United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EMB Report 85-CHM-6
April 1985
Air
Chromium Screening
Study Test Report

Coal Fired  Boiler
Adolph Coors
Golden,
Colorado

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             EMISSION TEST REPORT

        METHOD DEVELOPMENT AND TESTING
                 FOR CHROMIUM
            Coal-Fired Boiler No. 4
             Adolph Coors Company
               Golden, Colorado
             ESED Project No.  85/2
              (EMB No.  85-CHM-6)
                     by

            PEI  Associates, Inc.
             11499 Chester Road
               P.O.  Box 46100
        Cincinnati,  Ohio  45246-0100
           Contract No.  68-02-3849
       Work Assignment Nos.  14 and 20
                 PN 3615-14
                    3615-20
                Task Manager

            Mr.  Dennis Holzschuh
 Emission Standards and Engineering Division
    U.S.  ENVIRONMENTAL PROTECTION AGENCY
         EMISSION MEASUREMENT BRANCH
RESEARCH TRIANGLE PARK, NORTH CAROLINA  27711
                October 1985

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                                  CONTENTS
Figures                                                                 v
Tables                                                                 vi
Quality Assurance Element Finder                                     viii
Acknowledgment                                                         ix

1.   Introduction                                                     1-1

2.   Summary and Discussion of Test Results                           2-1

     2.1  Test protocol                                               2-1
     2.2  Particulate, hexavalent chromium, and arsenic
           test results                                               2-4
     2.3  Particle size distribution test results                     2-10
     2.4  Process samples analytical results                          2-20
     2.5  Visible emission observations                               2-21
     2.6  Total Chromium Test Results                                 2-22

3.   Project Quality Assurance                                        3-1

4.   Sampling Locations and Test Methods                              4-1

     4.1  Sampling locations                                          4-1
     4.2  Particulate and hexavalent chromium sample
            extraction and analysis                                   4-1
     4.3  Particle size distribution                                  4-7
     4.4  Process samples                                             4-10
     4.5  Arsenic                                                     4-11

5.   Process Description                                              5-1

     5.1  Boiler description/sampling program                         5-1
     5.2  Process conditions during testing                           5-2
     5.3  Conclusions                                                 5-16

Appendices

A    Computer Printouts and Example Calculations                      A-l
B    Field Data Sheets                                                B-l
C    Laboratory Data Sheets                                           C-l
D    Sampling and Analytical Procedures                               D-l
E    Equipment Calibration Procedures and Results                     E-l
                                     m

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                            CONTENTS (continued)
F    Quality Assurance Summary                                        F-l
G    Project Participants and Field Log                               G-l
H    Determination of Hexavalent Chromium Emissions From
       Stationary Sources                                             H-l
I    Determination of Total Chromium Emissions From Stationary
       Sources                                                        1-1
                                     iv

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                                   FIGURES
Number                                                                Page
 2-1      Particle Size Distribution Tests PSI-2 and -4 at the
           Baghouse Inlet                                             2-12
 2-2      Particle Size Distribution Tests PSO-1, -3, and -4 at
           the Baghouse Outlet                                        2-13
 2-3      No. 4 Boiler Baghouse Outlet Particle Size Distribution
           (Andersen Mark III Impactor - Runs AM 1 and 2)             2-18
 4-1      Boiler 4 Baghouse Inlet Test Location (No Scale)            4-2
 4-2      Boiler 4 Baghouse Outlet Test Location (No Scale)           4-3
 5-1      Coal Analytical Data                                        5-17

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                                   TABLES
Number                                                                Page
 2-1      Sampling and Analytical Parameters, No.  4 Boiler, Adolph
           Coors Company                                              2-2
 2-2      Summary of Sample and Flue Gas Data for Particulate/Cr
           and Arsenic Tests                                          2-5
 2-3      Summary of Particulate and Hexavalent Chromium Emissions
           Data                                                       2-6
 2-4      Arsenic Emissions Data                                      2-10
 2-5      Comparison of Particulate Concentrations as Measured by
           EPA Method 5 Versus Particle Size Distribution Impactors   2-14
 2-6      Summary of Hexavalent Chromium Size Distribution Data       2-19
 2-7      Process Sample Analytical Results                           2-21
 2-8      Summary of Total Chromium Emissions Data                    2-23
 3-1      Field Equipment Calibration                                 3-3
 3-2      Example Filter and Reagent Blank Analysis for Particulate   3-4
 3-3      Results of Preliminary Cr   Analysis on Blank Filter Media  3-6
 3-4      Linear Regression Data Spectrophotometer Calibration        3-6
 3-5      Blank Data for Cr   Analysis                                3-8
 3-6      Results of QC Samples                                       3-8
 3-7      QC Data for Total Cr by NAA                                 3-10
 5-1      Baghouse Design and Operating Characteristics               5-3
 5-2      Summary of Tests Conducted on Boiler 4, Adolph Coors
            Company, Golden, Colorado                                 5-4
                                      vi

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                             TABLES  (continued)

Number                                                               Page

 5-3      Process Data for Run l--Adolph  Coors  Company,  Boiler  4,
            March 18, 1985                                           5-5

 5-4      Process Data for Run 2--Adolph  Coors  Company,  Boiler  4,
            March 19, 1985                                           5-7

 5-5      Process Data for Run 3--Adolph  Coors  Company,  Boiler  4,
            March 20, 1985                                           5-10

 5-6      Process Data for Run 4--Adolph  Coors  Company,  Boiler  4,
            March 21, 1985                                           5-13
                                     VII

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                      QUALITY ASSURANCE ELEMENT FINDER
                                                                 Location
                                                             Section     Page
(1)  Title page
(2)  Table of contents
(3)  Project description
(4)  QA objective for measurement of data in terms
     of precision, accuracy,  completeness,  repre-
     sentativeness, and comparability
(5)  Sampling procedures

(6)  Sample custody
(7)  Calibration procedures and frequency

(8)  Analytical procedures

(9)  Data reduction, validation, and reporting

(10) Internal quality control  checks and frequency

(11) Performance and system audits and frequency
(12) Preventive maintenance procedures and schedules
(13) Specific routine procedures used to assess data
     precision, accuracy, and completeness of specific
     measurement parameters involved
(14) Corrective action
(15) Quality assurance reports to management

1
Appendix F
Section 3
Appendix D
Section 4
Appendix C
Appendix E
Section 3
Appendix D
Section 4
Appendix F
Section 3
Appendix F
Section 3
Appendix F
Section 3
Appendix F
Appendix F
Appendix F
Appendix F
m
1-1
F-2
D-l
C-l
E-l
D-l
F-3
F-5
F-3
F-12
F-4
F-ll
F-12
                                    vm

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                               ACKNOWLEDGMENT
     This test program was conducted for the Emission Standards and Engineer-
ing Division of the EPA Office of Air Quality Planning and Standards.

     Mr. Dennis Holzschuh, Emission Measurement Branch (EMB) Task Manager,
provided overall project coordination and guidance and observed the test
program.  Mr. Dwight Atkinson, representing Midwest Research Institute (MRI)
(an EPA contractor), monitored process operation throughout the test period.
Mr. Charles Bruffey was the PEI Project Manager.  Principal authors were
Messrs. Charles Bruffey and Thomas Wagner.
                                     IX

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                                  SECTION 1
                                INTRODUCTION

     The U.S. Environmental Protection Agency (EPA) is currently evaluating
several potentially toxic metals and their compounds.   One of these toxic
metals is chromium.  Neither New Source Performance Standards (NSPS) for
stationary sources nor National Emissions Standards for Hazardous Air Pollu-
tants (NESHAPS) currently include chromium emissions.   Available data on the
emission of chromium and its impact on air quality are limited.
     The Emission Measurement Branch (EMB) of EPA's Environmental Standards
and Engineering Division (ESED) requires contractor assistance in obtaining
representative chromium emissions data from several source categories so that
an accurate assessment of the potential problems can be made and appropriate
regulatory action developed.
     PEI Associates, Inc. (under contract to ESED-EMB) performed a series of
atmospheric emission tests on the No. 4 pulverized-coal boiler operated by
the Adolph Coors Company in Golden, Colorado.  All testing took place during
the period of March 18 through 21, 1985.
     Triplicate tests were conducted simultaneously at the inlet and outlet
of a fabric filter (baghouse) used to control particulate emissions from the
boiler to determine the concentrations and mass emission rates of particulate
matter, hexavalent chromium (Cr  ), and total chromium (Cr).  In addition,
particle size distribution tests were conducted during the particulate/chro-
mium tests at each location, and process samples (coal, boiler bottom ash,

                                     1-1

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and baghouse hopper ash) were collected and analyzed for Cr   and total
chromium.  Unofficial opacity (visible emission) data were also obtained
during each particulate/chromium test.
     At the completion of the particulate/chromium tests, a single test was
conducted simultaneously at each location to determine the concentration and
mass emission rate of inorganic arsenic.
     Section 2 summarizes and discusses the test results; Section 3 addresses
quality assurance considerations specific to this project; Section 4 describes
the sampling locations and test procedures; and Section 5 describes source
operation.  Appendix A presents sample calculations and computer printouts;
Appendices B and C contain the field data sheets and laboratory analytical
results, respectively; Appendix D details the sampling and analytical proce-
dures; Appendix E summarizes equipment calibration procedures and results;
Appendix F presents a project quality assurance summary; Appendix G contains
a list of project participants and a sampling log; and Appendices H and I
contain the basic sample and analytical methodology used to determine hexava-
lent and total chromium content.
     It should be noted that EPA performed the total chromium analysis of
collected samples by neutron activation analysis (NAA).  These data are
included in Section 2 of this report.
                                     1-2

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                                  SECTION 2
                   SUMMARY AND DISCUSSION OF TEST RESULTS

     This section details the results of the sampling program.   Subsections
are used to identify results from each test type (i.e.,  particulate/Cr  ,
particle size distribution, etc.), and results are expressed in  both  metric
and English units where applicable.

2.1  TEST PROTOCOL
     Table 2-1 presents the sampling and analytical protocol followed
throughout this project, the test identification, and the  sampling times for
each specific test type.
     In summary, EPA Method 5* sampling trains were used for simultaneous
extraction of samples from the baghouse inlet and outlet test locations.
Samples were collected over a 6-hour period by isokinetic, cross-sectional
traverse techniques.
     A total of six samples (three in and three out) were  collected for
determination of particulate, Cr   , and total Cr concentrations.  Method 5
analytical procedures were followed for the particulate  analysis, and proce-
dures recently developed by EPA for determination of Cr    content in  source
emission samples were used for the Cr   analysis.  These latter  procedures
entail extraction of the sample fractions (probe residue and filter particu-
late) with an alkaline solution followed by the diphenylcarbazide colorimetric
 40 CFR 60, Appendix A, Reference Method 5, July 1984.
                                     2-1

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               TABLE  2-1.   SAMPLING  AND ANALYTICAL  PARAMETERS,  NO.  4 BOILER,  ADOLPH COORS COMPANY
Run No.
PCI-1
PCO-1

PC I -2
PCO-2
PC I -3
PCO-3
PSI-1
PSO-1

PS I -2
PSO-2
PS I -3
PSO-3
PS I -4
PSO-4
AM-1
AM-2
AI-1
AO-2
PCI(l-3)
PCO(l-3)
AI-1
AO-1


Date (1985)
and time (24-h)
3/18 - 0925-1525
3/18 - 0925-1543

3/19 - 0810-1736
3/19 - 0810-1802
3/20 - 0820-1405
3/20 - 0821-1435
3/18 - 1610-1740
3/18 - 1012-1715

3/19 - 1131-1301
3/19 - 0715-1830
3/20 - 1105-1235
3/20 - 0753-1755
3/21 - 1220-1350
3/21 - 0815-1815
3/21 - 1415-1515
3/21 - 1605-1705
3/21 - 0850-1200
3/21 - 0856-1200
3/18-21





Test or
sample type
Participate
Cr 6
Total Cr




Particle
size
distribution








Arsenic

Process
samples
Coal
Bottom ash
Baghouse
ash
Sampling
location
Inlet
Outlet

Inlet
Outlet
Inlet
Outlet
Inlet
Outlet

Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Outlet
Outlet
Inlet
Outlet


Mills ASB
Boiler 4
No. 7 com-
partment
Sample parameters
'articulate
Methods
1-5
X
X

X
X
X
X
_
-

-
-
_
-
_
-
_
-
.
-


.
.
-

Particle
size dis- ,
tribution Cr 
X
X

X
X
X
X
X X
X X

X X
X X
X X
X X
X X
X X
X X
X X
_
-


-
.
-

Total
Cr
X
X

X
X
X
X
X
X

X
X
X
X
X
X
X
X
_
-


.
-
-

Arsenic
Method 108
-

-
-
.
-
.
-

-
-
_
-
_
-
.
-
X
X






Analytical parameters
Partlculate
Method 5
X
X

X
X
X
X
.
-

-
-
.
-
.
-
.
-
.
-


-
-
-

Particle
size dis-
tribution
:

-
-
.
-
X
X

X
X
X
X
X
X
X
X
.
-


_
_


Cr+6
X
X

X
X
X
X
-
X

X
X
-
X
-
X
-
-
-
-


X
X
X

Total
Cr
X

X
X
X
X
-
-

X
-
-
-
-
X
-
-
-
-


X
X
X

Arsenic
Method 108
-

-
-
-
-
-
-

-
-
-
-
_
-
.
-
X
X


-
-
-

ro
i
ro

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method.*  Neutron activation analysis was used to determine the total  chrom-
ium content of selected samples.  These data are summarized in Subsec-
tion 2.6.
     Particle size distribution measurements were made at each site during
the particulate/Cr   tests with an Andersen heavy grain loading impactor
(HGLI).  Three samples were collected at the baghouse inlet and four were
collected at the baghouse outlet.  Two additional samples were collected at
the baghouse outlet with a standard Andersen Mark III in-stack impactor to
validate the HGLI results.  Particle size fractions were analyzed gravimet-
rically, and size distribution curves were developed for each site.  At the
completion of the gravimetric analysis, a single run from the inlet test site
was analyzed for Cr   by individual stage.  The analytical procedures used
were similar to those for the particulate/Cr   samples.  Three of the four
sample runs at the baghouse outlet were composited by stage cut-point and
analyzed for Cr  .
     At the completion of the particulate/Cr   and particle size tests, a
single test was conducted simultaneously at each location according to proce-
dures described in EPA Reference Method 108.**  Method 108 provides both
filterable and gaseous arsenic concentration.  This test was conducted for 3
hours at each location by isokinetic, cross-sectional traverse techniques.
Total arsenic content was then determined by atomic absorption (AA) analysis.
     Process samples (pulverized coal, baghouse hopper fly ash, and boiler
bottom ash) that were collected during each day of testing were composited by
sample type and analyzed for Cr   and total chromium.
     The following subsections detail the results of the sampling program.
  Test Methods for Evaluating Solid Waste.  U.S. EPA SW-846, 2nd ed., July
  1982.
**
  40 CFR 60, Appendix A, Reference Method 108, July 1984.
                                     2-3

