 4, 5, and 6).
Heated, glass-lined sampling probes were used for all runs. In
the three simultaneous runs (runs 1-3) of Methods 5 and 5B, a
special dual-probe stack test system was used. The probe nozzles,
each connected to a separate sampling train, were spaced 4.4 cm
(1.75 in.) apart, allowing for simultaneous sampling through the
same sample ports. A conventional single sample train was used
for runs 4-6. Sample volumes of at least 1.7 dry standard m3
(60 dry standard ft3) were taken for all runs. The boiler was
running under steady state conditions (no soot blowing, no ash
unloading, etc.) during the emission testing.
The filters and dried acetone washes of the Method 5 and 5B runs
were weighed to a constant weight (until the sample weight did
not change more than 5 mg between successive weighings) prior
to sending the samples to EPA.
Methods 1-4 were used during all Method 5 and 5B sampling runs,
as in typical compliance monitoring. Plume opacity was observed
according to EPA Method 9 during all sampling runs. Three addi-
tional opacity observations were made after sampling was com-
pleted and are labelled Runs 7, 8, and 9.
The coal burned was considered to be representative of normal
feed. Grab samples of coal were taken before, during, and after
each run and combined to make one aggregate sample. The sulfur,
ash, moisture, and Btu content of each aggregate sample were
determined by ASTM methods.
-------
TABLE 1. SOURCE SAMPLING AND ANALYSES AT GENERAL MOTORS
CORPORATION, FISHER BODY DIVISION IN HAMILTON, OHIO
SAMPLING AND ANALYSIS REQUIREMENTS
MRC Job No. 103.1231
Total
no. of
samples
3
3
3
6
6
3
Sample
type
Particulate and
ORSAT at outlet
Particulate and
ORSAT at outlet
Particulate and
ORQAT Jit- niltlph
Coal
Opacity
Opacity
Sampling
method
5
SB
SB
Grab
9
9
Contract No. : 68-02-3547
Assignment
Company Name: CM Fisher Body Division
Industry: Industrial Boiler
Sampl e
collected
by
MRC
MRC
MRC
MRC
MRC
MRC
Minimum
sampling
time
100
100
100
Simultaeo
with abov
Simultane
with abov
After all
tests wer<
completed
Minimum
volume gas
sampled ft3
60
60
60
is
ms
Number : 2
Technical Directive: 19 and 20
Company Location: Hamilton, Ohio
Process: Coal -fired,
spreader stoker
Initial Analysis
Type Method By
Velocity,
tempera-
ture, H2O,
CO, COa,
Oa
Velocity,
tempera-
ture, H2O,
CO, COa,
Oa
Velocity,
tempera-
f-iiT-*» H n
CO, CO2,
02
-
Visual
observatio
Visual
observatio
1-4
1-4
1-4
i
MRC
MRC
MRC
MRC
MRC
Control Equipment: Multi-
cyclone , baghouse
Final Analysis
Type Method By
Particu-
late
S03,
HaSOi,
Particu-.
late
S03,
H2SO«
Particu-
late
S03,
HaSOu
S, Ash,
Moisture,
Bt-ll
5
-
SB
-
SB
-
ASTM
MRC
EPA
MRC
EPA
MRC
EPA
Bowser-
Morner Labs
-------
TEST RESULTS
The particulate emissions measured by Methods 5 and 5B are sum-
marized in. Tables 2 and 3. Totals reported for particulate
emissions represent all emissions measured by weighing the Meth-
od 5 and 5B samples. Following analysis for total particulates,
samples were transmitted to EPA for subsequent analysis.
Table 2 also shows the percent isokinetics for each run, which
ranged between 96.3% and 102.1%. Table 3 shows the percent of
the Method 5 concentrations represented by the Method 5B concen-
trations measured simultaneously at the same location. Particu-
late concentrations measured by Method 5B were between 94% and
100% those measured by Method 5.
Table 4 summarizes sampling duration, stack temperature, flow
rate, static pressure, and sample volume and water content.
Table 5 summarizes integrated gas analysis results. Integrated
Method 3 samples were taken from the exhaust of the Method 5B
train.
Table 6 summarizes the coal analysis results for percent moisture,
heat value, percent ash, and sulfur content.
Tables 7a-f summarize results of visible emissions observations
according to EPA Method 9 taken during Runs 1-6. Results for
three additional observations, which were taken after sampling
was completed, are shown in Tables-g-i and are labelled Runs 7,
8, and 9. Complete field data sheets are provided in Appendix A.
-------
TABLE 2. EMISSION DATA FOR GENERAL MOTORS CORPORATION,
FISHER BODY DIVISION, BOILER NO. 1 IN HAMILTON,
OHIO (METRIC UNITS) (MARCH 1-4, 1982)
Average emissions
Run Sampling
number Date method Pollutant
1
1
2
2
3
3
4
5
6
3-2-82
3-2-82
3-3-82
3-3-82
3-3-82
3-3-82
3-4-82
3-4-82
3-4-82
5
5B
5
5B
5
5B
5B
5B
5B
Particulate
Particulate
Particulate
Particulate
Particulate
Particulate
Particulate
Particulate
Particulate
Actual
g/dscm
0.169
0.164
0.184
0.171
0.182
0.183
0.161
0.124
0.137
kg/hr
3.51
3.39
3.89
3.54
3.79
3.76
3.29
2.24
2.36
tc
ng/J
95
93
101
94
100
100
127
77
86
.6
.0
.3
.7
.4
.6
.1
.4
.0
Corrected
> 12% C02 , Percent
g/dscm isokinetic
0
0
0
0
0
0
0
0
0
.229
.223
.245
.228
.242
.243
.328
.215
.206
99
96
98
99
100
98
96
102
99
.7
.8
.7
.2
.6
.2
.3
.1
.7
TVi-i o -i o -l-Vii» i-r^nff^n-t-fa-t-'i nn n«~>rtna 1 -i -r t*A i-«-> 1 ")*>/ t~Ti C1 — P V — — • uh*»T«a (7 1 R the
measured concentration in the stack, and %CO2 is the percent CO2 measured in the
stack.
