.f* ~?
r&r*
United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EMB Report 83-CDR 10
April 1 984
Air
Emission Test
Report
American Cyanamid
Company
Savannah, Georgia
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NSPS DEVELOPMENT
PARTICULATE AND PARTICLE SIZING EMISSIONS TESTING
TITANIUM DIOXIDE
SPRAY DRYER AND CALCINER SYSTEMS
AMERICAN CYANAMID COMPANY
SAVANNAH, GEORGIA
FEBRUARY 9-16, 1984
Compiled by:
ENTROPY
Post Office Box 12291
Research Triangle Park, N. C. 27709
68-02-3852
Work Assignment No. 2
EMB Project No. 81 REG 8
Task Manager
Dan Bivins
Emission Measurement Branch
Emissions Standards and Engineering Division
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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DISCLAIMER
Although the research described in this report has been funded wholly or
in part by the United States Environmental Protection Agency through
Contract 68-02-3852 to Entropy, it has not been subject to the Agency's peer
and administrative review and therefore does not necessarily reflect the
views of the Agency, and no official endorsement should be inferred.
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TABLE OF CONTENTS
LIST OF TABLES v
LIST OF FIGURES vii
1. INTRODUCTION 1-1
1.1 Background 1-1
1.2 Scope of the Project 1-1
1.3 American Cyanamid Testing Program 1-1
1.3.1 Source Applicability 1-1
1.3.2 Outline of Testing Program 1-2
1.4 Report Organization 1-2
2. SUMMARY AND DISCUSSION OF RESULTS 2-1
2.1 Introduction 2-1
2.2 Chloride Process 2-1
2.2.1 General 2-1
2.2.2 #312 Baghouse Inlet 2-1
2.2.3 #312 Baghouse Outlet 2-2
2.2.4 #322 Baghouse Outlet 2-2
2.2.5 Spray Dryers Stack 2-2
2.3 Sulfate Process . . 2-18
2.3.1 General 2-18
2.3.2 East and West I.D. Fan Outlets 2-18
2.3.3 East and West ESP Outlets 2-19
2.3.4 #2 Calciner Exhaust Stack 2-19
2.3.5 #2 Calciner Product Outlet 2-19
3. PROCESS DESCRIPTION AND OPERATION 3-1
3.1 Introduction 3-1
3.2 Pollutants/Sampling Points 3-1
3.2.1 Spray Dryers 3-1
3.2.1.1 . Particulate Mass and Particle Sizing 3-1
3.2.1.2 Visible Emissions 3-1
3.2.1.3 Feed and Product Samplers 3-1
3.2.2 Rotary Calciner #2 3-4
3.2.2.1 Particulate Mass and Particulate Sizing 3-4
3.2.2.2 Visible Emissions 3-4
(continued next page)
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ii
TABLE OP CONTENTS
(continued)
3.3 Process Description 3-4
3.3.1 Spray Dryers 3-4
3.3.2 Rotary Calclner #2 3-8
3.4 Process Conditions During Testing. . . 3-8
3.4.1 Spray Dryers 3-8
3.4.2 Rotary Calciner #2 3-10
4. SAMPLING LOCATIONS 4-1
4.1 Applicability of Sampling Sites 4-1
4.2 Chloride Process Sampling Locations 4-1
4.2.1 #312 Spray Dryer Inlet 4-1
4.2.2 #312 Settling Chamber Product Outlet . 4-1
4.2.3 #312 Baghouse Inlet 4-1
4.2.4 #312 Baghouse Product Outlet 4-4
4.2.5 #312 Baghouse Outlet 4-4
4.2.6 #322 Spray Dryer Inlet 4-4
4.2.7 #322 Baghouse Product Outlet ..... 4-4
4.2.8 #322 Baghouse Outlet 4-6
4.2.9 #312 and #322 Exhaust Stack, Particulate Sampling .... 4-6
4.2.10 #312 and #322 Exhaust Stack, Visible Emissions 4-6
4.3 Sulfate Process #2 Calciner Sampling Locations 4-9
4.3.1 #2 Calciner Inlet 4-9
4.3.2 Water Spray Cooler Outlet 4-9
4.3.3 East Side I.D. Fan Outlet 4-9
4.3.4 East Side I.D. Fan Inlet 4-9
4.3.5 West Side I.D. Fan Outlet 4-9
4.3.6 West Side I.D. Fan Inlet 4-13
4.3.7 East and West Sides ESP Outlets 4-13
4.3.8 #2 Calciner Exhaust Stack, Particulate Sampling 4-13
4.3.9 #2 Calciner Exhaust Stack, Visible Emissions 4-17
4.3.10 #2 Calciner Product Outlet 4-17
(continued next page)
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Ill
TABLE OF CONTENTS
(continued)
5. SAMPLING AND ANALYTICAL METHODS 5-1
5.1 Sampling Objectives 5-1
5.2 Particulate Emissions Testing 5-1
5.2.1 #312 Baghouse Inlet 5-1
5.2.2 #312 Baghouse Outlet 5-1
5.2.3 #322 Baghouse Outlet 5-1
5.2.4 East and West I.D. Fans Outlets 5-2
5.2.5 East and West I.D. Fans Inlets 5-2
5.2.6 East and West ESP Outlets 5-2
5.3 Sulfuric Acid Mist 5-2
5.4 Trace Metals Analysis 5-2
5.5 Sieve Analysis and Moisture Content 5-2
5.6 Plume Opacity 5-3
5.7 Fugitive Emissions 5-3
5.8 Particle Size Testing 5-3
6. QUALITY ASSURANCE 6-1
6.1 Introduction 6-1
6.2 Sampling Train Components 6-1
6.3 Preseparator and Cascade Impactors . 6-1
6.4 Sample Collection Substrates 6-1
6.5 Substrate Weighing 6-2
6.6 Sample Analysis 6-2
6.7 EPA Method 3 6-2
6.8 EPA Method 9 6-2
7. APPENDICES 7-1
7.1 Chloride Process Test Results and Example Calculations ... 1
7.1.1 #312 Spray Dryer Baghouse Inlet 2
7.1.2 #312 Spray Dryer Baghouse Outlet 25
7.1.3 #322 Spray Dryer Baghouse Outlet 39
7.1.4 #312 and #322 Spray Dryers Stack 59
(continued next page)
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IV
TABLE OF CONTENTS
(continued)
7.2 Sulfate Process #2 Calciner Test Results
and Example Calculations 63
7.2.1 #2 Calciner I.D. Fan Outlet (East) 64
7.2.2 #2 Calciner I.D. Fan Outlet (West) 84
7.2.3 #2 Calciner ESP Outlet (East) 105
7.2.4 #2 Calciner ESP Outlet (West) 108
7.2.5 #2 Calciner Stack Ill
7.3 Chloride Process Field Data 119
7.3.1 #312 Spray Dryer Baghouse Inlet 120
7.3.2 #312 Spray Dryer Baghouse Outlet 146
7.3.3 #322 Spray Dryer Baghouse Outlet 167
7.3.4 #312 and #322 Spray Dryers Stack 191
7.3.5 Visible Emissions, Method 9 205
7.4 Sulfate Process #2 Calciner Field Data 213
7.4.1 East I.D. Fan Inlet and Outlet . . . 214
7.4.2 West I.D. Fan Inlet and Outlet 235
7.4.3 #2 Calciner ESP Outlet (East) 255
7.4.4 #2 Calciner ESP Outlet (West) 264
7.4.5 #2 Calciner Stack 273
7.4.6 Visible Emissions . . . 287
7.5 Feed and Product Analytical Data 291
7.6 Sampling and Analytical Procedures 353
7.7 Calibration Data 407
7.8 Test Participants 480
7.9 Testing Protocol and Run/Sample Numbering
Cross-Reference 481
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List of Tables
Number Title Page
1-1 Test Schedule, Planned Vs. Actual 1-3
1-2 Test Log 1-4
Chloride Process
2-1 Particulate Emissions & Concentrations Summary 2-3
2-2 Collection Efficiencies Of Control Devices 2-4
Particulate Tests Summary of Results
2-3 #312 Spray Dryer Baghouse Inlet 2-5
2-4 #312 Spray Dryer Baghouse Outlet 2-6
2-5 #322 Spray Dryer Baghouse Outlet 2-7
2-6 Spray Dryers Stack 2-8
Summary of Particle Sizing Test Results
2-7 #312 Baghouse Inlet 2-9
2-8 #312 Baghouse Outlet 2-11
2-9 #322 Baghouse Outlet 2-13
Summary of Visible Emissions Observations
2-10 Spray Dryers Stack 2-15
2-11 Spray Dryers Stack 2-16
2-12 Spray Dryers Stack 2-17
Sulfate Process
2-13 Particulate Emissions and Concentrations Summary 2-20
2-14 Collection Efficiencies Of Control Devices 2-21
Particulate Tests Summary of Results
2-15 #2 Calciner, East I.D. Fan Outlet 2-22
2-16 #2 Calciner, West I.D. Fan Outlet 2-23
2-17 #2 Calciner, East ESP Outlet 2-24
2-18 #2 Calciner, West ESP Outlet 2-25
2-19 #2 Calciner Stack 2-26
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vi
List of Tables
(continued)
Number Title
Page
Summary of Particle Sizing Test Results
2-20 East I.i). Fan Outlet 2-27
2-21 West I.D. Fan Outlet 2-29
Summary of Visible Emissions Observations
2-22 #2 Calciner Stack 2-31
2-23 #2 Calciner Stack 2-32
2-24 #2 Calciner Stack . 2-33
Nitrogen Oxides (as N0ฃ) Testing Summary
2-25 #2 Calciner Stack 2-34
1 Emission Tests Conducted at American
Cyanamid Company 3-2
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vii
List of Figures
Number Title Page
1 Simplified Flow Diagram of Chloride Process 3-5
2 Simplified Flow Diagram of Sulfate Process 3-6
3 Flow Diagram for Emission Control System for
Spray Dryers 3-7
4 Flow Diagram for Emission Control System for
Rotary Calciner 3-9
4-1 Chloride Process and Sampling Points 4-2
4-2 #312 Baghouse Inlet Dimensions 4-3
4-3 #312 Baghouse Outlet Dimensions 4-5
4-4 #322 Baghouse Outlet Dimensions 4-7
4-5 Spray Dryers #312 and #322 Stack Dimensions 4-8
4-6 Sulfate Process and Sampling Points 4-10
4-7 #2 Calciner East and West Side I.D. Fan
Outlets Dimensions 4-11
4-8 #2 Calciner East I.D. Fan Inlet Dimensions 4-12
4-9 #2 Calciner West I.D. Fan Inlet Dimensions 4-14
4-10 #2 Calciner East and West ESP Outlet Dimensions 4-15
4-11 #2 Calciner Exhaust Stack Dimensions 4-16
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1-1
1. INTRODUCTION
1.1 Background. The Emission Measurement Branch (EMB) of the U.S. EPA
is directing a project designed to generate support data for a possible New
Source Performance Standards (NSPS) for calciners and dryers in the mineral
industries. Process-related emission factors are being determined from the
testing of controlled sources (for the various industries).
1.2 Scope of the Project. EMB is responsible for coordinating the
efforts of Entropy to achieve the goals of the testing program. Entropy has
been retained under EMB Contract No. 68-02-3852, Work Assignment No. 2 to
conduct testing programs at designated industrial facilities. Entropy is to
perform emission measurements at the recommended sampling locations, obtain
process feed and product samples, and, in conjunction with Research Triangle
Institute (RTI), conduct sample analyses as directed by the Industrial Studies
Branch of EPA (ISB). As directed by the Industrial Studies Branch of EPA
(ISB), Midwest Research Institute (MRI) will monitor process and operating
conditions in order to designate suitable testing conditions for the
respective processes and to provide a record of process and operational data
during the testing.
1.3 American Cyanamld Testing Program. This report covers stationary
source sampling performed at the American Cyanamid Company manufacturing plant
in Savannah, Georgia on February 9-16, 1984. Bill Trees, Chris Gingrich, and
Bill Roberts of American Cyanamid and Dan Bivins of EPA/EMB were present to
coordinate the testing. Yogesh N. Doshi and Lynda D. Carney of MRI monitored
the plant process and recorded operational data during the testing.
1.3.1 Source Applicability. American Cyanamid operates a titanium
dioxide (T102) production facility which is representative of the TiOo
pigment industry. The plant uses spray dryers and rotary calciners which are
the two most difficult processes within the industry to control. In addition,
T102 is believed to have the finest particle size distribution of materials
in the industry and, consequently, would represent "worst case" conditions.
