United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EMB Report 85-CHM-2
April 1985
Air
Chromium Screening
Study Test Report
Electric Arc &A.O.D.
Furnace
Carpenter
Technology, Inc.
Reading,
Pennsylvania
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EMISSION TEST REPORT
CARPENTER TECHNOLOGY
READING, PENNSYLVANIA
ESED 85/02
EMB No. 85-CHM-2
Prepared by
Entropy Environmentalists, Inc.
Post Office Box 12291
Research Triangle Park, North Carolina 27709
Contract No. 68-02-3852
Work Assignments No. 18 and 21
PN: 3018 and 3021
EPA Task Manager
Dennis Holzschuh
U. S. ENVIRONMENTAL PROTECTION AGENCY
EMISSION MEASUREMENT BRANCH
EMISSION STANDARDS AND ENGINEERING DIVISION
RESEARCH TRIANGLE PARK, NORTH CAROLINA 27711
September 1985
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CONTENTS
Figures iv
Tables . v
1.0 INTRODUCTION 1-1
2.0 PROCESS OPERATION 2-1
2.1 Process Description 2-1
2.2 Air Pollution Control System 2-6
2.3 Process Conditions During Testing 2-10
3.0 SUMMARY OF RESULTS 3-1
3.1 Particulate Matter, Hexavalent Chromium and Total Chromium 3-3
3.1.1 Electric Arc Furnace Exhaust 3-3
3.1.2 Argon-Oxygen Decarburization Vessel 3-7
3.1.3 Fabric Filter Discharge Stacks 3-9
3.2 Particle Size Distribution 3-11
3.3 Emissions in Units of Process Rate and Control Equipment
Collection Efficiency 3-12
3.3.1 Emissions in Units of Process Rate 3-14
3.3.2 Control Equipment Collection Efficiency 3-1.4
3.4 Summary of Analytical Results for Hexavalent and Total Chromium 3-16
4.0 SAMPLING LOCATIONS AND TEST METHODS 4-1
4. 1 Electric Arc Furnace Exhaust Duct (Sampling Location A) 4-1
4.2 Argon-Oxygen Decarburization Vessel Exhaust Duct (Sampling
Location B) 4-5
4.3 Fabric Filter (Baghouse) Discharge Stacks (Sampling
Locations C and D) 4-9
4.4 Fabric Filter Dust Hopper Screw Conveyors (Sampling
Location E) 4-9
4.5 Scavenger Duct (Sampling Location F) 4-11
4.6 Velocity and Gas Temperature 4-11
4.7 Molecular Weight 4-11
4.8 Particulate Matter 4-13
4.9 Particle Size Distribution 4-13
4.10 Hexavalent Chromium Content 4-14
4.11 Total Chromium Content 4-14
5.0 QUALITY ASSURANCE 5-1
ii
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CONTENTS (Continued)
APPENDICES
TEST RESULTS AND EXAMPLE CALCULATIONS A-1
Particulate, Hexavalent Chromium and Total Chromium A-3
Example Particulate Test Calculations . A-9
Particle Sizing Field Data and Results Tabulation and Graphs A-46
Summary of Hexavalent Chromium Particle Sizing A-63
Summary of Total Chromium Particle Sizing A-63
Total Chromium Analysis Calculation A-66
Explanation of Total Chromium Analysis Calculation Table A-67
Process Rate Calculation Table A-68
FIELD AND ANALYTICAL DATA B-1
Particulate Matter B-3
Particle Size Distribution B-49
Total Particulate Analysis B-74
Particle Size Distribution Analysis B-86
Hexavalent Chromium Analysis B-95
Total Chromium Analysis B-103
SAMPLING AND ANALYTICAL PROCEDURES C-1
Determination of Total Particulate Emissions C-3
Determination of Hexavalent Chromium Emissions C-8
Determination of Total Chromium Content C-15
Characterization of Gas Flow Angles at Sampling Points
Using a Three-Dimensional Directonal Probe C-22
Determination of Particle Size Distribution C-28
Grab Samples C-35
CALIBRATION AND QUALITY ASSURANCE DATA D-1
MRI PROCESS DATA E-1
Process Operating and Test History E-3
Baghouse Operating Parameters E-11
Process and Emission Capture Efficiency Observations During
EAF Testing E-12
Process and Emission Capture Efficiency Observations During
ADD Vessel Testing E-24
TEST PARTICIPANTS AND OBSERVERS F-1
iii
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FIGURES
Number . Page
2.1 CarTech - Reading Plant Layout. . 2-2
2.2 Flow Diagram for the Manufacture of Speciality Steel at Cartech. 2-4
4.1 Process Air Flow Schematic of Electric Arc Furnace, Argon-Oxygen
Decarburization Vessel/ and Fabric Filter. 4-2
4.2 Electric Arc Furnace Exhaust Duct (Sampling Location A). 4-4
4.3 Argon-Oxygen Decarburization Vessel Exhaust Duct
(Sampling Location B). 4-7
4.4 Argon-Oxygen Decarburization Vessel Exhaust Duct, Top View
Showing Scavenger Duct. 4-8
4.5 Baghouse Stacks (Sampling Locations C and D). 4-10
4.6 Scavenger Duct (Sampling Location F) . 4-12
IV
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TABLES
Number Page
2.1 UHP EAF and No. 2 ADD Vessel Specifications 2-3
2.2 Total Furnace Enclosure Specifications 2-7
2.3 Baghouse Design Specifications 2-9
2.4 Typical Operating Values 2-11
2.5 EAF Final Operating Parameters 2-13
2.6 AOD Vessel Final Operating Parameters 2-14
3.1 Testing Schedule for Carpenter Technology 3-2
3.2 Summary of Flue Gas Conditions 3-5
3.3 Summary of Particulate, Hexavalent Chromium, and Total
Chromium Emissions 3-6
3.4 Summary of Particle Size Distribution 3-13
3.5 Summary of Emission Rates in Units of Process Rate and Efficiency 3-15
3.6 Summary of Analytical Results for Hexavalent and Total Chromium 3-17
3.7 Summary of Analytical Results for Hexavalent and Total Chromium
Quality Assurance Samples 3-20
4.1 Sampling Plan for Carpenter Technology 4-3
5.1 Field Equipment Calibration 5-2
5.2 Particle Size Blank Filter and Reactivity Filter Analysis 5-5
5.3 Audit Report Chromium Analysis 5-6
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1.0 INTRODUCTION
During the week of March 4, 1985, Entropy Environmentalists, Inc.
conducted an emission measurement program at Carpenter Technology's (CarTech)
Specialty Steel Plant located in Reading, Pennsylvania. The purpose of this
program was to determine the quantity and form of chromium emissions associated
with the production of stainless steels.
Comprehensive testing was conducted on an electric arc furnace (EAF) and
an oxygen-argon decarburization (AOD) vessel and a fabric filter which controls
both of these.
This plant was selected for source testing for the following reasons:
o The emission capture systems at the plant are considered to be the
most effective technology to capture emissions from EAF's and AOD
vessels. A total furnace enclosure captures emissions from the
EAF. A diverter stack directs AOD vessel emissions to a canopy
hood for capture. Any emissions escaping the canopy hood are
captured by two scavenger ducts above the canopy hood. Based on
observation of fugitive dust flows during a pretest plant visit,
nearly 100 percent capture occurs. This efficient capture permits
an accurate estimate of uncontrolled emissions as determined by
testing the inlet to the control device.
o The uncontrolled emissions should be representative of the
industry. The plant manufacturers steel products having chromium
contents typical of those used industry wide (17 to 19 percent
chromium).
o Inlet testing ports were already available for the EAF and AOD
vessel.
o The fabric filter is of positive-pressure design, which is typical
of the industry.
1-1
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o The New Source Performance Standards (NSPS) for EAF's and AOD vessels
are based on the use of fabric filters as "best demonstrated control
technology." Emissions from the fabric filter at CarTech are in
compliance with the NSPS (the plant achieved a 0.016 gr/dscf with no
visible emissions in a 1982 test).
Particulate concentrations and mass emission rates were measured at the
EAF and AOD vessel exhausts and at the fabric filter stacks using U. S.
Environmental Protection Agency (EPA) Reference Method 5.* Total chromium
concentrations and hexavalent chromium concentrations were measured at the same
locations by further analysis of the Method 5 samples using the alternate
sample preparation and analytical procedures as described in Appendix C. Flue
gas flow rates, temperature, moisture content, and composition [oxygen (O2),
carbon dioxide (C02), and carbon monoxide (CO)] were measured in conjunction with
the particulate tests. In addition, the particle size distribution of
particulate matter in the EAF and AOD vessel exhaust gases was determined along
with hexavalent and total chromium distribution by particle size.
Representative samples of the dust collected by the fabric filter were
collected during the particulate tests for determination of the hexavalent and
total chromium content of the material entering the fabric filter.
Messrs. Michael Maul and William Maxwell [Midwest Research Institute (MRI)]
monitored process operation throughout the test period. Mr. Dennis Holzschuh
(EPA Task Manager) of the Emission Measurement Branch (EMB) and Mr. Al Vervaert
of the Industrial Studies Branch (ISB) observed the test program. Mr. Larry
Geiser, Senior Air Quality Control Engineer, served as the contact for Carpenter
Technology.
* 40 CFR 60, Appendix A, Reference Method 5, July 1, 1981
1-2
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This report is organized into several sections addressing various aspects
of the testing program. Immediately following this introduction is the
"Process Operation" section which includes a description of the process and
control device tested. Following this is the "Summary of Results" section
which presents table summaries of the test data and discusses these results.
The next section, "Sampling Locations and Test Methods" describes and
illustrates the sampling locations for emissions testing and grab sampling and
then explains the sampling strategies used. The final section, "Quality
Assurance," notes the procedures used to ensure the integrity of the sampling
program. The Appendices present the complete Test Results and Example
Calculations (Appendix A); Field and Analytical Data (Appendix B); Sampling and
Analytical Procedures (Appendix C); Calibration Data (Appendix D); MRI Process
Data (Appendix E); and Test Participants and Observers (Appendix F).
