United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EMB Report 82-IBR-i 8
June 1982
Air
Industrial Boilers
Emission Test Report
Burlington Industries
Clarksville, Virginia
-------
INDUSTRIAL BOILERS
Final Report
BURLINGTON INDUSTRIES
BOILER NO. 6
Clarksville, Virginia
July 12-16, 1982
Technical Directive 25
by
Duane R. Day
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 76/13)
EMB No. 82/IBR/18
T.O. '• George. UV
17 February 1983
MONSANTO RESEARCH CORPORATION
DAYTON LABORATORY
Dayton, Ohio 45407
0201/A-M
-------
CONTENTS
Figures iv
Tables v
1. INTRODUCTION 1
2 . SUMMARY OF RESULTS 4
Description of monitoring 4
Test results 4
3. PROCESS DESCRIPTION 28
Boiler/dual mechanical collector
system description 28
4. LOCATION OF SAMPLING POINTS 32
Inlet 32
Outlet 32
Coal system 32
5. SAMPLING AND ANALYSIS 37
Stack sampling and analysis 37
Coal sampling and analyses 39
Sample handling 39
Data reduction 39
Quality assurance 39
APPENDICES
A. Field sampling data sheets and computer coding forms. . A-l
B. Printouts of sampling results and emission
calculations B-l
C. Boiler monitoring data (supplied by Radian) C-l
D. Analytical results (particulate and coal) D-l
E. Project participants E-l
111
-------
FIGURES
Number Page
1 Schematic diagram of Boiler No. 6 at
Burlington Industries, Inc. in Clarksville,
Virginia 2
2 Boiler/dual mechanical collector process
flow diagram 29
3 Inlet sampling ports to Boiler No. 6 at Burlington
Industries, Inc. in Clarksville, Virginia .... 33
4 Traverse point location at inlet for Boiler No. 6
at Burlington Industries, Inc. in Clarksville,
Virginia 34
5 Fan, stack, and sample port dimensions for outlet
for Boiler No. 6 at Burlington Industries, Inc.
in Clarksville, Virginia 35
6 Traverse point location at outlet for Boiler No. 6
at Burlington Industries, Inc. in Clarksville,
Virginia 36
7 Particulate sampling train - EPA Method 5B 38
IV
-------
TABLES
Number Page
1 Source Sampling and Analysis at Burlington
Industries, Inc. in Clarksville, Virginia .... 3
2 Particulate Emission Data for Burlington
Industries, Inc. Boiler No. 6 in Clarksville,
Virginia, July 12-16, 1982 (Metric Units) .... 5
3 Emission Data for Burlington Industries, Inc.,
Boiler No. 6 in Clarksville, Virginia,
July 12-16, 1982 (English Units) 7
4 Summary of Duration of Sampling, Stack Temperature,
Stack Flow Rate, Sample Volume, Sample Water
Content, and Static Pressure at Burlington
Industries, Inc. Boiler No. 6 in Clarksville,
Virginia 9
5 Summary of Integrated Gas Analysis Results at
Burlington Industries, Inc. Boiler No. 6 in
Clarksville, Virginia 11
6 Summary of Andersen Particle Size Results 12
7a Summary of Method 9 Plume Opacity Observations at
Burlington Industries, Inc. Boiler No. 6 in
Clarksville, Virginia - Run No. 1 18
7b Summary of Method 9 Plume Opacity Observations at
Burlington Industries, Inc. Boiler No. 6 in
Clarksville, Virginia - Run No. 2 19
7c Summary of Method 9 Plume Opacity Observations at
Burlington Industries, Inc. Boiler No. 6 in
Clarksville, Virginia - Run No. 3 20
7d Summary of Method 9 Plume Opacity Observations at
Burlington Industries, Inc. Boiler No. 6 in
Clarksville, Virginia - Run No. 4 21
-------
TABLES (continued)
Number Page
7e Summary of Method 9 Plume Opacity Observations at
Burlington Industries, Inc. Boiler No. 6 in
Clarksville, Virginia - Run No. 5 22
7f Summary of Method 9 Plume Opacity Observations at
Burlington Industries, Inc. Boiler No. 6 in
Clarksville, Virginia - Run No. 6 23
7g Summary of Method 9 Plume Opacity Observations at
Burlington Industries, Inc. Boiler No. 6 in
Clarksville, Virginia - Run No. 7 24
7h Summary of Method 9 Plume Opacity Observations at
Burlington Industries, Inc. Boiler No. 6 in
Clarksville, Virginia - Run No. 8 25
7i Summary of Method 9 Plume Opacity Observations at
Burlington Industries, Inc. Boiler No. 6 in
Clarksville, Virginia - Run No. 9 26
8 Summary of Coal Analysis at Burlington Industries,
Inc. Boiler No. 6 in Clarksville, Virginia. ... 27
9 Boiler Design and Operating Data 30
VI
-------
SECTION 1
INTRODUCTION
Emissions from Boiler No. 6 at the Burlington Industries, Inc.
plant in Clarksville, Virginia were tested 12-16 July 1982 by the
U.S. Environmental Protection Agency (EPA) and Monsanto Research
Corporation (MRC). This work was performed for the Emission
Measurement Branch of the U.S. EPA under Contract No. 68-02-3547,
Work Assignment No. 2.
The boiler tested is a 68,070 kg steam/hr (150,000 Ib steam/hr)
capacity coal-fired boiler. Coal is fed into the combustion
chamber by flippers onto a traveling grate where over-fire jets
provide air to aid combustion. It is equipped with double
cyclone-type mechanical dust collectors pollution control equip-
ment. Figure 1 is a schematic diagram of the installation show-
ing the locations sampled.
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 objective for sampling at Burlington Industries, Inc. in
Clarksville, Virginia is to determine the double mechanical col-
lectors performance under variable load conditions. Sampling was
performed using a Method 5 train at a temperature of 160°C ± 14°C
(320°F ± 25°F), which will be referred to as Method 5B testing.
Table 1 summarizes the monitoring performed at this plant. Test-
ing consisting of three simultaneous runs of Method 5B at the
inlet and outlet of the double mechanical collector at each of
three boiler leadings (base load, 2/3, and 1/3), Method 9 visible
emission with each run, Andersen particle sizing after each run
at the inlet and outlet to the double mechanical collectors, and
coal sampling during every run from the feed belt to the spreader
stoker.
This project was a joint project between EPA and MRC. EPA was
responsible for project organization, Method 5B testing on the
inlet and outlet of the double mechanical collectors, and
Method 9 visible emission readings. The particle sizing, all
particulate and particle sizing analyses, data reduction, and
report writing was the responsibility of MRC.
-------
ROOF LINE
TO
ATMOSPHERE
I
STACK
OUTLET
SAMPLING
LOCATIONS
BOILER
FAN
INLET
SAMPLING
LOCATION
MULTICYCLONES
Figure 1. Schematic diagram of Boiler No. 6 at
Burlington Industries, Inc. in
Clarksville, Virginia.
-------
TABLE 1. SOURCE SAMPLING AND ANALYSIS AT BURLINGTON
INDUSTRIES, INC. IN CLARKSVILLE, VIRGINIA
oo
SAMPLING AND ANALYSIS REQUIREMENTS
MRC Job No. 101. u:>24
Total
no. of
samples
i
3
.1
.1
6
3
3
3
3
6
3
3
3
3
f,
aBoil
b .
cpoi i
*W
Sample
type
<; rticulate at
outlet3
Particulate at
inlet0
Con.l
Visible emissions
Particle size at
inlet and outlet
Particulate at
out 1 et
Particulate at
i nlet
Coal
visible emissions
Part i cle si ze
at inlet and outli
Pnrt i culate at
outlet0
Particulate at
inlet"
Coal
Visible emissions
Particle size at
inlet and outlet
•r .11 fill 1 load.