-------
TABLE 3. EMISSION DATA FOR GENERAL MOTORS CORPORATION,
FISHER BODY DIVISION, BOILER NO. 1 IN HAMILTON,
OHIO (ENGLISH UNITS) (MARCH 1-4, 1982)
Average emissions
Run Sampling
number Date method Pollutant
1
1
2
2
3
3
4
5
6
3-2-82
3-2-82
3-3-82
3-3-82
3-3-82
3-3-82
3-4-82
3-4-82
3-4-82
5
5B
5
5B
5
5B
5B
5B
5B
Particulate
Particulate
Particulate
Particulate
Particulate
Particulate
Particulate
Particulate
Particulate
Actual
gr/dscf
0.074
0.072
0.080
0.075
0.080
0.080
0.071
0.054
0.060
t
Ib/hr Ib/mm Btu
7.73
7.48
8.57
7.81
8.34
8.28
7.26
4.93
5.20
0.22
0.22
0.24
0.21
0.23
0.23
0.29
0.18
0.20
Percent of Method 5
Corrected gr/dscf represented
o 12% C02,3 by Method 5B gr/dscf
gr/dscf at outlet
0.100
0.098 97
0.107
0.099 94
0.106
0.106 100
0.143 NAb
0.094 NA
0.090 NA
3 12
'2-
tion in the stack, and %C02 is the percent C02 measured in the stack.
NA = not applicable.
-------
00
TABLE 4. SUMMARY OF DURATION OF SAMPLING, STACK TEMPERATURE, STACK
FLOW RATE, SAMPLE VOLUME, SAMPLE WATER CONTENT, AND STATIC
PRESSURE AT GENERAL MOTORS CORPORATION, FISHER BODY DIVISION,
BOILER NO. 1 IN HAMILTON, OHIO
Run
number
1
2
3
4
5
6
Sampling
method
5
SB
5
5B
5
5B
5B
SB
SB
Duration
of
sampling,
min
108
108
108
108
108
108
108
108
108
Measured
stack
temperature
°C °F
218
218
217
217
218
218
203
196
196
424
424
422
422
424
424
398
386
384
Stack
flow rate
dscm/
min
347
345
353
344
347
343
340
302
286
dscf/
min
12,250
12,170
12,450
12,140
12,240
12,110
12,010
10,670
10,110
Sample
dscm
1.9
1.9
2.0
1.9
2.0
1.9
1.9
1.8
1.7
volume
dscf
68.6
67.3
70.3
67.7
70.4
66.8
65.0
62.2
57.6
Sample
water
content,
%
4.2
4.9
4.2
7.2
5.3
6.5
4.8
5.8
5.7
Stack static
pressures
cm HyO
-0.46
-0.46
-0.46
-0.46
-0.46
-0.46
-0.46
-0.46
-0.46
in. H?0
-0.18
-0.18
-0.18
-0.18
-0.18
-0.18
-0.18
-0.18
-0.18
-------
TABLE 5. SUMMARY OF INTEGRATED GAS ANALYSIS AT GENERAL MOTORS
CORPORATION, FISHER BODY DIVISION, BOILER NO. 1 IN
HAMILTON, OHIO (MARCH 1-4, 1982)
Run
number
1
2
3
4
5
6
C09, %
8.8
9.0
9.0
5.9
6.9
8.0
CO, %
0.0
0.0
0.0
0.0
0.0
0.0
02, %
11.2
10.9
10.9
13.9
12.1
12.1
N2, %
80.0
80.1
80.1
80.1
81.0
79.9
Dry molecular
weight
kg/kg mole
(Ib/lb mole)
29.9
29.9
29.9
29.5
29.6
29.8
TABLE 6. SUMMARY OF COAL ANALYSIS AT GENERAL MOTORS CORPORATION, FISHER BOD
DIVISION, BOILER NO. 1 IN HAMILTON, OHIO (MARCH 1-4, 1982)
Run
number
Total
moisture,
percent
Heating value
Joule/gram
dry
as received
dry
Ash, percent
as received dry as received
Btu/lb
Sulfur, percent
dry as received
1
2
3
4
5
6
6.2
6.9
7.0
8.0
7.4
7.6
32,690
32,270
32,480
31,780
32,110
28,210
30,670
30,060
30,230
29,230
29,760
26,070
14,070
13,890
13,980
13,680
13,820
12,140
13,200
12,940
13,010
12,580
12,810
11,220
5.2
5.7
5.8
6.3
6.1
8.3
4.9
5.3
5.4
5.8
5.7
7.6
0.75
0.83
0.83
1.06
0.80
0.73
0.70
0.78
0.77
0.97
0.74
0.68
-------
TABLE 7a. SUMMARY OF METHOD 9 VISIBLE EMISSION OBSERVATIONS
AT GENERAL MOTORS CORPORATION, FISHER BODY DIVISION,
BOILER NO. 1 IN HAMILTON, OHIO - RUN 1
Date: 3-2-62
Type of Discharge: Stack
Height of Point of Discharge: 100 ft
Wind Direction: Nest
Color of Plume: White
Observer Name: Dennis J. Gault
Distance from Observer to Discharge Point: 30 ft
Direction of Observer from Discharge Point: South
Height of Observation Point: 75 ft
Description of Background: Red vater tower
Type of Plant: automobile
Location of Discharge: Boiler Ho. 1 stack
Description of Sky: Overcast
Wind Velocity: 15-20 Bph
Detached Flume: No
Duration of Observation: 225 min.
