United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EMB Report 83-SLD-2
June 1983
Air
Secondary Lead
Smelter
Arsenic,
Cadmium, and
Lead Emissions
General Battery
Corporation
Reading,
Pennsylvania
-------
SOURCE SAMPLING REPORT FOR
GENERAL BATTERY CORPORATION:
MEASUREMENT OF ARSENIC/LEAD/CADMIUM
UNIT #1
SECONDARY LEAD SMELTER PROCESS
READING, PENNSYLVANIA
Contract No. 68-02-3545
Work Assignment No. 15
EPA Project Officer: Frank Clay
Prepared for:
Emission Measurement Branch
Emission Standards and Engineering Division
U.S. Environmental Protection Agency
Research Triangle Park, North Carolina 27711
Prepared by:
M. Hartman and C. Stackhouse
TRW, Environmental Operations
Post Office Box 13000
Research Triangle Park, North Carolina 27709
-------
TABLE OF CONTENTS
Section Page
1 INTRODUCTION 1-1
2 SUMMARY AND DISCUSSION OF RESULTS 2-1
2.1 Emission Rate Results for Arsenic, Cadmium,
and Lead 2-1
2.2 Arsenic/Lead/Cadmium Results 2-7
2.3 Method 108 Comparison Runs - Standard Vs. Hot ... 2-7
2.4 S02/S03 Results 2-8
2.5 Particulate Results 2-8
2.6 Stationary Gas Results 2-17
2.7 Process Material Results 2-17
3 SMELTER OPERATIONS AND PROCESS EMISSION
CONTROL EQUIPMENT 3-1
3.1 Process Description 3-1
3.2 Process Emission Control Equipment 3-2
4 SAMPLING LOCATIONS . 4-1
4.1 Baghouse Inlet 4-1
4.2 Scrubber Inlet 4-1
4.3 Scrubber Outlet 4-5
5 SAMPLING AND ANALYSIS METHODS 5-1
5.1 EPA Reference Methods Utilized During Testing
of the Reading Facility 5-1
5.2 EPA Reference Method 108 and Modified 108 Hot
for Arsenic/Lead Sampling 5-2
5.3 Analytical Methods 5-3
5.4 Process Sampling 5-8
(continued)
-------
TABLE OF CONTENTS (Concluded)
Section Page
APPENDICES
A RESULTS A-l
B FIELD DATA SHEETS B-l
C EXAMPLES OF ANALYTICAL RUNS C-l
D METHOD 108 GENERAL DESCRIPTION D-l
E SAMPLING TEST PLAN E~l
F TEST LOG F-l
G PERSONNEL G-l
H PROCESS DATA H-l
m
-------
LIST OF FIGURES
t
Page
Schematic diagram of the secondary lead plant
at General Battery in Reading, Pennsylvania 2-2
4-1 General Battery, Reading, Pennsylvania: schematic
of the baghouse/scrubber system with the gas
sampling locations 4-2
4-2 General Battery, Reading, Pennsylvania: baghouse
inlet location with sample traverse points 4-3
4-3 General Battery, Reading, Pennsylvania: scrubber
inlet location with sample traverse points 4-4
4-4 General Battery, Reading, Pennsylvania: scrubber
outlet location with sample traverse points 4-6
5-1 General Battery, Reading, Pennsylvania: Method 108
sampling train 5-4
IV
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LIST OF TABLES
Table Page
2-1 General Battery Plant Process Unit #1 - Reading,
Pennsylvania - Summary of Emission Rate Results .... 2-3
2-2 General Battery Plant Process Unit #1 - Reading,
Pennsylvania - Removal Efficiency for Arsenic 2-4
2-3 General Battery Plant Process Unit #1 - Reading,
Pennsylvania - Removal Efficiency for Cadmium 2-5
2-4 General Battery Plant Process Unit #1 - Reading,
Pennsylvania - Removal Efficiency for Lead 2-6
2-5 General Battery Plant Process Unit #1 - Reading,
Pennsylvania - Arsenic Emission Rates 2-9
2-6 General Battery Plant Process Unit #1 - Reading,
Pennsylvania - Cadmium Emission Rates 2-10
2-7 General Battery Plant Process Unit #1 - Reading,
Pennsylvania - Lead Emission Rates 2-11
2-8 Comparison of Method 108 Standard and Hot Runs:
Front Half V:;. Back Half Capture Efficiencies 2-12
2-9A General Battery Plant Process Unit #1 - Reading,
Pennsylvania - Summary of S02 Analysis 2-13
2-9B General Battery Plant Process Unit #1 - Reading,
Pennsylvania - Summary of S02 Analysis 2-14
2-10A General Battery Plant Process Unit #1 - Reading,
Pennsylvania - Summary of Particulate Results 2-15
2-10B General Battery Plant Process Unit #1 - Reading,
Pennsylvania - Summary of Particulate Results 2-16
2-11 General Battery Plant Process Unit #1 -
Reading, Pennsylvania 2-18
3-1 Sample Point Key for Diagram of General Battery
Secondary Lead Plant, Reading, Pennsylvania 3-3
5-1 General Battery, Reading, Pennsylvania:
Method 108 Recovery Procedures 5-5
-------
1. INTRODUCTION
TRW Energy and Environmental Division conducted arsenic testing at
the General Battery Plant, Process Unit #1 at Reading, Pennsylvania
under Contract #68-02-3545, Project #83-SNF-15 to EPA/EMB. The inlet
and outlet locations around the two control devices, fabric filter
baghouse and wet scrubber systems, were tested June 19, 1983, to
June 23, 1983. The purpose of the sampling and field measurement was
part of the Arsenic Emission Test Program for secondary lead smelters
sponsored by the Office of Air Quality Planning and Standards in
coordination with Emission Standards and Engineering Division (ESED) and
Emission Measurement Branch (EMB), of the U.S. Environmental Protection
Agency.
The immediate objective of the sampling was to obtain sufficient
multimedia samples of the Unit #1 secondary lead smelter process and
with subsequent analytical procedures, to perform an arsenic material
balance. The ultimate objective of the emission testing program is
providing data for developing arsenic emission factors and establish
arsenic emission control device efficiencies for process sources of
arsenic emissions at secondary lead smelters.
The primary sampling method was EPA Draft Method 108 with EPA
Reference Methods 1, 2, 3, and 6 used for flow and gas constituents.
Special Method 108 runs were performed with the train maintained at
process temperatures. The testing was performed by the field test crew
from TRW's Research Triangle Park Operations. Mr. Neil Lebo of General
Battery provided the 1iason between the test crew and General Battery
operations. Present and representing the Environmental Protection
Agency was Mr. Frank Clay - Emission Measurement Branch (EMB) and
Mr. Lee Beck - Emission Standards and Engineering Division (ESED).
Also, present was Mr. Larry Keller of Radian Corporation for monitoring
the process and collecting process samples during testing periods.
-------
2. SUMMARY AND DISCUSSION OF RESULTS
Figure 2-1 is a schematic diagram of the secondary lead plant. The
smelter operation at the Reading Plant is used to regenerate lead for
use in new batteries. The furnace exhaust gas passes through an after
burner section. The gas exitting the afterburner is cooled by a large
array of surface gas coolers using the ambient air to cool the gases.
The exhaust gases then are pulled through an I.D. fan to the baghouse
preceding a venturi scrubber. The exhaust stack immediately follows the
demister section of the scrubber. The three sample locations were: the
baghouse inlet prior to the I.D. fan (BHI), the baghouse outlet or
scrubber inlet (baghouse outlet - scrubber inlet referred to in this
report as scrubber inlet (SCI)) prior to the venturi scrubber (SCI), and
the venturi scrubber outlet (SCO). The sample location specifics are
provided in Section 5.
2.1 EMISSION RATE RESULTS FOR ARSENIC, CADMIUM, AND LEAD
The emission rate results of the Method 108 tests conducted at
General Battery on Process Unit #1 is summarized in Table 2-1. A further
breakdown of the results is provided in Section 2.2. Tables 2-2 to 2-4
present the removal efficiency of the baghouse system and the complete
system. The baghouse system was calculated from the difference of the
emission rate between the baghouse inlet (BHI) location and the baghouse
outlet or scrubber inlet (SCI) location. The complete system was
calculated from the difference of the emission rate between the baghouse
inlet to the scrubber outlet (SCO) location.
The complete system had a removal efficiency of 99.61% for arsenic,
99.95% for cadmium, and 99.91% for lead. The baghouse system had a
removal efficiency of 99.57% for arsenic, 99.87% for cadmium, and 99.70%
for lead. There was a problem with the BHI-3 Standard Method 108 run
but the efficiency was calculated by using the BHI-3 hot results. The
-------
Reverbcratory Furnace
Inputs
Reverberator/ Furnace
ro
ro
Reverberator/ Furnace
Products
Blast Furnace Inputs
Blast Furnace
Furnace
Offgas
Baghouse
Baghouse
Offgas
Lime
Scrubber
Scrubber
Offgas
Flue Dust
Scrubber Sludge
Figure 2-1.