1-3
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2.0 PROCESS OPERATION
2.1 Process Description
CarTech 1s a stainless and specialty steel producer. The Reading
plant produces over 400 grades of steel that are grouped 1n several general
categories Including stainless steel, tool steel, electronic alloys, alloy
steel, high temperature steel, and valve steel. The major steel products
at the Reading plant Include billets, bars, and wire. CarTech 1s unique
compared to other stainless steel producers because of the size and shape
of Its products. The formulation of Its stainless steel, though, 1s
typical of other producers. This CarTech plant has six EAF's and two AOD
vessels. (At present, two of the six EAF's are not operating.) Figure 2-1
Illustrates the plant layout, Including EAF and AOO vessel locations, and
the emissions capture system. The ultra-high powered (UHP) EAF (EAF "F")
and the No. 2 AOD vessel were both tested during this test program.
The UHP EAF was Installed 1n 1982 and has a rated capacity of 32 tons
per cycle. Refractory has been added to the bottom of the UHP EAF, allow-
ing, at present, a maximum production of 26 tons of steel production per
heat cycle. Typical production 1n the UHP EAF 1s between 20 and 22 tons
per heat cycle. The furnace 1s equipped with a total furnace enclosure
(TFE) to contain and capture emissions. The No. 2 AOD vessel has a rated
capacity of 30 tons per heat cycle. However, the size of the outer shell
limits Its production to a maximum of 25 tons per heat cycle. Typical
production 1n the No. 2 AOO vessel 1s between 20 and 22 tons per heat
cycle. Design specifications for the UHP EAF and No. 2 AOD vessel are
listed 1n Table 2-1.
Figure 2-2 presents a simplified process flow diagram. Normal
operation of the UHP EAF at the Reading plant consists of charging, Initial
melting, and backcharglng with cold scrap, alloys, and fluxes; further
melting of the charge and backcharge; and tapping the molten metal Into a
ladle. Normal No. 2 AOD vessel operations Include charging the vessel with
molten metal produced by the UHP EAF and with fluxes and alloys; refining
the molten charge; and tapping the refined metal Into a ladle. The refined
metal 1s then transferred to a continuous caster where metal billets are
produced.
2-1
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0}
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TABLE 2-1. UHP EAF AND NO. 2 AOD VESSEL SPECIFICATIONS
UHP Electric Arc Furnace
Furnace manufacturer
Roof ring diameter, ft
Transformer rating, kva
Type refractory
Meltdown time for Initial charge, m1n
Meltdown rate, tons/h
Backcharge
Heat cycles, number/wk
Type of steel produced
Material charged per heat,
tons
Metal tapped, tons
Type slag
Tapping temperature, °F
Furnace cooling mechanism
Tapping method
Doors
Lectromelt NT
13.2
15,000/16,800
Basic
45
30
One
60
Stanlnless steel/specialty
22 1n two charges
20
Basic
2900
Water cooled panels that begin
4.5 ft below the furnace top.
Tapping pit for accommodation of
ladle
Slag door; fluxes and oxygen
lancing door.
No. 2 argon-oxygen decarfaurlzatlon vessel
Average charge size, tons
Metal tapped, tons
Vessel dimensions:
Diameter, ft
Height, ft
Tapping temperature, °F
Refining time (average), h
22
20
9.2
14.5
(2700-3020)
1.6
2-3
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STORAGE BINS
ro
i
TO STIRRING
AREA AND
CONTINUOUS
CASTER
CHARGE PAH/BUCKET
TRANSFER
BUCKET
SLAGGING
Figure 2-2. "Flow Diagram For The Manufacture Of Specialty Steel At CarTech.
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The charge material to the UHP EAF 1s typically 80 percent clean scrap
(often composed of "18-8 scrap" that contains 18 percent chromium and
8 percent nickel) and 20 percent additives (such as Hme, charge chrome
[ferrochrome], ferronlckel, and Iron ore). The composition of the
additives varies and 1s dependent on final product specifications." Steel
to which chrome has been added has an average chrome content of 17 to 19
percent, which 1s typical 1n the Industry. Most additives are discharged
directly Into charge buckets from enclosed storage bins. Scrap and
additives are charged and backcharged to the UHP EAF 1n a prewelghed charge
bucket carried by an overhead crane. Pneumatic cylinders open the
b1-parting front-end doors and the roof doors of the total furnace
enclosure (TFE) to permit entry of the charge bucket and crane cable.
After charging 1s completed, the TFE doors are closed. The charge 1s
melted for approximately 45 minutes by three l6-1nch diameter electrodes,
which have a maximum electrical rating of 16,800 kva and are powered by a
transformer operating from a primary, 3 phase, 60 hertz (Hz) voltage supply
of 13,800 volts. After the Initial 45-minute melting period, the TFE doors
are opened to allow one back charge, which brings the UHP EAF up to full
melting capacity, and are then closed again to allow the melt to
continue. Complete melting can take from 1 to 1.5 hours. Oxygen lancing
1s used during the melting phase, when needed, to speed up melting or bring
molten metal back up to temperature for tapping. At the end of the melt, a
sample of molten metal is taken for analysis.
After completion of the melting phase, the TFE doors are opened again,
the UHP EAF 1s tipped at a 42° angle, and the molten metal is discharged or
tapped into a ladle located in a pit next to and below the EAF. After
tapping, the ladle is removed from the pit by the overhead crane and is
transported to a slagging station where slag floating on the surface of the
molten steel is skimmed. Following slag skimming, the crane takes the
molten metal in the ladle to the No. 2 AOD vessel for refining. The molten
metal 1s then poured directly into the AOO vessel. Decarburization begins
almost Immediately after charging. An oxygen and argon gas mixture (used
1n a ratio of 3:1) 1s blown through the molten bath. The oxygen decreases
carbon 1n the molten metal by converting it to carbon monoxide (CO) gas.
The argon both reduces the partial pressure of and dilutes the CO gas,
2-5
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thereby allowing chromium to oxidize more slowly than the carbon to
Increase the amount of chromium retained. Sometimes nitrogen is used 1n
the blowing gas as a replacement for argon. After blowing has occurred for
15 to 30 minutes, the vessel is tilted at a 90° angle for a temperature
check. If the temperature 1s close to 3182°F, and 1f additional additives
are required, additions of alloys and fluxing agents are made to meet final
product specifications. During the next hour, the vessel 1s alternated
between two positions: an upright position for blowing or stirring the
molten bath with an argon and oxygen mixture (one part argon to three parts
oxygen) and a tilted position, 90° from upright, for temperature
measurement, sample acquisition, and alloy and flux addition. Near the end
of the heat, slag 1s poured off into a slag pot to remove the lime and
Impurities. At the end of the heat, after a final sample of the molten
metal is analyzed, final additions are made and melted Into the bath by
stirring with argon or nitrogen.
Between each EAF heat, unformed refractory material is sprayed onto
the EAF refractory lining to seal any weak spots in the lining. The AOD
vessel does not require refractory coating between heats and is used nearly
continuously.
After being refined 1n the No. 2 AOD vessel, the molten metal 1s
transferred to a teeming ladle which discharges from the bottom. The ladle
1s transported to the stirring station where the temperature is lowered by
the addition of argon gas. The molten metal is discharged from the ladle
into a tundlsh; a refractory-lined trough with holes in the bottom.
Refractory plugs regulate the flow of the molten metal from the tundlsh to
the water-cooled continuous caster that forms the metal into a continuous
billet. As the metal cools in the caster, the billet 1s pulled through the
caster by a chain. The billet continues to cool as it passes through the
caster. At the end of the caster, torches are used to cut the billet into
the desired size.
2.2 AIR POLLUTION CONTROL SYSTEM
Table 2-2 presents specifications for the TFE. The TFE has a
10,000 acfm a1r-curta1n fan that continuously blows air across the roof
opening during the entire heat cycle. Emissions are contained and directed
2-6
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TABLE 2-2. TOTAL FURNACE ENCLOSURE SPECIFICATIONS
UHP EAF Total Furnace Enclosure—Building 113
Airflow:
Main exhaust volume, acfm
A1r curtain supply, acfm
A1r curtain exit velocity, ft/s
Structure:
Dimensions, ft
Material, gauge
Doors:
Dimensions, (ft)
Dampers:
Controls for the pneumatic cylinders:
Other features:
150,000
10,000
125
42 x 51 x 35
H1-r1b alumlnlzed sheeting, 18
2 horizontal roof doors—
16 x 7
2 vertical front doors—
10.5 x 35.3
Exhaust—two position
Melt/charge or tap
A1r curtain—two -position
Melt/charge or tap
Tapping station—buttons
1. Damper mode—melt/charge
or tap
2. Vertical doors—open or
closed
3. Tap side roof door—open
or closed
4. Melt/charge roof door—
open or closed
Main control room—buttons
1. All doors open or all
doors closed
Removable roof panels
Emergency compressed air
supply (tank)
2-7
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by the airflow to one of two exhaust hoods located Immediately beneath the
TFE roof. The exhaust hood capture system has a ventilation rate of
150,000 acfm and 1s able to collect the emissions effectively even when the
doors of the TFE are open. Using dampers, the air curtain can be
positioned to direct emissions from either melting/charging or tapping to
the exhaust hood located above the furnace and tapping areas. Dampers also
determine which exhaust hood 1s operating. At present, the tapping air
curtain position and Its respective exhaust hood are not used since the
melting/charging position does an adequate job 1n collecting tapping
emissions. The captured emissions are ducted to a positive-pressure
baghouse.
The process emissions generated during the refining process 1n the
No. 2 AOO vessel are captured by a canopy hood built Into the building roof
trusses about 43 ft above the mouth of the vessel. The fumes are directed
to the canopy hood by a dlverter stack located 5 ft above the mouth of the
AOD vessel. The dlverter stack 1s movable and swings out of the way when
the vessel 1s charged or tapped. The shop roof above the No. 2 AOO 1s
closed, and any emissions not captured by the canopy hood remain Inside the
building. These uncaptured emissions are drawn Into two scavenger ducts
located 1n the peak of the roof between the canopy hood and the continuous
caster area. The scavenger ducts are not equipped with hoods and consist
only of an open piece of ductwork. Total ventilation applied to the No. 2
AOO vessel capture system 1s 300,000 acfm. The canopy hood and scavenger
ducts join to form a main circular duct that connects with the UHP EAF
ductwork upstream of the positive-pressure baghouse.
