United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EMB Report 82-IBR-17
April 1982
Air
Industrial Boilers
Emission Test Report
General Motors Corporation
Lansing, Michigan
-------
INDUSTRIAL BOILERS
Final Report
GENERAL MOTORS CORPORATION
FISHER BODY DIVISION
BOILER NO. 2
Lansing, Michigan
April 19-26, 1982
Technical Directives 23 and 24
by
Duane R. Day
Carol S. Smith
Prepared for
Environmental Protection Agency
Office of Air Quality Planning and Standards
Emission Measurement Branch
Research Triangle Park, NC 27711
Contract No. 68-02-3547
Work Assignment No. 2
(ESED 17/13)
EMB NO. 82-IBR-17
November 5, 1982
MONSANTO RESEARCH CORPORATION
DAYTON LABORATORY
Dayton, Ohio 45407
-------
CONTENTS
Figures iv
Tables v
1. Introduction 1
2. Summary of Results 4
Description of monitoring 4
Test results 5
3. Process Description (provided by Radian Corporation). . 31
Boiler system description 31
Side stream separator system description 34
4. Location of Sampling Points 37
Inlet 37
Outlet 37
Coal feed system 37
Baghouse 43
5. Sampling and Analysis Procedure 46
Summary 46
Stack sampling 46
Stack sample analyses 49
Coal sampling and analyses 49
Data reduction 49
Quality assurance 50
Appendices
A. Field log and sample identification log A-l
B. Printouts of sampling results and emission
calculations B-l
C. Boiler monitoring data (supplied by Radian Corporation) C-l
D. Analytical results, quality control, and coal
analyses results D-l
E. Project participants E-l
0187/A-I iii
-------
FIGURES
Number Page
1 Schematic diagram of mechanical dust collector
and baghouse sample locations at GM Corporation,
Fisher Body Division in Lansing, Michigan .... 2
2 Boiler sidestream separator process flow diagram. . 32
3 Inlet sampling ports to mechanical collector for
Boiler #2 at GM Corporation, Fisher Body
Division in Lansing, Michigan 38
4 Traverse point location at inlet to mechanical
collector for Boiler #2 at GM Corporation,
Fisher Body Division in Lansing, Michigan .... 39
5 Port location on outlet of mechanical collector
for Boiler #2 at GM Corporation, Fisher Body
Division in Lansing, Michigan 40
6 Traverse point locations for outlet of mechanical
collector on Boiler #2 at GM Corporation,
Fisher Body Division in Lansing, Michigan .... 41
7 Photographs of coal scale, inlet and outlet ports
for Boiler #2, GM Corporation, Fisher Body
Division in Lansing, Michigan 42
8 Sample port location at inlet to baghouse for
Boiler #2 at GM Corporation, Fisher Body
, . , . Division in Lansing, Michigan 44
,' i ..•""•''•-
9 Traverse point location at inlet to baghouse for
Boiler #2 at GM Corporation, Fisher Body
Division in Lansing, Michigan 45
10 Particulate sampling train - EPA Method 5B 47
IV
-------
TABLES
Number
1 Source Sampling and Analyses at GM Corporation,
Fisher Body Division in Lansing, Michigan . .
2 Particulate Emission Data for General Motors
Corporation, Fisher Body Division, Boiler
No. 2 in Lansing, Michigan, April 19-26,
1982 (Metric Units)
Particulate Emission Data for General Motors
Corporation, Fisher Body Division, Boiler
No. 2 in Lansing, Michigan, April 19-26,
1982 (English Units) ............... 8
Summary of Duration of Method 5B Sampling,
Boiler Loading, Stack Temperature, Stack
Flow Rate, Sample Volume, Sample Water
Content, and Static Pressure at General
Motors Corporation, Fisher Body Division,
Boiler No. 2 in Lansing, Michigan ........ 10
Summary of Integrated Gas Analysis Results at
General Motors Corporation, Fisher Body
£>oo.j.fci JMO. z 111 Liciiitoxiig , I'iicnigan ... i/
6 Summary of Andersen Particle Size Results ..... 13
7a Summary of Method 9 Visible Emission Observations
at General Motors Corporation, Fisher Body
Division, Boiler No. 2 in Lansing, Michigan
Run No. 1-1/2 .................. 21
7b Summary of Method 9 Visible Emission Observations
at General Motors Corporation, Fisher Body
Division, Boiler No. 2 in Lansing, Michigan
Run No. 2-1/2 .................. 22
7c Summary of Method 9 Visible Emission Observations
at General Motors Corporation, Fisher Body
Division, Boiler No. 2 in Lansing, Michigan
Run No. 3-1/2 .................. 23
-------
TABLES (continued)
Number Page
7d Summary of Method 9 Visible Emission Observations
at General Motors Corporation, Fisher Body
Division, Boiler No. 2 in Lansing, Michigan
Run No. 1-2/3 24
7e Summary of Method 9 Visible Emission Observations
at General Motors Corporation, Fisher Body
Division, Boiler No. 2 in Lansing, Michigan
Run No. 2-2/3 25
7f Summary of Method 9 Visible Emission Observations
at General Motors Corporation, Fisher Body
Division, Boiler No. 2 in Lansing, Michigan
Run No. 3-2/3 26
7g Summary of Method 9 Visible Emission Observations
at General Motors Corporation, Fisher Body
Division, Boiler No. 2 in Lansing, Michigan
Run No. 1-1/3 27
7h Summary of Method 9 Visible Emission Observations
at General Motors Corporation, Fisher Body
Division, Boiler No. 2 in Lansing, Michigan
Run No. 2-1/3 28
7i Summary of Method 9 Visible Emission Observations
at General Motors Corporation, Fisher Body
Division, Boiler No. 2 in Lansing, Michigan
<<-_•- '•->''• •• 'Run No:- 3^-1/3 .3.-^ ? ;-v-v;.j.;. .-.'.. • • - •• - 29
8 Summary of Coal Analysis at General Motors Corpora-
tion, Fisher Body Division, Boiler No. 2 in
Lansing, Michigan, April 19-26, 1982 30
9 Boi3
10 Side Stream Separator Design and Operating Data . . 35
VI
-------
SECTION 1
INTRODUCTION
Emissions from Boiler No. 2 at the General Motors Corporation,
Fisher Body Division Plant in Lansing, Michigan, were tested
April 19-26 by Monsanto Research Corporation (MRC). This work was
performed for Emission Measurement Branch of the U.S. Environmental
Protection Agency (EPA) under Contract 68-02-3547, Work Assignment
No. 2.
The boiler tested is Boiler No. 2, a 81,720 Kg steam/hr (180,000
Ib steam/hr) capacity, coal-fired boiler fed by a moving bed
spreader stoker. It is equipped with a baghpuse and cyclone-type
mechanical dust collector pollution control equipment. Figure 1
is a schematic diagram of the installation showing the mechanical
dust collector and baghouse sampling locations.
The purpose of the sampling program was to provide background
information on well-controlled industrial boilers for the develop-
ment of new source performance standards. Within this framework
the objectives of the sampling at General Motors Corporation in
Lansing, Michigan were: 1) to determine the effect of raising
the temperature 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
emissions measured downstream of the cyclone; and 2) to determine
the effect of varying.boiler load conditions on particulate emis-
p-innp. Method 5 testing with the filter and probe at 160 ± 14°C
(320 ± 2b°F) will be referred to as Method 5B testing.
Table 1 summarizes the monitoring performed at this plant. Phase I
testing consisted of three simultaneous runs of Method 5B at the
inlet and outlet of the mechanical collector at each of 3 different
boiler loadings (2/3, 1/2, and 1/3 capacity), Method 9 visible
emissions simultaneous with each run, and Andersen particle sizing
corresponding to each run at the inlet and outlet.
During Phase II testing, an additional three runs were performed
at the multicyclone outlet during Boiler No. 2 swing load condi-
tions. Also, three Method 5B and three Andersen particle sizing
runs were performed at the inlet to the baghouse collector located
downstream of the dust collector as shown in Figure 1.
Grab samples of coal were taken during every run by sampling from
the feed belt to the spreader stoker. The sulfur, ash, moisture,
and Btu content of each sample were determined according to ASTM
Methods.
-------
TO STACK
BOILf R
ECONOMIZER
6'
20'
ooo
ID
COLLECTOR
INLET
SAMPLING
PORTS
OUTLET SAMPLING PORTS
ROOF LINE
ID FAN
BAGHOUSE FAN
MECHANICAL
COLLECTOR
BAGHOUSE
INLET
SAMPLING
PORTS
ASH
BAGHOUSE
ASH
Figure 1. Schematic diagram of mechanical dust collector and baghouse sampling
locations at GM Corporation, Fisher Body Division in Lansing, Michigan.
-------
TABLE 1. SOURCE SAMPLING AND ANALYSES AT GM CORPORATION,
FISHER BODY DIVISION IN LANSING, MICHIGAN
SAMPLING AND ANALYSIS REQUIREMENTS
MRC Job Ho. 101. 12211
Total
no. of
samples
. 3
3
3
9
9
9
3
3
3
Sample
type
Paniculate, ORSAT
at inlet & outlet
Participate, ORSAI
at inlet & outlet
Participate, ORSAI
at inlet & outlet
Coal
Opacity
Particle sizing
at inlet & outlet
Particulate, ORSAT
at outlet
Particulate, ORSAI
at inlet to baghru
Particulate sizing
at inlet to baghoi
Sampling
method
a 5B
1 5B
a 5B
Grab
9
Andersen
b 5B
se 5B
Andersen
se
Contract No. : 6S-n?-35*7 Assignment Number: 2
Technical Directive: 23 j 24
Company Name: Fisher1Body°Division \^mpany Location: Lansing, Michigan
Industry: Industrial Boiler 12 Process: Coal-fired
spreader stoker
Sampl e
collected
by
MRC
MRC
MRC
MRC
MRC
MRC
MRC
MRC
MRC
Minimum
sampl ing
time
120
120
120
Sitnul ta
wi th al
Simul tai
wi th al
After i
listei
120
120
Aft
list
Minimum
vol ume qa s
sampled ft3
60
60
60
peous
iove
eous
ove
ach run
above
60
60
r run
d above
Initial Analysis
Type Method By
Velocity,
temp, H20,
CO,C02,Oa
Veloci ty ,
temp, H20,
CO,C02,02
Veloci ty,
temp, H20,
CO,C02,02
Visual
Observatio
Veloci ty,
temp , H20 ,
CO C05,0,
Velocity,
temp, H20,
CO,C02,02
1-4
1-4
1-4
,
1-4
1-4
Control Equipment: Multicyclone
and Baghouse
MRC
MRC
MRC
MRC
MRC
MRC
Final Analysis
Type Method By
Particulat
Particulat
Particulat
S, Ash,
moisture,
Particle
sizing
Particulat
Particle
sizing
! 5
; 5
! 5
ASTM
Andersen
i 5
5
Andersen
MRC
MRC
MRC
Bowser-
Morner Labs
MRC
MRC
MRC
MRC
Phase I testing at 2/3, 1/2, and 1/3 boiler loading.