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2.2  PARTICIPATE, HEXAVALENT CHROMIUM, AND ARSENIC TEST RESULTS
     Simultaneous Method 5* tests were conducted at the baghouse inlet and
outlet test locations.   These samples were analyzed for particulate and Cr
concentrations, and the resulting data were used to characterize the removal
efficiency across the baghouse.   In addition,  a single test was conducted
simultaneously at each  location  (by EPA Method 108 sampling and analytical
procedures) to characterize uncontrolled and controlled arsenic emissions
from this type of source.  During all testing, the boiler load was at least
80 percent of rated capacity (see Section 5).
     Table 2-2 summarizes pertinent sample and flue gas data for the particu-
late/Cr   and arsenic tests, and Table 2-3 presents the reported particulate
and Cr   emission results.  All  data have been blank-corrected.
     Volumetric flow rates are expressed in cubic meters per minute (m3/min)
and actual cubic feet per minute (acfm) at stack conditions.  Flow rates
corrected to standard conditions [20C and 760 mmHg (68F and 29.92 in.Hg)
and zero percent moisture] are expressed as dry normal cubic meters per
minute (dNm3/min) and dry standard cubic feet per minute (dscfm).
     Filterable particulate concentrations are expressed in milligrams per
dry normal cubic meter (mg/dNm3) and grains per dry standard cubic foot
(gr/dscf).  Filterable particulate represents that material collected in the
sample probe and on the sample filter, which were both maintained at approxi-
mately 121C (250F).  Hexavalent chromium concentrations are expressed in
micrograms per gram (yg/g) and micrograms per dry normal cubic meter
(yg/dNm3).  Mass emission rates  are reported in kilograms per hour and pounds
per hour.
 40 CFR 60, Appendix A, Reference Method 5, July 1984,
                                     2-4

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                  TABLE  2-2.    SUMMARY OF SAMPLE AND  FLUE GAS  DATA FOR  PARTICULATE/CR+6  AND ARSENIC  TESTS
Run
No.
PCI-1
PCO-1
PCI-2
PCO-2
PCI-3
PCO-3
Date
(1985)
3/18
3/18
3/19
3/19
3/20
3/20
PCI (Inlet) av
PCO (Ou
AI-1
(Arseni
AO-1
tlet) a
3/21
c)
3/21
Sampling
duration,
min
360
360
180
360
180
360
erage
verage
180
180
Sample
volume,
dNm3
3.79
7.93
2.95
7.95
3.11
7.98
3.28
7.95
3.15
3.94
dscf
133.67
279.99
104.20
280.895
109.90
281.31
115.92
280.73
111.095
138.993
Isokinetic
sample
rate, %
106.3
102.9
97.9
101.8
94.1
100.0
99.4
101.6
100.0
98.2
Volumetric flow rate*
Actual
mVrnln
3730
4577
3911
4656
4143
4710
3928
4648
4118
4608
acfm
131,700
161,600
138,100
164,400
146,300
166,300
138,700
164,100
145,400
162,700
Standard
dNm'/min
1784
2223
1869
2257
2050
2300
1901
2260
1951
2314
dscfm
63,000
78.500
66 ,000
79,700
72,400
81 ,200
67,100
79,800
68,900
81,700
Temperature
C
153
158
152
159
154
161
153
159
156
162
F
307
317
305
318
309
321
307
319
313
323
Moisture
content,
%
13.8
13.2
13.5
12.8
10.6
12.4
12.6
12.8
14.0
9.8
Gas coaiDO-
sitlon, t
o
6.5
6.8
7.4
7.2
7.1
8.3
7.0
7.4
7.95
7.3
C02
13.2
12.8
12.0
13.5
12.9
12.9
13.1
13.1
12.55
13.0
CO
0
0
0
0
0
0
0
0
0
0
Gas velocity*"
mps
11.2
10.4
11.7
10.5
12.4
10.7
11.8
10.5
12.3
10.4
fps
36.6
34.0
38.4
34.6
40.6
35.0
38.5
34.5
40.4
34.2
Static
pressure,
in.HjO
-7.5
-0.02
-7.5
-0.02
-7.5
-0.02
-7.5
-0.02
-7.5
-0.02
ro
en
           Standard conditions:  20C  (68F), 760 mmHg (29.94 in.Hg) and zero  percent moisture.
           Gas composition as determined from Integrated bag samples collected during each test.  Analysis performed with an Orsat gas analyzer.
          ""Measured flue gas velocity  In meters per second and feet per second.

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 I
CTi
                      TABLE 2-3.   SUMMARY  OF  PARTICULATE  AND  HEXAVALENT  CHROMIUM  EMISSIONS DATA

Run
No.
PCI-1
PCO-1
PCI-2
PCO-2
PC I -3
PCO-3

Date
(1985)
3/18
3/18
3/19
3/19
3/20
3/20
Filterable concentration3
Total
filterable
weight, grams
54.269
0.6075
42.39
0.6985
47.011
0.7706
Participate
mg/dNm3
14,319
76.6
14,369
87.9
15,116
96.7
gr/dscf
6.3
0.034
6.3
0.038
6.6
0.042
Cr+ (blank corrected)
Total Cr+b/
U9/9
0.40
0.30
0.22
0.20
0.22
0.10
sample, ug
21.7
0.18
9.3
0.14
10.3
0.08
gg/dNm3
5.7
0.02
3.2
0.02
3.3
0.01
Mass emission rate
Particulate
kg/h
1534
10.2
1610
11.9
1858
13.3
Ib/h
3382
22.5
3550
26.2
4097
29.4
Cr+6
kg/h
0.00045
-
0.00036

0.0004
~
Ib/h
0.001
<0.0001
0.0008
<0.0001
0.0009
<0.0001

Collection.
efficiency. t.r
Particulate
QQ 1


99.4
QQ &

Cr'u
QQ C


99.6
QQ 0

                Standard conditions:  20C  (68"F), 760 mmHg (29.94 in.Hg) and zero percent moisture.
               "Collection efficiency:  Inlet concentratlcn^^tlet^oncentrati^n

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     As reported in Table 2-2, sample volumes were generally consistent,
ranging from 2.95 to 3.79 dNm3 for the inlet trains and from 7.93 to 7.97
dNm3 for the outlet trains.  The inlet sampling times were adjusted after
Test PCI-1 to account for the heavy particulate loading at this site.   Test
PCI-1 was conducted for 6 hours at a reduced sampling rate of approximately
0.01 dNm3/min (0.37 scfm).  Tests PCI-2 and 3 were conducted for 3 hours by
sampling 30 minutes every hour on the hour for 6 hours.  A sampling rate of
approximately 0.02 dNm3/min (0.58 scfm) was realized for these tests.   Iso-
kinetic sampling rates ranged between 94.1 and 106.3 percent, which is within
the acceptable range of 90 to 110 percent.
     Volumetric gas flow rates at the baghouse inlet ranged from 3730 to 4143
m3/min (131,700 to 146,300 acfm) and averaged 3928 m3/min (138,700 acfm) for
the three particulate/Cr   tests.  The average volumetric flow at standard
conditions was 1901 dNm3/min (67,100 dscfm).  Flue gas temperatures ranged
from 152 to 154C (305 to 309F) and averaged 153C (307F).  The moisture
content of the gas stream averaged 12.6 percent, and the average oxygen (02)
and carbon dioxide (002) contents were 7.0 and 13.1 percent, respectively.
     Arsenic sample and flue gas data reported in Table 2-2 are comparable to
data associated with the particulate/Cr   tests with the exception of the
outlet moisture content.  The measured moisture content (9.8 percent) is
approximately 23 percent lower than the average moisture content (12.8 per-
cent) determined during the particulate/Cr   tests.  There were no leakage
problems associated with this run, and calculations were rechecked to pre-
clude calculation error as a source of the low bias.  An error in recording
the weight of each impinger might have occurred for this run; however, the
overall effect on sample results is believed to be negligible.
                                     2-7

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     As shown in Table 2-3, inlet particulate concentrations ranged from
14,319 to 15,116 mg/dNm3 (6.3 to 6.6 gr/dscf) and averaged 14,601 mg/dNm3
(6.4 gr/dscf).  The average mass emission rate for the three tests was 1667
kg/h (3676 Ib/h).
     The inlet hexavalent chromium concentration ranged from 0.22 to 0.40
yg/g (3.2 to 5.7 yg/dNm3) and averaged 0.28 yg/g (4.1 yg/dNm3) for the three
tests.  The average Cr   mass emission rate was 0.0004 kg/h (0.0009 Ib/h).
The total quantity of Cr   per sample ranged from 9.3 to 21.7 yg.
     At the baghouse outlet, volumetric gas flow rates ranged from 4577 to
4710 m3/min (161,600 to 166,300 acfm) and averaged 4648 m3/min (164,100
acfm).  The average gas flow rate at standard conditions was 2260 dNm3/min
(79,800 dscfm).  Flue gas temperatures ranged from 158 to 161C (317 to
321F) and averaged 159C (319F).  The moisture content of the gas stream
averaged 12.8 percent, and the average Op and C02 contents were 7.4 and 13.1
percent, respectively.
     Outlet particulate concentrations ranged between 76.6 and 96.7 mg/dNm3
(0.034 and 0.042 gr/dscf) and averaged 87.1 mg/dNm3 (0.038 gr/dscf).  The
average mass emission rate for the three tests was 11.8 kg/h (26.0 Ib/h).
The outlet Cr+  concentrations ranged between 0.08 and 0.30 yg/g (0.01 and
0.02 yg/dNm3), and the total quantity of Cr+  per sample was less than 0.20
yg.  An approximate detection limit of 0.1 yg/g Cr   was established for the
outlet samples, based on a 25-ml sample volume.  Accordingly, the reported
Cr   results are essentially at the detection limit of the analytical method
(see Section 3).
     The back-half or impinger solutions from Tests PCI and PCO-1 were also
analyzed for Cr+  content.  PCI-1 (inlet) back-half Cr   content was 0.7 yg
                                     2-8

-------
in 690 ml of sample, or 0.001 yg/ml.   PCO-1 (outlet)  back-half Cr   content
was 0.3 yg in 1145 ml of sample, or 0.0003 yg/ml.   Average blank reagent
values were less than 0.006 yg/ml, which indicates that the reported values
for each location are essentially at the detection limit of the analytical
method.
     The particulate-removal efficiency of the baghouse was greater than 99
percent based on both the measured inlet and outlet particulate concentra-
tions and mass emission rates.  Hexavalent chromium collection efficiencies
based on the measured Cr   concentrations and the  total quantity of Cr
collected in the filterable fraction (probe and filter) were comparable to
the particulate collection efficiency.
     No major problems were encountered during the particulate/Cr   tests.
Extended sampling times were necessary to assure collection of sufficient
sample so that Cr   levels could be quantified.  The 3.05-m (10-ft), glass-
lined, sampling probe that PEI used at the inlet location was not of suffi-
cient length to reach the final traverse point in  the 4x6 sampling point
matrix established for this site.  Therefore, Traverse Point 5 was sampled
twice in each port because the velocity head and gas temperature at this
point were comparable to the average gas velocity  and temperature in the
duct.
     A 3.05-m (10-ft) glass-lined probe was used at both sites to preclude
possible biases in Cr   and total Cr measurements, which might have resulted
from the use of a stainless-steel-lined probe.  Previous test experience has
shown that the use of glass liners longer than 3.05 m results in excessive
breakage and leakage problems.
     Table 2-4 summarizes the arsenic emissions data obtained at this source.
                                     2-9

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                     TABLE 2-4.  ARSENIC EMISSIONS DATA
Run No.
AI-1
AO-1
Date
(1985)
3/21
3/21
Sampling
location
Inlet
Outlet
Concentration
Total
filterable
arsenic sample
weight, yg
525
6.4
yg/dNm3
167
1.6
mg/dNm3
0.17
0.002
Arsenic
collection
efficiency, %
>99.0
     Arsenic was found exclusively in the filterable fraction (probe and
filter) of each sampling train.  The inlet sample showed a total  arsenic
weight of 525 yg or 167 yg/dNm3 compared with 6.4 yg (1.6 yg/dNm3)  for the
outlet sample.  This single test indicated an arsenic collection  efficiency
of more than 99 percent.