Table 2-3 presents specifications of the positive-pressure baghouse
that 1s used to control emissions from the UHP EAF and No. 2 AOO vessel.
Although the baghouse has a design capacity of 676,000 acfm, it currently
treats only 450,000 acfm (150,000 acfm from the UHP EAF and 300,000 acfm
from the No. 2 AOD vessel). The actual air-to-cloth ratio 1s 2.08 to 1.
About two-thirds of the clean exhaust gas is discharged through 10 stub
stacks, while the other third leaks out of the baghouse after passing
through the fabric bags. Baghouse inspection and maintenance are performed
once per day.
2-8
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TABLE 2-3. BAGHOUSE DESIGN SPECIFICATIONS
Baghouse
Type
No. of compartments
Total number of bags
Bag size, ft
Bag material
Bag arrangement
Gross a1r-to-cloth ratio
Net a1r-to-cloth ratio
(19 compartments)*
Inlet gas temperature °F
Total air capacity, acfm
Reverse air fan, hp
Reverse air fan capacity, acfm
Standard pressure at 70°F, 1n. Hg
Compartment pressure, (1n w. c.)
Siding, gauge
Exhaust fans
Number of fans
Type
Wheel
Individual capacity, acfm
Drive
Motor hp
Voltage
Revolutions per minute
Brake horsepower at 70 °F
Standard pressure at 70°F, In. Hg
Custom, pressurized, ventilated
20
2,400
1 x 31.5
Dacron—seamless
6 rows x 20
3.18:1
3.02:1
150
676,000
125
23,000
15
4-6
CORTEN, 20
Double Inlet, centrifugal with
back stops
Radial tip, blade liners
225,333
Direct coupled
700
2,300
705
672
12.8
aOne compartment at a time is isolated in order to be cleaned.
2-9
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The pressure drop across each compartment of the baghouse ranges from
4 to 6 Inches water column. Each Dacron bag contains seven anti-collapsing
rings that are attached to the Inside of the bag and are spaced at even
Intervals along the length of the bag. The dust collected on the Inside of
the bags 1s' dislodged by reverse air cleaning. One compartment at a time
1s removed from service and subjected to a reverse air stream. The dust
from the compartment being cleaned falls Into a hopper below the
compartment and 1s conveyed pneumatically to a storage bin.
2.3 PROCESS CONDITIONS DURING TESTING
The EAF, AGO vessel, their associated capture equipment, and the
baghouse were all monitored to ensure normal operation throughout the
test. The process parameters monitored were production rates, percent
chromium 1n the product, time and order for all process steps, secondary
voltage to the EAF electrodes, and type and quantity of gases used 1n the
AGO vessel. Observations of the emission capture equipment were made about
every 15 minutes and estimates of capture efficiency recorded. Baghouse
operating parameters monitored Included inlet flue gas temperature, main
duct pressure drop, compartment being cleaned, and Individual compartment
pressure drops. Typical operating values for the EAF, AGO vessel, and
baghouse are listed in Table 2-4.
Process parameters and observations recorded during the test program
are presented 1n Appendix E. Also presented for each sample run 1s a time
chart which summarizes the process events (e.g., charges, blowing periods,
taps, etc.) which occurred during each test run. All processes operated
within normal limits throughout the test. Inlet and outlet testing were
not performed simultaneously. The outlet test runs spanned an average of
2.5 heats per test run while the inlet test runs covered one full heat per
test run for both the EAF and AGO vessel.
During the first heat of the first test run on Wednesday, March 6, the
EAF encountered a series of minor delays because of the occurrence of power
shortages which required that the power supply to the EAF be temporarily
turned off. Plant personnel consider this to be within the limits of
normal operation during certain times of the month. The interruptions
caused a 15 to 20 minute increase 1n the actual melting time typically
2-10
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TABLE 2-4. TYPICAL OPERATING VALUES
Electric Arc Furnace
Duration, m1n:
• Charging 5 to 10
Tapping . 3 to 5
02 lancing 3 to 5
Melting 60 to 90
Secondary voltage, volts 200 to 300
Process weight 20 to 22 tons
Percent chromium 17 to 19
kWh/heat 9,000
02/heat, scf 2,642
AOD Vessel
Duration, m1n:
Charging • 1
Blowing 75 to 90
Slagging 5 to 10
Tapping 1 to 3
Rate of gas use, scfh:
Initial blow (15 to 30 33,000 02, 11,000 Ar and/or N2
m1n. duration)
Further refining (60 m1n. duration) 11,000 02, 33,000 Ar and/or N2
Stirring 28,000 Ar
Total gas usage, scf 55,000 to 66,000
Baghouse
Inlet flue gas temp., °F 120 to 130
Average compartment AP, in. w.c. 4 to 6
Main duct AP, in. w.c. 10 to 11
2-11
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leeded to produce the steel. Because of minor emissions that were still
omlng from the furnace when melting was suspended, and the lengthened melt
1me, emissions per ton of steel produced should be higher than 1f the
ower Interruptions had not occurred. The test results appear to support
his.
On Thursday, March 7, the first EAF heat of the second test run had a
hortened melting time because no backcharge was needed. When the charge
aterlal 1s not composed of as much bulky scrap, all raw materials can be
harged 1n one step. The decreased melting time needed should slightly
ecrease emissions per ton of steel produced. The reduced melting time,
hough, was offset by Increased oxygen lancing time used (-5 minutes) to
alse the melt temperature. Emissions from oxygen lancing appeared heavier
han melting. The data suggest that the added oxygen lancing emissions
ept emissions per ton of steel produced at a typical level.
Because of communication problems, the samples taken during the
ackcharge and tap of the first test EAF heat were gathered at times when
eltlng, rather than charging or tapping, was occurring. However, because
he mistaken sampling period accounted for only a small portion of the
otal test run (-8 minutes out of the I06-m1nute sampling period and 2 out
f 17 charges, backcharges, and taps included in the test run) and the fact
hat emissions observed during the mistaken sampling periods were
elatlvely light, the correctness of the charge/tap test run is not
ansidered unduly compromised.
Based on the visual observations performed, the TFE generally captured
3 to 100 percent of the emissions from EAF charging and melting.
aproximately 97 percent capture efficiency was achieved during tapping.
nisslons from oxygen lancing were the heaviest for all EAF process
teps. Capture efficiency by the TFE during oxygen lancing was estimated
3 be 95 percent. The AOD vessel diverter stack and canopy hood generally
iptured nearly 100 percent of the emissions during blowing and stirring of
le AOD vessel. Approximately 90 percent of emissions were usually
iptured during charging, slagging, and tapping of the AOO vessel. Any
nisslons not captured by the hood were captured by the scavenger duct
Astern.
2-12
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TABLE 2-5. EAF FINAL OPERATING PARAMETERS
Heat No.
62002
62003
62024
62027
62028
62031
62032
62035
Process
weight,
1b
43,780
43,340
42,700
44,320
45,400
33,600
34,160
43,920
Percent
chromium
18
18
18.5
18
17
19
21
18
02
use,
ft
2,500
2,000
4,500
7,000
2,000
3,000
5,500
2,500
kWh/
heat,
10 z
107
• 93
78
86
96
68
79
90
Tap
temp.,
°F
2948
2966
2930
2912
2948
2948
2948
2948
2-13
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TABLE 2-6. AOD VESSEL FINAL OPERATING PARAMETERS
Heat No.
61999
62002
62023
62024
62027
62028
62031
62032
Process
weight,
Ib
63,350
64,930
58,445
57,895
62,560
58,300
43,640
50,005
Percent
chromium
18
18
19
18
18.5
17
19
20
02
use,
ft3
32,960
31,200
29,720
20,560
25,590
21,630
22,680
28,880
Ar
US|,
ft1
29,650
26,000
29,380
11,970
14,280
22,170
18,250
13,170
N2
use,
ftj
1,650
1,610
2,170
3,570
5,720
6,340
5,800
Tap
temp. ,
°F
2876
2867
2930
2867
2894
2885
2885
2912
2-14
-------
3.0 SUMMARY OF RESULTS
Particulate matter and particle size distribution tests were conducted at
the electric arc furnace (EAF) outlet and the argon-oxygen decarburization
(ADD) vessel outlet. A particulate matter test was also run at the EAF outlet
exclusively during charging, recharging, and tapping of the EAF. Particulate
matter tests were run at the outlet of the fabric filter which controlled the
emissions from both the EAF and ADD vessel. No particle size distribution
tests were run at the fabric filter outlet due to the extremely low concen-
tration of emissions discharged. Also as a result of the low concentration of
pollutants at the fabric filter discharge, two particulate trains were run
simultaneously in an effort to obtain a quantifiable amount of hexavalent
chromium. One train collected samples in discharge stacks No. 1 through 5 and
the other in stacks No. 6 through 10. Table 3.1 summarizes the testing
schedule.
In brief, the uncontrolled emissions from the EAF averaged 117 pounds per
hour of particulate, 0.01 pounds per hour of hexavalent chromium and 9.9 pounds
per hour of total chromium. The uncontrolled EAF emissions during charging,
recharging, and tapping averaged 50 pounds per hour of particulate, 0.002
pounds per hour of hexavalent chromium, and 3 pounds per hour of total
chromium. The uncontrolled emissions from the AOD vessel averaged 202 pounds
per hour of particulate, 0.76 pounds per hour of hexavalent chromium, and 21
pounds per hour of total chromium. The controlled emissions from the fabric
filter controlling both the EAF and AOD vessel averaged 5.6 pounds per hour of
par- ticulate matter, 0.0005 pounds per hour of hexavalent chromium, and 0.14
pounds per hour of total chromium.
3-1
-------
TABLE 3.1. TESTING SCHEDULE FOR CARPENTER TECHNOLOGY
Date
(1985)
3/6
3/7
Sample Type
Participate
Participate
Particle Size
Participate
P articulate
Particle size
Reactivity
Participate
Particle size
Electric Arc Furnace
Exhaust
Run
No.
