United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EMB Report 85-CHM-9
May 1985
Air
Chromium Screening
Study Test Report
Municipal Incinerator
Tuscaloosa,
Alabama
-------
EMISSION TEST REPORT
METHOD DEVELOPMENT AND TESTING
FOR CHROMIUM
Municipal Refuse Incinerator
Tuscaloosa Energy Recovery
Tuscaloosa, Alabama
ESED Project No. 85/2
EMB No. 85-CHM-9
by
PEI Associates, Inc.
11499 Chester Road
P.O. Box 46100
Cincinnati, Ohio 45246-0100
Contract No. 68-02-3849
Work Assignment Nos. 14, 18, and 20
PN 3615-14, 3615-18, 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
January 1986
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CONTENTS
Figures iv
Tables v
Quality Assurance Element Finder vi
Acknowledgment vii
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 2-3
2.3 Particle size distribution test results 2-10
2.4 Process sample analytical results 2-16
• 2.5 Visible emission observations 2-17
2.6 Nitrogen oxide test results 2-17
2.7 Hi-volume sample 2-18
2.8 Total Chromium Test Results 2-20
3. Quality Assurance 3-1
4. Sampling Locations and Test Procedures 4-1
4.1 Sampling locations 4-1
4.2 Particulate, hexavalent chromium, and total chromium
sample extraction and analysis 4-1
4.3 Particle size distribution 4-7
4.4 Process samples 4-8
4.5 Arsenic 4-9
5. Process Operation 5-1
5.1 Process description 5-1
5.2 Air pollution control system 5-3
5.3 Process conditions during testing 5-3
5.4 Summary of process operations during testing 5-13
(continued)
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CONTENTS (continued)
Appendices
A Computer Printouts and Example Calculations A-l
B Field Data Sheets B-l
C Laboratory Data C-l
D Sampling and Analytical Procedures D-l
E Calibration Procedures and Results E-l
F Quality Assurance Summary F-l
G Project Participants and Sampling Log G-l
H Draft Test Method for Hexavalent Chromium Emissions From
Stationary Sources H-l
I Draft Protocol for Determination of Total Chromium Emissions
From Stationary Sources 1-1
0 Process Data 0-1
IV
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FIGURES
Number Page
2-1 Particle Size Distribution Tests PSI-2, -3, and -4 at
the ESP Inlet 2-12
2-2 Particle Size Distribution Tests PSO-1, -2, and -3 at
the ESP Outlet 2-13
2-3 Hi-Volume Sampler 2-19
4-1 ESP Inlet Sampling Location 4-2
4-2 ESP Outlet Sampling Location 4-3
5-1 Cross Section of Typical Modular Incinerator 5-2
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TABLES
Number Page
2-1 Sample and Analytical Parameters 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 Summary of 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 Process Sample Analytical Results 2-16
2-7 Nitrogen Oxide Emissions Data 2-17
2-8 Summary of Total Chromium Emission Data 2-20
3-1 Field Equipment Calibration 3-3
3-2 Example Filter and Reagent Blank Analysis for Particulate 3-4
3-3 Linear Regression Data Spectrophotometer Calibration 3-4
3-4 QC Data for Total Chromium Analysis by NAA 3-7
5-1 Tuscaloosa Energy Recovery Incinerator ESP Design
Specifications 5-4
5-2 Summary of Tests Conducted on the Tuscaloosa Energy
Recovery Incinerator, Tuscaloosa, Alabama 5-5
5-3 Process Data for Run l--Tuscaloosa Energy Recovery
May 21, 1985 5-7
5-4 Process Data for Run 2--Tuscaloosa Energy Recovery
May 22, 1985 . 5-9
5-5 Process Data for Run 3--Tuscaloosa Energy Recover
May 23, 1985 5-11
VI
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QUALITY ASSURANCE ELEMENT FINDER
(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
Location
Section Page
m
1-1
Appendix F
Section 3
Appendix D
Section 4
Appendix C
Appendix E
Section 3
Appendix D
Section 4
Appendix A
Appendix F
Section 3
Appendix F
Section 3
Appendix F
Section 3
Appendix F
F-2
D-l
C-l
E-l
D-l
A-l
F-3
F-5
F-3
F-12
Appendix F F-4
Appendix F F-ll
Appendix F F-12
VII
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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. Ron Myers, Industrial Studies Branch (ISB) project engineer and
Mr. Steve Schliesser, 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, David Osterhout, and Thomas Wagner.
vm
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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 Consumat Municipal Refuse Incinerators
operated by Tuscaloosa Energy Recovery in Tuscaloosa, Alabama. All testing
took place during the period of May 21 through 23, 1985.