Schematic diagram of the secondary lead plant at
General Battery in Reading, Pennsylvania.
Blast Furnace Products
-------
ro
Table 2-1. GENERAL BATTERY PLANT PROCESS UNIT #1
READING, PENNSYLVANIA
SUMMARY OF EMISSION RATE RESULTS
BHI-1
SCI-1
sco-i
BHI-2
SCI-2
SCO-2
BHI-3H
SCI-3
SCI-3H
SCO-3
BHI-4
BHI-4H
Arsenic emi
(Ibs/hr)
2.90
4.73 x 10"2
1.80 x 10"2
8.48
4.95 x 10"3
1.80 x 10"2
7.86
5.10 x 10"2
4.61 x 10"2
2.78 x 10"2
6.18
4.62
ssion rates
(kg/hr)
1.31
2.15 x 10"2
8.17 x 10"3
3.85
2.24 x 10"3
8.14 x 10"3
3.56
2.31 x 10"2
2.09 x 10"2
1.26 x 10"2
2.81
2.10
Cadmium emi
(Ibs/hr)
16.37
1.64 x 10"2
2.03 x 10"3
8.13
1.50 x 10"2
2.08 x 10"3
8.64
8.66 x 10"3
1.20 x 10"2
1.81 x 10"3
3.63
3.48
ssion rates
(kg/hr)
7.43
7.45 x 10"3
9.19 x 10"4
3.69
6.78 x 10"3
9.44 x 10"4
3.92
3.93 x 10"3
5.44 x 10"3
8.23 x 10"4
1.65
1.58
Lead emission rates
(Ibs/hr)
258.39
8.36 x 10"1
8.78 x 10"2
804.10
2.00
1.36 x 10"1
599.09
1.93
2.06
1.58 x 10"1
441.6
315.7
(kg/hr)
117.20
3.79 x 10"1
3.90 x 10"2
364.74
9.09 x 10"1
6.16 x 10"2
271.74
8.78 x 10"1
9.36 x 10"1
7.15 x 10"2
200.4
143.3
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Table 2-2. GENERAL BATTERY PLANT PROCESS UNIT #1
READING, PENNSYLVANIA
REMOVAL EFFICIENCY FOR ARSENIC
Emission rate (Ibs/hr)
Sample location
BHI
SCI
SCO
Removal Efficiency
Baghouse System
Complete System
Run #1
2.90
0.0473
0.0180
1%)
98.37
99.38
Run #2
8.48
0.00495b
0.0180
99.94C
99.79
Run #3
7.86a
0.0510
0.0278
99.35
99.65
Average removal
efficiency
98.86
99.61
BHI-3H results used because BHI-3 run was aborted.
Suspect number, analytical results being rechecked.
GThis number not used for average of baghouse system.
-------
Table 2-3. GENERAL BATTERY PLANT PROCESS UNIT #1
READING, PENNSYLVANIA
REMOVAL EFFICIENCY FOR CADMIUM
Sample location
Emission rate (Ibs/hr)
Run #1
Run #2
Run #3
Average removal
efficiency
BHI
SCI
SCO
16.37
0.0164
0.00203
8.13
0.0150
0.00208
8.64
0.00866
0.00181
Removal Efficiency (%)
Baghouse System 99.90 99.81 99.90
Complete System 99.99 99.97 99.90
99.87
99.95
2-5
-------
Table 2-4. GENERAL BATTERY PLANT PROCESS UNIT #1
READING, PENNSYLVANIA
REMOVAL EFFICIENCY FOR LEAD
Sample location
BHI
SCI
SCO
Removal Efficiency
Baghouse System
Complete System
Emission
Run #1
258.39
0.836
0.0878
_£%}
99.68
99.97
rate
Run #2
804. 10
2.00
(Ibs/hr)
Run #3
599.09
1.93
Average removal
efficiency
0.136 0.158
99.75
99.98
99.68
99.97
99.70
99.97
-------
comparison of the Standard and Hot Method 108 runs provided results of
1-14% difference for arsenic and lead with cadmium results varying to
approximately 25%.
2.2 ARSENIC/LEAD/CADMIUM RESULTS
The sampling for arsenic/lead/cadmium was performed in accordance
with procedures set forth in the Standard Method 108 for determination
of particulate and gaseous arsenic emissions from non-ferrous smelters.
The standard sampling trains were operated according to Federal Register
guideline with the addition of a cyclone system for particulate collection
at the BHI location due to high grain loading. Also special hot trains
were operated at process temperatures as a comparison study. The operation
and results are discussed in Section 2.3.
2.3 METHOD 108 COMPARISON RUNS - STANDARD VS. HOT
A comparison study was performed at the BHI and SCI sample locations.
The purpose of the study was to see if gaseous arsenic at a stack
temperature greater than 250°F would condense on the filter (creating an
artificially high arsenic loading on the filter) rather than passing
through the filter and being caught by the impingers. Two trains were
operated simultaneously: one train according to Method 108, while the
special train (hot train) maintained a filter temperature that was as
close as possible to the process gas temperature. The Standard 108
train traversed the stack while the hot train sampled from a single
point. (A second comparison run was required at the BHI location when
the high temperature (>400°F) destroyed the Standard 108 filter system
during the third test period.)
If gaseous arsenic above 250°F condenses on the filter of a Standard
Method 108 train, then a train with the filter temperature maintained at
the stack gas temperature should allow the gaseous arsenic to pass
through the filter and be caught by the impingers. It would be expected,
then, that if the two trains were operated simultaneously as previously
described, the per cent arsenic caught in the front half of the hot
train would be less than the Standard 108 train, and back half of the
hot train would be greater than the Standard 108 train.
The two completed comparison runs were SCI-3/3H and BHI-4/4H; the
hot trains were operated at temperatures from 370-400°F. The results of
2-7
-------
the simultaneous sampling are shown in Table 2-5. At each location, the
per cent arsenic collected in the back half of the hot trains was greater
than the per cent arsenic collected in the back half of the corresponding
Standard 108 train. The per cent arsenic collected in the front half of
the Standard 108 train was higher than the per cent arsenic collected in
the front half of the corresponding hot train. Thus from these limited
data, it appears that some gaseous arsenic may indeed condense on the
filter if the process gas temperature is above the filter temperature.
In looking at Table 2-5, it is possible to see that the hot train
filter temperature at the SCI location was maintained more closely to
the process gas temperature than was the filter temperature at the BHI
location. This may partially account for the percentage differences in
the results from the two locations.
In addition to the arsenic analysis, the trains in the comparison
study were also analyzed for cadmium and lead. Arsenic, cadmium, and
lead results are found in Tables 2-6 to 2-8.
2.4 S02/S03 RESULTS
One Method 6 test run was completed at each site for providing
oxides of sulfur concentrations. Also, the Method 108 H202 impingers
solution were analyzed for all the 108 test runs. The concentration
results from the analysis are presented in Tables 2-9A and 2-9B.
2.5 PARTICIPATE RESULTS
Tables 2-10 and 2--10B present the results of the particulate analysis
on the front half of the Method 108 runs. The analytical work sheet is
provided in Appendix C.
The results are consistent with the higher reduction efficiencies
across the baghouse (BHI location to SCI location). The Method 108
analytical procedures for metals caused difficulty in weighing of the
particulate catch. Due to the fact that the drying of the probe rinse
and cyclone catch (used at BHI location only) for weighing would have
caused loss in the metal analysis, the priority was determined for
performing the analysis first and then attempting to dry the digested
particulate catch. Therefore, the particulate results for the filter
(weighed dry before digesting) are accurate. But, the probe rinse and
cyclone catches will be biased low because the digesting of the metals
would produce lower particulate results.