Al
CTA
S1A
A2
CTA
S2A
A3
S3A
Test Time
24 h clock
1233-1513
1235-1755
1712-1727
0930-1055
0931-1724
1152-1212
1519-1632
1727-1742
Argon-Oxygen
Decarburization Vessel
Exhaust
Run
No.
Bl
SIB
B2
S2B
Rl
B3
S3B
Test Time
24 h clock
1218-1446
1533-1543
0905-1119
1150-1205
1215-1230
1513-1652
1659-1711
Fabric Filter
Discharge Stacks
Nos. 1-5
Run
No.
Cl
C2
C3
Test Time
24 h clock
1234-1806
0929-1353
1512-1932
Fabric Filter
Discharge Stacks
Nos. 6-10
Run
No.
01
D2
D3
Test Time
24 h clock
1237-1806
0933-1355
1516-1935
U)
I
10
-------
The particle size distribution tests showed that almost all of the
particulate matter emissions from both the EAF and ADD vessel were less than
10 ym in diameter. The overall collection efficiency of the fabric filter was
98.966 percent by weight for particulate emissions, 99.963 percent by weight
for hexavalent chromium emissions, and 99.726 percent by weight for total
chromium emissions.
In the-following sections, the results addressed above and additional
results are presented and discussed in detail according to the emission type
and sample location. The computer printouts of the emission calculations can
be found in Appendix A. The original field data sheets and the analytical data
are located in Appendix B.
3.1 PARTICULATE MATTER, HEXAVALENT CHROMIUM, AND TOTAL CHROMIUM
Particulate matter tests (EPA Method 5) along with the determination of
the associated flue gas flow rate were conducted at the EAF outlet, AOD vessel
outlet, and fabric filter discharge stacks. The particulate matter samples
were initally analyzed using gravimetric techniques to determine the mass of
particulate matter. Then the samples were further analyzed for hexavalent.and
total chromium. Complete descriptions of each sampling location and the
sampling and analytical procedures are given in Chapter 4.
3.1.1 Electric Arc Furnace Exhaust
The electric arc furnace (EAF) exhaust measurements represent the uncon-
trolled emissions from the EAF over one complete cycle. A separate particulate
test was conducted during the charging, recharging, and tapping portion of the
EAF cycles and represents the uncontrolled emissions for those portions of a
cycle.
3-3
-------
Flue Gas Conditions and Isokinetic Sampling Rate - A summary of the flue
gas conditions at the EAF exhaust is presented in Table 3.2. The volumetric
flow rate for the three runs conducted over the entire cycle and for the run
conducted only during the charging, recharging, and tapping portion of the
cycle were very consistent. The volumetric flow rate averaged 295,000 actual
cubic meters per hour (10,420,000 actual cubic feet per hour) with a flue gas
temperature of 26°C (78°F), and the moisture content and composition of
ambient air. The volumetric flow rate at standard conditions averaged 289,000
dry standard cubic meters per hour (10,210,000 dry standard cubic feet per
hour). Standard conditions are 20°C (68°F), 760 mm Hg (29.92 in. Hg) and
dry. The flue gas conditions for the charging, recharging, and tapping were
similar.
The isokinetic sampling rate was within the allowable range for all runs.
Particulate Emissions - The particulate mass rates from the EAF over three
sample runs (see Table 3.3) were variable. This variability is primarily due
to the variability in the duration of the heat sampled. The particulate
emissions averaged 184 milligrams per dry standard cubic meter (0.0805 grains
per dry standard .cubic foot), and 53.2 kilograms per hour (117 pounds per
hour).
The EAF emissions during charging, recharging and tapping averaged 75.3
milligrams per dry standard cubic meter (0.033 grains per dry standard cubic
foot) and 22.8 kilograms per hour (50 pounds per hour). In an effort to obtain
a quantifiable amount of hexavalent chromium, only a single test was run over
the entire test program for the charging, recharging, and tapping portions of
the cycle.
3-4
-------
TABLE 3.2. SUMMARY OF FLUE GAS CONDITIONS
Run
No.
Date
(1985)
Test Time
24 h clock
Volumetric Flow Rate
Actual3
acmh
x 105
acfh
x 106
Standard6
dscfflh
x 106
dscfh
x 106
Stack
Temperature
°C
°r
Moisture
%
°2
co2
%
CO
%
Isoklnetlc
%
Electric Arc Furnace Exhaust
Al
A2
A3
3/6
3/7
3/7
1233-1513
0930-1 055
1519-1632
Average
0.295
0.292
0.298
0.295
10.43
10.30
10.52
10.42
0.291
0.286
0.290
0.289
10.27
10.12
10.25
10.21
23
26
28
26
73
78
82
78
0.0
0.0
0.0
0.0
20.9
20.9
20.9
20.9
0.0
0.0
0.0
0.0
0.0
Q.O
0.0
0.0
95.5
96.6
97.0
97.0
U)
I
01
Electric Arc Furnace Exhaust, Charging and Tapping
CTA
3/6
1235-1724
0.311
10.98
0.303
10.71
24
76
0.4
20.9
0.0
0.0
99.7
Argon-Oxygen DecarburIzatlon Vessel Exhaust
B1
B2
B3
3/6
3/7
3/7
1218-1446
0905-1119
1513-1652
Average
0.670
0.675
0.697
0.681
23.67
23.83
24.61
24.04
0.645
0.662
0.679
0.662
22.79
23.37
23.96
23.37
29
26
28
28
85
78
82
82
0.1
0.1
0.1
0.1
20.9
20.9
20.9
20.9
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
97.5
95.2
97.5
97.5
Fabric FIIter Discharge Stacks
C1
01
C2
02
C3
03
3/6
3/7
3/7
1234-1806
1237-1806
0929-1353
0933-1355
1512-1932
1516-1935
Average
0.209
0.180
0.208
0.192
0.208
0.197
0.398
7.39
6.36
7.35
6.77
7.34
6.97
14.06
0.203
0.175
0.204
0.188
0.203
0.192
0.388
7.18
6.18
7.22
6.65
7.15
6.79
13.72
29
29
28
28
31
31
29
85
85
82
82
87
87
85
0.0
0.0
0.0
0.0
0.0
0.0
0.0
20.9
20.9
20.9
20.9
20.9
20.9
20.9
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
95.6
99.2
97.7
99.1
97.2
98.9
97.9
Volumetric flow rate In actual cubic meters per hour (acmh) and actual cubic feet per hour (acfh) at stack conditions.
Volumetric flow rate In dry standard cubic meters per hour (dscmh) and dry standard cubic feet per hour (dscfh). .
The average represents the combination of C and D.
-------
TABLE 3.3. SUMMARY OF PARTICIPATE, HEXAVALENT CmOMILM, AND TOTAL CHROMIUM EMISSIONS
Run
No.
Date
(1985)
Part leu late
concentration
mg/dscm
gr/dscf
mass emissions
kg/h
Ib/h
Hexavalent Chromium
concentration
mg/dscm
x I0~3
gr/dscf
x 10~3
mass emissions
kg/h
x 10~3
Ib/h
x 10"3
Total Chromium
concentration
mg/dscm
gr/dscf
x 10~3
mass emissions
kg/h
Ib/h
Electric Arc Furnace Exhaust
Al
A2
A3
3/6
3/7
3/7
Average
112.79
255.83
183.79
184
0. 0493
0.1118
0. 0803
0. 0805
32.80
73.29
53.37
53.2
72.31
161.58
117.66
117
31.96
6.44
8.47
15.6
0.0140
0.0028
0.0037
0.0068
9.29
1.84
2.46
4.5
20.49
4.07
5.42
10.0
9.28
18.94
18.25
15.5
4.06
8.28
7.98
6.8
2.70
5.43
5.30
4.5
5.95
11.96
11.69
9.9
Electric Arc Furnace Exhaust, Charging and Tapping
B1
B2
B3
3/6
3/7
3/7
Average
164.17
130.45
121.43
139
0.0717
0.0570
0.0531
0.0606
105.83
86.33.
82.40
91.6
233.54
190.32
181.66
202
406.7
616.6
536.5
520
0.178
0.269
0.234
0.23
262.4
408.0
364.1
345
578.6
899.6
802.6
760
14.00
13.61
14.87
14.2
6.12
5.95
6.50
6.2
9.03
9.00
10.09
9.4
19.91
19.85
22.25
20.7
Fabric Filter Discharge Stacks0
C1, D1
C2, 02
C3, 03
3/6
3/7
3/7
Average
3.45
3.12
1.50
2.69
0.0015
0.0014
0. 0007
0.0012
3.231
2.957
1.452
2.55
7.122
6.516
3.267
5.64
0.169
0.161
0.322
0.22
0.00007
0.00007
0.00014
0.00009
0.158
0.154
0.312
0.21
0.309
0.337
0.688
0.45
0.0605
0.0552
0.0823
0.066
0.0265
0.0241
0.0360
0.021
0.0567
0.0533
0. 0797
0.063
0.125
0.1 15
0.176
0.139
Numbers are composites of C and 0 runs and the mass emission rates were calculated based on the
sum of the dry standard volumetric flow rate from the AOO and EAF.
-------
Hexavalent Chromium Emissions - The hexavalent chromium emissions were
variable when compared to the corresponding particulate run and averaged 283,
25, and 46 micrograms of hexavalent chromium per gram of particulate matter
emissions. The reason for the high concentration of hexavalent chromium during
the first run is unknown. The charging, recharging,, and tapping run emissions
were 43 micrograms of hexavalent chromium per gram of particulate matter. The
hexavalent chromium emissions from the EAF averaged 0.016 milligrams per dry
standard cubic meter (6.8 x 10 grains per dry standard cubic foot) and
0.0045 kilograms per hour (0.01 pounds per hour). The mass emissions from the
charging, recharging and tapping run were about one fourth those at the EAF
exhaust.
Total Chromium Emissions - The total chromium emissions were fairly
consistent when compared to the corresponding particulate runs, and .averaged
82, 74, and 99 milligrams of total chromium per gram of particulate matter
emis- sions. The charging, recharging, and tapping run emissions were 60
milligrams of total chromium per gram of particulate matter emissions. The
total chromium emissions from the EAF exhaust averaged 15.5 milligrams per dry
standard cubic meter (0.0068 grains per dry standard cubic foot) and 4.5
kilograms per hour (9.9 pounds per hour). The charging, recharging, and
tapping emissions were slightly less than one third of the EAF exhaust
emissions. The total chromium content of the emissions measured at the EAF
exhaust was about one thousand times that of the hexavalent chromium content.