Spray dryers are used in the chloride process to produce rutile pigment
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1-2
(used primarily in paints), while rotary calciners are used in the sulfate
process to generate rutile pigment and anatase pigment (used in the paper
industries).
Emissions from the processes are controlled by two or more types of
equipment in series. Settling chambers and baghouses are used primarily for
product recovery, while cyclones, wet electrostatic precipitators, and
scrubbers provide the additional emission control needed to meet state
requirements.
1.3.2 Outline of Testing Program. Emission measurements were performed
at the spray dryer system within the chloride process and at the calciner
system within the sulfate process. Table 1-1 provides a comparison of the
original testing plan and the actual tests performed; the testing program as
performed is outlined in Table 1-2, which provides test dates, sampling
locations, and test methods.
1.4 Report Organization. Immediately following is the "Summary of
Results" section. Appendices 7.1 and 7.2 present the complete results of
testing at the chloride and sulfate processes; field data can be found in
Appendices 7.3 and 7.4. The two processes are described in the "Process
Description and Operation" section, while Appendix 7.5 presents feed and
product analytical data. The next section, "Sampling Locations," provides a
comprehensive description and illustration for each location; "Sampling and
Analytical Procedures" follows, describing the sampling strategy used.
Descriptions of the equipment and procedures can be found in Appendix 7.6.
The final section, "Quality Assurance," notes the procedures used to ensure
the Integrity of the sampling program; Appendix 7.7 provides pertinent
calibration data. Appendix 7.8 contains a listing of the Entropy test
participants and their roles in the testing program.
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1-3
TABLE 1-1
TEST SCHEDULE
Planned Vs. Actual
Type of Sample
Number of Samples Taken
Planned Actual
Chloride Process
Spray Dryers System
#312 Spray Dryer
Spray Dryer Inlet
Settling Chamber Product Outlet
Baghouse Product Outlet
Baghouse Inlet
Baghouse Outlet
#322 Spray Dryer
Spray Dryer Inlet
Baghouse Product Outlet
Baghouse Outlet
Exhaust Stack
feed 3
product 3
product 3
particulate 3
particle size 6
particulate 3
particle size 6
feed 3
product 3
particulate 3
particle size 6
particulate 3
particle size 6
visible emissions 3
4
4
4
4
8
4
4
4
4
4
6
4
0
3
Sulfate Process
#2 Calciner System
Water Spray Cooler Outlet
#2 Rotary Calciner Inlet
East ID Fan Inlet
East ID Fan Outlet
West ID Fan Inlet
West ID Fan Outlet
East ESP Outlet
West ESP Outlet
#2 Calciner Exhaust Stack
product 3
feed 3
velocity 0
particulate 3
particle size 6
velocity 0
particulate 3
particle size 6
particulate 3
particle size 6
particulate 3
particle size 6
particulate 3
particle size 6
nitrogen oxides 3
visible emissions 3
3
3
2
3
6
2
3
6
3
0
3
0
3
0
3
3
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1-4
TABLE 1-2
TEST LOG
CHLORIDE PROCESS
Test 1, February 9, 1984
1312 Baghouse Inlet
Particulate
Particle Size
#312 Baghouse Outlet
Particulate
Particle Size
#322 Baghouse Outlet
Particulate
Particle Size
Spray Dryer Stack
Particulate
Visible Emissions
Run
Number
1
S-l-A
S-l-B
S-1-B2*
4
S-4-A
S-4-B
11:23
16:40
17:45
15:56
09:35
14:03
16:15
Finish
Time
13:31
16:41
17:46
15:57
11:44
15:12
17:00
7**
S-7-A
S-7-B
09:35
15:45
15:21
10:58
15:46
15:22
10
10
09:40
09:35
11:46
11:35
Test 2, February 11, 1984
#312 Baghouse Inlet
Particulate
Particle Size
#312 Baghouse Outlet
Particulate
Particle Size
#322 Baghouse Outlet
Particulate
Particle Size
Spray Dryer Stack
Particulate
Visible Emissions
2
S-2-A
S-2-B
5
S-5
8
S-8-A
S-8-B
11
11
09:05
12:40
13:19
09:05
09:30
09:00
10:50
11:55
09:00
09:02
10:40
12:41
13:20
12:26
13:00
10:08
10:51
11:56
12:31
11:02
* S-l-B was overloaded; S-1-B2 was performed on February 13 for replacement
** Run 7 consists of component runs 7A & 7B; refer to summary of results for
details
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1-5
TABLE 1-2
(continued)
TEST LOG
- - CHLORIDE PROCESS - -
Test 3, February 11, 1984
#312 Baghouse Inlet
Particulate
Particle Size
#312 Baghouse Outlet
Particulate
Particle Size
Particle Size QC
//322 Baghouse Outlet
Particulate
Particle Size
Spray Dryer Stack
Particulate
Visible Emissions
Run
Number
3
S-3-A*
S-3-A2*
S-3-B
6
S-6**
Bl, Rl***
9
S-9-A**
S-9-B
12
12
Start
Time
13:54
16:22
14:52
16:49
14:02
14:12
14:45
13:51
15:44
16:10
14:00
14:00
Finish
Time
15:14
16:23
14:53
16:50
16:14
17:19
15:45
14:58
15:45
16:11
16:10
14:10
Test 4, February 16, 1984
#312 Baghouse Inlet
Particulate
#312 Baghouse Outlet
Particulate
#322 Baghouse Outlet
Particulate
Spray Dryer Stack
Particulate
Visible Emissions
28 09:45 11:47
29 09:45 11:49
30 09:46 10:52
31 09:50 12:02
31 10:05 12:06
* S-3-A was overloaded; S-3-A2 was performed on February 13 for replacement.
** S-6 catch weights were negligible; S-9-A catch was overloaded; neither run
is tabulated in the results.
*** Quality Control Reactivity Run Rl and Blank Run Bl performed February 13.
(continued next page)
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1-6
TABLE 1-2
(continued)
TEST LOG
SULFATE PROCESS
Test 1, February 14, 1984 Run Start Finish
Number Time Time
92 Calciner East I.D. Fan Outlet
Particulate 13 15:55 17:04
Particle Size S-13-A* 18:01 18:06
S-13-B 18:37 18:42
#2 Calciner West I.D. Fan Outlet
Particulate 16 15:55 16:39
Particle Size S-16-A 18:34 18:39
S-16-B 19:00 19:05
#2 Calciner East ESP Outlet
Particulate 19 15:50 16:58
#2 Calciner West ESP Outlet
Particulate 22 15:50 16:54
92 Calciner Stack
Particulate 25 15:54 17:00
Visible Emissions 25 15:49 16:49
Nitrogen Oxides 25 A-D 15:56 16:56
Test 2, February 15, 1984
#2 Calciner East I.D. Fan Outlet
Particulate 14 09:35 12:04
Particle Size S-14-A 16:14 16:29
S-14-B 17:00 17:15
#2 Calciner East I.D. Fan Inlet
Velocity Traverse V-14 13:05 13:45
#2 Calciner West I.D. Fan Outlet
Particulate 17 11:15 12:00
Particle Size S-17-A 16:00 16:15
S-17-B 16:55 17:20
$2 Calciner West I.D. Fan Inlet
Velocity Traverse V-17 12:30 13:00
* S-13-A was overloaded; therefore no results were tabulated.
(continued next page)
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1-7
TABLE 1-2
(continued)
TEST LOG
SULFATE PROCESS
Test 2, February 15, 1984 Run Start Finish
Number Time Time
#2 Calciner East ESP Outlet
Participate 20 09:40 10:48
#2 Calciner West ESP Outlet
Particulate 23 09:39 10:42
#2 Calciner Stack
Particulate 26 09:39 10:56
Visible Emissions 26 09:35 10:35
Nitrogen Oxides 26 A-D 09:41 10:45
Test 3, February 15, 1984
//2 Calciner East I.D. Fan Outlet
Particulate 15 14:13 14:50
Particle Size S-15-A 17:40 17:55
S-15-B 18:25 18:40
#2 Calciner East I.D. Fan Inlet
Velocity Traverse V-15 16:00 16:30
#2 Calciner West I.D. Fan Outlet
Particulate 18 14:14 15:15
Particle Size S-18-A 17:51 18:16
S-18-B 18:40 19:05
#2 Calciner West I.D. Fan Inlet
Velocity Traverse V-18 16:40 17:15
#2 Calciner East ESP Outlet
Particulate 21 14:15 15:33
#2 Calciner West ESP Outlet
Particulate 24 14:14 16:22
#2 Calciner Stack
Particulate 27 14:17 15:34
Visible Emission 27 14:16 15:16
Nitrogen Oxides 27 A-D 14:20 15:22
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2-1
2. SUMMARY AND DISCUSSION OF RESULTS
2.1 Introduction. The testing of the two TiOฃ production systems are
treated as two distinct sets of data. Chloride process-spray dryers system
test results are discussed in Section 2.2, while the sulfate process-
it 2 calciner system testing is discussed in Section 2.3.
2.2 Chloride Process. A summary of the parciculate emissions and
concentrations at the chloride process sampling locations is presented in
Table 2-1; efficiencies of the control devices are summarized in Table 2-2.
Run-by-run data summaries of the particulate testing are provided by location
in Tables 2-3 to 2-6; particle sizing data is tabulated in Tables 2-7
to 2-9. The average plume opacity was 9% (results for tests 1, 2, and 4 were
6%, 15%, and 5%, respectively); refer to Tables 2-10 to 2-12 for the
tabulated results.
2.2.1 General. The results presented in Table 2-2 are reasonably
consistent considering the nature of the process and the control equipment.
Some of the variability in the data is probably due to variations in the
production loads on the two spray dryers. It is recommended that the
production data presented in Section 3 be reviewed in conjunction with the
test results.
The original test plan scheduled three test sets. However, a fourth
test was performed because the production load during the first test set was
slightly below the minimum desired load. Only particulate and opacity
measurements were taken during the fourth test set; no particle size tests
were performed. Because initial inspection of the test site revealed that
there were no fugitive emissions, EMB and Entropy made a joint decision to
cancel the scheduled Method 22 observations.
When comparing flue gas flow rates between locations, it is important to
note the increase in excess air due to leakage through the system. Due to
leakage of excess air into the system, the flow rates increase significantly
as the flue gases approach the stack.
2.2.2 #312 Baghouse Inlet. At the #312 Baghouse Inlet, each 24-minute
test was performed such that the 24 minutes were distributed over the 120
minute outlet sampling period. The efficiency calculation therefore assumes
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2-2
that the 24-minute inlet tests are representative of the 120 minute testing
Interval. The same Is true of the efficiency data presented for the Peterson
Scrubber, I.e., the tests at the Spray Dryers Stack and at the #312 Baghouse
Outlet lasted 120 minutes, whereas the tests at the #322 Baghouse outlet
lasted 60 minutes.
The original test plan scheduled three sets of particle size runs (three
runs per set) at each location. During the sampling at the #312 Baghouse
Inlet, It was observed that runs S-l-B and S-3-A were overloaded. Two
additional runs, S-1-B2 and S-3-A2, were performed as replacements two days
after the completion of the third test set.
2.2.3 #312 Baghouse Outlet. At the #312 Baghouse Outlet, four particle
size runs were performed* Very small quantities of particulate were captured
in the impactor during those runs because the flue gas particulate
concentration was low; the catch for particle size run S-6 was negligible and
is not tabulated at all in the results. Due to the limited catch and time
constraints imposed by the plant and process operations, it appeared
impractical, if not impossible, to secure a catch which would satisfy EMB
requirements. Therefore, a joint decision was made by EMB and Entropy to
discontinue particle size testing at this location.
2.2.4 #322 Baghouse Outlet. Due to the heavy particulate loading
encountered at this location during Test 1, particulate run 7 was divided
into two components which were performed, processed, and analyzed as two
separate runs. Component run 7A was performed on 25% of the duct cross
section (one port), while component run 7B was performed on 75% of the cross
section (three ports); an equivalent run 7 was calculated from component data
using appropriate weighting parameters for averaging selected parameters,
particulate concentrations, etc. Since only the sampled duct areas of each
component run are used in the emission rates and air flow rates calculations,
the sum of component runs 7A and 7B represents the emissions and flows of the
total cross section.
Six particle size runs were performed at the #322 Baghouse Outlet;
however, run S-9-A was overloaded and is not tabulated.