2-8
-------
Table 2-5. GENERAL BATTERY PLANT PROCESS PLANT UNIT #1
READING, PENNSYLVANIA
ARSENIC EMISSIONS
BHI-3
(ABORT)
BHI-3-H
BHI-4
BHI-4-H
SCI-3
SCI-3-H
Stack
temperature
468
474
424
423
379
380
Filter
temperature
269
397
238
372
251
388
Temperature
difference
-77
-51
+8
Arsenic sampled
Front
(Mg)
91.0
30.8
25.1
0.562
0.415
Back
(Mg)
0.875
0.2
0.3
0.162
0.222
Total
(Mg)
91.875
31.0
25.4
0.724
0.637
Front
(gr/OSCF)
0.027
0.0213
0.0151
1.47 x 10
0.0001
Arsenic concentration
Back
(gr/DSCF)
0.0003
0.0001
0.0002
"4 4.26 x 10"5
0. 00006
Total
(gr/DSCF)
0.029
0.0214
0.153
1.90 x 10"4
0.00016
Arsenic
Front half
99.05
99.35
98.82
77.62
65.15
collection
Back half
(X)
0.95
0.65
1.18
23.38
34.85
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ro
i
Table 2-6. GENERAL BATTERY PLANT PROCESS PLANT UNIT #1
READING, PENNSYLVANIA
ARSENIC EMISSION RATES
BHI-1
SCI-1
SCO-1
BHI-2
SCI-2
SCO-2
BHI-3H
SCI-3
SCI-3H
SCO-3
BHI-4
BHI-4H
Volume
meter
(DSCF)
46.375
57.963
69.011
48.070
61.985
74.331
48.869
58.879
60.309
70.131
22.319
25.688
Flow
rate
(DSCFM)
33,463
33,855
33,642
34,119
33,954
34,995
31,668
31,413
32,975
32,153
33,655
35,359
Arsenic
sampled
(nig)
30.4
0.615
0.280
90.4
0.0684
0.289
91.9
0.724
0.637
0.460
31.0
25.4
Arsenic
concentration
(gr/DSCF)
1.01 x 10"2
1.63 x 10"4
6.25 x 10"5
2.90 x 10"2
1.70 x 10"5
5.99 x 10"5
2.80 x 10"3
1.89 x 10"4
1.63 x 10"4
1.01 x 10"4
2.14 x 10"2
1.53 x 10"1
Arsenic
emission rate
(Ibs/hr)
2.90
4.73 x 10"2
1.80 x 10"2
8.48
4.95 x 10"3
1.80 x 10"2
7.86
5.10 x 10"2
4.61 x 10"2
2.78 x 10"2
6.18
4.62
(kg/hr)
1.31
2.15 x 10"2
8.17 x 10"3
3.85
2.24 x 10"3
8.14 x 10"3
3.56
2.31 x 10"2
2.09 x 10"2
1.26 x 10"2
2.80
2.10
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ro
i
Table 2-7. GENERAL BATTERY PLANT PROCESS UNIT #1
READING, PENNSYLVANIA
CADMIUM EMISSION RATES
BHI-1
SCI-1
SCO-1
BHI-2
SCI-2
SCO-2
BHI-3H
SCI-3
SCI-3H
SCO- 3
BHI-4
BHI-4H
Volume
meter
(DSCF)
46.375
57.963
69.011
48. 070
61.985
74.331
48.869
58.879
60.309
70.131
22.319
25.688
Flow
rate
(DSCFM)
33,463
33,855
33,642
33,119
33,954
34,995
31,668
31,413
32,975
32,153
33,655
35,359
Cadmi urn
sampled
(mg)
172
0.213
0.0315
86.9
0.207
0.0335
101
0.123
0.166
0.0300
18.2
19.1
Cadmi urn
concentration
(gr/DSCF)
5.71 x 10"2
5.66 x 10"5
7.03 x 10"6
2.78 x 10"2
5.14 x 10"5
6.94 x 10"6
3.18 x 10"2
3.22 x 10"5
4.24 x 10"5
6.59 x 10"6
1.26 x 10"2
1.15 x 10"2
Cadmium
emission rate
(Ibs/hr)
16.37
1.64 x 10"2
2.03 x 10"3
8.13
1.50 x 10"2
2.08 x 10"3
8.64
8.66 x 10"3
1.20 x 10"2
1.81 x 10"3
3.63
3.48
(kg/hr)
7.43
7.45 x 10~3
9.19 x 10~4
3.69
6.78 x 10"3
9.44 x 10"4
3.92
3.93 x 10"3
5.44 x 10"3
8.23 x 10"4
1.58
1.51
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ro
i
Table 2-8. GENERAL BATTERY PLANT PROCESS UNIT #1
READING, PENNSYLVANIA
LEAD EMISSION RATES
BHI-1
SCI-1
SCO-1
BHI-2
SCI-2
SCO-2
BHI-3H
SCI-3
SCI-3H
SCO-3
BHI-4
BHI-4H
Volume
meter
(DSCF)
46.375
57.963
69.011
48.070
61.985
74.331
48.869
58.879
60.309
70.131
22.319
25.688
Flow
rate
(DSCFM)
33,463
33,855
33,642
34,119
33,954
34,995
31,668
31,413
32,975
32,153
33,655
35,359
Lead
sampled
(ing)
2,714
10.835
1.365
8,601
27.645
2.185
7,005
27.485
28.595
2.605
2,214
1,734
Lead
concentration
(gr/DSCF)
9.01 x 10'1
2.88 x 10~3
3.05 x 10"4
2.75
6.87 x 10"3
4.53 x 10"4
2.21
7.19 x 10~3
7.30 x 10~3
5.72 x 10"4
1.53
1.04
Lead
emission
(Ibs/hr)
258.39
8.36 x 10'1
8.78 x 10"2
804. 10
2.00
1.36 x 10"1
599.09
1.93
2.06
1.58 x 10"1
441.6
315.7
rate
(kg/hr)
117.20
3.79 x 10"1
3.90 x 10"2
364. 74
9.09 x 10"1
6.16 x 10^2
271.74
8.78 x 10"1
9.36 x 10"1
7.15 x 10"2
192.4
137.5
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ro
i
Table 2-9A. GENERAL BATTERY PLANT PROCESS UNIT #1
READING, PENNSYLVANIA
SUMMARY OF S02 ANALYSIS
Run
BHI-1
BHI-2
BHI-3
BHI-3-H
BHI (Method 6)
BHI-4
BHI-4-H
ppm
2676
2542
Aborted
3256
3225
1386
1280
Run
SCI-1
SCI-2
SCI-3
SCI-3-H
SCI (Method 6)
ppm Run
2870 SCO-1
2780 SCO-2
3513 SCO-3
3580
2855 SCO (Method 6)
ppm
308
112
216
173
-------
Table 2-9B. GENERAL BATTERY PLANT PROCESS UNIT #1
READING, PENNSYLVANIA
SUMMARY OF S02 ANALYSIS
TRW
Lab #
4823
4827
4826
4824
4830
4827
4836
4842
4853
4848
4858
4863
4867
4871
4875
4879
4883
4887
Field
Run #
BHI
SCO
SCI
BHI
SCO
SCI
BHI-1
BHI-2
BHI-4
BHI-3-H
BHI-4-H
SCI-1
SCI-2
SCI-3
SCI-3-H
SCO-1
SCO-2
SCO-3
Sample
type
so3a
S03
S03
S02b
S02
S02
108C
108
108
108
108
108
108
108
108
108
108
108
Sample volume
(Vm) (son)
0.34
0.52
0.52
0.34
0.52
0.52
1.31
1.36
0.63
1.38
0.73
1.04
1.76
1.67
1.71
1.98
2.11
1.99
Total col
(mg)
4.24
0.215
2.59
2,869
236
3,887
9,183
9,056
2,288
11,771
2,449
12,331
12,821
15,369
16,040
1,596
618
1,128
lected
(ppm)
3.8
0.1
1.5
3,221
173
2,853
2,676
2,542
1,386
3,256
1,280
2,870
2,780
3,513
3,580
308
112
216
aMethod 6 - IPA impinger.
Method 6 - H202 impinger.
cMethod 108 - H202 impinger.
2-14
-------
Table 2-10A. GENERAL BATTERY PLANT PROCESS UNIT #1
READING, PENNSYLVANIA
SUMMARY OF PARTICULATE RESULTS3
ro
i
Run
BHI-1
BHI-2
PHT-^
BHI-3-H
BHI-4
BHI-4-H
gr/DSCF
3.74
5.29
ARDRTFR
8.50
2.84
2.95
Ib/hr
1071
1521
2306
820
894
Run
SCI-1
SCI-2
- SCI-3
SCI-3-H
gr/DSCF
.0056
.0086
.0092
.0078
Ib/hr Run
1.62 SCO-1
2.49 SCO-2
2.48 SCO- 3
2.19
gr/DSCF Ib/hr
.0011 .303
.0109 3.28
. 0015 . 400
Suspect low results, see explanation in Section 2.5.