3.1.2 Argon-Oxygen Decarburization Vessel
The argon-oxygen decarburization (AOD) vessel measurements represent the
uncontrolled emissions from the AOD vessel over one complete cycle. A scavenger
duct entered the AOD vessel exhaust duct after the AOD vessel discharge and prior
to the sampling location. Although the canopy hood usually collects the
emissions coming off the AOD vessel, the scavenger duct system ensures nearly
100% capture of emissions, and on some occasions can be a significant source of
3-7
-------
emissions. The effects of the dilution air from the scavenger duct on the
measured emissions from the AOD vessel would result in lower pollutant
concentrations, but have no effect on mass emission rates.
Flue Gas Conditions and Isokinetic Sampling Rate - A summary of flue gas '
conditions at the AOD vessel exhaust is presented in Table 3.2. The volumetric
flow rate (which includes the flow rate from the scavenger duct) was very
consistent for a'll runs and averaged 681,000 actual cubic meters per hour
(24,040,000 actual cubic feet per hour) with a flue gas temperature of 28°c
(82°F) and the moisture content and composition of ambient air. The
volumetric flow rate at standard conditions averaged 662,000 dry standard cubic
meters per hour (23,370,000 dry standard cubic feet per hour). Standard
conditions are 20°C (68°F), 760 mm Hg (29.92 in. Hg) and dry.
The isokinetic sampling rate was well within the allowable range for all
sample runs.
Particulate Emissions - The particulate emissions from the AOD vessel were
fairly consistent (see Table 3.3) and averaged 139 milligrams per dry standard
cubic meter (0.061 grains per dry standard cubic foot) and 92 kilograms per hour
(202 pounds per hour).
Hexavalent Chromium Emissions - The hexavalent chromium concentrations were
much higher for the AOD vessel than the EAF and averaged 2480, 4730, and 4420
micrograms of hexavalent chromium per gram of particulate matter for runs 1B,
2B, and 3B, respectively. The hexavalent chromium emissions averaged 0.5 milli-
grams per dry standard cubic meter (0.00023 grains per dry standard cubic foot)
and 0.35 kilograms per hour (0.76 pounds per hour).
Total Chromium Emissions - The values for total chromium content of the
emissions for the AOD vessel exhaust were variable when compared to their
corresponding particulate run values, and were slightly higher when compared to
3-8
-------
the EAF exhaust emissions. The total chromium contents of the emissions
measured were 85, 104, and 123 milligrams of total chromium per gram of par-
ticulate emissions. The total chromium emissions averaged 14 milligrams per
dry standard cubic foot (0.0062 grains per dry standard cubic foot), and
9.4 kilograms per hour (20.7 pounds per hour).
3.1.3 Fabric Filter Discharge Stacks
• The fabric filter discharge emissions represent the combined controlled
emissions from the EAF and AOD vessel. Both the EAF and AOD vessel emissions
are ducted to a common plenum prior to entering the fabric filter. The
emissions are controlled by the pressurized fabric filter which has 10 stub
stacks and is open at the bottom. The original design was probably intended to
allow dilution air to be brought in from the bottom by natural draft. However,
the design of the 10 stub stacks was too small and a back pressure is created
by the stacks. As a result, during the test program only about 40 percent of
the total volumetric flow actually was discharged through the stacks; the
remainder exited through the bottom and other openings in the fabric filter.
The concentration of particulate discharged through the bottom and other
openings of the fabric filter housing was assumed to be the same as that
measured in the stacks and the mass emissions were calculated based on the
volumetric flow rate to the fabric filter. As previously stated, two sample
trains were operated simultaneously in an effort to collect a quantifiable
amount of hexavalent chromium for each sample run.
Flue Gas Conditions and Isokinetic Sampling Rate - A summary of the flue
gas conditions at the ten stub stacks of the fabric filter discharge is
presented in Table 3.2. Runs C1, C2, and C3 represent the flue gas conditions
from stacks No. 1 through 5 and runs D1, D2 and D3 represent the flue gas
conditions from stacks No. 6 through 10. The composites of runs C1 and D1, C2
and D2, and C3 and D3 represent the flow from all ten stacks for each run. The
3-9
-------
volumetric flow rate was very consistent, similar to the two ducts entering the
fabric filter housing, and averaged 398,000 actual cubic meters per hour
(14,060,000 actual cubic feet per hour) with a flue gas temperature of 29°C
(85 F) and the moisture content and composition of ambient air. The volum-
etric flow rate at standard conditions averaged 388,000 cubic meters per hour
(13,720,000 dry standard cubic feet per hour). Standard conditions are 20°C
(68°F), 760 mm Hg (29.92 in. Hg), and dry. The volumetric flow rate from the
stacks represent only 40 percent of the total flow to the fabric filter.
The isokinetic sampling rate was within the allowable range for all runs.
Particulate Emissions - The particulate emissions from the fabric filter
were very low and fairly consistent from run to run (see Table 3.3). Some of
the variability in measured results is likely due to the levels measured which
were just in the quantifiable range and subject to a greater degree of sampling
and analytical error.
The concentration values'represent the emissions measured in the stack
discharge. The mass emissions represent the measured concentration times the
total flow rate to the fabric filter. The pollutant concentration for the
emissions discharged out the bottom of the housing was assumed to be the same
as that measured in the stacks. The particulate emissions averaged 2.7'
milligrams per dry standard cubic meter (0.0012 grains per dry standard cubic
foot) and 2.6 kilograms per hour (5.6 pounds per hour).
Hexavalent Chromium Emissions - The hexavalent chromium concentration was
variable averaging 49, 52, and 215 micrograms of hexavalent chromium per gram
of particulate emissions. The hexavalent chromium emissions averaged
— 3 fi
0.22 x 10 milligrams per dry standard cubic meter (0.09 x 10 grains per
dry standard cubic foot) and 0.00021 kilograms per hour (0.00045 pounds per
3-10
-------
hour). These results were just in the quantifiable limit and are subject to a
greater degree of analytical error.
Total Chromium Emissions - The total chromium emissions at the fabric
filter exhaust and the total chromium content of the hopper dust both reflect
the fact that a large volume of previously collected material is present in the
fabric filter. The exhaust emissions show a greater impact because this
material is retained on the bags. The total chromium concentration at the
outlet increased with each run from 17 milligrams per gram for the first run,
through 18 milligrams per gram for the second run, to 55 milligrams per gram
for the last run. The outlet value for the first run reflects less than 20
percent of the inlet total chromium content while the value for the last run
was about one-half the inlet total chromium content. The total chromium
concentration of the hopper dust collected was 74, 75, and 82 milligrams for
the three runs, respectively. The total chromium emissions at the outlet
averaged 0.066 milligrams per dry standard cubic meter (0.021 x 10 grains
per dry standard cubic meter) and 0.063 kilograms per hour (0.14 pounds hour).
These emission values are likely to be biased low by a factor of about three,
because a fabric filter retains particulate on the bags and then releases it
over a period of time.
3.2 PARTICLE SIZE DISTRIBUTION
Particle size runs were conducted in the EAF and AOD vessel exhaust
ducts. The first of the three runs at each location was conducted at a point
of average velocity. The second and third runs at the same location were
conducted at a point with the same velocity as the first run. This sampling
procedure was followed to ensure that the particle cut-size for all three runs
would be the same on similar stages.
The total mass of particulate matter collected on each stage was
determined using a gravimetric technique. Stages were then combined in a
manner to obtain a quantifiable amount of hexavalent chromium and determine the
3-11
-------
particle size distribution of chromium. The particle size distribution results
are presented in Table 3.4 and the corresponding calculations and plots can be
found in Appendix B. The particle size distribution for both the EAF and ADD
vessel showed that about 95 percen-t of all the particles, by weight, were less
than 10 ym in diameter. No particle size distribution runs were made at the
fabric filter outlet due to the extremely low concentration of pollutant.
The particle size distribution for the hexavalent chromium emissions are
also presented in Table 3.4. The particle size distribution from the AOD
vessel showed that the majority of hexavalent chromium emissions were less than
1 ym in diameter. A large amount of hexavalent chromium was present in the AOD
samples and the results of these analyses are considered to be representative.
The particle size distribution samples for the EAF contained only a small
amount of hexavalent chromium and are therefore subject to a much higher degree
of analytical error. The particle size distributions for both the EAF and the
AOD vessel exhaust emissions were similar to the corresponding particulate
emission particle size distribution.
3.3 EMISSIONS IN UNITS OF PROCESS RATE AND CONTROL EQUIPMENT COLLECTION
EFFICIENCY
The emission testing was conducted at the EAF and the AOD vessel exhausts
to correspond to one heat. The testing was conducted from the initial charging
and ran until the final tapping. The process rate represented the total weight
charged divided by the length of the heat. The tables in Appendix E give the
process weight and duration of heats. The process rate calculation table at
the end of the Appendix A summarizes the calculations for the process rate on
an hourly basis.
The fabric filter discharge stack tests were conducted during approxi-
mately two and one-half heats for both the EAF and the AOD vessels. The pro-
cess rates presented in the process rate calculation table represent the total
weight charged for all heats tested during a particular run divided by the
3-12
-------
TABLE 3.4. SIMM/WY OF PARTICLE SIZE DISTRIBUTION
U)
I
Run
No.
Date
(1985)
Test Time
24 h clock
Particulate
wt. less than size, %
1 Pm
5 ym
lOym
Hex aval en t Chromium
wt. less than size, %
1 pm
5ym
lOy m
Total Chromium
wt. less than size, %
1 M m 1 5 Mm 1 10Wm
Electric Arc Furnace Exhaust
S1A
S2A
S3A
3/6
3/7
3/7
1712-1727
1152-1212
1727-1742
Average
29
37
28
31
86
87
82
85
96
95
94
95
45»
68*
74*
44*
76*
87*
Argon-Oxygen Decarbur Izatlon Vessel Exhaust
SIB
S2B
S3B
3/6
3/7
3/7
1533-1543
1150-1205
1659-171 1
Average
50
40
38
43
90
89
80
86
95
96
92
94
65*
91*
97*
55*
80*
87*
*Composlte.
