Ln'ted St

 ncv
      •'lards
Research Tpar.rjls Park NC 277' 1
Air
Calciners and
Dryers Emission
Test Report

North American
Refractories
Company
Farber, Missouri
EMS Report 84-CDR-1 4
March 1 984

-------
                 NSPS DEVELOPMENT
PARTICULATE AND PARTICLE SIZING EMISSIONS TESTING
             CLAY ROTARY DRYER SYSTEM
           NORTH AMERICAN REFRACTORIES
                 FARBER, MISSOURI
                MARCH 12-15, 1984
                   Compiled by:

                     ENTROPY
              Post Office Box 12291
       Research Triangle Park, N. C. 27709
                    68-02-3852
                  ESED No. 81/08
                EMB No. 84-CDR-14
                   Task Manager

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

-------
                              TABLE OF CONTENTS

1.   INTRODUCTION	   1-1
     1.1    Background	   1-1
     1.2    Scope of the Project	   1-1
     1.3    North American Refractories Company Testing Program   ...   1-1
     1.3.1     Source Applicability 	   1-1
     1.3.2     Outline of Testing Program . . .	   1-2
     1.4    Report Organization 	   1-2

2.   SUMMARY AND DISCUSSION OF RESULTS	   2-1
     2.1    Summary	   2-1
     2.2    Discussion	   2-1

3.   PROCESS DESCRIPTION AND OPERATION  	   3-1
     3.1    General	   3-1
     3.2    Calcining Process	   3-1
     3.2.1     Raw Material	   3-1
     3.2.2     Rotary Dryer	   3^1
     3.2.2.1      Dryer Design Capacity 	   3-1
     3.2.2.2      Dryer Exhaust Gases   ... 	 ....   3-3
     3.2.3     Storage	   3-3
     3.3    Process Conditions During Testing 	   3-3
     3.3.1     Monitoring Procedures  	   3-3
     3.3.2     Test Interruptions	   3-4
     3.3.3     Control Equipment  	   3-4
     3.3.4     Production Rates 	   3-4
     3.3.5     Moisture Content 	   3-5
     3.4    Discussion/Conclusions  .... 	   3-5

 4.  SAMPLING LOCATIONS	-	   4-1
     4.1    Suitability of Sampling Sites	   4-1
     4.2    Rotary Dryer Inlet (Sample Location A)  „  	   4-1
     4.3    Rotary Dryer Inlet (Observation Location B) 	   4-1
     4.4    Rotary Dryer Outlet (Observation Location  C)  	   4-1
     4.5    Rotary Dryer Outlet (Sample Location D) 	   4-1
     4.6    Cyclone .Inlet (Sample Location E)	   4-1

                            (continued next page)

-------
                              TABLE OP CONTENTS
                                 (continued)

     4.7    Scrubber Inlet (Sample Location F)  	   4-3
     4.8    Scrubber Outlet Stack (Sample Location G) 	   4-3
     4.9    Scrubber Outlet Stack (Observation Location H)  	   4-3

5.   SAMPLING AND ANALYTICAL METHODS	   5-1
     5.1    Sampling Objectives   	   5-1
     5.2    Particulate Emissions Testing 	   5-1
     5.3    Trace Metals Analysis 	   5-1
     5.4    Sieve and Moisture Content Analysis 	   5-1
     5.5    Plume Opacity and Fugitive Emissions  	   5-1
     5.6    Particle Size Testing	   5-1

6.   QUALITY ASSURANCE	   6-1
     6.1    Introduction	   6-1
     6.2    Sampling Train Components ....... 	   6-1
     6.3    Preseparator and Cascade Impactors  ..... 	   6-1
     6.4    Sample Collection Substrates  	   6-2
     6.5    Substrate Weighting 	   6-2
     6.6    Sample Analysis	   6-2
     6.7    SPA Method 3	   6-2
     6.8    EPA Method 9	   6-2

7.   APPENDICES	     1
     7.1    Plastic Clay Test Results and Example Calculations  ....     2
     7.1.1     Particulate  	     2
                 Cyclone Inlet & Example Calculations for Run 1  ....     3
                 Scrubber Inlet (Cyclone Outlet)  	     8
                 Scrubber Outlet Stack  	    10
     7.1.2     Particle Sizing	    12
                 Cyclone Inlet  	    13
                 Scrubber Inlet (Cyclone Outlet)  	    24

                            (continued next page)

                                      ii

-------
                         TABLE OF CONTENTS
                            (continued)

7.2    Flint Clay Test Results	.   36
7.2.1     Participate	   36
            Cyclone Inlet  	   37
            Scrubber Inlet (Cyclone Outlet)  ..... 	   39
            Scrubber Outlet Stack  	   41
7.2.2     Particle Sizing	   43
            Cyclone Inlet	   44
            Scrubber Inlet (Cyclone Outlet)  	   58
7.3    Plastic Clay Field and Analytical Data	   68
7.3.1     Particulate	   68
            Cyclone Inlet  .	   69
            Scrubber Inlet (Cyclone Outlet)  	   80
            Scrubber Outlet Stack  	   92
7.3.2     Particle Sizing	104
            Cyclone Inlet  ..... 	  105
            Scrubber Inlet (Cyclone Outlet)	Ill
7.3.3     Visible Emissions Results and Reader Certification ...  117
7.3.4     Trace Metals Analytical Results  . . *	138
7.4    Flint Clay Field and Analytical Data	140
7.4.1     Particulate	140
            Cyclone Inlet & Example Calculations for Run 1 ....  141
            Scrubber Inlet (Cyclone Outlet)  	 .  151
            Scrubber Outlet Stack ' 	  163
7.4.2     Particle Sizing	175
            Cyclone Inlet  	  176
            Scrubber Inlet (Cyclone Outlet)  	  184
7.4.3     Visible Emissions Results and Reader Certification . . .  188
7.4.4     Trace Metals Analytical Results  	  221
7.5    Sampling and Analytical Procedures	  223
7.6    Feed and Product Analytical Data	319
7.7    Calibration Data		386
7.8    Entropy Test Participants   	415
                                iii

-------
                             LIST OP TABLES
Number      Title                                                  Page
  1-1       Testing Protocol and Run/Sample Numbering               1-3
              Cross-Reference
  2-1    .   Particulate Emission Rates and Concentrations           2-2
              and Control Equipment Efficiencies (Plastic Clay)
  2-2       Particulate Emission Rates and Concentrations           2-3
              and Control Equipment Efficiencies (Flint Clay)

            Particulate Tests Summary - Plastic Clay;
  2-3         Cyclone Inlet                                         2-4
  2-4         Scrubber Inlet (Cyclone Outlet)                       2-5
  2-5         Scrubber Outlet Stack                                 2-6

            Particulate Tests S'j™"ary - Flint Clay;
  2-6         Cyclone Inlet                                         2-7
  2-7         Scrubber Inlet (Cyclone Outlet)                       2-8
  2-8         Particulate Tests Summary Scrubber Outlet Stack       2-9

            Particle Sizing Tests Summary - Plastic Clay;
  2-9         Cyclone Inlet                                        2-10
 2-10         Scrubber Inlet (Cyclone Outlet)                      2-12

            Particle Sizing Summary - Flint Clay;
 2-11         Cyclone Inlet                                        2-14
 2-12         Scrubber Inlet (Cyclone Outlet)                      2-16

            Six Minute Summary of Visible Emissions - Flint Clay;
 2-13         Scrubber Outlet Stack - Run 2                        2-18
 2-14         Scrubber Outlet Stack - Run 3                        2-19
 2-15         Scrubber Outlet Stack - Run'4                        2-20

            Six Minute Summary of Visible Emissions - Plastic Clay;
 2-16         Scrubber Outlet Stack - Run 5                        2-21
 2-17         Scrubber Outlet Stack - Run 6                        2-22

            Operating Conditions
  3-1         Run No. 1 - Plastic Clay                              3-6
  3-2         Run No. 2 - Flint Clay                                3-7
  3-3         Run No. 3 - Flint Clay                                3-8
  3-4         Run No. 4 - Flint Clay                                3-9
  3-5         Run No. 5 - Plastic Clay                             3-10
  3-6         Run No. 6 - Plastic Clay                             3-11

  3-7       NARCO Test Production Summary                          3-12
                                   iv