Set
Summary
number Start
1
2
3
4
5
6
7
8
9
10
11
9:53
9:59
10:05
10:11
10:17
10:23
10:29
10:35
10:41
10:47
10:54
of average
Time
End
9:58
10:04
10:10
10:16
10:22
10:28
10:34
10:40
10:46
10:52
10:59
opacity
Sum
120
120
125
130
145
130
120
125
135
145
130
Opacity
Average
5
5
5.2
5.4
6.0
5.4
5
5.2
5.6
6.0
5.4
Test began
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
11:00
11:06
11:12
11:18
11:24
11:30
11:36
11:42
11:48
11:55
12:01
12:07
12:13
12:19
12:25
12:31
12:37
12:43
12:49
13:00
13:06
13:12
13:18
13:24
13:30
13:36
13:42
11:05
11:11
11:17
11:23
11:29
11:35
11:41
11:47
11:53
12:00
12:06
12:12
12:18
12:24
12:30
12:36
12:42
12:48
12:54
13:05
13:11
13:17
13:23
13:29
13:35
13:41
13:45
130
130
145
145
150
145
135
145
135
155
125
125
125
125
125
140
120
125
130
135
125
130
125
150
170
130
70
5.4
5.4
6.0
6.0
6.3
6.0
5.6
6.0
5.6
6.5
5.2
5.2
5.2
5.2
5.4
5.8
5
5.2
5.4
5.6
5.2
5.4
5.2
6.3
7.1
5.4
5.8
Test ended
average
• •*
15
".10
£
u
s. .
o 5
0
, all sets
S.6
RUN1
i i
TIME, hours
10
-------
TABLE 7b. SUMMARY OF METHOD 9 VISIBLE EMISSION OBSERVATIONS
AT GENERAL MOTORS CORPORATION, FISHER BODY DIVISION,
BOILER NO. 1 IN HAMILTON, OHIO - RUN 2
Date: 3-3-82
Type of Discharge: Stack
Height of Point of Discharge: 100 ft
Wind Direction: East
Color of Plume: White
Observer Name: Dennis J. Gault
Distance from Observer to Discharge Point: 30 ft
Direction of Observer from Discharge Point: South
Height of Observation Point: 75 ft
Description of Background: Red water tower
Type of Plant: Automobile
Location of Discharge: Boiler No. 1 stack
Description of Sky: Overcast
Wind Velocity: 15-20 mph
Detached Plume: No
Duration of Observation: 1BO min.
Set
Summary
number Start
1
2
3
4
5
6
9:15
9:21
9:27
9:33
9:39
9:45
of average opacity
Time
End
9:20
9:26
9:32
9:38
9:44
9:50
Sum
110
110
135
115
120
110
Opacity
Average
5.0
5.0
6.1
5.0
5.2
5.2
Test began
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
9:51
9:57
10:03
10:09
10:16
10:22
10:28
10:34
10:40
11:00
11:06
11:12
11:18
11:24
11:31
11:37
11:43
11:49
11:55
9:56
10:02
10:08
10:14
10:21
10:27
10:33
10:39
10:45
11:05
11:11
11:17
11:23
11:29
11:36
11:42
11:48
11:54
12:00
130
120
160
115
130
125
130
145
115
120
135
110
130
130
125
120
120
135
125
5.7
5.5
7.0
5.5
5.4
6.0
5.9
6.3
5.2
5.0
5.9
5.0
5.7
5.7
5.2
5.5
5.5
5.9
5.4
Test ended
26
27
26
29
30
Average
15
* 10
»— i
o
^
1
TIME, hours
2
RUN 2
A-
3
11
-------
TABLE 7c. SUMMARY OF METHOD 9 VISIBLE EMISSION OBSERVATIONS
AT GENERAL MOTORS CORPORATION, FISHER BODY DIVISION,
BOILER NO. 1 IN HAMILTON, OHIO - RUN 3
Date: 3-3-82
Type of Discharge: Stack
Height of Point of Discharge: 100 ft
Wind Direction: East
Color of Plume: White
Observer Name: Dennis J. Gault
Distance from Observer to Discharge Point: 30 ft
Direction of Observer from Discharge Point: South
Height of Observation Point: 75 ft
Description of Background: Red water tower
Type of Plant: Automobile
Location of Discharge: Boiler No. 1 stack
Description of Sky: Overcast
Hind Velocity: 15-20 nph
Detached Plume: No
Duration of Observation: 180 nin.
