&EPA
            United States
            Environmental Protection
            Agency
           Office of Air Quality
           Planning and Standards
           Research Triangle Park NC 27711
EMB Report 83-CDR-1
October 1983
            Air
Calciners and
Dryers

Emission Test
Report
A.  P. Green
Company
Mexico, Missouri

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                NSPS DEVELOPMENT
PARTICULATE AND PARTICLE SIZE EMISSIONS TESTING
             ROTARY CALCINER/COOLER
        A.P. GREEN REFRACTORIES COMPANY
                MEXICO,  MISSOURI
              OCTOBER 17-21,  1983
                  Compiled by:

      TRC Environmental Consultants,  Inc.
              800 Connecticut Blvd.
       East Hartford,  Connecticut  06108
                   68-02-3543
             Work Assignment No.  8
            TRC Project No.  2177-E84
            EMB Report No.  83-CDR-l
                  Task Manager

                Dennis Holzschuh
          Emission Measurement Branch
  Emissions Standards and Engineering Division
      Research Triangle Park,  N. C.,  27711
  OFFICE OF AIR QUALITY PLANNING AND STANDARDS
      OFFICE OF AIR, NOISE,  AND RADIATION
     U. S. ENVIRONMENTAL PROTECTION AGENCY
      RESEARCH TRIANGLE PARK,  N. C., 27711

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                                   PREFACE




    The  work  herein  was  conducted  by  personnel  from  TRC   Environmental




Consultants, Inc.  (TRC), The Radian Corporation, AP Green Refractories  Company




in Mexico, Missouri, and the U.S. Environmental Protection Agency  (EPA).




    The  scope  of  work,  issued  under  EPA  Contract   No.   68-02-3543,  Work




Assignment  No.  8, was  under  the supervision of  the  TRC  Work   Assignment




Manager, Mr. Eugene A. Brackbill.  Mr.  Leigh  A. Gammie  of TRC served as  Field




Team Leader and  was  responsible for summarizing the  test  and analytical data




in this  report.   Sample  analyses were  performed in Mexico,  Missouri under  the




direction of Ms.  Ellen M. Scanlon  and  at  the TRC laboratory in East Hartford,




Connecticut under  the direction of Mr.  Samuel S. Cha.



    Radian personnel  were responsible  for  monitoring  the  process   operations




during the testing program  and for preparing Section 3.0 (Process  Description




and Operation).




    Personnel  of  the AP  Green Refractories  Company   whose assistance  and




guidance contributed greatly to  the  success  of  the test program  included  Mr.




Glen  E.  Werner,  Chemist,  Environmental  Control and Mr.  Robert  E. Besalke,




Manager,  Environmental Control.




    Mr.  Dennis  Holzschuh,  Office of  Air  Quality  Planning and   Standards,




Emission  Measurement  Branch,   EPA,  served  as  Technical  Manager  and   was




responsible for coordinating the emission  test program.




    Further information  relating to this test  program can  be  found  in  the




"Site Test Plan  for  NSPS Development,  Particulate and  Particle Size Emissions




Testing,   Rotary  Calciner, AP  Green Refractories  Company,  Mexico, Missouri"




prepared August 1983 and in Appendix H.
                                     -ii-

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                               TABLE OF CONTENTS


SECTION                                                                   PAGE

                   PREFACE	ii

  1.0              INTRODUCTION  	   1
      1.1            Background	1
      1.2            Brief Process Description	2
      1.3            Measurement Program 	   4
          1.3.1        Rotary Calciner Multiclone Inlet	4
          1.3.2        Rotary Calciner Venturi Scrubber Outlet	4
          1.3.3        Rotary Calciner Inlet 	   5
          1.3.4        Rotary Cooler Outlet	5
          1.3.5        Blank Evaluations	5
      1.4            Particle Size Distribution Measurements	5
          1.4.1        Analysis	6
          1.4.2        Data Reduction	6
      1.5            Description of Report Sections  	   7

  2.0              SUMMARY OF RESULTS	8
      2.1            Rotary Calciner - Participate  Matter  Tests	8
      2.2            Rotary Calciner - Particle Size  Tests 	  13
          2.2.1        Multiclone Inlet - Test Parameter Summary	13
          2.2.2        Venturi Scrubber Outlet - Test Parameter  Summary   .  17
      2.3            Impactor Data at Interpolated  Particle Diameters   .  .  19
          2.3.1        Rotary Calciner - Multiclone Inlet	19
          2.3.2        Rotary Calciner - Venturi Scrubber  Outlet 	  23
      2.4            Comparative Data Analysis	23
          2.4.1        Rotary Calciner - Multiclone Inlet	  23
          2.4.2        Rotary Calciner - Venturi Scrubber  Outlet	29
      2.5            Averaged Distributions for Tests 1, 2, and  3  ....  29
      2.6            Comparison of Cumulative  Percent Less than  10  microns  29
      2.7            Visible Emissions 	  36
      2.8            Fugitive Emissions  	  36
      2.9            Sieve and Moisture Analysis-Feed and  Product Material  41
          2.9.1        Feed Material	41
          2.9.2        Product Material  	  41
          2.9.3        Trace Metals Analysis	41

  3.0              PROCESS DESCRIPTION AND OPERATION  	  45
      3.1            General	45
      3.2            Calcining Process	45
          3.2.1        Raw Material	45
          3.2.2        Rotary Calciner	46
          3.2.3        Calciner Design Capacity  	  46
          3.2.4        Calciner Exhaust Gases   	  46
          3.2.5        Storage	49
      3.3            Process Conditions During Testing 	  49
          3.3.1        Monitoring Procedures . .  .  •.	49
          3.3.2        Production Rates  	  51

  4.0              SCOPE  OF THE SAMPLING PROGRAM BY SITE	56
      4.1            Multiclone Inlet - Participate Matter Tests	56
                                    - iii -

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                               TABLE OF CONTENTS
                                  (continued)
SECTION
PAGE
      4.2            Multiclone Inlet - Particle Sizing Tests	56
      4.3            Venturi Scrubber Outlet - Participate Matter Tests .  59
      4.4            Venturi Scrubber Outlet - Particle Sizing Tests  . .  59
      4.5            Venturi Scrubber Outlet - Opacity Observations   . .  63
      4.6            Rotary Calciner Inlet Transfer Point	63
      4.7            Rotary Cooler Outlet Transfer Point	63

  5.0              SAMPLING AND ANALYTICAL METHODS  	  67
      5.1            Preliminary Measurements 	  67
      5.2            Participate Matter Tests	68
      5.3            Gas Analysis	71
      5.4            Particle Size Tests	71
          5.4.1        Sample Recovery	75
          5.4.2        Sample Drying and Weighing 	  76
          5.4.3        Data Reduction	77
      5.5            Plume Opacity - Venturi Scrubber Outlet	77
      5.6            Fugitive Emissions - Rotary Calciner Inlet 	  77
      5.7            Feed and Product Material - Grab Samples	77

  6.0              QUALITY ASSURANCE  	  79
      6.1          Introduction	79
      6.2          Sampling Train Components  	  79
      6.3          Pre-Separators and Cascade Impactors - Particle Size
                     Tests	79
      6.4          Sample Collection Substrates - Particle Size Tests . .  80
      6.5          Substrate Weighing - Particle Size Tests 	  80
      6.6          Blank Sample - Particle Size Test	81
      6.7          Sample Recovery	81
      6.8          EPA Method 3	82

APPENDICES

      A            PARTICULATE DATA SUMMARIES  	     83
          A.I        Multiclone Inlet	     84
          A. 2        Venturi Scrubber Outlet	     89

      B            PADRE DATA SUMMARIES	     99
          B.I        Multiclone Inlet	    100
          B.2        Venturi Scrubber Outlet 	    107

      C            FIELD DATA SHEETS	    115
          C.I        Multiclone Inlet - Method 5	    116
          C.2        Multiclone Inlet - Method 3	    128
          C.3        Multiclone Inlet - Particle Size	    133
          C.4        Venturi Scrubber Outlet - Method 5  	    146
          C.5        Venturi Scrubber Outlet - Method 3  	    153
                                    -IV-

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                               TABLE OF CONTENTS
                                  (continued)
APPENDICES                                                                PAGE


          C.6        Venturi Scrubber Outlet - Particle Size 	    157
          C.7        Visible Emissions 	    164
          C.8        Fugitive Emissions  	    173

      D            FILTER WEIGHT DATA	    176
          D.I        Particulate Tests 	    176
          D.2        Particle Size Tests	    184

      E            SAMPLING EQUIPMENT CALIBRATION DATA 	    194
          E.I        Particulate Sampling Train	    195
          E.2        Particle Size Sampling Train  	    207

      F            PROCESS SAMPLES, LABORATORY SIEVE
                       ANALYSIS/MOISTURE CONTENT 	    214

      G            BLANK EVALUATION RESULTS  	    221

      H            SCOPE OF WORK	    224

      I            PROJECT PARTICIPANTS  	    236

      J            PADRE'S USER GUIDE	    238

      K            CHAIN OF CUSTODY FORMS  	    284

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                               LIST OP FIGURES

FIGURE                                                                     PAGE

  1-1       Overhead View-Rotary  Kiln/Cooler AP  Green Refractories
              Mexico, Missouri  ....................       .3

  2-1       Inlet and Outlet Particle Size Distributions Based upon
              Interpolated Diameters, Test 1  .............      33

  2-2       Inlet and Outlet Particle Size Distributions Based upon
              Interpolated Diameters, Test 2  .............      34

  2-3       Inlet and Outlet Particle Size Distributions Based upon
              Interpolated Diameters, Test 3  .  ............      35
  3-1       Partial Flow Diagram for Fire Clay Plant
   4-1       Overhead View-Rotary Kiln/Cooler, AP Green Refractories,
                Mexico, Missouri   ........ ...........     57

   4-2       Inlet Sampling Location, AP Green Refractories, Mexico,
              Missouri  ........................     58

   4-3       Particle Size Tests, Inlet Sampling Location, AP Green
              Refractories, Mexico, Missouri  .............     60

   4-4       Outlet Sampling Location, AP Green Refractories, Mexico,
              Missouri  .... ....................     61

   4-5       Particle Size Tests, Outlet Sampling Location, AP Green
              Refractories, Mexico, Missouri  .............     62

   4-6       Overhead View-Rotary Kiln/Cooler, AP G'reen Refractories
              Mexico, Missouri  ....................     54

   4-7       Raw Material, Grab Sample Location,  AP Green .Refractories
              Mexico, Missouri  ....................      65

   4-8       Overhead View-Indoor Inlet Raw Material Transfer Point,
              Fugitive Emissions Inspection, AP Green Refractories,
              Mexico, Missouri  .   . . . ................      66

   5-1       Modified EPA Particulate Sampling Train, August 18, 1977,
              Federal Register  ....................      69

   5-2       Integrated Bag Sampling Train ...............      72

   5-3       Particle Size Distribution Sampling Train .........      73
                                     -VI-

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                                LIST OP TABLES

TABLE                                                                      PAGE

  2-1       Summary of Results EPA Method 5  Test_s  Inlet  to Hulticlone
              and Outlet from Venturi Scrubber	       9

  2-la      Summary of Results EPA Method 5  Tests  inlet  to Multiclone.       10

  2-lb      Summary of Results EPA Method 5  Tests  inlet  to Multiclone
              and Outlet from Venturi Scrubber  	      11

  2-lc      Summary of Results EPA Method 5  Tests  Inlet  to Multiclone  .      12

  2-2       Summary of Test Parameters Particle  Size  Distribution
              Measurement Tests inlet to Multiclone - Test 1   	      14

  2-3       Summary of Test Parameters Particle  Size  Distribution
              Measurement Tests Inlet to Multiclone - Test 2   	      15

  2-4       Summary of Test Parameters Particle  Size  Distribution
              Measurement Tests Inlet to Multiclone - Test 3   	      16

  2-5       Summary of Test Parameters Particle  Size  Distribution
              Measurement Tests Outlet from  Venturi Scrubber,  AP Green
              Refractories Company,  Mexico,  Missouri   	      18

  2-6       Impactor Data Summary at Interpolated  particle Diameters
              Particle Size Distribution Tests,  AP Green Refractories
              Company, Rotary Calciner, inlet  to Multiclone, Mexico,
              Missouri	      20

  2-7       Impactor Data Summary at Interpolated  particle Diameters
              Particle Size Distribution Tests,  AP Green Refractories
              Company, Rotary Calciner, Inlet  to Multiclone, Mexico,
              Missouri	      21

  2-8       Impactor Data Summary at interpolated  Particle Diameters
              Particle Size Distribution Tests,  AP Green Refractories
              Company, Rotary Calciner, inlet  to Multiclone, Mexico,
              Missouri	      22

  2-9       Impactor Data Summary at Interpolated  Particle Diameters
              Particle Size Distribution Tests,  AP Green Refractories
              Company, Rotary Calciner, Outlet from Venturi Scrubber,
              Mexico,  Missouri  	      24

  2-10      Comparative CPLT* Data for Test  1, particle  Size
              Distribution Tests,  AP Green Refractories Company,
              Rotary Calciner, Outlet from Venturi Scrubber,
              Mexico,  Missouri  	      25

  2-11      Comparative CPLT* Data for Test  2, Particle  Size
              Distribution Tests,  AP Green Refractories Company,
              Rotary Calciner, Inlet to Multiclone, Mexico, Missouri   .      27

                                    -vii-

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                                LIST OP TABLES
                                  (Continued)

TABLE                                                                      PAGE

  2-12      Comparative CPLT* Data for Test 3, Particle Size
              Distribution Tests, AP Green Refractories Company,
              Rotary Calciner, Inlet to Multiclone,  Mexico,  Missouri,
              October 21, 1983	     28

  2-13      Comparative CPLT* Data for Test 1, Particle Size
              Distribution Tests, AP Green Refractories company,
              Rotary Calciner, Inlet to Multiclone and Outlet from
              Venturi Scrubber, Mexico, Missouri, October 13, 1983  . .     30

  2-14      Comparative CPLT* Data for Test 2, Particle Size
              Distribution Tests, AP Green Refractories Company,
              Rotary Calciner, Inlet to Multiclone and Outlet from
              Venturi Scrubber, Mexico, Missouri, October 20, 1983  . .     31

  2-15      Comparative CPLT* Data for Test 3, Particle Size
              Distribution Tests, AP Green Refractories Company,
              Rotary Calciner, Inlet to Multiclone and Outlet from
              Venturi Scrubber, Mexico, Missouri, October 21, 1983  . .     32

  2-16      Comparison of Cumulative Percent Less Than 10 un, Particle
              Size Distribution Tests, AP Green Refractories Company,
              Rotary Calciner, Inlet to Multiclone and Outlet from
              Venturi Scrubber, Mexico, Missouri  	     37

  2-17      Visible Emissions Observations at the Rotary Calciner -
              Venturi Scrubber Outlet, AP Green Refractories Company,
              Mexico, Missouri  	     33

  2-18      Fugitive Emissions Observations at the Rotary Calciner -
              Hopper Inlet, AP Green Refractories Company,  Mexico,
              Missouri	     40

  2-19      Peed Material Samples, Sieve Analysis/Moisture Content,
              AP Green Refractories Company, Mexico, Missouri 	     42

  2-20      Product Material Samples, Sieve Analysis/Moisture Content,
              AP Green Refractories Company, Mexico, Missouri 	     43

  2-21       Trace  Metals Analytical Results Impinger Reagents
               and  Method 5 Filters	     44

  3-1       Data for the  Clay  Calciner at A.P. Green Refractories Company,
              Mexico, Missouri   	     48

  3-2       Data for Emission Control  Equipment for the 'Calciner/Cooler
              at A.P. Green Refractories Company, Mexico, Missouri ...      50

  3-3       Operating Conditions —Run No.  1—  , October 18, 1983  ...      52
                                     -vi11-

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                            .  LIST OF TABLES
                                 (Continued)
TABLE                                  .                                     PAGE

  3-4      Operating Conditions —Run No. 2—, October 20, 1983               53
                                                                • • • • •

  3-5      Operating Conditions —Run No. 3—, October 21, 1983	     54

  4-1      Visible Emissions Observation Locations, A.P. Green
             Refractories Company, Venturi Scrubber Outlet Stack,
             Mexico, Missouri  	      63

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1.0 INTRODOCTION




1. 1 Background




    The United  States Environmental Protection  Agency (EPA)  is  developing a




new source  performance  standard  (NSPS)  for  the  generic source  category of




calciners and  dryers.  The primary  focus will  be control particulate matter




(PH) emissions.   Because of the  interest and emphasis  upon limiting ambient




air concentrations of  inhalable particulates,  EPA is also planning to collect




emission  data  relative  to  particle   size   distributions  and  the  emission



fraction  with  an  equivalent  aerodynamic diameter  equal  to  or  less  than 10



micrometers (urn).  This fraction  is  designated as the PM,Q category.