•r at 1/3 load.
Sampling
method
Mt
53
Grabd
9
Andersen
5B
5B
Grab
9
Andersen
SB
5B
c;rabd
9
Andersen
Contract N(
). : i •• ii •- r .1 / Assiq
nment Number: , Technical Directive: :•'•
Company Name: Mm i m.ii..i> in.|... in.-. |Com»any Location: <-|.,r>" vi I !• . vi r-iiin.i
Industry: IM.I>I-:< T i.ii n.,i |. r Process: r-,..,i -n r. -i Control Equipment: nouhl"
M"','hrTn i '-.-) I 'oll^rtor
Sample
collected
by
r:l'A
EPA
MRC
EPA
MRC
EPA
EPA
MRC
EPA
MRC
EPA
KPA
MRC
EPA
MHO
Minimum
sampl ing
time
J. hr Of 0
2 hr 01 r,
Simu I tail"
with ahov
Len.|l.h of
After 'iB
2 lir or 6
2 hr or 6
Si niu 1 1 nne
above
Lenyth of
Aft.'r 5B
2 hr or r.
2 hr or 6
S i mu 1 ta ne
abovo
[,I'IK|I h of
After r'B
Minimum
volume gas
sampled ft3
1 f|3
1 ft3
HIS
SB test
.est
) ft3
1 ft.3
>us with
in test
i •:; t
ft3
ft3
ms with
IB test
.est
Initial Analy
Type Method
Veloeit y.
temp. , Ha"
Velocity,
temp. , \\2f
Visual
observe t i c
Veloci ty ,
temp. , !i2O
Velocity,
temp. , MaO
Visual obs
Velocity,
temp. , MaO
Velocity,
t.-m|.. , H20
Visual ol>s
1-4
OHKAT
1--1
OPSAT
1
1-4
ORSAT
1-4
ORSAT
'rvations
1-4
, ORSAT
1-4
, ORSAT
*rvat ions
sis
By
!TA
F.PA
EPA
EPA
EPA
EPA
EPA
EPA
EPA
Final Analysis
Type Method
pa r t- i cu 1 a t
Part iculat
S, Ash, Bt
moi sture
Particle
si 7.1 riq
Part iculat
Part iculat
S, Ash, Bt
moisture
Part i cle
s i z i nij
Pnrt i culat
Particular
S, Ash, Bt
moisture
particle E
5
i ASTM
e 5
e S
1 , ASTM
5
e 5
i , ASTM
izino
By
MPr
MRC
Bowser-
Mornor
MRC
MRC
MRC
Bowser-
Morner
MRC
MRC
MRC
Bowsei —
Morner
MRC
-------
SECTION 2
SUMMARY OF RESULTS
DESCRIPTION OF MONITORING
Table 1 summarizes the monitoring that was performed at the
Burlington Industries, Inc. plant. Method 5B sampling consisted
of three simultaneous runs at the inlet and outlet of the double
mechanical collectors at each of three boiler loadings (base load,
2/3, and 1/3). The boiler was operating under normal operating
conditions at each boiler loading. Soot blowing occurred once
during each of the three load conditions. Methods 1-4 were used
during all Method 5B runs, as in typical compliance monitoring.
Coal samples were taken at the beginning, middle, and end of each
test and combined to obtain a representative sample. Coal burned
was considered to be representative of normal feed. Analyses was
performed for sulfur, ash, Btu, and moisture content.
Visible emissions were taken at the stack outlet by EPA Method 9
over the duration of each Method 5B particulate test.
Andersen particle sizing was performed at the inlet and outlet
to the double mechanical collectors after each Method 5B test.
TEST RESULTS
Particulate emissions measured by Method 5B at the collector
inlet and outlet are summarized in Tables 2 and 3, in metric and
English units, respectively. Tables 2 and 3 also show that the
percent isokinetic for each sampling run ranged between 101.4%
and 107.5%, except for Run 1 inlet, which was 123.9%. This high
isokinetic value was caused by the use of a nozzle whose size was
below the sensitivity of the nomograph. The nozzle size was
corrected for the second run.
-------
TABLE 2. PARTICULATE EMISSION DATA FOR BURLINGTON INDUSTRIES,
INC. BOILER NO. 6 IN CLARKSVILLE, VIRGINIA,
JULY 12-16, 1982 (METRIC UNITS)
Average emissions
Run
number
1
1
2
2
3
3
4
4
5
5
6
6
Date
7-12-82
7-12-82
7-13-82
7-13-82
7-13-82
7-13-82
7-14-82
7-14-82
7-14-82
7-14-82
7-14-82
7-14-82
Location
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Boiler
load
base
base
base
base
base
base
2/3
2/3
2/3
2/3
2/3
2/3
Actual
g/dscm
0.208
2.616
0.206
5.463
0.217
4.761
0.185
4.597
0.207
4.868
0.198
9.263
kg/hr
11.81
126.6
11.99
317.0
12.73
264.2
11.82
275.7
12.40
283.94
12.04
562.4
ng/J
95.4
1,235
104.3
2,883
102.4
2,247
91.2
2,061
96.1
2,222
91.9
4,229
Corrected
to 12% C02,a
g/dscm
0.247
3.018
0.252
6.974
0.255
5.657
0.227
5.061
0.237
5.459
0.221
10.29
Percent
isokinetic
104.3
123.9
104.5
104.1
104.5
104.0
106.8
107.5
105.3
100.4
104.3
101.4
(continued)
-------
TABLE 2 (continued)
Average
Run
number
7
7
8
8
9
9
Date
7-15-82
7-15-82
7-15-82
7-15-82
7-16-82
7-16-82
Location
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Boiler
load
1/3
1/3
1/3
1/3
1/3
1/3
Actual
g/dscm
0
3
0
3
0
2
.212
.603
.223
.876
.223
.994
emissions
kg/hr
10
166
10
147
11
148
.45
.1
.86
.4
.23
.1
ng/J
126.9
2,054
124.1
2,097
129.4
1,603
Corrected
to 12% C02,a
g/dscm
0
5
0
5
0
4
.310
.087
.308
.056
.319
.037
Percent
isokinetic
101
106
103
106
102
104
.4
.0
.3
.3
.7
.0
aTVi-ie -i c
1-Ho ^nnfon
1~Kat"-inr» r»r»rr
na 1 -i ToH t-t
T 1 9
9? rn_
p —
r v
•• i c
i-Vio moAci
ir-^H
'2-
%C02
concentration in the stack, and percent C02 is the percent C02 measured in the stack.