Phase II testing at swing load.
Phase II testing at new location.
-------
SECTION 2
SUMMARY OF RESULTS
DESCRIPTION OF MONITORING
Table 1 summarizes the monitoring that was performed at the Lansing
Plant. Phase I sampling consisted of 3 test runs of Method 5B at
each of three boiler loading conditions at the mechanical dust
collector exhaust performed simultaneously with Method 5B sampling
at the mechanical collector inlet. Because of the 18-foot duct width
at the multicyclone inlet sampling point, two Method 5B sampling
trains were set up on opposite sides of the duct to simultaneous-
ly sample the entire width of the duct. The boiler was operating
under steady state conditions (no soot blowing or ash loading)
at 1/2 capacity during the first set of runs, at 2/3 capacity for
the second set, and at 1/3 loading for the final set.
Phase II sampling consisted of three runs of Method 5B conducted
at the mechanical collector outlet only, with the boiler operating
at a variable or "swing load" capacity. As a part of the Phase II
sampling, three runs of Method 5B were performed at the inlet to
the baghouse collector simultaneously with the Phase I testing at
the 2/3 capacity boiler loading condition.
Methods I through 4 were used during all Method 5B sampling runs,
as in typical compliance sampling runs. Sample volumes of at
least 0.91 dry standard m3 (32 dry standard ft3) were taken during
nine B tnl-al of 91 ^article PI'FP measurements were taken
lected at all sampling points, at the 2/3, 1/2, and 1/3 boiler
load conditions immediately before or after the Method 5B runs, at
a point of average velocity as determined by the Method 5B data.
In addition, plume opacity was measured by EPA Method 9 during all
of the Phase I emission testing.
Feed coal samples were taken at the spreader-stoker inlet to the
boiler. Samples were composited from individual samples collected
T-ir-fnT-p. cH Twiner. anri after each test rn^ The su]fur, ash,
_^^_, mnu ^.i_u i_uiii_c.iii_ Oj. c_ci^.j.i ctyyi.tyo.ue: Sd.lltp.Lfc V/BTfe Qfc
ASTM methods.
-------
TEST RESULTS
Particulate emissions measured by Method 5B at the collector
inlet, outlet, and baghouse inlet are summarized in Tables 2 and
3, in metric and English units, respectively. Tables 2 and 3 also
show that the percent isokinetics for each sampling run ranged
between 98.2 and 103.6, within the acceptable range of 90% to 110%
for all except the first run, which was not isokinetic.
The amounts of particulates, water, and gas volumes reported for
the multicyclone inlet runs represent the combined totals collec-
ted by the two inlet sampling trains. Velocity traverse data from
both sampling trains have been combined for representative isoki-
netic duct sampling conditions over the entire width of the duct.
Emissions were calculated using the F-factor method described in
40 CFR 60.45 by the equation:
E = CF 20'9
20.9 - %02'
where E = emission rate, lb/106 Btu
C = particulate concentration, Ib/dscf
F = constant for coal used, 9,820 dscf/106 Btu
%O2 = percent oxygen in stack
Tables showing all the calculations for emissions are shown in the
latter part of Appendix B.
Emissions were not calculated from Run IT-1-1/2 because the sample
probe was dipped into a dust pile while sampling which resulted in
a non-representative sample.
Table 4 summarizes sampling duration, stack temperature, flow
rate, static pressure, sample volume, and water content. Baghouse
stack temperature data (runs FI-2/3) taken by the temperature
sensor attached to the probe were incorrect due to the high nega-
tive pressure of the stack (-8 in. H20) which sucked in cooler
outside air past the sensor. Baghouse stack temperature used in
Table 4 are based on readings taken at the traverse points fur-
thest from the sampling port.
Table 5 summarizes the integrated gas analysis results for the
samples taken from the exhaust of the Method 5B train.
Table 6 summarizes the results of the Andersen Cascade impactor
sampling. Figures for Andersen results are shown in Appendix A
with the Andersen data sheets. Andersen sampling was performed
at a point of average velocity as determined from the Method 5B
data. With the exception of Run 1-2-1/2, all runs were conducted
under isokinetic conditions.
-------
BLE 2. PARTICULATE EMISSION DATA FOR GENERAL MOTORS CORPORATION,
FISHER BODY DIVISION, BOILER NO. 2 IN LANSING, MICHIGAN,
APRIL 19-26, 1982 (METRIC UNITS)
Average emissions
Run
number te
IT-1-1/2 4 9-82
0-1-1/2
IT-2-1/2 4 '.0-82
0-2-1/2
IT-3-1/2 4 !0-82
0-3-1/2
IT-1-2/3 4 21-82
0-1-2/3
FI-1-2/3
IT-2-2/3 4-22-82
0-2-2/3
FI-2-2/3
IT-3-2/3 4-22-82
0-3-2/3
FI-3-2/3
Location
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Baghouse inlet
Inlet
Outlet
Baghouse inlet
Inlet
Outlet
Baghouse ii
-------
TABLE 2 (continued)
Average emissions
Run
number
IT-1-1/3
0-1-1/3
IT-2-1/3
0-2-1/3
IT-3-1/3
0-3-1/3
0-1-SL
0-2-SL
0-3-SL
Date
4-24-82
4-24-82
4-24-82
4-26-82
4-26-82
4-26-82
Location
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Outlet
Outlet
Outlet
Boiler
load
1/3
1/3
1/3
1/3
1/3
1/3
SLd
SLd
SLd
Actual
g/dscm
2.2267
0.1262
1.7338
0.1303
2.1755
0.1292
0.2019
0.2026
0.1682
kg/hr
83.724
8.463
60.551
8.267
71.041
7.959
12.906
12.957
10.280
ng/J
980.6
72.42
763.5
64.60
1,050.0
62.36
83.06
88.15
71.41
Corrected
to 12% C02,a
g/dscm
2.8425
0.1941
2.2615
0.1907
2.7393
0.1723
0.2330
0.2431
0.2103
Percent
isokinetic
99.8
100.4
99.7
98.5
102.4
101.8
100.2
98.7
98.5
TK-1 *• 4 t- 4
A *•« 1 o
-------
00
TABLE 3. EMISSION DATA FOR GENERAL MOTORS CORPORATION, FISHER
- BODY DIVISION, BOILER NO. 2 IN LANSING, MICHIGAN,
APRIL 19-26, 1982 (ENGLISH UNITS)
Average emissions
Run
number
IT-1-1/2
0-1-1/2
IT-2-1/2
0-2-1/2
IT-3-1/2
0-3-1/2
IT-1-2/3
0-1-2/3
FI-1-2/3
IT-2-2/3
FI-2-2/3
0-2-2/3
IT-3-2/3
0-3-2/3
FI-3-2/3
Date Location
4-19-82 Inlet
Outlet
4-20-82 Inlet
Outlet
4-20-82 Inlet
Outlet
4-21-82 Inlet
Outlet
Baghouse inlet
4-22-82 Inlet
Outlet
Baghouse inlet
4-22-82 Inlet
Outlet
Baghouse inlet
Boiler
load
1/2
1/2
1/2
1/2
1/2
1/2
2/3
2/3
2/3
2/3
2/3
2/3
2/3
2/3
2/3
Actual
gr/dscf
_b
0.0606
1.2956
0.0482
2.1288
0.0546
2.5531
0.0639
4.7834
1.7860
0.0895
4.1254
2.9197
0.0720
4.2403
Ib/hr
_b
15.570
326 . 848
12.231
432.633
13.386
768.567
19.632
324.210
417.626
24.483
273.587
909.971
19.818
275.935
lb/106
Btu
_b
0.19
2.56
0.11
4.21
0.12
5.20
0.14
9.73
3.76
0.21
8.68
6.02
0.19
8.74
Corrected
to 12% C02,a
gr/dscf
_b
0.1173
1 . 2744
0.0536
2.0274
0.0649
2.6119
0.0703
4.9061
1.8637
0.1013
4.3048
3.0467
0.0960
4.4247
Percent
isokinetic
_c
103.7
100.0
100.0
103.6
103.6
103.0
100.9
103.4
98.2
101.3
101.0
99.2
99.3
99.6
(continued)
-------
TABLE 3 (continued)
Average emissions
Run
number
iT-i-m
o-i-i/:
IT-2-1/
o-2-i/:
IT-3-1/
o-3-i/:
0-1-SL
0-2-SL
0-3-SL
Date
4-24-82
4-24-82
4-24-82
4-26-82
4-26-82
4-26-82
Location
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Outlet
Outlet
Outlet
Boiler
load
1/3
1/3
1/3
1/3
1/3
1/3
SLd
SLd
SLd
Actual
gr/dscf
0.9728
0.0551
0.7575
0.0569
0.9505
0.0565
0.0882
0.0885
0.0735
Ib/hr
184.577
18.657
133.489
18.226
156.616
17.546
28.453
28.565
22.663
lb/106
Btu
2.28
0.17
1.77
0.15
2.44
0.14
0.19
0.20
0.17
Corrected
to 12% C02,a
gr/dscf
1.2418
0.0703
0.9880
0.0830
1.1968
0.0753
0.1018
0.1062
0.0919
Percent
isokinetic
99.8
100.4
99.7
98.5
102.4
101.8
100.2
98.7
98.5
TV. -10 i • t
J 4-« 1 t°, 1
T> r> — r
12
A.l*Ata» J • l.»lt^ V.Wilv.^11 *-i a l..LWtl I1W1 Ilia^ J.A««^ VI VV* X£*~o v»vo • ^* — ^ ^* O /^/% ' **>&^-&^- s» ^.*^ W«AL •n^vAwvftAi
•6UO2
concei ration in the stack, and percent C02 is the percent C02 measured in the stack.
