ites
Agen
andards
-ark NC 2
EMB Report S3-CDR-11
April 1984
Calciners and
Dryers Emission
Test Report
•
C.E. Minerals
Muicoa Plant
Andersonville,
Georgia
-------
NSPS DEVELOPMENT
PARTICULATE, SULFUR DIOXIDE, AND NITOGEN OXIDES EMISSIONS
AND PARTICLE SIZING TESTING
#4 ROTARY CALCINER
C.E. MINERALS MULCOA PLANT
ANDERSONVILLE, GEORGIA
APRIL 17 & 18, 1984
Compiled by:
Entropy
Post Office Box 12291
Research Triangle Park, N. C. 27709
68-02-3852
Work Assignment No. 8
EMB Project No. 81/08
EMB Report No. 83-CDR-ll
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
-------
TABLE OF CONTENTS
SECTION PAGE
1. INTRODUCTION 1-1
1.1 Background 1-1
1.2 Scope of the Project 1-1
1.3 C.E. Minerals Mulcoa Plant Testing Program 1-1
1.3.1 Source Applicability 1-1
1.3.2 Outline of Testing Program 1-2
1.4 Report Organization 1-4
2. SUMMARY AND DISCUSSION OF RESULTS 2-1
2.1 Summary 2-1
2.2 Discussion 2-1
3. PROCESS DESCRIPTION AND OPERATION 3-2
3.1 Production of Calciner Feed 3-2
3.1.1 Raw Material 3-2
3.1.2 Fuel 3-2
3.1.3 Pellet Formation 3-2
3.1.4 Pellet: Drying . 3-2
3.1.5 Pellets as Feed 3-4
3.2 Calcining; Process 3-4
3.2.1 Kilns 3-4
3.2.2 Calcine 3-4
3.2.3 Exhaust Emissions 3-6
3.2.4 Control Equipment 3-6
4. SAMPLING LOCATIONS 4-1
4.1 Suitability of Sampling Sites 4-1
4.2 Rotary Calciner Feed Inlet (Sample Loc. A) 4-1
4.3 Vibrating Grate Cooler Product Outlet (Sample Loc. B) . . . 4-1
4.4 Vibrating; Grate Cooler Multiclone Outlet (Sample Loc. G). . 4-1
4.5 Multiclone Inlet (Sample Loc. C) 4-1
4.6 I.D. Fan Inlet East & West (Sample Loc. D & E) 4-4
4.7 Scrubber Exhaust Stack (Sample Loc. F & Observation Loc. G) 4-2
(continued next page)
-------
ii
TABLE OF CONTENTS
(continued)
SECTION PAGE
5. SAMPLING AND ANALYTICAL METHODS 5-1
5.1 Sampling Objectives 5-1
5.2 Particulate and Sulfur Dioxide Emissions Testing 5-1
5.3 Trace Metals Analysis 5-1
5.4 Sieve and Moisture Content Analysis 5-1
5.5 Plume Opacity 5-1
5.6 Particle Size Testing 5-1
5.7 Nitrogen Oxides Testing 5-1
6. QUALITY ASSURANCE 6-1
6.1 Introduction 6-1
6.2 Sampling Train Components 6-1
i6.3 Preseparator and Cascade Impactors 6-1
6.4 Sample Collection Substrates 6-2
6.5 Substrate Weighting 6-2
6.6 Sample Analysis 6-2
6.7 EPA Method 3 6-2
6.8 EPA Method 9 6-2
7. APPENDICES 1
7.1 Test Results and Example Calculations 2
7.1.1 Particulate and Sulfur Dioxide 2
7.1.1.1 Multiclone Inlet 2
7.1.1.2 I.D. Fan Inlet East & West 5
7.1.1.3 Scrubber Exhaust Stack and Example Calculations ... 10
7.1.2 Particle Sizing 16
7.1.2.1 Multiclone Inlet 17
7.1.2.2 I.D. Fan Inlet East & West 33
7.1.3 Nitrogen Oxides, Scrubber Exhaust Stack 62
7.2 Field and Analytical Data 66
7.2.1 Particulate and Sulfur Dioxide 66
( continued next page)
-------
ill
TABLE OF CONTENTS
(continued)
SECTION
APPENDICES
7.2.1.1
7.2.1.2
7.2.1.3
7.2.2
7.2.2.1
7.2.2.3
7.2.3
7.2.4
7.2.5
7.3
7.4
7.5
7.6
66
76
90
100
100
Multiclone Inlet
l.D. Fan Inlet East & West
Scrubber Exhaust Stack
Particle Sizing
Multiclone Inlet .