-------
Table 2-10B. GENERAL BATTERY PLANT PROCESS UNIT #1
READING, PENNSYLVANIA
SUMMARY OF PARTICULATE RESULTS
Run
BHI-1
SCI-1
SCO-1
BHI-2
SCI-2
SCO-2
BHI-3H
SCI-3
SCI-3H
SCO-3
BHI-4
BHI-4H
Volume
meter
(DSCF)
46.375
57.963
69.011
48.070
61.985
74.331
48.869
58.879
60.309
70.131
22.319
25.688
Particulate results
Filter + Probe/cyclone
(mg) (mg)
6,183.8
21.0
4.7
7,162.8
34.5
52.6
11,173.5
35.2
30.3
6.6
2,382.3
2,489.3
5,100
a
a
9,330
a
a
15,730
a
a
a
1,730
2,420
} - Total
(mg)
11,238.5
21.0
4.7
16,492.8
34.5
52.6
26,903.5
35.2
30.3
6.6
4,112.3
4,909.3
Particulate
concentration
(gr/DSCF)
3.73
5.58 x 10"3
1.05 x 10"3
5.28
8.57 x 10"3
1.09 x 10"2
8.48
9.21 x 10"3
7.74 x 10"3
1.45 x 10~3
2.84
2.94
No cyclone used or substantial amount of particulate in probe at these
locations.
^Suspect low results, see explanation in Section 2.5.
2-16
-------
2.6 STATIONARY GAS RESULTS
EPA Reference Method 3 (Gas Analysis for Carbon Dioxide, Oxygen,
Excess Air, and Dry Molecular Weight; Federal Register 42 FR 41768) was
utilized to characterize the flue gas. The results are provided in
Appendix A computer printouts and example field chromatograms are included
in Appendix C.
2.7 PROCESS MATERIAL RESULTS
The process material samples were composited and analyzed by atomic
absorption. The results are presented in Table 2-11. A description of
the process is provided in Section 3 and a further description with the
process sampling information is provided in Appendix H.
2-17
-------
Table 2-11. GENERAL BATTERY PLANT PROCESS UNIT #1 - READING, PENNSYLVANIA
ro
i
i—"
CO
Sample Identification
Process/Ventilation Baghouse Dust
Feed to Reverb
Process/Ventilation Baghouse Dust
Feed to Reverb
Process Baghouse Dust
Process/Ventilation Baghouse Dust
Feed to Reverb
Process Baghouse Dust
Ventilation Baghouse Dust
Ventilation Baghouse Dust
Ventilation Baghouse Dust
Scrubber Sludge fron 11 Cone
Scrubber Sludge from fl Cone
Scrubber Sludge fron fl Cone
fl Scrubber Slurry
fl Scrubber Slurry
fl Scrubber Slurry
Composite Blast Furnace Slag, Blast fl
Composite Reverb Furnace Slag, Reverb fl
Coupes ite Blast Furnace Slag, Blast fl
Composite Reverb Furnace Slag, Reverb fl
Sample Time
10:00 am
1:00 pm
10:00 am
6:05 pm
1:00 pm
10:00 am
6:00 pm
1:00 pm
6:30 pm
11:30 am
1:15 pm
6:30 pm
11:25 am
1:15 pm
9:15am-2:35pm
9: 50am- 5: 00pm
12: 10-2: 15pm
12: 10-2: 15pm
Sample date
6/21/83
6/22/83
6/21/83
6/21/83
6/22/83
6/21/83
6/21/83
6/22/83
6/21/83
6/21/83
6/22/83
6/21/83
6/21/83
6/22/83
6/21/83
6/21/83
6/22/83
6/22/83
TRW no.
4803
4804
4805
4806
4807
4808
4809
4810
4811
4812
4813
4814
4815
4816
4896
4897
4898
4899
Arsenic (mg/g)
5.19
14.3
5.82
7.22
7.39
8.99
10.3
8.85
1.48 X 10"2
3.7 X 10"2
1.52 X 10"2
1.15 X 10"2
8.79 X 10"3
8.80 X 10"3
1.83 X 10"4
4.96 X 10"3
6.97 X 10*4
4.64 X 10"3
Cadmium (mg/g)
9.55
8.73
10.2
10.2
11.2
2.67
7.72
2.67
7.25 X 10"2
5.17 X 10"3
5.83 X 10"3
4.09 X 10"3
4.86 X 10"3
1.69 X 10"3
1.32 X 10"2
2.12
1.48 X 10"2
1.57
Lead (mg/g)
242
249
324
185
290
225
315
248
0.186
0.271
0.233
0.165
0.200
0.105
7.54
532
21.3
623
(continued)
-------
Table 2-11. Continued
ro
i
Sample Identification
Blast Furnace Metal
Blast Furnace Metal
Blast Furnace Metal
Blast Furnace Metal
Blast Furnace Metal
Blast Furnace Metal
Blast Furnace Metal
Blast Furnace Metal
Blast Furnace Metal
Blast Furnace Metal
Blast Furnace Metal
Blast Furnace Metal
Blast Furnace Metal
Blast Furnace Metal
Blast Furnace Metal
Reverb Furnace Metal
Reverb Furnace Metal
Reverb Furnace Metal
Reverb Furnace Metal
Sample Tine
10:00 am
9:15 an
10:50 an
11:40 an
12:36 an
1:05 pn
2:35 pn
4:35 pn
5:55 pn
6:55 pn
8:00 pn
12:10 pm
12:30 pn
1:30 pn
2:15 pn
10:50 am
5:00 pm
12:15 pn
1:50 pm
Sample date
6/21/83
6/21/83
6/21/83
6/21/83
6/21/83
6/21/83
6/21/83
6/21/83
6/21/83
6/21/83
6/21/83
6/22/83
6/22/83
6/22/83
6/22/83
6/21/83
6/21/83
6/22/83
6/22/83
TRW no.
4900
4901
4902
4903
4904
4905
4906
4907
4908
4909
4910
4911
4912
4913
4914
4915
4916
4917
4918
Arsenic (sg/g)
4.07 X 10"2
0.425
1.75 X 10"2
0.362
4.23 X 10"2
7.54 X 10"3
4.86 X 10"2
2.22 X 10"2
1.61 X 10"2
3.26 X 10"2
4.62 X 10"2
0.504
6.39 X 10"2
2.66 X 10"2
NO
8.9 X 10"4
1.77 X 10"3
ND
1.91 X 10"3
Cadaiua (stg/g)
0.107
6.65 X 10"2
6.95 X 10"2
9.16 X 10"2
3.76 X 10"2
4.00 X 10"2
4.94 X 10"2
6.23 X 10"2
3.09 X 10"2
1.99 X 10"2
8.00 X 10"2
0.139
9.10 X 10"2
6.90 X 10"2
5.68 X Ifl"2
1.34 X 10"2
5.31 X 10"2
2.07 X 10"2
4.54 X 10"2
Lead (sg/g)
865
936
937
885
946
981
882
987
849
722
753
924
822
894
889
836
887
851
906
(continued)
-------
Table 2-11. Concluded
•i\»
o
Sample Identification
Yard Sample fl; Reverb Slag, Dross and
Battery Group Mix
Yard Sample 12; Rerun Blast Furnace
Slag Heel
Yard Sample *3, Battery Group and
Dross Mix
Yard Sample 14, Blast Furnace Slag
Yard Sample f5, Shredded Batteries, Whole
Yard Sample 16, Coke
Yard Sample 17, Reverb Slag
Yard Sample 18, Refining Dross Sample
Yard Sample 19, Industrial Battery Plates
Yard Sample flO, Regular Battery Plates
Sample Time Sample date
6/22/83
6/22/83
6/22/83
6/22/83
6/22/83
6/22/83
6/22/83
6/22/83
6/22/83
6/22/83
TRW no.
4919
4920
4921
4922
4923
4924
4925
4926
4927
4928
Arsenic (mg/g)
1.22
5.47 X 10"2
1.00
4.86 X 10"2
0.270
8.9 X 10"2
3.01
1.24
0.105
0.143
Cadmium (mg/g)
0= 328
4.48 X 10"3
0.327
9.65 X 10"2
1.00 X 10"2
4.49 X 10"3
0.392
0.399
4.64 X 10"3
2.29 X 10"3
Lead (mg/g)
494
4.12
448
8.71
378
2.92
275
720
348
474
-------
3. SMELTER OPERATIONS AND PROCESS EMISSION CONTROL EQUIPMENT*
3.1 PROCESS DESCRIPTION
The General Battery plant in Reading Pennsylvania is a large secondary
lead smelter with a total rated lead production capacity of 240 tons/day.
The primary lead-bearing input materials to the plant are recycled
lead-acid batteries obtained from various sources and battery plant
scrap obtained from the adjacent battery manufacturing facilities.
Arsenic is present in these materials as an alloying agent in the lead
used to manufacture most battery plates (i.e., all lead-acid battery
plates except for those used in maintenance-free calcium-lead batteries).