    EPA's Emission Standards  and  Engineering  Division (ESED)  selected  the AP




Green Refractories Company plant  in Mexico, Missouri as a  site for an emission




test program.  This plant utilizes a rotary calciner for drying various types




of clays  used  in manufacturing refractory brick.  This facility is considered




to employ process and emission control technology  representative of dryers and



calciners in  the clay industry.   The  collected  data will be  used to develop




controlled and  uncontrolled emission  rates.   The  particle  size data  may be



used  to  develop  additional   regulations for  PM   .   The  test   program  was




designed to provide a portion of the emission  data base  required  for NSPS for




processes associated with clay industries.




    EPA engaged  TRC  to measure  particulate  concentrations,  emission  rates,




mass flowrates, particle size distributions, and plume opacities at the rotary




calciner and its associated air pollution control  equipment.  All measurements



made at this facility were performed during times  of normal  production process




operation as described in Section  3.0,  Process Description and Operations.
                                      -1-

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1.2  Brief Process Description




     Figure  1-1 presents a schematic of   the  rotary  kiln/cooler   facility.




This facility is described very basically  as follows:




     AP   Green   Refractories  utilizes   a   Vulcan   Iron   Works    rotary




calciner/cooler  for  the  purpose of calcining several different clays   that




will  be  used in various refractory  manufacturing  processes.   The   rotary




calciner/cooler has a design  and  actual  production rate of 8  tons per  hour




(tph).  Production rate is determined by a scale.  The rotary calciner/cooler




operates approximately 24 hours per  day.   Natural  gas  is the primary  fuel




used  in  drying  the raw material.  Heat  is applied counter flow to the  raw




material.




     At the discharge end of the rotary calciner, the hot raw material  passes




over  a  bar  screen  to  remove large lumps which are sent to a reject pile.




Material  that  passes through the bar screen is fed into the rotary  cooler.




Ambient  air is drawn through the cooler from its discharge end  to  cool  the




clay.  The air then passes through the rotary calciner.   The  cooled product




is discharged from the rotary cooler into  a collection pit.




     Exhaust gases exit the rotary  calciner between 25,000 and 35,000 actual




cubic feet per minute (acfm) at an approximate temperature of 800°F.  Gases




then pass through a settling chamber  and  a multiclone collector manufactured




by the Zurn Company.  Leaving the multiclone,  gases pass through an American




Air  Filter Model 28, venturi scrubber, a mist eliminator,  an  induced  draft




(ID) fan, and then through an exhaust stack.  The venturi scrubber uses water




as the scrubbing  medium.  The water is injected at approximately 350 gallons




per minute (gpm).  The designed gas flowrate is 25,000 to 35,000 acfm with an




operating temperature of approximately 160°F.  The control system has a gas




pressure drop of 30-33 inches of water column across the entire system.
                                 -2-

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             rrrrrremwrm 111111111111111 n 11111111111111111111111111111111 i 111111111 n 1111 m-
                                     MATERIALS BUILDING
                           ROADWAY
I
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I
       AREA
                        KILN
                      CONTROL
                      BUILDING
                                  GAS OR OIL
                                   BURNERS
                MATERIALS
                BUILDING
N
\RGE
I
ROTARY !
COOLER j

i
I
J

ROTARY KILN
CALCINER

  KILN MATERIALS
CHARGING EQUIPMENT
                                                                                    EXHAUST
                                                                                     STACK
                                                                                                   I.D.  FAN
                                                  MIST
                                               ELIMINATOR
                                                                                     VENTURI
                                                                                     SCRUBBER
                                                                                        NOTE:   DRAWING NOT TO SCALE
       iimiiiMMiiiiiiiririitiiiiiiiiiiiiiiN
        PERIMETER FENCE
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                                      SALVAGE  YARD
                                                         Figure 1-1
                                                Overhead View-Rotary Kiln/Cooler
                                                     AP Green Refractories

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1.3 Measurement Program




    The measurement program was conducted at the AP  Green  Refractories  company




facility in  Mexico,  Missouri during  the week  of  October   17-21,  1983.  The




emission  tests  were   designed  to  characterize  uncontrolled  and  controlled




emissions from  the  rotary calciner/cooler pollution control  equipment  and to




determine particle size distribution.



    TRC  personnel  were   responsible   for   sampling  and  analyzing   process



emissions.    Concurrently,  Radian  was  responsible  for  monitoring  pertinent



process operation parameters.  The components of the measuring program  were as




follows:








    1.3.1 Rotary Calciner  Multiclone  Inlet




          Particulate Matter  Tests




          Three tests run  concurrently with  the  venturi scrubber outlet  tests.



         Particle Size Distribution Tests



         Three tests  run  simultaneously with the particulate matter tests.








    1.3.2 Rotary Calcinec  Venturi Scrubber Outlet




         Particulate Matter  Tests




         Three tests run  concurrently with  the  multiclone  inlet tests.




         Particle Size Distribution Tests




         Three tests  run  simultaneously with the particulate matter tests.



         Visible Emissions




         The opacity  of  the scrubber  outlet  plume was monitored during the



    particulate matter tests.




         Pressure Drop Across Scrubber



         The gas pressure drop across  the  scrubber  was  measured periodically




    during  each particulate matter test.




                                     -4-

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1.3.3  Rotary Calciner Inlet
       Raw Material Samples
         Grab  samples  of  the  raw  material  (feed)  clay  were  collected
periodically, during  each  participate  matter  test.   These  samples  were
subsequently subjected to moisture content and sieve analyses.
       Fugitive Emissions
       Fugitive emission inspections  were  performed  during the particulate
matter  tests.   Inspections  were  conducted at the point in which  the  raw
material entered the hopper inlet.


1.3.4  Rotary Cooler Outlet
       Product Samples
        Grab samples of the finished  product  were  collected  periodically,
during  each  particulate  matter  test.   These  samples  were  subsequently
subjected to moisture content and sieve analyses.


1.3.5  Blank Evaluations
        At  the  completion of the emission tests,  a  cascade  impactor  was
assembled and charged as if ready to perform  a  test.  The unexposed cascade
impactor was recovered  and  each  individual  filter  weighed  in  order  to
establish proper laboratory clean-up technique.


1.4    Particle Size Distribution Measurement
       Particle size distribution measurements  were  performed using cascade
impactors with a pre-separator ahead of the impactor.  TRC used the new style
Andersen right angle inlet pre-separator.
        Testing  was  performed  in  general  accordance  with the procedures
developed by EPA's Industrial Environmental Research Laboratory (IERL).   The
IERL.
                                 -5-

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document  describing   these  procedures   is   currently   in   draft   form.    The

generalized sampling scheme employed had seven steps:


    1.  The pre-separator  and  impactor were  assembled  and  leak  checked.
        This was performed at  the field laboratory site which was  remote
        from the sampling site.

    2.  The sampling train was  assembled and  leak checked.

    3.  The pre-separator/impactor assembly was positioned  in  the  exhaust
        stream  with the  nozzle perpendicular  to the  flow  streamlines.
        The  purpose  of  this   step  was  to  preheat  the  pre-separator/
        impactor assembly to exhaust stream temperature.

    4.  After the. pre-separator/impactor  reached exhaust stream  tempera-
        ture,  the  assembly was rotated to orient the nozzle parallel  to
        the flow streamlines.  Sampling began immediately thereafter.

    5.  At the end of the specified sampling  time period/ the sample  flow
        was  shut   off  and   the   pre-separator/impactor   assembly   was
        withdrawn from the exhaust stream.

    6.  The pre-separator/impactor assembly  was then purged with  ambient
        air to  remove  any  free  or  condensed moisture  which  may  have
        collected within the. impactor.

    7.  After    completion   of   the   purge,    the  sampling   train  was
        disassembled.   The  pre-separator/impactor   assembly  was   then
        transported to  the field  laboratory for disassembly  and  sample
        recovery.


    1.4.1  Analysis

    The analysis portion of this program consisted of recovering the  collected

particulate sample  fractions  from  the pre-separator  and  each  stage  of  the

cascade impactor.  These sample fractions  were then weighed.  All  sample dish

and  impactor  substrate  weighings  were performed  at  the   field   laboratory.

These included both the pre-test (tare) and collected sample weighings.
    1.4.2  Data Reduction

    Data  reduction  for the particle size  distribution  measurement tests  used

EPA's  Particulate  Data  Reduction  System  (PADRE).   PADRE  is  an . interactive
                                     -6-

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computer program used to  enter,  reduce and analyze  cascade  impactor data for




particle size  distributions.   PADRE can be  used to store,  review,  edit, and




analyze data,  and,  through a variety  of  data checks,  to  identify suspect or




invalid data.   Impactor  stage cut-points  (D_n)  are  calculated and  cumulative




and  differential  mass  concentrations  are   determined  and   interpolated  to



standard diameters.  PADRE performs data reduction using three definitions of



particle diameter:   (1) physical  (Stokes's),  (2) aerodynamic  or Task Group on




Lung   Dynamics  (TGLD),   and   (3)   aerodynamic  impaction   (Mercer's).   The




aerodynamic  impaction  definition  was  used  for the data  developed  by  these



tests.   Data  entry was  performed  using  a  portable  terminal  connected via




telephone  modem hook-up  to the  National  Computer  Center (NCC)  in Research




Triangle Park, North Carolina.








1.5 Description Of Report Sections



    The  remaining  sections of  this  report  present  the  Summary  of  Results




(Section  2),   Process  Description and  Operations  (Section  3),  Scope  of the




Sampling Program by  Site  (Section  4),  Sampling  and Analytical Methods  (Section




5),  and   Quality   Assurance  (Section  6).    Descriptions   of   methods  and




procedures, field  and  laboratory data,  and  calculations  are  presented in the




various appendices, as noted in the Table of  Contents.
                                      -7-

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2.0 SUMMARY OP RESULTS

    This  section  presents  summary  tables of  results  and narrative  on  the

emission  tests  conducted during  the week  of October  17-21,  1983  at  the AP

Green  Refractories   Company   facility   in  Mexico,  Missouri.   Testing   was

performed  on emissions  entering  the  rotary calciner  multiclone  inlet   and

exiting the venturi scrubber outlet.

    EPA Method 5 samples were analyzed at the TRC  laboratory in  East Hartford,

Connecticut.  Particle size samples  were  analyzed  at the TRC field  laboratory

located in the motel room (Mexico, Missouri).



2.1 Rotary Calciner - Particulate Matter  Tests

    Inlet To Multiclone and Outlet From  Venturi  Scrubber

    A  summary  of particulate uncontrolled  and  controlled  emissions from  the

rotary calciner is shown  in  Table 2-1.   The  average venturi  scrubber removal

efficiency is 99.9 percent.   Table 2-la presents a  data  summary for a fourth

test  run  at  the  inlet  location  only.   This  test  was  run  due  to a  high

isokinetic  sampling  rate  (118%)  generated during  the  first  test  run.    The

results from Table  2-la  were not  included  in the overall  averaging in  Table

2-1;  instead  the results are  presented for  informational  purposes  only.   At

the completion of Test 1  (inlet location),  TRC and the EPA task manager agreed

to change the sampling procedure  at  this  location  in order to maintain proper

isokinetic sampling.   The changes are listed below:


    1.  Decrease sampling points from 49  (seven  points per port)  to 28
        (four points  per  port).

    2.  Increase sampling time from  2 minutes per  point to 4 minutes per
        point.
                                     -8-

-------
                                                                              TABLE 2-1

                                                                         SUMMARY OP RESULTS
                                                                         BPA METHOD 5 TESTS
                                                        INLBT TO MULTICLOHB AND OUTLET FROM VBNTURI SCRUBBER
                                                                    AP GRBBN REFRACTORIES COMPANY
                                                                          MEXICO, MISSOURI
I
VO
I
Run Number
Date
Tine
Location
Volume of Gaa Sampled (ACF)
Volume of Gaa Sampled (OSCP)1
Volumetric Flowrate (ACPH)2
Volumetric Flowrate (DSCPM)3
Percent Moisture By Volume
Average Duct Temperature (°P)
Percent oxygen (Dry)
Percent Carbon Dioxide (Dry)
Molecular Weight (Duct)
Partlculate Collected (Mg)4
Particulate Concentration (Gralna/DSCP)
emission Rate ( Pounds )/Hour)
Percent Isoklnetics
Percent Removal Efficiency5
1
10/18/83
1053—1528
Inlet
21.80
22.08
40000
13000
18.5
653
11.2
5.8
27.27
11269.44
7.87
869.7
118.7
99
1048—1514
Outlet
110.62
110.34
17000
12000
20.2
143
12.2
4.8
26.98
86.18
0.012
1.23
107.7
.86
2
10/20/83
1025 	 1415
inlet
40.69
41.58
41000
13000
21.1
842
11.3
5.5
26.94
28280.88
10.5
1150.2
106.4
99
0955—1450
Outlet
105.30
104.53
17000
12000
19.4
144
13.0
4.4
27.04
37.84
0.0056
0.57
102.3
.95
3
10/21/83
0915—1120
Inlet
39.99
40.83
41000
13000
21.8
851
10.4
6.0
26.89
23800.54
9.03
964.4
106.8
99.
0908 	 1236
Outlet
117.47
116.42
18000
12000
19.8
145
12.7
4.6
27.0
40.53
0.0054
0.57
102.1
94
Average
Inlet
34.16
34.83
41000
13000
20.5
849
11.0
5.8
27.03
21116.95
9.14
994.8
110.6
99.92

Outlet
111.13
110.43
17000
12000
19.8
144
12.6
4.6
27.01
54.85
0.0077
0.79
104.4

         1 Dry standard cubic feet « 6B°F,  29.92  Inches llg.
         ij Actual cubic feet per minute.
           Dry standard cubic feet per minute.
         4 Milligrams (nozzle,  probe,  and filter  catch).
         5 ,..	 /inlet  (Ib^hr -.outlet. ,(Ib/hrV
           Efficiency
\
                                 (Inlet  (Ib/hrrj
                               100

-------
                                  TABLE 2-la

                              SUMMARY OF RESULTS
                              EPA METHOD 5 TESTS
                              INLET TO  MULTICLONE
                         AP GREEN REFRACTORIES COMPANY
                               MEXICO,  MISSOURI
Run Number                                                        4
Date                                                          10/21/83
Time                                                         1205	1426
Location                                                        Inlet

Volume of Gas Sampled (ACF)                                      40.94
Volume of Gas Sampled (DSCF)1                                    41.04
Volumetric Flowrate (ACFM)2                                      42000
Volumetric Flowrate (DSCFM)3                                     13000
Percent Moisture By Volume                 '                       20.6
Average Duct Temperature (°F)                                     837
Percent Oxygen (Dry)                                              11.5
Percent Carbon Dioxide (Dry)                                      5.2
Molecular Weight (Duct)                                           26.96

Particulate Collected (Mg)4                                   20584.52
Particulate Concentration (Grains/DSCF)                            7.77
Emission Rate (Pounds)/Hour)                                     874.8
Percent Isokinetic                                               101.8


1 Dry standard cubic feet S 68°F,  29.92  inches Hg .
  Actual cubic feet per minute.
3 Dry standard cubic feet per minute.
4 Milligrams (nozzle, probe, and filter catch)
                                     -10-

-------
                                                                         TABLE 2-lb (metric)

                                                                         SUMHABV Of RESULTS
                                                                         EPA METHOD 5 TESTS
                                                        INLET TO MOLTICLONE AMD OUTLET FROM VEHTURI SCRUBBER
                                                                   AP CHBBN REFRACTORIES COMPANY
                                                                          MEXICO, MISSOURI
I
H-
Run Number
Date
Time
Location
Volume of Gas Sampled (AM3)
Volume of Gas Sampled (NM3)1
Volumetric Flowrate (MJ/Min)2
Volumetric plowrate (NM3/Mln)3
Percent Moisture By Volume
Average Duct Temperature (°C)
Percent Oxygen (Dry)
Percent Carbon Dioxide (Dry)
Molecular Height (Duct)
particulate Collected (Hg)4
Participate Concentration (Mg/NH3)
Emission Rate (G«/Hr)S
Percent Isokinetics
Percent Removal Efficiency'
1
10/18/83
1053— 1528
Inlet
0.62
0.63
1133
365
18.5
456
• 11.2
5.8
27.27
11269.44
18020.77
3.94 x 105
118.7
99
1048—1514
Outlet
3.13
3.12
481
340
20.2
62
12.2
4.8
26.98
86.18
27.46
5.58 x 102
107.7
.86
2
10/20/83
1025—1415 0955 	 1450
Inlet Outlet
1.15
1.18
1161
368
21.1
450
11.3
5.5
26.94
28280.88
24027.69
5.22 x 10
106.4

2.98
2.96
481
340
19.4
62
13.0
4.4
27.04
37.84
12.77
5 2.57 X 102
102.3
99.95
3
10/21/83
0915 	 1120
inlet
1.13
1.16
1161
368
21.8
455
10.4
6.0
26.89
23800.54
20663.82
4.37 x 105
106.8
99.
0908—1236
Outlet
3.33
3.30
510
340
19.8
63
12.7
4.6
27.0
40.53
12.29
2.60 X 102
102.1
94
Inlet
0.97
0.99
1152
367
20.5
454
11.0
5.8
27.03
21116.95
20915.53
4.51 X 11
110.6

Average
Outlet
3.15
3.13
491
340
19.8
62
12.6
4.6
27.01
54.85
17.51
I5 3.58 x 102
104.0
99.92
         1 Normal cubic meters a.  20°C,  760 on Hg.
           Actual cubic meters per  minute.
           Nornal cubic Deters per  minute.
         * Milligrams (nozzle, probe, and filter catch).
         5 Grans Per Hour
         ,               /Inlet (gn/hr  - outlet (gm/hr)\
         6 Efficiency -  \'
                                  inlet  Ign/hrl
JlOO

-------
                              TABLE 2-lc (metric)


                              SUMMARY OP RESULTS
                              BPA METHOD 5 TESTS
                              INLET TO MULTICLONE
                         AP GREEN REFRACTORIES COMPANY
                               MEXICO,  MISSOURI
Run Number                                                        4
Date                                                          10/21/83
Time                                                         1205	1426
Location	inlet

Volume of Gas Sampled (AM3)                                       1.16
Volume of Gas Sampled (NM3)                                       1.16
Volumetric Plowrate (M3/Min)                                      1189
Volumetric Plowrate (NM3/Min)                                     368
Percent Moisture By Volume                                        20.6
Average Duct Temperature (°C)                                     447
Percent Oxygen (Dry)                                              11.5
Percent carbon Dioxide (Dry)                                      5.2
Molecular Weight (Duct)                                          26.96

Particulate Collected (Mg)4                                   20584.52
Particulate Concentration (Mg/NM3)                             17780.49
Emission Rate (Gm/Hr)5                                        3.97 x 105
Percent Isokinetics                                             101.8
1 Normal cubic meters @ 20°C,  760  mm Hg.
2 Actual cubic meters per minute.
3 Normal cubic meters per minute.
4 Milligrams (nozzle, probe,  and filter  catch)
^ Grams per hour.
                                     -12-

-------
    With the decrease  in  sampling points,  volumetric flowrates still  remained


consistent throughout the  four inlet tests.