-------
TABLE 3. EMISSION DATA FOR BURLINGTON INDUSTRIES, INC., BOILER NO. 6
IN CLARKSVILLE, VIRGINIA, JULY 12-16, 1982 (ENGLISH UNITS)
Average emissions C
Run
number
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
Date
7-12-82
7-12-82
7-13-82
7-13-82
7-13-82
7-13-82
7-14-82
7-14-82
7-14-82
7-14-82
7-14-82
7-14-82
7-15-82
7-15-82
7-15-82
7-15-82
7-16-82
7-16-82
Location
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Boiler
load
base
base
base
base
base
base
2/3
2/3
2/3
2/3
2/3
2/3
1/3
1/3
1/3
1/3
1/3
1/3
Actual
gr/dscf
0.091
1.143
0.090
2.387
0.095
2.080
0.081
2.008
0.090
2.127
0.086
4.047
0.093
1.574
0.097
1.693
0.098
1.308
Ib/hr
26.04
279.2
26.42
698.8
28.06
582.4
26.05
607.8
27.34
626.0
26.55
1,239.9
23.05
366.1
23.94
324.9
24.75
326.5
lb/106 to
Btu
0.22
2.87
0.24
6.70
0.24
5.22
0.21
4.79
0.23
5.16
0.21
9.82
0.29
4.77
0.29
4.87
0.30
3.73
Corrected
12% C02/a
gr/dscf
0.108
1.319
0.110
3.047
0.112
2.471
0.099
2.211
0.103
2.385
0.096
4.497
0.136
2.222
0.134
2.208
0.140
1.764
Percent
isokinetic
104.3
123.9
104.5
104.1
104.5
104.0
106.8
107.5
105.3
100.4
104.3
101.4
101.4
106.0
103.3
106.3
102.7
104.0
aThis is
the concentration
normalized to li
)O/ (If) (-<
*/o \~V2 • u
- r jt 12 -
%C02 '
where C is
the measur
concentration in the stack, and percent C02 is the percent CO2 measured in the stack.
-------
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
%02 = percent oxygen in stack
Tables showing all the calculations for emissions are shown in the
latter part of Appendix B.
Emission rate was calculated for Run 1 inlet even though the
isokinetic value was over the EPA acceptable limit of 110%.
Table 4 summarizes sampling duration, stack temperature, flow
rate, sample volume, water content, and static pressure.
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 Runs 1 and 2 inlet, and Runs 1 and 7
outlet, all runs were conducted under isokinetic conditions.
Runs 1 inlet and outlet were conducted a second time under
isokinetic conditions. The particle size inlet data may not be
fully representative to actual flue gas particle size conditions
due to the following:
• Inlet sampling was not performed following EPA/Federal
Register methods (see Section 4), resulting in points of
zero flow.
• Short sampling durations were used (2 minutes) at only a few
sample points (vs. the more desirable large number of sample
points and longer sample time) due to large particulate con-
centration at inlet.
• Excess sample was collected on first stage of impactor
resulting in inadequate distribution on remaining stages.
Tables 7a-7i summarize results of nine visible emissions observa-
tions taken according to EPA Method 9 during all of the emission
testing. *
Coal analysis data is summarized in Table 8.
8
-------
TABLE 4. SUMMARY OF DURATION OF SAMPLING, STACK TEMPERATURE, STACK FLOW RATE,
SAMPLE VOLUME, SAMPLE WATER CONTENT, AND STATIC PRESSURE AT
BURLINGTON INDUSTRIES, INC. BOILER NO. 6 IN CLARKSVILLE, VIRGINIA
Run
number
1
1
2
2
3
3
4
4
5
5
6
6
Location
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Duration
of
sampling,
min
120
72
120
54
120
54
120
54
120
54
120
54
Measured
stack
temperature
Op Op
172
173
170
175
172
172
181
186
179
182
179
182
342
343
338
346
340
340
357
366
354
359
354
360
Stack
flow rate
dscm/
min
943
805
968
965
974
922
1,062
997
998
969
1,012
1,009
dscf/
min
33,340
28,430
34,220
34,080
34,430
32,590
37,540
35,230
35,270
34,260
35,760
35,670
Sample
volume
dscm
2.23
0.87
2.27
0.95
2.27
0.90
2.49
1.00
2.33
0.92
2.39
0.96
dscf
72.4
30.8
80.2
33.5
80.1
31.8
83.8
35.5
82.3
32.6
84.4
33.9
Sample
water
content,
%
6.5
7.5
6.4
7.3
7.1
5.9
6.3
7.5
6.8
5.5
6.5
5.7
Stack static
pressures
cm H20
0.76
-3.8
0.76
-3.8
0.76
-3.8
0.76
-3.8
0.76
-3.8
0.76
-3.8
in. H20
0.30
-1.5
0.30
-1.5
0.30
-1.5
0.30
-1.5
0.30
-1.5
0.3
-1.5
(continued)
-------
TABLE 4 (continued)
Run
number
7
7
8
8
9
9
Location
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Duration
of
sampling
min
120
54
120
54
120
54
Measured
stack
, temperature
°C °F
154
159
156
160
157
159
309
318
313
319
314
317
Stack
flow rate
dscm/
min
819
766
809
632
836
822
dscf/
min
28,940
27,070
28,590
22,340
29,530
29,060
Sample
volume
dscm
1.85
0.76
1.86
0.64
1.88
0.80
Sample
water
content,
dscf %
65
26
65
22
66
28
.3
.9
.7
.5
.4
.4
5
3
6
6
5
5
.3
.7
.2
.0
.7
.2
Stack static
pressures
cm H20
0
-3
0
-3
0
-3
.76
.8
.76
.8
.76
.8
in. H20
0.30
-1.5
0.30
-1.5
0.30
-1.5
-------
TABLE 5. SUMMARY OF INTEGRATED GAS ANALYSIS RESULTS
AT BURLINGTON INDUSTRIES, INC. BOILER NO. 6
IN CLARKSVILLE, VIRGINIA
Run
Percent
Dry
molecular
weight
kg/kg mole
number
I
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
Location
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
C02
10.1
10.4
9.8
9.4
10.2
10.1
9.8
10.9
10.5
10.7
10.7
10.8
8.2
8.5
8.7
9.2
8.4
8.9
CO
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
02
8.9
9.2
10.0
10.4
9.2
9.2
9.7
8.6
9.0
8.8
9.0
8.8
11.7
11.2
11.0
10.7
11.4
10.6
N2 (Ib/lb mole)
81.0
80.4
80.2
80.2
80.6
80.7
80.5
80.6
80.5
80.5
80.3
80.4
80.1
80.3
80.3
80.1
80.2
80.5
29.97
30.03
29.97
29.92
30.0
29.98
29.96
30.12
30.04
30.06
30.07
30.08
29.78
29.81
29.83
29.90
29.80
29.85
11
-------
TABLE 6. SUMMARY OF ANDERSEN PARTICLE SIZE RESULTS
to
Flow rate Percent