The lead product produced by the plant is used primarily for new battery
manufacture and can contain various levels of arsenic depending on the
buyer's specifications.. Metallic arsenic is added directly to the
refining kettles to meet some of the specifications.
r
The General Battery plant has two reverberatory furnaces; two blast
furnaces; ten refining kettles; two fabric filter/wet scrubber systems
for treating process offgases from the reverberatory and blast furnaces;
and two sanitary baghouse systems for treating ventilation gases from
the refining kettles, smelting furnace tapping points, and other
ventilation sources. Arsenic emission tests were performed on the
#1 baghouse/wet scrubber system that treats the combined offgas from the
#1 blast furnace/reverberatory furnace pair.
Each of the two reverberatory furnaces has a rated lead production
capacity of 70 tons/day. The reverberatory furnace charge consists of
shredded whole batteries including the case, battery plant scrap, and
recycled baghouse dust captured by the process baghouse and sanitary
baghouse systems. The shredded plastic cased batteries and battery
^Authored by Radian, Incorporated.
-------
plant scrap (i.e., decased battery group materials and battery plant
drossed) are charged continuously to the reverberatory furnaces by ram
feeders that are fed by hoppers containing feed mixture. The baghouse
dust is charged continuously to the reverberatory furnaces using a screw
conveyor system. The feed materials are smelted in the furnace by
combusting natural gas with oxygen-enriched air. Reverberatory furnace
slag and reverberatory furnace lead are tapped from the furnace on an
irregular basis when the lead in the furnace accumulates to a sufficiently
high level. Typically,, lead and slag are tapped from the furnace once
every 3 or 4 hours. Data on the #1 reverberatory furnace feed rates and
metal production rates during the test periods are contained in Appendix H.
The #1 reverberatory furnace ran smoothly with no upset conditions
during each of the test periods. The average hourly lead production
from the #1 reverberatory furnace was 9,500 pounds of lead per hour
during the test periods.
Each of the two blast furnaces has a rated lead production capacity
of 50 tons/day. The charge materials to the blast furnace consist of
reverberatory furnace slag, refining kettle dross, and fluxing agents
(coke, iron, and limestone). The blast furnace is charged roughly every
20 minutes in 5,000 Ib. charges that are introduced to the top of the
furnace through a "thimble" that is filled using front end loaders.
Lead is tapped from the blast furnace continuously while slag is tapped
approximately every 40-50 minutes. Data on the #1 blast furnace feed
rates and metal production rates during the test periods are contained
in Appendix H. The #1 blast furnace ran smoothly with no upset conditions
during each of the test periods. The average hourly lead production
from the #1 blast furnace was 5,400 pounds of lead per hour during the
test periods.
3.2 PROCESS EMISSION CONTROL EQUIPMENT
Offgases from each blast furnace/reverberatory furnace pair are
combined and sent to an afterburner to destroy combustibles. The
afterburner offgas from each furnace pair are cooled in U-tube cooling
system before being directed to one of two process baghouse/wet scrubber
systems for removal of particulate matter and S02 (see Figure 2-1 and
Table 3-1). Each of the process baghouses consists of seven equivalent
sections, each section containing 80 fiberglass bags (30 ft. long and
3-2
-------
Table 3-1. SAMPLE POINT KEY FOR DIAGRAM OF GENERAL BATTERY
SECONDARY LEAD PLANT, READING, PENNSYLVANIA
Sample point Description
A Combined reverberatory and blast furnace offgas
downstream of afterburner (afterburner not shown)
B Baghouse offgas
C Lime scrubber offgas
D Baghouse flue dust catch
E Lime scrubber sludge
F Crushed battery plates, lead scrap
G Recycled flue dust
H Miscellaneous reverberatory furnace inputs
I Semisoft lead
J Reverberatory furnace slag
K Drosses
L Reverberatory furnace slag
M Recycle blast furnace slag
N Battery scrap
0 Coke
P Miscellaneous blast furnace inputs
Q Hard lead
R Blast furnace slag, matte
3-3
-------
inches in diameter). The bags are cleaned using reverse air pulses
every 30 minutes, and equal time intervals are maintained between reverse
flow in all sections. Representative baghouse inlet temperature data and
individual section pressure drop data are contained in Appendix H for
the #1 process baghouse during the test periods. A bag breakage occurred
in Section 6 of process baghouse #1 prior to the sampling period during
which test runs BHI-1, SCI-1, and SCO-1 were completed. Section 6 was
sealed off prior to the sampling period and the baghouse operated using
only six sections during the sampling run. However, it is expected that
this would not significantly affect the arsenic emissions measurements
made other than the effect of the increased air to cloth ratio. The
#1 process baghouse ran smoothly with no unusual occurrences during all
of the other test periods. Section 6 was repaired prior to the next
sampling period, and the #1 process baghouse ran smoothly with no unusual
occurrences during all subsequent test periods. The inlet temperature
to the baghouse ranged from 330°F to 468°F during the tests.
Offgases from each of the two process baghouse systems are sent to
venturi scrubbers. The lime scrubbers have a design S02 removal efficiency
of 99 percent. Approximately 2,000 gpm of a 15 to 20 percent lime
slurry solution are introduced at the throat of each of the two venturi
scrubbers. The scrubbing system was designed to maintain a pH value
of 8 to 10 and to operate under a design pressure drop of 8 inches of
water. Scrubber sludge is periodically removed from the system using
tank trucks. Scrubber operating data and scrubber sludge removal rates
for venturi scrubber system #1 are contained in Appendix H. The system
operated normally with no upset conditions during all of the test periods.
The scrubber slurry pH ranged from pH 6.8 to pH 7.6, which is lower than
the design pH range but is representative of normal operation at the
General Battery plant. The pressure drop across the throat of the
scrubber was not measured, but the pressure drop across the throat and
the demister was typically between 13 and 14 inches of water. The
scrubber slurry recirculation rate ranged from 2,100 to 2,150 gallons
per minute. Approximately 7,500 gallons of scrubber sludge was removed
from venturi scrubbing system #1 during each 8 hour shift of the two day
test period.
3-4
-------
Table 2-11. GENERAL BATTERY PLANT PROCESS UNIT #1 - READING, PENNSYLVANIA
ro
i
»-«
CO
Sample Identification
Process/Ventilation Baghouse Dust
Feed to Reverb
Process/Ventilation Baghouse Dust
Feed to Reverb
Process Baghouse Dust
Process/Ventilation Baghouse Dust
Feed to Reverb
Process Baghouse Dust
Ventilation Baghouse Dust
Ventilation Baghouse Dust
Ventilation Baghouse Dust
Scrubber Sludge from fl Cone
Scrubber Sludge from fl Cone
Scrubber Sludge from fl Cone
fl Scrubber Slurry
fl Scrubber Slurry
fl Scrubber Slurry
Composite Blast Furnace Slag, Blast fl
Composite Reverb Furnace Slag, Reverb fl
Composite Blast Furnace Slag, Blast fl
Composite Reverb Furnace Slag, Reverb fl
Sample Time
10:00 am
1:00 pm
10:00 am
6:05 pm
1:00 pm
10:00 am
6:00 pm
1:00 pm
6:30 pm
11:30 am
1:15 pm
6:30 pm
11:25 am
1:15 pm
9:15am-2:35pm
9:50am-5:00pm
12: 10-2: 15pm
12: 10-2: 15pm
Sample date
6/21/83
6/22/83
6/21/83
6/21/83
6/22/83
6/21/83
6/21/83
6/22/83
6/21/83
6/21/83
6/22/83
6/21/83
6/21/83
6/22/83
6/21/83
6/21/83
6/22/83
6/22/83
TRW no.