    The  venturi  scrubber  outlet  particulate concentration  and  emission rate


for Test 1  is  approximately  double that of Test?2 and  3.   At this time there


is no known explanation.






2.2 Rotary Calciner - Particle Size Tests


    2.2.1 Multiclone Inlet - Test Parameter Summary


    Tables 2-2, 2-3, and 2-4 present a summary of the three  tests  performed  at


the  inlet  location.    All   tests  were  run  in conjunction with the  inlet


particulate  tests  and  simultaneously  with the  outlet  tests.  Prior  to each


particle  size  test,  gas  stream  velocity,  temperature,  and  static   pressure


measurements were  performed  at  the four  predetermined sampling  points.    An


average velocity was  calculated;  this  average  velocity .was then  used to set


the sample flow rate for all four sampling  points.


    Actual  moisture  determination  for   each   particle   size   run  was  not


performed.  The "volume of water  collected* was  determined  by back calculating


using the following equation:
    Water Collected During Method 5 Test'.
        Method 5 Sample Volume (acf)     /   \Particle  Size  Sample Volume  (acf


where :


    X = water collected during particle size run




    It  should be  noted  that on  Table  2-2 and  all  other  tables  standard

                                              o
(normal)  conditions  have been  defined as  70 P and  29.92  inches  of mercury


instead  of the  68 P  and  29.92  inches  of  mercury   normally  associated with


emission  measurement  calculations.   This  variation  conforms  to  the standard


conditions definition incorporated by the PADRE  program.




                                     -13-

-------
                                       TABLE  2-2

                               SUMMARY OP TEST PARAMETERS
                      PARTICLE SIZE DISTRIBUTION MEASUREMENT TESTS
                                   INLET TO MULTICLONE
                             AP GREEN REFRACTORIES COMPANY
                                    MEXICO,  MISSOURI
Test Number
Run Number
Date
Start Time
Duration (Min. )
Ambient Pressure (Inches Hg)
Stack Pressure (Inches H20)
Stack Temperature (°F)
Percent Carbon Dioxide (Dry)
Percent Oxygen (Dry)
Percent Moisture
Molecular Weight (Duct)
Stack Gas Velocity (Ft/Sec)1
Impactor Temperature (°F)
Impactor Flow Rate (ACFM)2
Nozzle Diameter (Inches)
Dry Gas Meter Temperature (°P)
Dry Gas Meter Cal. Factor
Orifice Pressure Drop (Inches H20)
Volume Water Collected (ml)
Sample Volume (ACF)
Sample Volume (NCF)3
Percent Isokinetics
1 Feet per second.
^ Actual cubic feet per minute.
3 Normal cubic feet @ 70° F, 29.92
* Port 3/Point 1
** Pnrt- ^/Dnini- 1
1
P3/P1*
10-18-83
1145
0.25
29.42
-0.69
860
5.8
11.2
18.5
27.27
50.0
860
0.219
0.1891
60
1.01
0.13
0.24
0.049
0.050
105.7


inches Hg.

1
P3/P2
10-18-83
1240
1
29.42
-0.69
872
5.8
11.2
18.5
27.27
50.0
872
0.586
0.1892
65
1.01
0.13
0.91
0.186
0.187
100.3




1
P5/P1**
10-18-83
1505
2
29.42
-0.69
830
5.8
11.2
18.5
27.27
50.0
830
0.582
0.1891
67
1.01
0.13
1.87
0.383
0.383
99.8




1
P5/P2
10-18-83
1538
2
29.42
-0.69
830
5.8
11.2
18.5
27.27
50.0
830
0.596
0.1891
' 67
1.01
0.13
1.91
0.392
0.392
102.1




Note:  Particle size  distributions  are  based upon an assumed particulate density
      of 1  gram/cc;  actual  particulate density is 2.65 to 3.00 grams/cc.
                                        -14-

-------
                                        TABLE 2-3

                               SUMMARY OP TEST PARAMETERS
                      PARTICLE SIZE DISTRIBUTION MEASUREMENT TESTS
                                   INLET TO MULTICLONE
                              AP  GREEN REFRACTORIES COMPANY
                                    MEXICO, MISSOURI
Test Number
Run Number
Date
Start Time
Duration (Min.)
Ambient Pressure (Inches Hg )
Stack Pressure (Inches H20)
Stack Temperature (°F)
Percent Carbon Dioxide (Dry)
Percent Oxygen (Dry)
Percent Moisture
Molecular Weight (Duct)
Stack Gas Velocity (Ft/Sec)1
Impactor Temperature (°F)
Impactor Flow Rate (ACFM)2
Nozzle Diameter (Inches)
Dry Gas Meter Temperature (°F)
Dry Gas Meter Cal. Factor
Orifice Pressure Drop (Inches H20)
Volume Water Collected (ml)
Sample Volume (ACF)
Sample Volume (NCP)3
Percent Isokinetics
1 Feet per second.
2 Actual cubic feet per minute.
3 M/tvmal ^iitii^ f t*t*t- » irP P TO Q7 •
2
P3/P1
10-20-83
1015
2
29.32
-0.60
855
5.5
11.3
21.1
26.94
50.0
855
0.663
0.1891
63
1.01
0.15
2.38
0.411
0.412
113.7


i nr»hac tin
2
P5/P1
10-20-83
1105
2
29.32
-0.60
850
5.5
11.3
21.1
26.94
50.0
849
0.604
0.1892
61
1.01
0.135
2.18
0.375
0.378
103.7



2
P5/P2
10-20-83
1312
2
29.32
-0.60
830
5.5
11.3
21.1
26.94
50.0
827
0.623
0.1891
61
1.01
0.135
2.28
0.393
0.396
107.1



2
P3/P2
10-20-83
1426
2
29.32
-0.60
840
5.5
11.3
21.1
26.94
50.0
832
0.636
0.1892
60
1.01
0.135
2.31
0.399
0.403
109.5



Note: Particle size distributions  are  based upon an assumed particulate density
      of 1 gram/cc; actual particulate density  is 2.65 to 3.00 grams/cc.
                                         -15-

-------
                                         TABLE  2-4

                                 SUMMARY OP TEST PARAMETERS
                        PARTICLE SIZE DISTRIBUTION MEASUREMENT TESTS
                                    INLET  TO MULTICLONE
                               AP GREEN REFRACTORIES COMPANY
                                      MEXICO, MISSOURI
Test Number
Run Number
Date
Start Time
Duration (Min.)
Ambient Pressure (Inches Hg)
Stack Pressure (Inches H20)
Stack Temperature (°F)
Percent Carbon Dioxide (Dry)
Percent Oxygen (Dry)
Percent Moisture
Molecular Weight (Duct)
Stack Gas Velocity (Ft/Sec)1
Impactor Temperature (°F)
Impactor Flow Rate (ACFM)2
Nozzle Diameter (Inches)
Dry Gas Meter Temperature (°F)
Dry Gas Meter Cal. Factor
Orifice Pressure Drop (Inches E^O)
Volume Water Collected (ml)
Sample Volume (ACF)
Sample Volume (NCF)3
Percent Isokinetics
3
P3/P1
10-21-83
0935
2
29.18
-0.65
867
6.0
10.4
21.8
26.89
50.0
865
0.655
0.1891
56
1.01
0.14
2.39
0.394
0.399
112.5
3
P3/P2
10-21-83
1030
2
29.18
-0.65
856
6.0
10.4
21.8
26.89
50.0
855
0.695
0.1891
58
1.01
0.14
2.56
0.423
0.426
119.3
3
P5/P1
10-21-83
1122
2
29.18
-0.65
843
6.0
10.4
21.8
26.89
50.0
843
0.663
0.1891
59
1.01
0.14
2.47
0.408
0.411
113.8
3
P5/P2
10-21-83
1235
2
29.18
-0.65
840
5.2
11.5
20.6
26.96
51.7
840
0.666
0.1891
59
1.01
0.14
2.30
0.417
0.420
110.0
        Feet per second.
        i T3^ u £/<=!. O^V*W14U *
     2  Actual cubic feet per minute.
     3  Normal cubic feet @ 70° F, 29.92
Hg.
Note: Particle size distributions are based upon an assumed  participate density
      of 1 gram/cc; actual particulate density is 2.65  to  3.00  grams/cc.
                                          -16-

-------
     The  sampling period for each point was two minutes in duration with the




exception  of  the  first two runs of Test 1.  Run 1 of Test 1  was  for  0.25




minutes.  After a visual inspection of each individual  impactor substrate, a




decision was made to increase the sampling period to one (1) minute.  TRC and




the EPA  task  manager  agreed  that  the  increase  in time would aid in the




sampling technique (i.e., impactor flow rate, isokinetic sampling, and proper




particulate weight gain on each substrate).




     At the completion of the second run, on Test 1, each substrate was again




visually inspected.   The  sample  time  of one (1) minute seemed a little to




short  regarding  particulate weight gain on each substrate.  In an effort to




avoid  an  "underloading"  problem  on  the  substrates,  the sample time was




increased to two (2)  minutes.   The  increase  to two (2) minutes per sample




point would further enhance the sampling technique.




     Four  (4) impactors were used for each test  (one  impactor  per  sample




point).   All  tests  were  within   the  IERL  prescribed  isokinetic  range




of 100 +_ 20  percent  and were within the Andersen prescribed  impactor  flow




rate  range  of  0.5  to  0.75 actual cubic feet per minute (acfm).  Run 1 of




Test 1 had a low impactor flow rate (0.22 acfm); this was probably due to the




very short sampling time of 0.25 minutes.








     2.2.2  Venturi Scrubber Outlet - Test Parameter Summary




     Table 2.5 presents a summary of the three  tests performed  at the outlet




location.  One impactor was used for each test  (one impactor  per four sample




points).  All tests were run in conjunction with the outlet particulate tests




and simultaneously with the inlet tests.  Velocity measurements, sample  flow




rate  determination, and moisture determination were performed  in  the  same




manner as the inlet particle size tests.




     Due to the low particulate loadings  at  the outlet sampling location, a




change was made between Test 1 and Test 2.  Impactor nozzle diameters were




                                  -17-

-------
                                       TABLE  2-5

                               SUMMARY OF TEST PARAMETERS
                      PARTICLE SIZE DISTRIBUTION MEASUREMENT TESTS
                              OUTLET PROM VENTURI SCRUBBER
                              AP GREEN REFRACTORIES  COMPANY
                                    MEXICO,  MISSOURI
Test Number
Run Number
Date
Start Time
Duration (Min.)
Ambient Pressure (Inches Hg)
Stack Pressure (Inches H20)
Stack Temperature (°F)
Percent Carbon Dioxide (Dry)
Percent Oxygen (Dry)
Percent Moisture
Molecular Weight (Duct)
Stack Gas Velocity (Ft/Sec)1
Impactor Temperature (°F)
Impactor Flow Rate (ACFM)2
Nozzle Diameter (Inches)
Dry Gas Meter Temperature (°F)
Dry Gas Meter Cal. Factor
Orifice Pressure Drop (Inches ^0)
Volume Water Collected (ml)
Sample Volume (ACF)
Sample Volume (NCF)3
Percent Isokinetics
1 Feet per second.
Actual cubic feet per minute.
3 Mni-mal s*nK-l/* f at*t- a 7fl° 0 TQ QO
1
5
10-18-83
1045
240
. 29.39
-0.17
134 '
4.8
12.2
20.2
26.98
36.7
134
0.525
0.1891
64
1.01
0.99
464.7
86.43
86.94
120.5


4 n/**l*Aa tin
2
5
10-20-83
0955
240
29.23
-0.19
136
4.4
13.0
19.4
27.04
36.7
136
0.785
0.250
60
1.01
0.99
665.1
130.72
131.79
104.3



3
5
10-21-83
0910
240
29.12
-0.22
135
4.6
12.7
19.8
27.00
38.3
134
0.793
0.250
58
1.01
0.99
680.2
131.34
132.43
101.0



Note: Particle size distributions  are  based upon an assumed particulate density
      of 1 gram/cc;  actual  particulate density is 2.65 to 3.00 grams/cc.
                                         -18-

-------
increased from  a  0.1891  inch  to  0.250  inch.  This change in nozzle size
increased  the  sampled  volumes  and  impactor flowrates to a more desirable
level.  The increase in  sample  volume  also  allowed  for a more measurable
weight gain on each substrate.


2.3  Impactor Data at Interpolated Particle Diameters
     A particularly useful feature of EPA's Particulate Data Reduction System
(PADRE)  is  its ability to provide  comparable  data  for  several  runs  by
interpolating the particle size distribution data to a common set of standard
particle  diameters.   These  diameters are 20.0, 15.0, 10.0, 6.0, 2.5., 1.25,
1.00, 0.625, 0.30, and 0.10 um.  However, the interpolation is performed only
within the range of actual measured data.  That is, if the smallest cut-point
at  which the sample is collected is 1.00 um, no values at the small standard
diameters can be interpolated.


     2.3.1  Rotary Calciner - Multiclone Inlet
     Tables 2-6, 2-7,  and  2-8  present  summaries  of the impactor data for
Tests 1, 2, and 3, respectively, on a "cumulative  percent mass less than the
interpolated diameter" (CPLT) basis.  The following nomenclature was used for
each run number:
                            P3/P1 - Port 3/Point 1
                            P3/P2 - Port 3/Point 2
                            P5/P1 - Port 5/Point 1
                            P5/P2 - Port 5/Point 2
Port 3 was located above the centerline  of  the  rectangular horizontal duct
and  Port  5 was located below the centerline.  Four runs were performed  per
test at the inlet location.  Each run  had  its  own impactor assembly (i.e.,
four impactors were used per test).
                                   -19-

-------
                                       TABLE 2-6

               IMPACTOR DATA SUMMARY AT INTERPOLATED PARTICLE DIAMETERS
                           PARTICLE SIZE DISTRIBUTION TESTS
                             AP GREEN  REFRACTORIES COMPANY
                                    ROTARY  CALCINER
                                  INLET TO  MULTICLONE
                                   MEXICO,  MISSOURI
Test Number
Run Number
Date
Start Time
Duration (Min.)

P3/P1
10-18-83
1145
0.25

P3/P2
10-18-83
1240
1
1
PS/PI
10-18-83
1505
2

P5/P2
10-18-83
1538
2
Interpolated Diameter (un)    Cumulative Percent Mass Less Than Interpolated Diameter

          20.00                              40.36       40.80       40.98      59.74
          15.00                              28.22       28.43       28.41      47.89
          10.00                              17.30       16.78       16.18      31.18
           6.00                               8.92        7.45        5.88      10.90
           2.50                               4.76        2.25        1.34       1.71
           1.25                               3.42        1.28        1.07       0.50
           1.00                               3.15        0.74        0.59       0.18
Note: Particle size distributions  are based upon an assumed participate  density
      of 1 gram/cc; actual  particulate density is 2.65 to 3.00 grams/cc.
                                     -20-

-------
                                     .TABLE 2-7

               IMPACTOR DATA SUMMARY AT  INTERPOLATED PARTICLE DIAMETERS
                           PARTICLE SIZE DISTRIBUTION TESTS
                             AP GREEN REFRACTORIES COMPANY
                                    ROTARY CALCINER
                                  INLET TO MULTICLONE
                                   MEXICO,  MISSOURI
Test Number
Run Number
Date
Start Time
Duration (Min.)