-------
                          LIST OF FIGURES


Number      Title                                              Page
  3-1       Plastic and Flint Clay Processing                   3-2

  4-1       Process Flow Schematic Showing Sampling Locations   4-2

  4-2       Rotary Dryer Cyclone Inlet                          4-4

  4-3       Rotary Dryer Scrubber Inlet (Cyclone Outlet)        4-5

  4-4       Rotary Dryer Scrubber Outlet Stack                  4-6

-------
                                    1-1
1.   INTRODUCTION

     1.1  Background.  The Emission Measurement Branch (EMB) of the U.S.
Environmental Protection Agency (EPA) is directing a project designed to
generate support data for New Source Performance Standards (NSPS) for
calclners 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. 2 to conduct testing programs at designated
industrial facilities.  Entropy is to perform emission measurements at the
recommended sampling locations, obtain process feed and product samples, and,
in conjunction with Research Triangle.Institute (RTI), conduct sample
analyses.  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  North American Refractories Company (NARCO) Source Testing
Program.  The present report covers stationary source sampling performed at
the NARCO manufacturing plant in Farber, Missouri on March 12-15, 1984 to
characterize emissions from the refractory manufacturing processes and
pollution control equipment.  Steve Sutton of NARCO 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.  NARCO operates a McDermott, direct-fired,
rotary dryer.  The raw clay is placed in a hopper which feeds the clay into
an Eagle crusher.  Emissions from the rotary dryer system are controlled by a
cyclone and a scrubber.  The reasons for selecting this plant are as
followst  NARCO is considered to be a well-maintained facility; no EMB
approved data exists on a rotary fire clay dryer drying a worst-case clay
type; and NARCO processes Missouri plastic and flint clays which are both
reported to be  the most difficult to control.

-------
                                     1-2
     1.3.2  Outline of Testing Program.  EPA Method 5  testing was  conducted
simultaneously at the cyclone inlet, at the scrubber inlet  (cyclone  outlet),
and at the scrubber outlet stack to determine the  particulate emissions  from
two types of fire clay: flint clay (Brohard) and Missouri plastic  clay.
During the processing of each of the two clays, three  sets  of EPA  Method 5
runs were performed for a total of six sets.   Each set  consisted  of three
simultaneous runs, i.e., one run at each of the three  sampling  locations.
The impinger reagents from one Method 5 run at each location were  analyzed
for trace metals.
     Concurrent with five of the six sets of Method 5  runs, Method 9  opacity
readings were taken at the dryer inlet conveyor belt and at the scrubber
outlet stack.  Eight particle sizing runs were performed at the cyclone
inlet, while seven were performed at the scrubber  inlet  (cyclone outlet).
One reactivity run was performed as a control measure  at the cyclone inlet.
Feed and product samples were taken for moisture content and sieve analysis.
Table 1-1 presents a test log which summarizes the test  dates,  sampling
locations, run or sample numbers, and the types of testing  performed.
     1.4  Report Organization.  Section 1, "Introduction," briefly describes
the purpose of  the testing program, the responsibilities  of  the  project
participants, the NARCO facility, and the  specific  tests  that were
conducted.  Section 2 presents a comprehensive  summary  of all test results,
including pollutant emission rates and concentrations,  control equipment
collection efficiencies, and particle sizing  results.   Detailed  information
describing the  process and operating conditions during  the test  is contained
in Section 3.   Section 4 describes the various  sampling locations used in  the
testing program.  Section 5 contains the sampling and analytical procedures
employed at the NARCO facility.  The quality  assurance  procedures utilized in
this testing program are included in Section  6.
     Section 7, "Appendices," contains all relevant  supporting documentation
for the testing program.  Appendices 7.1 and  7.2 present  detailed results  for
the plastic and flint clay tests, respectively.  Appendices  7.3  and 7.4 con-
tain all sampling and analytical data for  the plastic and flint  clay  emis-
sions  testing,  respectively.  Descriptions of sampling  and analytical proce-
dures  are provided in Appendix 7.5.  Analytical results for  feed and  product
samples are included as Appendix 7.6.  Equipment calibration data are includ-
ed in  Appendix  7.7; Appendix 7.8 contains  a list of Entropy  test participants.

-------
                              1-3
                             TABLE 1-1
                        TESTING PROTOCOL AND
                RON/SAMPLE NUMBERING CROSS-REFERENCE
                                Plastic Clay
                            	 Test Set 	
     Flint Clay
	 Test Set 	
Objective
Particulate


Particle
Sizing
Sieving/
Moisture
Opacity

>ampj.ing
Method
EPA 5


Cascade
Impact or
Grab
Sample
EPA 9

Location*
CI
SI
SO
CI
SI
DI
DO
DI
SO
i
3/12
1
4
7
X
X
1
1
X
X
e.
3/15
Htm
14 tm
17 on
S11A&B
S14A&B
5
5
5
5
j
3/15
12
15
18
S12A&B
S15A&B
6
6
6
6
i
3/13
2
5
8
S2A&B
S5A
2
2
2
2
L
3/14
3tm
6tm
9tm
S3A
S6A&B
3
3
3
3
o
3/14
10
13
16
S10A
X
4
4
4
4
 * DI - Dryer Inlet
   DO - Dryer Outlet
   CI - Cyclone Inlet
   SI - Scrubber Inlet
   SO - Scrubber Outlet Stack
 X - Testing not performed
tm - Method 5 particulate catch-and  distilled water from impingers
         analyzed for trace metals.

-------
                                    2-1
2.   SUMMARY AND DISCUSSION OF RESULTS

     2.1  Summary.  Tables 2-1 and 2-2 present the emission rates and
concentrations and control equipment efficiencies for the participate testing
performed during the processing of plastic clay and flint clay,
respectively.  Run-by-run summaries of the particulate results for the
plastic clay testing are presented in Tables 2-3 through 2-5, while
Tables 2-6 through 2-8 present run-by-run summaries of the flint clay
testing; detailed results appear in Appendix 7.1.  Particle sizing summations
are given in Tables 2-9 through 2-12.  Individual run summaries of the
visible emissions observations are presented in Tables 2-13 through 2-17.

     2.2  Discussion of Results.  The emissions rates at the scrubber outlet
stack varied inversely with the efficiency of the cyclone; the scrubber
efficiency was only slightly lower during the flint clay condition than the
plastic clay condition.
     Due to equipment problems and the length of process time available on
the first day of testing, no particle sizing runs performed at any of the
sampling locations; throughout the testing program no particle sizing runs
were performed at the scrubber outlet stack due to the presence of water
droplets in the exhaust gases.  Test times at certain locations varied due to
the length of process time available.
     EMB chose to perform EPA Method 9 (visible emissions) instead of
EPA Method 22 (fugitive emissions) at the rotary dryer inlet observation
location; due to adverse weather conditions, no visible emissions readings
were taken at either observation location during the first day of testing.
Opacity measurements were planned at the rotary dryer outlet; however, during
a  presurvey of the sampling locations, it was discovered that from the dryer
outlet  to the scrubber outlet stack, the process was a closed system.
     After the completion of.run 7 at the scrubber outlet stack, it was
discovered that the thermocouple temperature readout was measuring low by
approximately 38°F.  The scrubber inlet/outlet temperatures for the
subsequent runs were reviewed, and a representative stack temperature of
130°F was used for the emissions calculations.  However, the temperature
adjustment resulted in an over isokinetic sampling rate of 113.7%.
     During the first particulate run (run 1) at the cyclone inlet, heavy
particulate loading caused the positive pitot to plug, making it necessary to
back-calculate a velocity from the scrubber inlet; limited process time
restricted the run to the horizontal sampling traverse only.