Emissi >n rates not calculated due to nonrepresentative sample taken.
Becau: • of an error in temperature of meter, the first inlet run was not performed
under sokinetic conditions.
Swing oad, variable load - approximately 2/3 capacity at time of sampling.
-------
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. 2 IN LANSING, MICHIGAN
Run
number
IT-1-1/2
0-1-1/2
IT-2-1/2
0-2-1/2
o IT-3-1/2
0-3-1/2
IT-1-2/3
0-1-2/3
FI-1-2/3
IT-2-2/3
0-2-2/3
FI-2-2/3
IT-3-2/3
0-3-2/3
FI-3-2/3
Duration Measured
of stack
sampling, temperature
Location min °C °F
Total inlet3
Outlet
Total inlet
Outlet ; ;
Total inlet
Outlet
Total inlet
Outlet
Baghouse inlet
Total inlet
Outlet
Baghouse inlet
Total inlet
Outlet
Baghouse inlet
132
126
144
126
144
126
144
126
108
144
126
108
144
126
108
140b
144
138b
142
139b
141
150b
153
147C
144b
1«
147C
147b
153r
147°
283b
291
280b
287
282b
286
301b
308
296C
291b
299
296C
297b
298
296°
Stack
flow rate
dscm/
min
698
849
834
848
672
810
988
1,015
224
753
904
219
1,031
910
215
dscf/
min
24,648
29,978
29,437
29,959
23,714
28,589
34,879
35,833
7,909
26,586
31,915
7,738
36,413
32,139
7,594
volume
dscm
1.22
0.95
1.95
0.93
1.62
1.49
2.39
1.40
1.76
1.12
1.25
1.69
2.01
1.62
1.63
dscf
43.06
33.42
68.77
32.50
57.36
52.60
84.47
49.29
62.32
39.27
44.09
59.57
71.02
57.04
57.70
Sample
water
content,
%
7.76
6.26
6.10b
7.22
8.81b
7.00
7.94b
7.37
7.44
7.42b
6.55
7.51
7.83b
7.20
7.40
Stack static
pressures
cm H20
-2.54
-0.38
-2.54
-0.38
-2.54
-0.38
-5.08
-0.38
-20.32
-5.08
-0.38
-20.32
-5.08
-0.38
-20.32
in. H20
-1.00
-0.15
-1.00
-0.15
-1.00
-0.15
-2.00
-0.15
-8.00
-2.00
-0.15
-8.00
-2.00
-0.15
-8.00
(continued)
-------
TABLE 4 (continued)
Run
number
IT-1-1/3
0-1-1/3
IT-2-1/3
0-2-1/3
IT-3-1/3
0-3-1/3
0-1-SL
0-2-SL
0-3-SL
Location
Total inlet
Outlet
Total inlet
Outlet
Total inlet
Outlet
Outlet
Outlet
Outlet
Duration Measured
of stack
sampling, temperature
min °C °F
144
95
144
100
144
95
120
120
120
137b
141
135b
142
134b
143
152
151
150
278b
285
275b
288
274b
289
306
304
301
Stack
flow rate
dscm/
min
626
1.118
579
1,058
533
1,027
1,066
1,066
1,019
dscf/
min
22,114
39,476
20,445
37,371
18,819
36,269
37,645
37,656
35,981
volume
dscm
1.49
1.51
1.39
1.48
1.33
1.41
1.81
1.78
1.70
dscf
52.76
53.39
48.96
52.20
46.99
49.76
63.84
62.89
59.93
Sample
water
content.
Stack static
pressures
% cm H20
7.14b
5.80
7.45b
6.60
7.07b
6.55
8.10
8.36
7.40
-2.
-1.
-2.
-1.
-2.
-1.
-0.
-0.
-0.
54
27
54
27
54
27
38
38
38
in. H20
-1.00
-0.50
-1.00
-0.50
-1.00
-0.50
-0.15
-0.15
-0.15
Total inlet runs were conducted with two sampling trains at Inlet A and Inlet B.
Average value for A and B sampling runs combined.
"Stack temperature for 3 baghouse runs as determined at the traverse point furtherest from the port
opening of baghouse inlet. High negative pressure at this location prevented accurate readings
at nearer points.
-------
TABLE 5. SUMMARY OF INTEGRATED GAS ANALYSIS RESULTS AT GENERAL
MOTORS CORPORATION, FISHER BODY DIVISION, BOILER
NO. 2 IN LANSING, MICHIGAN, APRIL 19-26, 1982
Run
number
IT-1-1/2
0-1-1/2
IT-2-1/2
0-2-1/2
IT-3-1/2
0-3-1/2
IT-1-2/3
0-1-2/3
FI-1-2/3
IT-2-2/3
0-2-2/3
FI-2-2/3
IT-3-2/3
0-3-2/3
FI-3-2/3
IT-1-1/3
0-1-1/3
IT-2-1/3
0-2-1/3
IT-3-1/3
0-3-1/3
0-1-SL
0-2-SL
0-3-SL
Percent
Location
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Baghouse inlet
Inlet
Outlet
Baghouse
Inlet
Outlet
Baghouse inlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Outlet
Outlet
Outlet
C09
10.6
6.2
12.2
10.8
12.6
10.1
11.7
10.9
11.7
11.5
10.6
11.5
11.5
9.0
11.5
9.4
7.8
9.2
8.2
9.4
7.8
9.2
9.2
8.2
CO
0.2
1.3
0.2
0.3
0.4
0.9
0.2
0.5
0.2
0.7
0.2
0.7
1.5
0.9
1.5
0.7
1.0
1.2
1.1
0.2
0.7
0.4
0.9
0.9
0,
7.8
11.7
6.1
8.1
6.1
7.6
6.5
7.3
6.5
7.0
8.6
7.0
6.3
9.7
6.3
8.3
10.3
8.4
9.8
8.3
10.3
8.4
8.4
9.8
Dry
molecular
weight
kg/ kg mole
N, (Ib/lb mole)
81.4
80.8
81.5
80.8
80.9
81.4
81.5
81.2
81.5
80.8
80.6
80.8
81.0
80.4
81.0
81.6
80.8
81.2
80.9
81.6
80.8
81.2
81.2
80.9
30.0
29.5
30.2
30.1
30.3
29.9
30.1
30.0
30.1
30.1
30.0
30.1
30.2
30.0
30.2
29.8
29.6
29.8
29.7
29.8
29.6
29.8
29.8
29.7
12
-------
TABLE 6. SUMMARY OF ANDERSEN PARTICLE SIZE RESULTS
to
Flow rate Percent
Location Run acm/min acf/min isokinetic Stage
Inlet 1-1-1/2 0.018 0.65 91.1 0
1
2
3
4
5
6
7
Final filter
Outlet 0-1-1/2 0.019 0.67 96.4 0
1
2
3
4
5
6
7
Final filter
Inlet 1-2-1/2 0.026 0.91 122.3 0
1
2
3
4
5
6
7
Size
range ,
(jm
>12.9
8.1-12.9
5.5-8.1
3.8-5.5
2.4-3.8
1.2-2.4
0.74-1.2
0.50-0.74
0.0-0.50
>13.0
8.2-13.0
5.4-8.2
3.9-5.4
2.4-3.9
1.2-2.4
0.74-1.2
0.50-0.74
0.0-0.50
>11.4
7.1-11.4
4.8-7.1
3.3-4.8
2.2-3.3
1.0-2.2
0.64-1.0
0.43-0.64
Percent
in size
range
94.86
2.24
0.79
0.40
0.66
0.26
0.26
0.13
0.40
40.32
4.03
10.48
15.32
9.68
8.07
1.61
2.42
8.07
92.98
2.03
0.92
1.85
0.55
0.37
0.37
0.19
Cumulative
percent,
-------
TABLE 6 (continued)
Flow rate Percent
Location Run acm/min acf/min isokinetic Stage
Outlet 0-2-1/2 0.019 0.68 100.4 0
1
2
3
4
5
6
7
Final filter
Inlet 1-3-1/2 0.020 0.69 107.0 0
1
2
3
4
5
6
7
Final filter
Outlet 0-3-1/2 0.019 0.67 101.1 0
1
2
3
4
5
6
7
Final filter
Size
range ,
(jm
>13.0
8.1-13.0
5.5-8.1
3.8-5.5
2.4-3.8
1.2-2.4
0.74-1.2
0.50-0.74
0.0-0.50
>12.9
8.1-12.9
5.4-8.1
3.7-5.4
2.4-3.7
1.2-2.4
0.74-1.2
0.50-074
0.0-0.50
>13.1
8.2-13.1
5.5-8.2
3.8-5.5
2.4-3.8
1.2-2.4
0.75-1.2
0.51-0.75
0.0-0.51
Percent
in size
range
56.58
5.37
6.34
2.44
9.27
8.29
0.49
2.93
8.29
83.09
4.86
2.47
1.60
0.29
2.83
2.18
2.03
0.65
14.47
14.47
15.79
2.63
7.90
17.11
10.52
7.90
9.21
Cumulative
percent,
-------
TABLE 6 (continued)
in
Flow rate Percent
Loca ion Run acm/min acf/min isokinetic Stage
Inlet 1-1-2/3 0.020 0.72 102.1 0
1
2
3
4
5
6
7
Final filter
Outlet 0-1-2/3 0.019 0.66 96.6 0
1
2
3
4
5
6
7
Final filter
Inlet 1-2-2/3 0.023 0.80 105.9 0
1
2
3
4
5
6
7
Final filter
Size
range ,
pm
>12.4
7.8-12.4
5.2-7.8
3.6-5.2
2.3-3.6
1.15-2.3
0.72-1.15
0.49-0.72
0.0-0.49
>13.2
8.2-13.2
5.6-8.2
3.8-5.6
2.4-3.8
1.2-2.4
0.75-1.2
0.51-0.75
0.0-0.51
>12.0
7.4-12.0
5.0-7.4
3.5-5.0
2.2-3.5
1.0-2.2
0.67-1.0
0.47-0.67
0.0-0.47
Percent
in size