-------
total time from the start of the first heat to the completion of tapping for
the last heat.
3.3.1 Emissions in Units of the Process Rate
The emissions in units of the process rate are shown in Table 3.5. The
values for emissions in units of process rate for particulate and total
chromium from the EAF were consistent. The first run value for the hexavalent
chromium emissions in units of process rate at the EAF exhaust'was much higher
than those for the other two runs. The reason for these higher results are not
known.
The AOD vessel emissions measurements in units of process rate were fairly
consistent for particulate, hexavalent, chromium, and total chromium.
The fabric filter discharge stack emissions in units of process rate were
variable. All of the test results seem reasonable, since only a small amount
of emissions could be collected during the emission tests.
3.3.2 Control Equipment Collection Efficiency
The EAF and AOD vessel exhaust emissions are ducted together in a common
plenum prior to their entrance into the fabric filter housing. It is not
possible to separate the collection efficiency for the different locations
based on the emission results and particle size distribution. The overall
collection efficiency is assumed to be the same for both processes. The
collection efficiency of the fabric filter for both the EAF and AOD vessel
averaged 98.966 percent by weight for particulate matter, 99.963 percent by
weight for hexavalent chromium, and 99.726 percent by weight for total chromium
(see Table 3.5).
The greater collection efficiency shown for hexavalent chromium and total
chromium was due in part to the fact that the fabric filter collects particu-
late and then releases material collected previously over a subsequent time
period. The actual collection efficiency for hexavalent and total chromium,
3-14
-------
TABLE 3.5. SLMMWY OF EMISSION RATES IN UNITS OF fROCESS RATE AND EFFICIENCY
Date
(1985)
Run
Nos.
Process
Rate
tons/h
Uncontrolled Emissions
partfcul ate
Ib/ton
hex av a lent
chrom 1 um
Ib/ton
x 10~3
total
chrom 1 um
Ib/ton
Controlled Emissions
partlcul ate
Ib/ton
x 10~3
hex aval ent
chrom 1 um
1 b/ton
x 10'6
total
chromium
Ib/ton
x 10~3
Collection Efficiency
partlcul ate
%
hex aval ent
chromium
%
total
chromium
%
EAF Exhaust
u>
I
3/6
3/7
3/7
1A
2A
3A
Average
8.31
14.90
14.61
12.6
8.70
10.84
8.05
9.2
2.47
0.27
0.37
1.04
0.72
0.80
0.80
0.77
ADD Exhaust
3/6
3/7
3/7
IB
28
36
Average
12.67
12.89
16.05
13.9
18.43
14.76
1 1.32
14.8
45.67
69.79
50.01
55.2
1.57
1.54
1.39
1.50
Fabric Filter Discharge Stacks
3/6
3/7
3/7
1C/1D
2C.2D
3C.3D
Average
18.78
26.09
23.61
22.8
380
250
140
260
16.5
12.9
29.1
19.5
6.7
4.4
7.5
6.2
98. 599
99.023
99.277
98.966
99.966
99. 982
99.942
99.963
99. 707
99.812
99.658
99. 726
-------
although not greatly different, would probably be similar to the collection
efficiency for the particulate emissions.
3.4 SUMMARY OF ANALYTICAL RESULTS FOR HEXAVALENT AND TOTAL CHROMIUM
The summary of analytical results of hexavalent chromium and total
chromium for all samples collected is presented in Table 3.6. The analytical
data sheets are contained in Appendix B. The results shown in Table 3.6 for
hexavalent chromium are the results obtained by the EPA tentative method for
hexavalent chromium. The values presented for total chromium content are based
on the results obtained by Neutron Activation Analysis (NAA). In some cases,
the results reported for total chromium are the sum of the hexavalent chromium
content in the sample filtrate (from an extraction for Cr ) and the chromium
in the extraction residue as measured by Neutron Activation Analysis. A table
showing the total chromium calculations for each sample can be found at the end
of Appendix A of this report.
The hexavalent chromium concentration was variable for most sampling
locations. The variability of results for the particle size distribution tests
and the fabric filter discharge emissions may reflect some analytical
imprecision due to the small amount of hexavalent chromium analyzed. Some of
the variability in the results for the fabric filter hopper material analyzed
may be due to the fact that the sample had to be taken from the' screw conveyors
instead of the hoppers themselves. Sampling at both the EAF and AOD vessel
sampling locations resulted in collection of sufficient material for accurate
analyses. Overall, the goals of obtaining quantifiable emissions were
obtained.
One set of impinger contents (or back half particulate catch) was analyzed
for each sampling location. The purpose of this analysis was to reconfirm the
3-16
-------
TABLE 3.6. SUMMARY OF ANALYTICAL RESULTS FCR HEXAVALENT AND TOTAL CKRCMIUM
Run
No.
Sample
Type
Sample
No.
Analyzed
Amount of
Samp 1 e
Analyzed
Haxavalent Chromium
Results
yg
Concentration
yg/g
Amount of
Samp 1 e
Analyzed
Total Chromium
Results
mg
Concentration
mg/g
Electric Arc Furnace Exhaust
1A
1A
2A
3A
CTA
S1A.S2A.S3A
S1A.S2A.S3A
S1A,S2A,S3A
Part leu late Front Half
Implnger Contents
Part leu late Front Half
Partlculate Front Half
Part icu late Front Half
Particle Size, Large
Particle Size, Medium
Particle Size, Small
C-193
C-204
C-194
C-195
C-196
C-190
C-191
C-192
324 mg
493 mg
321 mg
233 mg
32 mg
103 mg
87 mg
91.6
12.4
14.8
10.1
1.0
0.8
1.3
283
24.8
46.3
43.3
31.2
7.8
14.9
Residue
4 ml of 25
Residue
Residue
Residue
Residue
Residue
Residue
26.66
0.008
36.49
31.90
14.09
1.60
5.66
4.31
82
Negligible
74
99
60
50
55
50
Argon-Oxygen Decarburization Vessel Exhaust
IB
IB
2B
3B
S1B,S2B,S3B
S1B,S2B,S3B
S1B,S2B,S3B
Part icu late Front Half
Impinger Contents
Partlculate Front Half
Part icu late Front Half
Particle Size, Large
Particle Size, Medium
Particle Size, Smal 1
C-197
C-208
C-198
C-199
C-187
C-188
C-189
399 mg
364 mg
213 mg
18 mg
43 mg
55 mg
989
1720
942
25.3
118
194
2473
4914
4710
1406
2744
3527
Residue
4 ml of 25
Residue
Residue
Residue
Residue
Residue
34.04
0.002
37.96
26.11
1.14
3.59
4.13
85
Negl iglble
104
123
63
83
75
OJ
I
Fabric Filter Discharge Stacks
1C, ID
1C, ID
2C,2D
3C,3D
Partlculate Front Half
Implnger Contents
Partlculate Front Half
Partlculate Front Half
C-200
C-211
C-201
C-202
39 mg
31 mg
15 mg
1.9
1.6
3.2
47.5
53.3
213.3
Residue
4 ml of 81
Residue
Residue
0.68
0.001
0.55
0.82
17
Negl iglble
18
55
Fabric Filter Hopper Materials
IE
2E
3E
Hopper Material
Hopper Material
Hopper Material
C-214
C-215
C-216
1205
657
1210
162.7 mg
151.2 mg
154.8 mg
11.97
11.29
12.65
74
75
82
(continued)
-------
TABLE 3.6. SIMMARY OF ANALYTICAL RESULTS FOR HEXAVALENT AND TOTAL CHROMIUM (continued)
Run
No.
Sample
Type
Sample
No.
Analyzed
Amount of
Sampl e
Analyzed
Haxavalent Chromium
Results
P9
Concentration
V 9/9
Amount of
Samp 1 e
Analyzed
Total Chromium
Results
mg
Concentration
mg/g
BIank SampIes
Blank (Particle Size)
Filter Blank & Acetone
C-218
C-203
Total
Total
0.6
<0.2
N/A
N/A
Res (due
Residue
46
1.8
N/A
N/A
CD
-------
fact, established by the method development and evaluation study, that a
significant amount of hexavalent chromium and/or total chromium does not pass
through the front half. The analytical results for the impinger contents for
runs 1A, 1B, and 1C/1D show that the amount of hexavalent chromium passing
through the filter was negligible (see Table 3.6). Runs 2 and 3 show that the
amount of total chromium passing through the filter is also negligible.
Quality assurance audit samples were analyzed for both methods. As shown
in Table 3.7, no bias was present and the results are considered acceptable.
3-19
-------
TABLE 3.7. SUMMARY OF ANALYTICAL RESULTS FOR HEXAVALENT AND TOTAL CHROMIUM QUALITY ASSIRANCE SAMPLES
l
to
O
Run
No.
Sample
Type
Sample
No.
True
Value
Hexavalent Chromium
Results
pg/ml
%
Dev.
Total Chromium
Results
n-g
%
Dev.
Quality Assurance Samples
—
--
—
—
—
Qua! ity Assurance
Qual Ity Assurance
Quality Assurance
Qual Ity Assurance
Qual Ity Assurance
C-217
QA12
QAI3
OA14
QA15
100yg/ml Cr*6
66.3 yg Cr
132.6 pg Cr
331.6 pg Cr
1326 yg Cr
99.2
-0.8
75.2
152.4
307.5
a
+ 13.4
+ 14.9
- 7.3
a
Sample lost during NAA.
-------
4.0 SAMPLING LOCATIONS AND TEST METHODS
This section describes the sampling locations and test methods used to
characterize emissions from an electric arc furnace and an argon-oxygen
decarburization vessel at Carpenter Technology's Speciality Steel Plant in
Reading, Pennsylvania. A total of six sampling locations were used in the
emission testing program. At four sampling locations, emissions testing was
conducted for particulate matter, total chromium content, and hexavalent
chromium content. At two of these four locations additional testing included
determination of particle size distribution and chromium distribution with
respect to particle size. At another sampling location grab samples of the
dust collected by the fabric filter were taken for hexavalent and total
chromium analysis. At the last sampling location only a velocity traverse was
conducted to characterize the gas flow at that location. The relative
positions and the type of testing conducted at each location are shown in the
simplified process flow diagram (see Figure 4-1) and accompanying Table 4.1.