P3/P1
10-20-83
1015
2

P5/P1
10-20-83
1105
2
2
P5/P2
10-20-83
1312
2

P3/P2
10-20-83
1426
2
Interpolated Diameter (un)    Cumulative Percent Mass Less Than Interpolated Diameter

          20.00                      67.98         45.32        48.24         50.16
          15.00                      57.31         33.15        36.01         38.14
          10.00                      40.85         20.46        22.17         24.21
           6.00                      19.82          8.74         8.16          9.78
           2.50                       4.82          3.52         1.14          1.85
           1.25                       1.27          1.89         0.20          0.46
           1.00                       0.61          1.31         0.06          0.26
Note: Particle size distributions  are  based upon an assumed participate density
      of 1 grara/cc; actual particulate density is 2.65 to 3.00 grams/cc.
                                     -21-

-------
                                        TABLE  2-8

                IMPACTOR DATA SUMMARY AT INTERPOLATED PARTICLE DIAMETERS
                            PARTICLE SIZE DISTRIBUTION TESTS
                              AP  GREEN  REFRACTORIES COMPANY
                                    ROTARY CALCINER
                                   INLET TO MOLTICLONE
                                    MEXICO,  MISSOURI
Test Number
Run Number
Date
Start Time
Duration (Min.)
3
P3/P1
10-21-83
0935
2
P3/P2
10-21-83
1030
2
P5/P1
10-21-83
1122
2
P5/P2
10-21-83
1235
2
 Interpolated Diameter (un)     Cumulative Percent Mass Less Than Interpolated Diameter

           20.00                          65.52         57.92        56.25        50.79
           15.00  '                       53.55         46.20        44.65        38.90
           10.00                          37.50         30.45        29.74        25.09
            6.00                          17.61         12.03        12.86        10.73
            2.50                           3.41          1.71         3.08         2.23
            1.25 '                          0.44          0.59         1.19         1.03
            1.00                           0.34          0.34         0.82         0.67
Note: Particle size distributions are based upon an assumed particulate  density
      of 1 gram/cc;  actual  particulate density is 2.65 to 3.00 grams/cc.
                                      -22-

-------
    2.3.2  Rotary Calciner - Venturi Scrubber Outlet

    Table  2-9 presents  the  summary  of  the impactor  data for Tests 1, 2>  and  3

on  a   'cumulative  percent mass  less  than  the  interpolated  diameter*  (CPLT)

basis.

    Only  one run  was performed per  test at  the  outlet  location.   The  same

impactor assembly was used for all  four sampling points.



2.4 Comparative Data Analysis

    The  preceding   section   provided   impactor  data  of  standard   particle

diameters  which  allowed  an  evaluation of  the results  from  individual  runs.

This section presents  a comparative data analysis  including basic statistics.

Data presented  in this  section  were developed using  PADRE's  data comparison

routine.   This  routine  permits comparison of  data  for two or  more  runs of  a

specified test  as identified by a site  code and date.   For example:


    1.  The four runs performed during  Test  1 (inlet)  can be compared.

    2.   Test 1  (outlet)  can not be  compared to Test 2  (outlet) because of .
        the different site code and date.


Therefore,  the comparative  data  analyses are  presented  on  an  individual test

basis.



    2.4.1  Rotary Calciner - Multiclone Inlet

    Table  2-10   presents the  comparative  CPLT  data   for  runs  performed  on

October 18, 1983.  Comparison of minimum  and maximum  CPLT of all interpolated

diameters  shows a  wide range.   At 10 urn the  CPLT  ranges from 31.18 percent to

16.18 percent.  This  wide range is also  reflected  by the  calculated relative

standard deviation (RDS  = standard  deviation divided  by  the mean,  times 100)
                                     -23-

-------
                                       TABLE 2-9

               IMPACTOR DATA SUMMARY AT INTERPOLATED PARTICLE DIAMETERS
                           PARTICLE SIZE DISTRIBDTION TESTS
                             AP GREEN REFRACTORIES COMPANY
                                   ROTARY CALCINER
                             OUTLET PROM VENTURI SCRUBBER
                                   MEXICO,  MISSOURI
Test Number                            1                     2                  3
Run Number                  .1                     1                  1
Date                               10-18-83              10-20-83           10-21-83
Start Time                            1045                  0955               0910
Duration (Min.)                       240                   240                240


Interpolated Diameter (un)     Cumulative Percent Mass Less Than Interpolated Diameter

          20.00                       78.2                  99.0               96.1
          15.00                       63.6                  88.6               89.9
          10.00                       60.5                  66.0               81.9
           6.00                       58.6                  44.9               62.1
           2.50                       58.6                  34.9               43.8
           1.25                       56.2                  31.9               39.6
           1.00                       45.8                  21.8               24.3
           0.63                        0                     0                  0
      !?T± /1Ze dlrrilbuti°ns  are  based uP°o ^ assumed particulate  density
      of 1 gram/cc;  actual  particulate density is 2.65 to 3.00 grams/cc.
                                     -24-

-------
                                              TABLE 2-10

                                   COMPARATIVE CPLT*  DATA FOR TEST 1
                                   PARTICLE SIZE DISTRIBUTION TESTS
                                     AP GREEN REFRACTORIES COMPANY
                                            ROTARY  CALCINER
                                          INLET TO  MULTICLONE
                                           MEXICO,  MISSOURI
                                           OCTOBER IB, 1983



1
to
in
1





interpolated Diameter (pro)1
Run Number
P3/P1
P3/P2
P5/P1
P5/P2
Minimum
Maxmum
Average
Standard Deviation
Relative Standard Deviation (%)
20.00
40.36
40.80
40.98
59.74
40.36
59.74
45.57
9.52
20.94
15.00
Cumulative
28.22
28.43
28.41
47.89
28.22
47.89
33.24
9.77
29.39
10.00
Percent Less
17.30
16.78
16.18
31.18
16.18
31.18
20.36
7.23
35.51
6.00
Than
8.92
7.45
5.88
10.90
5.88
10.90
8.29
2.13
25.69
2.50
Interpolated
4.76
2.25
1.34
1.17
1.34
4.76
2.51
1.55
61.75
1.25
1.00
Diameter
3.42
1.28
1.07
0.50
0.50
3.42
1.57
1.28
81.53
3.15
0.74
0.59
0.18
0.18
3.15
1.17
1.35
115.38
* Cumulative Percent Less Than
1 Microns
     Note:  Particle  size  distributions are based upon an assumed participate density
           of  1 gram/cc;  actual particulate density is 2.65 to 3.00 grams/cc.

-------
which  is an  indicator  of precision.  The  RSD ranged  from  115.38 percent  at

1.00 urn to 20.94 percent at 20.0 urn and averaged 52.7 percent.

    Table  2-11  presents the comparative  CPLT data  for  the  runs  performed  on

October 20, 1983.  Comparison of minimum  and maximum CPLT at all  interpolated

diameters  show  a  wide range.   At 10 urn the  CPLT  ranges from 40.85 percent  to

20.46  percent.   The RSD  at  all interpolated  diameters, except  one  6.00  wn,

are slightly  smaller than those of the  October  18, 1983 tests.   RSD  ranged

from  98.21 percent  at  1.00  urn  to 17.07  percent  at  20.0  \tm  and   averaged

51.9 percent.

    Table  2-12  presents the  comparative  CPLT  data for  the  runs performed  on

October 21, 1983.   It is notable that  the  RSD at  all  interpolated diameters

are significantly  smaller  than  those of  the previous  two  tests.   RSD  ranged

from 46.30 percent  at 1.00 urn  to  9.85 percent at  20.0 von and  averaged 26.1

percent.  At 10 urn the CPLT ranged  from 37.50 percent to 25.09 percent.

    Comparing all  three tests,  no  apparent  trends  are  present  in relation to

sample  point  locations  (upper  or   lower).   For example, the  following  table

shows the CPLT 10  urn for each  run:


                         CPLT 10 urn  - Multiclone Inlet

    Run Number          Test  1               Test 2              Test 3
P3/P1
P3/P2
P5/P1
P5/P2
17.30
16.78
16.18
31.18
40.85
24.21
20.46
22.17
37.50
30.45
29.74
25.09
      P3 - Port 3 upper location
      P5 - Port 5 lower location


    The differences between  the upper  and lower point runs may  be  due to the

poor inlet sampling location.   Both-upstream  and downstream disturbances were

less than 1.0 equivalent duct diameter.
                                     -26-

-------
                                                              TABLE 2-11

                                                   COMPARATIVE CPLT* DATA FOR TEST 2
                                                   PARTICLE SIZE DISTRIBUTION TESTS
                                                     AP GREEN REFRACTORIES COMPANY
                                                            ROTARY  CALCINER
                                                          INLET TO  MULTICLONE
                                                           MEXICO,  MISSOURI
                                                           OCTOBER 20, 1983
I
to
Interpolated Diameter (Mm)1
Run Number
P3/P1
P5/P1
P5/P2
P3/P2
Minimum
Maximum
Average
Standard Deviation
Relative Standard Deviation (%)
20.00

67.98
45.32
48.24
50.16
45.32
67.98
52.92
10.23
17.07
15.00
Cumulative
57.31
33.15
36.01
38.14
33.15
57.31
41.15
10.97
26.66
10.00
Percent Less
40.85
20.46
22.17
24.21
20.46
40.85
26.92
9.41
34.96
6.00
Than
19.82
8.74
8.16
9.78
8.16
19.82
11.63
5.51
47.38
2.50
Interpolated
4.82
3.52
1.14
1.85
1.14
4.82
2.83
1.66
58.66
1.25
Diameter
1.27
1.89
0.20
0.46
0.20
1.89
0.96
0.77
80.21
1.00

0.61
1.31
0.06
0.26
0.06
1.31
0.56
0.55
98.21
                * Cumulative Percent Less Than
                1 Microns
                 Note: Particle size distributions are based  upon  an  assumed particulate density
                       of 1  gram/cc; actual particulate density  is 2.65 to 3.00 grams/cc.

-------
                                                          TABLE 2-12

                                              COMPARATIVE CPLT* DATA FOR TEST  3
                                               PARTICLE SIZE  DISTRIBUTION  TESTS
                                                AP GREEN REFRACTORIES COMPANY
                                                       ROTARY CALCINER
                                                     INLET TO MULTICLONE
                                                       MEXICO,  MISSOURI
                                                       OCTOBER  21,  1983
i
to
oo
t
Interpolated Diameter (Mm)1
Run Number
P3/P1
P3/P2
P5/P1
P5/P2
Minimum
Maximum
Average
Standard Deviation
Relative Standard Deviation (%)
20.00

64.52
57.92
56.25
50.79
50.79
64.52
57.37
5.65
9.85
. 15.00
Cumulative
53.55
46.20
44.65
38.90
38.90
53.55
45.83
6.03
13.16
10.00
Percent Less
37.50
30.45
29.74
25.09
25.09
37.50
30.70
5.12
16.68
6.00
Than
17.61
12.03
12.86
10.73
10.73
17.61
13.31
3.00
22.54
2.50
interpolated
3.41
1.71
3.08
2.23
1.71
3.41
2.61
0.78
29.89
1.25
Diameter
0.44
0.59
1.19
1.03
0.44
1.19
0.81
0.36
44.44
1.00

0.34
0.34
0.82
0.67
0.34
0.82
0.54
0.25
46.30
            * Cumulative Percent Less Than
            1 Microns
             Note:  Particle  size distributions are based upon an assumed particulate density
                   of  1 gram/cc; actual particulate density is 2.65 to 3.00 grams/cc.

-------
    2.4.2  Rotary Calciner - Venturi  Scrubber  Outlet




    Foe the outlet location  one  run  was performed per test.  Comparative data




analyses were  not performed for  the outlet  tests because  of  PADRE'3 data




comparison routine.  As  stated  before, this routine permits comparison of data




for two or more runs  of a specified test - each outlet  test  had  one  run.




    Table 2-9 presents the summary of the CPLT data.








2.5 Averaged Distributions for Tests  1,  2, and 3




    A  comparison (inlet to  outlet)  on a  test basis was  performed using  the




average interpolated CPLT data  from  individual test runs.   The averages yield




a single particle  size distribution  for each  test.  Average  interpolated CPLT




data was performed on the inlet test  runs only.




    Tables  2-13,  2-14,  and  2-15  present the  averaged  interpolated diameter



data for Tests 1,  2, and  3,  respectively.  Figures  2-1,  2-2,  and 2-3 show  the




inlet and outlet particle size distributions  based  upon  interpolated  diameters



I:or Tests 1, 2, and 3,  respectively.



    All outlet  test  distributions appear  to  be bi- or  tri-modal.   Test 1  on




t:he inlet  appears  to  be  bi-modal.  However,  Tests  2  and  3  inlet definitely




appear to be single mode log-normal.




    Tables  2-13,  2-14, and  2-15  also  show the  fractional  efficiency of each




interpolated  diameter.   The  efficiencies  reveal   typical  venturi  scrubber



performance  (i.e.,  very  high  efficiency  above  1  micron, with   a  rapidly



decreasing efficiency below 1 micron).








2.6 Comparison of Cumulative Percent  Less Than 10 ym




    During the  course  of the calciner/dryer  NSPS development,  EPA  is planning




to  collect  data  on   the  particulate  emission fraction  with   an  equivalent
                                     -29-

-------
                                                        TABLE 2-13

                                             COMPARATIVE CPLT*  DATA FOR TEST 1
                                             PARTICLE SIZE DISTRIBUTION TESTS
                                               AP GREEN REFRACTORIES COMPANY
                                                      ROTARY CALCINER
                                   INLET TO MULTICLONE AND OUTLET FROM VBNTURI SCRUBBER
                                                     MEXICO, MISSOURI
                                                     OCTOBER 18, 1983
i
u>
o
i
Interpolated Diameter (urn)1
Run Number Location
P3/P1
P3/P2 Inlet
P5/P1
P5/P2
Average
1 Outlet
Efficiency
20.00
15.00
Cumulative
40.36
40.80
40.98
59.74
45.47
78.2
99.894
28.22
28.43
28.41
47.89
33.24
63.6
99.909
10.00
Percent Less
17.30
16.78
16.18
31.18
20.36
60.5
99.975
6.00
Than
8.92
7.45
5.88
10.90
8.29
58.6
2.50
interpolated
4.76
2.25
1.34
1.71
2.51
1.25
Diameter
3.42
1.28
1.07
0.50
1.57
1.00

3.15
0.74
0.59
0.18
1.17
58.6 56.2 45.8
99.983 99.974
99.925
98.628
           * Cumulative Percent Less Than
           1 Microns
           Note: Particle size distributions  are based upon an assumed participate density
                 of 1 gram/cc; actual  particulate density is 2.65 to 3.00 grams/cc.

-------
                                                        TABLE 2-14

                                             COMPARATIVE CPLT* DATA FOR TEST 2
                                             PARTICLE SIZE DISTRIBUTION TESTS
                                               AP GREEN REFRACTORIES COMPANY
                                                      ROTARY CALCINER
                                   INLET TO MULTICLONE AND OUTLET FROM VENTURI SCRUBBER
                                                     MEXICO, MISSOURI
                                                     OCTOBER 20, 1983
          Interpolated Diameter  (win)1
                                       20.00
          15.00
          10.00
          6.00
         2.50
         1.25
         1.00
i
Ul
Run Number

P3/P1
P3/P2
P5/P1
P5/P2
Average
          Efficiency
                               Location
                                Inlet
                                Outlet
     Cumulative Percent Less Than Interpolated Diameter
67.98
45.32
48.24
50.16
57.31
33.15
36.01
38.14
40.85
20.46
22.17
24.21
19.82
8.74
8.16
9.78
4.82
3.52
1.14
1.85
1.27
1.89
0.20
0.46
0.61
1.31
0.06
0.26
52.92
41.15
26.92
11.63
2.83
0.96
0.56
                                       99.0      88.6      66.0      44.9     34.9      31.9      21.8

                                       99.998    99.951    99.732   99.626   99.128   98.629   97.855
            Cumulative Percent Less Than
            Microns
           Note: Particle size distributions  are  based upon an assumed particulate density
                 of 1 gram/cc; actual particulate density  is 2.65 to 3.00 grams/cc.

-------
                                       • 1 • i • 11
                                             TABLE  2-15
                                  COMPARATIVE CPLT* DATA FOR TEST 3
                                  PARTICLE SIZE DISTRIBUTION TESTS
                                    AP GREEN REFRACTORIES COMPANY
                                           ROTARY CALCINER
                         INLET TO MULTICLONE AND OUTLET FROM VBNTURI SCRUBBER
                                          MEXICO,  MISSOURI
                                          OCTOBER  21, 1983




1
CJ
to
1
Interpolated Diameter (pm)1
Run Number Location
P3/P1
P3/P2
P5/P1 Inlet
P5/P2
Average
20.00
64.52
57.92
56.25
50.79
57.37
15.00
Cumulative
53.55
46.20
44.65
38.90
45.83
10.00
percent Less
37.50
30.45
29.74
25.09
30.70
6.00
Than
17.61
12.03
12.86
10.73
13.31
2.50
Interpolated
3.41
1.71
3.08
2.23
2.61
1.25
Diameter
0.44
0.59
1.19
1.03
0.81
1.00
0.34
0.34
0.82
0.67
0.54
                      Outlet
Efficiency
96.1      89.9      81.9     62.1    43.8     39.6     24.3

99.974    99.970    99.963   99.960  99.335   98.863   98.548
* Cumulative Percent Less Than
1 Microns
 Note: Particle size distributions  are  based upon an assumed particulate density
       of 1 gram/cc; actual particulate density is 2.65 to 3.00 grams/cc.