Run Location acm/min acf/min isokinetic
1A Inlet 0.025 0.88 100.6
1A Outlet 0.027 0.95 104.7
2 Inlet 0.030 1.06 125.8
Stage
0
1
2
3
4
5
6
7
8
0
1
2
3
4
5
6
7
8
0
1
2
3
4
5
6
7
8
Size
range,
|jm
>11.43
7.08-11.43
4.49-7.08
3.32-4.49
2.11-3.32
1.04-2.11
0.64-1.04
0.44-0.64
0.00-0.44
>11.00
6.82-11.00
4.32-6.82
3.20-4.32
2.04-3.20
1.00-2.04
0.61-1.00
0.42-0.61
0.00-0.42
>10.44
6.47-10.44
4.10-6.47
3.03-4.10
1.93-3.03
0.95-1.93
0.58-0.95
0.40-0.58
0.00-0.40
Percent
in size
range
92.6
2.9
2.7
1.8
0
0
0
0
0
33.5
6.0
15.1
10.8
10.8
6.3
4.8
6.0
6.8
24.1
16.7
8.9
17.6
13.7
8.9
10.1
0
0
Cumulative
percent,
-------
TABLE 6 (continued)
Flow rate Percent
Run Location acm/min acf/min isokinetic
2 Outlet 0.024 0.84 94.3
3 Inlet 0.026 0.92 104.6
3 Outlet 0.026 0.91 100.1
Stage
0
1
2
3
4
5
6
7
8
0
1
2
3
4
5
6
7
8
0
1
2
3
4
5
6
7
8
Size
range,
pm
>11.73
7.27-11.73
4.61-7.27
3.41-4.61
2.17-3.41
1.06-2.17
0.66-1.06
0.45-0.66
0.00-0.45
>11.22
6.95-11.22
4.40-6.95
3.26-4.40
2.07-3.26
1.02-2.07
0.63-1.02
0.43-0.63
0.00-0.43
>11.26
6.97-11.26
4.42-6.97
3.27-4.42
2.08-3.27
1.02-2.08
0.63-1.02
0.43-0.63
0.00-0.43
Percent
in size
range
14.3
17.4
13.2
11.9
11.7
10.1
6.7
3.6
10.9
79.1
3.3
3.4
2.9
3.0
2.8
1.7
2.2
1.6
17.9
15.8
16.1
11.6
10.0
7.4
7.6
8.0
5.6
Cumulative
percent,
-------
TABLE 6 (continued)
Flow rate Percent
Run Location acm/min acf/min isokinetic
4 Inlet 0.030 1.07 108.1
4 Outlet 0.029 1.02 99.1
5 Inlet 0.026 0.93 100.8
Stage
0
1
2
3
4
5
6
7
8
0
1
2
3
4
5
6
7
8
0
1
2
3
4
5
6
7
8
Size
range,
|jm
>10.40
6.44-10.40
4.08-6.44
3.02-4.08
1.92-3.02
0.94-1.92
0.58-0.94
0.40-0.58
0.00-0.40
>10.65
6.60-10.65
4.18-6.60
3.09-4.18
1.97-3.09
0.96-1.97
0.59-0.96
0.41-0.59
0.00-0.41
>11.14
6.90-11.14
4.37-6.90
3.23-4.37
2.06-3.23
1.01-2.06
0.62-1.01
0.43-0.62
0.00-0.43
Percent
in size
range
71.4
0.9
3.8
6.0
2.9
2.9
3.3
3.8
5.1
21.6
5.2
19.5
9.5
10.8
15.6
8.7
3.9
5.2
86.0
0
0
6.1
0.6
0
0
0
7.3
Cumulative
percent,
-------
TABLE 6 (continued)
en
Flow rate
Run Location acm/min acf/min
5 Outlet 0.028 0.98
6 Inlet 0.028 0.99
6 Outlet 0.027 0.96
Percent
isokinetic Stage
102.2 0
1
2
3
4
5
6
7
8
100.2 0
1
2
3
4
5
6
7
8
101.2 0
1
2
3
4
5
6
7
8
Size
range ,
urn
>10.86
6.73-10.86
4.26-6.73
3.15-4.26
2.01-3.15
0.98-2.01
0.61-0.98
0.42-0.61
0.00-0.42
>10.80
6.69-10.80
4.24-6.69
3.14-4.24
2.00-3.14
0.98-2.00
0.60-0.98
0.41-0.60
0.00-0.41
>10.97
6.79-10.97
4.31-6.79
3.19-4.31
2.03-3.19
0.99-2.03
0.61-0.99
0.42-0.61
0.00-0.42
Percent
in size
range
59.8
11.6
8.9
7.7
5.7
4.2
0.3
0.3
1.5
81.2
3.3
3.0
5.5
1.5
2.7
1.5
-1.5
2.7
40.5
15.8
15.3
8.5
6.5
5.5
2.3
3.3
2.2
Cumulative
percent,
-------
TABLE 6 (continued)
Flow rate Percent
Run Location acm/min acf/min isokinetic
7 Inlet 0.024 0.85 102.3
7 Outlet 0.025 0.89 80.3
8 Inlet 0.022 0.77 106.3
Stage
0
1
2
3
4
5
6
7
8
0
1
2
3
4
5
6
7
8
0
1
2
3
4
5
6
7
8
Size
range,
pm
>11.62
7.20-11.62
4.56-7.20
3.37-4.56
2.15-3.37
1.05-2.15
0.65-1.05
0.45-0.65
0.00-0.45
>11.37
7.05-11.37
4.47-7.05
3.30-4.47
2.10-3.30
1.03-2.10
0.64-1.03
0.44-0.64
0.00-0.44
>12.26
7.59-12.26
4.81-7.59
3.56-4.81
2.27-3.56
1.11-2.27
0.68-1.11
0.47-0.68
0.00-0.47
Percent
in size
range
48.1
7.6
11.6
9.7
7.6
7.6
4.1
1.4
2.4
26.5
14.5
15.0
12.2
10.3
9.4
5.3
4.3
2.6
64.5
2.1
4.6
5.3
5.7
3.2
6.4
4.2
3.9
Cumulative
percent,
-------
TABLE 6 (continued)
Flow rate
Run Location acm/min acf/min
8 Outlet 0.026 0.92
9 Inlet 0.036 1.26
9 Outlet 0.026 0.93
Percent
isokinetic Stage
93.6 0
1
2
3
4
5
6
7
8
100.7 0
1
2
3
4
5
6
7
8
93.8 0
1
2
3
4
5
6
7
8
Size
range,
[jm
>11.17
6.92-11.17
4.39-6.92
3.24-4.39
2.07-3.24
1.01-2.07
0.62-1.01
0.43-0.62
0.00-0.43
>9.56
5.92-9.56
3.75-5.92
2.78-3.75
1.77-2.78
0.87-1.77
0.53-0.87
0.37-0.53
0.00-0.37
>11.16
6.91-11.16
4.38-6.91
3.24-4.38
2.06-3.24
1.01-2.06
0.62-1.01
0.43-0.62
0.00-0.43
Percent
in size
range
38.0
14.6
12.1
12.1
11.8
8.1
2.5
0.6
0
35.0
10.3
12.3
9.0
9.0
7.7
5.0
7.3
4.3
25.0
13.5
14.6
13.1
12.1
7.7
7.3
5.2
1.7
Cumulative
percent,
-------
TABLE 7a. SUMMARY OF METHOD 9 PLUME OPACITY OBSERVATIONS
AT BURLINGTON INDUSTRIES, INC. BOILER NO. 6 IN
CLARKSVILLE, VIRGINIA (JULY 12, 1982) - RUN 1
Date: 7/12/B2
Type of Discharge: Stack
Height of Point of Discharge: 55 ft
Wind Direction: Not available
Color of Plume: Black
Observer Name: Frank Clay
Distance from Observer to Discharge Point: 200 ft
Direction of Observer from Discharge Point: Not available
Height of Observation Point: 25 ft
Sampling Time: 1 - 15:38-18:13
Type of Plant: Industrial Boiler
Location of Discharge: Mechanical Collector Exhaust
Description of Sky: Blue, hazy, scattered clouds
Hind Velocity: 0-10 mpti
Location of Observation: Above stack outlet
Duration of Observation: 155 nin
Set
number
1
2
3
4
5
6
7
e
9
10
11
12
13
14
15
16
17
IB
19
20
21
22
23
24
25
26
Average ,
all sets
Summary
Start
15:36
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
17:33
17:39
17:45
17:51
17:57
18:03
16:09
of average opacity
Time
End
15:44
15:50
15:56
16:02
16:06
16:14
16:20
16:26
16:32
16:36
16:44
16:50
16:56
17:02
17:08
17:14
17:20
17:26
17:32
17:38
17:44
17:50
17:56
18:02
18:06
18:13
Sum
155
75
80
170
170
120
70
115
175
155
200
110
115
135
190
135
135
140
180
365
460
140
190
220
125
145
Opacity
Average
6.5
3.1
3.3
7.1
7.1
5.0
2.9
4.8
7.3
6.5
8.3
4.6
4.8
5.6
7.9
5.6
5.6
5.8
7.5
15.2
19.2
5.8
7.9
9.2
5.2
6.0
6.6
a.