Set
Summary
number Start
1
2
3
4
5
6
7
13:37
13:43
13:49
13:55
14:01
14:07
14:13
of average opacity
Time
End
13:42
13:48
13:54
14:00
14:06
14:12
14:18
Sum
120
140
145
125
130
140
125
Opacity
Average
5.0
5.8
6.3
5.4
5.4
5.8
5.4
Test began
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
14:19
14:25
14:31
14:33
14:45
14:51
14:57
15:03
15:09
-15:34
15:40
15:46
15:52
16:00
16:06
16:12
16:18
16:24
14:24
14:30
14:36
14:44
14:50
14:56
15:02
15:08
15:14
15:39
15:45
15:51
15:57
16:05
16:11
16:17
16:23
16:29
145
135
125
135
140
150
145
145
125
115
105
130
120
145
150
135
150
135
6.0
5.6
5.4
5.9
6.1
6.3
6.3
6.0
5.7
5.0
5.0
5.4
5.2
6.3
6.3
5.9
6.8
5.9
Test ended
26
27
28
29
30
16:30
16:36
16:42
16:35
16:41
16:47
16:48 16:53
16:54
16:59
145
140
125
145
150
Average, all sets
15
"10
o. ,
o 5
0
6.0
5.8
5.4
6.3
6.3
5.8
RUN 3
0
1
TIME, hours
2
3
12
-------
TABLE 7d. SUMMARY OF METHOD 9 VISIBLE EMISSION OBSERVATIONS
AT GENERAL MOTORS CORPORATION, FISHER BODY DIVISION
BOILER NO. 1 IN HAMILTON, OHIO - RUN 4
Date: 3-4-82
Type of Discharge: Stack
Height of Point of Discharge: 100 ft
Wind Direction: South-West
Color of Plume: White
Observer Name: Dennis J. Gault
Distance from Observer to Discharge Point: 30 ft
Direction of Observer from Discharge Point: South
Height of Observation point: 75 ft
Description of Background: Red water tower
Type of Plant: Automobile
Location of Discharge: Boiler No. 1 stack
Description of Sky: Overcast
Wind Velocity: Calm
Detached Plume: No
Duration of Observation: 180 min.
Set
number
1
2
3
4
5
Test began
6
7
B
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Test ended
25
26
27
28
29
30
Summary
Start
9:07
9:13
9:19
9:25
9:31
9:37
9:43
9:49
9:55
10:01
10:07
10:13
10:19
10:25
10:31
10:37
10:43
10:49
10:55
11:01
11:09
11:15
11:21
11:27
11:33
11:39
11:45
11:51
11:57
12:03
of average opacity
Time
End
9:12
9:18
9:24
9:30
9:36
9:42
9:48
9:54
10:00
10:06
10:12
10:18
10:24
10:30
10:36
10:42
10:48
10:54
11:00
11:06
11:14
11:20
11:26
11:32
11:38
11:44
11:50
11:56
12:02
12:08
Sum
200
235
185
135
125
200
275
230
200
175
155
140
110
190
125
170
140
95
120
115
110
110
130
115
130
120
110
105
145
145
Opacity
Average
10.0
9.8
9.3
6.4
6.0
8.7
12.5
10.0
9.1
7.3
7.8
7.0
7.9
9.5
6.9
9.4
7.4
5.3
6.0
6.4
5.2
6.1
6.8
6.1
6.2
6.3
5.8
S.B
6.6
7.3
Average, all sets
7.5
1 2
TIME, hours
13
-------
TABLE 7e. SUMMARY OF METHOD 9 VISIBLE EMISSION OBSERVATIONS
AT GENERAL MOTORS CORPORATION, FISHER BODY DIVISION,
BOILER NO. 1 IN HAMILTON, OHIO - RUN 5
Date: 3-4-82
Type of Discharge: Stack
Height of Point of Discharge: 100 ft
Wind Direction: West to Southwest
Color of Plume: White
Observer Name: Dennis J. Gault
Distance from Observer to Discharge Point: 30 ft
Direction of Observer from Discharge Point: South
Height of Observation Point: 75 ft
Description of Background: Hater tower
Type of Plant: Automobile
Location of Discharge: Boiler No. 1 stack
Description of Sky: Overcast
Wind Velocity: 15-25 mph
Detached Plume: No
Duration of Observation: 144 min.
Set
Summary
number Start
1
2
3
4
12:20
12:26
12:32
12:38
of average opacity
Time
End
12:25
12:31
12:37
12:43
Opacity
Sum Average
185
135
190
120
9.3
6.4
9.5
6.3
Test began
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
12:44
12:50
12:56
13:02
13:08
13:14
13:26
13:32
13:38
13:44
13:50
13:56
14:02
14:08
14:14
14:20
14:31
14:37
12:49
12:55
13:01
13:07
13:13
13:19
13:31
13:37
13:43
13:49
13:55
14:01
14:07
14:13
14:19
14:25
14:36
14:42
130
125
120
130
115
90
105
115
140
130
125
145
135
115
130
130
150
185
5.7
5.7
6.3
6.2
6.1
5.6
5.8
6.4
6.4
6.5
6.9
6.9
7.1
6.8
7.7
7.7
8.8
8.4
Test ended
23
24
Average
15
* 10
t
o
a. 5
0
0
14:43
14:49
, all sets
k K
^v
V,
0
14:48
14:54
—
,
1
TIME, hours
140
120
RUN 5
-^\
1
2
7.0
6.7
6.8
3
14
-------
TABLE 7f.