l.D. Fan Inlet East & West 112
Visible Emissions, Scrubber Exhaust Stack 130
Nitrogen Oxides, Scrubber Exhaust Stack 145
Trace Metals Analytical Results 150
Sampling and Analytical Procedures 153
Feed and Product Analytical Data 239
Entropy Test Participants . 259
Calibration Data 260
-------
iv
LIST OF TABLES
Number Title Page
1-1 Testing Protocol and Run/Sample Numbering 1-3
Cross-Reference
2-1 ParticulLate Emissions and Concentrations, Summary . . 2-2
and Control Equipment Efficiencies
Particulate Tests Summary of Results
2-2 Multiclone Inlet 2-3
2-3 I.I). Fan Inlet, East 2-4
2-4 I.I). Fan Inlet, West 2-5
Particulate and Sulfur Dioxide Summary of Results
2-5 Scrubber Stack 2-6
Summary of Particle Sizing Test Results
2-6 Multiclone Inlet 2-8
2-7 I.D. Fan Inlet, East 2-10
2-8 I.D. Fan Inlet, West 2-12
Nitrogen Oxides Emissions Rates and Concentrations
2-9 Scrubber Stack 2-14
Summary of Visible Emissions
2-10 Run 1 2-15
2-11 Run 2 2-16
2-12 Run 3 2-17
3-1 Data For Rotary Kilns 3-5
-------
LIST OF FIGURES
Number Title Page
3-1 Simplified Process Flow Diagram 3-3
4-1 Process Flow Schematic Showing Sampling Locations . . 4-2
4-2 Multiclone Inlet 4-3
4-3 I.D. Fan Inlet East & West 4-5
4-4 Scrubber Exhaust Stack 4-6
-------
1-1
1. INTRODUCTION
1.1 Background. 'Che Emission Measurement Branch (EMB) of the United
States Environmental Protection Agency (EPA) is directing a project designed
to generate support data for New Source Performance Standards (NSPS) for
calciners and dryers in the mineral industries. Emission standards for the
various industries may be developed based upon process-related emission
factors determined from the testing of controlled sources.
1.2 Scope of the Project. The EMB is responsible for coordinating the
efforts of Entropy and Midwest Research Institute (MRI) to achieve the goals
of the testing program. Entropy has been retained under the EMB Contract No.
68-02-3852, Work Assignment No. 8 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. 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 C.E. Minerals Mulcoa Plant Testing Program. The present report
covers stationary source sampling performed at the C.E. Minerals #3 Plant in
Andersonville, Georgia on April 17 and 18, 1984 to characterize emissions
from the #4 rotary calciner and associated air pollution control equipment.
Dilip Jain and Siva Soora of C.E. Minerals and Dennis Holzschuh of EPA EMB
were present to coordinate the testing. Amy J. Kowalski of MRI monitored the
plant process and recorded operational data during the testing.
1.3.1 Source Applicability. The C.E. Minerals Mulcoa plant uses rotary
calciners for the drying of pulverized or extruded clay. The plant's use of
coal-fired rotary calciners represents the most difficult emissions control
situation in the clay refining industry. The plant is considered to be well
operated and well maintained, as well as providing feasible opportunities for
inlet testing.
-------
1-2
1.3.2 Outline of Testing Program. Emission measurements were performed
at the multiclone inlet, at the I.D. fan inlets (east & west) and at the
scrubber exhaust stack. Table 1-1 outlines the testing program, giving test
dates, sampling locations, test methods, and run numbers.
-------
TABLE 1-1
TESTING PROTOCOL AND
RUN/SAMPLE NUMBERING CROSS-REFERENCE
------- Sampling
Objective Method
Particulate ' EPA 5
Participate/ EPA 5 & 8
Sulfur Dioxide
Particle
Sizing
Nitrogen
Oxides
Sieving/
Moisture
Opacity
Cascade
Irapactor
EPA 7
Grab
Sample
EPA 9'
Location*
4/17
Test Set
4/17 4/18
MI
IE
IW
SE
MI
IE
IW
SE
CI
VP
VM
SE
1
4
7
10
S1A&B
S4A&B
S7A&B**
10
1
1
1
1
2tm
5tm
8tm
lltm
S2A&B
S5A&B
S8A&B
11
2
2
2
2
3
6
9
12
S3A&B
S6A&B
S9A&B**
12
. 3
3
3
3
tm Method 5 particulate catch and distilled water from impingers analyzed
for trace metals
* Sampling Location Legend:
MI - Multiclone Inlet
IE - I.D. Fan Inlet East
IW - I.D. Fan Inlet West
SE - Scrubber Exhaust Stack
CI - Calciner Inlet
VM - Vibrating Grate Cooler Multiclone Outlet
VP - Vibrating Grate Cooler Product Outlet
** The results of runs S7B and S9B are not tabulated in this report.
Run S7B was underloaded; run S9B was overloaded.
-------
1-4
1.4 Report Organization. Immediately following is the "Summary of
Results" section. Appendix 7.1 presents the complete results of each run;
field data can be found in Appendix 7.2. The source and the process are
described in the "Process Description and Operation" section. 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 7.3, while Appendix 7.4 presents
analytical documentation. The final section, "Quality Assurance," notes the
procedures used to ensure the integrity of the sampling program; Appendix 7.6
provides pertinent calibration data. Appendix 7.5 contains a listing of the
Entropy test participants and their roles in the testing program.
-------
2-1
2. SUMMARY AND DISCUSSION OF RESULTS
2.1 Summary. Table 2-1 presents a summary of the particulate and
sulfur dioxide emissions and concentrations at the sampled locations, as well
as particulate collection efficiencies for the multiclone. Run-by-run
summaries of the particulate testing are provided for the multiclone inlet
and for the I.D. fans east and west in Tables 2-2 through 2-4, respectively.
Table 2-5 summarizes the results of particulate and sulfur dioxide testing
performed at the scrubber exhaust stack. Detailed results of all particulate
and sulfur dioxide testing appear in Appendix 7.1.1.
Tables 2-6 through 2-8 present the particle sizing test results for each
of the sampled locations; particle sizing was not performed at the scrubber
exhaust stack due to moisture in the flue gas. Appendix 7.1.2 presents the
detailed results of particle size testing.
Nitrogen oxides (as M^) results are summarized in Table 2-9; complete
results are given in Appendix 7.1.3.
Opacity observations (runs 1-3) are reported in Tables 2-10, 2-11, and
2-12. No visible emissions were observed throughout the testing; field data
is presented in Appendix 7.2.3.