O
-r-
J
j
/O
18
-------
TABLE 7b. SUMMARY OF METHOD 9 PLUME OPACITY OBSERVATIONS
AT BURLINGTON INDUSTRIES, INC. BOILER NO. 6 IN
CLARKSVILLE, VIRGINIA (JULY 13, 1982) - RUN 2
Date: 7/13/82
Type of Discharge: Stack
Height of Point of Discharge: 55 ft
Wind Direction: North
Color of Plume: Black
Observer Name: Frank Clay
Distance from Observer to Discharge Point: 150 ft
Direction of Observer from Discharge Point: Not available
Height of Observation Point: 25 ft
Sampling Time: 1 - 8:30-8:46, 2 - 8:57-9:44, 3 - 10:36-12:43
Type of Plant: Industrial Boiler
Location of Discharge: Mechanical Collector Exhaust
Description of Sky: Gray, overcast
Wind Velocity: 5 «ph
Location of Observation: Above sjack outlet
Duration of Observation: 252 din
JO-
-------
TABLE 7c. SUMMARY OF METHOD 9 PLUME OPACITY OBSERVATIONS
AT BURLINGTON INDUSTRIES, INC. BOILER NO. 6 IN
CLARKSVILLE, VIRGINIA (JULY 13, 1982) - RUN 3
Date: 7/13/82
Type of Discharge: Stack
Height of Point of Discharge: 55 ft
wind Direction: North
Color of Plume: Black
Observer Name: Frank Clay .,..,<....».. v
Distance from Observer to Discharge Point: 160 ft
Direction of Observer from Discharge Point: Not available
Height of Observation Point: 25 ft
Sampling Time: 1 - 14:36-18:04
Type of Plant: Industrial Boiler
Location of Discharge: Mechanical Collector Exhaust
Description of Sky: Gray, overcast
Wind Velocity: 5-10 «ph
Location of Observation: Above stack outlet
Duration of Observation: 206 Bin
JO-
.
J
e
a.
O
10
Set
number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Average ,
all sets
Summary
Start
14:38
14:44
14:50
14:56
15:02
15:08
15:14
15:20
15:26
15:32
15:38
15:44
15:50
15:56
16:02
16:08
16:14
16:20
16:26
16:32
16:38
16:44
16:50
16:56
17:02
17:08
17:14
17:20
17:26
17:32
17:38
17:44
17:50
17:56
18:02
of average opacity
Time
End
14:43
14:49
14:55
15:01
15:07
15:13
15:19
15:25
15:31
15:37
15:43
15:49
15:55
16:01
16:07
16:13
16:19
16:25
16:31
16:37
16:43
16:49
16:55
17:01
17:07
17:13
17:19
17:25
17:31
17:37
17:43
17:49
17:55
18:01
16:04
Opacity
Sum
120
105
180
135.
b
ioob
200
95
120
95
35.
65b
105
100
405C
115
235b
190
220
115
165
275
245
155
175
225
ISO
190
170
145
100
130
l«b
"s"
Average
5.0
4.4
7.5
5.6
1.6
4.6
6.3
4.0
5.0
4.0
1.5
2.8
4.4
4.2
16.9
4.8
9.8
8.6
9.2
4.8
7.7
11.5
10.2
6.5
7.3
9.4
7.5
7.9
7.1
6.0
4.2
5.4
5.4
8.3
8.6
6.6
^w
~Tir
20
-------
TABLE 7d SUMMARY OF METHOD 9 PLUME OPACITY OBSERVATIONS
AT BURLINGTON INDUSTRIES, INC. BOILER NO. 6 IN
CLARKSVILLE, VIRGINIA (JULY 14, 1982) - RUN 4
Date. 7/14/82
Type of Discharge: Stack
Height of Point of Discharge: 55 ft
Wind Direction: Northeast
Color of Plume: Black
Observer Name: Frank Clay
Distance from Observer to Discharge Point: 160 ft
Direction of Observer from Discharge Point: Not available
Height of Observation Point: 25 ft
Sampling Time: 1 - 8:16-8:29, 2 - 8:47-9:00. 3 - 9:05-9:12,
Type of Plant: Industrial Boiler
Location of Discharge: Mechanical Collector Exhaust
Description of Sky: Gray
Hind Velocity: 0-5 nph
Location of Observation: Above stack outlet
Duration of Observation: 162 rain total
4 - 9:42-10:57
Summary of average opacity
Set
number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Average ,
all sets
Time
Start
8:16
8:22
8:47
8:53
8:59
9:05
9:08
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
End
8:21
8:27
8:52
8:58
9:00
9:07
9:12
9:47
9:53
9:59
10:05
10:11
10:17
10:23
10:29
10:35
10:41
10:47
10:53
10:57
Opacity
Sum
b
80b
270e
25of
15b
7SD
255e
120
120
210
150
110
90
100
125
160
20b
6°b
80b
50
Average
7.2
4.7
11.3
13.9
15.0
10.7
12.8
5.0
5.0
8.8
6.3
4.6
3.8
4.2
5.2
6.7
0.8
2.7
4.0
4.6
6.9
/O
21
-------
TABLE 7e. SUMMARY OF METHOD 9 PLUME OPACITY OBSERVATIONS
AT BURLINGTON INDUSTRIES, INC. BOILER NO. 6 IN
CLARKSVILLE, VIRGINIA (JULY 14, 1982) - RUN 5
Date; 7/14/82
Type of Discharge: Stack
Height of Point of Discharge: 55 ft
Wind Direction: Northeast
Color of Plume: Black
Observer Name: Frank Clay
Distance from Observer to Discharge Point: 160 ft
Direction of Observer from Discharge Point: Not available
Height of Observation Point: 20 ft
Sampling Time: 1 - 12:07-14:22
Type of Plant: Industrial Boiler
Location of Discharge: Mechanical Collector Exhaust
Description of Sky: Gray
Hind Velocity: 5 nph
Location of Observation: Above stack outlet
Duration of Observation: 135 Bin total
Summary of average opacity
Set
number
1
2
3
4
5
6
7
B
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Average ,
all sets
Time
Start
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
13:43
13:49
13:55
14:01
14:07
14:13
14:19
End
12:12
12:18
12:24
12:30
12:36
12:42
12:48
12:54
13:00
13:06
13:12
13:18
13:24
13:30
13:36
13:42
13:48
13:54
14:00
14:06
14:12
14:18
14:24
Opacity
Sum
150
125
135
155
135
135
110
115
105
135
120b
80
120
190
95
85
125b
130
130
120
95f
175r
40
Average
6.3
5.2
5.6
6.5
5.6
5.6
4.6
4.8
4.4
5.6
5.2
3.3
5.0
7.9
4.0
3.7
5.4
5.4
5.4
5.0
4.0
6.0
5.0
5.3
2>0
.