4803
4804
4805
4806
4807
4808
4809
4810
4811
4812
4813
4814
4815
4816
4896
4897
4898
4899
Arsenic (mg/g)
5.19
14.3
5.82
7.22
7.39
8.99
10.3
8.85
1.48 X 10"2
3.7 X 10"2
1.52 X 10"2
1.15 X 10"2
8.79 X 10"3
8.80 X 10*3
1.83 X 10"4
4.96 X 10"3
6.97 X 10"4
4.64 X 10"3
Cadmium (mg/g)
9.55
8.73
10.2
10.2
11.2
2.67
7.72
2.67
7.25 X 10"2
5.17 X 10"3
5.83 X 10"3
4.09 X 10"3
4.86 X 10"3
1.69 X 10"3
1.32 X 10"2
2.12
1.48 X 10~2
1.57
Lead (mg/g)
242
249
324
185
290
225
315
248
0.186
0.271
0.233
0.165
0.200
0.105
7.54
532
21.3
623
(continued)
-------
Table 2-11. Continued
ro
i
Sanple Identification
Blast Furnace Metal
Blast Furnace Metal
Blast Furnace Metal
Blast Furnace Metal
Blast Furnace Metal
Blast Furnace Metal
Blast Furnace Metal
Blast Furnace Metal
Blast Furnace Metal
Blast Furnace Metal
Blast Furnace Metal
Blast Furnace Metal
Blast Furnace Metal
Blast Furnace Metal
Blast Furnace Metal
Reverb Furnace Metal
Reverb Furnace Metal
Reverb Furnace Metal
Reverb Furnace Metal
Sample Tine
10:00 an
9:15 an
10:50 an
11:40 an
12:36 an
1:05 pm
2:35 pn
4:35 pn
5:55 pn
6:55 pn
8:00 pn
12: 10 pn
12:30 pn
1:30 pn
2:15 pn
10:50 am
5:00 pm
12:15 pra
1:50 pm
Sample date
6/21/83
6/21/83
6/21/83
6/21/83
6/21/83
6/21/83
6/21/83
6/21/83
6/21/83
6/21/83
6/21/83
6/22/83
6/22/83
6/22/83
6/22/83
6/21/83
6/21/83
6/22/83
6/22/83
TRW no.
4900
4901
4902
4903
4904
4905
4906
4907
4908
4909
4910
4911
4912
4913
4914
4915
4916
4917
4918
Arsenic (ng/g)
4.07 X 10"2
0.425
1.75 X 10~2
0.362
4.23 X 10"2
7.54 X 10"3
4.86 X 10"2
2.22 X 10"2
1.61 X 10"2
3.26 X 10"2
4.62 X 10"2
0.504
6.39 X 10"2
2.66 X 10"2
NO
8.9 X 10"4
1.77 X 10"3
ND
1.91 X 10"3
Cadaiua (jng/g)
0.107
6.65 X 10"2
6.95 X 10"2
9.16 X 10"2
3.76 X 10"2
4.00 X 10"2
4.94 X 10"2
6.23 X 10"2
3.09 X 10"2
1.99 X 10"2
8.00 X 10"2
0.139
9.10 X 10"2
6.90 X 10"2
5.68 X 10"2
1.34 X 10"2
5.31 X 10"2
2.07 X 10"2
4.54 X 10~2
Lead (eg/g)
865
936
937
885
946
981
882
987
849
722
753
924
822
894
889
836
887
851
906
(continued)
-------
Table 2-11. Concluded
IS*
I
Sample Identification
Yard Sample fl; Reverb Slag, Dross and
Battery Group nix
Yard Sample f2; Rerun Blast Furnace
Slag Heel
Yard Sample f3, Battery Group and
Dross Mix
Yard Sample 14, Blast Furnace Slag
Yard Sample f5. Shredded Batteries, Whole
Yard Sample f6, Coke
Yard Sample 17, Reverb Slag
Yard Sample 18, Refining Dross Sample
Yard Sample 19, Industrial Battery Plates
Yard Sample 110, Regular Battery Plates
Sample Time Sample date
6/22/83
6/22/83
6/22/83
6/22/83
6/22/83
6/22/83
6/22/83
6/22/83
6/22/83
6/22/83
TRW no.
4919
4920
4921
4922
4923
4924
4925
4926
4927
4928
Arsenic (mg/g)
1.22
5.47 X 10"2
1.00
4.86 X 10"2
0.270
8.9 X 10"2
3.01
1.24
0.105
0.143
Cadmium (mg/g)
0.328
4.48 X 10"3
0.327
9.65 X 10"2
1.00 X 10"2
4.49 X 10"3
0.392
0.399
4.64 X 10"3
2.29 X 10"3
Lead (mg/g)
494
4.12
448
8.71
378
2.92
275
720
348
474
-------
3. SMELTER OPERATIONS AND PROCESS EMISSION CONTROL EQUIPMENT*
3.1 PROCESS DESCRIPTION
The General Battery plant in Reading Pennsylvania is a large secondary
lead smelter with a total rated lead production capacity of 240 tons/day.
The primary lead-bearing input materials to the plant are recycled
lead-acid batteries obtained from various sources and battery plant
scrap obtained from the adjacent battery manufacturing facilities.
Arsenic is present in these materials as an alloying agent in the lead
used to manufacture most battery plates (i.e., all lead-acid battery
plates except for those used in maintenance-free calcium-lead batteries).
The lead product produced by the plant is used primarily for new battery
manufacture and can contain various levels of arsenic depending on the
buyer's specifications. Metallic arsenic is added directly to the
refining kettles to meet some of the specifications.
The General Battery plant has two identical reverberatory furnaces;
two identical blast furnaces; ten refining kettles; two identical fabric
filter/wet scrubber systems for treating process offgases from the
reverberatory and blast furnaces; and two identical sanitary baghouse
systems for treating ventilation gases from the refining kettles, smelting
furnace tapping points, and other ventilation sources. Arsenic emission
tests were performed on the #1 baghouse/wet scrubber system that treats
the combined offgas from the #1 blast furnace/reverberatory furnace
pair.
Each of the two reverberatory furnaces has a rated lead production
capacity of 70 tons/day. The reverberatory furnace charge consists of
shredded whole batteries including the case, battery plant scrap, and
recycled baghouse dust captured by the process baghouse and sanitary
baghouse systems. The shredded plastic cased batteries and battery
^Authored by Radian, Incorporated.
-------
plant scrap (i.e., decased battery group materials and battery plant
drossed) are charged continuously to the reverberatory furnaces by ram
feeders that are fed by hoppers containing feed mixture. The baghouse
dust is charged continuously to the reverberatory furnaces using a screw
conveyor system. The feed materials are smelted in the furnace by
combusting natural gas with oxygen-enriched air. Reverberatory furnace
slag and reverberatory furnace lead are tapped from the furnace on an
irregular basis when the lead in the furnace accumulates to a sufficiently
high level. Typically, lead and slag are tapped from the furnace once
every 3 or 4 hours. Data on the #1 reverberatory furnace feed rates and
metal production rates during the test periods are contained in Appendix H.
The #1 reverberatory furnace ran smoothly with no upset conditions
during each of the test periods. The average hourly lead production
from the #1 reverberatory furnace was 9,500 pounds of lead per hour
during the test periods.
Each of the two blast furnaces has a rated lead production capacity
of 50 tons/day. The charge materials to the blast furnace consist of
reverberatory furnace slag, refining kettle dross, and fluxing agents
(coke, iron, and limestone). The blast furnace is charged roughly every
20 minutes in 5,000 Ib. charges that are introduced to the top of the
furnace through a "thimble" that is filled using front end loaders.
Lead is tapped from the blast furnace continuously while slag is tapped
approximately every 40-50 minutes. Data on the #1 blast furnace feed
rates and metal production rates during the test periods are contained
in Appendix H. The #1 blast furnace ran smoothly with no upset conditions
during each of the test periods. The average hourly lead production
from the #1 blast furnace was 5,400 pounds of lead per hour during the
test periods.
3.2 PROCESS EMISSION CONTROL EQUIPMENT
Offgases from each blast furnace/reverberatory furnace pair are
combined and sent to am afterburner to destroy combustibles. The
afterburner offgas from each furnace pair are cooled in U-tube cooling
system before being directed to one of two process baghouse/wet scrubber
systems for removal of particulate matter and S02 (see Figure 2-1 and
Table 3-1). Each of the process baghouses consists of seven equivalent
sections, each section containing 80 fiberglass bags (30 ft. long and
3-2
-------
Table 3-1. SAMPLE POINT KEY FOR DIAGRAM OF GENERAL BATTERY
SECONDARY LEAD PLANT, READING, PENNSYLVANIA
Sample point Description
A Combined reverberatory and blast furnace offgas
downstream of afterburner (afterburner not shown)
B Baghouse offgas
C Lime scrubber offgas
D Baghouse flue dust catch
E Lime scrubber sludge
F Crushed battery plates, lead scrap
G Recycled flue dust
H Miscellaneous reverberatory furnace inputs
I Semi soft lead
J Reverberatory furnace slag
K Drosses
L Reverberatory furnace slag
M Recycle blast furnace slag
N Battery scrap
0 Coke
P Miscellaneous blast furnace inputs
Q Hard lead
R Blast furnace slag, matte
3-3
-------
inches in diameter). The bags are cleaned using reverse air pulses
every 30 minutes, and equal time intervals are maintained between reverse
flow in all sections. Representative baghouse inlet temperature data and
individual section pressure drop data are contained in Appendix H for
the #1 process baghouse during the test periods. A bag breakage occurred
in Section 6 of process baghouse #1 prior to the sampling period during
which test runs BHI-1, SCI-1, and SCO-1 were completed. Section 6 was
sealed off prior to the sampling period and the baghouse operated using
only six sections during the sampling run. However, it is expected that
this would not significantly affect the arsenic emissions measurements
made other than the effect of the increased air to cloth ratio. The
#1 process baghouse ran smoothly with no unusual occurrences during all
of the other test periods. Section 6 was repaired prior to the next
sampling period, and the #1 process baghouse ran smoothly with no unusual
occurrences during all subsequent test periods. The inlet temperature
to the baghouse ranged from 330°F to 468°F during the tests.