-------
                                  2-2
                               TABLE  2-1
             PARTICDLATE EMISSIONS &  CONCENTRATIONS  SUMMARY
                   AND  CONTROL EQUIPMENT  EFFICIENCIES
                              Plastic Clay

Emission Rates, Ib/hr:
Cyclone Inlet
Scrubber Inlet
(Cyclone Outlet)
Scrubber Outlet Stack
Emission Rates, kg/hr:
Cyclone Inlet
Scrubber Inlet
(Cyclone Outlet)
Scrubber Outlet Stack
Concentration, gr/DSCF:
Cyclone Inlet
Scrubber Inlet
(Cyclone Outlet)
Scrubber Outlet Stack
Collection Efficiency, %:
Cyclone
Scrubber
Concentration, mg/DSCM:
Cyclone Inlet
Scrubber Inlet
1

1,907
389.5
3.57

864.8
176.7
1.62

42.03
6.26
0.051

85.11
99.19

96,171
14,329
- iesc aet — - - — -
2 3

2,435 1,989
343.4 196.0
2.55 1.67

1,104 902.3
155.8 88.9
1.16 0.757

59.35 50.09
5.65 3.19
0.038 0.024

90.48 93.63
99.33 99.25

135,807 114,601
6,911 5,791
Average

2,109
309.6
2.60

957.0
140.5
1.18

50.49
5.03
0.038

89.74
99.26

115,526
9,010
  (Cyclone Outlet)
Scrubber Outlet Stack
115.5
86.2
53.6
85.1

-------
                                   2-3
                                TABLE 2-2
              PARTICULATE EMISSIONS & CONCENTRATIONS SUMMARY
                    AND CONTROL EQUIPMENT EFFICIENCIES
                                Flint Clay

Emission Rates, Ib/hr:
Cyclone Inlet
Scrubber Inlet
(Cyclone Outlet)
Scrubber Outlet Stack
Emission Rates, kg/hr:
Cyclone Inlet
Scrubber Inlet
(Cyclone Outlet)
Scrubber Outlet Stack
Concentration, gr/DSCF:
Cyclone Inlet
Scrubber Inlet
(Cyclone Outlet)
Scrubber Outlet Stack
Collection Efficiency, 7,:
Cyclone
Scrubber
Concentration, mg/DSCM:
Cyclone Inlet
Scrubber Inlet
1 2 3

1,543 906.8 1,608
174.5 143.9 384.9
2.03 2.61 3.18

699.9 411.3 729.5
79.2 65.3 174.6
0.921 1.18 1.44

36.78 23.64 38.36
3.02 2.53 6.40
0.030 0.039 0.046

91.79 89.30 83.32
99.01 98.46 99.28

84,156 54,082 87,770
6,911 5,791 14,634
Average

1,352
234.4
2.61

613.6
106.4
1.18

32.93
4.99
0.038

88.14
98.92

75,336
9,112
  (Cyclone Outlet)
Scrubber Outlet Stack
68.0
89.8
105.0
87.6

-------
                                2-4







                            TABLE 2-3




                PARTICDLATE TESTS SUMMARY  OF RESULTS




                    Plastic Clay - Cyclone Inlet

Run Date
Test Train Parameters:
Volume of Dry Gas
Sampled, SCF*
Percent Isokinetic
Stack Parameters:
Temperature, Deg. F
Air Flow Rates
SCFM* , Dry
ACFM, Wet
Method 5 Results (English):
Catch, milligrams
Concen. , grains/DSCF*
Emissions, pounds/hour
Method 5 Results (Metric):
Concen., milligrams/DSCM*
Emissions, kilograms/hour
1
03/12/84

13.613
103.3

160
5,292
7,412

37,075.7
42.03
1,906.6

96,170.6
864.8
11
03/15/84

9.777
102.5

139
4,787
6,857
••
37,602.9
59.35
2,435.1

135,807.1
1,104.5
12
03/15/84

9.534
103.3

138
4,633
6,613

30,942.6
50.09
1,989.3

114,601.0
902.3
* 68 Deg. F. - 29.92 in. Hg.

-------
                                2-5








                            TABLE 2-4




                PARTICDLATE TESTS SUMMARY  OP RESULTS




                   Plastic Clay - Scrubber Inlet

Run Date
Test Train Parameters:
Volume of Dry Gas
Sampled, SCF*
Percent Isokinetic
Stack Parameters:
Temperature, Deg. F
Air Flow Rates
SCFM* , Dry
ACFM, Wet
Method 5 Results (English):
Catch, milligrams
Concen., grains/DSCF*
Emissions, pounds/hour
Method 5 Results (Metric):
Concen. , milligrams/DSCM*
Emissions, kilograms/hour
4
03/12/84

26.393
100.4

132
7,256
10,109

10,709.9
6.26
389.5

14,328.6
176.7
14
03/15/84

16.412
98.8

132
7,086
9,776

6,012.2
5.65
343.4

12,935.4
155.8
15
03/15/84

16.508
98.1

133
7,176
9,962

3,408.9
3.19
196.0

7,291.7
88.9
* 68 Deg. F. - 29.92 in. Hg.

-------
                                 2-6








                             TABLE 2-5




                PARTICULATE TESTS SUMMARY  OF RESULTS




                Plastic Clay -  Scrubber  Outlet  Stack
                                                 17            18
Run Date
Test Train Parameters:
Volume of Dry Gas
Sampled, SCF*
Percent Isokinetic
Stack Parameters:
Temperature, Deg. F
Air Flow Rates
SCFM*. Dry
ACFM, Wet
Method 5 Results (English):
Catch, milligrams
Concen. , grains/DSCF*
Emissions, pounds/hour
Method 5 Results (Metric):
Concen. , milligrams/DSCM*
Emissions, kilograms/hour
03/12/84

82.266
113.7

130
8,258
10,748

269.2
0.051
3.57

115.5
1.62
03/15/84

61.237
110.5

134
7,904
10,366

149.5
0.038
2.55

86.2
1.16
03/15/84

60.702
105.1

132
8,240
10,677

92.9
0.024-
1.67

53.6
0.757
* 68 Deg. F. - 29.92 in. Hg.

-------
                                2-7








                             TABLE 2-6




                PARTICDLATE TESTS  SUMMARY OF RESULTS




                    Flint Clay -  Cyclone Inlet

Run Date
Test Train Parameters:
Volume of Dry Gas
Sampled , SCF*
Percent Isokinetic
Stack Parameters:
Temperature, Deg. F
Air Flow Rates
SCFM*, Dry
ACFM, Wet
Method 5 Results (English):
Catch, milligrams
Concen. , grains/DSCF*
Emissions, pounds/hour
Method 5 Results (Metric):
Concen. , milligrams/DSCM*
Emissions, kilograms/hour
2
03/13/84

10.148
104.0

150
4,895
6,776

24,185.8
36.78
1,543.1

84,156.3
699.9
3
03/14/84

9.521
106.8

153
4,476
6,566

14,582.4
23.64
906.8

54,082.1
411.3
10
03/14/84

9.797
100.5

149
4,891
6,952

24,352.0
38.36
1,608.2

87,770.4
729.5
* 68 Deg. F. - 29.92 in.  Hg.

-------
                                 2-8


                              TABLE 2-7

                PARTICIJLATE TESTS SUMMARY OF RESULTS

                     Flint Clay - Scrubber Inlet



                                     5            6           13

Run Date                         03/13/84     03/14/84     03/14/84

Test Train Parameters:
  Volume of Dry Gas                25.581       25.203       16.578
    Sampled, SCF*

  Percent Isokinetic                103.6        103.7        100.7

Stack Parameters:

  Temperature, Deg. F                 136          140          145

  Air Flow Rates
    SCFM*, Dry                      6,741        6,634        7,022

    ACFM, Wet                       9,440        9,506       10,126

Method 5 Results (English):

  Catch, milligrams               5,006.4      4,133.0      6,870.3

  Concen., grains/DSCF*              3.02         2.53         6.40

  Emissions, pounds/hour            174.5        143.9        384.9

Method 5 Results (Metric):

  Concen., milligrams/DSCM*       6,910.6      5,790.6     14,633.6

  Emissions, kilograms/hour          79.2         65.3        174.6


* 68 Deg. F. - 29.92 in. Hg.

-------
                                 2-9







                             TABLE 2-8




                PARTICTJLATE TESTS SUMMARY OP RESULTS




                 Flint Clay - Scrubber Outlet Stack
Run Date
Test Train Parameters:
Volume of Dry Gas
Sampled, SCF*
Percent Isokinetic
Stack Parameters:
Temperature, Deg. F
Air Flow Rates
SCFM*. Dry
ACFM, Wet
Method 5 Results (English):
Catch, milligrams
Concen. , grains /DSCF*
Emissions, pounds/hour
Method 5 Results (Metric):
Concen. , milligrams/DSCM*
Emissions, kilograms/hour
8
03/13/84
67.713
108.5

134
7,964
10,645
130.4
0.030
2.03

68.0
0.921
9
03/14/84
58.717
108.0

132
7,759
10,262
149.4
0.039
2.61

89.8
•1.18
16
03/14/84
46.662
109.9

133
8,078
10,909
138.8
0.046
3.18

105.0
1.44
* 68 Deg. F. - 29.92 in. Hg.