The results of trace metals analyses are reported in Appendix 7.2.5.
2.2 Discussion of Results. At the I.D. fan inlet west location,
particle sizing runs 7B and 9B were not tabulated in the results due to an
extremely low catch (underloaded), and extremely large catch (overloaded),
respectively.
In order to calculate particulate removal efficiencies of the multiclone
and scrubbers, a particulate concentration representing a combined inlets
value is necessary. A technique for eliminating any bias due to uneven air
flow distribution through the two fans was used in calculating the
equivalent, weighted average concentrations as follows:
Sum of A-!>ide & B-Side Emissions, Ib/hr 7,000 gr/lb
Ceq= * = gr/DSCF for
Sum of A-Side & B-Side Flow Rates, SCFM 60 min/hr combined
inlets
554.15 + 463.07 7,000
= * = A'°278 Sr/DSCF
-------
2-2
TABLE 2-1
PARTICULATE EMISSIONS & CONCENTRATIONS SUMMARY
AND CONTROL EQUIPMENT EFFICIENCIES
Emission Rates, Ib/Hr:
Multiclone Inlet
I.D. Fan Inlet, East
I.D. Fan Inlet, West
Scrubber Stack
Concentration, Gr/DSCF:
Multiclone Inlet
I.D. Fan Inlet, East
I.D. Fan Inlet, West
Equivalent I.D. Fan Inlet
Scrubber Stack
Collection Efficiency, %:
Multiclone
Scrubber
Emission Rates, Kg/Hr:
Multiclone Inlet
I.D. Fan Inlet, East
I.D. Fan Inlet, West
Scrubber Stack
Concentration, mg/DSCM:
Multiclone Inlet
I.D. Fan Inlet, East
I.D. Fan Inlet, West
Scrubber Stack
1
2,192.95
554.15
463.07
8.37
7.5227
4.3930
3.6634
4.0278
0.0336
46.46
99.16
994.7
251.4
210.0
3.80
17,212
10,051
8,382
76.89
- iest aec
2
2,361.38
564.37
471.38
8.08
8.2405
4.3858
3.7308
4.0614
0.0315
50.72
99.21
1,071.1
256.0
213.8
3.67
18,855
10,035
8,537
72.12
3
1,947.90
553.04
458.11
8.98
7.1672
4.1514
3.7454
3.9570
0.0344
44.79
99.14
883.5
250.9
207.0
4.07
16,399
9,499
8,570
78.77
Average
2,167.41
557.18
464.18
8.48
7.6434
4.31
3.7132
4.0154
0.0331
47.32
99.17
983.1
252.7
210.0
3.85
17,489
9,862
8,496
75.93
-------
2-3
TABLE 2-2
PARTICULATE TESTS SUMMARY OF RESULTS
Multiclone Inlet
1 2 3
Run Date 04/17/84 04/17/84 04/18/84
Test Train Parameters:
Volume of Dry Gas 31.526 29.831 30.040
Sampled, SCF*
Percent Isokinetic 107.5 103.5 109.9
Stack Parameters:
Temperature, Deg. F 593 601 602
Air Flow Rates
SCFM*, Dry
ACFM, Wet
Method 5 Results (English):
Catch, milligrams
Concen. , grains/DSCF*
Emissions, pounds/hour
Method 5 Results (Metric):
Concen., milligrams/DSCM*
Emissions, kilograms/ hour
34,010
78,921
15,367.5
7.5227
2,192.95
17,212.4
994.7
33,432
78,066
15,929.3
8.2405
2,361.38
18,855.4
1071.1
31,708
73,375
13,951.5
7.1672
1,947.90
16,399.4
883.5
* 68 Deg. F. - 29.92 in. Hg.
-------
2-4
TABLE 2-3
PARTICIPATE TESTS SUMMARY OF RESULTS
I.D. Fan Inlet, East Side
456
Run Date 04/17/84 04/17/84 04/18/84
Test Train Parameters:
Volume of Dry Gas 25.334 26.926 27.172
Sampled, SCF*
Percent Isokinetic 102.4 106.7 104.0
Stack Parameters:
Temperature, Deg. F 549 545 555
Air Flow Rates
SCFM*. Dry
ACFM, Wet
Method 5 Results (English):
Catch, milligrams
Concen. , grains/DSCF*
Emissions, pounds/hour
Method 5 Results (Metric):
Concen., milligrams/DSCM*
Emissions, kilograms/ hour
14,717
33,312
7,211.5
4.3930
554.15
10,051.4
251.4
15,013
33,970
7,652.4
4.3858
564.37
10,035.4
256.0
15,542
34,752
7,309.4
4.1514
553.04
9,498.8
250.9
* 68 Deg. F. - 29.92 in. Hg.
-------
2-5
TABLE 2-4
PARTICULATE TESTS SUMMARY OF RESULTS
I.D. Fan Inlet, West Side
Run Date
Test Train Parameters:
Volume of Dry Gas
Sampled, SCF*
Percent Isokinetic
Stack Parameters:
Temperature, Deg. F
Air Flow Rates
7 8
04/17/84 04/17/84
27.582
105.6
543
26.633
102.0
539
04/18/84
25.955
102.7
545
SCFM*, Dry
ACFM, Wet
Method 5 Results (English):
Catch, milligrams '
Concen. , grains/DSCF*
Emissions, pounds/hour
Method 5 Results (Metric):
Concen., milligrams/DSCM*
Emissions, kilograms/hour
14,747
33,246
6,547.5
3.6634
463.07
8,382.2
210.0
14,740
33,331
6,438.7
3.7308
471.38
8,536.6
213.8
14,270
32,223
6,299.2
3.7454
458.11
8,569.8
207.0
* 68 Deg. F. - 29.92 in. Hg.