Triplicate tests were conducted simultaneously at the inlet and outlet
of an electrostatic precipitator (ESP) used to control particulate emissions
from the combined gas streams of four modular incinerators to determine the
concentrations and mass emission rates of particulate matter, hexavalent
chromium (Cr ), and total chromium (Cr). In addition, particle size dis-
*
tribution tests were conducted during the particulate/chromium tests at each
1-1
-------
location, and process samples (ESP hopper ash) were collected during each
test day and analyzed for Cr and total chromium. EPA representatives
obtained opacity (visible emission) data during each particulate/chromium
test and also collected samples for determination of nitrogen oxides (NO )
A
concentration.
Prior to the commencement of the particulate/chromium tests, a single
test was conducted simultaneously at each location to determine the concen-
tration 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 analyt-
ical procedures; 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; Appendix H
describes the draft test method for hexavalent chromium from stationary
sources; and Appendix I presents the draft protocol for determining total
chromium emissions from stationary sources.
It should be noted that the U.S. EPA performed the total chromium anal-
ysis of selected 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 ESP inlet and outlet test locations. Samples
were collected over a 5-hour period by isokinetic, cross-sectional traverse
techniques.
A total of six samples (three inlet and three outlet) 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
40 CFR 60, Appendix A, Reference Method 5, July 1984.
2-1
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TABLE 2-1. SAMPLE AND ANALYTICAL PARAMETERS
Run No.
PCI-1
PCO-1
PCI-2
PCO-2
PCI-3
PCO-3
PSO-1
PSI-2
PSO-2
PSI-3
PSO-3
PSI-4
AI-1
AO-1
PCI(l-3)
PCO(l-3)
AI-1
AO-1
Date (1985)
and time (24-h)
5/21 - 1247-1823
5/21 - 1246-1735
5/22 - 1254-1602
5/22 - 0910-1520
5/23 - 0841-1427
5/23 - 0846-1140
5/21 - 1530-1730
5/22 - 1238-1438
5/22 - 1208-1508
5/23 - 1158-1359
5/23 - 1040-1340
5/23 - 1512-1642
5/21 - 0836-1127
5/21 - 0836-1128
5/21-23
Test or
sample type
Participate
Cr 6
Total Cr
Particle
size
distribution
Arsenic
Process
samples
ESP hopper
ash
Sampling
location
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Inlet
Outlet
Sample parameters
Particulate
Methods
1-5
X
X
X
X
X
X
_
-
-
_
-
-
.
-
-
Particle
size dis-
tribution
-
-
-
_
-
X
X
X
X
X
X
_
-
-
Cr+6
X
X
X
X
X
X
_
-
-
_
-
-
_
-
-
Total
Cr
X
X
X
X
X
X
_
_
-
_
-
-
_
-
-
Arsenic
Method 108
-
-
-
_
-
_
_
-
_
-
-
X
X
.
Analytical parameters
Partic-
ulate
Method 5
X
X
X
X
X
X
_
_
-
_
-
-
_
-
_
Particle
size dis-
tribution
-
_
-
_
-
X
X
X
X
X
X
_
-
_
Cr+6
X
X
-
X
-
_
.
-
_
-
-
_
-
X
Total
Cr
X
X
X
X
X
X
.
_
-
_
X
X
_
-
X
Arsenic
Method
108
-
-
-
_
-
_
.
-
.
-
-
X
X
_
ro
ro
-------
entail extraction of the sample fractions (probe residue and filter particu-
late) with an alkaline solution followed by the diphenylcarbazide colorimet-
ric method.* Samples of ESP hopper ash collected during each day of testing
were also analyzed for Cr using this same basic analytical technique.
Particle size distribution measurements were made at each site during
the particulate/Cr tests with an Andersen Mark III in-stack impactor. Four
samples were collected at the ESP inlet and three were collected at the ESP
outlet. Particle size fractions were analyzed gravimetrically, and size
distribution curves were developed for each site.
Prior to the particulate/Cr and particle size tests, a single test was
conducted simultaneously at each location according to procedures described
in EPA Reference Method 108.** Method 108 provides inorganic arsenic concen-
tration. This test was conducted for 2 hours at each location by isokinetic,
cross-sectional traverse techniques. Total arsenic content was then deter-
mined by atomic absorption (AA) analysis.