2.3  PARTICLE SIZE DISTRIBUTION TEST RESULTS
     At each site, an Andersen HGLI was used to measure particle  size dis-
tribution during each particulate/Cr   test.  This in-stack impactor consists
of two single-jet impaction chambers followed by a third-stage cyclone and a
backup thimble.  Although this impactor normally would not be used  to extract
samples from a gas stream with a low particulate concentration, its use was
advantageous in this case because it contains no filter media (except the
backup thimble).  This eliminates the need for filter blank corrections for
Cr   and permits a more accurate quantification of Cr   size distribution. A
total of three inlet samples (designated PSI) were collected over a 90-minute
period at a single point representing the average gas velocity and  temper-
ature in the duct.
     Four samples were collected at the baghouse outlet over an 8-  to 10-hour
sampling period to assure sufficient sample in each stage for both  gravimet-
ric and Cr   analysis.  These samples (designated PSO) were collected from
                                     2-10

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two separate sampling points, each representing the average gas velocity and
temperature in the duct.
     For validation of the outlet particle size results, two additional
measurements (designated AM) were made with a standard Andersen Mark III
multistage impactor.
     Each particle size test was conducted according to the procedures
described in the HGLI operations manual.  Isokinetic sampling rates were set
initially, and constant cut-point characteristics were maintained throughout
the sampling period.  Specifications state that the gas flow rate through the
impactor at stack conditions should be maintained between 0.3 and 0.7 acfm to
avoid distortion of individual stage cut-points.  With the exception of Test
PSO-2 (outlet), this criterion was met.  Isokinetic sampling rates ranged
from 112 to 116 percent for the inlet tests and 96 to 103 percent for the
outlet tests.
     Cumulative size distribution curves representing the total weight of
particulate matter smaller than the indicated aerodynamic particle diameter
[in micrometers (ym)l were established for each test location.  The cut-
points for each HGLI test were determined graphically from information sup-
plied by the manufacturer, and all particle size results are based on a par-
ticle density of 1 g/cm3.  Data reduction for the HGLI runs was performed by
computer programming with moisture, molecular weight, and temperature data
obtained from the particulate/Cr   tests.  The HGLI data reduction and inter-
mediate calculations are presented in Appendix A of this report.
     Figures 2-1 and 2-2 present the best-fit curves for the inlet and outlet
particle size distribution tests.  Table 2-5 presents a comparison of
                                     2-11

-------
r\>
i
                                            1.0
                     10.0

PARTICLE SIZE,  micrometers
                 Figure 2-1.   Particle size  distribution  tests PSI-2 and  -4  at the baghouse  inlet.

-------
                            1.0
                     10.0
PARTICLE SIZE,  micrometers
100
Figure 2-2.   Particle size  distribution tests  PSO-1, -3 and  -4 at the baghouse outlet.

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    TABLE 2-5.  COMPARISON OF PARTICULATE CONCENTRATIONS AS MEASURED  BY
         EPA METHOD 5 VERSUS PARTICLE SIZE DISTRIBUTION IMPACTORS
Run No.
PSI-2
PCI-1
PSI-3a
PCI-2
PS I -4
PCI-3
PSO-1
PSO-2
PCO-1
PSO-3
PCO-2
PSO-4
PCO-3
Test location
Baghouse inlet


Baghouse outlet



Sample type
Particle size - HGLI
Method 5 - Parti cul ate
Particle size - HGLI
Method 5 - Particulate
Particle size - HGLI
Method 5 - Particulate
Particle size - HGLI
Particle size - HGLI
Method 5 - Particulate
Particle size - HGLI
Method 5 - Particulate
Particle size - HGLI
Method 5 - Particulate
Particulate concentration
mg/dNm3
18,413
14,319
8,385
14,369
18,216
15,116
63.1
64.8
76.6
91.8
87.9
88.5
96.7
gr/dscf
8.1
6.3
3.7
6.3
7.9
6.6
0.028
0.028
0.034
0.04
0.038
0.039
0.042
Sample biased low; results not used in development of inlet size distribution
curves.
                                  2-14

-------
particulate concentrations obtained from the particle size tests with those
obtained by Method 5 tests.
     One test from each location was excluded from the data used to plot the
curves.  Test PSI-3 (inlet) was voided because of an apparent loss of sample
during removal of the assembly from the duct.  Because this site was under a
7.5-in. (water) negative pressure, a small  flow had to be maintained through
the sampling train during removal of the impactor from the stack to prevent
the sample from being drawn out of the impactor through the sample nozzle.
     The particulate concentration data from this run were about 55 percent
lower than the data from Tests PSI-2 and PSI-4, which indicates some loss of
samples.  Thus, data were not used in developing the inlet size distribution
curve.  As mentioned previously, results of Test PSO-2 (outlet) were voided
because the calculated flow rate through the impactor (sl.O cfm) exceeded the
manufacturer's recommended maximum value of 0.7 cfm.  Therefore, data from
Runs PSO-1, -3, and -4 were used to develop the outlet size distribution
curves.
     For the two inlet runs (PSI-2 and -4), the size distribution curve
showed that about 40 percent by weight of the particles had a nominal diam-
eter of 12 micrometers or less.  The calculated average particulate concen-
tration for these runs was 18,315 mg/dNm3 (8.0 gr/dscf) compared with a
three-test Method 5 average of 14,601 mg/dNm3 (6.4 gr/dscf).  This indicates
about a 20 percent difference in average values between the two measurements.
The percentage difference between the methods is acceptable according to the
applicable criterion in the Inhalable Particulate (IP) protocol.*  This
 Procedures Manual for Inhalable Particulate Samplers Operation, prepared by
 Southern Research Institute for EPA, Contract No. 68-02-3118, November 1979.
                                     2-15

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protocol states that a comparison of the total  mass concentrations  between
particle size and Method 5 sample runs should not differ from the means  by
more than 50 percent.
     The HGLI Stages 1, 2, and 3 cut-points for Test PSI-2 were 11.8,  6.2,
and 2.0 ym, respectively.  Thirty-eight percent of the particles were  less
than 11.8 ym, 22 percent were less than 6.2 ym, and 6 percent were  less  than
2 ym.  The stage cut-points for Test PSI-4 were 11.6, 6.2, and 2 ym.   Forty
percent of the particles were less than 11.6 ym, 23 percent were less  than
6.2 ym, and 4 percent were less than 2 ym.
     The size distribution curves for the three outlet tests (PSO-1,  -3, and
-4) showed that about 55 percent by weight of the particles had a nominal
diameter of 10.5 ym or less.  The average calculated particulate concentra-
tion for these runs was 81.1 mg/dNm3 (0.03 gr/dscf) compared with a three-
test Method 5 average of 87.1 mg/dNm3 (0.038 gr/dscf).  This indicates less
than a 10 percent difference between the two measurements.
     The stage cut-points for Test PSO-1 were 10.4, 5.4, and 1.5 ym,  respec-
tively.  Fifty percent of the particles were less than 10.4 ym, 36  percent
were less than 5.4 ym, and 7 percent were less than 1.5 ym.  For Test  PSO-3,
the stage cut-points were identical to those established for PSO-1.  Fifty-
five percent of the particles were less than 10.4 ym, 35 percent were  less
than 5.4 ym, and 4 percent were less than 1.5 ym.  Test PSO-4 exhibited
similar characteristics; 53 percent of the particles less than 10.5 ym,  40
percent were less than 5.5 ym, and 4 percent were less than 1.5 ym.
     The outlet results are considered representative of particle size dis-
tribution in the gas stream at the time of testing.  The data consistency and
comparability to the average Method 5 results substantiate this conclusion.
                                     2-16

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The inlet results are somewhat suspect because only two sets of valid data
were available for evaluation; however, the data reproducibility and overall
comparability with the Method 5 results indicate these results are represent-
ative of particle size distribution in the gas stream during testing.
     Figure 2-3 depicts the size distribution curve developed from data
collected by a standard Andersen Mark III multistage impactor.  Two 60-minute
tests were conducted at the conclusion of the test program to validate the
HGLI results.  The results from these tests compared favorably with the HGLI
tests in which approximately 45 to 55 percent of the particles were less than
10.5 ym.
     In an effort to characterize Cr   size distribution, select particle
size samples from each location were analyzed for Cr   by procedures similar
to those used on the Method 5 samples.  Inlet Test PSI-2 was analyzed by
individual stage, whereas outlet Samples PSO-1, -2, and -3 were composited by
stage cut-point and analyzed for Cr  .  Table 2-6 presents the results of the
Cr   size distribution analysis.
     The size distribution Cr   concentrations presented in Table 2-6 are
generally consistent with the Method 5 Cr   data.  The inlet Cr   concentra-
tion determined for Stage 1 (11.8-ym cut-point) was 0.24 yg/g; for Stage 2
(6.2-ym cut-point), it was 2.85 yg/g; and for Stage 3 (2.0-ym cut-point), it
was 2.15 yg/g.  Based on a total particulate weight of 12.449 g, the quantity
of Cr   in this sample was 11.9 yg, with a corresponding concentration of
0.95 yg/g.
     The outlet Cr   concentration for the composite Stage 1 (10.4-ym cut-
point) sample was 0.32 yg/g; for Stage 2 (5.4-ym cut-point), it was 1.1 yg/g;
and for Stage 3 (1.5-ym cut-point), it was 0.65 yg/g.  Based on a total
                                     2-17

-------
            tt.t


            M.I
ro
i
Co
                                                                        10.0

                                                   PARTICLE SIZE, micrometers
100
                       Figure 2-3.  No.  4 boiler baghouse outlet particle  size distribution.

                                 (Andersen Mark III Impactor - Runs AM-1 and -2)

-------
     TABLE  2-6.   SUMMARY OF HEXAVALENT CHROMIUM SIZE DISTRIBUTION DATA
Location
Inlet




Outlet




Run No.
PSI-2
PSI-2
PSI-2
PSI-2
PSI-2
PSO(l-3)
PSO(l-3)
PSO(l-S)
PSO(l-3)
PSO(l-3)
Sample
description
Stage I/acetone
residue
Stage 2/acetone
residue
Stage 3/acetone
residue
Backup thimble
Total
Stage I/acetone
residue
Stage 2/acetone
residue
Stage 3/acetone
residue
Backup thimble/
residue
Total
Stage
cut-point,
ym
11.8
6.2
2.0
<2.0
-
10.4
5.4
1.5
<1.5
-
Parti c-
ulate
weight per
stage, g
7.6694
2.004
2.003
0.7719
12.449
0.6269
0.2095
0.3516
0.0194
1.233C
Total
Cr+6,
yg
1.85
5.73
4.30
Nonde- .
tectable0
11.88
0.20
0.22
0.23
Nonde- .
tectable
0.65
Cr+6
concen-
tration,
yg/g
0.24
2.85
2.15
-
0.95
0.32
1.1
0.65
-
0.53
 Reported  resulted  are  blank-corrected.
      than  or  equal  to  the  thimble blank.
Includes  total  thimble weight  for  PSO-1, -2, and -3.
                                   2-19

-------
particulate weight of 1.233 g, the quantity of Cr   in the composited sample
was 0.65 yg with a corresponding concentration of 0.53 yg/g.
     The Cr   analytical results from the inlet Method 5 samples  ranged from
0.2 to 0.4 yg/g.  The inlet Method 5 samples were analyzed in an  identical
manner as the particle size samples; i.e., weighed quantities of  loose par-
ticulate were extracted and analyzed, which precluded the need for a  Cr
blank filter corrections.  Baghouse hopper fly ash samples also were  col-
lected during the test period, and Cr+  levels of approximately 0.7 yg/g were
reported.  These data are presented in Subsection 2.4 of this report.  Based
on the overall comparability of the inlet Method 5, baghouse hopper fly ash,
and size distribution Cr   data, and considering the low levels of Cr+  at
this source, the Cr   size distribution data appear to be representative of
actual gas stream conditions during the test period.  These data  do show that
most of the Cr   emissions are concentrated in Stages 2 (6 to 7 ym) and 3
(1.5 to 2.0 ym) at both sites.

2.4  PROCESS SAMPLE ANALYTICAL RESULTS
     Table 2-7 summarizes Cr   analytical results from pulverized coal,
boiler bottom ash, and baghouse hopper and samples collected during each day
of testing.  Grab samples of each were collected at least once an hour over
an 8-hour testing period.  Samples were placed in separate polyethylene
containers and sent to our Cincinnati laboratory, where they were composited
by sample type into a single, representative sample.  Weighed portions of
each sample type were then extracted and analyzed for Cr+  by procedures
similar to those used in analyzing the emission test samples.
                                     2-20

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                TABLE 2-7.  PROCESS SAMPLE ANALYTICAL RESULTS
Sample type
Baghouse dust
(composite for
3/18 to 3/21)
Boiler bottom
ash (composite
for 3/18 to
3/21)
Pulverized
_ _ _ -I a
coal
Coal
Ash
(composite
for 3/18 to
3/21)
Labora-
tory ID
EE836-EE840


EE841-EE844



EE845-EE849






Particu-
late weight
analyzed, g
10.298


10.9213





44.1519
5.0044



Total
Cr+6, yg
7.0


0.9





-
0.61



Cr concen-
tration, yg/g
0.68


0.08





0.014
0.12



 The coal samples were "ashed" prior to analysis.   The ash content of the
 coal was approximately 11 percent.