-------
2-6
TABLE 2-5
PARTICULATE AND SULFUR DIOXIDE TESTS SUMMARY OF RESULTS
Scrubber Stack
10 11 12
Run Date 04/17/84 04/17/84 04/18/84
Test Train Parameters:
Volume of Dry Gas 88.220 91.896 91.630
Sampled, SCF*
Percent Isokinetic 99.0 100.2 98.2
Stack Parameters:
Temperature, Deg. F 140 140 141
Air Flow Rates
SCFM*, Dry 29,064 29,915 30,432
ACFM, Wet 41,994 43,217 43,558
Method 5 Results (English):
Catch, milligrams 192.1 187.7 204.4
Concen., grains/DSCF* 0.0336 0.0315 0.0344
Emissions, pounds/hour 8.37 8.08 8.98
Method 5 Results (Metric):
Concen., milligrams/DSCM* 76.8895 72.1231 78.768
Emissions, kilograms/hour 3.80 3.66 4.07
Method 8 Sulfur Dioxide (English):
Catch, Milligrams 2,871.8 3,006.8 2,772.0
Concen., ppmbyvol., dry 432.06 434.27 401.52
Emission, pounds/hour 125.15 129.48 121.78
(continued on next page)
-------
2-7
TABLE 2-5
PARTICULATE AND SULFUR DIOXIDE TESTS SUMMARY OF RESULTS
Scrubber Stack
(continued)
10 11 12
Run Date 04/17/84 04/17/84 04/18/84
Method 8 Sulfur Dioxide (Metric):
Concen., milligrams/DSCM* 1,149.46 1,155.35 1,068.22
Emissions, kilograms/hour 56.77 58.73 55.24
* 68 Deg. F. - 29.92 in. Hg.
-------
2-8
TABLE 2-6
SUMMARY OF PARTICLE SIZING TEST RESULTS
Multiclone Inlet
SAMPLING DATA
Date
Start Time
Finish Time
Impactor Flow Rate (1/min)
Isokinetic Ratio (%)
STACK DATA
Temperature (degrees C)
Moisture (%)
Velocity (m/min)
EMISSION DATA
Concentration (mg/dscra)
Percent Recovery (PS cone./
M-5 cone.)
Cumulative % Mass less than
10 microns
Concentration < 10 microns:
From PS runs, rag/dscra
.From M-5 runs, mg/dscm
Emission Rate < 10 microns
(kg/hr, from M-5 runs)
PS Run 1
4/17/84
1323,1412
1325,1413
21.90
108.5
309
12.3
643.4
13,297
62.0
42.0
5,670
8,996
418
PS Run 2
4/17/84
1751,1846
1753,1847
21.90
105.3
322
12.2
650.1
6,655
32.0
58.0
3,850
12,116
621
PS Run 3
4/18/84
1401,1434
1403,1436
15.30
103.9
320
11.6
471.1
8,019
44.0
34.0
2,600
6,164
300
Av e raj
317
12.0
588.2
9,324
46.0
45.0
4,040
9,091
446
PS: Particle Size Run
M-5: Method 5 Particulate Run
-------
2-9
COMPANY NAME
ADDRESS.
PARTICLE SIZE DISTRIBUTION
CE Mineirals Mulcoa Plant
Andersonville, Georgia
AVERAGE OF RUNS la,lb,2a,2b,
3a,3b
SAMPLING LOCATION Multiclone Inlet
DATE!s) 4/17/84 , 4/18/84
DENSITY = 1 GM/CM
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PERCENT OF PARTICLES LESS THAN INDICATED SIZE
-------
2-10
TABLE 2-7
SUMMARY OF PARTICLE SIZING TEST RESULTS
I.D. Fan Inlet, East Side
SAMPLING DATA
Date
Start Time
Finish Time
Impactor Flow Rate (1/min)
Isokinetic Ratio (%)
STACK DATA
Temperature (degrees C)
Moisture (%)
Velocity (m/min)
EMISSION DATA
Concentration (mg/dson)
Percent Recovery (PS cone./
M-5 cone.)
Cumulative % Mass less than
10 microns
Concentration < 10 microns:
From PS runs, mg/dscm
From M-5 runs, mg/dscm
Emission Rate < 10 microns
(kg/hr, from M-5 runs)
PS Run 4
4/17/84
1243,1258
1247,1302
17.70
103.8
289
13.1
538.4
8,777
87.0
47.0
4,120
4,724
118
PS Run 5
4/17/84
1745,1755
1747,1757
17.10
105.9
281
13.4
528.5
9,406
94.0
47.0
4,400
4,716
120
PS Run 6
4/18/84
1414,1424
1416,1426
17.60
110.7
294
11.8
661.5
8,884
93.0
32.0
2,770
2,944
78
Averaj
288
12.8
576.1
9,022
91.0
42.0
3,763
4,121
105
PS: Particle Size Run
M-5: Method 5 Particulate Run
-------
COMPANY NAME
2-11
PARTICLE SIZE DISTRIBUTION
CE Minerals Mulcoa Plant
AVERAGE OF
, 5b,
ADDRESS Andersonville, Georgia
SAMPLING LOCATION
DATE! s ) 4/17/84. 4/18/84
1-D- Fan Inlet East- side
DENSITY = I CM/CM
6a,6b
ft n '
on =
70.. -
50 - -:
£
40 :
30 • :
1 i
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IT
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5 10 IS 20 30 40 SO 60 70 SO 85 90 95 98
PERCENT OF PARTICLES LESS THAN INDICATED SIZE
-------
2-12
TABLE 2-8
SUMMARY OF PARTICLE SIZING TEST RESULTS
I.D. Fan Inlet, West Side
SAMPLING DATA
Date
Start Time
Finish Time
Impactor Flow Rate (1/min)
Isokinetic Ratio (%)
STACK DATA
Temperature (degrees C)
Moisture (%)
Velocity (m/min)
EMISSION DATA
Concentration (mg/dscm)
Percent Recovery (PS cone./
M-5 cone.)