As indicated in Table 2-1, the selected emission and process samples
were analyzed for total chromium (Cr). This analysis was performed by the
U.S. EPA using NAA.
The following subsections detail the results of the sampling program.
2.2 PARTICIPATE, HEXAVALENT CHROMIUM, AND ARSENIC TEST RESULTS
Simultaneous Method 5* tests were conducted at the ESP inlet and outlet
test locations. Samples from both sites were analyzed for particulate and
inlet samples were analyzed for Cr concentrations, and the resulting data
*Test Methods for Evaluating Solid Waste. U.S. EPA SW-846, 2nd ed., July
1982.
**
40 CFR 61, Appendix B, Reference Method 108, July 1984.
2-3
-------
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.
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.
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 [20°C and 760 mmHg (68°F 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 121°C (250°F). Hexavalent chromium concentrations are expressed in
micrograms per gram (yg/g) and micrograms per dry normal cubic meter (yg/dNm3),
where applicable. Mass emission rates are reported in kilograms per hour and
pounds per hour.
As reported in Table 2-2, sample volumes were fairly consistent, ranging
from 1.65 to 2.41 dNm3 for the inlet trains and from 4.14 to 5.82 dNm3 for
the outlet trains. Sampling times varied from the desired time of 300 min-
utes for a variety of reasons. Test Runs PCI-1 and PCO-1 were abbreviated to
243 and 226.6 minutes, respectively, due to adverse weather conditions. As a
result, complete cross-sectional traverses were not completed at either
location. Three of twenty total points at the inlet and four of twenty
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-2A
PCO-2
PC I -3
PCO-3
PCI (In
PCO (On
AI-1
(Arseni
AO-1
Date
(1985)
5/21
5/21
5/22
5/22
5/23
5/23
let) a\
tlet) <
5/21
c)
5/21
i
Sampl ing
duration,
min
243
226.6
150
300
300
150
erage
verage
120
120
Sample
volume
dNnv*
1.654
4.141
2.204
5.822
2.413
4.750
2.090
4.904
1.728
2.233
dscf
58.409
146.217
77.840
205.594
85.217
167.715
73.822
173.175
61.013
78.856
Isokinetic
sampling
rate, *
104.9
96.4
99.2
97.0
100.4
96.3
101.5
96.3
103.7
97.8
Volumetric flow rate8
Actual
mVmin
2152
2685
2498
2772
2557
3050
2402
2834
2300
2642
acfm
76,000
94,800
88,200
97,900
90,300
107,700
84,800
100,100
81,200
93,300
Standard
dNmVmin
915
1204
1065
1270
1085
1325
1022
1271
997
1209
dscfm
32,300
42,500
37,600
44,900
38,300
46,800
36,100
44,900
35,200
42,700
Temperature
"C
306
279
326
287
336
313
323
293
297
273
r
583
534
619
549
637
595
613
559
567
524
Moisture
content.
15.6
15.7
12.4
-d
11.6
13.2
13.2
13.4
15.4
14.9
Gas compo-
sition.b %
°z
9.2
10.5
10.8
11.8
10.9
11.7
10.3
11.3
9.2
10.5
C6,
9.0
7.5
8.6
6.6
8.6
7.0
8.7
7.0
9.0
7.5
Gas
velocity
mps
14.1
22.1
16.3
22.8
16.7
25.1
15.7
23.3
15.0
21.7
fps
46.1
72.4
53.5
74.8
54.7
82.3
51.4
76.4
49.2
71.2
Static
pressure,
1n.HzO
-2.4
-0.60
-2.4
-0.60
-2.4
-0.60
-2.4
-0.60
-2.4
-0.60
cn
aStandard conditions: 20"C (68°F), 760 ramHg (29.94 in.Hg) and zero percent noisture.
bGas composition as determined from integrated bag samples collected during each test. Analysis performed with an Orsat gas analyzer.
cHeasured flue gas velocity In meters per second and feet per second.
Moisture not determined; broken silica gel Impinger. Inlet value used in calculations.
-------
TABLE 2-3. SUMMARY OF PARTICULATE AND HEXAVALENT CHROMIUM EMISSIONS DATA
Run
No.