range
90.41
2.75
3.80
1.14
0.28
0.38
0.29
0.19
0.76
28.67
10.04
8.60
19.35
6.09
12.19
2.51
2.51
10.04
80.04
3.99
6.37
2.04
2.28
0.38
0.67
1.71
2.47
Cumulative
percent,
-------
TABLE 6 (continued)
Flow rate Percent
Location Run acm/min acf/min isokinetic Stage
Outlet 0-2-2/3 0.019 0.66 100.3 0
1
2
3
4
5
6
7
Final filter
Inlet 1-3-2/3 0.022 0.76 105.8 0
1
2
3
4
5
6
7
Final filter
Outlet 0-3-2/3 0.019 0.66 99.7 0
1
2
3
4
5
6
7
Final filter
Size
range ,
\im
>13.2
8.2-13.2
5.6-8.2
3.8-5.6
2.4-3.8
1.2-2.4
0.75-1.2
0.51-0.75
0.0-0.51
>12.4
7.7-12.4
5.2-7.7
3.6-5.2
2.3-3.6
1.1-2.3
0.70-1.1
0.48-0.70
0.0-0.48
>13.2
8.2-13.2
5.6-8.2
3.8-5.6
2.4-3.8
1.2-2.4
0.75-1.2
0.51-0.75
0.0-0.51
Percent
in size
range
26.34
8.78
10.25
3.90
13.17
13.66
5.85
4.88
13.17
78.07
5.06
3.07
3.99
1.53
2.45
2.15
0.92
2.76
17.07
11.22
7.80
13.66
10.24
9.76
7.81
6.34
16.10
Cumulative
percent,
-------
TABLE 6 (continued)
Flow rate Percent
Location Run acm/min acf/min isokinetic Stage
Inlet 1-1-1/3 0.021 0.75 102.4 0
1
2
3
4
5
6
7
Final filter
Outlet 0-1-1/3 0.020 0.69 100.9 0
1
2
3
4
5
6
7
Final filter
Inlet 1-2-1/3 0.020 0.69 102.8 0
1
2
3
4
5
6
7
Final filter
Size
range ,
(jm
>12.5
7.8-12.5
5.2-7.8
3.6-5.2
2.3-3.6
1.1-2.3
0.70-1.1
0.48-0.70
0.0-0.48
>12.9
8.1-12.9
5.4-8.1
3.7-5.4
2.4-3.7
1.2-2.4
0.74-1.2
0.50-0.74
0.0-0.50
>12.7
8.0-12.7
5.4-8.0
3.7-5.4
2.4-3.7
1.2-2.4
0.73-1.2
0.49-0.73
0.0-0.49
Percent
in size
range
86.24
3.52
2.52
2.18
0.84
0.84
1.17
0.17
2.52
18.71
10.32
13.55
10.97
12.26
7.74
6.45
7.10
12.90
87.67
3.04
2.53
1.18
1.52
0.17
1.01
0.51
2.37
Cumulative
percent,
-------
TABLE 6 (continued)
Flow rate Percent
Location Run acm/min acf/min isokinetic Stage
Outlet 0-2-1/3 0.020 0.69 100.5 0
1
2
3
4
5
6
7
Final filter
Size
range ,
pm
>12.9
8.1-12.9
5.4-8.1
3.7-5.4
2.4-3.7
1.2-2.4
0.74-1.2
0.50-0.74
0.0-0.50
Percent
in size
range
23.72
7.11
9.48
10.28
17.00
10.28
6.72
4.74
10.67
Cumulative
percent,
13.1
8.2-13.1
5.6-8.2
3.8-5.6
2.45-3.8
1.25-2.45
0.75-1.25
0.52-0.75
0.0-0.52
>12.6
7.8-12.6
5.3-7.8
3.6-5.3
2.3-3.6
1.1-2.3
0.71-1.1
0.48-0.71
0.0-0.48
86.62
4.25
2.02
1.39
1.67
1.53
0.77
0.84
0.91
20.24
5.95
4.76
11.91
10.71
7.14
12.50
14.88
11.91
13.38
9.13
7.11
5.72
4.05
2.52
1.75
0.91
0.0
79.76
73.81
69.05
57.14
46.43
39.29
26.79
11.91
0.0
(continued)
-------
TABLE 6 (continued)
Flow rate
Location Run acm/min acf/min
Baghouse inlet FI-1-2/3 0.019 0.68
Baghouse inlet FI-2-2/3 0.020 0.69
Baghouse inlet FI-3-2/3 0.019 0.68
Percent
isokinetic Stage
102.4 0
1
2
3
4
5
6
7
Final filter
104.0 0
1
2
3
4
5
6
7
Final filter
101.8 0
1
2
3
4
5
6
7
Final filter
Size
range ,
|jm
>12.8
8.0-12.8
5.4-8.0
3.7-5.4
2.4-3.7
1.2-2.4
0.73-1.2
0.49-0.73
0.0-0.49
>12.9
8.1-12.9
5.4-8.1
3.7-5.4
2.4-3.7
1.2-2.4
0.74-1.2
0.50-0.74
0.0-0.50
>13.0
8.1-13.0
5.5-8.1
3.8-5.5
2.4-3.8
1.2-2.4
0.74-1.2
0.50-0.74
0.0-0.50
Percent
in size
range
74.14
4.37
3.90
2.95
3.66
2.24
3.78
1.65
3.31
86.36
0.44
5.90
3.08
0.44
0.35
0.97
2.11
0.35
75:00
7.44
3.37
2.11
4.50
2.81
0.56
0.70
3.51
Cumulative
percent,
-------
Tables 7a-7i summarize results of nine visible emissions observa-
tions taken according to EPA Method 9 during all of the Phase I
emission testing.
Coal analysis data is summarized in Table 8.
20
-------
TABLE 7a. iSUMMARY OF METHOD 9 VISIBLE EMISSION OBSERVATIONS AT
GENERAL MOTORS CORPORATION, FISHER BODY DIVISION,
BOILER NO. 2 IN LANSING, MICHIGAN - RUN NO. 1-1/2
Date. 4-19-82
Type of Discharge: Stack
Height of Point of Discharge: ISO ft
Wind Direction: W
Color of Plume: Brown to black
Observer Name. Vasu B. Kulkarni
Distance Prom Observer to Discharge Point: 200 ft
Direction of Observer From Discharge Point: SE
Height of Observation Point: Ground level
Description of Background: Blue sky, changing to dark gray cloudy iky
Type of Plant: automobile
Location of Discharge: Boiler t2 Stack
Description of Sky: Cloudy
Wind Velocity: S-10 aph
Detached Plume: No
Duration of Observation: 174 Bin total
Summary of average opacity
Set
number
1
2
3
4
5
6
Test began
7
8
9
10
11
12
13
14
15
16
17
16
19
20
" 21
22
23
24
25
26
27
26
29
Test ended8
Average,
all sets
Time
Start
14:10
14:16
14:32
14:26
14:34
14:40
14:46
14:52
14:58
15:04
15:10
15:15
15:22
15:28
15:34
15:40
15:46
15:52
15:58
16:04
16:10
16:16
16:22
16:28
16:34
16:40
16:46
16:52
16:58
End
14:15
14:21
14:27
14:33
14:39
14:45
14:51
14:57
15:03
15:09
15:15
15:21
15:27
15:33
15:39
15:45
15:51
15:57
16:03
16:09
16:15
16:21
16:27
16:33
16:39
16:45
16: SI
16:57
17:03
Opacity
Sum
140
110
210
160
120
135
175b
125b
105b
30b
180b
400.
160b
220b
310
225
275
280.
95b
45C
205
210
190.
155b
230
285.
250d
average
S.6
4.6
8.8
6.7
5.0
S.6
7.3.
6 .3.
10. Ob
9.5b
7 5C
«-SK
11. 3b
16.7.
12. 3b
13. Bb
12.9
9.4
11.5
11.7
10. 6b
S.6C
B.S
B.8
7.9K
9.7b
9.6
11.9.
10.4d
9.3
21
-------
TABLE 7b. SUMMARY OF METHOD 9 VISIBLE EMISSION OBSERVATIONS AT
GENERAL MOTORS CORPORATION, FISHER BODY DIVISION,
BOILER NO. 2 IN LANSING, MICHIGAN - RUN NO. 2-1/2
Date: 4-20-B2 Type of Plant: Automobile
Type of Discharge: Stack Location of Discharge: Boiler 12 Stack
Height of Point of Discharge: ISO ft Description of Sky.- Overcast to clearing
Wind Direction: V Wind Velocity: 10 mph
Color of Plume: Black Detached Plume: Mo
Observer Name: Vasu B. Kulkarni Duration of Observation: 174 Bin total*
Distance From Observer to Discharge Point: 2SO ft
Direction of Observer From Discharge Point: S
Height of Observation Point: Ground level
Description of Background: Dark gray clouds, changing to blue sky
Summary of average opacity
Set
number
1
Test began
2
3
4
5
6
7
B
9
10
11
12
13
14
15
16
17
16
19
20
21
22
23
24
Test ended
25
26
27
28
29
Average ,
all sets
. except 23
Time
Start
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
10:46
10:54
11:00
11:06
11:12
11:18
11:24
11:30
11:36
11:42
11:48
11:54
12:00
12:06
12:12
12:18
End
9:35
9:41
9:47
9:53
9:59
10:05
10:11
10:17
10:23
10:29
10:36
10:41
10:47
10:53
10:59
11:05
11:11
11:17
11:23
11:29
11:35
11:41
11:47
11:53
11:59
12:05
12:11
12:17
12:23
Opacity
Sum
130
140fa
60b
120.