Cumulative % Mass less than
10 microns
Concentration < 10 microns:
From PS runs, mg/dscm
From M-5 runs, mg/dscm
Emission Rate < 10 microns
(kg/hr, from M-5 runs)
PS Run 7
4/17/84
1350
1352
30.00
109.3
293
13.3
852.4
6,191
74.0
72.0
4,429
5,951
149
PS Run 8
4/17/84
1833,1857
1835,1859
23.80
109.9
286
13.9
682.9
6,241
73.0
55.0
3,430
4,695
118
PS Run 9
4/18/84
1454
1456
14.80
108.4
279
13.6
423.2
5,273
62.0
46.0
2,425
3,942
96
Averag
286
13.6
652.8
5,902
70.0
57.0
3,428
4,862
121
PS: Particle Size Run
M-5: Method 5 Particulate Run
\
-------
2-13
COMPANY NAME
ADDRESS _.
PARTICLE SIZE DISTRIBUTION
CE Minerals Mulcoa Plant AVERAGE OF RUNS^a .83,813,93
Andersonville, Georgia
SAMPLING LOCATION I.D. Fan Inlet West-side
DATE!s) 4/17/84. 4/18/84
DENSITY = I GM/CM3
ft n a
70 , -
50- :
40 =
30 "
? n
i -
1 O _ «-
9 *
26 ''
^
3 1
o =
_" :
Q 3 3
UI i
N :
01 2 H
u :
u :
OL 9 =
a . =
7 .S
2 • .
. 1 —
1
(
V_J
^1
^
G
;)
o
V^>
v_x
(
D
c
V
^
i riii i
5 10 IS 20 30 40 50 60 70 SO 85 90 95 98
PERCENT OF PARTICLES LESS THAN INDICATED SIZE
-------
2-14
TABLE 2-9
NITROGEN OXIDES (AS N02) EMISSION RATES & CONCENTRATIONS
SUMMARY OF RESULTS
Scrubber Stack
-
Run Date
Sample Number
Parameters per Run:
Air Flow Rate, dry SCFM
Nitrogen Oxides (as N02 ) Results:
Concentration, ppm, dry
Emissions, Lb/Hr
10
04/17/84
10A-10D
29,060
265.5
55.2
- K.un numoers -
11
04/17/84
11A-11D
29,920
311.4
66.7
12
04/18/84
12A-12D
30,430
321.0
69.9
-------
2-15
TABLE 2-10
SUMMARY OF VISIBLE EMISSIONS
Run 1
Date: 4/17/84
Type of Discharge: Stack
Height of Point of Discharge: 120'
Wind Direction; West-North-West
Color of Plume:_White
Observer No.:
Distance from Observer to Discharge Point:
Direction of Observer from Point: South
Type of Plant: Clay
Location of Pischarge:Multiclone
Description of Sky;Partly Cloudy
Wind Velocity; 8-12
Detached Plume: No
Duration of Observation; 197 min.
950 '
Height of Observation Point; Ground level
Description of Background; Partly Cloudy
Set Time
Number Start End
SUMMARY OF AVERAGE OPACITY
Opacity Set Time
Sum Average Number Start End
Opacity
Sum Average
1
2
3
4
5
6
7
8
9
10
11
12
0958
1004
1010
1016
1022
1028
1034
1040
1046
1152
1158
1204
1004
1010
1016
1022
1028
1034
1040
1046
1152
1158
1204
1210
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
13
14
15
16
17
18
19
20
21
22
23
1210
1216
1222
1228
1234
1240
1246
1252
1258
1304
1310
1216
1222
1228
1234
1240
1246
1252
1258
1304
1310
1315
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
- 3
O
2
o
U 2
1 HR
30
TIME
-------
2-16
TABLE 2-11
SUMMARY OF VISIBLE EMISSIONS
Run 2
Date: 4/17/84
Type of Discharge: Stack
Height of Point of Discharge: 120*
Wind Direction; West-North-West
Color of Plume; White
Observer No.:
Distance from Observer to Discharge Point:
Direction of Observer from Point: South
Type of Plant; Clay
Location of Discharge;Multiclone
Description of Sky:Partly Cloudy
Wind Velocity: 12-15
Detached Plume: No
Duration of Observation: 150 min.
800'
Height of Observation Point; Ground level
Description of Background: Partly Cloudy
Set Time
Number Start End
SUMMARY OF AVERAGE OPACITY
Opacity Set Time
Sum Average
Number
Start End
Opacity
Sum Average
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1500
1506
L512
1518
1524
1530
1536
1542
1548
1554
1600
1606
1612
1618
1506
1512
1518
1524
1530
1536
1542
1548
1554
1600
1606
1612
1618 .