2.2.5 Spray Dryers Stack. No particle size runs were performed in the
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2-3
TABLE 2-1
PARTIGULATE EMISSIONS & CONCENTRATIONS SUMMARY
Chloride Process
Test Set
2 3
Emission Rates, Ib/hr:
#312 Spray Dryer Baghouse
Inlet, Runs 1-3 & 28
Outlet, Runs 4-6 & 29
#322 Spray Dryer Baghouse
Outlet, Runs 7Eq-9 & 30
Spray Dryer Stack
Runs 10-12 & 31
1,412 1,818 2,041 2,024
0.22 0.11 0.79 0.89
507.5 506.5 480.3 357.2
8.06 8.11 8.87 5.26
Average
1,824
0.50
462.9
7.58
Concentration, Gr/DSCF:
#312 Spray Dryer Baghouse
Inlet, Runs 1-3 & 28
Outlet, Runs 4-6 & 29
#322 Spray Dryer Baghouse
Outlet, Runs 7Eq-9 & 30
Spray Dryer Stack
Runs 10-12 & 31
20.7
0.0024
24.7
0.0011
28.1
0.0077
28.8
0.0091
4.19 4.09 3.86 2.91
0.023 0.027 0.029 0.020
25.6
0.0051
3.76
0.025
Emission Rates, kg/hr;
#312 Spray Dryer Baghouse
Inlet, Runs 1-3 & 28
Outlet, Runs 4-6 & 29
#322 Spray Dryer Baghouse
Outlet, Runs 7Eq-9 & 30
Spray Dryer Stack
Runs 10-12 & 31
640.7 824.6 925.7 918.1 827.3
0.10 0.052 0.36 0.40 0.23
230.3 229.8 217.8 162.0 210.0
3.65 3.68 4.02 2.38 3.43
Concentration, mg/DSCM;
#312 Spray Dryer Baghouse
Inlet, Runs 1-3 & 28
Outlet, Runs 4-6 & 29
#322 Spray Dryer Baghouse
Outlet, Runs 7Eq-9 & 30
Spray Dryer Stack
Runs 10-12 & 31
47,336 56,437 64,202 65,855 58,458
5.59 2.54 17.7 20.7 11.63
9,583 9,350 8,822 6,662 8,604
53.1 60.7 67.0 45.6 56.6
-------
2-4
TABLE 2-2
COLLECTION EFFICIENCIES OF CONTROL DEVICES
Chloride Process
1 2 3 4 Average
//312 Spray Dryer Baghouse
Emissions Elate, Ib/hr
Inlet 1,412 1,818 2,041 2,024 1,824
Outlet 0.22 0.11 0.79 0.89 0.50
Collection Efficency, 99.98 99.99 99.96 99.96 99.97
Percent
Peterson Scrubber
Emissions Rate, Ib/hr
Inlet* 507.7 506.6 481.1 358.1 463.4
Outlet 8.06 8.11 8.87 5.26 7.58
Collection Efficiency, 98.41 98.40 98.16 98.53 98.36
Percent
* "Inlet" emissions are the sum of the #312 and #322 Baghouse Outlet
emissions rates; "Outlet" emissions are those measured at the
Spray Dryer Stack.
-------
2-5
TABLE 2-3
PARTICULATE TESTS SUMMARY OF RESULTS
Chloride Process
#312 Spray Dryer Baghouse Inlet
28
Run Date 02/09/84 02/11/84 02/11/84 02/16/84
Test Train Parameters;
Volume of Dry Gas 16.345 11.408 10.849 10.469
Sampled, SCF*
Percent Isokinetic 96.2 106.7 102.9 103.8
Stack Parameters;
Temperature, Deg. F 298 299 299 302
Air Flow Rates
SCFM*, Dry 7,966 8,599 8,485 8,205
ACFM, Wet 14,342 15,938 15,846 15,403
Method 5 Test Results;
Catch, Milligrams 21,911.2 18,233.2 19,725.8 19,524.9
Concentration,
Grains Per DSCF* 20.69 24.67 28.06 28.78
Milligrams Per DSCM 47,336 56,437 64,202 65,855
Emission Rate,
Pounds Per Hour 1,412.5 1,818.0 2,040.8 2,024.1
Kilograms Per Hour 640.7 824.6 925.7 918.1
* 68 Deg. F. - 29.92 in. Hg.
-------
2-6
TABLE 2-4
PARTICULATE TESTS SUMMARY OF RESULTS
Chloride Process
#312 Spray Dryer Baghouse Outlet
29
Run Date
Test Train Parameters:
Volume of Dry Gas
Sampled, SCF*
Percent Isokinetic
Stack Parameters:
Temperature, Deg. F
Air Flow Rates
SCFM*, Dry
ACFM, Wet
Method 5 Test Results:
Catch, Milligrams
Concentration,
Grains Per DSCF*
Milligrams Per DSCM
Emission Rate,
Pounds Per Hour
Kilograms Per Hour
02/09/84
83.379
106.7
260
10,711
17,985
13.2
0.0024
5.59
0.22
0.10
02/11/84
95.903
109.4
269
12,017
20,286
6.9
0.0011
2.54
0.11
0.052
02/11/84
96.103
110.4
271
11,936
20,282
48.2
0.0079
17.7
0.79
0.36
02/16/84
82.161
97.9
270
11,504
19,089
48.2
0.0091
20.7
0.89
0.40
* 68 Deg. F. - 29.92 in. Hg.
-------
2-7
TABLE 2-5
PARTICULATE TESTS SUMMARY OF RESULTS
Chloride Process
#322 Spray Dryer Baghouse Outlet
Run Date
Test Train Parameters;
Volume of Dry Gas
Sampled, SCF*
Percent Isoklnetic
Stack Parameters;
Temperature, Deg. F
Air Flow Rates
SCFM*, Dry
ACFM, Wet
Method 5 Test Results;
Catch, Milligrams
Concentration,
Grains Per DSCF*
Milligrams Per DSCM
Emission Rate,
Pounds Per Hour
Kilograms Per Hour
7Eq
8
106.
2060)
103.8
218
95.3
218
30
02/09/84 02/11/84 02/11/84 02/16/84
23.327(D 23.346 21.521 23.182
104.2
222
14,140(1) 14,462 14,532 14,311
21,848(1) 22,971 22,199 21,971
NA 6,181.6 5,376.9 4,373.7
4.19(3) 4.09 3.86 2.91
9,583(3) 9,350 8,822 6,662
507.5(1) 506.5 480.3 357.2
230.3(1) 229.8 217.8 162.0
* 68 Deg. F. - 29.92 in. Hg.
(D Sum of 7A and 7B
(2) Average of 7A and 7B
(3) Average weighted by flow rate (7A & 7B)
-------
2-8
TABLE 2-6
PARTICULATE TESTS SUMMARY OF RESULTS
Chloride Process
Spray Dryers Stack
10 11 12 31
Run Date
Test Train Parameters:
Volume of Dry Gas
Sampled, SCF*
Percent Isokinetic
Stack Parameters:
Temperature, Deg. F
Air Flow Rates
SCFM*. Dry
ACFM, Wet
Method 5 Test Results:
Catch, Milligrams
Concentration,
Grains Per DSCF*
Milligrams Per DSCM
Emission Rate,
Pounds Per Hour
Kilograms Per Hour
02/09/84
115.727
106.8
124
40,507
. 51,013
174.0
0.023
53.1
8.1
3.65
02/11/84
95.630
100.3
136
35,636
47,515
164.5
0.027
60.7
8.1
3.68
02/11/84
96.121
101.8
124
35,317
44,659
182.5
0.029
67.0
8.9
4.02
02/16/84
-
86.013
105.6
135
30,773
41,778
111.1
0.020
45.6
5.3
2.38
* 68 Deg. F. - 29.92 in. Hg.
-------
2-9
TABLE 2-7
SUMMARY OF PARTICLE SIZING TEST RESULTS
#312 Baghouse Inlet
SAMPLING DATA
Dace
Stare Time
Finish Time
Total Run Time, minutes
Impactor Flow Rate (1pm)
Isokinetic Ratio (%)
STACK DATA
Temperature (ฐC)
Moisture (Z)
Velocity (m/mln)
EMISSION DATA
Concentration (mg/dsm3)
Percent Recovery (PS cone./
M-5 cone.)
Cumulative X Mass less than
10 microns
Concentration less than 10 microns:
From PS runs, mg/dsrn^
From M-5 runs, mg/dsm^
Emission Rate less than 10
microns (kg/hr, from M-5 runs)
PS Run 1*
2/09,13/84
1556, 1640
1557, 1641
2
21.9
106.0
148
21.4
1,238
37,385
79.0
14.57
ins:
5,070
6,897
93.3
PS Run 2*
2/11/84
1240, 1319
1241, 1320
2
24.4
108.7
149
22.2
1,337
20,970
37.2
33.91
7,840
19,138
279.6
PS Run 3*
2/11,13/84
1452, 1649
1452, 1650
2
24.2
107.0
150
22.8
1,355
20,455
31.9
29.65
6,160
19,036
274.5
Average
___
149
22.1
1,310
26,270
49.4
26.04
6,357
15,024
215.8
PS: Particle Size Run
M-5: Method 5 Participate Run
*: Represents two component runs, A & B.
-------
2-10
PARTICLE SIZE DISTRIBUTION
COMPANY NAME American Cyanamid Company
ADDRESS Savannah. Georgia
AVERAGE OF RUNS 1. 2. 3
SAMPLING LOCATION #312 Baghouse Inlet
DATE(sJ 02/09/84,,02/-11/8VW _
DENSITY = J GM/CM
100
I
I
o
ID
K
0)
13
u
30 *
70 5
50 =
rtft.. -
30- =
3 :
8:
7;
s:
I
3 =
.'9 !
.8 '
7 -
s {
2 ""
ฉ
Q
\^f
G)
ฉ
(T)
(T>
^y
^
<
y
I T II ^ ^ I '^'^i^1'' I'lTI III1I1ITT lilllllirilll il!l III) III! IIIIIMII ITI I I I IT. 1 I 1 I I I I
2 5 10 IS 20 30 40 50 60 70 80 85 90 95 98
PERCENT OF PARTICLES LESS THAN INDICATED SIZE
-------
2-11
TABLE 2-8
SUMMARY OF PARTICLE SIZING TEST RESULTS
#312 Baghouse Outlet
SAMPLING DATA
PS Run 4*
PS Run 5
Average
Date
Start Time
Finish Time
Total Run Time, minutes
Impactor Flow Rate (1pm)
Isokinetic Ratio (Z)
STACK DATA
Temperature (ฐC)
Moisture (%)
Velocity (m/min)
EMISSION DATA
Concentration (mg/dsm^)
Percent Recovery (PS cone./
M-5 cone.)
Cumulative Z Mass less than
10 microns
Concentration less than 10 microns
From PS runs, mg/dsm^
From M-5 runs, mg/dsm^
Emission Rate less than 10
2/09/84
1403, 1615
1512, 1700
110
24.1
109.1
127
18.7
585
9.92
177.46**
83.63
8.21
4.67
0.0836
2/11/84
0930
1300
210
25.8
113.6
134
19.1
481
1.24
48.82
95.20
1.18
2.42
0.0495
131
18.9
533
5.58
113.2
89.42
4.70
3.55
0.0666
microns (kg/hr, from M-5 runs)
PS: Particle Size Run
M-5: Method 5 Particulate Run
*: Represents two component runs, A & B
**: Excessive preseparator catch
-------
2-12
PARTICLE SIZE DISTRIBUTION
COMPANY NAME American Cyanamid Company
ADDRESS Savannah,. Georgia
SAMPLING LOCATION #312 Baghouse Outlet
DATE(s) 02/Q9/84, 02/11/84
AVERAGE OF RUNS.
4, 5
DENSITY = I GM/CM
I
u
s
o
in
K
0)
u
u
70 -
50 :
no -
3O , :
f ft
9 :
j
. 9 =
ft _=
7 =
A. S
2
z
5 I
0 I
(V)
*A*
5 Z
(=)
0 3
(I
VI
0 ^
^y
10 :
ฉ
>0 (
>0 7
0 8
0 (
@.
IS 9
0 <
ฉ
1 1
IS 9
PERCENT OF PARTICLES LESS THAN INDICATED SIZE
-------
2-13
TABLE 2-9
SUMMARY OF PARTICLE SIZING TEST RESULTS
#322 Baghouse Outlet
SAMPLING DATA
Date
Start Time
Finish Time
Total Run Time, minutes
Impactor Flow Rate (1pm)
Isokinetic Ratio (Z)
STACK DATA
Temperature (ฐC)
Moisture (Z)
Velocity (m/min)
EMISSION DATA
Concentration (mg/dsm^)
Percent Recovery (PS cone./
M-5 cone.)