The subsections which follow further describe each sampling location and
applicable test methods.
4.1 ELECTRIC ARC FURNACE EXHAUST DUCT (SAMPLING LOCATION A)
Particulate matter, hexavalent chromium, total chromium, particle size
distribution, and chromium distribution with respect to particle size
distribution were measured in the duct which carries exhaust gases from the
electric arc furnace (EAF) to the fabric filter inlet. A schematic of this
sampling location is shown in Figure 4-2. Two sampling ports spaced 90°
4-1
-------
Stacks 1-5
Sampling Location C
Stacks 6-10
Sampling Location D
Sampling
Location A
Electric
Arc
Furnace
(EAF)
1111111111
Fabric Filter
Sampling
Location E
Dust
Collection
from continuous
caster |(fan off)
Sampling
Location B
Sampling
Location F
Argon-Oxygen
Decarburization
(AOD) Vessel
Figure 4.1. Process Air Flow Schematic of Electric Arc Furnace,
Argon-Oxygen Decarburization Vessel, and Control Equipment.
4-2
-------
TABLE 4.1. SAMPLING PLAN FOR CARPENTER TECHNOLOGY
Sample Type
Sampling
Locations
Number
of Samples
Methods
Particul ate matter
Hexavalent chromium
Total chromium
Particle size distribution
Hexavalent and total chromium
distribution by particle size
Hexavalent chromium, total
chromium
A, B, C, D
A, B, C, D
A, B, C, D
A, B
A, B
3
3
3
3
3
3 grab
EPA Method 5
EPA 5 using Tentative
EPA Method for Hexavalent
Chromium
EPA 5 using EPA Protocol
for Total Chromium
Impactor (Andersen, Flow
Sensor)
Impactor using Tentative
EPA Method for Hexavalent
Chromium and EPA Protocol
for Total Chromium
Gravimetric, Tentative
EPA Method for Hexavalent
Chromium, EPA Protocol
for Total Chromium
4-3
-------
75.75"
2 axes
I 1.75"
Section M-M
from Electric Arc Furnace
Sampling
Figure 4.2. Electric Arc Furnace Exhaust Duct (Sampling Location A)
4-4
-------
apart in the 77.5 inch diameter slanted round duct. These ports were located
96 feet (15.2 duct diameters) downstream of a bend in the duct and 19 feet (3.0
duct diameters) upstream of another bend in the duct.
For the Method 5 testing (used for particulate matter, hexavalent
chromium, and total chromium determinations), a total of 12 points (2 axes, 6
points per axis), as per Method 1, were sampled during each EAF heat. Since
the exact time for each heat was not known until the heat was complete, the
sampling time per point was established to ensure a complete run at a minimal
heat time. When the heat continued beyond the time it took to conduct a
complete run, the sampling train continued to traverse the duct until the heat
was completed. Total sampling times for the three runs conducted were 154, 80,
and 70 minutes.
For particle size testing (including hexavalent and total chromium
distribution by particle size), the first test run was conducted at a point of
average velocity. To ensure consistent cut-sizes on the impactor plates, the
second and third runs were' conducted at points having the same velocity as the
first run.
An additional sampling train 'was run throughout the entire test program at
the EAF exhaust sampling location, but only during periods of charging,
tapping, and recharging of the EAF. The sample was collected using single
point sampling, and the total sampling time over the two-day period was 102
minutes. The sample was taken to represent the charging, recharging, and
tapping emissions, and was analyzed for total particulate matter, hexavalent
chromium content, and total chromium content.
4-5
-------
4.2 ARGON-OXYGEN DECARBURIZATION VESSEL EXHAUST DUCT (SAMPLING LOCATION B)
Particulate matter, hexavalent chromium, total chromium, particle size
distribution, and hexavalent and total chromium distribution with respect to
particle size were measured in the duct which carries exhaust gases from the
argon-oxygen decarburization (AOD) vessel to the fabric filter inlet. Sche-
matics of this sampling location are shown in Figures 4-3 and 4-4. Seven ports
were installed on the side of the slightly inclined square duct (104" x 104").
These ports were located 122 inches (1.17 duct diamteters) downstream of the
intersection of a duct from the scavenger duct and 47 inches (0.45 duct
diameters) upstream of a bend in the duct to the fabric filter. Because of the
close proximity of 2 potential flow disturbances, this location did not meet
EPA Method 1 sampling requirements. To check for the degree of flow
disturbance at this location, the angle of flow misalignment was measured at
each sampling point using a three-dimensional directional probe (see
Appendix C). The average of the angles measured was less than 10 degrees.
For the EPA Method 5 sampling (used for particulate matter, hexavalent
chromium, and total chromium determinations), a total of 49 points (7x7
matrix), as per Method 1, were sampled. As for the EAF heats, the exact time
for the AOD cycles was not known before the cycle itself was completed. Thus,
the sampling time per point was established to ensure a complete run at the
predicted minimum heat time. When the cycle(s) continued beyond the time it
took to conduct a complete run, the sampling train continued to traverse the
duct until the cycle was completed. Total sampling times for the three runs
conducted were 131, 118, and 88 minutes.
For the particle size tests (including hexavalent and total chromium
distribution by particle size), the first test run was conducted at a point of
4-6
-------
To Baghouse
Section N-N
.Sampling Port
3-1/2"
7 axes
7 points/axis
49 total points
From Hood
.N
Scavenger Duct
Figure 4.3. Argon-Oxygen Decarburization Vessel Exhaust Duct
(Sampling Location B).
4-7
-------
47"
LT
104"
122"
Flow
104"
Scavenger Duct
TOP VIEW
Figure 4.4. Argon-Oxygen Decarburization Vessel Exhaust Duct,
Top View Showing Scavenger Duct.
4-8
-------
average velocity. To ensure consistent cut-sizes on the impactor plates, the
second and third runs were conducted at points having the same velocity as the
first run.
4.3 FABRIC FILTER (BAGHOUSE) DISCHARGE STACKS (SAMPLING LOCATIONS C AND D)
Ten identical stacks are used to exhaust the fabric filter. Particulate
matter, hexavalent chromium, and total chromium were measured at these
discharge stacks. Two EPA Method 5 trains were run simultaneously for each
run; the first train sampled in stacks No. 1 through 5, the second train
sampled in stacks No. 6 through 10. In each 66 inch diameter stack, two
sampling ports spaced 90° apart were located 132 inches (2.0 stack diameters)
downstream from the inlet to the stack and 26 inches (0.39 stack diameters)
upstream of the stack exit. A schematic of the sampling location is shown in
Figure 4-5.
For the EPA Method 5 sampling (used for particulate matter, hexavalent
chromium, and total chromium determinations), at least 6 points (1 axis of the
stack) were sampled in each stack (Method 5D). Each point was sampled for 8
minutes. Sampling at the discharge stacks started and ended with cycles at the
EAF. Total times for the three sets of runs conducted were 288, 240, 240, 285,
240, and 240 for runs C1, C2, C3, D1, D2, and D3, respectively.
No particle size testing was conducted at the discharge stacks due to the
extremely low concentration of emissions.
4.4 FABRIC FILTER DUST HOPPER SCREW CONVEYORS (SAMPLING LOCATION E)
Grab samples representative of the material collected by the fabric filter
were taken once during each test run from each of the two hopper screw
conveyors. The samples were taken towards the end of the test run series to
4-9
-------
2 axes
6 points/axes
12 total points
66" Diameter
3
nle
Fan
t
s
— 1
Sampling Sampling
Location C Location D
! II 1
oooooooooo
123456789 10
West
East
66"
Sampling Port
Roof Line
Figure 4.5. Fabric Filter Stacks (Sampling Locations C and D)
4-10
-------
allow time for dust representative of the run to be discharged from the hoppers
and to move through the screw conveyors. The samples from each of the two
screw conveyors were combined into a single sample for that test run series and
were analyzed for hexavalent chromium and total chromium content.
4.5 SCAVENGER DUCT (SAMPLING LOCATION F)
A scavenger duct is located in the peak of the roof between the AOD vessel
canopy hood and the continuous caster area. Any emissions escaping the canopy
hood are contained by the closed roof and drawn into either one of the two
openings in the scavenger duct. This scavenger duct is joined with the canopy
hood duct prior to the AOD vessel exhaust sampling location. To determine its
contibution to the total flow, a velocity traverse was conducted in the
scavenger duct prior to its entry into the main AOD vessel exhaust duct.
Three sampling ports were located along one side of the 58 inch square
horizontal duct. These ports were 72 inches (1.24 duct diameters) downstream
of a flow disturbance in the duct and 277 inches (4.78 duct diameters) upstream
of the intersection with the main AOD vessel exhaust duct. A schematic of the
sampling location is shown in Figure 4-6. For the traverse, a total of 12
points (3x4 matrix) were tested.
4.6 VELOCITY AND GAS TEMPERATURE
A type S pitot tube and an inclined draft gauge manometer or two
differential pressure gauges in-paralled were used to measure the gas velocity
pressure (Ap). Velocity pressures were measured at each sampling point across
the duct to determine an average value according to the procedures outlined in
Method 2 of the Federal Register.* The temperature at each sampling point was
measured using a thermocouple and digital readout. The sampling points at the
fabric filter outlet were selected according to Method 5D.
4-11
-------
EAF Duct
P J_
72'
58'
H A
n B
3 axes
4 points/axis
12 total points
Section P-P
277".
o A
Flow o B
SIDE VIEW
Figure 4.6. Scavenger Duct (Sampling Location F)
4-12
-------
4.7 MOLECULAR WEIGHT '
Flue gas composition was determined utilizing procedures described in
Method 3 of the Federal Register.* A bag sample was collected during each
particulate test run. The bag contents were analyzed using an Orsat Gas
Analyzer.