     The total Cr   content of the composite boiler bottom ash and sample was
0.9 yg, with a corresponding concentration of 0.08 yg/g.   As noted in the
previous section, the composite baghouse hopper fly ash sample showed a total
Cr   content of 7.0 yg, with a corresponding concentration of 0.68 yg/g.
Pulverized coal samples showed a Cr   concentration of 0.014 yg/g.
2.5  VISIBLE EMISSION OBSERVATIONS
     Unofficial visible emission observations were made by the EPA Task
Manager during each particulate/Cr   test.  Opacity readings were consist-
ently less than 5 percent for each test.  Raw data sheets are contained in
Appendix B of this report.
                                     2-21

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2.6  TOTAL CHROMIUM TEST RESULTS
     Table 2-8 summarizes the total Cr content of selected emission samples
analyzed by NAA.  Analytical data as received from EPA are included in Appen-
dix C of this report along with example calculations.
     In summary, NAA is an analytical technique dependent on the measurement
of the number and energy of gamma and X-rays emitted by the radioactive iso-
topes produced in the sample matrix by irradiation with thermal neutrons from
a nuclear reactor.  Typically, the sample matrix plus  appropriate standards
of the element(s) of interest are irradiated for a selected time period in
the neutron flux core region of a research nuclear reactor.  After irradi-
ation and appropriate radioactive decay, a gamma-count energy spectrum is
obtained by counting the sample on a nuclear detection system.
     As reported in Table 2-8, inlet Method 5 samples  designated PCI 1
through 3 and outlet Method 5 samples designated PCO 2 and 3 were submitted
for analysis.  In addition, inlet particle size Run PSI-2 and outlet particle
size Run PSO-4 were submitted for analysis by individual stage cut point.
Composite process samples (coal, boiler bottom ash, and baghouse hopper fly
ash) were also analyzed for total Cr content.
     The total Cr content of the inlet samples on a yg/g basis ranged between
                                                    3
62 and 97 yg/g.  Total Cr concentrations on a yg/dNm  basis ranged betwen 936
               3
and 1385 yg/dNm  with corresponding mass emission rates ranging between 0.11
kg/h (0.25 Ib/h) and 0.14 kg/h (0.3 Ib/h).
     The total Cr content of the outlet samples on a yg/g basis ranged be-
                                                              3
tween 89 and 110 yg/g.  The total Cr concentration in a yg/dNm  basis ranged
                           3
between 7.8 and  10.6 yg/dNm  with corresponding mass emission rates of
                                     2-22

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                   TABLE  2-8.   SUMMARY OF  TOTAL  Cr EMISSION  DATA
Run
No.
PCI-1
PCI-2
PCI-3
PCO-2
PCO-3
PSI-2
PSO-4
-
-
-
Sample type
and location
Filterable particulate
baghouse inlet
Filterable particulate
baghouse inlet
Filterable particulate
baghouse inlet
Filterable particulate
baghouse outlet
Filterable particulate
baghouse outlet
Particle size baghouse
inlet
Stage 1 (11.8 um)
Stage 2 (6.2 ym)
Stage 3 (2.0 um)
Particle size baghouse
outlet
Stage 1 (10.5 urn)
Stage 2 (5.5 um)
Stage 3 (1.5 um)
Baghouse dust composite
Boiler bottom ash com-
posite
Coal composite
Total"
particulate
collected,
g
54.269
42.390
47.011
0.6985
0.7706
7.669
2.004
2.003
0.2407
0.0638
0.1858
-
-
-
Particulate
sample weight
analyzed by
NAA, g
0.5041
0.1052
0.1231
0.3322
0.407
0.100
0.1062
0.1147
0.0988
0.0533
0.0952
0.2721
0.1514
0.277
Total Crc
results by
NAA, vg
48.7
8.8
7.62
29.7
44.7
8.70
11.79
7.23
31.18
12.38
22.56
12.55
7.36
2.22
Total Crd
concen-
tration
by NAA,
ug/9
96.7
83.7
61.9
89.4
109.8
87.0
111.0
63.0
315.6
232.3
237.0
46.1
48.6
8.01
Total Cre
content
of sample,
ug
5248
3546
2910
62.4
84.6
667
222
126
1015
76.0
14.8
44.0
134.8
-
-
-
Total Cr
concentration,
ug/dNrr.s
1385
1202
936
7.8
10.6
1504
23.5
-
-
-
'Total particulate (probe residue and filter) collected during sample run.
 Particulate weight analyzed by NAA.
cTotal Cr results by NAA.
dTotal Cr(C) divided by particulate weight analyzed by NAA(b).
eTotal Cr concentration (ug/g) multiplied by total particulate weight collected(a).
                                                2-23

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0.001 kg/h (0.003 Ib/h) and 0.001 kg/h (0.003 Ib/h), respectively.   These
data generally follow the participate and Cr   emission data in that greater
than 98 percent of the total Cr is effectively removed by the baghouse con-
trol device.                                                             '
     The inlet particle size distribution data for total Cr showed  Cr concen-
trations of 87 yg/g for Stage 1 (11.8 ym), lll.O yg/g for Stage 2 (6.2 ym),
and 63 yg/g for Stage 3 (2.0 ym).  An overall Cr concentration of 1504
yg/dNm  was determined for this sample, which is generally comparable to the
total Cr concentration determined from the Method 5 samples.
     The outlet particle size distribution data for total Cr showed Cr con-
centrations of 316 yg/g for Stage 1 (10.5 ym), 232 yg/g for Stage 2 (5.5 ym),
                                                                            2
and 237 yg/g for Stage 3 (1.5 ym).  An overall Cr concentration of 24 yg/dNm
was determined for this sample.  It should be noted that thimble samples from
both particle-size runs were submitted for analysis.  The total Cr content  of
blank thimbles submitted with the actual samples was highly variable, howev-
er, making a quantitative analysis of total Cr less than 2 ym impossible.
     Process samples analyzed for total Cr yielded the following results:
     0    Baghouse dust:  46.1  yg/g
     0    Boiler bottom ash:  48.6 yg/g
     0    Coal:  8.0 yg/g
These data were determined from composited samples collected during each test
day.
                                     2-24

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                                  SECTION 3
                          PROJECT QUALITY ASSURANCE

     The application of quality assurance procedures to source emission
measurements ensures accurate emission-testing results.  Quality assurance
guidelines provide the detailed procedures and actions necessary for defining
and producing acceptable data.  In this project, five documents were used in
the preparation of a source-specific test plan that would ensure the collec-
tion of acceptable data:  1) the EPA Quality Assurance Handbook Volume II,
EPA-600/4-77-0271; the PEI Emission Test Quality Assurance Plan; the PEI
Laboratory Quality Assurance Plan; Determination of Hexavalent Chromium
Emissions From Stationary Sources, December 13, 1984; and EPA Protocol for
Emissions Sampling for Both Hexavalent and Total Chromium, February 22, 1985.
Two of these are PEI's general guideline manuals and define the company's
standard operating procedures followed by the company's emission testing and
laboratory groups.
     In this specific test program, which was reviewed by EPA's Emission
Measurement Branch, the following steps were taken to ensure that the testing
and analytical procedures produced quality data:
     0    A sample of the No. 4 boiler baghouse hopper catch was+obtained
          during the February pretest survey and analyzed for Cr 6 content.
          These data were used to Define sampling times and rates so that a
          quantifiable level of Cr 6 was collected.
     0    Prior to the field test, several filter media commonly used in
          source sampling (glass fiber, paper, and Teflon) y_ere analyzed for
          Cr 6 content to establish background levels of Cr 6, as the source
          levels were expected to be in the microgram range.  Glass-fiber

                                     3-1

-------
          filters were selected for sampling because of their proven  durabil-
          ity under the expected source conditions (temperature)  and  the
          extended sampling times (6 hours) required at this source.
     0    Calibration of all field sampling equipment.
     0    Checks of train configuration and calculations.
     0    Onsite quality assurance checks, such as leak checks of the sam-
          pling train, pitot tube, and Orsat line and onsite quality  assur-
          ance checks of all test equipment prior to use.
     0    Use of designated analytical equipment and sampling reagents.
     0    Internal and external audits to ensure accuracy  in sampling and
          analysis.
     Table 3-1 lists the specific sampling equipment used  to perform  the
particulate/Cr  , particle size distribution, and arsenic  tests as well  as
the calibration guidelines and limits.  In addition to the pre- and post-test
calibrations, a field audit was performed on the metering  systems and temper-
ature-measurement devices used during sampling.  These data are summarized in
Table 3-1, and copies of the field audit data sheets are presented in Appen-
dix B of this report.
     The PEI project manager performed the onsite sample calculations, and
computer programming was used to validate the data upon return to PEI's
Cincinnati laboratory.  Minor discrepancies between the hand calculations and
computer printouts are due primarily to rounding off of values.  Computerized
example calculations are presented in Appendix A.
     The following subsections summarize the quality assurance activities
performed during the analytical phase of this project.   As a check of the
gravimetric analytical procedure, blank filter and reagent (acetone)  were
analyzed in a fashion similar to that used for the actual  field samples.
Table 3-2 summarizes the blank analysis data.  These data  indicate good
analytical technique.

                                     3-2

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                                 TABLE 3-1.  FIELD EQUIPMENT CALIBRATION.
Equipment
Meter box
Pilot tube
Digital indicator
Thermocouple
and stack
thermometer
Orsat analyzer
Impinger
thermometer
Trip balance
Barometer
Dry gas
thermometer
Probe nozzle
ID
No.
FB-8
FB-9
FB-10
FB-11
T-002
187
386
126
121
257
141
1-1
1-2
Mettler
No. 743985
Plant
FB-8
FB-9
FB-10
FB-11
6-101
5-111
6-107
Part, size
Calibrated
against
Wet test meter
Standard pi tot
tube
Millivolt signals
ASTM-3F
Standard gas
ASTM-3F
Type S weights
NBS traceable
barometer
ASTM-3F
Caliper
Allowable
error
AH (? ^.0.15
(Y iO.5 Y post-test)
Cp 0.01
0.5%
1.5%
(*2% saturated)
10.5%
*2F
0.5 g
0.10 in.Hg
(0.20 post-test)
5F
Dn 0.004 in.
Actual
error
+0.09; -0.02
+0.04; +0.5
-0.11; -0.2
-0.08; -1.05
0.84
0.84
0.40
0.41
+0.19
+0.19
0 (02)
0 (COZ)
+1F
+ 1F
+0.5
-
In - +4F; Out - +3F
In - +2"F: Out - +3F
In - -1F; Out - 0F
In - 1F; Out - +4"F
0.003
0.001
0.0
0.002
0.001
Within
allowable
limits
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
-
X
X
X
X
X
X
X
X
X
Comments
Y = 0.997; Audit All P 1.88
Y = 0.971; Audit ill P 2.03
Y = 0.976; Audit AH P 1.67
Y = 0.997; Audit AH P 1.24
(Field audit results)
From Geometric Spec.
40 CFR Appendix A; Reference Method 2
Field audit results = +0.23%
Field audit results = +0.5%
Maximum
Maximum
Audit value
02 and C02 - 5.0%

Maximum deviation
Plant barometer (high altitude)
Maximum deviations
Maximum deviations
Maximum deviations
Maximum deviations
Inlet
Outlet
CO
CO

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                TABLE 3-2.   EXAMPLE FILTER AND REAGENT BLANK
                          ANALYSIS FOR PARTICIPATE
Sample type and
filter number
Participate - 8510126
Reeve Angel 934 AH
Acetone blank3
Water blank
Original tare
weight, mg
363.8
99661. 5b
100869. 0C)d
NAe
Blank
weight, mg
364.2
99669.0
100872.8
NA
Net
weight, mg
0.4
7.5
(0.054 mg/g)
3.8
(0.034 mg/g)
NA
 177 ml evaporated and desiccated before weighing.
 Particle size acetone blank (0.01 mg/g used in calculations),
Method 5 acetone blank (0.01 mg/g used in calculations).
 142 ml evaporated and desiccated before weighing.
eNA = Not applicable.
                                     3-4

-------
     Table 3-3 presents the results of the blank filter analysis  for Cr   .
Glass-fiber, ceramic, silica-fiber, paper filters, and Teflon  filters were
evaluated.  Hexavalent chromium background levels ranged from  0.8 yg for the
silica-fiber thimble to 100 yg for ceramic thimbles.   PEI utilized Reeve
Angel 934 AH glass-fiber filters (0.9 yg Cr+6) for this study  because of
their proven durability at the temperatures required  for sampling and the
extended sampling times needed to assure collection of sufficient sample for
 +6    ,
Cr   analysis.
     The blank filter data in conjunction with Cr  data from  the pretest
survey sample were used to formulate a workable test  plan to quantify the low
Cr   levels at this source.
     Emission and process samples were analyzed in two separate batches.  The
baghouse inlet samples and process samples were analyzed on April 3, 1985,
and the remaining samples on April 11, 1985.   Table 3-4 summarizes the linear
regression data of the spectrophotometer calibration  for these samples.
     The detection limit established for the  April 3  sample batch was less
than 0.009 yg/ml for an absorbance 0.005.  For samples analyzed on April 11,
a detection limit of less than 0.005 yg/ml was established at  an  absorbance
of 0.005.
     Because the concentration of hexavalent  chromium in these solid samples
were extremely low, the amount of alkaline extraction solution and the final
dilution volume of this extract were kept at  a minimum consistent with Method
3060 from Test Methods for Evaluating Solid Waste.*   This proportion is 4  ml
of alkaline extraction solution per gram of solid diluted to a final volume
of 10 ml.  Filters and thimbles require larger amounts of extraction solution
*U.S. EPA SW846, 2nd ed., July 1982.
                                     3-5

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  TABLE 3-3.   RESULTS OF PRELIMINARY Cr+6 ANALYSIS ON BLANK FILTER MEDIA
Type of filter media
Glass-fiber thimble (BGI)
Alundum (ceramic) thimble
Silica-fiber thimble (BGI)
S+S glass-fiber thimble
Glass-fiber filter (RA934AH)
Paper filter (Whatman)
Teflon (2.0-yg pore size)
Weight of
filter media, g
2.54
37.6
3.36
2.14
0.34
0.61
0.0830
Cr+6,
ug/g
1.0
2.9
0.23
0.78
2.5
1.8
2.5
Total Cr+6,
pg
2.5
100
0.8
1.7
0.9
1.1
0.21
     TABLE 3-4.   LINEAR REGRESSION DATA SPECTROPHOTOMETER CALIBRATION



Sample
description
PCI 1-3
Process
samples



PCI 1-3
All parti-
cle size
fraction
PCI-1 and
PCO-1 back
halves



Date
(1985)
4/3





4/11






Cr+6
standard
concen-
tration,
yg/ml
0
0.1
0.2
0.3
0.4
0.5
0
0.1
0.2
0.3
0.4
0.5




Absorb-
ance
0.0
0.077
0.159
0.236
0.322
0.401
0.0
0.134
0.268
0.403
0.536
0.679




Y-Intercept


-0.0020






-0.0016






Slope9


0.8049






1.3531






Correlation
coefficient


0.99990






0.99995
%


Different cells used on each day.   Flow-through cells were used on April  3;
standard cells were used on April  11.
                                    3-6