-------
                                                         CUMULATIVE PERCENT LESS  THAN
microns
    I
    u>
    U)
    I
          0.01   0.05 0.1  0.2   0.5   1~
                                                    10
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::::::;::::-::'::j:j3'.-::
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t of Venturi Scrubber
iTTimTrrrmnTnrn
—

9
8
7
6
5
4
. 2
microns
(urn)
i
.9
8
7
6
.4
3
2
1
30   40  50   60   70
80
90
95
98   99
99.8 99.9
99.99

-------
                                      PROBABILITY X 2 LOG CYCLES
                                                                                   AC anttn
     10

     9

     8

     7
     5


     40



     30





     20
microns
 (urn)
     lO
      9

 i   8
 r   7
      6

      5
                                                  CUMULATIVE PERCENT  LESS THAN

•_—
- --'
--
-~=^
TS
-.=-=
"LTT"
^_-
--_-


	

--


	
-—
- —
::.-
. — .
• -_i:
". ^:
".m
in'
:~
••-:


—

.
:?.
-'
•'.:

•-
'-

—


—

-
— •
• —
r:
—
— •

'-

--•



-

_













~ ; -

~_
~









I

-"
-

":.
-™
. _







.• —


_-

—

~r"



-
-
,j
V


':-
--'

.-_
T,

Note
-


-








-_•




-
-




-•

rt
•::
•_-


—


—


__

-

-
-

•-'-

~:
•-•


-
-

.
~
_.






-
-


-

-
-
--
-•
-._.
.~
-•
7]



-
-

.

~- :

:.: '-.-:. — -.:• •: ' - -- . : -: : -•-.-••
" ~T^ ~— TT ". - r • . ' - : " .-.-•-.
. " ' • ~ ~- : -. •- ';"•': . • ' . " : : : "
P|:-;... ;,:,:-, -r - .-,::r;.;
- . - :-.-._: - T - : : : - : : :.: r.
: . • : .• : - - • : _ : r - - - —
~ '

-
~::: :•:-"!
-.. '. ' : •_
~.~— .' - ~ ~
:: : -P.~
. • - - : ..-_
• • ~: ~. ~.~
.-.
-.

-,~ .
-•
~



T


: Particle size distributions are based upon an assumed particulate density
of 1 gram/cc; actual particulate density Is 2.65 to 3.00 grams/cc.
: .- .
i ." : :






— .



... . . .

-i::;:
L • •

"-..-.'

IT . : : " .
1. . '
- - '





....

1
r-- . -rz: :~ ~ :; - : ; ::::: ••• :••-::.:: :













)


. . . 	 . _ . 	 	 - 	 	
_. 	 ---» 	
- : -1 	 	 - - . r : : : : :.--:•-.-::
- ' 	 	 -• " ~ 	 - ' "
	 	 • - '-: :- 	

"V?=E^=Hr-Sr-!:!' --1 = -;;--
t ill"" 1 T":l 1 :l 1 l:nl 1 II Illl Hi T If I:rH
. - • : 	 z ,"--.""," ". " . ~ . ~ r ~ '; r i
.:•-:: 	 -..: -::...-: :-:;-.:::.
~~ —.~.-~~: ' . " : : .:.:..
	 ••_.":.. - - - : .
- - - c ;

•--- • 	 	 - -• • - • - -

--- 	 - 	 -
_..... 1
to
igJL,.,!!,,!^! iJ^iin-
1 1 1 1 1 1^11 JXUJ I.JJ-J II1||I UJ.LJ j.J_L| |. I
- - - 	 -- r I r 	








«
I . i




• '

.... . ......... . . 	
\-.---.--.--.---^-.---=r •••.:•.•••.-•- = ---

- : - ': '. '. :. : i : : - ~ £ - -:.:-----• = = = ~ —
	 - • - - -- :;: 	


' • - : - - -.-• -. • -. : 1"- : 1 ~ = - -• • • -• : E - ' " " - - - - —
IfniflltflftlllHIttii
.,_. ._..__ 	 . . . .. 	 	
r- 	
—
—


—








_.


—

—
—

	
=-
. •]
:H
I. •-IIJ-j-J-l
_ _ . . .


	 ....



t 1
1 I






	 	
	 : r r - •
	 ....

	 . . _ ^
= - j -. r

"T~. . . ' ~ z r .
- - - — —
	 ...


	 —










	
	 	
;::-«-=-
~ : - ~ r ~: ~r
.:.--.-!.—
. . _
- - - 	 	 —

~ ~ ~ ' ~ ~~ ~i

-
__-


-


-
--
-
-
-
~
-

~
...
'~
^ :

—


_. .
— -
— .
-
— -
— •
~Z1 '
== '•
~~

.:..








---







-
-

--

_


-
-
r:
-•
~
'--
-

: "•-": Figure 2-2
-- Inlet and Outlet Par
":.: 	 Based upon Interpola
; - Test 2
ticle Size Distributions
ted Diameters


A: Inlet to Multiclone
O: Outlet of Venturi Scrubber
^ ^ nX^ TTr^^^^K^^
L-^ '•^^•rrr^H

r
x~
— .
;f.
^f.r
=r
HI-
HE
—
...
-•_



—
_


—
=
—
".
=1-
^i:
Er.
^;
—
5
--
_
—
--
-.-
.-r
rr;
:~.
jT-ri-
r—
-•^
^'
•_ —
-^,


	
	


	
	
	
~I.
^r=-
r^r
nn~.

rrr
~ZL

--
—
—

       ^^9*n   I r^ft^^r i
 10

 9

 8

 7
                                                                                                                                 microns
 (urn)
9

8

7

6


5

-------
                               |./,*Z PROBABILITY X 2 LOG CYCLE'S
                                                                                  4 r* orv * r\
  10
   9
   8
   7

   6

   5

   40
                                                CUMULATIVE.PERCENT LESS THAN
  20
microns

       10
       9
    i  a
       7

       6

       5
un
I
,~



'7r
"rr-
r?
FT.
'-=.
.^.'
'"77


—
	
...


i —
—
i7™
-:
—--

-• -
~- '
..::
-
-
~


--
~
EF
-V
T:
~

—

	





—
-:
'-"•
--



-





\ .-















•:..
•
• •: .
-"'-'.. .' '
. . .::•_.

T -"•.:""' T- :
Note: Particle size distributions are based upon an a
of 1 gram/cc; actual particulate density is 2.6
T "
. .
1 . 7
_




- .


r. -.
-


-



'.~Z
. ' '/"
7

"
-


. ~-"
-:
-_



-".





-*
—

-



-
V
—







'.£
"T-_
77_.





—
-

...
_

•^
-
-


,
-



—
—
-—


—
-




~-
•--

r-
-
-_
::

..

_. .._ . .
. •. _ :
.
....





- - - -



- - -
:• - -: .
-----
:.:'..'
'.'-

- ~ • •


- '••'•'

Q _ .
0.01 0.05 0.1 0.2, 0? 1
r ".
". ~'.
'777!
. —





	

—

- - —
- : : -:L.
	 _.._
; . . -:=.:.
• • ' ,-rr.f
.-.
:. " -;.
. "::-:
'-''-• -A
. s
.
• -
	 . 	 _. . 	 . _ .
— ... 	 	 . .- . -
--.-:- zz~ :::--" . z:~
	 . ......







	 	 	 	


- - • 	 	 -
=--- •-.-.----. : '---:
	 -"'• •" :: ------
'7^- = ?.? I"': ll ; -- = r=-
^Tilnirffl

:. ." .--'_. 7 '.: ' . .'"::„"
~; .-...- ~ :..'.' ' . : ' '
~ :'. 77 "; - 7 ; ; . : : : " ; -
— :" :_ '-':-•;•_•'• :..'-_--
------ - - --
- •>
-..•;• : . . :.•:..: •:•.:..
- • 	 	
::::-.::•.:. •-:::•--::-: " r






/
. [



(
' *
	 ' - - - - - ' 	
\
-:-::. ::::.:' r :: r. .. r
...:.:::..:.:. : ; _ : : . . :
----- :;-Mh = = = E"
'-.-.'i ' - : : ' : : : : • : : = = : r f rr. =

. ~ '.7 ' . '.~ ~ ' :::~ : -!•'•* -till
•;:.-;T:-- •;•:-]
;.::•: •":::'. -;::: ini
.::.. 5(1. ';.: . : BdS

: 	 • -
• ' . . .



SSUffl
5 to
-
- : :











.,:,.


- •:•
: :





-



_


-':.


_


'•'

•-.



- . -





j
.;.
-



- If
T
:-~.
ed particulate density
3.00 grams/cc.
:: ..
'.'.-





	


,
>•
	



•.•.-.-.-.--


...
IT ~











--
--

--
"1
- r.
rr.


-
-










-


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=|

-

-
~
-















-



-
r:
_.



—

i

—

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-
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—.:
^.

—
r~
—






rt

—

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=

.r:

	 	 - -
~ 	 ~ ' I I „
..-77 '777








— --




-- • -

_. :-
— -i : : :.
	 	 - - -
_—- : r -

. . ...
: T:;.









. . .. _






r : - : r.
Ei = E =

~ ' - ~ .


-
-




-

-



-

-
-
-


-
"-





-_



-

--
E

-

-
—




—

	

-


—
-

IZZ


t




-


-








-r

•-' •
-• '
— -•



— i
— •
— .


-- ---
—


= ..:
— :: =
•:-.-.

Figure 2-3
at and Outlet Particle Size Distribut
sd upon Interpolated Diameters
Test 3
A: Inlet to Multicone
Q: Outlet of Venturi Scrub
hTiriniiiiiiTiir





mnimii




\----
-
-. r."



\



'---- —
^Ln
. _ —







	 	




	

- r :.. _-
====,
- -—
-. .. ... .__
. .- -:: zr
ions
ber
II
-"

:.'j~
—

7,."
T?"
•_-•
'— :
~^'
:-.
......
^77'




	
	

	

-•-
-•
—
==_.
.-.—
T~
~UL
EE
—
—
—

2 5 10 20 '" 30 40 50 60 70 80 90 95 98 99 99.8 99.9 99.99
                                                                                                                                     10
                                                                                                                                     a

                                                                                                                                     8

                                                                                                                                     7

                                                                                                                                     6

                                                                                                                                     5
                                                                                                                               microns

-------
aerodynamic  diameter equal  to, or  less  than,  10  urn  because of  the  current



emphasis  upon limiting  ambient  air  concentrations of  inhalable  particulates.




It  was  of particular interest  during  this test program  to determine  whether




consistent  results  could be  obtained  at  particle  diameters  of  10  urn  or




smaller.  Table  2-16 presents  a comparative summary of the  cumulative  percent




mass  less  than 10  urn for  the  three tests  (inlet  and  outlet).  Comparison  of




the inlet and  outlet locations at CPLT 10 urn shows  a wide  range.



    The relative standard deviations for  the  inlet and  outlet tests were  20.1



and 16.0 percent, respectively.








2.7 Visible Emissions




    The'  opacity  of  the  venturi  scrubber  outlet was  monitored  during   the




emission  testing program by  a  certified  visible emission  observer.    All




observation locations conformed to the guidelines  of EPA Method 9.  The outlet




plume was monitored during two of the three emission tests.  Observations were



not performed during the third  test  due  to  the poor visibility  caused  by



inclement weather.  All  opacities were  zero, and these  data are shown in Table




2-17.








2.8 Fugitive Emissions




    Fugitive  emission (FE)  observations  were  monitored  during  the  emission




testing program by an FE observer.  All observation locations conformed to  the



guidelines of  EPA Method  22.  The rotary  calciner hopper  inlet was monitored



during  two  of  the  three emission  tests.  Observations  were not  performed



during the third test due  to the rainy weather.  The inclement weather caused



the feed material to become almost a "muddy' substance.   All observations were




zero,  and these data are shown  in Table 2-18.
                                     -36-

-------
                                  TABLE 2-16

               COMPARISON OP CUMULATIVE PERCENT LESS THAN  10 um
                       PARTICLE SIZE DISTRIBUTION TESTS
                        AP GREEN REFRACTORIES COMPANY
                               ROTARY  CALCINER
             INLET TO MULTICLONE AND OUTLET PROM VENTURI SCRUBBER
                               MEXICO,  MISSOURI


Teat No.                    Inlet CPLT 10 um            Outlet CPLT IQum

   1                               20.36                     60.5

   2                               26.92                     66.0

   3                               30.70                     81.9
     Note:  Particle  size distributions are based upon an assumed  particulate density
           of  1 gram/cc; actual particulate density is 2.65  to  3.00 grams/cc.
                                     -37-

-------
                                  TABLE 2-17

           VISIBLE EMISSIONS OBSERVATIONS AT THE ROTARY CALCINER -
           VENTORI SCRUBBER OUTLET, AP GREEN REFRACTORIES COMPANY,
                               MEXICO,  MISSOURI
  Date
18 Oct 83
 Test
Number
Six-Minute
Time Period

1048 - 1053
1054 - 1059
1100 - 1105
1106 - 1111
1112 - 1117
1118 - 1123
1124 - 1129
1130 - 1135
1136 - 1141
1136 - 1141
1142 - 1147
1148 - 1153
1154 - 1159
1200 - 1205
1206 - 1211
1212 - 1217
1218 - 1223
1224 - 1229
1230 - 1235
1236 - 1241
1242 - 1247
1248 - 1253
1254 - 1259
1300 - 1305
1306 - 1311
1312 - 1317
1318 - 1323
1324 - 1329
1330 - 1335
1336 - 1341
1342 - 1343*
1448 - 1453
1454 - 1459
1500 - 1505
1506 - 1511
1512 - 1517
1518 - 1523
AVERAGE
Average Opacity
   (Percent)

      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
Observer Location
                                           1000 Ft. NE of Outlet
*Method 5 test stopped to maintain simultaneous  sampling with  the  inlet tests.
                                     -38-

-------
                            TABLE 2-17  (continued)

           VISIBLE EMISSIONS OBSERVATIONS AT THE ROTARY CALCINER -
           VENTORI SCRUBBER OUTLET, AP GREEN REFRACTORIES COMPANY,
                               MEXICO,  MISSOURI
  Date
 Test
Number
20 Oct 83
Six-Minute
Time Period

1014 - 1019
1020 - 1025
1026 - 1031
1032 - 1037
1038 - 1043
1044 - 1049
1050 - 1055
1056 - 1101
1102 - 1107
1108 - 1113
1114 - 1119
1120 - 1125
1126 - 1131
1132 - 1137
1138 - 1143
1144 - 1145*
1315 - 1320
1321 - 1326
1327 - 1332
1333 - 1338
1339 - 1344
1345 - 1350
1351 - 1356
1357 - 1402
1403 - 1408
1409 - 1414
1415 - 1420
1421 - 1426
1427 - 1432
1433 - 1438
1439 - 1444
1445 - 1450
1451 -
AVERAGE
Average Opacity
   (Percent)

      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
      0
    -  0
 Observer Location

600 Ft. NE of Outlet
'Method 5 test stopped to maintain simultaneous  sampling with  the  inlet tests.
                                     -39-

-------
                                 TABLE 2-18

                FUGITIVE EMISSIONS OBSERVATIONS AT THE ROTARY
           CALCINER - HOPPER INLET, AP GREEN REFRACTORIES COMPANY,
                              MEXICO, MISSOURI
  Date
18 Oct 83
  Run
Number
20 Oct 83
Twenty-Minute
Time Period

1045 - 1105
1115 - 1135
1145 - 1205
1215 - 1235
1245 - 1305
1315 - 1335
   Total

1010 - 1030
1040 - 1100
1110 - 1130
1140 - 1200
1210 - 1230
1240 - 1300
1310 - 1330
1340 - 1400
1410 - 1430
   Total
 Accumulated
Emission Time
   (Min;Sec)

      0:0
      0:0
      0:0
      0:0
      0:0
      0:0
      0:0

      0:0
      0:0
      0:0
      0:0
      0:0
      0:0
      0:0
      0:0
      0:0
      0:0
 Observer Location

Natural light behind
observer.  Observer
in doorway of con-
veyor belt shed.
                                           Natural light behind
                                           observer.   Observer
                                           in doorway of con-
                                           veyor belt shed.
                                    -40-

-------
2.9  Sieve and Moisture Analysis - Feed and Product Materials




     Samples of the feed (raw  material  clay)  and  product  materials  were




collected during each  emission  test.   Samples from each location were then




composited.  Sieving  and  moisture  content  analyses  were performed on the




composite  samples  in  accordance  with ANSI/ASTM Standard C92-76:  Standard




Test Methods for Sieve Analysis and Water Content of Refractory Materials.