4.8 PARTICULATE MATTER
Method 5, as described in the Federal Register,* was used to measure
particulate grain loading at locations A, B, C, and D. All tests were
conducted isokinetically by traversing the cross-sectional area of the stack
and regulating the sample flow rate relative to the flue gas flow rate as
measured by the pitot tube attached to the sample probe. A sampling train
consisting of a heated, glass-lined probe, a heated 87 mm (3.4 inches) diameter
glass fiber filter (Gelman A/E), and a series of Greenburg-Smith impingers was
employed for each test. An acetone rinse of the nozzle, probe, and filter
holder portion's of the sample train was made at the end of each test. The
acetone rinse and the particulate caught on the filter media were dried at room
temperature, desiccated to a constant weight, and weighed on an analytical
balance. Total filterable particulate matter was determined by adding these
two values•
4.9 PARTICLE SIZE DISTRIBUTION
Particle size samples were obtained using Andersen Mark III Cascade
Impactors. These in-stack, multistage cascade impactors have a total of eight
stages, followed by a back-up filter stage. Their particle cut-off sizes
* 40 CFR 60, Appendix A, Reference Methods 2, 3, and 5, July 1, 1980.
4-13
-------
range nominally from 0.5 to 15 microns. Substrates were 64 mm diameter glass
fiber filters. A constant sampling rate was maintained through the test
period. Sampling rates were set for isokinetic sampling as long as the
sampling rate did not exceed the recommended flow rate for the impactor. See
Appendix C for detailed sampling procedures.
Three impactor runs each were conducted at the EAF and AOD vessel exhaust
ducts. None were conducted at the fabric filter discharge stacks due to the
extremely low concentration of emissions present. At the locations sampled, a
point of average velocity was sampled. With the exception of selection of the
sampling point locations, the procedures used followed those recommended in the
"Procedures Manual for Inhalable Particulate Sampler Operation" developed for
EPA by the Southern Research Institute.*
4.10 HEXAVALENT CHROMIUM CONTENT
Hexavalent chromium content was determined utilizing procedures described
in the tentative EPA Method "Determination of Hexavalent Chromium Emissions
from stationary Sources" (see Appendix C). The Method 5 filter catch collected
and weighed for each Method 5 run was taken and analyzed for hexavalent
chromium content using this method. If was also used to determine the
hexavalent chromium content of representative portions the fabric filter dust
samples collected.
4.11 TOTAL CHROMIUM CONTENT
Total chromium content was determined using procedures described in the
"EMB Prototcol for Sample Preparation and Emission Calculation of Field Samples
for Total Chromium" in combination with Neutron Activation Analysis (NAA) (see
*Prepared for EPA under Contract No. 68-02-3118, November 1979.
4-14
-------
Appendix C). Samples collected during Method 5 runs and first submitted to
analysis for hexavalent chromium were then analyzed for total chromium using
this method. The total chromium content of the fabric filter dust samples were
also determined using these procedures using a representative portion of the
sample.
4-15
-------
5.0 QUALITY ASSURANCE
Because the end product of testing is to produce representative emission
results, quality assurance is one of the main facets of stack sampling.
Quality assurance guidelines provide the detailed procedures and actions
necessary for defining and producing acceptable data. Two such documents were
used in this test program to ensure the collection of acceptable data and to
provide a definition of unacceptable data. These documents are: the EPA
Quality Assurance Handbook Volume III, EPA-600/4-77-027 and Entropy's "Quality
Assurance Program Plan" which has been approved by the U. S. EPA, EMB.
Relative to this test program, the following steps were taken to ensure
that the testing and analytical procedures produce quality data.
o Calibration of field sampling equipment. (Appendix D describes
calibration guidelines in more detail.)
o Checks of train configuration and on calculations.
o On-site quality assurance checks such as sampling train, pitot
tube, and Orsat line leak checks, and quality assurance checks of
all test equipment prior to use.
o Use of designated analytical equipment and sampling reagents.
Table 5.1 summarizes the on-site audit data sheets for the sampling
equipment used for particulate testing at each sampling location, including
deviation limits. In addition to the pre- and post-test calibration audits, a
field audit was performed on the meter boxes used for sampling. Entropy used
the procedures described in the December 14, 1983 Federal Register (48FR55670).
In addition, the analytical 'balance used for filter weighing was audited with
Class "S" weights. Appendix D includes the audit run data sheets for each dry
gas meter used for particulate testing and audit data sheets for the other
sampling equipment.
5-1
-------
TABLE 5.1. FIELD EQUIPMENT CALIBRATION
Equipment
Reference
Allowable
Error
Actual
Error
Wi thi n
Allowable
Limits
Electric Arc Furnace Exhaust Duct
Meter box (N-8)
Meter box thermometer
Impinger thermometer
Stack thermometer
Stack thermocouple
Trip balance
Analytical balance
Wet test meter
ASTM-3F at ambient
temperature
ASTM-3F at ambient
temperature
ASTM-3F at stack
temperature
ASTM-3F at stack
temperature
IOLM standard weight
Class "S" standard
weight
Y + 0.03Y
5°F
2°F
7°F
7°F
0.5 grams
0.1 mg
0.009
0°F
0°F
4°F
1°F
OK
0.07 mg
^
i/
^
V
V^
^
Argon-Oxygen Decarburization Vessel Exhaust Duct
Meter box (N-7)
Meter box thermometer
Impinger thermometer
Stack thermometer
Stack thermocouple
Trip balance
Analytical balance
Wet test meter
ASTM-3F at ambient
temperature
ASTM-3F at ambient
temperature
ASTM-3F at ambient
temperature
ASTM-3F at stack
temperature
IOLM standard weight
Class "S" standard
weight
Y + 0.03Y
5°F
2 Op
7°F
7°F
0.5 grams
0.1 mg
-0.005
3°F
1°F
3°F
1°F
OK
0.07 mg
^
1/
1/
^
^
^ ,
S
Electric Arc Furnace Exhaust Duct, Charging and Tapping
Meter box (N-12)
Meter box thermometer
Impinger thermometer
Stack thermometer
Stack thermocouple
Trip balance
Analytical balance
Wet test meter
ASTM-3F at ambient
temperature
ASTM-3F at ambient
temperature
ASTM-3F at ambient
temperature
ASTM-3F at stack
temperature
IOLM standard weight
Class "S" standard
weight
Y + 0.03Y
5°F
2 Op
7°F
7°F
0.5 grams
0.1 mg
0.019
3°F
1°F
4°F
2°F
OK
0.07 mg
^
-------
TABLE 5.1. FIELD EQUIPMENT CALIBRATION (continued)
Equipment
Reference
Allowable
Error
Actual
Error
Within
Allowable
Limits
Fabric Filter Discharge Stacks No s. 1-5
Meter box (N-6)
Meter box thermometer
Impinger thermometer
Stack thermometer
Stack thermocouple
Trip balance
Analytical balance
Wet test meter
ASTM-3F at ambient
temperature
ASTM-3F at ambient
temperature
ASTM-3F at stack
temperature
ASTM-3F at stack
temperature
IOLM standard weight
Class "S" standard
weight
Y + 0.03Y
5°F
2°F
7°F
7°F
0.5 grams
0.1 mg
0.001
2°F
0°F
i Or
i Oc
OK
0.07 mg
V^
/
V
/
V
I/
1/
Fabric Filter Discharge Stacks Nos. 6-10
Meter box (N-3)
Meter box thermometer
Impinger thermometer
Stack thermometer
Stack thermocouple
Trip balance
Analytical balance
Wet test meter
ASTM-3F at ambient
temperature
ASTM-3F at ambient
temperature
ASTM-3F at ambient
temperature
ASTM-3F at stack
temperature
IOLM standard weight
Class "S" standard
weight
Y + 0.03Y
5°F
2°F
7°F
7°F
0.5 grams
0.1 mg
0.001
2°F
1°F
1°F
1°F
OK
0.07 mg
\^
^v
S}jr
^
*~v
/
V
5-3
-------
As a check on the reliability of the method used to analyze the filters
for particle size tests, sets of filters that had been preweighed in the lab
were resubmitted for replicate analysis. Table 5.2 summarizes these results.
Audit solutions prepared by the EPA were used to check the analytical
procedures of the laboratories conducting the hexavalent and total chromium
analyses. Table 5.3 presents the results of these analytical audits. The
audit tests show that the analytical techniques were good.
The sampling equipment, reagents, and analytical procedures for this test
series were in compliance with all necessary guidelines set forth for accurate
test results as described in Volume III of the Quality Assurance Handbook.
5-4
-------
TABLE 5.2. PARTICLE SIZE BLANK FILTER AND REACTIVITY FILTER ANALYSIS
Sample type
Particle size
blank run filters
3260
A260
B261
A261
B262
A262
B263
A263
SF139
Particle size
reactivity run
fil ters
B276
A276
B277
A277
B278
A278
B279
A279
SF143
Original tare
weight, mg
161.12
146.48
161.50
147.12
163.12
147.05
161.59
146.81
268.17
163.30
146.35
165.03
148.19
164.30
147.24
164.00
146.56
269.11
Blank weight,
mg
•
161.10
146.51
161.49
147.12
163.19
147.00
161.63
146.80
268.10
163.29
146.36
165.13
148.20
164.25
147.24
164.01
146.59
269.11
Net weight,
mg
-0.02
+0.03
+0.01
0.00
+0.07
-0.05
+0.04
+0.01
+0.07
-0.01
+0.01
+0.10
+0.01
-0.05
0.00
+0.01
+0.03
0.00
5-5
-------
TABLE 5/3. AUDIT REPORT CHROMIUM ANALYSIS
Plant:
Task No.:
Date samples received:
Sample analyzed by:
Reviewed by:
Date analyzed:
Date of review:
Sample
Number
C-M
Qfr-lt.
&fr-/^
AA-rf
-T
ftfr-'S
ug/ml
Cr+6 or Cr
/oOjrt/fiJCs*
1 '
MA^Cs
IttA^Cr
33/.6^C^
7
l$Z(o «cCs
' 1
Source of
Sampl e
047)
M8S
/D6S
A/-S5
/Ug.5
Audit
Value
nt-
15,2-
/5*,4
30 7-. 5~
^
.
Relative
error, %
-V.&
+-I3.4
+ 14.1
- 7.3
51
5-6
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