-------
                                        2-10



                                    TABLE  2-9

                      SUMMARY OF PARTICLE SIZING TEST RESULTS

                            Plastic Clay -  Cyclone  Inlet
SAMPLING DATA

  Date

  Start Time
  Finish Time

  Impactor Flow Rate (1/min)

  Isokinetic Ratio (Z)


STACK DATA

  Temperature (degress 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: Particle Size Run
M-5: Method 5 Particulate Run
PS Run 11
3/15/84
1256, 1325
1256, 1325
21.81
105.3
61.3
20.0
1,154
80,250
59.0
15.55
12,400
20,371
165.7
PS Run 12
3/15/84
1512,1546
1512,1546
22.06
109.9
58.3
19.5
1,118
22,570
19.7
9.03
1,740
10,314
81.2
Averai
	
	
	
	
59.8
19.8
1,136
51,410
39.3
12.29
7,070
15,342
123.4

-------
                             .    2-11

                    PARTICLE SIZE DISTRIBUTION


COMPANY NAME North American Refractories Company    AVERAGE OF RUNS HA. 11B, 12A

ADDRESS _ Farber . Missouri _                & 12B
SAMPLING
                    Cyclone Inlet
             3-15-84
  CO

  I
  u
  (0
  u
  u


  \
                              DENSITY = I  CM/CM
1 ft ---'

70 =



** •

1O .1 .. L
9 '




4^—*

(:

9 «
8 ^
7 -


5

2"

.t —
















)















































(T)
V-/






















































0















































































































































































































































































                  5    10  IS 20    30   40  SO 60  70   80 85  90    95   98
                     PERCENT OF PARTICLES LESS THAN  INDICATED SIZE

-------
                                     2-12


                                 TABLE  2-10

                   SUMMARY OF PARTICLE SIZING TEST RESULTS

                        Plastic Clay - Scrubber 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/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: Particle Size Run
M-5: Method 5 Particulate Run
PS Run 14
3/15/84
1305, 1338
1307, 1340
19.46
102.5
58.6
18.9
1,056
10,590
81.8
41.62
4,270
5,302
64.8
PS Run 15
3/15/84
1535, 1557
1536, 1558
21.72
111.5
58.6
16.6
1,086
3,913
53.6
34.81
1,570
2,478
30.2
Averagi
	
	
	
	
58.6
17.8
1,071
7,251
67.7
38.21
2,920
3,890
47.5

-------
COMPANY
ADDRESS
                    2-13

      PARTICLE  SIZE  DISTRIBUTION

North American Refractories Company
Farber, Missouri
                                                   AVERAGE OF RUNS 14A. 14B.-15A..
                                                                   &  15B
SAMPLING LOCATION
                    Scrubber Inlet
           3/15/84
                              DENSITY =  I GM/CM
  U
  i
   e
   to
  H
  to
  U
  U

00 =
70 '

30- i"
jto.. -



9 !
I i


3 :
:
M -



9 — c

7 =






.1 —













































0
fa
<./


3






















G



















































A
\.






















K
s_


s























r^


























rr\
^



























































































































































































                                         I    I   I     I  I   I
                  S    10  IS  20   30  40  50  60 70   80  85  90    95   93
                     PERCENT OF PARTICLES LESS THAN  INDICATED SIZE

-------
                                        2-14



                                    TABLE  2-11

                      SUMMARY OF PARTICLE SIZING TEST  RESULTS

                             Flint  Clay - Cyclone Inlet
SAMPLING DATA

  Date

  Start Time
  Finish Time

  Impactor Flow Rate (1/min)

  Isoklnetic 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: Particle Size Run
M-5: Method 5 Particulate Run
PS Run 2
3/13/84
1730
1732
31.35
156.0
62.5
14.8
1,119
18,510
21.9
80.91
14,973
67,325
559.92
PS Run 3
3/14/84
1527
1527
20.73
105.4
62.0
19.5
1,095
57,870
107
4.0
2,314
2,163
16.45
PS Run 10
3/14/84
1736
1736
22.68
107.3
65.5
17.5
1,178
57,950
66
23.71
13,742
20,187
167.78
Averag
	
	
	
	
63.3
17.3
1,131
44,776
64.9
36.20
10,343
29,891
248.05

-------
                                 2-15
                   PARTICLE  SIZE DISTRIBUTION

COMPANY NAME- North American Refractories  Company    AVERAGE OF RUMS  2B, 3A. & 10A
ADDRESS _ Farber, Missouri _
SAMPLING LOCATION
                    Cyclone Inlet
          3/13/84  & 3/14/84
                             DENSITY - I  CM/CM
  I
  U
  i
   o
   10
  K
  0)
  III
  U




50 :
5
40 -
30— -:


1 « r
a *
:

* :
fl =
3—"


9 :
8 2
. 7 ^




j

. I —
















0
)




















































-------
                                      2-16



                                  TABLE  2-12

                    SUMMARY OF PARTICLE SIZING TEST  RESULTS

                          Flint Clay - Scrubber  Inlet
SAMPLING DATA

  Date

  Start Time
  Finish Time

  Impactor Flow Rate (1/min)

  Isokinetic Ratio (Z)


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: Particle Size Run
M-5: Method 5 Particulate Run
PS Run 5
3/13/84
1703
1705
20.05
107.1
58.8
17.0
1,043
4,862
70.3
70.44
3,424
4,837
55.44
PS Run 6
3/14/84
1546,1623
1548,1625
20.12
112.6
58.6
18.7
995
8,780
151.6
46.40
4,090
2,663
30.03
Averagi
	
	
	
	
58.7
17.9
1,019
6,821
110.9
58.42
3,757
3,750
42.73

-------
                                 2-17
COMPANY

ADDRESS
                   PARTICLE  SIZE DISTRIBUTION


              North American Refractories Company  AVERAGE OF RUNS SA, fiA ,  & 6R
              Farber, Missouri
SAMPLING
                    Scrubber Inlet
PATENS)  3/13/84 &  3/14/84
                             DENSITY = 1  CM/CM
  s
  u
   o
   IR
  n


an..,. 5
70 5


40 '
* ** -'

in, ...

:


3 — ^
4 I



9 -4
ft «-/
7 s


























C;


^^
i •
N-*






2


















• J
^










S I

















©











Illl
0 I





























Illl
9 2













/















fill (HI
0 1













r\
j














IMIIIIII
0 '





























I1IMIII
10 !










v«/


















mi mi
>0 C









(



















Illl Mil
tO 7









a



















iimiiii
0 8





























Illl
0 {





























Illl
5 9





























iiii
0 <





























IS 9
                     PERCENT OF PARTICLES LESS THAN INDICATED SIZE

-------
                                        2-18
                                  TABLE 2-13

                         SUMMARY OP VISIBLE EMISSIONS

                                     Run 2
Date: 3/13/84
Type of Discharge; Stack
Height of Point of Discharge:
Wind Direction; East         '
                  60
Color of Plume: White
Observer: J. R. Iserman
Distance from Observer to Discharge Point:
Direction of Observer from Point: West
                   Type of Plant;  Drying Kiln - Clay
                   Location of Discharge;Scrub. Outlet
                   Description of  Sky;  Overcast	
                   •Wind Velocity;  0-5	
                   Detached Plume; Slighty detached
                   Duration of Observation;  166 min.
                  150'
Height of Observation Point; Ground level
Description of Background; Light Gray
Set
  1
  2
  3
  4
  A

  6
  7
  8
  9
 10
 11
 12
 13
 14
Time
1445
1451
1457
1503
1509
1515
1521
1527
1533
1539
1545
1551
1557
1603
1451
1457
1503
1509
1515
1521
1527
1533
1539
1545
1551
1557
1603
1609
  SUMMARY OF AVERAGE OPACITY