Offgases from each of the two process baghouse systems are sent to
venturi scrubbers. The lime scrubbers have a design S02 removal efficiency
of 99 percent. Approximately 2,000 gpm of a 15 to 20 percent lime
slurry solution are introduced at the throat of each of the two venturi
scrubbers. The scrubbing system was designed to maintain a pH value
of 8 to 10 and to operate under a design pressure drop of 8 inches of
water. Scrubber sludge is periodically removed from the system using
tank trucks. Scrubber operating data and scrubber sludge removal rates
for venturi scrubber system #1 are contained in Appendix H. The system
operated normally with no upset conditions during all of the test periods.
The scrubber slurry pH ranged from pH 6.8 to pH 7.6, which is lower than
the design pH range but is representative of normal operation at the
General Battery plant. The pressure drop across the throat of the
scrubber was not measured, but the pressure drop across the throat and
the demister was typically between 13 and 14 inches of water. The
scrubber slurry recirculation rate ranged from 2,100 to 2,150 gallons
per minute. Approximately 7,500 gallons of scrubber sludge was removed
from venturi scrubbing system #1 during each 8 hour shift of the two day
test period.
3-4
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4. SAMPLING LOCATIONS
This section presents descriptions of the sampling locations with
sample points used during the source testing program at the General
Battery Plant in Reading, Pennsylvania. Figure 2-1 presents a schematic
diagram of the process flow with gaseous and process sampling locations.
Figure 4-1 provides a schematic of the baghouse/scrubber system with the
gas sampling locations. The gaseous and process sample locations are
described in Table 3-1 utilizing the sample point key for Figure 2-1.
The gaseous sample locations A, B, and C were referenced during the test
as the Baghouse Inlet (BHI), Scrubber Inlet (SCI), and Scrubber
Outlet (SCO) respectively.
4.1 BAGHOUSE INLET
Two sample ports were located at the Baghouse Inlet position.
Figure 4-2 provides a description of the BHI position with the location
of the sample traverse points. Six traverse points were utilized for
each test port to traverse the cross section of the duct. Ten minute
sample periods at each sample point gave a 120 minute test run period.
This run had one more run than the other two locations; because the high
temperatures of the process during Run #3 destroyed the source train
filter system. Also only one port was traversed during Runs 3 and 4
because of the high temperatures.
The testing at the BHI location included a preliminary velocity
traverse by EPA Method 2, a S02/S03 determination by EPA Method 6,
four Standard EPA Method 108 test runs (Test Run #3 was aborted),
two Modified EPA Method 108 test runs, and four stationary gas determi-
nation in accordance with EPA Method 3.
4.2 SCRUBBER INLET
Two sample ports were located at the Scrubber Inlet position.
Figure 4-3 provides a description of the SCI position with the location
-------
PROCESS FLOW DIAGRAM
ro
SCO
Venturl Scrubber
Baghouse
w
Bag House Inlet (BHI)
Scrubber Inlet (SCI)
Scrubber Outlet (SCO)
Afterburner
Section
S
I
1
Figure 4-1. General Battery, Reading, Pennsylvania: schematic of the
baghouse/scrubber system with the gas sampling locations.
-------
BAGHOUSE INLET (BHI)
53"
Traverse Point Number
1
2
3
4
5
6
Distance from Sample Port, Inches
2.3
7.8
15.
37.
45.
50.7
Figure 4-2. General Battery, Reading, Pennsylvania: baghouse inlet
location with sample traverse points.
4-3
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SCRUBBER INLET (SCI)
Traverse Point Number
1
,2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Distance from Sample Port, Inches
1.0
1.6
2.6
3.8
5.0
6.3
.8
9.3
11.0
13.0
15.5
19.1
28.9
32.5
35.0
37.0
38.7
40.2
41.7
43.0
44.2
45.4
46.4
56.0
Figure 4-3. General Battery, Reading, Pennsylvania:
location with sample traverse points.
scrubber inlet
4-4
-------
of the sample traverse points. Twenty-four traverse points were utilized
for each test port to traverse the cross section of the duct. Sample
periods of 150 seconds per sample point were maintained for a 120 minute
test run period. Three test runs were completed at the SCI location.
The testing at the SCI location included a preliminary velocity
traverse by EPA Method 2, a S02/S03 determination by EPA Method 6, three
standard EPA Method 108 test runs, one Modified EPA Method 108 test run,
and three stationary gas determinations in accordance with EPA Method 3.
4.3 SCRUBBER OUTLET
Two sample ports were located at the Scrubber Outlet position.
Figure 4-4 provides a description of the SCO position with the location
of the sample traverse points. Twenty-four traverse points were utilized
for each test port to traverse the cross section of the duct. Sample
periods of 150 seconds per sample point were maintained for a 120 minute
test run period. Three test runs were completed at the SCI location.
The testing at the SCO location included a preliminary velocity
traverse by EPA Method 2, a S02/S03 determination by EPA Method 6, three
standard EPA Method 108 test runs, one modified EPA Method 108 test run,
and three stationary gas determination in accordance with EPA Method 3.
4-5
-------
SCRUBBER OUTLET (SCO)
Traverse Point Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Distance from Sample Port, Inches
1.0
1.9
3.3
4.8
6.3
7.9
'9.7
11.6
13.8
16.3
19.4
23.9
36.1
40.6
43.7
46.2
48.4
50.3
52.1
53.7
55.2
56.7
58.1
59.0
Figure 4-4. General Battery, Reading, Pennsylvania:
location with sample traverse points.
scrubber outlet
4-6
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5. SAMPLING AND ANALYSIS METHODS
This section presents general descriptions of sampling and analytical
procedures employed during the source testing project conducted at the
secondary lead smelter of General Battery's Reading, Pennsylvania.
Standard EPA sampling and analysis procedures are detailed in the Federal
Register and the modified procedure are presented in Appendix D.
5.1 EPA REFERENCE METHODS UTILIZED DURING TESTING OF THE READING FACILITY
The following EPA Reference Methods were used during this emission
testing program. These methods are taken from "Standards of Performance
for New Stationary Sources," Appendix A, Federal Register, Volume 42,
No. 160, Thursday, August 18, 1977, pp 41755 ff.
• Method 1 - Sample and Velocity Traverses for Stationary Sources -
This method specified the number and location of sampling
points within a duct, taking into account duct size and shape
and local flow disturbances. In addition, this method discusses
the pitot-nulling technique used to establish the degree of
cyclonic flow in a duct.
• Method 2 - Determination of Stack Gas Velocity and Volumetric
Flow Rate - This method specifies the measurement of gas
velocity and flow rate using a pitot tube, manometer and
temperature sensor. The physical dimensions of the pitot tube
and its spatial relationship to the temperature sensor and any
sample probe are also specified.
• Method 3 - Gas Analysis for C02, 02, Excess Air and Dry Molecular
Weight - This method describes the extraction of a grab or
integrated gas sample from a stack and the analysis of that
sample for C02 and 02 with a thermal conductivity gas
chromatograph.
-------
• Method 4 - Determination of Moisture Content in Stack Gases -
This method describes the extraction of a gas sample from a
stack and the removal and measurement of the moisture in that
sample by condensation impingers. The assembly and operation
of the required sampling train is specified.
Monitoring of emission conditions during the Method 108 periods
were maintained at the three gaseous sampling locations. The conditions
monitored were the stationary gas contents, the gas flow rate, the
moisture per cent particulate levels, and the S02 concentrations.
A single point integrated bag sample was obtained over each test
run at the separate test locations. The samples were analyzed in the
field by gas chromatography with thermal conductivity detection (GC/TC).
Analyzed sample runs were compiled, calculated, and recorded for providing
stationary gas levels.
The gas flow rate was determined from the Method 108 Isokinetic
sampling results. Based on EPA Methodology, the flow rate during the
test period was calculated and Isokinetic rate determined.
The moisture level present in the sampled gas stream was determined
by utilizing the differential volumes of the Method 108 impingers. The
impinger solution volume changes and silica gel weight changes were
measured and recorded (before rinses) so that water vapor concentrations
could be determined.
The particulate levels present during the sample runs were determined
according to EPA Method 5. The Method 108 filters were weighed prior to
and after the test run for determining the particulate catch over the
test period.