•j
-------
TABLE 7f. SUMMARY OF METHOD 9 PLUME OPACITY OBSERVATIONS
AT BURLINGTON INDUSTRIES, INC. BOILER NO. 6 IN
CLARKSVILLE, VIRGINIA (JULY 14, 1982) - RUN 6
Dale. 7 14 ST
Type of Discharge: Stack
Height of Point of Discharge:
Wind Direction: Northeast
Coloi of Flume. Black
Observer Name: Frank Clav
Type of Plant: Industrial Boiler
Location of Discharge: Mechanical Collector Exhaust
55 ft Description of Sky: Cray
wind Velocity: 3-5 mph
Location of Observation: Above stack outlet
Duration of Observation: 107 mm total
Distance from Observer to Discharge Point: 160 ft
Direction of Observer from Discharge Point: Not available
Heigh: of Observation Point: 20 ft
Sair.pling Tune: 1 - 15:40-15:57, 2 - 16:00-16:29, 3 - 16:33-17:16,
4 - 17:34-17:49
e
c.
C
10
SuT.T.ary of averaat opacity
Set
number
1
2
3
4
5
6
7
£
c
1C
11
1 2
13
14
1 5
- c.
17
16
19
2C
Average ,
all'sets
Tune
Start
IS
15
15
16
16
16
16
16
16
16
16
It
16
16
17
1 7
17
17
17
17
40
46
52
00
05
11
17
23
21
33
36
42
46
54
00
0£
12
34
39
45
End
15
15
15
16
16
16
16
16
16
16
16
U
16
16
17
17
17
17
17
17
45
51
57
04
10
16
22
28
29
35
41
47
53
59
05
1!
16
38
44
49
Opacity
Sum
135
120
95
80
105
120
100
90,
25f.g
409
90
100
80
40f
265°
45
109
1009
70
O9
Average
5
5
4
5
4
5
4
3
4
3
3
4
3
2
6
1
0
5
2
0
3
6
0
0
0
4
0
2
8
2
3
8
2
3
4
6
9
5
0
9
0
B
-
23
-------
TABLE 7g. SUMMARY OF METHOD 9 PLUME OPACITY OBSERVATIONS
AT BURLINGTON INDUSTRIES, INC. BOILER NO. 6 IN
CLARKSVILLE, VIRGINIA (JULY 15, 1982) - RUN 7
Date: 7/15/82
Type of Discharge: Stack
Hught of Point of Discharge: 55 ft
Wind Direction: North
Color of Plume: Black
Observer Naflie: Frank Clay
Distance from Observer to Discharge Point: 160 ft
Direction of Observer frorc Discharge Point: Not available
Heioht of Observation Point: 20 ft
Sa-pling Tijne: 1 - 10:00-12:05
Type of Plant: Industrial Boiler
Location of Discharge: Mechanical Collector Exhaust
Description of Sky: Gray
Hind Velocity: 0-10 nph
Location of Observation: Above stack outlet
Duration of Observation: 125 Bin
Summary of average opacity
Set
number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
16
19
20
21
average,
all sets
Time
Start
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
11:42
11:48
11:54
12:00
End
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
11:47
11:53
11:59
12:05
Opacity
Sum
315
240
350
265
275
300
280
245
245
275
265
240
270
280
295
270
275
315
305
345
2559
Average
13.1
10.0
14.6
11.0
11.5
12.5
11.7
10.2
10.2
11.5
11.0
10.0
11.2
11.7
12.3
11.2
11.5
13.1
12.7
14.4
12.6
11.2
o-
O
u
efi!
24
-------
TABLE 7h. SUMMARY OF METHOD 9 PLUME OPACITY OBSERVATIONS
AT BURLINGTON INDUSTRIES, INC. BOILER NO. 6 IN
CLARKSVILLE, VIRGINIA (JULY 15, 1982) - RUN 8
Date: 7/15/82
Type of Discharge: Stack
Height of Point of Discharge: 55 ft
Wind Direction: North
Color of Flume: Black
Observer Name: Frank Clay
Distance from Observer to Discharge Point:
Direction of Observer from Discharge Point
Height of Observation Point: 20 ft
Sampling Time: 1 - 13:18-15:47
Type of Plant: Industrial Boiler
Location of Discharge: Mechanical Collector Exhaust
Description of Sky: Gray
Wind Velocity: 0-5 nph
Location of Observation: Above stack outlet
Duration of Observation: 147 nin
160 ft
Not available
30
.50'
7-
-r-
> *
j
a.
O
/c
Summary of average opacity
Set
number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Average,
all sets
Time
Start
13:18
13:24
13:30
13:36
13:42
13:48
13:54
14:00
14:06
14:12
14:18
14:24
14:30
14:36
14:42
14:46
14:54
15:00
15:06
15:12
15:18
15:24
15:30
15:36
15:42
End
13:23
13:29
13:35
13:41
13:47
13:53
13:59
14:05
14:11
14:17
14:23
14:29
14:35
14:41
14:47
14:53
14:59
15:05
15.11
15:17
15:23
15:29
15:35
15:41
15:47
Opacity
Sum
270
285
295
295
315
255b
325
320
315
335
56 5C
275
330
260
340
395
390
400
455
440
410
395
375
270
135^
Average
11.3
11.9
12.3
12.3
13.1
11.1
13.5
13.3
13.1
14.0
23.5
11.5
13.8
10.8
14.2
16.5
16.3
16.7
19.0
18.3
17.1
16.5
15.6
11.3
11.3
14.3
^
0
U
1
'X
J
\
3 V
25
-------
TABLE 7i. SUMMARY OF METHOD 9 PLUME OPACITY OBSERVATIONS
AT BURLINGTON INDUSTRIES, INC. BOILER NO. 6 IN
CLARKSVILLE, VIRGINIA (JULY 16, 1982) - RUN 9
Datp. 7/)6'6r
Type of Discharge: Stack
He:?1; of Point of Discharge. 55 ft
W;nd ruection: Northeast
Color of Plume: Black
Observer Name: Frank Clay
Distance from Observer to Discharge Point:
Tirectjon of Observer from Discharge Point
Hucht of Observance Point: 20 ft
Ssrrlir.g Time: 1 - 9:06-11:11
Type of Plant: Industrial Boiler
Location of Discharge: Mechanical Collector Exhaust
Description of Sky: Gray
wind Velocity: 5 mph
Location of Observation: Above stack outlet
Duration of Observation: 123 nan
160 ft
Not available
Summary of averaoe opacity
Set
n'ori er
1
r
3
4
5
6
7
E
9
1C
i:
12
13
14
1:
It
17
16
1C
20
21
Average .
all sets
Time
Start
9
9
9
9
9
9
9
c
Q
10
10
10
10
10
10
10
10
10
10
11
11
:06
:14
:20
:26
:32
:3B
:44
:50
:56
:02
:06
:14
:20
:26
:32
:36
:44
:50
:56
:02
:06
End
9
9;
9:
9:
9
9
9
9:
10:
10:
10:
10
10
10:
10:
10:
10:
10:
11:
11:
11 :
:13
:19
:25
:31
:37
:43
:49
:55
01
:07
13
:19
:25
:31
:37
:43
49
.55
:01
:07
:11
Opaci tv
Eurr
285
245
240
260
240
240
245
260
295
205
245
280
220
220
215
225
235
240
250
250
1309
Averaae
11
10
10
10
10
10
10
10
12
B
10.
11
9
9
9
9.
9.
10
10
10.
10.
10.
.9
.2
.0
.8
.0
.0
.2
.8
.3
.5
2
.7
.2
.2
.0
.4
.6
.0
.4
.4
.8
2
Tctai observation time includes periods when no
readings were taken.
Several observations not made due to steam plume
obscuring view.