SUMMARY OF
AT GENERAL
BOILER NO.
METHOD 9 VISIBLE EMISSION OBSERVATIONS
MOTORS CORPORATION, FISHER BODY DIVISION,
1 IN HAMILTON, OHIO - RUN 6
Date: 3-4-82
Type of Discharge-. Stack
Height of Point of Discharge: 100 ft
Wind Direction: South-West
Color of Plume: White
Observer Name: Dennis J. Gault
Distance from Observer to Discharge Point: 30 ft
Direction of Observer from Discharge Point: South
Height of Observation Point: 75 ft
Description of Background: Red water tower
Type of Plant: Automobile
Location of Discharge: Boiler No. 1 stack
Description of Sky: Overcast
Wind Velocity: 15-25 mph
Detached Plume: No
Duration of Observation: 142 min.
Set
Summary
number Start
of average opacity
Time
End
Opacity
Sum Average
Test began
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
15:11
15:17
15:23
15:29
15:35
15:41
15:47
15:53
15:59
16:05
16:13
16:19
16:25
16:31
16:37
16:43
16:49
16:55
17:01
15:16
15:22
15:28
15:34
15:40
15:46
15:52
15:58
16:04
16:10
16:18
16:24
16:30
16:36
16:42
16:48
16:54
17:00
17:06
140
125
140
200
170
180
120
135
135
170
150
160
125
150
135
140
150
140
155
7.4
5.4
7.0
8.7
7.7
8.2
6.0
6.1
6.1
7.4
6.8
7.0
6.6
7.1
7.5
7.0
6.8
6.1
6.7
Test ended
20
21
22
23
24
Average
1C
i?
* 10
fc
0
17:07
17:15
17:21
17:27
17:33
, all sets
17:12
17:20
17:26
17:32
17:38
165
170
175
150
95
7.2
7.4
7.6
6.5
6.3
6.9
•
/^
0
— -^ — ~\
1
1
TIME, hours
RUN 6
x— "-v
2
3
15
-------
TABLE 7g. SUMMARY OF METHOD 9 VISIBLE EMISSION OBSERVATIONS
AT GENERAL MOTORS CORPORATION, FISHER BODY DIVISION,
BOILER NO. 1 IN HAMILTON, OHIO - RUN 7
Date: 3-5-82
Type of Discharge: Stack
Height of Point of Discharge: 100 ft
Wind Direction:
Color of Plume: White
Observer Name: Dennis J. Gault
Distance from Observer to Discharge Point: 30 ft
Direction of Observer from Discharge Point: South
Height of Observation Point: 75 ft
Description of Background: Red water tower
Type of Plant: Automobile
Location of Discharge: Boiler No. 1 stack
Description of Sky: Overcast
Wind Velocity: Calm
Detached Plume: No
Duration of Observation: 60 min.
Summary of average opacity
Set
number
Time
Start
End
Opacity
Sum
Average
1
2
3
4
5
6
7
8
9
10
10:30
10:36
10:42
10:48
10:54
11:00
11:06
11:12
11:18
11:24
10:35
10:41
10:47
10:53
10:59
11:05
11:11
11:17
11:23
11:29
Average, all sets
15
fc
o
135
130
145
155
160
160
155
165
140
170
5.9
5.9
6.3
6.7
6.7
6.7
6.7
6.9
6.1
7.4
6.5
RUN 7
1 2
TIME, hours
16
-------
TABLE 7h. SUMMARY OF METHOD 9 VISIBLE EMISSION OBSERVATIONS
AT GENERAL MOTORS CORPORATION, FISHER BODY DIVISION,
BOILER NO. 1 IN HAMILTON, OHIO - RUN 8
Date: 3-5-82
Type of Discharge: Stack
Height of Point of Discharge: 100 ft
Wind Direction:
Color of Plume: White
Observer Name: Dennis J. Gault
Distance from Observer to Discharge Point: 30 ft
Direction of Observer from Discharge Point: South
Height of Observation Point: 75 ft
Description of Background: Red water tower
Type of Plant: Automobile
Location of Discharge: Boiler No. 1 stack
Description of Sky: Overcast
Wind Velocity: Calm
Detached Plume: No
Duration of Observation: 60 min.
Set
number
1
2
3
4
5
6
7
8
9
10
Average ,
Summary
Start
12:00
12:06
12:12
12:18
12:24
12:30
12:36
12:42
12:48
12:54
all sets
of average opacity
Time
End
12:05
12:11
12:17
12:23
12:29
12:35
12:41
12:47
12:53
12:59
Sum
130
120
110
115
120
140
95
100
120
140
Opacity
Average
5.9
6.0
5.5
6.1
6.0
6.1
5.0
5.6
5.5
6.1
5.8
15
.10
o
I 5
RUN 8
1 2
TIME, hours
17
-------
TABLE 7i. SUMMARY OF METHOD 9 VISIBLE EMISSION OBSERVATIONS
AT GENERAL MOTORS CORPORATION, FISHER BODY DIVISION,
BOILER NO. 1 IN HAMILTON, OHIO - RUN 9
Date: 3-5-82
Type of Discharge: Stack
Height of Point of Discharge: 100 ft
Wind Direction: West
Color of Plume: White
Observer Name: Dennis J. Gault
Distance from Observer to Discharge Point: 30 ft
Direction of Observer from Discharge Point: South
Height of Observation Point: 75 ft
Description of Background: Red water tower
Type of Plant: Automobile
Location of Discharge: Boiler No. 1 stack
Description of Sky: Overcast
Wind Velocity: Calm
Detached Plume: No
Duration of Observation: 60 min.