Cumulative Z Mass less than
10 microns
Concentration less than 10 microns:
From PS runs, mg/dsm^
From M-5 runs, mg/dsm3
Emission Rate less than 10
microns (kg/hr, from M-5 runs)
PS Run 7*
2/09/84
521, 1545
522, 1546
2
17.9
76.3
99
15.7
1,757
5,020
52.4
66.64
is:
3,270
6,386
153.5
PS Run 8*
2/11/84
1050, 1155
1051, 1156
2
13.7
81.2
104
16.8
1,031
5,860
62.7
63.67
3,650
5,953
146.3
PS Run 9*
2/11/84
1610
1611
1
12.8
93.7
104
13.6
1,017
4,838
54.8
68.76
3,326
6,066
149.8
Average
102
15.4
1,268
5,239
56.6
66.40
3,415
6,135
149.9
PS: Particle Size Run
M-5: Method 5 Particulate Run
*: Represents two component runs, A & B.
-------
2^14
PARTICLE SIZE DISTRIBUTION
COMPANY NAME American Cyanamid Company
ADDRESS Savannah,, Georgia _
SAMPLING
#322 Baghouse Outlet
027(19784.. 02/11/84
AVERAGE OF RUNS.
1, 8, 9
DENSITY = 1 GM/CM
u
i
o
in
U
N
yj
u
u
on . a
70..,,.,.=
go...- .. =
40 ^
30- :
10
93
3 "
:
4 =
9 :
o a
7 -
2 ..."
z
a
!> I
0 1
r
M
5 2
ฉ
o :
0 <
)
tiiiiin
10 !
(^
V!
mi in
iO (
ฎ.
Illl III!
iO 7
ฉ.
)
limn 1 1
0 S
Illl
0 {
1 1 1 1
15 9
Illl
0 <
1 1
IS 9
PERCENT OF PARTICLES LESS THAN INDICATED SIZE
-------
2-15
TABLE 2-10
AMERICAN CYANAMID COMPANY
SUMMARY OF VISIBLE EMISSIONS OBSERVATIONS
SPRAY DRYERS STACK
Date: 2/09/84
Run Number: 10
Highest 6 Minute Average Opacity, Z: 7.50
Highest Single Opacity Reading, Z: 10
Set
No.
1
2
3
4
5
6
7
8
9
10
Time
Start
0935
0941
0947
0953
0959
1005
1011
1017
1023
1029
End
0941
0947
0953
0959
1005
1011
1017
1023
1029
1035
Avg. %
Opacity
5.00
5.21
5.63
5.00
5.42
5.21
4.58
6.04
6.67
5.63
Set
No.
11
12
13
14
15
16
17
18
19
20
Time
Start
1035
1041
1047
1053
1059
1105
1111
1117
1123
1129
End
1041
1047
1053
1059
1105
1111
1117
1123
1129
1135
Avg. %
Opacity
5.00
5.63
6.04
5.21
5.63
4.58
6.67
5.63
7.50
5.00
-------
2-16
TABLE 2-11
AMERICAN CYANAMID COMPANY
SUMMARY OF VISIBLE EMISSIONS OBSERVATIONS
SPRAY DRYERS STACK
Date: 2/11/84
Run Number: 11
Highest 6 Minute Average Opacity, %: 19.4
Highest Single Opacity Reading, %: 25
Set
No.
1
2
3
4
5
6
7
8
9
10
Time
Start
0902
0908
0914
0920
0926
0932
0938
0944
0950
0956
End
0908
0914
0920
0926
0932
0938
0944
0950
0956
1002
Avg. %
Opacity
12.3
12.3
13.3
16.7
14.8
17.9
18.3
19.4
19.4
17.1
Set
No.
11
12
13
14
15
16
17
18
19
20
Time
Start
1002
1008
1014
1020
1026
1032
1038
1044
1050
1056
End
1008
1014
1020
1026
1032
1038
1044
1050
1056
1062
Avg. %
Opacity
16.9
14.8
15.2
15.0
14.0
12.9
14.2
12.5
11.9
13.5
-------
2-17
TABLE 2-12
AMERICAN CYANAMID COMPANY
SUMMARY OF VISIBLE EMISSIONS OBSERVATIONS
SPRAY DRYERS STACK
Date: 2/16/84
Run Number: 31
Highest 6 Minute Average Opacity, %: 6.46
Highest Single Opacity Reading, %: 15
Set
No.
1
2
3
4
5
6
7
8
9
10
Time
Start
1005
1011
1017
1023
1029
1035
1041
1047
1053
1059
End
1011
1017
1023
1029
1035
1041
1047
1053
1059
1105
Avg. %
Opacity
6.46
6.04
10.0
4.17
4.38
1.46
2.08
2.92
5.00
4.17
Set
No.
11
12
13
14
15
16
17
18
19
20
Time
Start
1105
1111
1117
1123
1129
1135
1141
1147
1153
1159
End
1111
1117
1123
1129
1135
1141
1147
1153
1159
1205
Avg. Z
Opacity
5.00
5.00
4.58
4.79
3.75
3.54
3.13
2.92
2.71
3.54
-------
2-18
Spray Dryers Stack due to the presence of water droplets in the flue gas.
Method 9 was not performed because of cloudy weather conditions.
2.3 Sulfate Process. A summary of the particulate emissions and
concentrations at the sulfate process sampling locations is presented in
Table 2-13; efficiencies of the control devices are summarized in Table 2-14.
Run-by-run data summaries of the particulate and sulfate testing are provided
by location in Tables 2-15 to 2-19; particle sizing data is tabulated in
Tables 2-20 and 2-21. Nitrogen oxides as NC>2 concentrations at the #2
Calciner Stack, although essentially zero, averaged 2.3 ppm dry for the three
runs. Nitrogen oxides results for each run are included in Table 2-21.
Average plume opacity readings during the three tests were zero; refer to
Appendix 7.4.6 for the field data.
\
2.3.1 General. As shown in Table 2-13 there is some variability in the
test results from one test set to the next. Uncontrolled variables which
could have affected the testing and influenced the test results include
changes in the process operations during the testing, fluctuations in the
performance of the control equipment, and particulate and gas flow pattern
oscillations resulting from the lack of straight run at the sampling locations
(only the stack had enough straight run to satisfy Method 1 requirements).
Due to the potential for variability, the average results of the three runs at
a given location is more reliable and should be used wherever possible.
When comparing flue gas flow rates between locations, it is important to
note the increase in excess air due to leakage through the system. There is,
in fact, an ambient air vent between the precipitator outlets and the scrubber
which is designed to allow excess air into the gas stream. Due to the
introduction of excess air into the system, the flow rates increase
significantly as the flue gases approach the stack.
Plans to perform Method 22 were abandoned when initial observation
revealed that emissions were steam rather than product. Consequently, no
Method 22 results are presented.
2.3.2 East and West I.D. Fan Outlets. At both the East and West I.D.
Fan Outlets, extremely poor flue gas flow patterns were encountered. Of
the 24 points in each duct, 12 showed a positive flow, and 12 showed a
-------
2-19
negative flow. For this reason, after the first test set (runs 13 and 16),
additional flue gas velocities and flow rates were measured upstream of the
1.0. fans (East and West I.D. Fan Inlets) at locations which provided more
stable flow patterns; the flow rates measured upstream of the fans were used
to calculate the particulate emissions rate. The participate concentrations
were still measured at the I.D. Fan Outlets by sampling only the positive
flow points. The decision to continue sampling at the I.D. fan outlets was
justified by assuming that the majority of the particles were less than ten
microns in size and that the minute particles would tend to behave like
gases, minimizing the importance of isoklnetics and stable flow patterns.
Particle size distribution data from these locations does indicate mass
median diameters of less than ten microns.
Six particle size runs were performed at each of the I.D. Fan Outlets.
Run S-13-A, performed on the East Side, was underloaded and therefore was not
presented in the summary of results section. All six particle size runs
performed at the West Side I.D. Fan Outlet are presented.
2.3.3 East and West ESP Outlets. No major problems were encountered at
the ESP outlets although the flow patterns were somewhat erratic. Particle
sizing was not performed at the ESP outlets because of the presence of water
droplets in the flue gas.
Method 3 was not performed for particulate runs 19 and 22 at the East
and West ESP outlets, respectively. Flue gas composition data from
subsequent runs at the respective locations was used for calculation
purposes: data from run 20 was used for run 19, while data from run 23 was
used for run 22.
2.3.4 #2 Calciner Exhaust Stack. Particle sizing was not performed at
the #2 Calciner Exhaust Stack because of the presence of water droplets in
the flue gas.
2.3.5 #2 Calciner Product Outlet. The performance of Method 22 was
abandoned when the observers determined that the fugitive emissions were
steam rather than product.
-------
2-20
TABLE 2-13
PARTICIPATE EMISSIONS & CONCENTRATIONS SUMMARY
Sulfate Process
Emission Rates, Ib/hr;
#2 Calciner Stack
Runs 25-27
Test Set
1 2
Average
I.D. Fan Outlet
East, Runs 13-15
West, Runs 16-18
ESP Outlet
East, Runs 19-21
West, Runs 22-24
#2 Calciner Stack
Runs 25-27
Emission Rates, kg/hi:
I.D. Fan Outlet
East, Runs 13-15
West, Runs 16-18
ESP Outlet
East, Runs 19-21
West, Runs 22-24
#2 Calciner Stack
Runs 25-27
Concentration, Gr/DSCF:
I.D. Fan Outlet
East, Runs 13-15
West, Runs 16-18
ESP Outlet
East, Runs 19-21
West, Runs 22-24
#2 Calciner Stack
Runs 25-27
Concentration, mg/DSCM:
I.D. Fan Outlet
East, Runs 13-15
West, Runs 16-18
ESP Outlet
East, Runs 19-2.1
West, Runs 22-24
181.2
98.5
4.80
3.82
2.13
146.7
33.2
2.18
1.73
0.87
1.956
1.504
0.0411
0.0402
0.0057
4,474.5
3,440.2
94.1
92.0
283.8
113.1
9.42
3.73
0.43
239.6
33.7
4.27
1.69
0.19
2.989
1.810
0.0739
0.0405
0.0011
6,839.8
4,141.9
169.0
92.7
270.4
144.7
4.28
4.20
1.01
206.2
39.1
1.94
1.90
0.46
2.993
2.112
0.0451
0.0448
0.0026
6,847.7
4,832.7
103.1
102.5
245.1
118.8
6.17
3.92
1.19
197.5
35.3
2.80
1.77
0.51
2.646
1.809
0.0534
0.0418
0.0031
6,720.6
4,138.3
122.1
95.7
0.87
0.19
0.46
0.51
-------
2-21
TABLE 2-14
COLLECTION EFFICIENCIES OF CONTROL DEVICES
Sulfate Process
Test Set
1 2 3 Average
Peterson Scrubber
Emissions Rate, Ib/hr
Inlet* 8.62 13.15 8.48 10.08
Stack 2.13 0.43 1.01 1.19
Collection Efficiency, 75.29 96.73 88.09 86.7
Percent
"Inlet" emissions are the sum of the East and West ESP Outlet
emissions; "Stack" emissions are .the #2 Calciner Stack emissions.
-------
2-22
\
TABLE 2-15
PARTICOLATE TESTS SUMMARY OF RESULTS
Sulfate Process
//2 Calciner, East I.D. Fan Outlet
13
14
15
Run Date
Test Train Parameters;
Volume of Dry Gas
Sampled, SCF*
Percent Isokinetic
Stack Parameters;
Temperature, Deg. F
Air Flow Rates**
SCFM*, Dry
ACFM, Wet
Method 5 Test Results;
Catch, Milligrams
Concentration,
Grains Per DSCF*
Milligrams Per DSCM
Emission Rate,
Pounds Per Hour
Kilograms Per Hour
02/14/84 02/14/84 02/14/84
19.512
95.7
603
10,809
30,684
2,472.5
181.2
146.7
20.785
95.4
598
11,078
31,517
4,026.1
283.8
139.6
11.396
87.4
560
10,539
29,850
2,210.0
1.956 2.989 2.993
4,474.5 6,839.8 6,847.7
270.4
206.2
* 68 Deg. F. - 29.92 in. Hg.
** Air flow rates are taken from velocity traverses performed at the #2
Calciner East I.D. Fan Inlet after Run 14 and Run 15; the average of
the air flows from Run 14 and Run 15 were used for Run 13.