55°
185
135b
50b
160D
715
55b
75b
200
160
200.
230b
»°b
***b
80°
235
b*C
385
55^
ISO*
200b
195b
80
Average
5.4
5.8.
5 0
5.0b
5-°b
5.0
7.7
5'6b
5'6b
8.0°
29. a
13 8r
6.?"
8.3
6.7
8.3.
10. 5b
7'9b
8'2b
5'°b
7.3°
9.8
b,c
16.0*
13. eb
7.9
10. Ob
9.3b
10.0
8.8
22
-------
TABLE 7c. SUMMARY OF METHOD 9 VISIBLE EMISSION OBSERVATIONS AT
GENERAL MOTORS CORPORATION, FISHER BODY DIVISION,
BOILER NO. 2 IN LANSING, MICHIGAN - RUN NO. 3-1/2
Date: 4-20-62 Type of Plant: Automobile
Type of Discharge: Stack Location of Discharge: Boiler *2 Stack
Height of Point of Discharge: 150 ft Description of Sky: Partly Cloudy
Wind Direction: W Hind Velocity: 10-15 «ph
Color of Plume: Black to brown Detached Plume. No
Observer Name: Vasu B. Kulkarni Duration of Observation: 168 Bin total
Distance From Observer to Discharge Point: 350 ft
Direction of Observer From Discharge Point: N changing to SE
Height of Observation Point: Ground level
Description of Background: Blue sky
Summary of average opacity
Set
number
Test began
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Is
16
17
IE
19
20
21
22
23
Test ended
24
25
26
27
28
Averag; .
all sets
except 5
and 11
Time
Start
14:40
14:46
14:52
14:58
15:04
15:10
15:16
15:22
15:28
15:34
15:40
15:46
15:52
JS-.5E
16:04
16:10
16:16
16:22
16:26
16:34
16:40
16:46
16:52
15:58
17:04
17:10
17:16
17:22
End
14:45
14: SI
14:57
15:03
15:09
15:15
15:21
15:27
15:33
15:39
15:45
15:51
15:57
16:03
16:09
16:15
16:21
16:27
16:33
16:39
16:45
16:51
16:57
17:03
17:09
17:15
17:21
17:27
Opacity
Sum
h
B5b
so
95°
75b
D
110
80?
30
"K
140b
_c
*°h
100b
4.
165.
215b
275
2£C'b
255b
175°
170C
145C
25Cb
150.
145b
200
70
Average
5.0?
5.0
6.8?
6.3?
b~
d U
5'°K
5 0
7-5t
7.0b
_c
5.0^
5 . 3,
5.0b
6.9.
10. 2b
11.5
11.7
9.4°
12.8b
11. 7D
10.6
12. 1C
10. 9b
7.5b
8.1b
8.3
5.8
7.9
-T.—i ,W.w>.
23
-------
TABLE 7d. SUMMARY OF METHOD 9 VISIBLE EMISSION OBSERVATIONS AT
GENERAL MOTORS CORPORATION, FISHER BODY DIVISION,
BOILER NO. 2 IN LANSING, MICHIGAN - RUN NO. 1-2/3
Date 4-21-6? Type of Plant: Autosnbile
Type of Discharge Stack Location of Discharge: ioiltr 12 Stack
Height of Point of Diich.ro*: ISO ft Description of Sky: Clear
Wind Direction: V Mine Velocity: 10-15 Bf>h
Color of Plune: Brown to black Detached Plua*: No
Observer Nai»e Vasu B. Kulkarni Duration of Observation: 1*1 »in total*
Distance Fro* Observer to Discharge Point: 250 ft
Direction of Observer From Discharge Point: 5
Height of Observation Point: Ground level
Description of Background. Blue aky
Set
number
1
2
3
4
Test began
5
t
7
B
9
10
11
12
13
14
15
16
17
IB
19
20
21
22
23
24
25
26
27
26
29
JO
31
32
33
14
35
36
37
Test ended
38
19
40
41
Average ,
•11 tats
except 7 ,
B. 9. 17.
ie. 21.
24. t 10
Suranft : *' of
Tine
5ta-t
10:25
10:31
10:37
10:43
10:49
10.55
11:01
11:07
11:13
11:19
11:25
11:31
11-37
11.43
11 49
11.55
12 01
12 37
12 !3
12 '.9
12.25
12.31
12 37
12:43
12:49
12:55
13:01
13:07
13:13
11:19
13:25
13 3]
13 37
13:43
13 49
13 55
14:01
14:07
14:11
14:19
14:25
average
opacity
Opacity
End
10:30
10:36
10:42
10:46
10:54
11:00
11:06
11:12
11:16
11:24
11:30
11:36
11:42
11:46
11:54
12:00
12:06
12:12
12:16
12:24
12:10
12:16
12:42
12:46
12:54
13:00
13:06
11:12
11:16
11:24
13:30
13:36
13:42
13:46
13:54
14:00
14:06
14:12
14:16
14:24
14:10
SUBI
460
495
460
175
430
155,
_c
_c
^c
430
460
275C
435
440
435
145f
*£
*f
270*
465
490,,
120*
.9
_g
145'
535
570
S4S,.
"°c
95C
535
610
595
575
505
575
S45
465
405
MO
averaoe
20.0
20.7
19.2
15.6
17.9
14.6.
c
c
_c
21.5
22.9,
17. 2C
16.1
16.3
16.1
17. 3f
~f
' r
16.9
19.4
20.4.
24.0*
.9
9
21.6*
22.3
23.6
22.7
».J«
23. ec
22.3
25.4
24.8
24.0
21.0
24.6
22.1
20.2
It. »
17.0
20.5
24
-------
TABLE 7e. SUMMARY OF METHOD 9 VISIBLE EMISSION OBSERVATIONS AT
GENERAL MOTORS CORPORATION, FISHER BODY DIVISION,
BOILER NO. 2 IN LANSING, MICHIGAN - RUN NO. 2-2/3
Date: 4-22-62 Type of PUnt: AutOBobile
Type of Discharge: Stick Location of Discharge: Boiler t2 Stack
Height of Point of Discharge: ISO ft Description of Sky: Clear
Wind Direction: u wind Velocity: 5-10 apt)
Color of Plume: Brown to black Detached Flune: No
Observer Name: Vacu B. Kulkarni Duration of Observation: 162 Bin total
Distance From Observer to Discharge Point: 200 ft
Direction of Observer From Discharge Point: HE, SE, S
Height of Observation Point: SO ft
Description of Background: Blue sky
Summary of average opacity
Set
number
1
2
Test began
3
4
5
6
7
E
9
K
11
12
13
14
15
Ifc
1"
16
19
20
21
"22
23
24
25
Test ended
26
27
Average .
all sets
Tine
Start
9:00
9:06
9, -12
9:16
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
11:12
11:18
11:24
11:30
11:36
End
9:05
9:11
9:17
9:23
9:29
9:35
9:41
9:47
9:53
9:59
10:05
10:11
10:17
10:23
10:29
10:35
10:41
10:47
10:53
10:59
11:05
11:11
11:17
11:23
11:29
11:35
11:41
Opacity
Sum
495
510
625
620
625
605
750
600
SB5
710
115C
685
BBS
950
845
795
660
755
490
440h
445C
c
305h
410
365
420
370
Average
20.6
21.3
26.0
25. B
26.0
25.2
31.3
25.0
24.4
29.6
28.6
36.9
36.9
39.6
35.2
33.1
35. B
31.5
32. 7?
22. Oh
22. 3C
23.1 =
17. 9h
17.1
16.0
17.5
23.1
26. B
o1
L
25
-------
TABLE 7f. SUMMARY OF METHOD 9 VISIBLE EMISSION OBSERVATIONS
GENERAL MOTORS CORPORATION, FISHER BODY DIVISION,
BOILER NO. 2 IN LANSING, MICHIGAN - RUN NO. 3-2/3
AT
Date: 4-22-82
Type of Discharge: Stack
Height of Point of Discharge: ISO ft
Wind Direction: NW
Color of Plume: Brown to black
Observer Name: Vasu B. Kulkarni
Distance From Observer to Discharge Point: 200 ft
Direction of Observer From Discharge Point: S
Height of Observation Point: SO ft
Description of Background: Blue sky
Type of Plant: Automobile
Location of Discharge: Boiler t2 Stack
Description of Sky: Clear
Wind Velocity: 10 nph
Detached Plume: No
Duration of Observation: 174 nin total
Summary of average opacity
Set
number
Test
1
2
began
3
4
5
6
7
6
9
10
11
12
13
14
15
16
17
18
19
20
21
'22
Test
23
24
25
2t
27
ended
28
29
Time
Start
13
14
14
14
14
14
14
14
14
14
14
15
15
15
IS
15
15
15
15
15
15
16
16
16
16
16
16
16
16
:S5
:01
:07
:13
:19
:25
:31
:37
:43
:49
:55
:01
:07
:13
:19
:25
:31
:37
:43
:49
:55
:07
: 13
:19
:25
:31
:37
:43
End
14
14
14
14
14
14
14
14
14
14
15
15
15
15
IS
IS
15
IS
15
15
16
16
16
16
16
16
16
:00
:06
:12
:16
:24
:30
:36
:42
:48
:54
:00
:06
:12
:1B
-.24
:30
:36
:42
:4B
:54
:00
:06
:12
:18
:24
:30
:36
16:40
16
:46
Opacity
Sum
440
530
460
460
490.