Summary of average opacity
Set
number
Time
Start
End
Opacity
Sum
Average
1
2
3
4
5
6
7
8
9
10
13:20
13:26
13:32
13:38
13:44
13:50
13:56
14:02
14:08
14:14
13:25
13:31
13:37
13:43
13:49
13:55
14:01
14:07
14:13
14:19
Average, all sets
15
10
190
140
165
160
185
175
165
175
155
155
7.9
6.1
6.9
6.7
7.7
7.3
6.9
7.3
6.7
6.7
7.0
RUN 9
1 2
TIME, hours
18
-------
SECTION 3
PROCESS DESCRIPTION
(Provided by Radian Corporation)
This section presents a generalized description of the boiler and
side stream separator processes. Both processes are discussed indi-
vidually in the following two subsections. Process descriptions
include flow diagrams and descriptions, equipment design data,
typical operating conditions and performance data.
The process data collected during all emission testing periods
are tabulated in Appendix C, Also present in Appendix C is a dis-
cussion of any process upsets or abnormalities that occurred during
the testing period. Some general comments on the process operation
are also included.
BOILER SYSTEM DESCRIPTION
The Fisher Body Hamilton plant is a metal stamping facility pro-
ducing automotive parts. Steam is required almost exclusively for
heating purposes and is supplied from three coal-fired boilers of
equal size (20,430 kg/hr or 45,000 Ib/hr) in a power plant adjac-
ent to the manufacturing facility.
The test boiler, show in Figure 2, is a Babcock and Wilcox unit
installed in 1946 and designed with a maximum continuous capacity
of 20,430 kilograms of dry saturated steam per hour at 1.2 MPa
(45,000 Ib/hr at 175 psig). Currently, the boiler rarely exceeds
a load of 15,890 kg/hr (35,000 Ib/hr). The boiler has a Detroit
Stoker traveling grate with front end ash discharge and coal is
fed into the boiler by two Detroit Stoker spreader stokers.
Design data for the boiler and stokers are presented in Table 8.
Predicted performance data for this unit at the time of installa-
tion is provided in Table 9.
Boiler bottom ash is reinjected through the rear overfire air jets
on a continuous basis. The rear overfire air jets are angled to
fire toward the center of the furnace, while the front two jets
fire straight toward the rear wall of the furnace. Soot blowing
operations normally occur once a day. The soot blowing system
uses compressed air generated in the powerhouse to clean the heat
exchanger tubes.
19
-------
ro
o
P.O. Fan
Boiler
Dilution Air Intake
Side Stream Take Offs
Mechanical
Collector
xhaust to
tack
Figure 2. Boiler/side stream separator process diagram.
-------
TABLE 8. DESIGN DATA FOR BOILER 1
Boiler
Economizer
Furnace
Stoker
Heat rate
Type
Boiler heating surface
Design steam pressure
No. of gas passes
(horizontal passes)
Volume
Width
Depth
Type
Grate type
No. of feeders
Effective grate area
Maximum continuous steam
Capacity
F-22-BG-6/54
5,831 ft2
175 psig
3
None
2,586 ft3
8' - 7-3/4"
13'
Detroit Rotograte
Spreader
2
120 ft2
45,000 Ib/hr
TABLE 9. PREDICTED PERFORMANCE DATA FOR
BOILER 1 AT TIME OF INSTALLATION
Steam leaving boiler (design)
Excess air leaving boiler (minimum)
Coal flow at rated capacity
Flue gas leaving boiler
Steam pressure
Gas temperature leaving boiler
Furnace draft los
Efficiency of unit
45,000 Ib/hr
2.1 tons/hr
33,000 acfm
175 psig
520°F
0.10" w.g.
79.9%
Unit one is capable of buring a wide range of coals. However, the
plant restricts coal purchases to the following specifications:
Sulfur content:
Heating value:
Ash content:
Sizing:
Moisture:
Ash fusion:
1.0% or less
Not less than 12,500 Btu/lb
Less than 10%
1-1/4" x 1/4" modified stoker coal
with not more than 15% passing
through a 1/4" screen
Not greater than 6%
Not less than 2,600°F
21
-------
Throughout the duration of the testing period a fuel additive,
Gamlenite 6201, was added to the coal at the weighing scale.
Gamlenite 6201 is a combination combustion improver, slag controller
and cold corrosion inhibitor. Gamlenite acts as a combustion cata-
lyst by lowering the auto ignition temperature of carbon. Therefore,
more carbon is burned in the combustion chamber rather than being
deposited on the tubes or carried out in the bottom or flyash. The
marketers of Gamlenite 6201 (Sybron Chemical) feel that Gamlenite may
act to slightly reduce uncontrolld particulate matter mass emissions
from stoker boilers. However, the extent of this reduction has not
been quantified.