Soot blowing occurred during this set.
Only 4 readings in this set.
Red stack background gave higher VI values (by ^5
Several observations not made due to smoke from
other stack obscuring viev.
'Not a full set of reading taken due to break.
3.0 i
7-
-f
0.
C
1C'
26
-------
TABLE 8. SUMMARY OF COAL ANALYSIS AT BURLINGTON INDUSTRIES,
INC. BOILER NO. 6 IN CLARKSVILLE, VIRGINIA
Heating value
Run
number
1
2
3
4
5
6
7
8
9
Total
moisture,
percent
2.73
2.42
2.65
2.41
2.90
2.66
2.14
2.86
2.04
Dry
32,942
33,011
32,816
32,633
33,083
32,909
32,612
32,814
33,218
Joule/gram
As
received
32,041
32,213
31,949
31,849
32,123
32,034
31,916
31,902
32.538
AMF
35,224
35,152
35,095
35,294
35,210
34,798
34,712
34,266
34,870
Dry
14,199
14,229
14,145
14,066
14,260
14,185
14,057
14,156
14,318
Btu/lb
As
received
13,811
13,885
13,771
13,728
13,846
13,808
13,757
13,751
14,025
AMF
15,183
15,152
15,127
15,213
15,177
14,999
14,962
14,770
15,030
Ash,
Dry
6.5
6.1
6.5
7.5
6.0
5.4
6.1
4.2
4.7
, percent
As
received
6.3
5.9
6.3
7.4
5.9
5.3
5.9
4.0
4.6
Sulfur, percent
Dry
0.82
0.70
0.70
0.63
0.70
0.88
0.78
0.68
0.86
As
received
0.79
0.69
0.68
0.62
0.68
0.85
0.77
0.66
0.85
-------
SECTION 3
PROCESS DESCRIPTION
(Supplied by Radian Corporation)
This section presents a generalized description and discussion of
the boiler and dual mechanical collector process at the Burlington
plant. This description includes a process flow diagram, general
equipment information, equipment design data, and design operating
parameters.
The process data collected during all emission testing periods are
tabulated in Appendix C. In addition, Appendix C presents a dis-
cussion which identifies any process upsets or abnormalities that
occurred during testing. Some general comments on the process
operation are also included.
BOILER/DUAL MECHANICAL COLLECTOR SYSTEM DESCRIPTION
Figure 2 presents a diagram of the industrial boiler tested at the
Burlington Industries fabric finishing plant in Clarksville,
Virginia. The inlet and outlet test ports are shown in addition
to all the major equipment components. Design and operating data
for the boiler are presented in Table 9.
The boiler shown in Figure 2 is a coal-fired spreader stoker which
is rated at a maximum continuous capacity of 68 x 103 kg/hr
(150 x 103 Ib/hr) steam. Steam is produced for use in various
processes throughout the fabric finishing plant and for space
heating. In general, the boiler tested is used to follow fluctu-
ations (swing loads) in steam demand at the plant. Use of this
boiler to follow load swings is preferred over the use of other
boilers at the plant because it responds more rapidly to steam
demand fluctuations.
As shown in Figure 2, coal is fed onto a traveling grate by four
identical spreader feeder mechanisms. Boiler bottom ash is dis-
carded continuously into the ash pit at the front end of the
boiler and removed from the ash pit three times a day via a pneu-
matic ash removal system. The pneumatic system was not operated
during the performance of any emission test. Exhaust gases exit
the furnace at 978°C (1790°F) and pass through the boiler section,
where steam and how water are generated. The boiler section also
28
-------
to
Overfi ro Air
System Ton (50 H.P.)
Ainliieiil.
Ai r-
7
Sic/mi Driini
Front And
Rear Overfi re
Ai r Headers
And Jets (20
Jets Per
Side)
Coal Feeder
el ing Grate And
Stoker Mechanism
\
Porcod
P,in (100 H.P.)
Inlet Test
Ports
1
To '• t.
000
,-^-
~ 1
- )
—
Air 1
countor-
w)
I
/
V
/
s~
>-,
i
i
L«v4
>
,
-
<
••
X
^N
)
<
/
-N
^
-^*
J
Dual Mechanic<
Collectors
)1
R~
s-
Inr
Tar
Outlet
-Test
Ports
Induced Draft
Fan {300 H.P.)
Tn Ash
Disposal
Silo
Figure 2. Boiler/dual mechanical collector process flow diagram.
-------
TABLE 9. BOILER DESIGN AND OPERATING DATA
Boiler installation date
Manufacturer
Stoker type
Number of stokers
Grate type
Rated capacity
(maximum continuous)
Overall boiler efficiency
Soot blowing system
Furnace/boiler draft loss
Ash discharge system
Steam data
Pressure (design)
Pressure (operating)
Temperature (operating)
Heating surface area
(furnace, boiler, air heater)
Convective section data
Number of gas passes
Gas temperature entering
Gas temperature leaving
Draft loss
Air preheater data
Number of flue gas passes
Flue gas temperature IN
Flue gas temperature OUT
Combustion air temperature IN
Combustion air temperature OUT
Draft loss
Overfire air system data
Number (front)
Number (rear)
Fly reinjection system
Coal specifications (design)
Sulfur
Ash
Btu/lb
Excess air (design)
1976
Zurn Erie City
Spreader stoker
4
Traveling grate front ash discharge
150,000 Ib/hr steam
Diamond Model G9B (4 steam soot
blowers used in boiler section)
0.1 - 1.53 inch w.c.
Pneumatic (ash pit, convective
section hopper, mechanical
collector hoppers)
250 psig
150 psig
366°F
16,110 ft2
3 vertical passes
1790°F
564°F
1.3 inch w.c.
1 (vertical)
400°F
350°F
80°F
335°F
1.39 inch w.c.
20 Jets
20 Jets
None
1.1%
6.6%
13,720
25%
30
-------
acts as a particulate matter trap. Particulate matter settles out
in the boiler section hopper which is evacuated three times a day
via the pneumatic ash removal system. All testing was performed
downstream of the boiler section and, therefore, its particulate
matter removal capability is not addressed in this test report.
At the boilers rated capacity, the flue gas temperature drop
across the boiler section is 681°C (1226°F). The boiler section
tubes are cleaned twice a day to remove particulate matter build-
up. Four identical sootblowers are activated by hand and high
pressure steam is used to clean all boiler section tubes over a
five minute period. Three of the nine tests include soot blowing
cycles.
As shown in Figure 2, the boil-er uses a single pass combustion
air preheater which heats incoming combustion air from ambient
temperature, 26°C (80°F), to 168°C (335°F). This increases the
boilers thermal efficiency and results in a system draft loss of
3.6 cm (1.4 inch) w.c. when the boiler operates at rated capacity.
The flue gas temperature drop across the preheater is about 8°C
(15°F).
The boiler has three electric motor driven fans which operate on
a continuous basis. Overfire air is supplied by a 37 kw (50 hp)
fan which pressurizes two headers: one for the front and one for
the rear overfire air jets. Combustion air is supplied by a 74 kw
(100 hp) forced draft fan while system pressure drops are overcome
by a 223 kw (300 hp) induced draft fan.