PCI-1
PCO-1
PC 1-2
PCO-2
PC I -3
PCO-3
Date
(1985)
5/21
5/21
5/22
5/22
5/23
5/23
Filterable concentration3
Total
filterable
weight, mg
297.1
314.9
264.9
520.0
323.3
397.1
Participate
mg/dNm3
179.6
76.0
120.1
89.2
133.9
83.5
gr/dscf
0.078
0.033
0.052
0.039
0.058
0.036
Cr (blank corrected)
ug/g
<1.7d
<1.7d
<1.7
Total Cr+6
1n sample, ug
<0.4
<0.4
<0.4
ug/dNm3
<0.24
<0.18
<0.17
Mass emission rate
Participate
kg/h
9.9
5.5
7.7
6.8
8.7
6.7
Ib/h
21.7
12.1
16.9
15.0
19.2
14.7
Cr*6
kg/h Ib/h
<0.013 <0.029
<0.012 <0.025
<0.011 <0.024
Collection.
efficiency, %
Particulate
49
3
23
C/b
-
-
-
Particulate
concentration
in gr/dscf
corrected
to 12% C02
0.104
0.053
0.073
0.071
0.081
0.062
ro
01
Standard conditions: 20°C (68°F), 760 mmHg (29.94 in.Hg) and zero percent moisture.
Inlet concentration - Outlet concentration
Collection efficiency:
Correction factor:
C
Inlet concentration
x 100 based on Inlet and outlet concentrations corrected to 12% CO,.
L12
12C
HUT
where C.. = concentration corrected to 12% CO^
C = concentration measured by Method 5
%CO., = as measured by Method 3
Note: A detection limit of 1.7 ug/g was established for these samples based on an approximate particulate weight of 0.3 grams using 50 ml total
volume.
-------
traverse points at the outlet were not sampled. Sample results were calcu-
lated using the total abbreviated test time, number of points sampled, and
the metered volume.
Particulate stratification, which could cause large biases in particu-
late measurement as a result of an incomplete sample traverse, was not a
significant factor because of the generally consistent gas flow pattern at
the sampling locations and the size of the particles (see Subsection 2.3).
Although the results from these runs could be suspect, the overall data
comparability would suggest the particulate results are representative of
source conditions. Between-run data variability is primarily a process and
control equipment related phenomenon (see Section 5).
Run PCI-2 was found to have an excessive leak rate at the port change
and was therefore repeated, but at a higher sampling rate and for 156 min-
utes.
Generally, the inlet sampling rates were kept lower than those at the
outlet in order to prevent the filter from plugging. A cyclone was used
during Run PCI-1; however, no loose particulate was collected and it was
eliminated for subsequent tests.
Isokinetic sampling rates ranged between 99 and 105 percent for the
inlet tests and between 96 and 97 percent for the outlet tests, all of which
are within the acceptable range of 90 to 110 percent.
Volumetric gas flow rates at the ESP inlet ranged from 2152 to 2557
m3/min (76,000 to 90,300 acfm) and averaged 2402 m3/min (84,800 acfm) for the
three particulate/Cr tests. The average volumetric flow at standard condi-
tions was 1022 dNm3/min (36,100 dscfm). Flue gas temperatures ranged from
306° to 336°C (583° to 637°F) and averaged 323°C (613°F). The moisture
2-7
-------
content of the gas stream averaged 13.2 percent, and the average oxygen ((L)
and carbon dioxide (CCL) contents were 10.3 and 8.7 percent, respectively.
Arsenic sample and flue gas data reported in Table 2-2 are comparable to
i C
data associated with the particulate/Cr tests.
As shown in Table 2-3, inlet participate concentrations ranged from
120.1 to 179.6 mg/dNm3 (0.052 to 0.078 gr/dscf) and averaged 144.5 mg/dNm3
(0.063 gr/dscf). The average mass emission rate for the three tests was 8.8
kg/h (19.3 Ib/h).
The inlet hexavalent chromium concentration was less than 1.7 ug/g,
which was determined to be the analytical detection limit for these samples.
The total quantity of Cr per sample was less than 0.4 yg.
At the ESP outlet, volumetric gas flow rates ranged from 2685 to 3050
m3/min (94,800 to 107,700 acfm) and averaged 2834 m3/min (100,100 acfm). The
average gas flow rate at standard conditions was 1271 dNm3/min (44,900 dscfm).
Flue gas temperatures ranged from 279° to 313°C (534° to 595°F) and averaged
293°C (559°F). The moisture content of the gas stream averaged 13.4 percent,
and the average 0^ and CQ^ contents were 11.3 and 7.0 percent, respectively.