SIDE STREAM SEPARATOR SYSTEM DESCRIPTION
The particulate matter collction equipment installed with Unit 1
at the time of construction was a mechanical collector manufac-
tured by Pratt-Daniel Corporation. In 1974, this collector was
replaced with a higher efficiency mechanical collector. Although
this installation resulted in a higher pressure drop across the
collector, no appreciable loss in boiler capacity was experienced,
as the induced draft fan was equipped with enough spare capacity
to overcome these losses. The new mechanical collector was in-
stalled after the boiler and before the induced draft fan and met
the following specifications:
Manufacturer: Western Prepcipitation Division
Joy Manufacturing Company
Type: 9VM Series
Number of tubes: 48
Tube size: 6"
Pressure drop: 3.5" w.g.
Design efficiency: 96.5%
The design efficiency listed above is qualified to apply if less
than 15 percent of the flyash particles are 10 uM in diameter
or less. The collector was designed for a continuous load of
20,430 kg/hr (45,000 Ib/hr) of steam with intermittent peaks of
22,700 kg/hr (50,000 Ib/hr).
In 1979 - 1980, the baghouse and mechanical collector take-offs
were installed on Unit One to collectively form the side stream
separator system. A 255 m3/min (9,000 acfm) induced draft fan,
located downstream of the baghouse, pulls between 12-15 percent
of the flue gas flow from the mechanical collctor hopper.
Because this fan is a constant cfm unit, the percentage flow to
the baghouse increases with decreasing overall flue gas flow rate
from the boiler. Flue gas flow rate decreases with decreasing
load. Therefore, as boiler load decreases percent flow to the
baghouse increases.
22
-------
Table 10 presents design data for the baghouse installed on Unit
One. The unit is a Western Precipitation PULSEFLO baghouse and
consists of a rectangular air tight housing containing an array
of filter bags suspended from a tube sheet. The housing is
approximately 6.9 m (22.5 ft) in height and 2.4 m (8 ft) wide.
TABLE 10. BAGHOUSE DESIGN DATA
Type
Filter bags:
Total quantity
Grounding
Material
Diameter
Length
Power requirements
Air requirements
Monitoring devices:
Annunciator
Pressure indicators
Temperature indicator
Model PF SQ 4508
Size 144
144
None
Teflon
4-1/2"
8 ft
480 V, 3
ph, 60 Hz
16.8 acfm at 100 to 125 psi
Panalarm Mod II-Series 10
Inlet & outlet gas pressure
Boiler outlet gas temperaturee
A solid-state timer is programmed to provide a smooth, continuous
cleaning cycle by pulsing each of the 12 rows of filter bags in
sequence. When the timer is energized, it will continuously pulse
each row of bags in sequence, automatically returning to the first
row after the last one has been pulsed. This bag cleaning system
operates on a continuous basis.
To lower the gas temperature entering the PULSEFLO filter, a mixing
tee is provided. The mixing tee contains two butterfly valves, one
20 cm (8 inch) and one 41 cm (16 inch). An air pressure signal con-
trols these valves to allow the mixing tee to effectively mix ambi-
ent air with the gas flow to lower the temperature entering the
PULSEFLO filter to 191°C (375°F). Temperatures above this value
would cause deterioration of the Teflon bag fabric used in these
units.
23
-------
SECTION 4
LOCATION OF SAMPLING POINTS
Emissions to the atmosphere from Boiler No. I were measured in
the smokestack. The coal fed into the boiler was sampled at the
end of the coal feed belts from the coal weighing devices that
dump coal into the spreader stokers.
STACK
Four 10.2 cm (4 in.) I.D. sampling ports are located on a 8.8 m
(29 ft) tall, 1.5 m (58 in.) I.D. round smokestack. The sampling
ports are 6.0 m (19.6 ft) downstream of the flue gas inlet (4.1 duct
diameters) and 2.8 m (9.1 ft) upstream of the stack outlet (1.9 duct
diameters) (see Figure 3). The maximum diameter of 58 in. at the
top of the stack was used in the determination of duct diameters
and number of traverse points required based on information given
in Reference [1]. This arrangement meets all criteria for an
acceptable measurement specified under EPA Methods 1-5.
A 36 point traverse was conducted at this location, with 18 points
being sampled at the Southwest (SW) and Southeast (SE) ports as
shown in Figure 4.
COAL FEED SYSTEM
Coal samples were taken from the end of the coal feed belts
that dump the coal into the spreader stokers located inside
the building.
[1] "Guidelines for Sampling in Tapered Stacks," by Tom Logan
and Roger Sigahara. From EPA 450/2-78-042D, Stack Sampling
Technical Information - A Collection of Monographs and Papers
U.S. EPA, Office of Air Quality Planning and Standards,
Research Triangle Park, NC 27711. October 1978.
24
-------
ROOF
STACK
4,4 INCH ID PORTS
INLET TO STACK
BUILDING
Figure 3. Fan, stack, and sample port dimensions
for General Motors Corporaton, Fisher
Body Division, Boiler No. 1 at
Hamilton, Ohio.
25
-------
NW PORT
SW PORT
NJ
1234567 • 9 10 It 12 13 14 151« 1718
4. 4 INCH ID PORTS
NE PORT
3.5"
SEPORT
TOP VIEW STACK
POINT
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
DISTANCE
%FROM
INNER STACK
1.4
4.4
7.5
10.9
14.6
18.8
23.6
29.6
38.2
61.8
70.4
76.4
81.2
85.4
89.1
92.5
95.6
98.6
INCHES FROM
INNER STACK
0.71
2.2
3.8
5.5
7.4
9.5
11.9
15.0
19.3
31.2
35.6
38.6
41.0
43.1
45.0
46.7
48.3
49.8
Figure 4. Traverse point location for General Motors Corporation,
Fisher Body Division, Boiler No. 1 at Hamilton, Ohio.