1624
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
15
.16
17
18
19
20
21
22
23
24
25
26
1624
1630
1636
1642
1646
1652
1658
1704
1710
1716
1722
1728
1630
1636
1642
1646
1652
1658
1704
1710
1716
1722
1728
1730
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
I HR
30
TIME
-------
2-17
TABLE 2-12
SUMMARY OF VISIBLE EMISSIONS
Run 3
Date: A/18/84
Type of Discharge; Stack
Height of Point of Discharge: 120'
Wind Direction; West-North-West
Color of Plume: White
Observer No.:
Type of Plant: Clay
Location of Discharge;Multiclone
Description of Sky: Clear
Wind Velocity; 8-10
Detached Plume: No
Distance from Obseiver to Discharge Point:
Direction of Observer from Point: South
Duration of Observation; 150 min.
800 '
Height of Observation Point; Ground level
Description of Background; Clear
Set
Number
Time
Start End
SUMMARY OF AVERAGE OPACITY
Opacity Set Time
Sum Average Number Start End
Opacity
Sum Average
1
2
3
4
5
6
7
8
9
10
11
12
1203
1209
1215
1221
1227
1233
1239
1245
1251
1257
1303
1309
1209
1215
1221
1227
1233
1239
1245
1251
1257
1303
1309
1315
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
13
14
15
16
17
18
19
20
21
22
23
24
1315
1321
1327
1333
1339
1345
1357
1403
1409
1415
1421
1427
1321
1327
1333
1339
1345
1351
1403
1409
1415
1421
1427
1433
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
O
I HR
30
TIME
-------
3-1
STATEMENT OF CONFIDENTIALITY
All information referenced in the Process Description as (Confidential
Addendum No. 1 through No. 7) have been deemed confidential by the C.E.
Minerals Mulcoa Plant officials. Due to this fact, this information has been
deleted from the final report and put under separate cover. Pending
determination by the Environmental Protection Agency of the confidentiality
of this information., they have been submitted as described to us for official
entry into our confidential files.
-------
I
3-2
3. PROCESS DESCRIPTION AND OPERATION
3.1 Production of Calciner Feed.
3.1.1 Raw Material. A simplified process flow diagram representative of
plant operations is shown in Figure 3-1. Kaolinitic clays are obtained from
nearby mining operations, transported to the plant by truck, and deposited in
outside storage piles. Various clays are withdrawn from storage piles and
mixed in predetermined proportions to obtain the desired product composition
and properties. (See Confidential Addendum, No. 1, for a description of
processing methods).
3.1.2 Fuel. The fuel used in this operation is natural gas. No. 2 fuel
oil is a standby fuel.
3.1.3 Pellet Formation. The clay is pulverized (see Confidential
Addendum, No. 2, for particle size information) in a roller mill swept with
heated air. The pulverized clay produced by the roller mill is mixed with
water in a pug mill, and the mixture is extruded to form 1.3 to 2.5 cm (0.5 to
1 in.) diameter pellets (referred to as "noodles") of varying lengths up to
about 0.6 m (2 ft.).
Some of the raw material bypasses the mills and is only processed through
the pug mill and extruder before being calcined. Mulcoa 47 (and Mulcoa 44, a
product very similar to Mulcoa 47 in composition) are produced using the bypass
method. C.E. Minerals personnel believe these bypass materials generate the
most difficult to control emissions. (Mulcoa 44 was being processed during the
testing).
3.1.4 Pellet Drying. Pellets produced by the extruder are dried on a
moving pan dryer (natural gas is used as fuel). This pellet dryer dries only
the surface of the pellets so that they do not stick together and their
handling properties are improved. The moisture content of the dried pellets is
20 to 22 percent, and they have a loose fill density of 1,600 to 1,760 kg/m3
(100 to 110 Ib/ft3) . The average water evaporation rate for the pellet dryer
is about 1,810 kg/h (4,000 Ib/h).
-------
Outside
Storage
Piles
Truck
Tiamporl
Vent
Vent
Collected .
Dust
Water
Vent
Wot Cyclone
Scruljljor •
Pallet Dryer
(Moving Pan)
1/2 - 1 In.
Diameter
Pellets
To Bulk Loading
To Bugged
Shipping
Figure 3-1. Simplified process flov; diagram for C-G Minerals plant at Andcrsonvllle, Georgia,
-------
3-4
3.1.5 Pellets as Feed. As shown in Figure 3-1, dried pellets are used as
feed material for the rotary calciner (kiln) and vibrating-grate cooler
system. The operations described above for mixing, fine grinding, and
extruding the clay are all designed to effect intimate contact of the clay
particles and to promote a chemical reaction that produces mullite during
calcining. All moisture and other volatile matter are removed during
calcining. The chemical reactions are as follows:
Heat
~ 2H20 > A1203 - 2Si02 + 2H20
Heat
3 (A12(>3 - 2Si02) > 3A1203 - 2Si02 + 4Si02
Mullite
Pellets produced using the bypass method contain particles that are
less uniform in size than those produced with the additional milling. This
causes them to break apart more during calcining, thus making emissions from
bypass materials more difficult to control than the emissions from other
mullite products.
3.2 Calcining Process.
3.2.1 Kilns. C.E. Minerals operates seven identical rotary kilns in
Andersonville, and each kiln is operated at its design capacity. Data for the
rotary kiln equipment is shown in Table 3-1. The kilns are operated
continously throughout the year except for occasions when a shutdown is
necessary to repair equipment. The maximum kiln temperature is 1540° to
1760°C (2800° to 3200°F) and the heat application method is counterflow.
The pulverized coal used as fuel has a heating value of about 30,260 kj/kg
(13,000 Btu/lb) and contains 5 to 6 percent ash and less than 1 percent sulfur.