-------
to cover the volume of material  being extracted.   This physical  requirement
increased the analytical  detection limit.
     Because the back-half impinger volumes were  larger (690 to  1145  ml)  than
the final dilution of the extracted front-half particulate,  the  impinger
contents had to be concentrated  by factors of 10  or 100 to give  comparable
detection limits.
     Table 3-5 presents the blank filter and reagent Cr   data.   Filter,
acetone, and water blanks were collected in the field and analyzed in the
same manner as the emission samples.
     Except for the filter/acetone fraction of the outlet samples and the
thimble fraction of the inlet and outlet particle size samples,  blank correc-
tions were minimal.  Because of  the large particulate sample collected at the
inlet, representative particulate samples of 10 g each were analyzed  without
blank interference from the filter.  The first three stages of the particle
size sampler do not use a sampling media; therefore, no blank interference
was present.  The three outlet particulate samples contained approximately  1,
1.5, and 2 times the filter blank, which contributes to the variability of
the hexavalent chromium concentration in these samples.  The amount of hexa-
valent chromium in the particle  size thimble fraction was indistinguishable
from the blank.  Duplicate analyses (extraction and colorimetric determina-
tion) were performed on the inlet particulate of Run 1, the composite of  the
baghouse dust, the composite coal sample, and the Mill B coal sample.  Also,
the first stage of the inlet particle size sample from Run 2 was checked  by
method of additions, and a liquid audit sample supplied by EPA was analyzed.
The results for these samples are presented in Table 3-6.
                                     3-7

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                  TABLE 3-5.  BLANK DATA FOR Cr+6 ANALYSIS
Sample type
Method 5
Filter/acetone
Impinger water
Impinger water
Particle size
thimble
Particle size
Reagent blanks
Participate
Filter/acetone
Particle size
Volume,
ml
25
690
1145
100
10
100
25
-
Hexavalent
chromium
content, yg
0.34
0.05a
0.09a
3.5
<0.08
<0.9 (inlet)
<0.2 (outlet)
-
Hexavalent chromium
contentration, yg/ml
_
-
-
-
-
-
-
<0.005
 Based on concentrated sample.
                      TABLE 3-6.  RESULTS OF QC SAMPLES
     Sample
 QC type
    Results
Particulate PCI-1
Baghouse dust (composite)
Coal (composite)
Coal (Mill  B)
Particulate (PSI-2)
Duplicate
Duplicate
Duplicate
Duplicate
Spike
Audit3
0.38, 0.42 yg/g
0.68, 0.63 yg/g
0.014, 0.015 yg/g
0.012, 0.012 yg/g
85% recovery
100 ppm
 100 ppm accepted value.
                                     3-8

-------
     One problem was encountered in the analysis of the coal  samples.   When
raw coal samples were extracted, a dark brown solution was obtained that
could not be analyzed by the colorimetric procedure.   The color was removed
from this solution by using activated charcoal, but the recovery of spiked
amounts of hexavalent chromium was negligible.  This problem resulted  from
the extraction of highly colored organic material from the coal.  The  values
reported for the coal samples were obtained from the ash after the coal
samples had been heated to 900C in a muffle furnace to eliminate the  inter-
ference from organic matter.  Lowering the temperatures did not eliminate all
of the organic interference.
     Table 3-7 presents QC data relative to the total Cr analysis by NAA.
Duplicate, audit, and blank data are presented.
                                     3-9

-------
                   TABLE 3-7.   QC DATA FOR TOTAL Cr BY NAA
    LAB No.
    Sample type
           Results,
           total  Cr
Run PCI-1
EE802/810
Baghouse dust
EE836/840
Coal
EE845/849
NBS coal
NBS fly ash
Alkaline
extract
Type I H20
Method 5 filter
  Acetone
Particle size
  Thimble
Duplicate analysis
Duplicate analysis

Duplicate analysis

Audit

Audit

Blank

Blank
Blank

Blank
7.11 yg; 5.93 yg
6.9/yg; 5.64 yg
0.93 yg; 1.29 yg
24.5 yg (34.4 yg/g Cr accepted
 value)
198 yg (196 yg/g Cr accepted
 value)
0 Cr
1.05 yg Cr (10X concentration)
15.7 yg Cr

29.5 yg Cr
                                     3-10

-------
                                  SECTION 4
                   SAMPLING LOCATIONS AND TEST PROCEDURES

     This section describes the sampling sites and the test methods  used  to
characterize participate and chromium emissions from Boiler 4.
4.1  SAMPLING LOCATIONS
     Flue gas samples were extracted from existing sampling ports  prior to
and after the baghouse that controls particulate emissions from Boiler 4.
Figures 4-1 and 4-2 show the test locations.
     At the baghouse inlet, four 8.9-cm (3i-in.) i.d.  sampling  ports were
located approximately 3.4 equivalent duct diameters (EDO) downstream and  0.85
EDO upstream from the nearest flow disturbances in a rectangular duct with  an
i.d. of 1.5 m x 3.7 m (5 ft x 12 ft).  At the baghouse outlet,  8.9-cm
(3i-in.) i.d. sampling ports were located approximately 3.5 EDO downstream
and 1.4 EDO upstream of the nearest flow disturbances in a rectangular duct
with an i.d. of 3.3 m x 2.2 m (10 ft 9 in. x  7 ft 2i in.).  Both locations
conformed to the minimum requirements for sampling port locations  specified
in Method 1 of the Federal Register.*

4.2  PARTICULATE AND HEXAVALENT CHROMIUM SAMPLE EXTRACTION AND  ANALYSIS
     Flue gas samples were simultaneously collected at the baghouse  inlet and
outlet test locations according to procedures outlined in EPA Reference
Method 5.**
  40 CFR 60, Appendix A, Reference Method 1, July 1984.
**
  40 CFR 60, Appendix A, Reference Method 5, July 1894.
                                     4-1

-------
                         4m(12 ft)
 1.5m (5 ft)
                6
                06
                06
ol

ol
                                                      SAMPLE PORTS
                         CROSS SECTION
    *1.8m(6 ft) = 0.8 EDO   7.3m(24 ft) = 3.3 EDO
ELBOW
+	FLOW       O
(TO BAGHOUSE)   O   el-5m (5 ft)
                                                 FLOW
                    ^SAMPLE PORTS

                  B8.9cm(3Js In.)  I.D.

               FROM
               NO 4
               BOILER
 2.4m(8 ft)
                                                         GRADE
                                        EDO  s Equivalent  duct diameters
    Figure  4-1.  Boiler 4 baghouse inlet  test location (no scale).
                                  4-2

-------
                                      ^3.3 m  (10 ft   9 in.)
WALL
          TO EXIT  STACK
60
o
60 60 60
o o o
1 1 1
                                                              2.2 m
                                                             (7 ft
                                                              2-1/2 in.)




^.




1
~7
ELBOW
3.3 m
(10 ft 9 in.)

D *~
A
O O Or O
M M W
4 - 8.9-cm (3*5-1. D.)
CROSS SECTION
;
f*i



I
3.6m(12 ft) = 1.9 EDO



4 -0.6m (2 ft) FLOOR
t

          FLOW
(FROM BAGHOUSE  AND  I.D.  FAN)
  j*9.1m(30 ft)  =  3.5 EDO
  I                       I
  I                       I
                                                  A S02/N0x MONITOR

                                                  D OPACITY MONITOR
                                                  EDO = EQUIVALENT
                                                        DUCT DIAMETER
     Figure  4-2.  Boiler 4 baghouse outlet test location (no scale).
                                   4-3

-------
Initially, the collected samples were analyzed gravimetrically by Method 5  to
determine participate concentration and mass emission rates.   At the comple-
tion of the gravimetric analysis, the samples were prepared and analyzed for
Cr   according to procedures described in a draft EPA method entitled "Deter-
mination of Hexavalent Chromium Emissions From Stationary Sources."   A copy
of the draft method is contained in Appendix H of this report.
     Before sampling began, velocity, static pressure, molecular weight,
moisture content, and temperature were measured to define sampling rates and
nozzle sizes are described in EPA Reference Methods 1 through 4.*  The degree
of turbulent flow at each location also was assessed according to procedures
described in EPA Reference Method 2.*  In this method, the face opening of
the Type-S pitot tube is aligned perpendicularly to the duct cross-sectional
plane, designated "0-degree reference."  Null (zero) pitot readings  obtained
at a 0-degree reference indicate an acceptable flow condition at a given
point.
     If the pitot reading is not zero at 0-degree reference, the pitot is
rotated (up to 90 degrees  yaw angle) until a null reading is obtained. The
value of the rotation angle (yaw) is recorded for each point and averaged
across the duct.  Method 2 criteria stipulate that average angular rotations
greater than  10 degrees indicate turbulent (nonaxial) flow conditions in
the duct(s).  This procedure was used to check several traverse points at
each location.  In each case, null pitot readings were observed at the 0-
degree reference.  These data, together with the velocity and temperature
profiles established for each location, indicated acceptable flow patterns
that would enable the extraction of representative samples at each site.
 40 CFR 60, Appendix A, Reference Methods 1 through 4, July 1984.
                                     4-4

-------
     A total of 24 sampling points were used to traverse the cross-sectional
area of the duct(s) at each location.  At the baghouse outlet,  each point was
isokinetically sampled for 15 minutes, which yielded a total test time of 360
minutes.  At the inlet location, two different sampling approaches were used.
During Test PCI-1, each point was sampled for 15 minutes for a  total  test
time of 360 minutes.  An undersized sample nozzle diameter was  used to main-
tain a sample rate of less than 0.5 cfm to prevent overloading  of the filter
because of the heavy particulate loading.  For the remaining two tests, the
nozzle diameter was increased, which resulted in a sample rate  of approxi-
mately 0.8 cfm.  Each point was sampled for 7.5 minutes, which  yielded a
total test time of 180 minutes.  Although these sampling trains started and
stopped with the outlet trains, they sampled for 30 minutes every hour on the
hour for 6 hours to preclude overloading the sample filter.
     Only five of six traverse points per port were sampled at  the inlet.
Point No. 5, which exhibited a velocity pressure approximately  equal  to the
average velocity pressure in the duct, had to be sampled twice  in each port
because of the type and length of sampling probe used.  PEI used a 3.05-m
(10-ft) glass-lined probe to preclude possible biases in Cr   and total Cr
measurements that the use of a stainless-steel lined probe could cause.
Previous test experience has shown that the use of glass-lined  probes longer
than 3.05 m (10 ft) results in excessive breakage and subsequent leakage
problems.
     The test and analytical procedures used are described briefly here, and
detailed procedures are presented in Appendix D.
                                     4-5

-------
4.2.1  Velocity and Gas Temperature
     A Type-S pi tot tube and an inclined draft gauge manometer were used to
measure the gas velocity pressures at the test sites.  Velocity pressures
were measured at each sampling point across the duct to determine an average
value.  Measurements were taken in the manner prescribed in Reference Method
2 of the Federal Register.*  The temperature at each sampling point was
measured with a thermocouple and digital readout.
4.2.2  Molecular Weight
     Flue gas composition was determined in accordance with the basic proce-
dures described in Reference Method 3.*  Grab samples were collected prior to
the start of any sampling to establish baseline contents of oxygen, carbon
dioxide, and carbon monoxide.  Integrated bag samples were collected during
each test and were analyzed with an Orsat gas analyzer.  The gas composition
at each test site remained consistent throughout the test series.
4.2.3  Particu1ate/Cr+6 and Total Cr
     Particulate, Cr  , and total Cr samples were collected as specified in
EPA Reference Method 5.*  All tests were conducted isokinetically by regulat-
ing the sample flow rate relative to the gas velocity in the duct (as mea-
sured by the pitot tube and thermocouple attached to the sample).  The basic  '
sampling train consisted of a heated glass-lined probe, a heated 7.6-cm
(3-in.) diameter glass-fiber filter (Whatman Reeve Angel 934 AH), and a
series of five Greenburg-Smith impingers followed by a vacuum line, vacuum
gauge, leak-free vacuum pump, dry gas meter, thermometers, and a calibrated
orifice.
     For determination of particulate concentration, the nozzle, probe, and
filter holder portions were rinsed with acetone at the end of each applicable
 40 CFR 60, Appendix A, Reference Methods 2, 3, and 5, July 1984.
                                     4-6

-------
test.  The acetone rinse and participate 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.
     Upon completion of the gravimetric analysis, the sample fractions  were
prepared and analyzed for Cr   according to procedures recently developed by
EPA.  In summary, the samples were digested in an alkaline solution and
analyzed by the diphenylcarbazide colorimetric method.*  Selected samples
were then shipped to EPA, where total chromium content of the samples was
determined by NAA.
     The volume of water collected in the impinger section of the sampling
train(s) was measured at the end of each sample run to determine the moisture
content of the flue gas.  The contents of the impingers were transferred to a
polyethylene container.  The impingers and all connecting glassware, includ-
ing the back half of the filter holder, were rinsed with distilled water and
the rinse was added to the container.  The impinger contents from Run PCI-1
were then analyzed for Cr   and later for total chromium by NAA.  The remain-
ing samples are being held in case EPA wishes further analysis.