     2.9.1  Feed Material




     The  sieve  analysis  and moisture content data are shown in Table 2-19.




The average moisture content was 9.1 percent.  The sieve analysis showed, for




all three tests, that at least 82 percent of the material was larger  than  1




millimeter.








     2.9.2  Product Material
     The sieve analysis and moisture content data are shown  in  Table   2-20.




The average moisture  content  was  zero percent.  The sieve analysis showed,




for  all  three  tests, that at least 90 percent of the material  was  larger




than 1 millimeter.








     2.9.3  Trace Metals Analysis




     For  one run at each location, the Method 5 particulate  catch  and  the




distilled water reagent from the impingers were analyzed for trace  metals by




using  atomic  absorption  or  inductively coupled argon plasma spectrometry.




Table 2-21 presents the results of the trace metals analysis.
                                  -41-

-------
                                  TABLE 2-19

                             FEED  MATERIAL SAMPLES
                        SIEVE ANALYSIS/MOISTDRE CONTENT
                         AP GREEN  REFRACTORIES COMPANY
                               MEXICO, MISSOURI
                                    Total Percent Retained On sieve
                                                  Test
Sieve Size                    1 	               2
  8 mm3                     26.1                 45.2                 56.5
  4 mm                      24.7                 22.1                 14.1
  2 mm                      20.2                 11.0*                 9.0
  1 mm                      11.2                  8.6                  7.0
850 umb                      1.8                  1.6                  1.4
710 urn                       1.6                  1.4                  1.2
300 vuo                       4.3                  1.2                  2.6
250 urn                       4.4                  4.4                  4.0
125 urn                       3.6                  2.9                  2.7
 63 urn                       1.7                  1.4                  1.3
Bottom Pan                   0.2                  0.2                  0.2
Percent Moisture             9.1                  8.8                  9.5
a millimeter
b micron
* some sample loss occurred
                                     -42-

-------
                                  TABLE  2-20

                           PRODUCT MATERIAL SAMPLES
                       SIEVE ANALYSIS/MOISTURE CONTENT
                        AP GREEN REFRACTORIES COMPANY
                               MEXICO, MISSOURI
                                    Total Percent  Retained On Sieve
Sieve Size
  8 rama
  4 mm
  2 mm
  1 mm
850 umb
710 urn
300 urn
250 urn
125 urn
 63 urn
Bottom Pan
1
38.6
24.9
18.2
9.4*
1.2
1.0
1.7
2.6
1.8
0.5
Test
2
52.1
27.9
13.3
4.3
0.5
0.3
0.3
0.8
0.3
0.1
3
71.2
20.4
6.5
1.3
0.1
0.1
0.1
0.1
0.1
0.1
Percent Moisture


a millimeter
  micron
* some sample loss occurred
                                     -43-

-------
                                   TABLE 2-21

                        TRACE METALS ANALYTICAL RESULTS
                     IMPINGER REAGENTS AND METHOD 5 FILTERS
Element

Beryllium (Be)

Calcium (Ca)

Chromium (Cr)

Iron (Fe)

Manganese (Mn)

Nickel (Ni)

Silicon (Si)

Titanium (Ti)

Vanadium (V)

Zinc (Zn)


Aluminum (Al)

Magnesium (Mg)

Lead (Pb)


Mercury (Hg)

Fluorine (F)
Inlet
Imp. 1
mi eg.
< 1
276
< 20
23.2
< 10
< 10
156
< 10
< 10
< 5
720
6.0
0.72
***
< 50
Outlet
Imp. 2
mi eg.
< 1
1,144
148
560
< 10
23.4
1,700
< 10
< 10
13.0
< 20
1,014
1.96
0.35
260
Outlet
Imp. 2
micg.
< 1
1,600
306
1,125
< 10
58.2
2,750
< 10
< 10
47.3
62.0
14.6
2.50
0.23
473
     * Analysis of filters only

   *** Not enough sample remaining to complete analysis.
                                  -44-

-------
3.0  PROCESS DESCRIPTION








3.1  General




     AP Green provides a complete  line  of refractory products and services.




The products include firebrick of all qualities—low, medium, high, and super




duty;  50  percent  to  99  percent  alumina;  mullite; silicon carbide;  and




zircon.  AP Green  also produces a full line of basic brick including chrome,




chrorae-magnesite, magnesite-chrorae, magnesite, and metal encased.   AP  Green




manufactures  insulating  firebrick,  ceramic fibers, industrial insulations,




and  all  types  of  mortars, plastics,  castables,  ramming  mixes,  gunning




materials, and special refractory mixes.








3.2  Calcining Process








     3.2.1  Raw Material




     Fire  clay  is a generic commodity term which encompasses many different




types of clay (including Missouri  flint  clays  and  plastic  clays) used in




manufacturing refractory products.  There are significant  variations  in the




chemical composition,  in the contained impurities (e.g., sulfur), and in the




particle size characteristics of  these  different clays.  For Missouri flint




clays,  about 75 percent of the particles are less than 1.0 urn and 96 percent




are less than 10 urn.  For Missouri plastic clays, 93 percent of the particles




are  less  than  10 urn, and 47 percent are less than 1.0 urn.  The bulk of the




raw  material  requirements  for this plant is provided by mining of Missouri




clay deposits.  Additional raw materials are shipped from other states or
                                      -45-

-------
are imported (e.g., calcined bauxite from China).  At this plant, about 15




different grades of clay are fed to the dryer, and the rotary kiln system is




used to calcine about 35 different clay materials.








     3.2.2  Rotary Calciner




     A partial process flow diagram of the AP Green facility is shown in




Figure 3-1.  The process unit tested is a rotary calciner which was




manufactured by Vulcan Iron Works and was installed in 1947.  The rotary




calciner is operated continuously 24 hours per day, 7 days per week as




required to meet product demand.  This kiln, which is 2.4m (8 feet) in




diameter and 36.6m (120 feet) long, is direct-fired (using natural gas or




No. 2 fuel oil) with the combustion gases entering at the discharge end




(counter flow).








     3.2.3  Calciner Design Capacity




     The design production rate and the actual production rate are both




7.2 Mg/h (8 tph).  The maximum gas temperature is 1316°C (2400°F), and the




retention time is approximately 60 minutes.  The fuel-to-product ratio is




4,885 MJ/Mg (4.2 million Btu/ton) of product.  The design exhaust gas flow




rate is 708 to 991 m3/min (25,000 to 35,000 ft3/min) at a temperature of




370° to 430°C (700° to 800°F).   Data for the the calciner are shown in




Table 3-1.








     3.2.4  Calciner Exhaust Gases




     The exhaust gas stream from the rotary kiln is passed through a settling




chamber, a multiclone collector, and a venturi scrubber to a vent stack.




Some of the collected dust is reused in plant processes.   Data for the
                                       -46-

-------
               R..II f ...
,'(
C OveiCtl
T
] 	 ,

__
V.,,l lo Vl« ** Coll.tl.d OulilJ. 1
WaUl ^»ll Yo.J
... [i]
i f^.
1 Coll.clo. 1
Ool.Uo 1 1 Wuil.
Yuid 1 Wale.
1 Dull
I 	 * 	 1
i
HeuleJ 1 OulilJ* Void IkiinJIIiiQ

i
L _ . I _L_
^- Cyclo... "L- K..r»«»»l SlIIIMud I.K P.I,.K.,y Jow
Swej.1 wlili Ciui
Collcclcil

Dutl
1 Gili
* f V —
Mng
fuiclxited
'. . < Mule.luU
i ' ' K
Mud 1 |.K. G.lnd|ng| 1 ^^ Ilutl1
iJIna 1 1 ? ^ "* 1
^ I I .i « 1
1 1

Piuuniullc Suwdull Puiclio
•"" Mill Conveying, SloclplU bogg.d
*'• iw«l" 1 Male.)
(No llealliiq)

... _ 1
	 " " I
M*iiiulaclmli>a Mulct Inl Sluiuno 1
•y u |
**Collect;c(l dust is mouLly returned
to process.
\
lo R«(iutlO*y Maiutfucltii ttty Pltiikl


>l

                                                                                          Je
                                                                                          »
                                                                                          a.
Figure 3-].  Partial  flow diagram for fire clay plant of A. P. Green Refractories  Company
       of  Mexico,  Missouri,  (handling and processing of raw materials prior  to  use
                          in refractory manufacturing plant).

-------
TABLE3-1. DATA FOR THE CLAY CALCINER AT A.  P.  GREEN REFRACTORIES COMPANY
                       PLANT AT MEXICO, MISSOURI '
Type of equipment

Manufacturer
Date of installation
Equipment dimensions:
  Inside diameter and length (ft)
Type of operation
Design production rate (tph)
Design evaporation rate, Ib water/h
Actual production rate, (tph)
Method of determining actual
Hours of operation, daily average
Hours of operation, weekly average
Retention time (minutes)
Maximum temperature (gas) (°F)
Heat aoplication method
Fuel used
Fuel to product ratio (million Btu/ton)
Exhaust gas flow:
  Design (ftVmin)
  Actual (ftVmin)
Feed moisture content (%) (Normal)
Final moisture content (%)
Product exit temperature (°F)
Rotary kiln calciner and
  rotary cooler
Vulcan Iron Works
1947

8 x 120 (calciner only)
Continuous
8
N/AC
8
Scale
24
Variable
60 to 90
2400 _
Counterf low
Natural gas or No. 2 fuel oil
25,000-35,000
N/A
10-15
0
900-1000
a>' Data Source:  Research Triangle Institute plant trip report to EPA dated
   February 4, 1982.  MRI plant trip report to EPA dated October 21, 1983.
  CN/A = Not available.
                                     -48-

-------
emission control equipment are shown in Table 3-2.  The venturi scrubber was




manufactured by American Air Filter Company (Size 28 Kinpactor).  The design




gas flow rate is 708 to 991 m3/min (25,000 to 35,000 acfm).  The operating




temperature is 49° to 71°C (120° to 160°F).  The gas pressure drop across the




throat or scrubber body is normally 6 to 6.7 kPa (24 to 27 in. w.c.).








     3.2.5  Storage




     At the discharge end of the rotary calciner, the hot clay passes over a




grizzly to remove small amounts of sinter (large lumps) formed by incipient




fusion.  These lumps are discharged onto a reject pile.  Material passing




through the grizzly is fed into a rotary cooler (1.5m _[5 ftj_ diameter by




18.3m _[60 ftj_ long and lined with refractory).  Ambient air drawn through the




cooler from its discharge end cools the clay and then passes through the




rotary calciner.  The cooled calcine is discharged from the rotary cooler




into a collection pit.  From this pit, the calcined clay is retrieved and




used in various refractory manufacturing processes.








3.3  Process Conditions During Testing








     3.3.1  Monitoring Procedures




     All processes were operated normally during the emission testing.  The




rotary calciner was fired with natural gas and Missouri flint clay was




calcined during all three runs.  This clay had been selected for calcining




because it was considered by plant personnel to be the most difficult to




control with respect to particulate emissions.  Operation of the rotary
                                       -49-

-------
       TABLE 3-2.   DATA FOR EMISSION CONTROL EQUIPMENT FOR THE
 CALCINER/COOLER AT A.  P.  GREEN REFRACTORIES COMPANY AT MEXICO, MISSOURI
                                                                     a,b
Types of control devices
                                               Rotary calciner/cooler
Primary/secondary



Data for primary control device (multiclone):

  Manufacturer

  Height of multiclone collector, ft
  Height of bottom cone, ft
  Inlet dimensions, in.
  Outlet dimensions, in.
  Gas pressure drop across multiclone,
    in. w.c.

Data for secondary control devices:

  Manufacturer
  Model number
  Design gas flow rate, acfm
  Actual gas flow.rate, acfm
  Operating temperature, °F
  Design inlet concentration, gr/dscf
  Scrubbing liquid
  Scrubbing liquid inlet pressure, psig
  I'cuid flow rate, gpm
  Gas pressure drop across throat or scrubber
    body, in.  w.c.
  GcS pressure drop across entire system, in.
    w.c. (primary plus  secondary control)

Maintenance operations:

  L-ibrication for scrubber pumps when
    operating
  Other maintenance and repairs
                                               Settling chamber, multi-
                                                 cyclone collector/
                                                 Venturi scrubber
                                               Zurn Industries—for
                                                 multiclone
                                               15.9
                                               8.9
                                               54 by 120
                                               36 by 120
                                               2.5
                                               American Air Filter Co.
                                               Size 28 Kinpactor
                                               25,000-35,000
                                               N/AC
                                               120°-160°
                                               4.0-14.0
                                               Water
                                               70-80
                                               280-350
                                               24-27

                                               30-33
                                                Daily

                                                Performed as  required  or
                                                  during downtimes
a,b
 Data  Source:   Research  Triangle  Institute  plant  trip  report to  EPA  dated
.February  4,  1982.   MRI  plant trip  report to  EPA  dated October 21,  1983.
:N/A = Not available.
                                    50-

-------
calciner is determined by the type of clay processed and the temperature


within the kiln necessary to achieve calcination without fusing  the clay  into


lumps.  The amount of clay fed to the calciner by the conveyor belt (which  is


equipped with a scale) was measured in the control booth by a totalizer.  The


calcined clay production rate during the three runs ranged from  7.5 Mg/h  (8.3


tph) to 8.6 Mg/h (9.5 tph).  This production level was slightly  greater than


the design production rate.  However, the quality of the calcined product did


not decline at the higher rate, therefore, personnel did not decrease  the


rate of clay fed to the calciner.  The calciner firing temperature was


adjusted manually by raising or lowering the fuel gas pressure.  The  firing


temperature during testing ranged from 1191°C (2175°F) to 1282°C (2340°F)


with an associated fuel gas pressure of 124 to 131+ kPa (18 to 19+ psi).  In


addition to those parameters mentioned above, the calciner feed-end


temperature, gas temperature at the venturi inlet, demister temperature,  and


the water flow rate to the venturi were also monitored; the recorded  data are


shown in Tables 3-3, 3-4, and 3-5.





     3.3.2  Production Rates


     American Air Filter specifies that, for the venturi scrubber, a  1,060  to


1,325  pm (280 to 350 gpm) water flow rate be maintained for gas flows


ranging from 708 to 991 m3/min (25,000 to 35,000 acfm).  These operating


conditions produce a design liquid-to-gas ratio of 1.3 to 1.5  /m3 (10  to

               o
11 gal/1,000 ft ).  During all the tests, the water flow rate remained


relatively constant with a range of 791 to 810 1pm (208 to 212 gpm) for a gas


flow of 491 m3/min (17,000 acfm).  Thus, the liquid-to-gas ratio during the


test is 1.4 1/m3 (12 gal/1,000 ft3).  The pressure drop across the venturi
                                        -51-

-------
                      TABLE 3-3.  OPERATING CONDITIONS--RUN NO.  1—OCTOBER 18,  1903
lime
OBOO
OU30
O'JUO
0930
1000
1030
1100
1130
1200
I/Ill
ui 1300
ro
1 1330
1400
1430
1SOO
1530
1600
Calclner
flrlncj
2175
2175
2175
2175
2175
2175
2175
2175
2175
a
"_*
--a
_a
2200
2200
2225
CalciiiLT
feed 'end
lump. . °F
880
820
840
840
020
040
040
840
U4U
(120
B20
020
820
820
820
020
820
Vcnturl
Inlet
leap. , °r
B50
740
770
645
740
745
7bO
750
7 SO
740
720
740
740
740
740
740
720
Oemisler
U»p., °F
118
120
120
120
120
120
120
120
120
120
120
120
120
120
120:
120
120
Water flow
rale lo
venlurl, gjim
210
210
210
210
210
210
209
210
209
209
208
200
208
210
210
,210
210
r 1 rcliox
pressure,
17
17
17*
18
IB
18
19+
19
I9>
10*
19
18»
19
19
18»
19
Total tons
• of clay fed
to calclner
02396.35
02400.74
02405. 12
02409.50
02413.87
02418.28
02422.70
02427.14
02431.57
02435.92
02440.27
02444.59
02448.91
02453.44
02457.97
02462.28
02466.60
Rale of
clay fed lo
calclner. tph

8.76
8.77
8.78
8.75
8.86
8.83
8.78
a. 07
0.67
8.70
8.85
8.64
8.84
9.06

8.63
Pressure
differential
across
venlurl
throat,
In. w.c.
26.1
26.1
26.2
26.2
26.2
26.2
26.2
26.2
26.2
26.2
26.2
2612
26.2
26.2
26.3
26.3
26.2
Electrical short  In gauge.