-------
2-23
TABLE 2-16
PARTICULATE TESTS SUMMARY OF RESULTS
Sulfate Process
ฃ2 Calciner, West I.D. Fan Outlet
16
17
18
Run Date
Test Train Parameters;
Volume of Dry Gas
Sampled, SCF*
Percent Isokinetic
Stack Parameters;
Temperature, Deg. F
Air Flow Rates**
SCFM*, Dry
ACFM, Wet
Method 5 Test Results;
Catch, Milligrams
Concentration,
Grains Per DSCF*
Milligrams Per DSCM
Emission Rate,
Pounds Per Hour
Kilograms Per Hour
02/14/84 02/15/84 02/15/84
14.415
93.1
523
1,404.4
98.5
33.2
12.470
95.5
480
1,462.7
113.1
33.7
12.748
98.2
482
7,641
20,219
7,289
19,295
7,992
21,143
1,744.7
1.504 1.810 2.112
3,440.2 4,141.9 4,832.7
144.7
39.1
* 68 Deg. F. - 29.92 in. Hg.
** Air flow rates are taken from velocity traverses performed at the #2
Calciner West I.D. Fan Inlet after Run 17 and Run 18; the average of
the air flows from Run 17 and Run 18 were used for Run 16.
-------
2-24
TABLE 2-17
PARTIGULATE TESTS SUMMARY OF RESULTS
Sulfate Process
#2 Calciner, East ESP Outlet
Run Date
Test Train Parameters;
Volume of Dry Gas
Sampled, SCF*
Percent Isoklnetlc
Stack Parameters;
Temperature, Deg. F
Air Flow Rates
19
20
39.407
100.4
150
44.150
103.0
150
21
02/14/84 02/15/84 02/15/84
32.909
103.0
148
SCFM*, Dry
ACFM, Wet
Method 5 Test Results:
Catch, Milligrams
Concentration,
Grains Per DSCF*
Milligrams Per DSCM
Emission Rate,
Pounds Per Hour
Kilograms Per Hour
13,623
20,282
105.0
0.0411
94.1
4.80
2.18
14,873
22,934
211.3
0.0739
169.0
9.42
4.27
11,081
16,742
96.1
0.0451
103.1
4.28
1.94
* 68 Deg. F. - 29.92 in. Hg.
-------
2-25
TABLE 2-18
PARTICULATE TESTS SUMMARY OP RESULTS
Sulfate Process
#2 Calciner, West ESP Outlet
Run Date
Test Train Parameters;
Volume of Dry Gas
Sampled, SCF*
Percent Isokinetic
Stack Parameters;
Temperature, Deg. F
Air Flow Rates
22
23
53.241
99.2
137
52.246
100.4
131
24
02/14/84 02/15/84 02/15/84
52.063
98.3
130
SCFM*, Dry
ACFM, Wet
Method 5 Test Results:
Catch, Milligrams
Concentration,
Grains Per DSCF*
Milligrams Per DSCM
Emission Rate,
Pounds Per Hour
Kilograms Per Hour
11,071
14,949
138.7
0.0402
92.0
3.82
1.73
10,740
14,200
137.1
0.0405
92.7
3.73
1.69
10,932
14,362
151.1
0.0448
102.5
4.20
1.90
* 68 Deg. F. - 29.92 in. Hg,
-------
2-26
TABLE 2-19
PARTICULATE TESTS SUMMARY OF RESULTS
Sulfate Process
#2 Calciner Stack
25
Run Date 02/14/84
Test Train Parameters;
Volume of Dry Gas 71.033
Sampled, SCF*
Percent Isokinetic 105.4
Stack Parameters;
Temperature,, Deg. F 132
Air Flow Rates
SCFM*, Dry 43,650
ACFM, Wet 55,030
Method 5 Test Results;
Catch, Milligrams 26.2
Concentration,
Grains Per DSCF*
Milligrams Per DSCM
Emission Rate,
Pounds Per Hour
Kilograms Pe:r Hour
Total Sulfates as H2S04;
Catch, Micrograms 5,121
Concentration,
Grains Per DSCF* 0.00111
Milligrams Per DSCM 2.55
Emission Rate,
Pounds Peir E!our 0.416
Kilograms Per Hour 0.189
* 68 Deg. F. - 29.9.2 in. Hg.
26
02/14/84
91.275
108.7
128
43,421
55,066
6.8
6,248
0.0011
2.41
0.393
0.178
27
02/14/84
91.218
105.5
132
44,748
55,426
15.6
0.0057
11.7
2.13
0.87
0.0011
2.63
0.43
0.19
0.0026
6.04
1.01
0.46
4,902
0.000829
1.90
0.318
0.144
-------
2-27
TABLE 2-20
SUMMARY OF PARTICLE SIZING TEST RESULTS
East I.D. Fan Outlet
SAMPLING DATA
Date
Start Time
Finish Time
Total Run Time, minutes
Impactor Flow Rate (1pm)
Isokinetic Ratio (Z)
STACK DATA
Temperature (ฐC)
Moisture (Z)
Velocity (m/min)
EMISSION DATA
Concentration (mg/dsm^)
Percent Recovery (PS cone./
M-5 cone.)
Cumulative Z Mass less than
10 microns
Concentration less than 10 microns:
From PS runs, mg/dsm^
From M-5 runs, mg/dsm^
Emission Rate less than 10
microns (kg/hr, from M-5 runs)
PS: Particle Size Run
M-5: Method 5 Particulate Run
*: Represents two component runs, A & B.
PS Run 13
2/14/84
1837
1842
5
20.5
97.6
319
22.2
1,293
952.1
21.3
55.46
is:
528.9
2,482
81.4
PS Run 14*
2/15/84
1614, 1700
1629, 1715
30
21.5
97.2
311
24.2
1,017
1,060
15.5
57.64
553.0
3,943
80.5
PS Run 15*
2/15/84
1740, 1825
1755, 1840
30
20.9
94.3
312
23.3
1,015
1,795
26.2
80.08
1,440
5,484
165.1
Average
314
23.2
1,108
1,269
21.0
64.39
840.6
3,970
109.0
-------
2-28
PARTICLE SIZE DISTRIBUTION
COMPANY NAME _ American Cyanamid Company
ADDRESS Savannah, Georgia _
SAMPLING LQgATioisi #2 Calciner East I. 'P. Fan Outlet
PATE(S> 02/14/84, 02/15/84 _
AVERAGE OF RUNS.
, 14, 15
DENSITY = I CM/CM
ง
8
u
o
in
3
(0
u
u
70.,.. =
50.. '
1
I o
5 "
3s
A "
9 a
a ... a
7 5
3
2
. I
(1
V-
ฎ
(7\
vi'
ฉ
^
V
G)
\*)
c
\l
I I I I I I I I I I I I I '
5 10 15 20 30 40 50 60 70 80 85 90 95 98
PERCENT OF PARTICLES LESS THAN INDICATED SIZE
-------
2-29
TABLE 2-21
SUMMARY OF PARTICLE SIZING TEST RESULTS
West I.D. Fan Outlet
SAMPLING DATA
Date
Start Time
Finish Time
Total Run Time, minutes
Impactor Flow Rate (1pm)
Isokinetic Ratio (Z)
STACK DATA
Temperature (ฐC)
Moisture (Z)
Velocity (m/min)
EMISSION DATA
Concentration (mg/dsm^)
Percent Recovery (PS cone./
M-5 cone.)
Cumulative Z Mass less than
10 microns
Concentration less than 10 microns:
From PS runs, mg/dsm^
From M-5 runs, mg/dsm^
Emission Rate less than 10
microns (kg/hr, from M-5 runs)
PS: Particle Size Run
M-5: Method 5 Particulate Run
*: Represents two component runs, A & B.
PS Run 16*
2/14/84
1834, 1900
1839, 1905
10
16.8
96.3
273
18.3
279.8
598.1
17.4
60.88
>ns:
370
2,094
20.2
PS Run 17*
2/15/84
1600, 1655
1615, 1720
40
10.6
87.9
260
18.1
246.9
321.5
7.76
72.08
231
2,986
24.3
PS Run 18*
2/15/84
1751, 1840
1816, 1905
50
11.4
94.6
259
20.2
248.7
656.4
13.6
71.29
492
3,445
27.9
Average
_
264
18.9
258.5
525.3
12.9
68.08
364
2,842
24.1
-------
2-30
PARTICLE SIZE DISTRIBUTION
COMPANY NAME American Cyanamid Company
ADDRESS Savannah Georgia
SAMPLING LOCATION #2 Calclner West I.D. Fan Outlet
DATE( s) 02/J4/84. 02/15/84
DENSITY = I GM/CM3
AVERAGE OF RUNS.
16, 17, 18
70- -;
50 -:
40 '
CO *
S :
o
5 10 "
9 l
~ 9 !
S ! i
H g :
5 3 i
ฐ 4 ^
0 :
in :
Q 3 :
H !
u :
J
o I
t 9 =
8 :
7 =
2
.1
^-'
ฉ
ฉ
P.
i)
I riii "i"""11
5 10 15 20 30 40 50 60 70 80 85 90 95 98
PERCENT OF PARTICLES LESS THAN INDICATED SIZE
-------
2-31
TABLE 2-22
AMERICAN CYANAMID COMPANY
SUMMARY OF VISIBLE EMISSIONS OBSERVATIONS
If 2 CALCINER STACK
Date: 2/14/84
Run Number: 25
Highest 6 Minute Average Opacity, Z: 0
Highest Single Opacity Reading, %: 0
Set
No.
1
2
3
4
5
6
7
8
9
10
Time
Start
1549
1555
1601
1607
1613
1619
1625
1631
1637
1643
End
1555
1601
1607
1613
1619
1625
1631
1637
1643
1649
Avg. I
Opacity
0
0
0
0
0
0
0
0
0
0
-------
2-32
TABLE 2-23
AMERICAN CYANAMID COMPANY
SUMMARY OF VISIBLE EMISSIONS OBSERVATIONS
#2 CALCINER STACK
Date: 2/15/84
Run Number: 26
Highest 6 Minute Average Opacity, %: 0
Highest Single Opacity Reading, %: 0
Set
No.
1
2
3
4
5
6
7
8
9
10
Time
Start
0935
0941
0947
0953
0959
1005
1011
1017
1023
1029
End
0941
0947
0953
0959
1005
1011
1017
1023
1029
1035
Avg. %
Opacity
0
0
0
0
0
0
0
0
0
0
-------
2-33
TABLE 2-24
AMERICAN CYANAMID COMPANY
SUMMARY OF VISIBLE EMISSIONS OBSERVATIONS
#2 CALCINER STACK
Date: 2/15/84
Run Number: 27
Highest 6 Minute Average Opacity, %: 0.42
Highest Single Opacity Reading, %: 5
Set
No.
1
2
3
4
5
6
7
8
9
10
Time
Start
1416
1422
1428
1434
1440
1446
1452
1458
1504
1510
End
1422
1428
1434
1440
1446
1452
1458
1504
1510
1516
Avg. Z
Opacity
0
0
0
0
0
0
0
0
0.42
0
-------
2-34
TABLE 2-25
NITROGEN OXIDES (AS N02) TESTING SUMMARY
Sulfate Process
#2 Calciner Stack
Run Date
Sample Numbers
Sampling Period
Nitrogen Oxides
1
02/14/84
25A-25D
1556-1656
(as N02) Results:
&un numoers
2
02/15/84
26A-26D
0941-1045
3
02/15/84
27A-27D
1420-1522
Concentration, ppm, dry
2.1
1.9
2.9
-------
3-1
3. PROCESS DESCRIPTION AND OPERATION /
3.1 Introduction. Source emission tests were conducted on Spray
Dryer #312, Spray Dryer #322, and Rotary Calciner #2 at the American Cyanamid
Company, Savannah, Georgia from February 8 through 16, 1984; Table 1
tabulates the tests performed. The tests were conducted by Entropy
Environmentalists, Inc. (Entropy) test crew, headed by Mr. Frank Phoenix.
The process was monitored by Mr. Yogesh Doshi and Ms. Lynda Carney of Midwest
Research Institute (MRI). Mr. William Trees of American Cyanamid coordinated
testing with plant personnel and provided process information. Mr. Dan
Blvins of EPA's Emissions Measurement Branch (EMB) was present during testing
to observe emission testing procedures.
3.2 Pollutants/Sampling Points.
3.2.1 Spray Dryers. Four tests on Spray Dryer #312 and Spray Dryer
#322 were completed at the following locations:
3.2.1.1 Particulate Mass and Particle Size. Particulate mass
determinations were performed at the inlet and outlet of the #312 Baghouse,
the outlet of the #322 Baghouse, and at the Peterson Scrubber Stack.
Particle size determinations were performed at the inlet and outlet of the
#312 Baghouse and the outlet of the #322 Baghouse during runs 1,2, and 3.