The measurement of the S02 concentration required a Method 6 train
to be run at each sampling site. The train was operated according to
EPA methodology. An effort was made for obtaining the Method 6 sample
during each test run, but the problem of operating a third train at the
BHI and SCI location allowed only one Method 6 sample to be taken.
5.2 EPA REFERENCE METHOD 108 AND MODIFIED 108 HOT FOR ARSENIC/LEAD
SAMPLING
Simultaneous sampling utilizing Method 5 trains modified for
Method 108 procedures were performed at the Baghouse Inlet (BHI), the
Scrubber Inlet (SCI), and the Scrubber Outlet (SCO). The Method 108
5-2
-------
procedure (Federal Register) was followed with the exception of the
Whatman Filter being replaced with a glass fiber filter (per request by
EMB/Frank Clay - see memo in Appendix D).
At the General Battery Unit #1 process, the gas stream leaving the
gas cooler was in excess of 250°F at the BHI location and the SCI location.
In order to insure the sampling methodology, two extra sampling trains
were designed to operate at 400°F. These trains were set up at both the
BHI and SCI locations for one test run with the Method 108 trains and
operated at approximately the process temperature.
The Method 108 train samples were used to provide moisture and
particulate data, in addition to the arsenic samples. Flow measurements
and stationary gas samples, were taken at the BHI, SCI, and SCO location
during the test runs. The EPA Reference Methods describe the methods
for obtaining moisture, particulate, S02, flow, and stationary gas
results.
The sampling train was prepared, set-up, and operated to collect
samples according to EPA Method 108. The only difference with standard
Method 108 methodology was the third impinger was maintained as a blank
for a moisture condensation check; since the low S02 concentration
levels did not require the three H202 impinger traps. The two trains
designed with the 400°F capabilities (referred to as the "hot" trains)
were operated according to Method 108 with the exception of the probe
and filter box will be maintained at the process temperature. Figure 5-1
provides the sampling system. Table 5-1 provides the sample handling
and transfer of impinger samples for the recovery procedure.
The sampling periods were in accordance with Standard U.S. EPA
methodology for particulate sampling (Method 5) as specified in the
Federal Register. The objective of the gaseous sampling activity was to
take three representative samples during the testing periods at the
three locations. The samples of the three locations were conducted
simultaneously. The extreme temperature conditions at the BHI location
caused the abortion of Run #3. Therefore, a Run #4 was completed at the
BHI location with a 108 and 108 HOT train.
5.3 ANALYTICAL METHODS
5.3.1 Analytical Method for Arsem'c/Lead/Cadmium Samples
Particulate and gaseous emissions of arsenic, lead, and cadmium
were isokinetically sampled from the source and collected on glass mat
5-3
-------
en
i
-p.
iTbtnMMtir
PROBE
PITOT
MANOMETER
BY-PASS MAIN
VALVE
ORIFICE
MANOMETER
AIR TIGHT
PUMP
DRY GAS
METER
Figure 5-1. General Battery, Reading, Pennsylvania: Method 108 sampling train.
-------
TABLE 5-1. GENERAL BATTERY, READING, PENNSYLVANIA: METHOD 108 RECOVERY PROCEDURES
Filter
Reanve
SMplt fl
FpVMt ftf FfltflP IfetldM
r>obe
Rinse 0.1 NaOH
Bspest RiRS*
Rinse 0.1 HaON
•rush (3 ttaas)
leisure Rinse Voluae
and Record
Measure Rinse VoluM
and Record
Glass Bottle
Label
Hark Height of Liqui
Ceaftlne with Front
Filter Rinse
1
.
Satvle ,2 | 1 Rinse HjO ]
en
i
tn
Silica 6t1
Nalgh
Record
Saapla
taplngtr «1. «. 13
Basa of Ft 1 tar Haider
Naasura VoluM
and Record
Rlnsa 0.1 NaOH
Rapaat Rlnsa
Rlnsa -30 «g 0.1 IU(
Rapaat Rlnsa
Measure Rlnsa Volw
and Record
Measure Rinse Volun
and Record
H
Class Bottle
Label
Nark Height of Liqui
Conblne with
Inplnger fl and 2
Sa*>leM |
taplngers 14 and 5
Measure Voluaw
Rinse -30 Hi VI H-0
Repeat Rlnsa —
Measure Rinse VoluM
. Glass Bottle
Label
Mirk Height of Liqui
i
Saaple 15
Rinse H20
Discard |
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filters and in water. The collected methods were then analyzed using
atomic absorption spectrophotometry.
5.3.1.1 Sample preparation. Participate samples and liquids were
prepared as described in Method 108, "Method for Determination of
Particulate and Gaseous Arsenic Emission from Non-Ferrous Smelters".
Each solid sample was first crushed approximately to a grain size
of one cubic centimeter in a jawcrusher manufactured by Chipmunk
Incorporated. The fragments were collected in a container lined with
high-purity Phillips 1-rnil-thick polyethylene film. The fragments were
then randomly mixed and placed in their original container. Between
each sample crushing, any residue left from the previous sample was
removed from the jawcrusher and the plastic lining was replaced with
Phillips polyethylene. The jawcrusher was brushed clean between each
sample.
Each crushed sample was ground into a fine powder with a Bilco
pulverizer. The particles were collected on a sheet of uncontaminated
polyethylene, and were transferred to the pre-washed bottles. Between
the grinding of each sample, the pulverizer was cleaned in a three-step
procedure. First, the pulverizer was brushed clean of excess sample
residue. Next, approximately 0.5 liters of quartz sand was ground in
the pulverizer to remove any remaining sample residue; the pulverized
quartz was then discarded. Finally, approximately 0.25 to 0.33 liters
of quartz sand was ground in the pulverizer to remove any sample material
possibly remaining in the machine. This pulverized quartz was collected
to exhibit any possible contamination from previous samples. This
material was taken as blank and checked for contamination. Disposal
polyethylene gloves were worn during the entire procedure, and were
changed after each sample crushing was completed.
Ore samples and particulate residues were treated as undissolved
solids by PARR acid digestion. Each sample (0.25 gm) was placed in a
PARR acid digestion bomb and 5 ml each of concentrated nitric acid and
hydrofluoric acids were added. The bomb was sealed and placed in the
oven for 5 hours at 150°C. The sample was then transferred to a 50 ml
polyproylene volumetric flask and diluted with deionized distilled
water.
5-6
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5.3.1.2 Sample analysis. Arsenic (>1.0 |jg/ml of As), lead, and
cadmium were determined by atomic absorption spectrophotometry with
background correction. Standard conditions used for each determination
is presented in the appendix (Figures C-3, C-4, and C-5). Arsenic
samples that contain less than 1 ug/ml were determined by hydride generation
utilizing a Perkin Elmer in H-10 hydride generation with determination
background correction (Figure C-6). Samples concentration outside the
analytical working range were diluted and reanalyzed.
5.3.2 Analytical Method for Stationary Gases
EPA Reference Method 3 (Gas Analysis for Carbon Dioxide, Oxygen,
Excess Air, and Dry Molecular Weight; Federal Register 42 FR 41768) was
utilized to characterize the flue gas. As permitted under Section 1.2,
Paragraph 2 of the reference document, a modification to the sampling
procedures and use of an alternative analytical procedure was implemented.
A single point integrated sample was collected. In lieu of an Orsat
analyzer, a gas chromatograph with a thermal conductivity detector
(GC/TCD) was utilized to measure the concentrations of oxygen (02),
carbon dioxide (C02), and nitrogen (N2) in the integrated bag sample.
An example of the filed chromatograms are presented in Appendix C.
This alternative field analytical method offers greater accuracy than an
Orsat and a permanent hard copy record of the analysis. Previous test
programs have demonstrated the acceptability of this substitution and
have been approved by regulatory authorities.
The gas chromatograph utilized was a Shimadzu GC-38T with a Shimadzu
®
Chromatopac to integrate and record the chromatogram peak area and peak
heights. Helium was the carrier gas. Compound separation was achieved
with a packed stainless steel Chromosorb 102/Molecular Sieve column.
Calibration gas standards were injected prior to and after sample by
injection for a quantification by retention time and peak area. A one
point calibration method was employed utilizing a Scotty II-Mix 10
calibration (±2% certified) mixture. This mixture contained stationary
gas components as follows:
• C02 - 14.8%
• 02 - 7.07%
• N2 - 78.13%
5-7
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5.4 PROCESS SAMPLING
Bulk grab sampling of process solids was obtained during each test
period. The sampling was performed by the Radian personnel on-site.
Most process samples were obtained from General Battery personnel. The
samples were labeled and transported in bulk form to the TRW-Research
Triangle Park Facility for compositing and analysis.
5-8
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