-------
                        TABLE  3-4.  OPERATING CONDITIONS—RUN NO.  2—OCTOBER 20,  1983



1 inie
0/110
0000
0030
O'JOO
0930
1000
1030
1 100
1130
1200
mo
1300
1330
1400
1430
1500
1530
1600


Calclner
firing
--b
2250
-b
2850
2250
2250
2250
2250
2250
2250
2300
2300
2325
2325
2325
2325
2325



Calclner
(cod- end
leni|>. . °F

020

020
020
020
020
020
020
020
1)20
U20
020
020
020
820
820



Venlurl
Inlcl
lCB1|>. , "I

--a

--*
--S
--fl
--*
--a
--a
--a
710
710
710
710
710
710
710




Ueralslcr
Icmp. . °r

110

no
112
112
114
114'
112
112
114
114
114
114
114?
114
114



Haler Mow
rale lu
venlurt, (J|>m

210

210
210
210
210
210
210
210
210
210
210
210
210
i210
210


f 1 rchox
(jas
pressure,
|>S|

18
10
10»
19
19
10.
19
10.
19
18*
10.
10.
IB"
10*
19
10.
10*


lolal Ions
of clay fed
lo calclner
02807.00
02815.73
02820. 12
02824.52
02828.93
02033.34
02837.75
02042. 16
02046.58
02851.00
02855.42
02859.04
02864.26
02868.67
02873. 16
02877.64
02001.07
02806.50


Rale of
clay fed lo
calclner, tph

8.60
8.81
8.79
8.82
8.82
8.03
8.02
8.84
8.84
0.84
8.04
0.90
8.83
8.71
0.97

8.46
Pressure
differential
across
venlurl
Ihroal,
in. w.c.

26.1
26.1
26.1
26.1
26.1
26.0
26.0
26.1
26.1
26.1
26.1
26.1
26.1
26.1
26.1
26.1
26.1
^t leclrital slioi I In ijauye.
 No reailiny taken.

-------
TABLE 3-5.   OI'fcKATJNG CONDI I IONS—RUN NO. 3—OCTOBER  21,  1983


lime
0700
01)00
0830
0900
0930
1000
1030
1100
1130
1200
1 1230
Ul
*~ 1300
1
1330
1400
1430


Cdlclnur
flrlnu
temp. . °F

2325
2325
2325
2325
2325
2325
2325
2325
2340
2340
2325
2325
2325
2325


Ca It liter
fcnil-eiul

840
840
840
040
840
040
840
840
840
840
840
840
040
840


Vent in 1
Inlet
temp. . °f

740
730
/40
737
740
740
740
730
740
735
730
725
720
730


Demlslcr
temp. , °F

115
112
112
112
110
112
110
110
110
110
110
110
110
116


Water flow
rate to
venlurl. OP»

221
215
209
200
212
211
212
212
214
214
214
214
214
214

Firebox
(jas
pressure, ••
psl

19*
19*
19*
19*
19*
19*
19*
19
18
18*
18
IB
.1°
18


Total tons
of clay fed
to calclner
03019.20
03028. 74
03032. aa
03037.03
03041.56
03046.08
03050.42
03054.76
03059. 14
03063.53
03067.95
03072.37
03076. 78
03081.19



Rate of
clay fed to
calctner, tph

9.M
a. 6a
8. 29
O.B6
9.05
a. 72
8.68
8.81
8.77
8.83
8.84
8.82

Pressure
differential
across
venlurl
lliroal.
In. w.c.

26.1
26.0
26.0
26.0
26.0
26.0
26.0
26.0
26.0
26.0
26.0
26.0
26.0
26.0

-------
also remained constant with an average  value  of 6.5 kPa (26 in. w.c.).  Due




to the consistency of the parameters  monitored, for both process and control




equipment, during testing it is believed the process was operating normally.




     Both fugitive and visible emission observations were made during testing




by  the  EMB  contractor.   During testing there were no observations greater




than 0 percent.
                                       -55-

-------
4.0 SCOPE OP THE SAMPLING PROGRAM BY SITB




    The primacy objectives of  this  emission measurement program was to obtain




the following data from the inlet and outlet  sampling  locations of the rotary



calciner/cooler pollution control devices:






    1.  Particulate matter concentrations




    2.  Particulate matter mass emission rates




    3.  Particle size distributions  of the  particulate matter






In addition, visible emissions observations were made at the exhaust stack and



fugitive emissions observations were performed  at  the  inlet transfer point of



the  rotary  calciner.   Grab  samples of  the  raw  material  and  product  were



collected for sieve analysis  and moisture content.



    An overhead view of the process  is shown in Figure  4-1.








4.1 Multiclone Inlet - Particulate Matter Tests




    Sampling was  performed in  the  34-inch by  57-inch  rectangular horizontal




duct which  connects  the  settling chamber  to  the  multiclone.   Seven sampling



ports were located 22 inches (0.4 equivalent duct diameters) upstream from the



settling  chamber  exhaust and  11   inches  (0.2   equivalent  duct  diameters)



downstream from a  90   bend into the multiclone.   The  inlet location is shown




schematically in Figure 4-2.   According  to  EPA Method 1 a total of 49 sampling




points were  used  (7  sampling  points per  traverse).   For  Tests  2,  3,  and  4




twenty-eight sampling points  were used (see Section  2.1).








4.2 Multiclone Inlet - Particle Sizing Tests




    The  particle  sizing  tests were  performed at  the  same  location  as  the



particulate  tests.   Presently  there   are  seven   sampling ports,  two  were
                                     -56-

-------
             11 rrti 11 mn 11111 n 11 in 1111111111111 nm 111 n 1111111 inti 111 n 11111111111111 n i
I
U1
       AREA
                                    MATERIALS BUILDING
                          ROADWAY
                       KILN
                      CONTROL
                      BUILDING
                                  GAS OR OIL
                                   BURNERS
                MATERIALS
                BUILDING
N
\RGF

ROTARY
COOLER




i
i
1
»

ROTARY KILN
CALCINER

                                                                                                   I.D.  FAN
                                                  MIST
                                               ELIMINATOR
  KILN MATERIALS
CHARGING EQUIPMENT
                                                                                        NOTE:   DRAWING NOT TO SCALE
       iittimiiiiimiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiM
        PERIMETER FENCE
                                                                       ^
                                 SALVAGE YARD
                                                         Figure 4-1
                                               Overhead View-Rotary Kiln/Cooler
                                                    AP
                                                                ssour

-------
00
I
U-22"-*
SETTLING
CHAMBER
\ /

11"
8i
0
o
8
07
« 	 33« 	 *
•*-
DUCT V
90° B
/\


II Til
END
T
57"
J.
                                                                                LADDER
                                                                                 CAGE
                                                                                                  SAMPLING
                                                                                                    PORTS
                                                                                      f   n^
                                                                                     FLOW
                      T
                       34"
                           SIDE VIEW
TOP VIEW
TRANSFER POINT
NUMBER

*





1
2
3
4
5
6
7
DISTANCE FROM
END OF PORT (Inches)
9.4
14.3
19.1
24.0
28.9
33.7
30.6
                                                                                  Figure 4-2
                                                                            Inlet Sampling Location
                                                                             AP Green Refractories
                                                                               Mexico, Missouri

-------
 utilized  for the particle size  tests  (Ports 3 and  5).   Pour sampling  points


were  used for  the particle  size  tests  (2  Points  per  traverse).   The  two


sampling  points for  both Ports  3  and  5  were located  15.5  inches  and  32.5


inches from  the outside of the port nipple,  respectively.  The particle  sizing


test  location  is shown schematically  in Figure 4-3.  The  sampling points as


shown in Figure 4-3 are Port 3 Point 1 (P3/P1), Port 3 Point 2 (P3/P2),  Port  5


Point  1  (PS/PI),  and Port 5  Point  2  (P5/P2).   Due to the  short distance of


straight duct  (less than  3  feet),  separate ports  for the  particle  size  and


particulate  sampling trains could not be provided.





4.3 Venturi Scrubber Outlet - Particulate Matter Tests


    Sampling was performed in a  38-inch  ID circular steel stack.  Two  sampling


ports  spaced  90   apart  were   located   387   inches  (10.2  duct  diameters)


upstream  from  the  ID  fan transition  and  117 inches  (3.1 duct  diameters)


downstream from the top of the stack.   According to  EPA  Method 1, 16  sampling


points were  used  for the particulate tests  (8  per  traverse).   The outlet


location is  shown schematically  in  Figure  4-4.   Three tests were performed at


this location.





4.4 Venturi Scrubber Outlet - Particle  Sizing Tests


    The  particle  sizing   tests   were  performed  on  the  same   stack  as   the

                                                       o
particulate  tests.  Two sampling ports were spaced  90  apart and  located 24


inches downstream from  the particulate test  ports.   Pour  sampling points were


used for the particle sizing tests  (2 points  per  traverse).   Each of  the  4


sample points  were  equally  spaced  (0.7  times  the  radius  {0.7R})  from  the


center of  the  circular duct.   The particle  sizing   test  location  is  shown


schematically in  Figure 4-4.  Figure  4-5  shows the  sampling  point distances


from the outside of the port  nipple.




                                     -59-

-------
                                     32.5"
     j k    i i
                                                                    PORT 1
        20.3"
                        P3/P1
P3/P2
                                                                    PORT 3
    36.5"
                        P5/P1
                          •
P5/P2
                    PORT 5
57"
                                                                    PORT 7
                                     34"-
                                Figure 4-3
                            Particle Size Tests
                          Inlet Sampling Location
                           AP  Green Refractories
                             Mexico, Missouri

                                     -60-

-------
s-r
_L ,4,"
 24"
JL
    363"
o
o
              FLOW
                         METHOD 5 TEST PORTS
                         PARTICLE SIZE TEST PORTS
                              \
                                 SAMPLE
                                 PLATFORM
                                                                           PORTS 90° APART
                                        I.D.
                                        FAN
TRAVERSE POINT
NUMBER
1
2
3
4
5
6
7
8
DISTANCE FROM
END OF PORT (Inches)
9.2
12.0
15.4
20.3
33.7
38.6
42.0
44.8
                                     Figure 4-4
                              Outlet Sampling Location
                                AP Green Refractories

-------
       Figure  4-5
   Particle  Size  Tests
Outlet Sampling Location
 AP  Green Refractories
    Mexico,  Missouri
        -62-

-------
 4.5 Venturi Scrubber Outlet - Opacity Observations

    All  opacity observations were  performed at  the  venturi scrubber  exhaust

stack  outlet  as  shown  in  Figure  4-4.   Observations  were  taken  from  two

locations on the ground level.  Each location is  shown in  the overhead  view of

the plant Figure 4-6.  All observation locations were chosen to conform to  the

guidelines of EPA Method 9.  Table 4-1 describes each observer  location.


                                  TABLE 4-1

                    VISIBLE EMISSIONS OBSERVATION  LOCATIONS
                         AP GREEN REFRACTORIES COMPANY
                        VENTORI SCRUBBER OUTLET STACK
                               MEXICO,  MISSOURI
Observer"
Location
OL-1
OL-2
Direction From
Discharge Point
Northeast
North-Northeast
Distance From
Discharge point
(feet)
1000
600
Height Above
Ground (ft. )
0
0
4.6 Rotary Calciner Inlet Transfer Point

    Grab  samples  and  fugitive  emissions  observations   were   taken  at  the

transfer point where the raw material  leaves  the  conveyor  belt  and enters the

rotary calciner hopper.  Figure  4-7  shows  the location where the  raw material

grab samples were taken.  The fugitive emissions observer location is shown in

Figure 4-8.



4.7 Rotary Cooler Outlet Transfer Point

    Grab  samples  were taken  from  the rotary  cooler  collection  pit.   The

collection pit lies directly below the outlet  of the  rotary cooler.
                                     -63-

-------
                     itti i itrrn ittrn 1111111111111111111111 ittiTi 1111 n 111111 \ i n 111111 n 111111
                                    MATERIALS BUILDING
                MATERIALS
                BUILDING
                          ROADWAY
-p-
I
N
\RGE

ROTARY
COOLER

1
1
1
u_
1
1

ROTARY KILN
CALCINER

      AREA
                       KILN
                      CONTROL
                     BUILDING
                                 GAS OR OIL
                                   BURNERS
  KILN MATERIALS
CHARGING EQUIPMENT
                                                                                    EXHAUST
                                                                                     STACK
                                                                                                   I.D.  FAN
                                                  MIST
                                                ELIMINATOR
                                                                                     VENTURI
                                                                                    SCRUBBER
                                                                                        NOTE:   DRAWING NOT TO SCALE
      mimiitiimmiiiiiiiiiiiiiiiiiiiim
       PERIMETER FENCE
                             SALVAGE  YARD
                                                         Figure  4-6
                                               Overhead  View-Rotary Kiln/Cooler
                                                    AP Green Refractories
                                                      Mexico, Missouri
                                           OC-2       OL-1

                                   OBSERVER LOCATIONS

-------
                             RAW
                          MATERIAL
                                     FEED
                                     CHUTE
     Figure 4-7
    Raw Material
Grab Sample Location
AP Green Refractories
  Mexico,  Missouri
       -65-

-------
                        STAIRWAY
        HOPPER
          TO
        ROTARY
         KILN
CONVEYOR
 FEED
CHUTE
DOORWAY
                      WINDOW
          WINDOW
                                                         OBSERVER LOCATION
                                 Figure 4-8  .
                            Overhead View-Indoor
                      Inlet  Raw Material Transfer Point
                       Fugitive  Emissions Inspection
                            AP Green Refractories
                              Mexico,  Missouri
                                     -66-

-------
 5.0 SAMPLING AND ANALYTICAL METHODS




    This section presents descriptions  of  the  sampling  and analysis procedures




 used  during  the sampling program performed at  AP Green  Refractories  Company




 Rotary   Calciner/Cooler,   in    Mexico,    Missouri   during    the    week    of




 October 17-21, 1983.




    This  sampling  program  required  that  both the  inlet  and  outlet  sampling




 locations  be  run  simultaneously  during the  particulate  matter  and  particle




 size  tests (four sampling trains running simultaneously).




    Andersen right-angle  inlet  pre-separators  and Mark III cascade  impactors




 were  used  in  general  accordance  with  manufacturer   recommended  operating




 procedures and the draft IERL guidelines.








 5.1 Preliminary Measurements




    Prior  to  the  start  of  the sampling program preliminary measurements,  of




 various sampling parameters, were  made  at   both  the  inlet  and outlet  sampling




 locations.  This preliminary work was performed  by a three-member crew  one  day




 before  the start  of  the  sampling  program.   Parameters  monitored  were   as




 follows:






    1.  Pull velocity and temperature traverse



    2.  Moisture content




    3.  C02 and 02  concentration




    4.  Particulate loadings






    The preliminary  data provided information  for  setting  up  the  sampling




nomograph   and  chosing  the  proper nozzle   size  to ensure  that  the flowrate




 through the  impactor would  be  less  than   0.75  actual  cubic feet  per minute



 (acfm).   The  particulate loadings  were determined  by   using  EPA  Method  17.
                                     -67-

-------
From the participate data  collected  during the Method 17 tests  sampling  times




were established for both  the particulate  and  particle size  tests.   One Method



17 test was performed at the inlet and outlet sampling location.








5.2 Particulate Matter Tests




    Particulate matter  sampling was  accomplished by  using  the modified  EPA




collection train,  Method  5,  described in  the  August 18, 1977  edition of  the




Federal Register.   It  is  shown  schematically in Figure  5-1  and consists of  a



nozzle, probe, filter, a flexible umbilical line, four impingers, vacuum pump,



dry gas meter, and an orifice flowmeter.   The TRC modification of the  standard




EPA Method 5 train consists of placing the umbilical tubing between  the filter




and  the impingers  when condensibles  are  not  collected.   This modification




makes  the  sampling  equipment  much   less  awkward.   Complete  sampling  train




calibrations are performed before and after every  test program.




    A nozzle (1) is attached to  a  stainless steel/glass-lined probe (2) which



is heated  to  prevent condensation.  Whatman EPM-100  fiber-glass filter paper



supported in a  4-1/2  inch  glass filter holder (3) was used  as the  collection



media.  The  filter assembly  was  enclosed in  a  heated  box  (4)  to  maintain



temperatures  ~250  F.   A thermocouple  (16) was located  inside  the  back half




of the filter holder to monitor the gas stream temperature and verify  that  the



temperature is  kept  below 270 F.  An  ice  bath containing  four  impingers  (5)




was attached to the back end of the filter by  a flexible umbilical  tube.  The




first two impingers contain distilled water, the  third  is dry, and  the fourth



contains silica gel  to remove  any remaining moisture.   Flexible  tubing (6),



vacuum  gauge  (7),  needle  valve  (8),  leakless  vacuum  pump  (9),  bypass valve




(10),  dry  gas  meter  (11),  calibrated  orifice and  inclined  manometer  (12)



complete the sampling train.  The stack velocity pressure was measured using  a
                                     -68-

-------
                                     THERMOCOUPLE
V0
                      STACK MALL
          LEGEND

 1 - NOZZLE
 2 - PROBE
 3 - FILTER HOLDER
 4 - FILTER HEATER BOX
 5 - IMPINGER ICE BATH
 6 - UMBILICAL CORD
 7 - VACUUM GAUGE
 8 - MAIN VALVE TO PUMP
 9 - PUMP
10 - BY-PASS VALVE
11 - DRY GAS METER
12 - ORIFICE AND MANOMETER
13 - PITOT TUBE AND MANOMETER
14 - STACK TEMPERATURE READOUT
15 - FLEXIBLE TUBING
16 - THERMOCOUPLE
                         FIGURE 5-1:
                                                            THERMOCOUPLE 16 .
                                              MODIFIED  EPA PARTICULATE SAMPLING TRAIN
                                                 AUGUST 18.  1977, FEDERAL REGISTER

-------
pitot  tube  and inclined manometer  (13).   The stack temperature was  monitored

by  a  thermocouple  that  was  attached  to  the   pitot   and  connected  to  a

potentiometer  (14).  A check valve was not used in the  TRC sampling  train.