The dual mechanical collector system was installed in 1976 by Zurn
Industries Air Systems Division. There was no collection effi-
ciency guarantee given with the system. In general, the collector
is made up of two identical single mechanical multitube cyclones
placed in series. Each collector has 15 cm (6 inch) diameter
cyclone tubes which result in a pressure drop of from 13 to 15 cm
(5 to 6 inches) w.c. when the boiler operated at maximum rated
capacity. Therefore, the total pressure drop for the dual
mechanical collector is between 25 and 30 cm (10 and 12 inches)
w.c. Particulate matter in the flue gas is removed by the centri-
fugal action of the cyclone tubes. The collected particulate
matter drops from the bottom of the cyclone tubes into one of two
ash hoppers. Both hoppers are evacuated three times a day via the
pneumatic ash removal system.
One month prior to the start of testing, the dual mechanical
collector was inspected for damage and wear. Some plugged tubes
were found and replaced.
31
-------
SECTION 4
LOCATION OF SAMPLING POINTS
INLET
Two 10.2 cm (4 in.) I.D. sampling ports are located on a 1.4 m
(4.4 foot) by 3.1 m (10.3 ft) rectangular duct. The sampling
ports are 0.38 m (1.2 ft) downstream of the 90° bend leading to
the first stage mechanical collector (0.19 duct diameters) and
0.86 m (2.8 ft) upstream of the pre-heater tubes (0.45 duct
diameters) as shown in Figure 3.
A 24-point traverse was performed at this location, with 12 points
sampled at each port as shown in Figure 4. A stainless steel
20-foot probe with heated filter box mounted on the end of the
probe was used to traverse the 16 foot duct. This location does
not meet all criteria under EPA Methods 1-5, however, this loca-
tion was selected as the best site to obtain particulate loadings
on the double mechanical collectors.
OUTLET
Two, 10.2 cm (4 in.) I.D. sampling ports are located on a 10.7 m
(35 ft) tall, 1.5 m (5 ft) I.D. round stack. The sampling ports
are 6.0 m (19.7 ft) downstream of the fan (3.9 duct diameters)
and 4.8 m (15.7 ft) upstream of the stack outlet (3.1 duct diam-
eters) as shown in Figure 5. The arrangement meets all criteria
for an acceptable measurement specified under EPA Methods 1-5.
A 40-point traverse was performed at this location with each
traverse being 20 points as shown in Figure 6.
COAL SYSTEM
Low sulfur, preweighed coal is fed continuously to the boiler
from flippers onto a traveling grate where over-fire jets provide
air to aid combustion. The coal was sampled at the Boiler No. 6
coal feed conveyor belt before, during, and after each run,
combined to obtain a representative sample, and stored in a
plastic container.
32
-------
2-4" PORTS-
RECTANGULAR DUCT-
123.5"X53"
53"
—AIR PRF-HEATER TUBES
r
34"
. t.
15"
FIRST STAGE
MECHANICAL COLLECTOR
AIR FLOW
SIDE VIEW
U)
U)
AIR FLOW TO
FIRST STAGE -«-
J
12
3.5"
u u
TOP VIEW
Figure 3.
Inlet sampling ports to Boiler No. 6 at Burlington
Industries, Inc. in Clarksville, Virginia.
-------
12 11 10
Traverse
point
number
1
2
3
4
5
6
7
8
9
10
11
12
9 8
4
Inside of
wall to
traverse
point,
inch
5.2
15.5
25.8
36.1
46.4
56.7
70.0
80.3
90.6
100.9
111.2
121.5
7654
H 10. r h—
TOP VIEW
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 2 1
^5.2"^ 24" 5;
— |3.5"K
PORT LENGTH
Traverse point
location from
outside of port,
inch
8.7
19.0
29.3
39.6
49.9
60.2
73.5
83.8
94.1
104.4
114.7
125.0
Figure 4. Traverse point location at inlet for
Boiler No. 6 at Burlington Industries,
Inc. in Clarksville, Virginia.
34
-------
2-4" I.D.
PORTS
ROOF LINE
STACK
FLUE GAS IN
4'-2"
15--4"
Figure 5. Fan, stack, and sample port dimensions
for outlet for Boiler No. 6 at Burlington
Industries, Inc. in Clarksville, Virginia.
35
-------
/
/
20 10 18 17 16 15 U 13 12 11 10 9
60"
\^_
L_T^
Inside of
wall to
Traverse traverse
point point,
number inch
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
0.78
2.34
4.02
5.82
7.74
9.90
12.2
15.0
18.4
23.3
36.7
41.6
45.0
47.8
50.1
52.3
54.2
56.0
57.7
59.2
\
\
87651321
X •
./ PORT
Distance
2-4"
/I.D. PORTS
5"
LENGTH
Traverse
location
point
from
of port, outside of port,
inch inch
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
9.
10.
12.
14.
16.
18.
20.
23.
26.
31.
45.
49.
53.
56.
58.
60.
62.
64.
66.
67.
3
8
5
3
2
4
7
5
9
8
2
1
5
3
6
8
7
5
2
6
Figure 6. Traverse point location at outlet for Boiler No. 6 at
Burlington Industries, Inc. in Clarksville, Virginia.
36
-------
SECTION 5
SAMPLING AND ANALYSIS
STACK SAMPLING AND ANALYSIS
The sampling and analysis methods used at the Burlington Indus-
tries, Inc. site are shown in Table 1. Three simultaneous runs of
Method 5B at the inlet and outlet to the double mechanical collec-
tors were conducted at each of three boiler loadings (base load,
2/3, and 1/3). A typical Method 5 stack test system was used for
sampling, except that oven and filter temperatures were maintained
at 160°C ± 14°C (320°F ± 25°F). Reeve Angel Type 934 AH filters
were used for the Method 5B testing. The filter temperatures were
monitored using thermocouples installed in the oven. Figure 7 is
a schematic diagram of the Method 5B test probe system.
Heated glass-lined probes were used at the outlet location.
Twenty-foot, stainless steel probes were used at the inlet loca-
tion. Due to wall constrictions and use of a 20-foot probe,
several points were not sampled (points 1 and 2 from Figure 4)
at the inlet.
Method 5B samples volumes of at least 65 cubic ft were taken
at the outlet and 22 cubic ft at the inlet. The flue gas velo-
city, temperature, flow rate, and oxygen and carbon dioxide
content were measured using EPA Methods 1-4 during all stack
sampling runs. The probes, nozzles, and filter holders were
rinsed with acetone and the acetone rinse was retained for
analyses with the particulate filters.
Acetone rinses and filters were dried and weighed according to
Method 5 procedures for gravimetric particulate analyses. The
weighing was repeated until the weight of particulates was within
1% of the net particulate amount on the previous weighing. Blank
filters and residue from the evaporation of clean acetone blanks
were analyzed along with stack samples for guality control.
Plume opacity was observed according to EPA Method 9 during each
of the sampling runs. In addition, Andersen particle sizing was
done at the inlet and outlet to the double mechanical collectors
immediately after each sampling run.
37
-------
00
TEMPFRATURE
SENSOR
„- PRORE
PITOT TUBE '
NOZZl E/IIHATED -
PROtlE
REVERSE TVPE
PITOT TUBE
THERMOMETER
CHECK VALVE
VACUUM LINE
.VACUUM GUAGE
HEATED AREA
FILTER HOLDER
THERMOMETERS
DRY GAS ORIFICE
METEH AND
MANOMETER
PITOTMAWOMETER
IMPINGERS
ICE BATH
Figure 7. Particulate sampling train - EPA Method 5B.
-------
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
boiler 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
methods (ASTM D3176 and D2015-66).
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 and EPA'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 as well as a table summariz-
ing emission calculations.
Appendix C (supplied by Radian Corporation) contains boiler moni-
toring 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.
39
-------
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 to code the computer input.
40
------- |