Outlet particulate concentrations ranged between 76.0 and 89.2 mg/dNm3
(0.033 and 0.039 gr/dscf) and averaged 82.9 mg/dNm3 (0.036 gr/dscf). The
average mass emission rate for the three tests was 6.3 kg/h (13.9 Ib/h). The
outlet particulate concentrations corrected to 12 percent COp averaged 0.062
gr/dscf. Based on the inlet Cr analytical results, no attempt was made to
analyze the outlet samples for Cr .
The particulate removal efficiency of the ESP was 49 percent for Test 1,
3 percent for Test 2, and 23 percent for Test 3 and averaged 25 percent based
on the average inlet and outlet particulate concentrations corrected to 12
percent COp.
2-8
-------
Two major problems were encountered during the particulate/Cr tests.
First, a thunderstorm forced the abbreviation of Run 1 after about four
hours. Second, during Run 2 at the inlet, an excessive leak rate was found
during the port change. The inlet run was voided and repeated. The repeat
test was conducted at a higher sampling rate and for half of the scheduled
time of 5 hours.
An analysis of the hexavalent chromium content of the ESP hopper fly ash
obtained during the April 1985 pretest survey indicated Cr levels at or
below the analytical detection limit for solid samples, or 0.1 yg/g.
Because the concentration of hexavalent chromium in these solid samples
was 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. Therefore, solid samples are desirable at these levels since there
is no need to cut the sample filter and blank-correct for background Cr
levels. Filters and/or thimbles require larger amounts of extraction solu-
tion to cover the volume of material being extracted. This physical require-
ment increases the analytical detection limit, as evidenced by the 1.7-yg/g
detection limit established by analysis of the ESP inlet samples. No loose
particulate was collected and the inlet filters were extracted as described
in the analytical method.
Table 2-4 summarizes the arsenic emissions data obtained at this source.
*U.S. EPA SW846, 2nd ed., July 1982.
2-9
-------
The inlet sample showed a total arsenic weight of 153.8 yg or 89.0
yg/dNm3 compared with 60.0 yg (27.1 yg/dNm3) for the outlet sample. This
single test indicated an arsenic collection efficiency of more than 69.5 per-
cent.
TABLE 2-4. SUMMARY OF ARSENIC EMISSIONS DATA
Run No.
AI-1
AO-1
Concentration
Date
(1985)
5/21
5/21
Sampling
location
Inlet
Outlet
TotaK
arsenic sample
weight, yg
153.8
60.9
yg/dNm3
89.0
27.3
mg/dNm3
0.089
0.027
Arsenic
collection
efficiency, %
£69
2.3 PARTICLE SIZE DISTRIBUTION TEST RESULTS
At each site an Andersen Mark III impactor was used to measure particle
size distribution during each particulate/Cr test. This in-stack impactor
consists of eight glass fiber filter impaction stages followed by a glass
fiber backup filter. A total of three samples were collected at a single
point of average velocity and temperature in each duct. Test times ranged
from 90 to 120 minutes at the inlet and 120 to 180 minutes at the outlet. An
initial test was conducted at the inlet using an Andersen HGLI, but the
results were voided due to insufficient particulate collection.
Each particle size test was conducted according to the procedures de-
scribed in the Mark III operations manuals. Isokinetic sampling rates were
set initially, and constant cut-point characteristics were maintained through-
out 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. This criterion was
2-10
-------
met in test each. Isokinetic sampling rates ranged from 82 to 96 percent for
the inlet tests and 82 to 103 percent for the outlet tests.
Cumulative size distribution data points representing the total weight
of particulate matter smaller than the indicated aerodynamic particle diam-
eter [in micrometers (ym)] were established for each test location. The cut-
points for each test were calculated by computer programs contained in "A
Computer-Based Cascade Impactor Data Reduction System"* (CIDRS) developed for
EPA by Southern Research Institute (SRI). All particle size results are
based on a particle density of 1 g/cm3. Data reduction for the particle size
runs was performed by computer programming with moisture, molecular weight,
and temperature data obtained from the particulate/Cr tests. The Mark III
data reduction calculations are presented in Appendix A of this report.
• Figures 2-1 and 2-2 present the size distribution plot for the inlet and
outlet particle size distribution tests. Table 2-5 presents a comparison of
particulate concentrations obtained from the particle size tests with those
obtained by Method 5 tests.