Particle size determinations were not performed at the Peterson Scrubber
Stack because of the: large amount of water vapor in the gas stream. Entropy
and EMB personnel decided not to perform particle size runs simultaneously
with mass runs because of the complexity of the test program.
3.2.1.2 Visible Emissions. Visible emission observations were made at
the Peterson Scrubber Exhaust Stack throughout runs 1 and 4. Opacity
readings could not be made during runs 2 and 3 because of overcast sky
conditions. Because: the spray dryer process inlet and outlet were totally
enclosed, no process fugitive emission observations were taken.
3.2.1.3 Feed and Product Samples. Feed samples were collected at the
inlets to both spray dryers for particle size and moisture analysis. Product
samples from the settling chamber of the #312 Spray Dryer and from the
-------
3-2
TABLE 1. EMISSION TESTS CONDUCTED AT AMERICAN CYANAMID COMPANY
Sampling point
Test type
Test method
Spray Dryers
No. 312 spray dryer feed inlet
No. 312 settling chamber product
oulet
No. 312 baghouse inlet
No. 312 baghouse outlet
No. 312 baghouse product outlet
No. 322 spray dryer feed inlet
No. 322 baghouse outlet
No. 322 baghouse product outlet
Petersen scrubber exhaust stack
Rotary Calciner No. 2
Rotary calciner feed inlet
Rotary calciner product outlet
East conditioning tower inlet
West conditioning tower inlet
Moisture content
Particle size sieve
Moisture content
Particle size sieve
Particulate concentration
Particle size
Particulate concentration
Particle size
Moisture content
Particle size sieve
Moisture content
Particle size sieve
Particulate concentration
Particle size
Moisture content
Particle size sieve
Visible emissions
Particulate concentration
Moisture content
Particle size sieve
Moisture content
Particle size sieve
Particulate concentrations
Particle size
Particulate concentration
Particle size
ASTM-D422
ASTM-02216
ASTM-D422
ASTM-D2216
EPA-5
EPA Draft
Method
EPA-5
EPA Draft
Method
ASTM-0422
ASTM-02216
ASTM-0422
ASTM-D2216
EPA-5
EPA Draft
Method
ASTM-D422
ASTM-02216
EPA-9
EPA-5
ASTM-0422
ASTM-02216
ASTM-D422
ASTM-02216
EPA-5
EPA Draft
Method
EPA-5
EPA Draft
Method
(continued)
-------
3-3
TABLE 1. (continued)
Sampling point
Test type
Test method
East wet ESP outlet
West wet ESP outlet
Peterson scrubber exhaust stack
Particulate concentration
Particulate concentration
Visible emissions
Particulate concentration
Acid mist
NO
Rotary Direct Dryer' (Chloride.ore dryer)
Rotary direct dryer feed inlet
Rotary direct dryer outlet
Moisture content
Particle size sieve
Moisture content
Particle size sieve
Steam-Tube Rotary Dryer (Sulfate ore dryer)
Steam-tube rotary dryer feed
inlet
Steam-tube rotary dryer
outlet
Tunnel Dryer (Sulfate process)
Rotary direct dryer feed inlet
Rotary direct dryer outlet
Moisture content
Particle size sieve
Moisture content
Particle size sieve
Moisture content
Particle size sieve
Moisture content
Particle size sieve
EPA-5
EPA-5
EPA-9
EPA-5
EPA-8
EPA-7
ASTM-D422
ASTM-D2216
ASTM-0422
ASTM-02216
ASTM-0422
ASTM-D2216
ASTM-0422
ASTM-D2216
ASTM-0422
ASTM-02216
ASTM-0422
ASTM-02216
Grab samples were not collected because the unit was not operating.
American Cyanamid will send the samples by mail when the unit resumes
operation.
-------
3-4
product hoppers of Che #312 and #322 Baghouses were also collected for
particle size and moisture analysis.
3.2.2 Rotary Calciner No. 2. Tests on Rotary Calciner 92 were
completed at the following locations:
3.2.2.1 Participate Mass and Particle Size. Particulate mass and
particle size determinations were performed at the inlets to the two
conditioning towers. Entropy and EMB personnel decided not to perform
particle size runs simultaneously with mass runs because of the complexity of
the test program. Only particulate mass determinations were performed at the
outlets of the two ESP's and the outlet of the Peterson Scrubber; particle
size determinations were not possible because of the large amount of water
vapor in the gas stream. Acid mist and NOX tests were conducted at the
Peterson Scrubber Exhaust Stack. Feed and product samples were collected for
particle size and moisture analysis.
3.2.2.2 Visible Emissions. Visible emission observations were made at
the Peterson Scrubber Exhaust Stack for the duration of all three test runs.
Because feed to the calclner is In a slurry form and feed discharge point is
totally enclosed, visible emission observations were not made. Similarly,
visible emission observations were not made at the calciner discharge and
because it was totally enclosed. Only steam emissions were noticed from the
cooler.
3.3 Process Description. This plant operates continuously, except for
breakdowns, 24 hours per day and 7 days per week. Titanium dioxide (T102
pigment is produced by both the chloride process, shown in Figure 1, and the
sulfate process, shown in Figure 2. The chloride process uses two spray
dryers and one rotary direct dryer, and the sulfate process uses two rotary
calclners, two steam-tube rotary dryers, and two tunnel dryers.
3.3.1 Spray Dryers. Figure 3 is a simplified flow diagram that shows
the emission control systems for both spray dryers. The two spray dryers are
used in the chloride process. Spray Dryer #312 was manufactured by Proctor
-------
HIHEHAL
(ml lit
1(01 All If UllltCI
OIIYEli ())
SCIlEENINti
COAIINU Ullll
S OXIDES
CUKE CI2
till OH I HAM UN
SOLIDS
AEHOUAL
OIL
1
CI2 HttVClt
MULING
HAU
TIO,
COULINli AHO
SOllttS PRECIPITATION
OX I DAI ION
Hi IHAIIUN
AND
UtUATElllMU
uiiviii
in
flUII) EHEIttiY
Hiit ma
SOUIUH
AHIMIHAIL
1
PACKAGING
U)
I
U1
1. Simplified flow diagram of chloride process--
American Cyanamid Company, Savannah, Georgia.
-------
TITANIUM ^
SIAG
STEAM- TUBE-ORE
UK VI It (2)
ROTARY
CALCINER (2)
RAW
COOLEttS (2)
GRINDING
K SALTS. PHOSPHATES.
CONDITIONING AGENTS
i.
CONDITIONING
PULVERIZING,
MILLING, AND
SCREENING
STEAM
II^SO,, INJECTION
OltiESTEK
FILTRATION.
UASH1NG. AND
DEMATERING
COATING WITH
HYDROUS OXIDES
T
SODIUM ALUtilNATE
FLUCCUEANT
.1
CONCEHTKATION
2n Oil Al Oft
TI2(SOJ3
LEACHING
flETKATlON
REAGENTS
(SOMETIMES)
i NUCLEA
PRECIPITATION
FILTRATION,
WASHING, AND
DEUATEIUNG
STEAM-TUBE
BELT DRYER (2)
.V
FLUID I-IIERGY
MILLING
Flyure 2. Simplified flow diayraiu of sulfate urocess--
Aiuerlcan Cyanaiuld Company, Savannah, Georgia.
PACKAGING
-------
AMBIENT
AIR
r
FEED '
" SPRAY DRYER SETTLING BAGHOUSE 1
AIR NO. 312 CHAMBER * Bftt>mju:>t *
- - - > '
V
J 1 !
i
1 - - t
i i
i i
PETERSON
SCRUBBER
- ->
\
1
S
T
A
C
K
I <
FEED
AIR
SPRAY DRYER
NO. 322
BAGIIOUSE
1 ' BY-PASS
U)
I I
PRODUCT
PROCESS FLOW
AIR FLOW
Fiyure 3. Flow diagram for emission control system for spray dryers at
American Cyanamid Company, Savannah, Georgia.
-------
3-8
and Schwartz (P&S) and Installed in 1965, and #322 was manufactured by Bowen
and installed in 1970. The dryers have separate combustion chambers and are
fired by natural gas. The process material is dried by a cocurrent flow of
hot air.
Material entering the spray dryers is in the form of a slurry. During
the tests the dryers were processing futile titanium dioxide. Most of the
product from Spray Dryer #312 settles out in a settling chamber. The exhaust
gas from the settling chamber then goes to a baghouse. The baghouse collects
most of the remaining dried product. All of the product from Spray Dryer
#322 is collected in a baghouse. The exhaust gas from both spray dryer
baghouses is manifolded to one high energy Peterson Scrubber.
There is a fresh air inlet in the Spray Dryer #312 system duct going to
the Peterson Scrubber. This duct also contains water sprays to improve the
particulate collection efficiency of the Peterson Scrubber.
3.3.2 Rotary Calciner No. 2. A simplified flow diagram that shows the
emission control systems for the rotary calciner is shown in Figure 4.
Rotary Calciner #2 was manufactured by Vulcan. The calciner has a separate
combustion chamber and is fired -by natural gas. The feed material is
titanium hydrosylate slurry, which is calcined by a counter-current stream of
hot air to form titanium dioxide crystals.
Particulate emissions from the calciner are controlled by two
conditioning towers (low-energy packed towers) in parallel, two wet ESP's in
parallel, and a Peterson Scrubber (high energy scrubber). The primary
purpose of the conditioning towers is to keep the wet ESP inlet gas
temperature less than 71 degrees Celsius (160 degrees Fahrenheit). The two
wet ESP's are used is the primarily for the control of acid mist emissions.
The Peterson Scrubber is the secondary control device for particulate
emissions and operates at a pressure drop of 5.5 kPA (22 to 30 in. w.c.).
3.4 Process Conditions During Testing
3.4.1 Spray Dryers. The operation of Spray Dryer #312 and Spray
Dryer #322 was monitored from a control panel that regulated the feed rates
and inlet and outlet air temperatures of the dryers. Fuel consumption for
-------
CONDITIONING
TOWER
WET ESP
PRODUCT
TO COOLER
4
"AIR *"
ROTARY
CALCINER
/
i
j ~ "
1 '
i
1=1 FEED
CONDITIONING
TOWER
WET ESP
\
PETERSON
SCRUBBER
S
T
A
C
K
OJ
vo
Figure 4. Flow diagram for emission control system for rotary calciner at
American Cyanamid Company, Savannah, Georgia.
-------
3-10
both dryers was monitored by natural gas meters. MR I recorded the process
data during the spray dryer tests. Air temperature and fuel usage were
consistent and Indicated steady state process operations during the test
runs. The baghouse compartment pressure drops for Spray Dryer #312 were
monitored from a control panel, and pressure drops for the baghouse on Spray
Dryer #322 were monitored from outside gauges. The Peterson Scrubber was
monitored by reading both the pressure drop across the scrubber and candle
column (similar to venturl scrubber throat) and the recirculation pump
pressure (only one of two pressure gauges was working). The Peterson
Scrubber and baghouse pressure drops were within normal plant operating
ranges. Water flow rates and pressure drops were constant. The packaging
rates provided by American Cyanamld will not be used as exact production
rates, since they are estimates. Exact production rates will be calculated
from feed analysis data. Percent capacity utilization will also be
calculated. The exact production rates and precent capacity utilization is
considered confidential by American Cyanamld.
Soon after run 1 was completed, Spray Dryer #322 was shut down to repair
a squeaking bearing in the fan. It was found that the feed meter for Spray
Dryer #322 was not functioning as the feed meter reading was the same after
the dryer stopped operating as it had been during normal operation. Also,
the natural gas consumption rate was 20 percent less than that during runs
2 and 3. Because of these observations, it was decided to conduct an
additional test run. The problem with the feed meter was corrected prior to
test runs 2, 3, and 4.
During run 2, the feed mechanism of the #312 Spray Dryer automatically
shut down for no apparent reason. At this point, testing was discontinued.
Plant personnel started the unit up again in 10 minutes, and within 1 hour,
the process achieved a steady state. Testing was then resumed. During run
4, particle sizing was not done because it was decided that the three
particle size runs completed earlier were sufficient.
3.4.2 Rotary Calciner No. 2. The calclner parameters that were
monitored include time per calciner revolution, fuel consumption, and gas and
feed material temperatures at 6 ft., 30 ft., and 85 ft. from the discharge
end.
-------
3-11
Feed tank level was measured and recorded by a plant operator. Rotary
calciner feed rates, temperatures, revolution rates, and natural gas usage
were consistent throughout the test runs, indicating steady state process
conditions. The process parameters monitored for the conditioning towers
were pressured drop and fresh water make up and recirculation rate. The ESP
parameters that were monitored included gas inlet temperatures, primary
voltage, and primary and secondary current. The make-up water rate, inlet
temperature, pressure drop, and pump pressure were monitored for the Peterson
scrubber. Control equipment, including the two conditioning towers, two
ESP's, and Peterson scrubber, displayed normal operating parameters.