465h
460
445
405
210h
80C
415
410
325
395*
405h
500
420
500
SB5,
405C
100C
430
430
330
420
335
L.
210h
135
Average ,
Average
IB
22
19
19
20
25
19
18
16
16
20
17
17
13
20
21
20
17
20
24
20
12
17
17
13
17
14
13
16
IB
3
1
2
2
4
B
2
5
9h
2h
oc
3
1
5.
8h
3h
B
S
8
4,
2C
Sc
9
9
8
5
0
u
lh
9
4
all sets
»•
|A4
26
-------
TABLE 7g. SUMMARY OF METHOD 9 VISIBLE EMISSION OBSERVATIONS AT
GENERAL MOTORS CORPORATION, FISHER BODY DIVISION,
BOILER NO. 2 IN LANSING, MICHIGAN - RUN NO. 1-1/3
Type of Plant: Automobile
Location of Discharge: Boiler *2 Stack
Description of Sky-. Clear
Hind Velocity: 5-10 «ph
Detached Plume: No
ISO ft
Date: 4-24-B2
Type of Discharge: Stack
Height of Point of Discharge:
Wind Direction: SW
Color of Plume: Dark brown to black
Observer Name-. Vasu B. Kulkarni
Distance From Observer to Discharge Point: 200 ft
Direction of Observer From Discharge Point: S
Height of Observation Point: 50 ft
Description of Background: Blue sky
Duration of Observation: 126 Bin total
Summary of average opacity
Set
number
Test began
1
2
3
4
5
6
7
B
9
10
11
12
13
14
15
16
"17
Test ended
18
19
20
21
Average ,
all sets
10-
*•
*"»
r-
~1
t
• •
Time
Start
8:15
8:21
6:27
8:33
6:39
8:45
6:51
8:57
9:03
9:09
9:15
9:21
9:27
9:33
9:39
9:45
9:51
9:57
10:03
10:09
10:15
End
8
8
8
8
8
8
8
9
9
9
9
9
9
9
20
:26
•32
:38
.44
:50
:56
= 02
:08
:14
:20
:26
:32
:38
9:44
9
9
10
10
10
10
:50
:56
:02
:OB
:14
:20
Opacity
Sum
475
535
570
610
600
605
385
370
410
360
235C
520
360
345
330
265
335
325
360
270
135
Average
19.8
22.3
23.8
25.4
25.0
25.2
16.0
15.4
17.1
15.0
19. 6C
21.7
15.0
14.4
13.6
11.0
14.0
13.5
15.0
11.3
11.3
17.4
\,
T.»»l , Vi^r
27
-------
TABLE 7h. SUMMARY OF METHOD 9 VISIBLE EMISSION OBSERVATIONS AT
GENERAL MOTORS CORPORATION, FISHER BODY DIVISION,
BOILER NO. 2 IN LANSING, MICHIGAN - RUN NO. 2-1/3
Dale: 4-14-62
Type of Discharge: Stack
Height of Point of Discharge: 150 ft
wind Direction: W
Color of Plume: Brown to black
Observer Name: Vasu B. Kulkarni
Distance From Observer to Discharge Point: 300 ft
Direction of Observer From Discharge Point: S
Height of Observation Point: 50 ft
Description of Background: Blue sky
Type of Plant: Automobile
Location of Discharge: Boiler «2 Stack
Description of Sky: Clear
Wind Velocity: 5-10 mph
Detached Plume: No
Duration of Observation: 126 Din total
Set
number
Summary of
average opacity
Time
Start
End
Opacity
Sum
Average
Test began
1
2
3
4
5
6
7
6
9
10
11
12
• ~
14
15
16
17
18
11:50
11:56
12:02
12:08
12:14
12:20
12:26
12:32
12:38
12:44
12:50
12:56
13:02
13:06
13:14
13:20
13:26
13:32
11:55
12:01
12:07
12:13
12:19
12:25
12:31
12:37
12:43
12:49
12:55
13:01
13:07
13:13
13:19
13:25
13:31
13:37
345
310
365
415
390
430
310
295
280
250^
180C
230
220
180
255
255
245
200
14.4
12.9
15.2
17.3
16.3
17.9
12.9
12.3
11.7
10.4
11. 3C
9.6
9.2
7.5
10.6
10.6
10.2
8.3
Test ended
19
20
21
Average ,
13:38
13:44
13:50
13:43
13:49
13:55
205
175
70
8.5
7.3
8.8
11.6
•11 sets
i»-
!••
*„
f-
"l
O
if
\
Vrx.
1
28
-------
TABLE 7i. SUMMARY OF METHOD 9 VISIBLE EMISSION OBSERVATIONS AT
GENERAL MOTORS CORPORATION, FISHER BODY DIVISION,
BOILER NO. 2 IN LANSING, MICHIGAN - RUN NO. 3-1/3
Date: 4-24-B2 Type of PUnt: Automobile
Type of Discharge: Stack Location of Discharge.: Boiler t2 Stack
Height of Point of Discharge: ISO ft Description of Sky: Clear
Wind Direction: W Wind Velocity: 5 «ph
Color of Plume: Dark brown to black Detached Plume: No
Observer Name: Vasu B. Kulkami Duration of Observation: 120 Bin total
Distance From Observer to Discharge Point: 250 ft
Direction of Observer From Discharge Point: N
Height of Observation Point: Ground level
Description of Background: Blue Iky
Summary of average opacity
Set
number
1
Test began
2
3
4
5
6
7
B
9
10
^ 1
12
13
14
15
16
n
Test ended
18
19
20
Average ,
all sets
Time
Start
15:30
15:36
15:42
15:4B
15:54
16:00
16:06
16:12
16:16
16:24
I i . 1 -
16:36
16:42
16:46
16:54
17:00
17:06
17:12
17:18
17:24
End
15:35
15:41
15:47
15:53
15:59
16:05
16:11
16:17
16:23
16:29
1 i : 3.1
16:41
16:47
16:53
16:59
17:05
17:11
17:17
17:23
17:29
Opacity
Sun
250
150
180
160
205
345
420
490
560
540
520
545
460
335
255
260
240
255
260
255
Average
10.4
6.3
7.5
6.7
6.6
14.4
17.5
20.4
23.3
22.5
21.7
22.7
19.2
14.0
10.6
10.6
10.0
10.6
10.8
10.6
11.6
*Total observation tine includes periods when no
opacity readings could be obtained because of
transient conditions.
Observations were interrupted by poor visibility
due to weather conditions and cloudy skies.
Observations were interrupted by the oove to a
different observation point.
Observations were suspended because of dark
clouds and poor light for observation.
Method 5B run was completed at 1801. Poor
weather conditions prevented plume opacity
observations during final hour of run.
Observations were interrupted 15 Bin because of
process changes.
'observations were Interrupted 19 Bin to obtain
ice.
Observations were interrupted because of inter-
ference from other stack plumes.
29
-------
TABLE 8. SUMMARY OF COAL AN? ,YSIS AT GENERAL MOTORS CORPORATION,
FISHER BODY DIVISIC I, BOILER NO. 2 IN LANSING, MICHIGAN
APRIL 19-26, 1982
Heating v Lue
Run
number
1-1/2
2-1/2
3-1/2
1-2/3
--2/3
-2/3
-1/3
-1/3
-1/3
-1-SL
-2-SL
-3-SL
Total
moisture ,
percent
11.47
18.81
13.01
13.25
12.48
4.33
10.20
11.75
11.63
15.33
15.08
14.30
Joule/gram
Dry
30,638
35,389
27,952
31,123
32,439
31,730
29,120
29,390
30,391
29,539
30,315
29,490
As '
received
27,123
28,730
24,316
27,000
28,391
30,354
26,150
25,938
26,858
25,010
25,472
25,273
Btu/lb
Di y
13,187
15,232
12,031
13,396
.13,962
13,657
12,534
12,650
13,081
12,714
13,048
12,693
As
received
11,674
12,366
10,466
11,621
12,220
13,065
11,255
11,164
11,560
10,765
11,080
10,878
Ash, percent
Dry
8.65
7.69
8.06
7.73
7.54
6.02
9.80
8.85
10.45
9.32
8.99
11.28
As
received
7.66
6.24
7.01
6.71
6.60
5.76
8.80
7.81
9.24
7.89
7.63
9.67
Sulfur, percent
Dry
1.05
0.90
0.98
0.86
1.02
0.81
1.14
1.04
0.95
1.29
1.22
1.72
As
received
0.92
0.73
0.86
0.75
0.89
0.77
1.03
0.92
0.84
1.09
1.03
1.48
-------
SECTION 3
PROCESS DESCRIPTION
(Provided by Radian Corporation)
This section presents a generalized description and discussion of
the boiler and side stream separator process. This description
includes a process flow diagram, equipment design data, design
operating parameters, actual operating parameters and emission
control performance data. The boiler and side stream separator
are discussed individually in the following two subsections.
The process data collected during all emission testing periods are
tabulated in Appendix C. Also present in Appendix C is a discus-
sion of any process upsets or abnormalities that occurred during
testing. Some general comments on the process operation are also
included.
BOILER SYSTEM DESCRIPTION
The Fisher Body plant in Lansing, Michigan is an auto body assemb-
ly plant operated by General Motors Corporation. Steam from the
plants power house is required for both heating and assembly line
operations at the Fisher Body and adjoining Oldsmobile assembly
plants. Steam is supplied from five coal fired spreader stoker
boilers. Three boilers are rated at 45,400 kg/hr (100,000 Ib/hr)
of steam (Boilers 7, 8, 11) while the remaining two (Boilers 1,
2) are rated at 81,720 kg/hr (180,000 Ib/hr) of steam. Particulate
emissions testing was conducted on Boiler 2, exclusively.
Figure 2 presents a process flow diagram for Boiler 2, which is a
Riley Stoker Company Spreader Stoker with a rated heat output
capacity of 81,720 kg/hr (180,000 Ib/hr) of saturated steam at
1.2 MPa (175 psig). The side stream separator is also shown.
Table 9 presents design and operating data for the boiler and
its associated equipment. Side stream separator design and
operating data are presented in the following subsection.