Opacity        Set         Time
Number   Start  End    Sum  Average
            10
            25
            30
            35
            45
            35
            70
            60
            65
            60
            85
            20
            10
            25
     0.42
     1.04
     1.25
     1.46
     1.88
      ,46
      .92
      .50
      .71
      .50
     3.54
     0.83
     0.42
     1.04
Number

  15
  16
  17
  18
  19
  20
  21
  22
  23
  24
  25
  26
  27
  28
•1609
 1615
 1621
 1627
 1633
 1639
 1647
 1653
 1659
 1705
 1711
 1717
 1723
-1729
1615
1621
1627
1633
1639
1645
1653
1659
1705
1711
1717
1723
1729
1731
                         Opacity
                                     Start   End    Sum  Average
45
65
35
30
50
65
35
25
45
50
.60
65
40
30
 1.88
 2.71
 1.46
 1.25
 2.08
 2.71
 1.46
 1.04
 1.38
 2.08
 2.50
 2.71
 1.67
*3.75
   *Represents 2 minutes of readings
             — 4

             r
             o
                                          30

                                         TIME
                                                           90

-------
                                       2-19
                                  TABLE 2-14

                         SUMMARY OP VISIBLE EMISSIONS

                                    Run 3
Date: 3/14/84
Type of Discharge; Stack
Height of Point of Discharge:^
Wind Direction: North
                     60'
Color of Plume: White
Observer: J. R. Iserman
Distance from Observer to Discharge Point:
Direction of Observer from Point: West
                             Type of Plant; Drying Kiln - Clay
                             Location of Discharge;Scrub. Outlet
                             Description of Sky; Overcast	
                             Wind Velocity; 5-10	
                             Detached Plume: No
                                   Duration of Observation;  150 min.
                                  150*
Height of Observation Point; Ground level
Description of Background; Light Gray
Set
  1
  2
  3
 .4.
  5
  6
  7
  8
  9
 10
   Time
Number   Start  End
1315
1321
1327
1333
1339
1345
1420
1426
1432
1438
1321
1327
1333
1339
1345
1349
1426
1432
1438
1444
            SUMMARY OF AVERAGE OPACITY

          Opacity        Set         Time

        Sum  Average    Number    Start   End
60
60
60
65
50
55
35
70
55
55
2.50
2.50
2.50
.2.71
2.08
*3.24
**4.38
2.92
2.29
2.29
11
12
13
14
15
16
17
18
19
20
1445
1451
1457
1503
1509
1515
1521
1527
1533
1539
1451
1457
1503
1509
1515
1521
1527
1533
1539
1545
                       Opacity

                     Sum  Average
60
50
45
50
60
55
60
50
35
30
  50
  08
1.87
  08
  50
  08
  50
  08
  46
1.25
  *Due to overcast conditions this reading represents only 4  minutes  &  15
     seconds
  **Represents two minutes of readings
             — 4
             i1
             r
             u
                        30
                                1 HR
                                          10

                                         TIME

-------
                                        2-20
                                  TABLE 2-15

                         SUMMARY OF VISIBLE EMISSIONS

                                    Run 4
Date; 3/14/84
Type of Discharge: Stack
Height of Point of Discharge:
Wind Direction; North	]
Color of Plume: White
                    60
Observer: J. R. Iserman
Distance from Observer to Discharge Point:
Direction of Observer from Point:  West
                            Type of Plant; Drying Kiln - Clay
                            Location of Discharge;Scrub. Outlet
                            Description of Sky; Overcast	
                            Wind Velocity; 10-15	
                                  Detached Plume: No
                                  Duration of Observation; 112 min.
                                 150'            	
Height of Observation Point; Ground level
Description of Background; Light Gray
Set
  1.
  2
 .3.
  4
  5
  6
  7
  8
  9
 10
   Time
Number   Start  End
1615
1621
1627
1633
1639
1715
1721
1727
1733
1739
1621
1627
1633
1639
1645
1721
1727
1733
1739
1745
            SUMMARY OF AVERAGE OPACITY

          Opacity        Set         Time

        Sum  Average    Number    Start  End
60
70
65
50
55
80
70
55
55
50
  50
  92
  71
  08
2.29
3,
2.
2.
2.
33
92
29
29
                                       Opacity

                                     .Sum  Average
         11
         12
         13
         14
1745   1751
1751   1757
1757   1803
1803   1807
55
60
70
40
 2.29
 2.50
 2.92
*2.50
2.08
  *Due to overcast, conditions this reading  represents only 4 minutes
             — 4
             *



             I'
             s*
             i
                                         30

                                        TIME

-------
                                        2-21
                                 TABLE  2-16

                         SUMMARY OF VISIBLE EMISSIONS

                                    Run  5
Date: 3/15/84
Type of Discharge; Stack
Height of Point of Discharge:
Wind Direction; North	~
Color of Plume; White	
Observer: J. R.
                              60'
                Iserman
Distance from Observer to Discharge Point:
Direction of Observer from Point:  West
                               Type  of Plant; Drying Kiln - Clay
                               Location  of Discharge:Scrub. Outlet
                               Description of Sky; Overcast	
                               Wind  Velocity; 5-10	
                               Detached  Plume: No
                               Duration  of Observation; 165 min.
                               150'
Height of Observation Point;  Ground level
Description of Background;  Gray
Set
Time
Number   Start  End
  1
  2
  3
 *4'
  5
  6
  7
  8
  9
 10
1100
1106
1112
1118
1124
1130
1136
1142
1148
1154
1106
1112
1118
1124
1130
1136
1142
1148
1154
1155
                           SUMMARY OF AVERAGE OPACITY

                         Opacity        Set         Time

                       Sum  Average    Number.    Start  End
50
35
45
60
50
45
50
70
35
15
2.08
1.46
1.87
2.50
2.08
1.87
2.08
2.92
1.46
*3.00
         Opacity

       Sum  Average
                             11
                             12
                             13
                             14
                             15
                             16
                             17
                             18
                             19
                             20
                                                 1245
                                                 1251
                                                 1257
                                                 1303
                                                 1309
                                                 1315
                                                 1321
                                                 1327
                                                 1333
                                                 1339
1251
1257
1303
1309
1315
1321
1327
1333
1339
1345
65
65
35
50
70
55
65
35
55
45
2.71
2.71
1.46
 .08
 .92
 .29
2.71
1.46
2.29
1.87
2.
2.
2.
   ^Represents 1.25 minutes of readings
             — 4
             r
                               I HR
                                         10

                                        TIME
                                                 2 HR

-------
                                        2-22
                                  TABLE 2-17

                         SUMMARY OP VISIBLE EMISSIONS

                                    Run 6
Date: 3/15/84
Type of Discharge; Stack
Height of Point of Discharge; 60
Wind Direction: North-North-East
Color of Plume: White
Observer: J. R. Iserman
Distance from Observer to Discharge Point:
Direction of Observer from Point: West
                                   Type of  Plant; Drying Kiln - Clay
                                   Location of Discharge:Scrub. Outlet
                                   Description of Sky; Overcast	
                                   Wind Velocity; 5-10	
                                   Detached Plume: No
                                   Duration of Observation;  105 min.
                                  150'
Height of Observation Point; Ground level
Description of Background; Gray
Set
  1
  2
  3
 *4
  5
  6
  7
  8
  9
 10
   Time
1415
1421
1427
1433
1439
1445
1451
1457
1503
1509
1421
1427
1433
1439
1445
1451
1457
1503
1509
1515
            SUMMARY OF AVERAGE OPACITY

          Opacity        Set         Time
Number   Start  End    Sum  Average
80
35
65
30
60
35
40
50
60
25
3.33
1.46
2.71
1.25
2.50
1.46
1.67
2.08
2.50
                                        Opacity
Number

  11
  12
  13
  14
  15
  16
  17
  18
                                       .Start  End    Sum  Average
1515
1521
1527
1533
1539
1545
1551
1557
1521
1527
1533
1539
1545
1551
1557
1600
75
75
35
50
65
45
85
35
 3.13
 3.13
 1.46
 2.08
 2.71
 1.87
 3.54
*2.92
1.04
   *Represents three minutes of readings
             u
             a
             r
                                         10

                                         TIME
                                                  2 MR

-------
                                     3-1
3.   PROCESS DESCRIPTION AND OPERATION

     3.1  General.  NARCO produces a variety of refractory brick and
specialty products using an assortment of raw materials.  A complete
description of NARCO's process operations was provided In an earlier MRI trip
report (final November 10, 1983).  The following discussion describes the
processing of plastic and flint clays.  Figure 3-1 is a general process flow
diagram of the clay process tested.