The east conditioning tower was partially plugged, causing an uneven
distribution in the volume of exhaust gas coming from the rotary calciner to
each of the two conditioning towers. The product quality, uncontrolled
emission level, and overall control process were not affected by this uneven
distribution. The conditioning towers maintained the inlet gas temperature
to the ESP's at less than 71 degrees Celsius (160 degrees Fahrenheit) during
all three test runs.
During runs 2 and 3, the west conditioning tower flow meter was not
functioning properly,. Between runs 2 and 3, the natural gas to the rotary
calciner was shut off for approximately 10 minutes because several bricks
from the calciner lining plugged the discharge end of the calciner. The
problem was immediately corrected, and run 3 was started when the kiln
achieved normal operation.
Plant processes were operated at or near normal operation capacity
during all three calciner test runs and during test runs 2, 3, and 4 of both
spray dryers. Process conditions were normal. Collected data are
representative of normal process conditions. Because of the broken feed
meter on Spray Dryer #322, the data gathered during the first run of the
spray dryer test may not be useful.
-------
4-1
4. SAMPLING LOCATIONS
4.1 Applicability of Sampling Sites. The primary goal of the testing
program was to characterize emissions from the spray dryer system (chloride
process) pollution control equipment and from the calciner system (sulfate
process) control equipment. In addition, moisture and sieving analyses were
performed on feed and product samples. Sampling sites appropriate to these
objectives were approved prior to testing.
4.2 Chloride Process Sampling Locations. Figure 4-1 illustrates
schematically the chloride process which incorporates two spray dryer
systems, i.e., spray dryers #312 and #322. The location of each sampling
site is indicated in Figure 4-1. Each of the sampling locations is
individually discussed and illustrated.
4.2.1 #312 Spray Dryer Inlet (Sampling Location A). Grab samples of
the feed to the spray dryer were collected during each Method 5 run for
moisture content determination. The tacky consistency of the feed made sieve
analysis inappropriate.
4.2.2 #312 Settling Chamber Product Outlet (Sampling Location B). Grab
samples of the product: from the settling chamber were collected during each
Method 5 run for sieve analysis and moisture content determination.
4.2.3 #312 Baghouse Inlet (Sampling Location C). Particulate emissions
and particle size distribution determinations were made in the 26-inch
diameter horizontal duct accessed through two sampling ports spaced 90
degrees apart. The sampling ports were located 61 inches (i.e., two duct
diameters) downstream from the spray dryer settling chamber and 15 inches
(i.e., one-half duct diameter) upstream from a 17 degree upward bend in the
duct. Figure 4-2 illustrates the inlet sampling location.
The original test: plan was to sample 24 points for five minutes each
(giving a total test time of 120 minutes), but the high particulate loading
in the duct made this plan impractical. EPA EMB and Entropy jointly approved
a revised particulate sampling plan in which 12 points (six points on each of
two traverse axes labeled A and B) were sampled for two minutes each,
-------
I.D. FANS
SPRAY DRYER
#312
SETTLING
CHAMBER
C
-o-
iB
90% PRODUCT
SPRAY DRYER
#322
o
PROCESS FLOW
AIR FLOW
GRAB SAMPLE
SAMPLING LOCATION
BAGHOUSE
B1
10% PRODUCT
I.D. FAN
T
I
PETERSON
SCRUBBER
i
BY-PASS I
s
T
A
C
K
BAGHOUSE
I
100% PRODUCT
A,B,B',b,b'
C,D,E
F
G
ASTM METHOD
METHOD 5, IMPACTOR
METHOD 5
METHOD 9
FIGURE 4-1. CHLORIDE PROCESS AND SAMPLING POINTS AT AMERICAN CYANAMID, SAVANNAH, GEORGIA
-------
TO
BAGHOUSE
TO
BAGHOUSE
EXTERIOR
WALL
2 AXES, EACH
WITH 6 'POINTS
(TOTAL 12 POINTS)
FROM SPRAY DRYER
N AND SETTLING CHAMBER
INSIDE BUILDING
26" INSIDE
DIAMETER
' ' ' I -Q
SECTION N-N
4"
FIGURE 4-2. #312 BAGHOUSE INLET DIMENSIONS WITH SAMPLING PORT AND POINT LOCATIONS
-------
4-4
resulting in a total sampling time of 24 minutes. Sampling was periodically
interrupted and resumed in order to distribute the 24 minutes of sampling
over the two-hour period of particulate sampling at the #312 Baghouse Outlet.
Two particle size runs were performed after each of the particulate runs
(runs 1,2, and 3) for a total of six particle size runs. For each run,
either points A-2 and A-5 or points B-2 and B-5 were sampled; sampling times
ranged from 20 seconds to one minute depending on the particulate loading
encountered.
4.2.4 #312 Baghouse Product Outlet (Sampling Location B'). Grab
samples of the product from the baghouse were collected during each Method 5
run for sieve analysis and moisture content determination.
4.2.5 #312 Baghouse Outlet (Sampling Location D). Sampling was
performed in a 48-inch diameter vertical duct accessed through two sampling
ports spaced 90 degrees apart. The ports were located 12 inches (0.3 stack
diameters) upstream and 42 inches (0.8 stack diameters) downstream from the
nearest flow disturbances, as shown in Figure 4-3.
A total of 24 sampling points were used for the particulate tests (12
sampling points on each of two traverse axes labeled A and B). Each point:
was sampled for five minutes resulting in a total test time of 120 minutes.
Four particle size runs were performed. The first two runs (performed
after particulate run 4) lasted for 45 and 60 minutes, respectively. A third
particle size run lasting 120 minutes was done simultaneous with particulate
run 5; the fourth particle size run lasted 176 minutes and was performed
simultaneous with particulate run 6.
4.2.6 #322 Spray Dryer Inlet (Sampling Location b). Grab samples of
the feed to the spray dryer were collected during each Method 5 run for
moisture content determination. The tacky consistency of the feed made sieve
analysis inappropriate.
4.2.7 #322 Baghouse Product Outlet (Sampling Location b'). Grab
samples of the product from the baghouse were collected during each Method 5
run for sieve analysis and moisture content determination.
-------
4-5
2 AXES, EACH WITH
12 POINTS (TOTAL
24 POINTS)
B p
48" DIAMETER
SECTION M-M
TO PETERSON
SCRUBBER
2 SAMPLING
PORTS
FLANGE
BUNION
I.D. FAN
FIGURE 4-3. #312 BAGHOUSE OUTLET DIMENSIONS WITH SAMPLING
PORT AND POINT LOCATIONS
-------
4-6
4.2.8 #322 Baghouse Outlet (Sampling Location E). Sampling was
performed in a 50-inch by 21-inch tapered duct positioned approximately 15
degrees from vertical. The duct was accessed through four sampling ports
located 100 inches downstream and 42 inches downstream from the nearest bend;
due to the taper of the duct, no straight run was available.
A total of 24 sampling points were used for the particulate tests, i.e.,
six sampling points on each of four traverse axes labeled A through D, as
shown in Figure 4-4. The original sampling time per point was five minutes;
however, after 21.77 minutes of testing in port A during the first run (1.77
minutes into point A-5), the sampling protocol was reevaluated and a joint
decision was made to sample the remaining points for two minutes in order to
shorten the net run time. The 21.77-minute sample of port A was designated
run 7A; the 36-mlnute sample was designated run 7B. For runs 8 and 9,
all 24 points were sampled for 2.5 minutes, resulting in a total run time
of 60 minutes.
Two particle size runs were performed after each of the three
particulate runs (runs 7, 8 and 9) for a total of six particle size runs.
During each run, a single point (either point A-4 or point C-4) was sampled
for 30, 45, or 60 seconds.
4.2.9 #312 and #322 Spray Dryers Exhaust Stack (Sampling Location F).
Sampling was performed in a 78-inch diameter vertical stack. Two sampling
ports (labeled A and B) spaced 90 degrees apart were located 78 inches (one
stack diameter) upstream from the stack outlet and 432 Inches (5.5 stack
diameters) downstream from the nearest flow disturbance.
A total of 24 sampling points were used for particulate testing (12
points on each of two traverse axes labeled A and B) as shown in Figure 4-5.
Each point was sampled for five minutes for a total test time of 120 minutes.
4.2.10 #312 and #322 Spray Dryers Exhaust Stack (Sampling Location G).
Plume opacity observations were performed at the exhaust stack according to
procedures outlined in EPA Reference Method 9. Cloudy weather conditions
prohibited the completion of opacity observations for test 3 (run 12) and
limited the observer's confidence in the reliability of test 4 (run 31).
-------
4-7
24 SAMPLING
POINTS
4 SAMPLING
PORTS
^^
-
1 1
A
1
x _
r
i
T
J~
|
*
*--
-
1 |
B
>u
i
i
~~!
~T ~
1
.
*
ป
1 I
c
_ 4. . .
1
1
~T "
..4
-
ป.-
-
ป
1
D
1
21
i
t
4"
1
SECTION L-L
FROM #322
BAGHOUSE
TO I.D. FAN
FIGURE 4-4. #322 BAGHOUSE OUTLET DIMENSIONS WITH SAMPLING
PORT AND POINT LOCATIONS
-------
4-8
78" DIAMETER
2 SAMPLING
PORTS
2 AXES, EACH
WITH 12 POINTS
(TOTAL 24 POINTS)
6"
=]B
SECTION M-M
BYPASS
FIGURE 4-5. SPRAY DRYERS #312 AND #322 STACK DIMENSIONS WITH
PORT AND POINT LOCATIONS
-------
4-9
4.3 Sulfate Process Sampling Locations. Figure 4-6 provides a
schematic Illustration of the sulfate process (which incorporates a rotary
calciner kiln) and gives the location of each sampling site. Each of the
sampling locations is Individually discussed and illustrated.
4.3.1 #2 Calciner Inlet (Sampling Location H). Grab Samples of the
feed to the rotary calciner were collected during each Method 5 run for
moisture content determination. Sieve analysis was inappropriate due to the
tacky consistency of the feed samples.
4.3.2 Water Spray Cooler Outlet (Sampling Location 1). Grab Samples of
the product exiting the water spray cooler were collected during each
Method 5 run for sieve analysis and moisture content determination.
4.3.3 East Side Calciner I.D. Fan Outlet (Sampling Location K).
Sampling was performed in a 72-inch diameter vertical duct which was accessed
by two sampling ports (labeled A and B) spaced 90 degrees apart. The ports
were located 36 Inches (0.5 duct diameters) upstream and 12 inches (0.2 duct
diameters) downstream from the nearest flow disturbances, as shown in
Figure 4-7.
A total of 24 sampling points (i.e., 12 points on each of two traverse
axes labeled A and B) were sampled for particulate. Each point was sampled
for 2.5 minutes, resulting in a net run time of 60 minutes.
Two particle size runs were performed after each particulate run, one at
point A-9 and one at point B-4. Runs S-13-A and S-13-B were each run for
five minutes; the other four runs were each performed for 15 minutes.
4.3.4 East Side I.D. Fan Inlet (Sampling Location K'). Velocity
traverses were performed in the 65-inch diameter duct which angled downward
in the direction of the gas stream flow, as shown in Figure 4-8. Access was
provided by a single port (labeled A) which was positioned 35 feet (6.5 duct
diameters) downstream from the nearest disturbance and four feet (0.7 duct
diameters) upstream from the nearest disturbance. Two twelve-point velocity
traverses were made along the single axis for each velocity run.
4.3.5 West Side I.D. Fan Outlet (Sampling Location L). Sampling was
performed in a 72-inch diameter vertical duct which was accessed by two
-------
EAST
ฎ *
ROTARY
CALCINER
KILN #2
O
PROCESS FLOW
AIR FLOW
GRAB SAMPLE
SAMPLE POINT
OBSERVATION POINT
I CONDITIONING
TOWER
WET
ESP
M
\
NO
\ PETERSON I
, SCRUBBER ~~U
O M1 ^-I.D. I
s
T
A
C
K
-I.D. FAN
WEST
CONDITIONING
TOWER
WET ESP
K',L' - METHOD 2
H,I - ASTM METHOD
K,L - METHOD 5, IMPACTOR
M,M' - METHOD 5
N f METHODS 5,7
O - METHOD 9
J - METHOD 22
FIGURE 4-6. SULFATE PROCESS AND SAMPLING POINTS AT AMERICAN CYANAMID, SAVANNAH, GEORGIA
-------
4-11
2 AXES, EACH WITH
12 POINTS, (TOTAL
24 POINTS)
TO CONDITIONING
TOWER
72" DIA.