Coal is fed onto a traveling grate by four identical spreader
feeder mechanisms. Boiler bottom ash is discarded continuously
into the ash pit at the front end of the boiler and removed from
the ash pit three times a day via a pneumatic ash removal system.
This system was not used during the performance of any emission
tests. Exhaust gases from the furnace exit the boiler and pass
through the boiler outlet hopper. The larger, partially burned
31
-------
O)
ro
baghouse temperature
control bleed line _
reinjection !'°ner Out1et
J
to stack
Induced draft
fan
outlet sampling ports
front and rear
overflre air jets
forced draft
fan
overflre air
fan
side stream
Inlet
sampling
ports
to ash
disposal silo
Figure 2. Boiler sidestre -n separator process flow diagram.
-------
TABLE 9. BOILER DESIGN AND OPERATING DATA
Year installed
Manufacturer
Stoker type
Grate type
Rated capacity
Boiler efficiency
Soot blowing system
Furnace draft leaving boiler
Bottom ash discharge system
Economizer data
Number of gas passes
Gas temperature entering
Gas temperature leaving
Draft loss
Overfire air system data
Number/diameter (front)
Number/diameter (rear)
Fly reinjection system data
Ash trap location
Reinjection port location
Coal specifications
Sulfur
Ash
Btu/lb
Excess air data
Actual
Manufacturers suggested
1976
Riley Stoker Company
Spreader Stoker
Traveling grate front ash discharge
180,000 Ib/hr steam
80.0%
None
-1.0 inch H20
Pnuematic
3 vertical passes
590°F
400°F
1.3 inch H20
14/1V Jets
28/1V jets
Boiler outlet hopper
Through rear overfire jets
0.77%
5.22%
13,200
55%
30%
33
-------
coal particles that settle out in this hopper are removed and
reinjected back into the furnace continuously through the
rear overfire air jets. It should be noted there is no soot
blowing system on Boiler 2.
As shown in Figure 2, Boiler 2 has an economizer which preheats
incoming boiler feedwater from 104°C to 154°C at 1.7 MPa (220°F to
310°F at 250 psig). This increases the boilers thermal efficiency
and results in a system draft loss of 3.3 cm (1.3 inch) wg. when
the boiler operates at rated capacity. The economizer also acts
as a particulate matter trap. Particulate matter settles out in
the economizer hopper which is evacuated three times a day via
the pneumatic ash removal system. All testing was performed
downstream of the economizer and, therefore, its particulate
matter removal capability is not addressed in this test report.
At the boiler rated capacity, the flue gas temperature drop
across the economizer is 88°C (190°F).
Boiler 2 has four fans operating on a continuous basis. Overfire
air is supplied by a 75 HP fan which pressurizes two headers: one
for the front and one for the rear overfire air jets. Combustion
air is supplied by a 150 HP forced draft fan while system pressure
drops are overcome by an 800 HP induced draft fan. The original
design of the boiler system specified the installation of a
scrubber. However, after the ID fan was installed GM opted to
purchase low sulfur coal rather than scrub to reduce S02 emissions.
Because the fan is designed to overcome the boiler system and
scrubber pressure drops, it is now considered by GM to be oversized.
This oversized fan results in a sensitive system that at times is
difficult to control and stabilize. A slight fan control adjustment
can subsequently result in a large system pressure change.
The fourth fan mentioned earlier is discussed in the following
subsection.
SIDE STREAM SEPARATOR SYSTEM DESCRIPTION
A flow diagram of the side stream separator system was presented
earlier in Figure 2. Design and operating data are presented in
Table 10. The mechanical collector described in Table 10 was
installed with the boiler in 1976. In 1980, the two module bag-
house was added to the system to filter a slip stream from the
mechanical collector hopper. The mechanical collector and bag-
house collectively form the side stream separator system.
The baghouse is designed to filter about 20 percent of the total
system flow when the boiler is operating at rated capacity. Under
these conditions, the operating air-to-cloth ratio is 1.8 m3/min/
m2 (6.0 CFM/ft2) and the pressure drop across either of the two
ik...--l J.^ 1C.1 crv. (4 inch) wg. The total filter area available
is 304 m2 (3267 ft2) of teflon bag fabric supported on mild steel
34
-------
TABLE 10. SIDE STREAM SEPARATOR DESIGN AND OPERATING DATA
Mechanical collector
Year installed
Manufacturer
Model
Collector efficiency
Tube diameter
Gas flow in
Pressure drop
Ash discharge system
Baghouse
Year installed
Manufacturer .
Collector efficiency
Cleaning system
Air/cloth
Pressure drop
Gas flowa (% of total flow)
Bag material
Number of modules
Operating temperature range
Temperature control system
Ash discharge system
1976
Western precipitation
9 VIOT
96.8%
9 inches
98,000 ACFM
2.9 inch w.g.
Pneumatic
1980
Western precipitation
99.8%
Pulse jet
6.0 CFM/ft2
4 inch H20
19,600 ACFM (20%)
Teflon
2
350-400°F
Economizer gas mix
Pneumatic
Flow at rated capacity.
At rated capacity with an inlet loading of 5 lb/106
Btu.
GLess than 1% of hot economizer inlet gas flow mixed
with baghouse inlet gas flow to increase inlet
temperature when required.
cages. Bag filter cleaning is accomplished by operation of the
pulse jet cleaning system. This system is operated on a continuous
basis by programmed timers which pulse the bags by rows. Each
row is individually controlled by an integral solenoid/diaphragm
valve. Pulse duration is manually programmed into the system
and depends on the inlet loading to the baghouse and subsequent
pressure drop.
As previously mentioned, the baghouse fan pulls about 20 percent
of the total flue gas flow from the mechanical collector hopper
into the baghouse. Because this fan is a constant speed unit,
the percentage flow to the baghouse increases with decreasing
overall flue gas flowrate from the boiler. Therefore, as the
boiler load decreases, percent flow to the baghouse increases.
35
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As shown in Figure 2, baghouse temperature is regulated by an
automatic valve which mixes hot economizer inlet gas with the
baghouse inlet gas. This mixing value maintains baghouse temper-
ature above the acid dew point and below the manufacturer's
recommended maximum bag fabric temperature. The operating range
is between 177°C to 204°C (350°F to 400°F). No more than 1
percent of the economizer inlet flowrate is required for baghouse
temperature maintenance.
Prior to the start of testing the baghouse and mechanical collector
were inspected for damage and wear. None was found. It should be
noted that the bags in module two are a few months newer than those
in module one. An overfilled hopper burned the old teflon bags in
module two and necessitated their replacement. The effect of this
age difference on the process parameters monitored is discussed
in Appendix C.
36
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SECTION 4
LOCATION OF SAMPLING POINTS
INLET
Four, 7.6 cm (3 in.) I.D. sampling ports are located on each side
of a 5.3 m (17.5 foot) by 1.4 m (4.6 foot) rectangular duct. The
sampling ports are 0.3 m (1 foot) downstream of the mechanical
collector (0.1 duct diameter) and 1.8 m (6 feet) upstream of the
economizer (0.9 duct diameters) as shown in Figure 3.
A maximum 48-point traverse was conducted at this location, with
12 points being sampled at each port as shown in Figure 4. Due
to the limited working space behind the ports (see Figure 3 end
view) a 6-foot probe was used on one side of the duct and an
10-foot probe was used on the opposite side of the duct. Heated,
flexible hoses were used from the probe to the oven box. Thus,
two Method 5B trains were operating simultaneously at the inlet
to sample all the points, except traverse point number 5 in
Figure 3 which was not sampled.
OUTLET
Three, 1.6 cm (4 in.). I.D. sampling ports are located on a 1.9 m
(6.2 foot) by 2.1 m (6.8 foot) rectangular duct. The sampling
ports are 1.7 m (5.5 feet) upstream of the 90 degree bend leading
to the stack (0.9 duct diameters) and 6.1 m (20 feet) downstream
of the cyclone collector (3.3 duct diameters), see Figure 5. This
arrangement meets all criteria for an acceptable measurement spe-
cified under EPA Methods 1-5. A 42-point traverse was conducted
at this location, with 14 points being sampled at each port as
shown in Figure 6.
COAL FEED SYSTEM
Low sulfur, preweighed coal is fed continuously to the boiler from
a coveyer-hopper and the spreader stoker. The coal was sampled at
the Boiler No. 2 coal feed from the conveyer belt, before during
and after each run. These samples were combined for each run and
stored in a plastic container. Photographs of the coal scale
along with inlet and outlet ports to Boiler No. 2 are shown in
Figure 7.
37
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w
oo
FrCTANGULAR AIR FLOW
f JCT \ FROM
SORTER
No. 2
• A q.o \
1/43 INCH ID P RTS
1 ( »
MULTICYCLONE \, ,
o
5
o/
f 1
y
LO"»L . . 79" . — «
^
i
SIDE VIEW
ECONOMIZER
FLANGE
WALL
3.5" PORT LENGTH -»i
FLOOR LINE
DUCT
< fi d1 *
12.5""
12.5"
12.5"
29.5"
C
: r
i IB1 •
S 1
5 1
I" UU
•• 11. 61 *
i
i
K
3" ID PORTS
4, 3 "ID PORTS
END VIEW
Figure 3. Inlet sampling ports to mechanical collector for Boiler #2
at GM Corporation, Fisher Body Division in Lansing, Michigan.