  •  A  nomograph  was  used  to  quickly determine the  orifice   pressure  drop

required  for  any  pitot  velocity pressure  and stack  temperature  to maintain

isokinetic sampling  conditions.   Sampling flow was  adjusted by means  of the

bypass valve.  Before and  after  each particulate  matter test run the sampling

train was leak-checked.            °

    At the end of each test, three sample  containers  were  used as follows:


    Container 1 - Filter
                    o

    Container 2 - Acetone/deionized-distilled  water  wash  of  probe  and
                  front  half of filter.   The  probe and nozzle  are washed
                  and brushed three times.

    Container 3 - Silica gel from the fourth  impinger.


    Due  to  the high particulate  loadings  at the  inlet  location,  all nozzle,

probe, and  filter  holder  washings  were  performed  with  deionized-distilled

water  instead  of the normal acetone  rinses.   This step was taken  to prevent

possible   nozzle  or probe  plugging  that  might have occured  if acetone  was

used.  This  change was  approved by  the  EPA  task manager.  No changes were

necessary for the outlet sampling train clean-up.

    The  samples  were  transported  to TRC's  laboratory  and   the   following-

analyses  performed:


    Container 1 - Transfer  the  filter  and  any loose  particulate matter
                  from the  sample container  to  a tared  glass  weighing
                  dish desiccate  and dry  to a constant  weight.  "Report
                  results to the  nearest 0.1  mg.

    Container 2 - Transfer the acetone/deionized-distilled  water washings
                  to a tared  beaker  and evaporate to  dryness  at ambient
                  temperature  and  pressure.    Desiccate   and  dry  to  a
                  constant weight. Report  results  to  the nearest  0.1 mg•
                                    • -70-

-------
    Container 3 - Weigh silica gel  to the nearest  0.5  g.   The weight of
                  the moisture entrapped  in  the  silica gel/  along with
                  the  volume  of  moisture  which  is   condensed   in  the
                  impingers,  is used to calculate the moisture content of
                  the flue gas.
    Due  to   the   high  gas  temperature   at   the  inlet  sampling   location
     o
(>800 P)  a   stainless   steel   lined   probe  was  used.   During  the  sample

recovery procedures this probe  and nozzle assembly was  brushed  and rinsed at

least six times.

    The  outlet  sampling location  used  a glass  lined  probe.   Sample  recovery

procedures dictated that the probe and nozzle assembly  be  brushed and rinsed

at least six times.



5.3 Gas Analysis

    The  composition of  the  gas  stream at each  sampling location was  analyzed

for oxygen and  carbon  dioxide during  each test in accordance with  40  CFR 60,

EPA  Reference  Method  3.    To   make   accurate   assessment  of   the  flue' gas

composition,   redundant  Orsat analyses  were  conducted  and  validated  by. the

procedure outlined  by  Shigehara et al.*  During  each  particulate matter test

run,  a  multi-point  integrated  sample   of  flue gas  was  taken  for  Orsat

analyses.  The integrated gas sampling train used for EPA Method 3 is shown in

Figure 5-2.



5.4 Particle Size Tests

    The  particle  size distribution sampling  train is  shown  schematically in

Figure  5-3.   The  train  consists  of a  nozzle,  Andersen  right-angle  inlet
*R.T.  Shigehara,  R.M. Neulicht,  and W.S.  Smith,  'Validating  Orsat Analysis
Data From  Fossil  Fuel-Fired Units."  Stack  Sampling News  4  (2)-.21-26 (August
1976).
                                     -71-

-------
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	 ITl
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TOGGLE'
S~ VALVE
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>•









••
«•«
RIGID LEAK 	 /
PROOF BOX
                                                    NEEDLE
                                                     VALVE
FIGURE 5-2: INTEGRATED BAG SAMPLING TRAIN
                   -72-

-------
  CASCADE
  IMPACTOR
  ASSEMBLY
J
                                                   VACUUM
                                                   TUBING
                                                                        THERMOMETER
         STACK WALL   HEATED
                       PROBE
I

PITOT TUBE


               V      RITOT
                    MANOMETER
                                                 ICE  BATH
                               THERMOMET
                          ORIFICE
                            1
                                            BYPASS VALVE
                                                          VACUUM GAUGE
                                                                                           VACUUM
                                                                                            LINE
                                                                              IMPINGER  WITH
                                                                               SILICA GEL
                                                         MAIN
                                                         VALVE
                                              AIR TIGHT
                                                PUMP
                                     DRY  GAS
                                     METER
           Figure 5-3:  Particle size distribution sampling train.

-------
pre-separator, Andersen  Mark  III cascade  irapactor,  probe, flexible  umbilical


line/  impinger,  vacuum  pump,  dry  gas meter,  and orifice  flowmeter.   Reeve


Angel  934AH fiberglass substrates were used  as the sample collection media  in


the impactor.  An  ice  bath  containing an impinger assembly was interconnected


to  the probe  by a  flexible  umbilical tube.   The impinger  assembly  removed



sample stream moisture prior to  the dry gas  meter.   A vacuum  gauge,  needle


valve, leakless  vacuum pump,  bypass valve,  dry gas meter, calibrated orifice,


and inclined manometer completed the sampling train.


    Stack  temperature  was  monitored using a  thermocouple  attached to the end


of the probe.   The impactor temperature was monitored by a  specially  placed


thermocouple inserted just behind the back-up filter.


    Prior to the start of each  particle size distribution  test,  TRC performed


velocity  and  temperature measurements  at  each  of the four  sampling points.


Measurements were performed in accordance with  EPA Method  2.   The preliminary


data were used co  set  up the  isokinetic sampling rate nomograph  and to select


a nozzle diameter  that would  provide a sampling rate  through  the impactor of


less than 0.75 actual cubic feet per minute  (acfm).


    Before each  particle  size measurement  run,  the assembled  sampling  trains


were  leak  checked.  The  acceptable  leak  rate was less  than 0.02  cfm  at  5


inches of mercury vacuum.  The pre-separatoc/impactor  assembly was then placed


at  the selected  sampling  point  with  the  nozzle perpendicular  to  the  flow


streamlines.   The  assembly remained  in this  orientation  until  the  impactor

                                   o
temperature  reached  to  within  5  P  of   the  gas stream temperature.   The


assembly was  then  rotated  to place  the  nozzle parallel  (into)   to  the  flow


streamlines and  the  sample pump  turned on.   A nomograph was used  to determine


the  required  orifice  pressure  drop  for maintenance  of  isokinetic  sampling


conditions.
                                     -74-

-------
    At  the  conclusion of  the  sampling  time period,  the  sample  flow was

shut-off  and  the pre-separator/impactor  assembly was  carefully  removed from

within the  duct  and maintained in the horizontal position.  Approximately one

cubic foot of ambient  air was  then drawn  through  the  sampling  train at a rate

of about 0.1 acfm to remove any residual  moisture.  A post-test leak  check was

not performed in order  to prevent disturbance  of  the collected sample.   After

completion of  the  ambient air purge,  the pre-separator/impactor  assembly was

disconnected from  the  probe.   The nozzle  and outlet  ends were  sealed with

Parafilm*; each  assembly  was kept vertical, and  carefully transported to the

clean-up area.

    The venturi  scrubber  outlet sampling  location presented some  problems due

to the  gas streams  high  moisture content ("20  percent).   Recovery  of Test

1's cascade impactor  filters  revealed  a  saturated back-up filter.  Individual

filters  ahead   of   the back-up   filter   were  damp  but  not  saturated  with

moisture.  In an attempt  to  prevent  this  problem  from  reoccuring,  the  entire

impactor  assembly   was wrapped  with  heater  tape  (Tests   2  and  3).   Opon

inspection  of  the  cascade   impactor  filters,   from Tests   2  and  3,  it was

discovered that  this  attempt  failed.   The  effect  of  the moisture  problem on

the results is  not known at  this time.



    5.4.1  Sample Recovery

    Sample recovery was performed  near the test site in  a  motel  room.   Inert

plastic  petri  dishes  were  used  to  contain  the  sample  fractions  and  were

identified as follows:
    Container 1 -             Brushings and loose particulate matter  from
                              the nozzle,  pre-separator,  interconnecting
                              coupling, and impact inlet throat.

    Container 2 through 10 -  Individual substrates and back-up filter.
                                     -75-

-------
The   brushings   and  loose   pacticulate  from   the   nozzle,  pre-separator,




interconnecting coupling, and impactor inlet throat was deposited into a  tared




aluminum  foil square  which  was  placed  in a  petri  dish  for  handling and



desiccation.




    A  Staticmaster*  non-static brush  and small  camel hair  artist's brushes




were used for the recovery of any loose particulate.




    Individual collection substrates were  recovered using  tweezers  only.  Any




loose particulate on the collection substrate support plate,  associated  cross-




bar and gasket, and the bottom of the  preceding  support  plate was placed into




tared aluminum foil squares along with the collection  substrate.








    5.4.2  Sample Drying and Weighing




    Desiccation and weighing of  the collected samples was performed near the




site in an  air-conditioned motel room.  The motel  room  made  for  a practical




weighing  area.   A relatively  low  and  constant  humidity  could   be   easily




maintained and traffic  into and out  of the room was easily controlled and kept




to a minimum.




    A Mettler Model HIS  analytical  balance capable  of weighing to the nearest



0.1  milligram (mg) was used.   All  substrates,  aluminum  foil  squares, and



pre-separator sample weighing pans  were desiccated and  weighed to  a constant




weight at  the weighing area.  Substrates  were weighed  in sets  and uniquely




identified.




    The  recovered samples were  placed in  a  tightly  sealed  desiccator  where




they remained for at least 12 hours.  After desiccation,  the  recovered samples




were  weighed.   Tared   aluminum  foil  squares  and  the   pre-separator   sample



weighing pans  were handled  only  with tweezers.   Only one post-test weighing



was  performed.   Reported final weights were not checked  to  a constant  final
                                     -76-

-------
weight.   The  substrates  and  loose  pacticulate  matter  was placed  back into




their  respective  petri  dishes after  weighing.   The petri  dishes  were sealed




with Parafilra*  for  transporting  and storage.  Appendix  D  contains the filter




weight data performed in the field.








    5.4.3  Data Reduction




    Data reduction was performed back at TRC using  the Particle Data Reduction




System (PADRE).  The PADRE user's guide  accompanies  this  report in  Appendix J.



    Final  data reduction  and  analysis  was  performed  return from the  field.



Appendix B contains the PADRE  data summaries  used for each  test.








5.5 Plume Opacity - Venturi Scrubber Outlet




    A  certified observer  monitored  the  stack plume opacity in accordance with




SPA Reference  Method  No.  9.  Visible emissions observations  were made during



the  first  two  particulate  tests.   Due  to  adverse  weather  conditions  VE



observations could not be made during the third test.   Field data sheets are



presented in Appendix C.








5.6 Fugitive Emisions - Rotary Calciner  Inlet




       Fugitive   emissions  observations  were  made  during  the  first  two




particulate test  at  the rotary calciner  inlet  transfer point.    Again due to



the high amount of rainfall observations were not made,  on  the saturated  clay,



during the  third  test.   Observations conformed  to  the guidelines  as specified



in EPA Method 22.  Field data sheets are presented  in  Appendix C.








5.7 Feed and Product Material  - Grab Samples




    A  composite sample of approximately 8 pounds was collected at  the  inlet to




the  rotary calciner and  outlet  from the  rotary cooler  during  the  course of
                                      -77-

-------
each  particulate  matter/particle  size  test.   The  samples  were stored  and




shipped in watertight containers.




    Back at the TRC  laboratory each sample was  analyzed  for moisture content



and sieve analysis according to ANSI/ASTM C 92-76:   Standard Test Methods Por



Sieve  Analysis  And  Water Content  Of  Refractory  Materials.   A  copy of  the



method and laboratory data is included  in Appendix P.
                                     -78-

-------
6.0 QOALITY ASSURANCE


6.1 Introduction


    TRC's emission measurement quality assurance program is designed to  ensure


that sampling  and analysis work  is performed  by  qualified people  using the


proper  equipment  in accordance  with written  procedures  in order  to provide


accurate and  representative  emission data.  The  program is based  upon BPA's


Quality Assurance  Handbook  for Air  Pollution  Measurement  Systems,  Volume III


(EPA-600/4-7-027b).  Additionally, quality assurance procedures recommended in


the draft  IERL guidelines  for particle  size  distribution  measurements were


incorporated in this program.
                                                             V




6.2 Sampling Train Components


    TRC's sampling equipment,  including nozzles, pitot  tubes,  dry gas meters,


orifices,   and  thermocouples,  were  uniquely   identified  and  calibrated  in


accordance with  documented procedures  and acceptance  criteria prior  to and


after the field test program.  Calibration data for the sampling equipment are


contained in Appendix B.





6.3 Pre-Separators and Cascade Impactors - particle Size Tests


    All nozzles,  pre-separators,  interconnecting  couplings,  impactor bodies,


plates, gaskets,  and  cross-bars  were cleaned  in  an ultrasonic bath  and then


visually   checked  for   cleanliness  prior   to   shipment   to  the    field.


Additionally,  ten randomly selected  holes on  each plate were  measured  to the


nearest 0.0001  inch diameter for comparison with  design  specifications.  The


acceptance criteria  was that  the average measured  hole diameter  had  to  be


within  0.001  inch of  the  design specifications.  The  Andersen hole diameter


specifications were as follows:
                                     -79-

-------
              Plate                         Hole Diameter  - inches

                0                                   0.0636
                1                                   0.0465
                2                                   0.0360
                3                                   0.0280
                4                                   0.0210
                5                                   0.0136
                6                                   0.0100
                7                                   0.0100
Hole diameter inspection data ace contained in Appendix E.

    Prior to  shipment  to the  field,  and prior  to  and after  each test, each

component  was  sealed   with Parafilra*  to  prevent  contamination  and  sample

loss.  After each sample recovery the pre-separator, impactor  body, and  plates

were brushed and visually inspected  for  cleanliness.



6.4 Sample Collection Substrates - Particle Size Tests

    Reeve Angel 934AH glass fiber sample collection substrates were used.  TRC

did not perform the acid wash preconditioning procedure described in the draft

IERL guidelines.   The  substrates were  supplied by Andersen,  who assured TRC

that the substrates would not  require  preconditioning.

    During  impactor  assembly,   sample  recovery,  and weighing,  the substrates

were handled with laboratory tweezers.  Finger contact with the substrates was

kept to an absolute minimum.



6.5 Substrate Weighing  - Particle Size Tests

    A  Nettler  HIS  analytical  balance capable  of weighing to  the nearest 0.1

milligram  (mg)  was  used.   Before  shipment  to the  field,   the  balance  was

inspected by a Nettler  representative.

    Each morning,  while in the  field,  the  balance  was checked  using  Class S

weights traceable through the State of Connecticut quality control standard to
                                     -80-

-------
the National  Bureau of Standards  (NBS).   Three weights  -  0.100  gram, 1.000




gram, and  13.00  grams - were used along with  a  zero check.  The balance  zero




was also checked after every fifth substrate weighing to ensure  representative



measurements.  Daily  balance quality  assurance data are presented in Appendix



D.








6.6 Blank Sample - Particle Size Test




    A blank control sample was run to determine if  any  collection substrate or




pre-separator  sample  weight  change  occurred  as  a  consequence of  impactor




preparation, transportation, sample recovery, or weighing operations.



    For the  blank  run, a  pre-separator/impactor  assembly  was prepared in an



identical  manner to  those  used for  the  actual  particle  size distribution




measurement runs.   The assembly was  transported to  the  sample  site  (inlet)



where it remained until the completion of  the  normal particle size test.  The




assembly was   then  transported  back  to  the  motel  room   were  it  was  then




subjected to the normal  sample  recovery  procedures.  Collection  substrate and




pre-separator  recovery  weighings  indicated no  weight gain.    Therefore,  no.



sample  weight  bias  was   introduced   by  the  preparation,  transportation,



recovery,   or  weighing  procedures.    Further  documentation  can   be   found  in



Appendix G.








6.7 Sample Recovery




    All sample recoveries were performed by one member of the field crew whose




sole task was sample  recovery.   Sample recovery was performed  in a motel room



especially set up for filter recovery.
                                     -81-

-------
6.8 EPA Method 3



    All  Method  3  analyses were  performed in  triplicate,  with  three passes




being performed through each absorbing  bubbler  to ensure complete absorption.




Each analyzer was  leak-checked according  to  the method prior to any analysis.




Samples were analyzed immediately  upon completion  of the  sampling.
                                     -82-

-------