4.3  PARTICLE SIZE DISTRIBUTION
     Samples for particle-size distribution measurements were collected at
the baghouse inlet and outlet by an Andersen HGLI.  This in-stack impactor
consists of two single-jet impaction chambers followed by a third-stage
cyclone and a backup filter.  The sampled gas stream enters the system
 Test Methods for Evaluating Solid Waste.  U.S. Environmental  Protection
 Agency, SW-846, 2nd ed., July 1982.
                                     4-7

-------
through the Stage 1 acceleration jet.   Particles with sufficient inertia  are
impacted against the bottom of the Stage 1 impaction chamber.   Smaller par-
ticles flow with the gas stream and exit the impaction chamber through three
vent tubes.
     Stage 2 of the HGLI is simply a scaled-down version of Stage 1  in which
the jet nozzle diameter and the distance from jet exit to impaction  surface
have been designed for the proper Stage 2 cut-point.
     Stage 3 of the HGLI is a small cyclone of the Southern Research Insti-
tute design.  A high-efficiency glass-fiber filter removes all  particles
remaining in the gas stream downstream of the cyclone.
     The Andersen HGLI was used at the inlet because of expected heavy par-
ticulate concentration, which would overload a standard multistage impactor.
Although this impactor normally would not be used to extract samples from a
baghouse outlet where particulate concentrations are low, it was used here
because it contains no filter media (except the backup filter), which elim-
inates the need for filter blank corrections to Cr   and total  chromium.
     Three samples were collected at the baghouse inlet and four were col-
lected at the baghouse outlet.  The inlet samples were collected from a
single point in the duct that was representative of the average velocity  and
temperature.  These tests were run for 90 minutes.  At the baghouse  outlet,
samples were collected from two different sampling ports and points, each of
which represented the average gas velocity and temperature in the duct.  The
use of two sampling points was necessary to allow movement of the particu-
late/Cr   sampling train, which was run concurrently with the particle size
train.  Test No. PSO-1 was conducted for 7 hours, and Tests PSO-2 through -4
                                     4-8

-------
were conducted for 10 hours each.  Isokinetic sampling rates were set ini-
tially, and constant cut-point characteristics were maintained throughout the
sampling period.
     At the completion of each test, the impactor samples were recovered in
accordance with procedures described in the HGLI operations manual.
     Each recovered fraction was then subjected to a gravimetric analysis in
accordance with EPA Reference Method 5 criteria.  Size distribution curves
representing the total weight percent of particulate matter smaller than the
indicated aerodynamic particle diameter (in micrometers) were established for
each run.
     The three cut-points for each Andersen HGLI test were determined graphi-
cally from information supplied by the manufacturer.  All particle size
results are based on a particle density of 1 g/cm3.  Data reduction and
intermediate result calculations were performed by CIDRS programs with mois-
ture contents and gas composition data obtained from the particulate/Cr
tests.*
     Following the size distribution gravimetric analysis, individual stages
from Test PSI-2 (inlet) were analyzed for Cr   in an effort to characterize
the Cr   size distribution.  The Cr   analysis for each individual stage was
performed by the same procedures used in the analysis of the particulate/Cr+
samples (Subsection 4.2 and Appendix D).  Portions of each stage from this
run were retained for total chromium analysis by NAA.  Samples from individ-
ual stages of Runs PSO-1 through -3 (outlet) were composited and analyzed for
*Southern Research Institute.  A Computer-Based Cascade Impactor Data Reduc-
 tion System.  Prepared for U.S. Environmental Protection Agency under Con-
 tract No. 68-022-131.  March 1978.
                                     4-9

-------
Cr  .  The compositing of samples from individual  stages was necessary to
assure adequate sample weights for quantification  of Cr  .   Samples from Run
PSO-4 were retained for total chromium analysis by NAA.
     Besides the Andersen HGLI size distribution tests, two additional tests
were conducted at the baghouse outlet with a standard Andersen Mark III
multistage impactor.  Size distribution data from these runs were used to
validate the HGLI size distribution data.
4.4  PROCESS SAMPLES

     During the particulate/chromium tests, the following process samples
were collected:
          Coal
     0    Boiler bottom ash
     0    Baghouse hopper ash
     Grab samples of each test were collected every 60 to 90 minutes or four
to six times during a 6-hour test run.  The grab samples from each test were
composited so that one representative sample of each sample type per test was
available for analysis.  Solid samples were extracted and analyzed for Cr
in accordance with procedures similar to those used for the Cr   analysis of
the particulate samples.  The analyses of the boiler bottom ash and baghouse
hopper catch were relatively straightforward and no problems were encount-
ered.  Coal samples were "ashed" in a muffle furnace at 900C prior to their
analysis to eliminate interference from organic material in the coal sample.
When raw coal samples were extracted, a dark brown solution was generated
that could not be analyzed by the colorimetric Cr   procedure.  A weighed
quantity of raw coal was placed in a muffle furnace and heated to 900C in an
effort to eliminate the organic interferent.  The remaining coal "ash" was

                                     4-10

-------
then analyzed for Cr   content.   Composite process samples  were also  analyzed
for total Cr content.
4.5  ARSENIC
     Arsenic concentrations were measured by EPA Reference Method 108.*   All
tests were conducted isokinetically by regulating the sample flow rate to
correspond to the gas velocity in the duct (as measured by the pitot  tube and
thermocouple attached to the sample probe).   The basic sampling train con-
sisted of a heated glass-lined probe, a heated 7.6-cm (3-in.) diameter glass-
fiber filter (Whatman Reeve Angel 934 AH), and a series of five Greenburg-
Smith impingers followed by a vacuum line, vacuum gauge, leak-free vacuum
pump, dry gas meter, thermometers, and a calibrated orifice.
     For determination of arsenic concentrations, the nozzle, probe,  and
filter holder portions were rinsed with 0.1  N NaOH at the end of each appli-
cable test.
     The filter and solids contained in the  0.1 N NaOH rinse of the front
half of the sampling train were prepped, combined, and analyzed for arsenic
(by atomic absorption).
     The volume of water collected in the impinger section of the sampling
train was measured at the end of each sampling run to determine the moisture
content of the flue gas.  The contents of the impingers were transferred to a
polyethylene container.  The impingers and all connecting glassware (includ-
ing the back half of the filter holder) were rinsed with 0.1 N NaOH,  and the
rinse was added to the container.  The contents of the impingers and  0.1 N
NaOH rinse also were analyzed for arsenic by atomic absorption.
*
 40 CFR 61, Appendix B, Reference.Method 108, July 1984.
                                     4-11

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                                  SECTION 5
                             PROCESS DESCRIPTION

     The following source description and summary of process data were pre-
pared by Midwest Research Institute (MRI), the EPA New Source Performance
Standard (NSPS) contractor.  Personnel from MRI were on site during the test
program to monitor and record all  pertinent boiler and baghouse operational
data.
     During the period from March 18-21, 1985, source emission tests were
conducted on Boiler 4 at the Adolph Coors Company plant in Golden, Colorado.
The tests were conducted by a five-person crew, headed by Chuck Bruffey, from
PEI Associates.  Dennis Holzschuh of the Emission Measurement Branch was
present during the testing to observe emission testing procedures.  The
process was monitored by Dwight Atkinson from MRI.  Paul Adams of the Adolph
Coors Company coordinated testing with plant personnel.

5.1  PROCESS DESCRIPTION/SAMPLING PROGRAM
     Boiler 4 is a tangentially-fired, vertical, upright unit manufactured by
Combustion Engineering and installed in 1976.  It has a rated capacity of
91.1 megawatts (311 x 10  Btu/h) and can produce 113,000 kilograms of steam
per hour (250,000 pounds per hour).  It operates on a base-load basis at
approximately 80 percent of capacity, 24 hours per day, 7 days per week.
     Coal for Boiler 4 typically comes from a Coors-owned mine in Keenesburg,
Colorado.  It has a maximum sulfur content of 0.4 percent and a typical ash
content of 10 percent.
                                     5-1

-------
     Particulate emissions are controlled by a baghouse manufactured by
Wheelabrator-Frye.  Design and operating characteristics of the baghouse are
given in Table 5-1.
     Table 5-2 outlines the tests conducted on Boiler 4.  All tests were
conducted when the boiler was operating at approximately 80 percent of capac-
ity.

5.2  PROCESS CONDITIONS DURING TESTING
     All processes were operated normally during emission testing.  The fol-
lowing parameters were recorded every 15 minutes during testing:  feed water
flow, superheater temperature, drum pressure, economizer temperature, percent
excess oxygen, volumetric air flow to boiler, steam flow, steam temperature,
baghouse pressure drop, baghouse inlet gas temperature, SOp concentration, NO
concentration, stack gas opacity, mill amperage, mill exhaust temperature,
and coal feed rate.  The S0~ and NO concentrations were read from a Lear
Siegler Model SM 810.  The opacity monitor was a Lear Siegler Model RM-41.
Tables 5-3 through 5-6 present results of the above observations.
     Testing was halted twice during the four runs, both times during Run 2.
On the first occasion, the inlet and outlet Method 5 trains were stopped 30
minutes into the run due to a ruptured filter disk on the inlet train.  The
filter disk was replaced, and testing was resumed in 31 minutes.  On the
second occasion, a temporary outage by the local power company tripped
Boiler 4 and resulted in its being down for approximately 2 hours and 20
minutes.  Testing was resumed when normal operation was reestablished after a
total elapsed time of 3 hours and 12 minutes.
                                     5-2

-------
        TABLE  5-1.  .BAGHOUSE DESIGN AND OPERATING  CHARACTERISTICS

      Boiler No.                           4
      Baghouse manufacturer               Wheelabrator-Frye
      No.  of compartments                 8
      No.  of bags per compartment         180
      A1r-to-cloth ratio                  2.6:1
      Bag  size, ft x ft                   0.6 x 22
      Bag  material                        Woven glass3
      Cleaning method                     Reverse air/shake**
      Pressure drop, in. of water         4 to 8
^Coated with silicon graphite.
bOff-line  cleaning.  On-line cleaning by low pressure drop, 7.5 psig,
 pulse jet.
                                   5-3

-------
           TABLE 5-2.   SUMMARY  OF  TESTS  CONDUCTED  ON  BOILER  4.
                  ADOLPH  COORS  COMPANY,  GOLDEN,  COLORADOa

Sampling point
Baghouse Inlet
Baghouse outlet

Test type
Participate concentration
Particle size
Participate concentration
Particle size
Particle size

Test Method
EPA Method 5
Andersen HGLIb
EPA Method 5
Andersen HGLI
Andersen
Mark III
Number
per
run
1
1
1
2C
Outside observation
  point
Visible emissions
EPA Method 9
aTests consisted of four runs, one each day on 3/18, 3/19, 3/20, and
 3/21/  Method 5 samples on the fourth day were gathered for arsenic
 analyses, all other6samples to be analyzed for particulate, total
 chromium, chromium"1" , and cadmium.
bHGLI = heavy grain loading impactor.
^Conducted during day 4, March 21, only.
^Each observation period was 6 minutes in duration.  These data were
 collected to support transmissometer data.
~4C
Coal bin
Bottom ash hopper
Baghouse dust
hopper
Coal sample
Bottom ash
Fly ash
Grab
Grab
Grab
~6
-6
-6
                                     5-4

-------
                TABLE 5-3.   PROCESS DATA FOR RUN 1ADOLPH  COORS COMPANY, BOILER 4. MARCH  18.  1985
in
Time
8:45
9:25
9:25
9:40
9:55
10:10
10:25
10:40
10:55
11:00
11:10
11:25
11:40
11:55
12:10
12:18
12:25
12:40
12:55
1:10
1:25
1:40
1:55
Feed-
water
Dow
gpro
460
500
start
500
500
500
500
490
500
soot
500
480
480
500
485
Super
heater
temp..
F
807
803
outlet
803
802
805
803
805
805
blowing
797
809
804
799
804
finished soot
500
500
500
500
490
490
500
802
803
807
810
815
803
806
Alr-
Econo- flow to
Drum ml*er Percent boiler,
pres. temp., excess x 1.000
psl "F 07. X acfm
870
870
220
220
H5 and Andersen
870
875
867
870
870
870
started
870
870
870
875
875
blowing
875
870
875
870
870
870
870
220
225
220
220
220
220

220
220
218
218
212

210
212
212
212
215
215
215
1.9
1.7
and
1.9
2.3
2.1
2.1
2.1
2.2

2.3
2.2
2.1
2.2
2.2

2.1
2.2
2.6
2.8
2.8
2.0
1.9
118
118
Inlet M5
118
120
120
120
122
122

122
122
122
122
122

120
122
120
122
120
120
120
Steam
flow,
x 1.000
Ib/h
200
205

200
205
200
205
205
205

205
205
200
205
207

205
205
205
205
205
207
207
Steam
temp.,
F
827
825

825
825
825
825
825
825

820
825
830
820
825

825
825
830
830
830
825
825
Bag-
house
AP, In.
11,0
7.2
7.3

8.4
8.2
8.2
7.7
8.4
. 8.0

9.0
9.1
8.6
9.0
7.5

8.4
7.1
8.8
8.0
8.7
6.6
7.0
S07,
ppm
280
275

270
260
270
265
275
260

250
260
255
260
240

250
245
240
260
240
260
260
NO.
ppm
160
160

160
160
165
165
165
165

165
165
165
165
170

165
165
165
165
170
165
165
Opacity,
X
4
1

1.5
2
2
2.5
1.5
1

4
3
4
4
2

2.5
1
2
2
2.5
3
1
Bag-
house
Inlet
stack
gas
temp.,
F
290
290

290
290
290
290
285
290

290
290
285
285
285

280
280
285
280
285
280
280
Mill
current,
amps
A B
27
28

28
28
28
28
28
28

28
28
28
28
28

28
28
28
28
28
28
28
24
24

24
24
24
24
24
24

24
24
24
24
24

24
24
24
24
24
24
24
Mill Coal
exhaust feed rate,
temp., F x 1.000 Ib/h
A B A B
125
125

125
125
125
126
126
126

125
125
124
124
123

123
123
123
123
124
124
124
123
124

124
124
125
125
125
125

124
124
123
123
122

122
122
122
123
123
123
123
16
16.3

16.3
16.3
16.3
16.3
16.3
16.3

16.3
16.3
16.3
16.3
16.3

16.3
16.3
16.3
16.3
16.3
16.5
16.3
18
18.3

18.3
18.3
18.3
18.3
18.3
18.3

18.3
18.3
18.3
18.3
18.3

18.3
18.3
18.3
18.3
18.3
18.3
18.3
                                                                                                        (continued)

-------
                                            TABLE 5-3.    (continued)
dr.
Air-
Feed- Super [cono- flow to
water heater Drum mlzer Percent boiler.