FLANGE
UNION
2 SAMPLING
PORTS
FLANGE
UNION
-~ 6.5"
SECTION N-N
FLANGE
UNION
I.D. FAN
(FROM CALCINER #2)
FIGURE 4-7.
#2 CALCINER EAST AND WEST SIDE I.D. FAN OUTLET
DIMENSIONS WITH SAMPLING PORT AND POINT LOCATIONS
-------
65" DIA.
TO
I.D. FAN
AXES: 1
POINTS/AXIS: 12
TOTAL POINTS: 12
SECTION P-P
1 SAMPLING PORT
FROM
CALCINER
I
I-1
IV)
FIGURE 4-8. #2 CALCINER EAST I.D. FAN INLET DIMENSIONS WITH SAMPLING PORT AND POINT LOCATIONS
-------
4-13
sampling ports (labeled A and B) spaced 90 degrees apart. The ports were
located 36 inches (0.5 duct diameters) upstream and 12 inches (0.2 duct
diameters) downstream from the nearest flow disturbances, as shown in
Figure 4-7.
A total of 24 sampling points (12 points on each of two traverse axes
labeled A and B) were sampled for particulate. Each point was sampled
for 2.5 minutes, resulting in a net run time of 60 minutes.
Two particle size runs were performed after each particulate run, one at
point A-4 and one at point B-4. Runs S-16-A and S-16-B were performed for
five minutes; the other four runs were 25 minutes in duration.
4.3.6 West Side I.D. Fan Inlet (Sampling Location L')ซ The west side
fan inlet duct was a 73-inch diameter duct which was identical to the east
side fan inlet duct in all other pertinent respects, as shown in Figure 4-9.
Velocity measurements proceeded in the manner described in paragraph 4.3.4.
4.3.7 East and West Side ESP Outlets (Sampling Locations M and M').
The east and west side ESP outlets were identical, and the same testing
procedures were used at both locations. Sampling was performed in a 54-inch
diameter vertical duct accessed through two ports (labeled A and B) spaced 90
degrees apart, as shown in Figure 4-10. The ports were located 45 inches
(0.2 duct diameters) downstream and 12 inches (0.8 duct diameters) upstream
of the nearest flow disturbances.
For particulate testing, 24 points (12 points on each of two traverse
axes labeled A and B) were sampled for 2.5 minutes each, resulting in a total
run time of 60 minutes.
4.3.8 #2 Calciner Exhaust Stack (Sampling Location N). Sampling was
performed in the 73-inch diameter exhaust stack of the sulfate process. Two
sampling ports 90 degrees apart were located 44 feet (7.2 stack diameters)
downstream of the by-pass duct from the Peterson scrubber, and 50 feet (8.2
stack diameters) upstream from the top of the stack, as shown in Figure 4-11.
For the particulate tests, a total of 12 points (six sampling points on
each of two traverse .axes labeled A and B) were sampled. For run 25, each
point was sampled for five minutes with a total test time of 60 minutes. For
runs 26 and 27, the total test time was increased to 72 minutes (six minutes
-------
73" DIA.
TO
I.D. FAN
AXES: 1
POINTS/AXIS: 12
TOTAL POINTS: 12
SECTION Q-Q
1 SAMPLING PORT
FROM
CALCINER
FIGURE 4-9. #2 CALCINER WEST I.D..FAN INLET DIMENSIONS WITH SAMPLING PORT AND POINT LOOATIONS
-------
54" DIA.
AXES: 2
POINTS/AXIS: 12
TOTAL POINTS: 24
54" DIA.
6"
SECTION R-R
SECTION S-S
AMBIENT
AIR
INTAKE
EAST SIDE
TO
SCRUBBER
I
M
U1
1
R
/
B
ESP
A
( 1
12"
A 1 j
1 45- !
R - S
' \
A
f /
o
B
ESP
A.
/
1
, s
WEST SIDE
FIGURE 4-10. #2 CALCINER EAST AND WEST ESP OUTLET DIMENSIONS WITH SAMPLING PORT AND POINT
LOCATIONS
-------
4-16
50'
44'
BYPASS
73"
AIR
FLOW
-o
73" DIAMETER
1 I 5.5"
2 AXES, EACH WITH
6 POINTS (TOTAL,
12 POINTS)
SECTION L-L
2 SAMPLING PORTS
FROM'
SCRUBBER
FIGURE 4-11.
jฑ2 CALCINER EXHAUST STACK DIMENSIONS WITH
PORT AND POINT LOCATIONS
-------
4-17
per point) in order to increase the total sample volume and particulate
catch. For the nitrogen oxides tests, a single point sample was taken.
4.3.9 #2 Calciner Exhaust Stack (Sampling Location 0). Plume opacity
observations were performed at the exhaust stack outlet in accordance with
the procedures outlined in EPA Reference Method 9.
4.3.10 #2 Calciner Product Outlet (Sampling Location J). Fugitive
emissions readings (according to EPA Reference Method 22) were abandoned when
judgement was made that steam, rather than product emissions, was being
observed.
-------
5-1
5. SAMPLING AND ANALYTICAL METHODS
5.1 Sampling Objectives. This section describes the sampling and
analytical procedures which were employed at the American Cyanamid Company
manufacturing plant: in order to gather data concerning emissions from the
pollution control equipment associated with the sulfate and chloride
processes used to produce titanium dioxide. In addition, moisture and
sieving analyses were performed on feed and product samples. The sampling
program included outlet tests for particulate emissions, nitrogen oxides,
particle sizing, and plume opacity.
5.2 Particulate Emissions Testing. Where appropriate, particulate
emissions sampling conformed to the standards and procedures set forth by EPA
Reference Methods 1-5 and described in 40 CFR Part 60, Appendix 7.3. It was
necessary at several locations to modify the test procedures in order to cope
with either heavy particulate loading or turbulent flow patterns.
5.2.1 #312 Baghouse Inlet. Due to heavy particulate loading, the
run times were reduced by changing the number of sampling points from 24
to 12 and the sampling time per point to two minutes, resulting in run times
of 24 minutes. This protocol was approved on site by EPA EMB and Entropy.
5.2.2 #312 Baghouse Outlet. The total amount of available straight run
did not allow the placement of the sampling ports to meet the Method 1
criteria for minimum upstream and downstream distances.
5.2.3 #322 Baghouse Outlet. Because the duct was tapered with no
available straight run, the placement of the sampling ports did not meet the
Method 1 criteria for minimum upstream and downstream distances.
Due to the heavy particulate loading encountered at this location during
Test 1 , particulate run 7 was divided into two components which were
performed, processed, and analyzed as two separate runs. The particulate
catch from each component run was analyzed separately. Moisture content and
flue gas composition were determined on a total run basis, with the same
values used in the calculations for each component run (run 7 A and 7B).
-------
5-2
5.2.4 East and West I.D. Fans Outlets. The total amount of available
straight run did not allow the placement of the sampling ports to meet the
Method 1 criteria for minimum upstream and downstream distances. Due to the
turbulent flow patterns present, the air flow rates measured were used only
for the isokinetic sampling rate calculations; air flow rates as measured at
the East and West 1.0. Fan Inlets were used for emission rates calculations.
5.2.5 East and West I.D. Fans Inlets. Because only one port was
available for the velocity traversing, each velocity run consisted of two
traverses of the same port. Due to the large amount of straight run,
however, no significant error in the air flow data is expected.
5.2.6 East and West ESP Outlets. The total amount of available
straight run did not allow the placement of the sampling ports to meet the
Method 1 criteria for minimum upstream and downstream distances.
5.3 Sulfuric Acid Mist. Sulfuric acid mist emissions from the #2
Calciner Stack were determined by analyzing the particulate catch for total
3ulfates and calculating the results as 112804.
5.4 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 spectrometry or by
inductively coupled plasma spectrometry. These metals are zinc, nickel,
iron, manganese, vanadium, calcium, silicon, aluminum, magnesium, fluorine,
beryllium, uranium, lead, and mercury.
5.5 Sieve Analysis and Moisture Content. Sieve analysis and moisture
content determinations were performed on the product samples. ASTM Method
D 2216 was used to analyze the samples for moisture content, while ASTM
Method D 422 was used for sieve analysis. Samples which could not be sieved
due to moisture content were analyzed using only the second portion of Method
D 422 (the hydrometer procedure).
-------
5-3
5.6 Plume Opacity. Visible emissions observations were performed in
accordance with EPA Reference Method 9 as described in 40 CFR Part 60.
However, cloudy atmospheric conditions prevented some of the scheduled
opacity readings.
5.7 Fugitive Emissions. Fugitive emissions were determined in
accordance with EPA Reference Method 22 as described in 40 CFR Part 60.
5.8 Particle Size Tests. Particle size determinations were made using
a right angle inlet preseparator, followed by an Andersen or Flow Sensor
Mark III cascade impactor. The test procedures were based upon the
publication, "Procedures for Cascade Impactor Calibration and Operation in
Process Streams - Revised 1979," developed by the Industrial Environmental
Research Laboratory (IERL) and Southern Research Institute. Particle size
testing was not performed at locations where water droplets were observed in
the duct.
-------
6-1
6. QUALITY ASSURANCE
6.1 Introduction. The goal of quality assurance for the project was to
ensure the accuracy of all data collected. The procedures used are contained
in Entropy's "Quality Assurance Program Plan," which was approved by the U.S.
EPA EMB in the contract agreement governing the project.
In order to ensure continuity among field testing personnel, daily
meetings were held before each day of the field testing. At the meetings,
results from the testing conducted on the previous day were reviewed.
Responsibilities were clearly delineated for each member of the testing team,
and questions were addressed and resolved immediately. In situations where
more than one person was performing similar activities, consistency was
ensured through communication at the meetings.
In addition to the general quality assurance measures, specific quality
assurance activities were conducted for several of the individual test
methods performed.
6.2 Sampling Train Components. Entropy's sampling equipment, including
nozzles, pitot tubes, dry gas meters, orifices, and thermocouples, was
uniquely identified and calibrated in accordance with documented procedures
and acceptance criteria prior to and at the completion of the field testing
program. All sampling equipment was manufactured by Nutech Corporation,
Andersen 2000, Flow Sensor, or by Entropy. Calibration data for the sampling
equipment are contained in Appendix 7.7.
6.3 Preseparator and Cascade Impactors. All internal components and
surfaces of the impactors were cleaned in an ultrasonic bath to ensure that
all surface impurities were removed, and visual inspections for cleanliness
were made prior to shipment to the field. After each sample recovery, the
preseparator, the impactor body, and the plates were rinsed with acetone to
ensure that all organic residuals and/or particulate matter were removed.
6.4 Sample Collection Substrates. Schleicker & Schuell #30 glass fiber
sample collection substrates were used for particle size testing. To prevent
contamination of the substrate surface, all filters were handled with
laboratory tweezers. This procedure was used during impactor assembly,
sample recovery, and weighing of the substrates.
-------
6-2
6.5 Substrate Weighing. An analytical balance capable of weighing to
the nearest 0.01 milligram (mg) was used. To ensure that no weight bias was
produced from the preparation, transportation, recovery, or weighing
procedures, two control samples were obtained during the test program.
A reactivity run was performed to ensure that the flue gases did not
interact with the substrate to produce extraneous results. For the
reactivity run, a solid filter was placed in the front section of the
impactor, and the impactor was introduced into the #312 Baghouse Outlet duct,
and a sample was pulled through the head using the parameters outlined for a
normal particle sizing run. The average difference between the pre- and
post-test weights, as shown in Appendix 7.3.2, was 0.14 milligrams, based
upon weight differences ranging from 0.00 to 0.34 milligrams.
A blank run was also performed to demonstrate that the impactor could be
assembled and disassembled without affecting the weight of the substrate.
The average difference between the pre- and post-assembly weights was 0.14
milligrams, based upon a difference ranging from 0.02 to 0.34 milligrams.
6.6 Sample Analysis. In order to reduce the probability of errors or
inconsistent results, one member of the field crew had sole responsibility
for the sample analysis procedure. Sample analysis was performed in a room
dedicated exclusively to filter weighing.
6.7 EPA Method 3. All Method 3 analyses were performed in triplicate.
Each analyzer was checked for leaks prior to any analysis as specified in the
method. Samples were analyzed within four hours of collection.
6.8 EPA Method 9. The visible emissions observers held current
certifications issued within the last 6 months. Documentation verifying the
observer's certifications are provided in Appendix 7.5.
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