Generally, the particle size distribution results indicate that most of
the particulate is less than 2.5 ym at both the inlet and outlet sites and
that the size distributions at both sites are very similar.
For the three inlet runs (PSI-2 through -4), the size distribution curve
showed that about 89 percent by weight of the particles had a nominal diam-
eter of 1.0 pm or less. The calculated average particulate concentration for
these runs was 166.6 mg/dNm3 (0.073 gr/dscf) compared with a three-test
Method 5 average of 144.5 mg/dNm3 (0.063 gr/dscf). This indicates about a 13
*
Southern Research Institute. A Computer-Based Cascade Impactor Data Reduc-
tion System. Prepared for U.S. EPA under Contract No. 68-022-131, March
1978.
2-11
-------
ro
ro
10.0
PARTICLE SIZE, micrometers
100
Fiaure 2-1. Particle size distribution tests PSI-2, -3, and -4
at the ESP inlet.
-------
U-n
ro
-»
10.0
PARTICLE SIZE, micrometers
100
Figure 2-2. Particle size distribution tests PSO-1, -2, and -3
at the ESP outlet.
-------
TABLE 2-5. COMPARISON OF PARTICIPATE CONCENTRATIONS AS MEASURED BY
EPA METHOD 5 VERSUS PARTICLE SIZE DISTRIBUTION IMPACTORS
Run No.
PCI-1
PSI-2
PCI-2
PS I -3
PCI-3
PS I -4
PSO-1
PCO-1
PSO-2
PCO-2
PSO-3
PCO-3
Test location
ESP inlet
ESP outlet
Sample type
Method 5 - Particulate
Particle size - Mark III
Method 5 - Particulate
Particle size - Mark III
Method 5 - Particulate
Particle size - Mark III
Particle size - Mark III
Method 5 - Particulate
Particle size - Mark III
Method 5 - Particulate
Particle size - Mark III
Method 5 - Particulate
Particulate concentration
mg/dNm3
179.6
125.8
120.1
164.1
133.9
209.8
66.6
76.0
85.3
89.2
92.4
83.5
gr/dscf
0.078
0.055
0.052
0.072
0.058
0.092
0.029
0.033
0.037
0.039
0.040
0.036
2-14
-------
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
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 size distribution curves for the first two outlet tests (PSO-1 and
-2) showed that about 87 percent by weight of the particles had a nominal
diameter of 1.0 ym or less. The third outlet test varied somewhat from the
first two tests. The size distribution curve for the third test (PSO-3)
showed that about 76 percent by weight of the particles had a nominal diam-
eter of 1.0-pm or less.
The average calculated particulate concentration for these runs was 81.4
mg/dNm3 (0.035 gr/dscf) compared with a three-test Method 5 average of 82.9
mg/dNm3 (0.036 gr/dscf). This indicates about a 2 percent difference between
the two measurements.
Both the inlet and outlet results are considered representative of
particle size distribution in the gas stream at the time of testing. The
data consistency and comparability to the average Method 5 results substanti-
ate this conclusion.
The data are also consistent with general incinerator operation. The
primary chamber of the incinerator operates in a substoichiometric condition
where refuse loaded into the chamber is partially oxidized. Combustible
gases and particulate generated in the primary chamber flow into the second-
ary chamber where combustion is completed under excess air conditions at
Procedures Manual for Inhalable Particulate Samplers Operation, prepared by
Southern Research Institute for EPA, Contract No. 68-02-3118, November 1979.
2-15
-------
temperatures of approximately 1150°C (2100°F). Under normal conditions, only
very fine participate and condensible gases would be expected to pass from
the secondary chamber. The similarity of inlet and outlet size distribution
data is a function of the ESP used to control emissions. Most of the fine
particulate (<2.5 ym) passes through the control device.
No attempt was made to characterize Cr size distribution due to the
low particulate concentrations at both sampling locations and the nondetect-
able levels of Cr in the inlet samples.
2.4 PROCESS SAMPLE ANALYTICAL RESULTS
Table 2-6 summarizes Cr analytical results from the ESP hopper samples
collected during each day of testing. Grab samples were collected periodi-
cally during the testing period. Samples were composited into a single,
representative sample for each day of testing. 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.