Time
2:10
2:25
2:40
2:55
3:10
3:25
3:40
3:40
3:55
4:10
4:10
4:25
4:40
4:55
5:10
5:15
5:25
5:40
5:40
flow temp., pres. temp
gpm "F psl F
490 806 870 218
500 806 870 218
510 804 870 220
480 807 870 220
500 807 870 220
465 805 870 220
480 805 870 220
stop H5 Inlet and outlet
490 806 870 220
start Andersen on Inlet
500 803 870 222
490 804 865 220
500 803 875 222
500 805 875 222
490 801 870 225
outlet Andersen stopped -
490 805 870 225
. , excess x 1,000
07. X
1.9
1.7
1.8
2.0
1.8
1.8
1.8
(test ended)
1.9

1.9
1.8
1.7
1.7
2.6
test ended
2.5
acfm
120
120
120
120
120
120
120

120

122
120
120
120
120

122
Steam
flow
x 1.000
Ib/h
207
207
210
205
210
210
210

205

207
210
210
210
200

200
Steam
temp..
F
825
825
825
825
827
827
827

825

825
825
825
825
825

825
Bag-
house
*P, In
H70
7.5
8.0
6.8
7.2
7.6
7.3
7.0

 7.4

8.4
8.0
7.1
7.6
8.1

6.8

S07.
ppm
250
260
245
250
250
250
240

265

260
250
250
250
230

240

NO.
ppm
165
165
165
165
165
165
165

165

165
165
165
165
165

170

Bag-
house
Inlet
stack
gas
Mill
current,
Opacity, temp., amps
X





2
1

1

2
2
1
1
2

1
F
280
285
280
280
285
285
285

285

285
285
290
290
290

290
A
28
28
28
28
28
28
28

28

28
28
28
28
27

27
B
24
24
24
24
24
24
24

24

24
24
24
24
23

23
Mill Coal
exhaust feed rate.
temp. ,
A
124
124
124
124
124
124
124

124

124
124
125
124
126

126
F
B
123
123
123
123
123
123
124

124

124
124
124
124
125

125
x 1,000 Ib/h
A
16.3
16.3
16.3
16.3
16.3
16.3
16.3

16.3

16.5
16.5
16.5
16.5
15.3

15.3
B
18.3
18.3
18.3
18.3
18.3
18.3
18.3

18.3

18.3
18.3
18.3
18.3
18.3

18.0
Inlet Andersen stopped - test ended
490 807 870 222
2.4
120
200
828
7.2
230
170
1
290
27
23
126
125
15.3
18.0

-------
TABLE 5-4
            PROCESS DATA FOR RUN  2AOOLPH COORS COMPANY, BOILER  4,  MARCH 19, 1985
1
Time
7:15
7:15
7:30
7:45
8:00
8:10
8:15
o, 8:30
Li 8:40
8:45
9:00
9:11
9:15
9:30
9:45
10:00
10:15
10:30
10:45
11:00
11:15
11:25
Teed- Super
water heater
flow temp.,
gpm F
Drum
pres.
psl
Alr-
Econo- flow to Steam
ml/er Percent boiler, flow
temp., excess x 1.000 x 1,000
F 0,. X acfra ' Ib/h
Dag-
Steam house
temp., AP. In. SO,, NO,
f 11,0 ppm ppm
Bag-
house
Inlet
stack Mill
gas current.
Opacity, temp., amps
X 'F A B
Hill Coal
exhaust feed rate.
temp.. 'F x 1.000 Ib/h
A B A B
start Andersen outlet
490 807
500 795
485 801
470 808
890
870
865
865
220
222
222
220
2.1
3.5
3.6
2.7
120
120
118
118
200
180
180
195
830
820
820
828
7.1 260 170
8.0 260 170
7.6 240 170
7.0 265 170
1
1
2
1
290
290
290
290
27 23
26 22
26 23
27 23
126 124 15.3 18.' 3
128 126 14.3 17.3
127 125 14.8 17.3
126 125 15.8 18.3
start M5 Inlet and outlet
460 814
480 803
stop testing
460 808
480 806
870
865
(Inlet
870
860
220
220
2.4
2.4
and outlet MS)
220
220
2.4
2.5
122
118
due to
120
120
195
195
825
825
Inlet sampling train
202
198
828
830
8.7 255 170
7.8 255 180
failure (ruptured
7.0 260 170
8.3 250 170
2
2.5
filter
2
1.5
290
290
holder)
290
290
27 24
27 23
126 125 15.8 18.3
126 125 15.8 18.3
(outlet Andersen kept running)
27 23
27 23
127 125 15.8 18.3
126 125 15.8 18.3
restart Inlet and outlet M5
460 811
490 802
490 806
480 807
470 807
480 809
480 808
480 811
460 807
started soot
865
865
870
870
875
880
865
865
875
blowing
222
222
220
220
222
220
220
220
220

2.5
2.4
2.5
2.3
2.2
2.2
2.5
2.3
2.4

118
118
118
120
120
120
120
118
118

200
200
200
200
200
202
200
200
200

830
825
825
825
825
828
825
830
828

7.8 250 170
7.0 270 170
8.0 250 170
6.8 250 170
7.4 250 170
7.5 260 170
6.8 265 170
7.3 250 170
7.9 250 170

2
2
3
2
1.5
2
3
1.5
2

290
290
290
290
290
290
290
290
290

27 23
27 23
27 23
27 23
27 23
27 23
27 23
27 23
27 23

126 125 15.8 18.3
126 125 15.8 18.3
126 125 15.8 18.3
126 125 15.8 18.3
127 125 15.8 18.3
127 125 15.8 18.3
127 125 15.8 18.3
127 126 15.8 18.3
127 125 15.8 18.3

                                                                                        (continued)

-------
                                                TABLE  5-4.  (continued)
00
Time
11:30
11:30
11:45
12:00
12:15
12:30
12:40
12:45
1:00
1:00
1:15
1:18
3:40
3:55
4:15
4:30
4:30
4:45
5:00
5:15
5:30
5:39
5:45
Feed- Super Econo-
water heater Drum ml7er
flow temp., prcs. temp..
gpm "F psl F
Air-
flow to Steam
Percent boiler, flow
excess x 1,000 x 1.000
0,, t acfm Ib/h
Steam
temp.,
F
Bag-
house
Inlet
Bag- stack
house gas
M1, In. S0;, NO, Opacity, temp.,
11,0 ppm ppm X *F
Mill
current,
amps
A B
Mill Coal
exhaust feed rate,
temp.. *F x 1.000 Ib/h
A B A B
Inlet Andersen begins
480
480
460
'l70
480
804 870
806 870
803 870
807 868
802 868
220
218
218
208
205
2.1
2.3
2.3
2.2
2.5
122
120
118
120
120
205
200
200
195
195
822
825
830
830
825
7.1 265 170 5 290
8.8 265 170 6.5 290
8.4 260 170 5 290
8.0 250 170 3 285
. 7.1 250 170 3 285
27
27
27
27
27
23
24
23
23
23
127 125
126 125
125 124
125 123
124 123
15.8 18.3
15.8 18.3
15.8 18.3
15.8 18.3
15.8 18.3
slopped soot blowing
470
804 865
205
2.6
118
200
825
8.2 265 170 2 285
27
23
124 122
15.8 18.3
Inlet Andersen ended
500
490
Boiler
Boiler
Boiler
490
resume
485
470
480
480
475
799 865
805 870
208
218
2.9
3.4
down due to power outage at
120
122
Public
200
200
820
825
6.8 265 170 1 285
7.3 260 170 2 285
27
27
23
23
124 123
124 123
15.8 18.3
15.8 18.3
Service Plant - Coma rx he Plant. All testing stopped.
back up on gas/coal
running on al 1
802 870
test
804 865
805 870
805 870
801 870
807 870
coal
218

215
212
212
215
215

2.7

2.7
2.7
2.5
2.6
2.6

122

210
120
120
122
122

195

198
195
200
195
200

825

825
825
825
825
825

6.9 not functioning properly 285

7.3 not functioning properly 285
8.0 not functioning properly 285
7.6 not functioning properly 285
8.7 not functioning properly 285
7.5 not functioning properly 285

27

27
27
27
27
27

24

23
23
23
23
23

121 120

122 121
123 121
123 122
123 122
123 122

15.8 18.0

15.8 18.2
15.8 18.2
15.8 18.2
15.8 18.1
15.8 18.1
Inlet M5 ended
470
811 870
215
2.5
120
195
825
7.1 not functioning properly 285
27
23
124 123
15.8 18.1
                                                                                                              (continued)

-------
                                              TABLE 5-4*.   (continued)




Time
6:00
6:02
6:15
6:30
6:30

Teed- Super
waler heater
flow temp..
gpro T
4/5 803


Drum
pres.
psl
870

Econo-
mizer
temp..
F
218


Percent
excess
07. X
2.7
Air-
flow to
bol ler.
x 1.000
acfm
120

Steam
flow
x 1.000
Ib/h
198


Steam
temp. (
F
825
Bag-
house
Inlet
Bag- stack
house gas
AP, In. SO,, MO, Opacity, temp..
H,0 ppm ppm X F
8.1 not functioning properly 285

Mill
current.
amps
A B
27 23

Hill
exhaust
temp..
A
124
outlet H5 ended :
475 809
480 804
865
870
218
218
2.9
2.7
122
122
195
200
825
825
7.7 not functioning properly 285
7.1 not functioning properly 285
27 23
27 23
124
124

Coal
feed rate.
"F x 1,000 Ib/h
BAB
123 15.8 18.1
i
123 15.B 18.1
123 15.8 18.1
outlet Andersen ended
en
i
to

-------
               TABLE 5-5,  PROCESS DATA FOR RUN 3ADOLPH COORS COMPANY, BOILER 4. MARCH 20, 1985
CJ1
I
Time
7:53
8:00
8:15
8:20
8:30
8:45
9:00
9:15
9:30
9:45
10:00
10:15
10:30
10:45
11:00
11:05
11:15
11:30
11:45
12:00
12:15
12:30
12:35
Feed- Super Fcono-
water heater Drum ml/er
flow temp., pres. temp.,
gpm F psl F
start Andersen outlet
460 819 870 220
500 820 870 220
start M5 outlet/Inlet
470 820 870 222
470 823 870 225
490 822 870 225
480 821 870 225
470 818 870 228
490 821 870 228
490 819 870 228
480 822 870 228
490 817 865 228
490 821 875 230
460 827 870 230
start Andersen on Inlet
500 815 870 230
470 823 870 228
490 819 865 228
460 823 870 230
490 821 875 232
480 814 865 232
Inlet Andersen ended
Percent
excess
0,, X
2.7
2.8

3.0
3.1
3.2
3.1
2.9
3.1
3.2
3.1
3.1
2.9
2.8

2.9
2.9
2.8
3.1
3.0
3.3

Air-
flow to Steam
boiler, flow
xl.OOO xl.OOO
acfm Ib/h
124
122

120
124
124
124
124
124
124
124
124
124
124

124
124
124
124
124
124

205
205

200
202
202
200
200
200
200
200
200
205
205

205
200
202
200
200
198

Steam
temp.,
F
840
825

840
840
838
838
835
840
835
835
835
835
840

830
840
840
840
840
835

Bag-
house
AP, In.
H?0
7.5
8.5

8.9
. 8.5
7.3
8.4
7.2
8.3
7.2
7.7
8.4
7.5
8.2

7.5
9.1
7.4
8.5
7.4
8.5

so,.
ppm
260
260

240
250
260
260
250
255
250
230
260
270
260

260
235
260
260
250
255

NO.
ppm
170
170

170
170
170
170
170
170
170
175
170
170
175

170
170
170
180
170
170

Opacity.
1
3

1
2
1
2
1
3
1.5
3
2.5
4
3

2
2.5
2
0
2
0

Bag-
house
Inlet
stack
gas
temp..
F
285
285

290
285
290
290
285
290
290
290
290
290
290

290
290
290
290
295
290

Mill
current,
amps
A B
27
27

27
27
27
27
27
27
27
27
27
27
27

27
27
27
27
27
27

24
24

24
24
24
24
24
24
24
24
24
24
24

24
24
24
24
24
24

Mill Coal
exhaust feed rate,
temp., *F xl.OOO Ib/h
A B A B
122
124

124
124
125
125
125
125
125
126
126
126
126

126
126
126
126
126
126

122
123

123
123
124
124
124
124
124
124
124
124
124

125
125
125
125
125
125

15.8
15.8

15.8
15.8
15.8
15.8
15.8
15.8
16.0
16.0
16.0
16.0
16.0

16.0
16.0
16.0
16.0
16.0
16.0

18.'3
18.3

18.3
18.4
18.4
18.4
18.4
18.4
18.4
18.4
18.4
18.4
18.4

18.4
18.4
18.4
18.4
18.4
18.4


-------
TABLE 5-5.  (continued)
Time
12:45

12:50
1:00
1:15
1:30
1:45
2:00
2:00
2:05
2:15
2:30
2:35
2:45
3:00
3:15
3:30
3:45
4:00
4:15
4:30
4:45
5:00
5:15
Feed- Super Econo-
watcr heater Drum mlzer
flow temp., pres. temp.,
gpm -F psl *F
470 820 870

start soot blowing
490 825 870
480 826 865
470 818 865
480 818 875
finished soot blowing
490 818 870
Inlet MS ended
440 823 880
500 818 870
outlet H5 ended
490 818 865
470 818 875
470 818 870
490 816 870
475 818 870
480 819 875
490 816 870
475 816 870
470 821 870
480 813 870
450 824 870
232


230
230
228
222

222

222
222

228
228
225
225
228
225
225
228
230
228
222
Percent
excess
0,, 
3.0


3.0
2.9
2.7
2.8

3.1

3.2
3.9

4.0
3.2
3.3
3.1
3.2
3.0
3.2
3.0
3.1
3.2
3.2
Air-
flow to Steam
boiler, flow
x 1.000 x 1.000
acfm Ib/h
124


124
124
124
124

124

124
124

124
124
125
125
124
124
124
124
124
124
124
205


200
200
205
205

200

205
200

200
202
198
202
198
200
200
202
200
200
200
Steam
temp.,
F
840


840
840
835
835

835

835
835

835
835
835
835
835
840
840
835
840
830
840
Bag-
house
P, In.
H,0
7.4


8.7
9.1
8.5
8.5

8.6

8.6
8.8

8.4
8.0
8.2
7.7
8.5
8.5
7.8
7.2
8.4
8.0
7.4
SO,,
ppm
265


260
255
250
250

235

250
250

245
250
250
250
245
255
240
250
250
220
250
Bag-
house
Inlet
stack
gas
NO, Opacity, temp..
ppm % 'f
170