3.2.2 Calcine. The hot calcine discharged from the rotary kiln is fed to
a vibrating-grate cooler (see Confidential Addendum, No. 3, for cooler
-------
3-5
TABLE 3-1. DATA FOR ROTARY KILNS USED AT
C-E MINERALS MULCOA PLANTS AT ANDERSONVILLE, GEORGIA
Equipment dimensions
Design production capacity
Method of determining actual
production rate
Hours of operation
Hours/day
Hours/week
Hours/year
Retention time (min)
Maximum kiln temperature (°F)
Heat application method
Fuel used
Fuel to product ratio (ton/ton)
Feed moisture content (%)
Feed particle size
Feed density, loose fill (lb/ft3)
Product moisture content (%)
Effect of over-calcining
Heat recovery system
Normal life of rotary kiln (yr)
Maintenance and repair practices
8 ft dia. by 150 ft long
(See Confidential Addendum, No. 5)
Electronic scale on conveyor .
feed belt
24
168
8,760
120
2,800 to 3,200
Counterflow
Coal (pulverized)
("See Confidential Addendum, No. 6} j
20-22
\ to 1 in. dia. pellets
100-110
0
Reduces quality
~ 80% of exhaust air from cooler
used as secondary air for kiln
50
Good preventive maintenance;
scheduled shutdowns for repairs
as necessary. Patching of
refractory lining is
infrequently required.
-------
3-6
dimensions). The clay pellets are moved through the cooler by the horizontal
vibration of the bed along the longitudinal axis. (See Confidential Addendum,
No. 4, for a description of cooler operation).
3.2.3 Exhaust Emissions. Air passes upward through the grate and the
vibrating bed of calcine. About 80 percent of the air leaving the cooler is
sent to the discharge end of the rotary kiln as secondary air for that unit.
The remainder of the air from the cooler is ducted through a multiclone
collector, an induced draft fan, and a vent stack. Exhaust gases from the
rotary kiln are ducted through a multiclone collector (manufactured by Zurn
Industries) , an exhaust fan, a venturi scrubber, and a vent stack to the
atmosphere. (See Confidential Addendum, No. 7, for vent stack dimensions).
3.2.4 Control Equipment. At the inlet to the scrubber the gas
temperature is about 2H6°C (600°F). This scrubber is constructed of 316
low-carbon stainless steel. Sulfur in the clay and coal results in acid
buildup in the scrubber water and causes corrosion problems. A system for
adding calcium oxide (CaO) to the scrubber water has recently been installed.
The water flow rate to the scrubber is 1,363 1/min (360 gpm). The pressure
drop across the scrubber is 4.5 kPa (18 in. w.c.). The design efficiency of
the wet scrubber is greater than 90 percent.
-------
4-1
4. SAMPLING LOCATIONS
4.1 Suitability of Sampling Sites. The primary goal of the testing
program was to characterize emissions from the #4 rotary calciner dryer.
Additionally, physical properties of the process feed stock and the product
were investigated. Sampling sites appropriate to these objectives were
approved prior to testing. Each sampling location is discussed individually,
and the position of each site within the system is illustrated in Figure 4-1.
4.2 Rotary Calciner Feed Inlet (Sampling Location A). Grab samples of
the feed to the rotary calciner were collected for sieve analysis and
moisture content determination. Samples were taken during each set of
simultaneous Method 5 runs.
4.3 Vibrating Grate Cooler Product Outlet (Sample Location B). Grab
samples of the product were collected for sieve analysis and moisture content
determination. Samples were taken during each set of simultaneous Method 5
runs.
4.4 Vibrating Grate Cooler Multiclone Outlet (Sample Location G). Grab
samples of the product were collected for sieve analysis and moisture content
determination. Samples were taken during each set of simultaneous Method 5
runs.
4.5 Multiclone Inlet (Sampling Location C). Particulate emissions and
particle size distribution testing was conducted in the 55-inch by 95-inch
expansion flume. Four sampling ports were positioned 40 feet from the
ground, 7.6 feet from the nearest upstream disturbance and 4.7 feet from the
nearest downstream disturbance. A schematic of the sampling location is
shown in Figure 4-2.
Particulate sampling was done using 24 points (i.e. six points located
on four traverse axes); each point was sampled for 2.5 minutes, resulting in
a total test time of 60 minutes.
Particle size runs were performed for either 1.5 or 2 minutes. During
each run, two points were sampled for equal lengths of time.
-------
4-2
ATMOSPHERE
u
. STACK
I
WET
CYCLONE
SCRUBBER
OBSERVATION POINT-I
SAMPLING POINT-F
ATMOSPHERE
STACK
SAMPLING
POINT-D
FAN
T 4
EAST 'CD (£>" WEST
SAMPLING
POINT-E
SAMPLING
POINT-C
SAMPLING
POINT-A
MULTICLONE
SAMPLING
POINT-G
FAN
MULTICLONE
I
PRODUCT IN
ROTARY
CALCINER
VIBRATING
GRATE
COOLER
AMBIENT AIR
-*—TO BULK
LOAD
SAMPLING /TO SCREENING,
POINT-B CRUSHING & BAGGING
A METHODS 5&8,7
<-—* TRACE METALS
• METHOD 9
® GRAB SAMPLE
O METHOD 5, IMPACTOR,
TRACE METALS
FIGURE 4-1. ROTARY CALCINER PROCESS SCHEMATIC SHOWING SAMPLING
LOCATIONS
-------
95"
4-3
55'
I.I
P B
24 SAMPLING POINTS
SECTION M-M
TO
MULTICLONE
FROM
CALCINER
.4 SAMPLING PORTS
FIGURE 4-2. MULTICLONE INLET DIMENSIONS WITH SAMPLING PORT
AND POINT LOCATIONS
-------
4-4
4.6 I.D. Fan Inlet East & West (Sampling Locations D & E). Particulate
emissions and particle size tests were performed in a 104.5-inch by 24.5-inch
rectangular duct. Five sampling ports were located 164 inches upstream and
120 inches downstream from the nearest flow disturbance, as shown in
Figure 4-3.