     3.2  Calcining Process.

     3.2.1  Raw Material.  NARCO maintains an open-pit mine near Martinsburg,
Missouri, approximately 30 miles from Farber, which serves as the source of
Missouri plastic  clay.  Flint clay is purchased from a mine in Wheelersburg,
Ohio, and is called  "Brohard" by plant personnel.  The two raw materials are
stored in outdoor stockpiles and are moved by front-end loader into a
hopper.  A drag feeder moves the clay from the hopper into an eagle crusher,
which reduces the material to less than 10.2 cm (4 In.) In size.  A partially
covered conveyor  belt carries the material to a chute where it is gravity-fed
into a rotary dryer.

     3.2.2  Rotary Dryer.  The McDermott, direct-fired, rotary dryer is 2.4 m
(8 ft) in diameter and 18.3 m (60 ft) long.  It rotates at a speed of 5 rpm
and has an average material retention time of about 16 minutes.  Actual
retention times vary with each raw material.  The maximum drying temperature
provided by natural gas firing (combustion chamber) is 927°C (1700°F).
The actual gas temperature in the dryer is 149° to 204°C (300° to
400°F).  Gas flow is cocurrent to process material flow, and there are  no
heat recovery or  recirculation systems associated with this dryer.  The
amount of moisture removed by the dryer ranges from 2 to 10 percent.

     3.2.2.1  Dryer Design Capacity.  The design  capacity of the dryer  also
varies with each  material processed.  The final moisture content required for
a usuable product dictates the rate at- which the  raw material can be
processed through the dryer.  Typical maximum production capacities for
plastic and flint clay are 27 Mg/h (30 tph) and 18 Mg/h (20 tph)
respectively.

-------
                     3-2
                     TRUCK
                      OUTDOOR
                       STOCKPILES
                     FRONT-END
                     LOADER
                        CRUSHER
                        HOPPER
                     DRAG FEEDER
                        EAGLE
                        CRUSHER
                     BELT CONVEYOR
                ROTARY
                DRYER
                     BELT CONVEYOR
                STORAGE
                 BINS
               ADDITIONAL
               PROCESSING
Figure 3-1 Plastic and flint clay processing.
           NARCO,  Farber,  Mo.

-------
                                     3-3
     3.2.2.2  Dryer Exhaust Gases.  The exhaust gases from the rotary dryer
pass through a cyclone (W.W. Sly, No. 48, Series 230) and a vane-type
scrubber (Entoleter, Model CF2-0511-11) before being emitted to the
atmosphere.  The partlculate captured by the cyclone Is recycled onto the
product conveyor belt at the dryer outlet.  The scrubber has a design gas
flow rate of 312 m3/min (11,100 acfm).  The inlet gas temperature is 93°C
(200°?), and the moisture content of the inlet gas is 0.08 Ib l^O/lb dry
gas.  The liquid flow rate is 75 1/min (20 gpm), and the gas pressure drop
across the scrubber is 2.7 to 3.2 kPa (11 to 13 in. w.c.).  The pressure drop
across the entire cyclone/scrubber system is 4.2 to 4.5 kPa (17 to I80in.
w.c.).

     3.2.3  Storage.  After drying, the material is belt-conveyed to the main
plant.  Storage bins, rated at 68 Mg (75 tons) each, are filled and emptied
as needed to meet NARCO production schedules.  There are no scales or other
monitors for determining production rate; however, the loader operator is
aware of how many "dips" of material fed to the dryer will fill each bin.
The actual bin capacity varies for each  raw material.  For flint and plastic
clay, each bin holds approximately 54 Mg (60 tons) of dried material.

     3.3  PROCESS CONDITIONS DURING TESTING

     3.3.1  Monitoring Procedures.  All  processes were operating normally and
at maximum  capacity during the emission  testing.  Test run Nos. 1, 5, and 6
were conducted during plastic  clay processing.  Run Nos. 2, 3, and 4 were
conducted during flint clay processing.  The dryer operation was monitored by
recording the combustion chamber  temperature at 15-minute intervals.  This
temperature gauge was located  in  a shed  at the feed end of the dryer.  The
furnace temperature ranged from 888° to  927°C (1630° to 1700°F)
during  the  testing.  The fuel  usage  rate was determined by taking natural gas
meter  readings at the start and finish of each test run.  The fuel usage rate
was determined by taking natural  gas meter readings at the start and finish
of each test  run.  The fuel usage rate was constant so more frequent gas
readings were not required.  The  average fuel usuage rate during the testing
was approximately 7.1 nr/min (250 ft^/min) for both clays.  This
corresponds to a fuel to product  ratio of approximately 600,000 Btu/ton of

-------
                                     3-4
flint clay and 465,000 Btu/ton of plastic clay.  A sample calculation for
flint clay is shown below:

            975 Btu   249.8 ft3   60 min         h
            	x	x	x	= 604,389 Btu/ton
              ft3        min         h       24.2 tons

     3.3.2  Test Interruptions.  On several occasions during test runs, the
dryer was shut off for employee break periods.  Testing was also discontinued
during dryer shutoffs.  In some cases the furnance was left on during the
break to avoid lighting it again and waiting for the dryer to reach its
proper operating temperature.  In these cases, the incremental gas usuage was
determined for the nontestlng periods and was subtracted from the total gas
usage given by the meter reading.

     3.3.3  Control Equipment.  The operation of the air pollution control
equipment was monitored by recording the gas pressure drop across the system
from a manometer installed by NARCO inside the scrubber building.  The
pressure drop across the cyclone/scrubber system ranged from 4.1 to 4.5 kPa
(16.5 to 18 in. w.c.) throughout the testing.  The average gas flow rate from
the scrubber stack was 10,500 acfm at 135°F.

     3.3.4  Production Rates.  The production rate was measured by recording
the number of loads (dips) fed to the eagle crusher.  The actual count was
provided to MRI by the front-end loader operator at various times throughout
each test run.  The crusher operator maintained a steady stream of raw
material to the dryer.  The conveyor belt feeding the dryer only operates at
one speed, so the production rate is varied by the depth and quantity of raw
material on the belt.
     In some cases, the final moisture content of the dried material is too
high for proper milling.  In these cases the crusher operator shuts off the
conveyor belt for 3 minutes to allow the dryer temperature to increase
slightly and to allow additional drying to occur.  This occurred twice during
run No. 2 (flint clay), at 2:30 p.m. and 3:10 p.m.  During all other test
runs the conveyor belt operated continuously.
     The actual production rafie for each run was calculated .using the weight

-------
                                     3-5
of an average load and the dip count given by the loader operator.  For test
runs on March 12, 14, and 15, a small loader owned by NARCO was used.  Due to
an electrical fire in this loader on March 13, a larger loader was  rented for
use on the 13th.  The original loader was repaired by the 14th and  was used
the rest of the week.  Each loader was weighed when full and empty  to
determine the weight of an average load.  The average production  rates during
testing of flint and plastic clay were 21.9 Mg/h (24.2 tph) and 28.6 Mg/h
(31.5 tph), respectively.  The dryer was operating at capacity at all times
to produce products with suitable final moisture contents.  Tables  3-1
through 3-6 present the actual operating conditions during each test run.
Table 3-7 summarizes the production data.

     3.3.5  Moisture Content.  The initial and final moisture contents of the
two clays were measured by NARCO personnel at the request of MRI.   The
initial moisture content of  the flint clay (Brohard) was 12.9 percent and the
final moisture  content was 1.9 percent.  The plastic clay had initial and
final moisture  contents of 11.9 and 4.1 percent, respectively.

     3.4  DISCUSSION/CONCLUSIONS

     Plant processes were operated at maximum capacity during all test  runs.
Collected data  are  representative of normal process conditions and  are useful
for NSPS development.  All scheduled emission test  runs were completed,
except for particle  size sampling at the scrubber outlet stack.   Particle
size testing was not possible at this location because of excessive moisture
in the gas stream.  Visible  emissions observations were made at the outlet
stack and the process feed inlet during five of  the six runs; darkness
prevented any readings from  being taken during run No. 1.  All fugitive
emission readings were zero  percent opacity.  Most  of the stack opacity
readings were also  zero percent; however, an occasional 5 to 10 percent
reading was  recorded.  The average opacity for all  test runs was  1.5 to 2
percent.  Mr. Sutton and other NARCO personnel were very helpful  in
maintaining  a consistent process operation throughout the week of testing.