170
170
170
170

170

170
170

190
175
175
170
180
170
170
170
170
170
170
2


4
4.5
4.5
2.5

6

3
6

5
2
3
3
3
3
3
4
4
3
4
285


290
295
290
285

285

285
290

285
285
290
285
285
285
290
290
290
285
285
Hill
current,
amps
A B
27


27
27
27
27

27

27
27

27
27
27
28
28
28
28
28
27
27
28
24


24
24
24
24

24

24
24

24
24
23
24
24
24
24
24
24
24
24
Mill Coal
exhaust feed rate.
terap., *F x 1,000 Ib/h
A B A B
127


126
125
125
124

124

124
124

125
124
124
124
125
125
124
124
124
124
124
125


125
124
124
123

123

122
123

123
123
123
122
123
123
122
122
123
123
123
16.0


16.0
16.0
16.0
16.0

16.0

16.0
16.0

16.0
16.0
16.0
16.0
16.0
16.0
16.0
16.0
16.0
16.0
16.1
18.4
I

18.4
18.4
18.4
18.4

18.4

18.4
18.4

18.4
18.4
18.4
18.4
18.4
18.4
18.4
18.4
18.4
18.4
18.4
                                                             (continued)

-------
                                          TABLE 5-5.   (continued)




Time
5:30

5:45

Feed-
'/ater
flow
gpra
470

490

Super
healer
temp..
F
8?I

817


Drum
pres.
ps
865

870

Econo-
wlzer
temp. ,
F
222

222


Percent
excess
0,. X
2.9

3.0
Air-
flow to
boiler.
x 1.000
acfm
124

124

Steam
flow
x 1.000
Ib/h
200

200


Steam
temp..
F
835

835

Bag-
house
ftP. In.
H,0
8.3

7.1



SO,.
ppm
245

260



NO.
ppm
170

170



Opacity,
X
3

3
Bag-
house
Inlet
stack
gas
temp..
F
285

285

Mill
current ,
amps
A B
28 24

28 24

Hill Coal
exhaust feed rate.
temp.. 'F xl.OOO Ib/h
A B A B
124 123 16.1 18.4
I
125 123 16.2 18.4
en
i

-------
              TABLE  5-6.   PROCESS DATA FOR RUN 4ADOLPH COORS COMPANY,  BOILER 4.  MARCH 21. 1985
en
i
Time
8:15
8:15
8:30
8:45
8:50
9:00
9:15
9:30
9:45
10:00
10:15
10:30
10:45
11:00
11:15
11:30
11:45
12:00
12:00
12:15
12:20
12:30
Feed-
water
flow
gpm
begin
530
500
460
begin
470
500
470
460
480
450
490
480
460
480
480
460
460
Super
heater
temp..
F
Drum
pres.
psl
Econo-
mizer
temp.,
F
Andersen outlet Note:
808
806
819
outlet
820
815
817
821
822
823
814
818
821
816
814
814
815
end Inlet and
430
begin
460
823
870
870
870
220
220
218
Percent
excess
0,. X
Air-
flow to Steam Bag-
boiler, flow Steam house
x 1,000 xl.OOO temp., aP, In. SO,,
acfm Ib/h *F H,0 ppm
: A Mill running
3.0
3.0
2.8
120
119
120
Keenesburg coal and B
200
200
200
830
830
835
7.3
7.0
7.3
NO.
ppm
Bag-
house
Inlet
stack Mill
gas current.
Opacity, temp., amps
X F A B
Mill running Colowyo coal (see
230
220
250
170
170
170
2
2
2
290
295
290
Mill Coal
exhaust feed rate.
temp.. 'F xl.OOO Ib/h
A B A B
Attachments 1 and 2).
25
25
25
22
22
22
127 136
127 136
128 136
13.3 16.3
13.5 16.3
13.5 16.3
and Inlet MS
865
870
865
870
870
870
865
870
870
870
870
865
870
outlet
870
215
218
218
218
218
218
218
218
220
220
220
220
222
M5
225
3.1
2.9
3.0
3.0
2.6
2.6
2.7
2.7
2.7
2.8
2.9
3.1
3.0
120
120
120
120
118
118
120
120
120
120
120
120
120
200
200
198
195
200
198
200
200
200
200
200
195
195
essentially all
3.2
120
195
840
835
835
835
835
835
835
835
835
835
835
835
835
Colowyo
840
8.3
6.9
7.3
.8.2
7.0
8.6
7.1
7.0
8.7
8.2
8.2
7.9
7.0
coal
7.0
225
260
250
245
250
250
255
260
260
260
245
245
240
burned
235
170
170
170
170
170
170
170
170
170
170
170
170
170

170
3
2.5
2
2.5
2
3
3
2
3.5
3
3
3
2

1
280
285
290
290
295
295
290
295
295
300
295
295
295

295
25
25
25
25
25
25
25
26
26
26
26
26
26

26
22
22
22
22
22
22
23
23
23
23
23
23
23

23
12B 134
128 134
128 133
128 132
128 131
128 130
128 130
127 130
127 129
128 129
127 129
128 129
127 127

127 127
13.5 16.3
13.8 16.3
13.8 16.5
13.8 16.4
14.3 16.7
14.3 16.8
14.3 16.8
14.3 16.8
14.3 16.8
14.4 17.0
14.4 17.0
14.4 17.0
14.4 17.0

14.5 17.0
Andersen on Inlet
813
870
228
3.2
122
192
840
7.2
270
170
3
295
26
23
128 128
14.5 17.0
                                                                                                       (continued)

-------
                                              TABLE 5-6  .   (continued)
en
i
Feed-
water
flow
Time qpm
12:30
12:45
:00
:1S
:30
:45
:48
:50
2:00
2:15
2:15 -
2:30
2:45
3:00
3:15
3:30
3:45
4:00
4:15
4:30
4:35 -
4:45
soot
460
450
480
480
440
soot
Super
heater
temp.,
*F
blowing
810
808
818
816
814
blowing
end Andersen
480
460
3:15
460
450
460
450
480
450
470
460
460
5:05
470
8158
812
first
816
817
813
818
817
818
816
819
813
second
816
Alr-
Econo- flow to Steam
Drum mlzer Percent boiler, flow
pres. temp., excess x 1,000 x 1,000
psl 'F 0,, < acfm Ib/h
Steam
temp.,
F
Bag-
house
aP, In.
HjO
SO,.
ppm
NO,
ppm
Opacity,
X
Bag-
house
Inlet
stack
gas
tewp..
F
Mill
current,
amps
A B
Mill Coal
exhaust feed rate,
temp.. "F x 1.000 Ib/h
A B A B
begins
865
870
875
865
870
ends
222
222
222
220
220

3.4
3.0
3.2
3.2
3.8

122
122
124
124
124

187
195
200
195
198

830
830
840
835
835

7.8
8.5
9.2
8.6
8.7

260
250
225
250
240

170
170
170
175
170

3
5
8
7
8

295
295
295
295
285

26
26
27
27
27

23
23
23
23
23

127
126
125
125
124

127
125
124
123
123

14.5
15.2
15.2
15.2
15.2

1710
17.6
17.6
17.6
17.6

on Inlet
865
870
Mark
870
870
870
865
870
875
870
870
865
Mark
870
220
222
3-Andersen
222
220
220
220
222
225
225
225
228
3-Andersen
228
4.5
3.5
on outlet
3.5
3.5
3.2
3.3
3.2
3.1
3.3
3.2
3.3
122
124

122
124
124
124
124
125
125
123
123
195
198

198
195
200
195
195
200
195
195
195
835
830

835
835
835
835
835
835
835
835
835
. 8.3
8.2

8.0
8.0
7.2
8.2
8.3
8.4
8.3
8.2
7.1
245
250

240
240
220
215
250
220
245
240
260
190
180

190
180
190
170
170
170
170
170
170
5
2

6
5
2
3
1
2
1
2.5
1
285
280

280
280
280
280
285
285
285
285
285
27
27

27
27
27
27
27
27
27
27
27
23
23

23
23
23
23
23
23
23
23
23
124
124

124
124
124
124
124
125
125
125
125
123
122

122
122
122
122
122
122
122
123
123
15.2
15.5

15.2
15.3
15.6
15.5
15.5
15.5
15.4
15.4
15.4
17.6
17.6

17.6
17.6
17.6
17.6
17.6
17.6
17.6
17.6
17.6
on outlet
3.3
123
197
835
8.1
250
170
2.5
285
27
23
125
123
15.4
17.6
                                                                                                              (continued)

-------
                                            TABLE 5-6,   (continued)
Feed- Super
water heater

Time
5:00

5:15
5:30
5:45
6:00
6:15
flow
gpm
460

470
480
450
450
end
temp..
F
820

815
816
819
815
Andersen
Drum
pres.
ps
870

870
865
870
870
Econo-
mizer
temp.,
F
228

230
225
228
230

Percent
excess
0?, X
3.2

3.3
3.3
3.3
3.4
Air-
flow to
boiler.
x 1.000
acfra
123

123
124
124
123
Steam
flow
x 1,000
Ib/h
198

198
195
195
195

Steam
temp..
F
835

835
835
835
835
Bag-
house
aP, In.
H,0
7.2

8.2
8.2
8.2
8.0


so,.
ppn
240

235
235
260
250


NO.
ppn
180

170
170
175
180


Opacity,
X
1

3
2
2
2
Bag-
house
Inlet
stack
gas
temp..
F
285

285
285
285
285
Hill

current .
amps
A
27

27
27
27
27

B
23

23
23
23
23
Mill

Coal
exhaust feed rate.
temp..
A
125

125
125
126
126
F
B
123

123
123
124
125
xl.OOO Ib/h
A B
15.4 17.6
i
15.4 17.6
15.4 17.6
15.4 17.6
15.5 17.6
on outlet
en
i

-------
     During Runs 1 through 3, Boiler 4 operated entirely on coal mined from
Coors1 Kennesburg Mine.  During the first 4 hours of Run 4, coal supplied to
Boiler 4 via the B mill was from a different mine operated by Colowyo Coal
Company.  A mill coal for the entire run and B mill coal for the remainder of
the run came from the Keenesburg Mine.  Samples of the coal from the two
mills were segregated during Run 4.  Figure 5-1 presents results of coal
analytical data performed on March 15, 1985.

5.3  CONCLUSIONS
     Personnel at the Adolph Coors Company were very cooperative.  Boiler 4
and its baghouse operated normally during emission testing.
                                     5-16

-------
            Haz*n Hrch, Inc.
            4601 Indiana SI.  Golden. Goto. 60403
            Tel: (303) 279-4501  Telex 45-860
REPORT OF ANALYSIS
Coors Energy Company
Nancy Hawkins
Poit Office Box 467
Golden Colorado  80402-0467
                                DATE
                                HRI PROJECT
                                HRI SERIES NO.
                                DATE RECD
                                CUST P.O.I
                               March  15 1985
                               009-18
                               29716-1
                               3/7/85
                               CE-0160V-K
                                SAMPLE IDENTIFICATION:
                                Keenesburg
                                2/25-3/3/85
REPORTING
BASIS >

PROXIMATE (I)

  MOISTURE
  ASH
  VOLATILE
  FIXED C

  TOTAL
AS RECD
 29.38
 11.33
                  DRY
 0.00
16.04
                                  EQH
                                                AIR DRY
18.10
13.14
SULFUR
BTU/LB
(IMF BTU/LB
MAF BTU/LB
AIR DRY LOSS (Z)
  0.41
  7572
 0.59
10722
12984
12771
 0.48
 8781
                         13.77
ULTIMATE 
  MOISTURE
  CARBON
  HYDROGEN
  NITROGEN
  SULFUR
  ASH
  OXYGEN*

    TOTAL
  CHLORINE**
FORMS OF SULFUR (AS S,Z)

  SULFATE
  PYRITIC
  ORGANIC
  TOTAL
                  0.41
                                  0.59
                                HGI        t        I MOISTURE
                                AS REC'D SP.6R. (G/CC)
                                FREE SMELLING INDEX

                                REPORT PREPARED BY:
NATER SOLUBLE ALKALIES  (!)

  NA20
  K20
                                OUDIUPH. FIFE/'/
                                COAL LABORATORt"1lANA6ER
*.OXYGEN BY DIFFERENCE.
 NOT USUALLY REPORTED AS PART OF THE ULTIMATE ANALYSIS
                  Figure 5-1.   Coal  analytical  data.
                                     5-17

-------
                            COLOUYO COAL COMPANY
                                      PLEASE ADDRESS ALL CORRESPONDENCE TO:

                                         QUALITY CONTROL LABORATORY
                                         COLOUYO COAL COMPANY
                                         5731  STATE HIGHUAY  13
                                         MEEKER, COLORADO  81641
                                         (303)  824-4451
TO: COORS ENERGY COMPANY
    P.O. BOX 467
    GOLDEN, COLORADO 80402
      ATTN: NANCY HAWKINS
                          DATE:  30685

                     SAMPLE DESCRIPTION:
                        COORS - STOKER
                           16
                         8  CARS
                       SHIPPED  304S5
                              DATE SAMPLED:    30485     BY:   LOSHBAUGH

                                        RECEIVED BY LAB:   3058S
LAB SAMPLE  NUMBER:  850305.01
                              SHORT PROXIMATE ANALYSIS

                        AS RECEIVED        DRY BASIS     DRY ASH FREE
XMOISTURE
XASH
XSULFUR
BTU/LB

16 .(,
3. 03
.46
11015.
OTHER
XXXXXXXXX
3.62
.55
13154 .

XXXXXXXXXXXX
XXXXXXXXXXXX
XXXXXXXXXXXX
13646 .

          AIR DRY LOSS  9.885C
          POUNDS S02 PER MILLION BTU
                    .84
 DISTRIBUTION:
                      DON PINGS
                      CHIEF CHEMIST BY: LL

1.CUSTOMER    S.TRAFFIC     3.ACCOUNTING
        4.PRODUCTION  5.ENGINEERING 6.LABORATORY
                          Figure 5-1  (continued)
                                    5-18

-------