For particulate tests, each of the I.D. fan inlet cross sections (east
and west) was divided into 25 equal areas (i.e. five sampling points along
each of five traverse axes). Of the 25 possible points, only 20 points were
sampled; the first point along each traverse axis was not sampled due to the
disruption of air flow along the air duct wall caused by high negative
pressure. Each of the 20 points was sampled for three minutes, resulting in
a total run time of 60 minutes.
Particle size runs ranged in length from 1.5 to 4 minutes. During each
run, two points were sampled for equal lengths of time.
4.7 Scrubber Exhaust Stack (Sample Location F, Observation Point I).
The particulate and particle size tests were performed in a 60-inch diameter
round duct. Two sampling ports spaced 90° apart are located approximately
26 feet downstream from the nearest flow disturbance (straightening vanes)
and 48 feet upstream from the stack gas exit point. A schematic of the
sampling location is provided in Figure 4-4.
The stack cross section was divided into 24 equal areas (i.e., two
traverse axes with 12 points each) for particulate and sulfur dioxide
emissions sampling. Each point was sampled for five minutes, resulting in a
total run time of 120 minutes.
Visible emissions observations and nitrogen oxides testing were also
performed at the scrubber exhaust stack.
Particle size testing was not performed at this location due to the
presence of moisture in the flue gas.
-------
4-5
5 AXES
4 POINTS/AXIS
20 TOTAL POINTS
4"~1_
1
1
^
_^ l_i_ ' !— ' — '_t_-
1 1
A
U U U U
B C D E
1
T
24.5"
~T
SECTION M-M
TO SCRUBBER
WEST
A
-
V
/\
i
1
1
I
\
y|
i
1
t
-24.5»_
I
. 1
1
FAN
TO SCRUBBER
X
1
1
,
/
EAST
A
M •
FIGURE 4-3. I.D. FAN
INLET
POINT LOCATIONS
>1
V
,. FRC
1
- 1
MULTICLONE
- i n A s "
i
00
A B
\
V
/
/
I
\ \
\x
l
i
C D E
/
\
\
\
. i
• 1
FAN /
/ /
^^'S
i \
164"
v
• 1
1
67" M
I
t
DUCT DIMENSIONS WITH SAMPLING PORT AND
(TYPICAL FOR EAST AND WEST INLETS)
-------
4-6
r
— H 60"
i
4
2
5
8'
6'
4"
1
— o —
A
I
!|>
1 '
i ! i
B
2 AXES
12 POINTS/AXIS
24 TOTAL POINTS
60" DIA.
SECTION L-L
2 SAMPLING PORTS
STRAIGHTENING VANES
FIGURE 4-4. SCRUBBER EXHAUST STACK DIMENSIONS WITH SAMPLING
PORT AND POINT LOCATIONS
-------
5-1
5. SAMPLING AND ANALYTICAL METHODS
5.1 Sampling Objectives. This section describes the sampling and
analytical procedures which were employed at the C.E. Minerals Mulcoa plant
in order to gather data concerning emissions from the #4 rotary calciner and
associated air pollution control equipment and to investigate physical
properties of the process feed stock and the product. The sampling program
included tests for particulate and sulfur dioxide, trace metals, and nitrogen
oxides emissions, sieve and moisture analysis on feed and product samples,
plume opacity, and particle size distribution. The sampling methods used are
fully described in Appendix 7.3, portions of which are extracted from 40 CFR
Part 60.
5.2 Particulate and Sufur Dioxide Emissions Testing. Where
appropriate, particulate emissions sampling conformed to the standards and
procedures set forth by EPA Reference Method 5. Method 8 was combined with
Method 5 testing at the scrubber exhaust stack for the determination of
sulfur dioxide. It was necessary at some locations to modify the test
procedures in order to cope with heavy particulate loading and/or high
negative pressure,,
5.3 Trace Metals Analysis. The Method 5 particulate catch and the
distilled water reagent from one run at each location were analyzed for trace
metals by using atomic absorption or inductively coupled argon plasma
spectrometry. These metals are zinc, nickel, iron, manganese, vanadium,
calcium, silicon, aluminum, magnesium, fluorine, beryllium, uranium, lead,
and mercury.
5.4 Sieve Analysis and Moisture Content. Sieve analysis and moisture
content determinations were performed on all feed and 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.
f
5.5 Plume Opacity. Plume opacity observations were performed in
accordance with EPA Reference Method 9 as described in 40 CFR Part 60.
-------
5-2
5.6 Particle Size Testing. Particle size determinations were made
using a right angle inlet preseparator, followed by an Andersen 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.
5.7 Nitrogen Oxides Testing. Nitrogen oxides emissions were determined
by utilizing the sampling and analytical procedures outlined in EPA Method 7.
Each Method 7 run consisted of four samples taken concurrently with the
Method 5 sampling.
-------
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 sind 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 or by Entropy. Calibration data for the sampling equipment are
contained in Appendix 7.9.
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 and a blank run.
The 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 stack, 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 Section 7.6, was 0.01 milligrams, based upon weight differences
ranging from 0.00 to 0.02 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 0.05 milligrams, based upon a difference
ranging from 0.01 to 0.10 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 7.2.3.
------- |