-------
SECTION 5
SAMPLING AND ANALYSIS PROCEDURES
SUMMARY
The sampling and analysis methods used at the Hamilton site are
shown in Table 1. Three simultaneous runs of Methods 5 and 5B
and three additional runs of Method 5B alone were conducted at
the stack downstream of all pollution control equipment. In all
simultaneous runs a special dual-probe stack test system, with
nozzle centers located 4.4 cm (1.7 in.) from each other, was used
for sampling by Methods 5 and 5B through the same ports.
The flue gas velocity, temperature, flow rate, oxygen content, and
carbon dioxide content were measured by EPA Methods 1-4 during all
the Method 5 and 5B stack sampling runs. Integrated gas samples
were taken from the exhaust of the Method 5B train.
Particulate analysis followed standard Method 5 gravimetric
procedures. All Method 5 and 5B filters and acetone probe
washes were dried and weighed to a constant weight.
During each stack sampling run representative grab samples of the
coal being burned were taken from the feed line to the spreader
stoker. The sulfur, ash, moisture, and heat content of the
samples were analyzed by ASTM Methods D3176 and D2015-66(72).
STACK SAMPLING
Heated glass-lined probes and Reeve Angel Type 934 AH filters
were used for the Method 5 and 5B testing. The filter tempera-
tures were monitored using thermocouples installed in the oven.
A special dual-probe stack test system was used for simultaneous
stack testing by Methods 5 and 5B through the same individual
stack ports. Figure 5 is a schematic diagram of the dual-probe
system. The nozzle centers of the Method 5 and 5B trains were
4.4 cm (1.75 in.) apart in this system. A single pitot tube
between the Method 5 and 5B sampling probes was used to measure
the flue velocity for both trains. Method 3 integrated bag samples
were taken from the exhaust of the Method 5B train. Method 5 and
5B sample volumes of at least 1.7 dry m3 (60 ft3) were taken.
When Methods 5 and/or 5B were used, Methods 1-4 were also used,
as in compliance monitoring.
27
-------
IMPINGERS
THERMOCOUPlf
THERMO COUPU
S-TYPE
VACUUM LINE
AIR-TIGHT
PUMP
Figure 5. Dual-probe sampling train.
28
-------
Plume opacity was observed according to EPA Method 9 during all
sampling runs.
STACK SAMPLE ANALYSES
Gravimetric particulate analyses according to standard Method 5
procedures were conducted on all Method 5 and 5B samples. The
Method 5 and 5B filters and acetone probe washes were dried and
weighed to a constant weight. The weighing was repeated until
the weight of the particulates was within 5 mg of the weight on
the previous weighing. Following particulate analyses, the sam-
ples were submitted to EPA for subsequent analyses.
COAL SAMPLING AND ANALYSES
Aggregate coal samples, corresponding to the coal burned during
each stack sampling run, were taken by grab sampling the coal
from the end of the coal feed belts that dump the coal into the
spreader stokers. Three grab samples were taken during each
sampling run, combined into one aggregate sample per run, and
stored in labelled bottles prior to analyses. Each coal sample
was analyzed for sulfur, moisture, ash, and Btu content according
to ASTM D3176 and D2015-66 bomb calorimetry methods.
SAMPLE HANDLING
Filters were transferred into closed clean containers. Deposits
of the inside of the sampling equipment were removed with acetone
and distilled water. The acetone rinse was bottled. This occurred
in the boiler room or on tables located near the stack. The coal
samples were sealed in plastic containers until ready for analysis.
Access to the samples was limited by storing them in a locked
truck, except when being handled by authorized individuals. The
samples were shipped in the truck to the MRC Dayton Laboratory
for analysis. Records of the chain of custody of the samples
have been maintained.
DATA REDUCTION
MRC's computer and programmable calculators were used to reduce
the analytical and field data to determine results. The "F"
value used to determine ng/joule (lb/106 Btu) emissions was taken
from the boiler emission regulations in 40CFR 60.45(f)(4)(ii).
Appendix A contains copies of all raw field data sheets and cod-
ing sheets for data processing.
Appendix B contains complete computer printouts of the results
of the sampling and emission calculations.
Appendix C (supplied by Radian Corporation) contains boiler
monitoring data during the testing.
29
-------
Appendix D contains the analytical report and a summary of the
results of the quality control and assurance procedures.
Appendix E identifies the people performing the sampling, analysis,
and data reduction.
QUALITY ASSURANCE
The quality assurance and control program included all applicable
procedures specified in the Federal Register for EPA Methods 1-5
and the procedures specified in the EPA Guidelines for the
Development of Quality Assurance Programs for these methods.
Standard ASTM procedures were used for the coal analysis. Bowser-
Morner Testing Laboratories, Inc., the coal analysis subcontractor,
participates in EPA's new quality assurance program for coal
sulfur, ash, and moisture content. This program involves the
analysis of samples provided by EPA.
The accuracy of the data used in computerized data processing was
checked by comparing the printout of the data used to calculate
results with the raw field data used to code the computer input.
30
------- |