-------
                                  3-6
                      TABLE 3-1  OPERATING CONDITIONS
             RUN NO.  1—MISSOURI PLASTIC CLAY—MARCH 12, 1984-
Dryer
furnace
Time temp. (°F)
6:00 p.m.
6:15
6:30
6:45
7:00
7:15
7:30
7:45
8:00
8:15
Weight per load
Production rate
Natural gas used
1700
1700
1700
1700
1700
1700
1700
1700
1700
1700
=2.9 tons
=• 22 loads
= 93,309 -
Scrubber
system,
AP (in. w.c.
18.0
17.0
17.0
17.0
17.0
18.0
17.0
17.0
17.0
18.0

2.9 tons ..
A load "
93,276 MCF _
Natural
gas meter Cumulative No.
reading, loads into
) (MCF)a hopper
93,276 1



13




93,309 22

1 60 min _ 28.2 tons
135 min h h
33,000 ft3 _ 244.4 ft3
135 min min
*MCF = 1,000 ft3.

-------
                                  3-7
                      TABLE 3-2  OPERATING CONDITIONS
                  RUN-NO.  2—FLINT CLAY—MARCH 13, 1984
Time
2:45 p.m.
3:00
3:15
3:30
3:45

4:00
4:15
4:30
4:45
5:00
5:15
5:30
Weight per
Production
Natural gas
Dryer
furnace
temp. (°F)
1700
1700
1700
1700
BREAK


1700
1700
1700
1700
1700
1700
load =4.6 tons
rate = 15 loads
used = 93,445 -
Scrubber
system,
AP (in. w.c
16.8
17.3
17.0
16.8
Natural
gas meter Cumulative No.
reading, loads into
.) (MCF)a hopper0
93,411 1


•5
PERIOD— DRYER AND GAS SHUT OFF
TESTING

17;0
17.0
17.3
17.5
17.8
18.0

4.6 tons
x load
93,411 MCF
DISCONTINUED

6
9
11


93,445 15

1 60 min _ 30.4 tons
x 135 min x h h
_ 34,000 ft3 _ 251.9 ft3
135 min min
JMCF = 1,000 ft3.
 Different front-end loader used for this run because of electrical
 problem with original loader.

-------
                                 3-8
                      TABLE 3-3 OPERATING CONDITIONS
                  RUN NO. 3--FLINT CLAY—MARCH 14, 1984
Time
1:15 p.m.
1:30
1:45
2:00
2:15
2:30
2:45
3:00
3:15
3:30
Dryer
furnace
temp. (°F)
1680
1680
1680
30 MIN
1670
1670
1670
1670
1670
1680
Scrubber
system,
AP (in. w.c.)
16.5
17.0
17.8
Natural
gas meter
reading,
(MCF)a
93,581


BREAK PERIOD—DRYER SHUT OFF (GAS
TESTING DISCONTINUED
17.3
17.5
17.5
17.5
17.5
17.8





93,624
Cumulative No.
loads into
hopper
1

8
STILL ON)



15

21
Weight per load  =2.2 tons

Production rate  = 21 loads   2.23 tons
                            x    load   x
             105 min
                       60 min _ 26.8 tons
Natural gas used = 93,624 - 93,581 MCF = 43.000 ft3 = 260.6 ft3/min
                                         135 min
                   260.6 ft3
                     mTn
x 30 min. = 7,818 ft3
  43,000-7,818 = 35,182 ft3 used during testing
*MCF = 1,000 ft3.
 Original loader.

-------
                                   3-9
                      TABLE 3-4  OPERATING CONDITIONS
                  RUN NO.  4—FLINT CLAY—MARCH 14,  1984
Natural
Dryer Scrubber gas meter Cumulative No.
furnace system, reading, loads into
Time temp. (°F) AP (in. w.c.) (MCF)a hopper0
4:00 p.m.
4:15
4:30
4:45
5:00
5:15
5:30
5:45
6:00
6:15
Weight per load
Production rate
Natural nac ncorl
1680
1680
1680
1680
30 MIN BREAK
1630
1630
1650
1650
1650
=2.2 tons
= 12 loads x
= q-i ecc _ Q-a
17.5 93,624
17.3
17.3
17.3
PERIOD— DRYER SHUT OFF
TESTING DISCONTINUED
16.8
17.8
16.8
17.0
17.0 93,656
2.2 tons 1 60
load A 105 min A
fi?d MPP = 32,000 f,t
1


7
(GAS STILL ON)

9
10

12
min 15.3 tons
h h
32,000 - 7,110 = 24,890 ft3 used during testing
?MCF =1,000 ft3.
 Original loader.

-------
                                   3-10
                      TABLE 3-5 OPERATING CONDITIONS
             RUN NO. 5—MISSOURI PLASTIC CLAY—MARCH 15,  1984

Time
11:00 a.m.
11:15
11:30
11:45
12:00

Dryer
furnace
temp. (°F)
1650
1680
1680
1680
LUNCH

Scrubber
system,
AP (in. w.c.)
17.4
17.4
17.0
17.2
BREAK— ORYER AND
Natural
gas meter
readi ng ,
(MCF)a
93,735



GAS OFF 12-12:

Cumulative No.
loads into
hopper
1

7

30 p.m.
                                GAS ON 12:30-12:45 p.m.
                                 TESTING DISCONTINUED

12:30

12:45 p.m.       1650           16.8                            13

1:00             1660           17.0

1:15             1660           17.0

1:30             1660           17.0                            19

1:45             1660           17.0           93,769           22

Weight per load    = 2.9 tons

Production rate    = 22 loads   2.9 tons      1      60 min   31.7  tons
                                  load   * 120 min x    h           h

Natural gas used   = 93,769 - 93,735  MCF =

                   251>.9 ft3 x 15 min = 3,779 ft3
                     mm

34,000 - 3,779 ft3 = 30,221 ft3 used during testing
     = 1,000 ft3.
 Original loader.

-------
                                  3-11
                      TABLE 3r6  OPERATING  CONDITIONS
             RUN  NO.  6—MISSOURI PLASTIC CLAY—MARCH 15,  1984
Natural
Dryer Scrubber gas meter Cumulative No.
furnace system, reading, loads into
Time temp. (°F) AP (in. w.c. ) (MCF)a hopper0
2:15 p.m. '
2:30
2:45
3:00
3:15
3:30
3:45
4:00
Weight per load
Production rate
Natural nac ncaH
1650
1650
1650
1650
1660
1660
1660
1660
=2.9 tons
= 21 loads ,
»
= q^ an? - <
17.0 93,775 1
17.0
17. 0 7
17.2
17.2 14
17.1
17.0 18
17.5 93,802 21

2.9 tons 1 60 min _ 34.6 tons
; load x 105 min x h h
^*» TTC U/*P fc / • UUU 1 U bw / • J> It
*MCF = 1,000 ft3.
 Original loader.

-------
                          3-12
        TABLE 3-7 NARCO TEST PRODUCTION SUMMARY
Test
run
1
2
3
4
5
6
Process
material
Plastic clay
Flint clay
Flint clay
Flint clay.
Plastic clay
Plastic clay
Production
rate (tons/h)
28.2
30.4
26.8
15.3
31.7
34.6
Fuel usage
(ftVmin)
244.4
251.9
260.6
237.0
251.9
257.1
AVERAGE PRODUCTION RATES:
    FLINT CLAY = 24.2 tons/h
  PLASTIC CLAY = 31.5 tons/h

-------
                                      4-1

4.    SAMPLING LOCATIONS

      4.1   Suitability of Sampling Sites.   The primary goal of the testing
program was to characterize emissions from the clay drying process pollution
control equipment.  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 Dryer Inlet (Sampling Location A).  Grab samples of the feed
to the rotary dryer were collected for sieve analysis and moisture content
determination.  Samples were taken during each set of simultaneous Method 5
runs.                                                           v

      4.3  Rotary Dryer Inlet (Observation Location B).  Method 9 visible
emissions were performed at the conveyor belt just as it enters the rotary
dryer.

