&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
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BUILDING
GAS OR OIL
BURNERS
MATERIALS
BUILDING
N
\RGE
I
ROTARY !
COOLER j
i
I
J
ROTARY KILN
CALCINER
KILN MATERIALS
CHARGING EQUIPMENT
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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.
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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.
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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
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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-
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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
20
10
9 :•-_- . . - : . . . -.:•:. r..^ _--_---:
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g — — — - - . - — - - — ..... — — — _
s=
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— ~ :: ; • ~ :. ~ — i r ::.:. — rr ~ r :i - : : : :
.
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8 = = = h; ^=^-=h; =!:; = = : = = = [ = = • = ;
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_: ------ - ---I"--::-.-::. --_--.. r :::::
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3 — . . _ . . - . . — . — . .
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----- — -- - - - - • - - £ —
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— — - — —
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1 / ..
•. - - - i - i : - : . ' : . ' .::--: - r . :-.._- -.-..
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, ._ -- -.. - ....._ -.,_ . _
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ions are based upon an assumed particulate density
rticulate density is 2.65 to 3.00 grams/cc.
• •-•- - - - -
...... Q . . . . f i , . .
! t 1
Ijjiy^y^y^
--- --
--E-?^-?-;;i::E;h:E?Er-:F;£ •;^NE^E = - = ---: -:
....:-•::::: L . ::..•:::.-'.—• ...: : • : : —
- • - - . . T1 :
::::.:: : : : : : Figure 2-
----•_- ~ ' ~ .."".''.' \~ ~ IIIICL dilu UUUIcL rarll
::-:::::: :::M:: Based upon Interpolate*
::::: '."•::.'."'•':".:: "." Test 1
-;
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1
Cl(
j 1
- -
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tributions E
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A: Inlet to Multiclone
/T\ • Hni-1 ^
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::::::;::::-::'::j:j3'.-::
" :; iimrnninTrrrrrrn IT
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
•_—
- --'
--
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TS
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P|:-;... ;,:,:-, -r - .-,::r;.;
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-
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: 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.
: .- .
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: "•-": 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^^
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r
x~
— .
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^^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
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r?
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Note: Particle size distributions are based upon an a
of 1 gram/cc; actual particulate density is 2.6
T "
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ed particulate density
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:: ..
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— 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-
-------
/
;
SAMPLE ^ '
IN
y
\
/
'
* — STACK TWO INCH FIBERGLASS
/— FILTER (OPTIONAL)
ITl
7"W
SAMPLE /
PROBE -'
/
QUICK f
CONNECTS I
/-FLOW METER
•
»
»
»
(OPTIONAL) / \ fj=llJ
/ \
0 0 I
n n
u u
/ 1 /\
/ » /BOX\
/ \ AIR
\ "' N^ OUT
\ "^
1 -N
, \
/ i»* 1
,' TEDLAR \
j M BAG \N
^ ^- "'
TOGGLE'
S~ VALVE
J"
>•
••
«•«
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
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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.
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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.
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