-------
6.4ft
TO WALL
-. <>1 1 ttfl
Lll.y *
1234S67B9101112
I ^8-8" 176" 125"
c
_3.5"
PORT If NGTH
. 4
, 1 "
,50""
•1
11.6ft
TO DUCT
'INSIDE DIMENSION, EXCLUDING INSULATION
Traverse
point
number
1
2
3
4
5
6
7
6
9
10
11
12
Inside of
wall to
traverse
point,
inch
8.82
26.45
44.08
61.71
/ -3 . Of
96.97
114-.60
132.23
149.86
167.49
185.12
202.75
Distance
of port,
inch
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
Traverse point
location from
outside of port,
inch
12.32
29.95
47.58
65.21
135.73
118.10
100.47
82.84
65.21
47.58
29.95
12.32
Figure 4. Traverse point location at inlet to mechanical
collector for Boiler #2 at GM Corporation,
Fisher Body Division in Lansing, Michigan.
39
-------
TO STACK
66"
46.5"
.74".
12", 22.5", 25.5" 15"
O O
t
FLOW
3, 4" PORTS
FLANGE AND VALVE
ROOF LINE
FRONT VIEW
i ur\ i u-iiu i n
SAMPLING
PORT
46.5"
81"
t:
FLANGE AND VALVE
•ROOF LINE
SIDE VIEW
Figure 5. Port location on outlet of mechanical col-
lector for Boiler #2 at GM Corporation,
Fisher Body Division in Lansing, Michigan.
40
-------
• 14
• 12
• II
• 10
• t
• 1
• 7
• 5
• 4
• 3
• 2
• 1
U
A
Inside of
wall to
Traverse traverse
point point,
number inch
1 2.89
2 8.68
3 14.46
4 20.25
5 26.04
6 31.82
7 37.61
8 43.39
9 49.18
10 54.96
11 60.76
12 66.54
13 72.32
14 78.11
'A"
81"
U U !L
B C
Traverse point
Distance location from
of port, outside of port,
inch inch
9.0 11.89
9.0 17.68
9.0 23.46
9.0 29.25
9.0 35.04
9.0 40.82
9.0 46.61
9.0 52.39
9.0 58.19
9.0 63.96
9.0 69.76
9.0 75.54
9.0 81.32
9.0 87.11
Figure 6. Traverse point locations for outlet of mechanical col-
lector on Boiler #2 at GM Corporation, Fisher Body
Division in Lansing, Michigan.
41
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Coal Scale
Inlet Dust Collector
Boiler No. 1
Outlet I.D. Fan
Boiler No. 2
Figure 7. Photographs of coal scale, inlet and outlet ports
for Boiler No. 2, General Motors Corporation,
Fisher Body Division, in Lansing, Michigan.
42
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BAGHOUSE
A third sampling point was located at the inlet of the baghouse
collector as shown in Figure 1. This duct was sampled at the
point near the inlet to the baghouse. The baghouse exhaust duct
emptied into the top of the dust collector at a point before the
roof level outlet sampling ports for the cyclone/dust collector.
Two, 1.6 cm (4 in.) I.D. sampling ports are located on a 0.73 m
(2.40 ft) diameter duct. The sampling ports are 1.5 m (4.9 ft)
upstream of the change in direction of flow (2.0 duct diameters)
and 1.5 m (4.9 ft) downstream of the duct 90° elbow (2.0 duct
diameters) as shown in Figure 8. A 36-point traverse was con-
ducted at this location, with 16 points being sampled at each
port as shown in Figure 9.
43
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4.9'
4.9'
SAMPLE PORTS
WALL
-2.4' DIA. DUCT
FROM
4 4 MECHANICAL
COLLECTOR
Figure 8. Samp] 2 port location at inlet to baghouse for
Boilf r #2 at GM Corporation, Fisher Body
Divif Lon in Lansing, Michigan.
-------
3.5"PORTl£NGTH
Traverse
point
number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Inside of
wall to
traverse
point,
inch
0.40
1.27
2.16
3.13
4.20
5.41
6.76
8.51
11.0
17.8
20.2
22.0
23.4
24.6
25.6
26.6
27.5
28.4
Distance
of port,
inch
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
Traverse point
location from
outside of port,
inch
3.9
4.8
5.7
6.6
7.7
8.9
10.3
12.0
14.5
21.3
23.7
25.5
26.9
28.1
29.1
30.1
31.0
31.9
Figure 9. Traverse point location at inlet to baghouse for Boiler
;:: „'_ GI: Corporation, Fisher Body Division in Lansing,
Michigan.
45
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SECTION 5
SAMPLING AND ANALYSIS PROCEDURE
SUMMARY
The sampling and analysis methods used at the Lansing site are
shown in Table 1. Three simultaneous runs of Method 5B at the
inlet and outlet of the multicyclone to Boiler No. 2 were con-
ducted at each of three different boiler loadings (2/3, 1/2, and
1/3 of boiler capacity). Three runs at the "swing load" variable
boiler loading were conducted at the multicyclone outlet only.
The three baghouse inlet runs were conducted simultaneously with
the inlet and outlet runs at the 2/3 boiler capacity load.
The flue gas velocity, temperature, flow rate, oxygen content, and
carbon dioxide content were measured by EPA Methods 1-4 during all
the Method 5B stack sampling runs. Integrated gas samples were
taken from the exhaust of the Method 5B train.
Particulate analysis followed standard Method 5 gravimetric pro-
cedures. All Method 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
e v'ovo a n a 1 T"7 e>H hv A^TM Mpthotfc: f>?17p, arii^ F>? 01 F>-fifi ( 17 > .
STACK SAMPLING
A typical Method 5 stack test system was used for sampling, except
that oven and filter temperatures were maintained at 160 ± 14°C
(320 ± 25°F). Heated glass-lined or stainless steel probes and
Reeve Angel Type 934 AH filters were used for the Method 5B test-
ing. The filter temperatures were monitored using thermocouples
installed in the oven. Figure 10 is a schematic diagram of the
Method 5B test probe system.
Method 5B sample volumes of at least 32 cubic feet were taken.
The probes, nozzles, and filter holders were rinsed with acetone.
When Method 5B was used, Methods 1 through 4 also were used, as
in compliance monitoring.
46
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,TEMPERATURE
SENSOR
THERMOMETER
CHECK VALVE
^- 07* m.
THERMOMETER*
VACUUM LINE
ACUUM OUAOE
HEATED AREA
FILTER HOLDER
PROBE [
REVERSE TYPE
PHOT TUBE
ORVOAS ORIFICt
METER AND
MANOMETER
PITOTMAMOMETER'
IMPINGE RS
ICE BATH
Figure 10. Particulate sampling train - EPA Method 5B.
-------
During several of the runs at both inlet and outlet locations,
zero velocity points were found. To maintain isokinetic sampling,
no sampling tiiue was spent at the zero velocity points and twice
the sampling time was spent at the next sample point. This method
has minimal effect on particulates collected and was approved by
the EPA representative on site during sampling. Obtaining an
average duct velocity is extremely difficult due to the zero
velocity points. Velocity calculations and volumetric flow rates
shown in Table 4 and Appendix B computer data sheets should be
reviewed with these restrictions in mind.
Due to space restrictions outside of the inlet duct, it was
impossible to reach the number 5 traverse point of each traverse.
The sampling time was made up by sampling at point number 4 for
twice as long.
As described in the field log (Appendix A-l) dust build-up
occurred in the inlet duct at the 1/3 boiler load condition. At
this location, the lower sample port was not used and sampling
time was increased from 3 min/point to 4 min/point. Some deposi-
tion and re-entrainment of particulates was assumed to occur onto
and from the dust pile. However, the effect on particulate samp-
ling was assumed minimal as the deposition and re-entrainment
effects most likely would balance out. This dust build-up reduced
the duct area by approximately 10% (and thus increased velocity
also). However, once again this has no effect on emission calcu-
lations which are based on mass of particulate collected and volume
of sample collected not stack velocity or area.
During sampling runs O-2-1/3 and O-3-1/3, the bottles containing
acetone wash for each run were not labelled properly and were
mixed. Each bottle was labelled with appropriate run number after
the team leader evaluated the situation.
Plume opacity was observed according to EPA Method 9 during eacn
of these sampling runs. In addition, Andersen particle sizing was
done at the inlet and outlet to the mechanical collector immedi-
ately before or after each sampling run.
At the baghouse inlet, three Method 5B runs were performed
simultaneously with the three mechanical collector inlet/outlet
runs at the 2/3 boiler load capacity. Andersen particle sizing
was performed at the baghouse inlet in addition to that at the
mechanical collector inlet and outlet.
Three additional Method 5B runs were performed at the outlet of
the mechanical collector for Boiler No. 2 at swing load conditions.
Actual percent capacity of the boiler (at swing load) was based on
steam demand. Neither plume opacity, (Method 9), or Andersen par-
ticle sizing, was performed during these three runs.
48
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STACK SAMPLE ANALYSES
Gravimetric particulate analyses according to standard Method 5
procedures were conducted on all Method 5B samples. The Method
5B filters and acetone proble washes were dried and weighed to a
constant weight. The weighing was repeated until the weight of
the particulates was within 0.9 mg of the weight on the previous
weighing.
Blank filters and residue from the evaporation of clean acetone
blanks were analyzed along with the stack samples for quality
control.
COAL SAMPLING AND ANALYSES
Coal samples, corresponding to the coal burned during each stack
sampling run, were taken from the conveyer belt feed line to
the spreader stoker three times during each sampling run. The
three samples were combined for one aggregate coal sample per
run and analyzed for sulfur, ash, moisture, and Btu content by
standard 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 occur-
red 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 coding
sheets for data processing.
Appendix B contains complete computer printouts of the results of
the sampling and emission calculations. For computer coding pur-
poses, letters Y, Z, and X were used for 1/2, 2/3, and 1/3 boiler
loading conditions, respectively, for run identification. For
example, IA-2-Y implies inlet side A, Run 2, 1/2 boiler load
capacity; or IT-3-X implies inlet total, Run 3, 1/3 boiler load
capacity.
49
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Appendix C (supplied by Radian Corporation) contains boiler
monitoring data during the testing.
Apprendix 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
Developement of Quality Assurance Programs for these methods.
Standard ASTM procedures were used for the coal analysis.
Bowser-Morner Testing Laboratories, Inc., the coal analysis sub-
contractor, 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 tc ccie the computer input.
50
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