      4.4  Rotary Dryer Outlet (Observation Location C).  Method 22 visible
emissions were planned for this location; however, during the presurvey of
the sampling locations, it was decided by the EPA EMB that, from the dryer
-outlet through the scrubber outlet stack, the process was a closed system.

      4.5  Rotary Dryer Outlet (Sampling Locations D).  Grab samples of the
product from the dryer were collected for sieve analysis and moisture content
 determination.  Samples were taken during each set of simultaneous Method 5
 runs.
                                                                     A •
      4.6  Cyclone Inlet (Sampling Location E).  Particulate emissions and
 particle size distribution determinations were made in the 19-inch diameter
 duct accessed through two sampling ports spaced 90 degrees apart.  The
 sampling ports were located 71 inches (i.e., 3.7 duct diameters) downstream
 from the dryer hopper and 70 inches (i.e., 3.7 duct diameters) upstream from
 the inlet to the cyclone.  Figure 4-2 illustrates the cyclone inlet sampling
 location.
      The original test plan was to sample 24 points for five minutes each
 (giving a total test time of 120 minutes), but the high particulate loading

-------
4-2
OBSERVATION
LOCATION C

ATMOSPHERE
-^ nn.cnrnvaTTOM
I
G
STACK O
|
1
I.D. FAN
|
1
SCRUBBER
A
PF
CYCLONE
1
• -..— . I
X_ A
^•9 E
ROTARY
DRYER
 GRAB SAMPLES
O SAMPLING LOCATIONS
• OBSERVATION POINT
FIGURE 4-1 PROCESS FLOW SCHEMATIC SHOWING SAMPLING LOCATIONS

-------
                                     4-3
in the duct made this plan impractical.  EPA EMB and Entropy jointly approved
a revised particulate sampling plan in which 12 points (six points on  each of
two traverse axes labeled A and B) were sampled for two minutes each,  for a
net run time of 24 minotes.

     4.7  Scrubber Inlet-Cyclone Outlet (Sampling Location F).  Particulate
emissions and particle size distribution determinations were made in the
17-inch by 25-inch rectangular duct accessed through a rectangular slot in
the duct.  Five traverse access points were located in the slot 73 inches
(i.e., 3.6 equivalent duct diameters) downstream from the cyclone outlet and
22 inches (i.e., 1.1 equivalent duct diameters) upstream from the inlet to
the scrubber.  Figure 4-3 illustrates the scrubber inlet sampling location.
     The original plan was to divide the duct cross section into 25 equal
areas and sample the centroid of each equal area for 2.5 minutes for a net
run time of 62.5 minutes; however, due to the high negative pressure
encountered at the location, only 20 of the 25 equal areas were sampled.  For
runs 4-6, the first point on each traverse axis was not sampled, and the
second point was sampled twice, as approved by EPA EMB.  During runs 13-15,
the second point was sampled only once anad the sampling time at each  point
was dropped to two minutes for a net run time of 40 minutes as per EPA EMB.

     4.8  Scrubber Outlet Stack (SamplingcLocation G).  Particulate emissions
determinations were made in the 18.5-inch (depth) by 19-inch (width)
rectangular stack accessed through a rectangular slot in the stack.  Five
traverse access points were located in the slot located 58 inches (i.e., 3.1
equivalent duct diameters) downstream from the scrubber outlet and 48  inches
(i.e., 2.6 equivalent duct diameters) upstream from the stack outlet.  The
scrubber outlet stack sampling location is illustrated in Figure 4-4.

     4.9  Scrubber Outlet Stack (Observation Location H).  Method 5
particulate emissions and Method 9 visible emissions were performed at the
stack outlet.

-------
                               4-4
                           19" DIAMETER
          1 AXIS
          12 POINTS/AXIS
          12 TOTAL POINTS

                                                 B
2 AXES
6 POINTS/AXIS
12 TOTAL POINTS
           SECTION L-L
              RUN 1
    SECTION L-L
 RUNS 2,3,10,11,12
FIGURE 4-2 CYCLONE INLET DIMENSIONS WITH SAMPLING PORT AND
           POINT LOCATIONS

-------
                               4-5
  25'
               .17"
                  +-4—-
            Tr~-T
              4  i 3
               _L
                       1
                                   NOTE:
FIRST POINT OF EACH
TRAVERSE AXIS WAS
NOT SAMPLED
                              B
                              •D
        L
           20 SAMPLING POINTS

             SECTION M-M
                                                        FROM
                                                        CYCLONE
BYPASS
TO STACK
TO
SCRUBBER
                             SAMPLING TRAVERSE
                             ACCESS
FIGURE 4-3 SCRUBBER  INLET  DIMENSIONS WITH SAMPLING PORT AND
           POINT LOCATIONS

-------
                                4-6
                 18.5'
                                 19'
                          - I  •  I  •  I. •  I  •
                                 __
                                I    I
 8  I  '
--- -- ,
                                I  '
                                  -I	lr- —
                                    I
                                        I
                          I    I    I    t   I
                          A   B    C    D   E
                         25 SAMPLING
                         POINTS
                            SECTION  R-R
        SAMPLING
        TRAVERSE
        ACCESS
                             FROM FAN
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 North American Refractories
Company facility in order to gather data concerning emissions from the clay
drying pollution control equipment and to investigate physical properties of
the process feed stock and the product.  The sampling program Included tests
for partlculate emissions and trace metals, sieve and moisture analysis on
feed and product samples, plume opacity, and particle size distribution.

     5.2  Particulate Emissions Testing.  Where appropriate, particulate
emissions sampling conformed to the standards and procedures set  forth by EPA
Reference Methods 1-5 and described in 40 CFR Part 60, Appendix 7.3.  It was
necessary at 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.  For one run at each location, the Method 5
particulate catch and the distilled water reagent from the impingers were
analyzed for trace metals by using atomic absorption or  inductively coupled
argon plasma spectrometry.  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.

     5.5  Plume Opacity and Fugitive Emissions.  Plume opacity observations
were performed in accordance with EPA Reference Method 9 as described in 40
CFR Part 60.  Fugitive emissions observations were made  using EPA Reference
Method 9 instead of EPA Reference Method 22 as per EPA EMB.

     5.6  Particle Size Tests.  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.

-------
                                     6-1
6.  QUALITY ASSURANCE

     6.1  Introduction.  The goal of quality assurance  for  the  project  was  to
ensure the accuracy of all data collected.  The procedures  used are  contained
in Entropy's "Quality Assurance Program Plan," which was  approved  by the  U.S.
EPA EMB in the contract agreement governing the project.
     In order to ensure continuity among  field testing  personnel,  daily
meetings were held before each day of the field testing.  At  the meetings,
results from the testing conducted on the previous day  were reviewed.
Responsibilities were clearly delineated  for each member  of the testing team,
and questions were addressed and resolved immediately.  In  situations where
more than one person was performing similar activities, consistency  was
ensured through communication at the meetings.
     In addition to the general quality assurance measures, specific quality
assurance activities were conducted for several of the  individual  test
methods performed.

     6.2  Sampling Train Components.  Entropy's sampling  equipment,  including
nozzles, pitot tubes, dry gas meters, orifices, and  thermocouples, was
uniquely identified and calibrated In accordance with .documented procedures
and acceptance criteria prior to and at the completion  of the field  testing
program.  All sampling equipment was manufactured by Nutech Corporation,
Andersen 2000 or by Entropy.  Calibration data for the  sampling equipment are
contained in Appendix 7.6.

     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.

-------
                                     6-2
     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.

     6.5  Substrate Weighing.  An analytical balance capable of weighing to
the nearest 0.01 milligram (mg) was used.  To ensure that  no weight  bias was
produced from the preparation, transportation, recovery,  or weighing
procedures, two control samples were obtained during the  test program.   A
reactivity run was performed to ensure that the flue gases did not interact
with the substrate to produce extraneous results.  For the reactivity  run, a
solid filter was placed In the front section of the  impactor, and  the
Impactor was introduced into the 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  was 0.000053
milligrams, based upon weight differences ranging from 0.00001 to 0.00017
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 0.000021 milligrams, based upon a difference ranging  from 0.00001  to
0.00006 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 7.2.4.

-------