TABLE 2-6. PROCESS SAMPLE ANALYTICAL RESULTS
Sample type
ESP fly ash
5/21
5/22
5/23
Labora-
tory ID
EL566
EL567
EL568a
Particu-
late weight
analyzed, g
10.0079
10.0540
10.0068
10.0136
Total
Cr+6, yg
2.81
1.13
1.43
1.28
Cr concen-
tration, yg/g
0.28
0.11
0.14
0.13
Duplicate analyses.
Note: Detection limit = 0.1 yg/g.
2-16
-------
The average total Cr content of the ESP hopper ash samples was 1.8 yg,
and concentrations ranged between 0.11 and 0.28 yg/g. These levels are
essentially at the analytical detection limit.
2.5 VISIBLE EMISSION OBSERVATIONS
Unofficial visible emission observations were made by an EPA representa-
tive during each particulate/Cr test. Opacity readings were generally less
than 5 percent with brief excursions to 10 and 20 percent during the second
day of testing. These excursions correlated to ESP operational problems as
noted by the calculated collection efficiency of 3 percent for the second
test day. Raw data sheets are contained in Appendix B of this report.
2.6 NITROGEN OXIDE TEST RESULTS
• Nitrogen oxide (NO ) testing was conducted by EMB personnel during the
/\
particulate/Cr testing. Sample collection and analysis procedures followed
those described in EPA Reference Method 7.* These data are summarized in
Table 2-7. Nitrogen oxide concentrations ranged from 90 to 217 ppm and
averaged 162 ppm during the test series.
TABLE 2-7. NITROGEN OXIDE EMISSIONS DATA
NOX
Run No.
TMI-1 through -8
TMI-9, -14b and
TMI-16 through -18
TMI-19 through -29
Particulate/
Cr+6 Run No.
PCI-1, PCO-1
PCI-2, PCO-2
PCI-3, PCO-3
Date
(1985)
5/21
5/22
5/23
Concentration, ppma
High
217
178
178
Low
162
90
137
Average
188
145
154
Data as reported by U.S. EPA.
3Run No. TMI-15 was not detectable and was therefore deemed invalid.
2
40 CFR 60, Appendix A, Reference Method 7, July 1984.'
2-17
-------
2.7 HI-VOLUME SAMPLE
As instructed by EPA, PEI attempted to collect sufficiently large quan-
tities of particulate at the ESP outlet so that Cr and other metals of
interest could be quantified. A hi-volume ambient air sample pump and filter
were used as shown in Figure 2-3. A single sample run was attempted during
the last test day. However, the pump motor overheated about 3i hours into
the test and sampling was terminated.
No attempt was made to analyze this sample based on the analytical
results for Cr from the inlet and process samples.
2.8 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
isotopes produced in the sample matrix by irradiation with thermal neutrons
from a nuclear reactor. Typically, the sample matrix plus appropriate stan-
dards 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 irradia-
tion 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-1 through -3 were submitted for
analysis. In addition, inlet particle size Run PSI-4 and outlet particle
size Run PSO-3 were submitted for analysis by individual stage cut point.
Process samples (ESP hopper fly ash) were also analyzed for total Cr content.
2-18
-------
ro
i
MANOMETER
STACK WALL
ICE BATH H RECIRCULATION
Figure 2-3. Hi-volume sampler.
-------
TABLE 2-8. SUMMARY OF TOTAL Cr EMISSION DATA
ro
ro
o
Run
No.
PCI-1
PC I -2
PC I -3
PCO-1
PCO-2
PCO-3
PSI-4
PSO-3
1
2
3
Sample type
and location
Filterable participate
ESP inlet
Filterable participate
ESP inlet
Filterable particulate
ESP inlet
Filterable particulate
ESP outlet
Filterable particulate
ESP outlet
Filterable particulate
ESP outlet
Particle size ESP inlet
Stage 0
Stage 1
Stage 2
Stage 3
Stage 4
Stage 5
Stage 6
Stage 7
Backup
Particle size ESP outlet
Stage 0
Stage 1
Stage 2
Stage 3
Stage 4
Stage 5
Stage 6
Stage 7
Backup
ESP fly ash
ESP fly ash
ESP fly ash
Total3
particulate
collected,
9
0.2971
0.2649
0.3278
0.3149
0.5200
0.3971
0.0068
0.0001
0.0002
0.0000
0.0007
0.0024
0.0028
0.0063
0.0902
0.0139
0.0011
0.0009
0.0006
0.0009
0.0007
0.0014
0.0037
0.0567
_
-
-
Particulate
sample weight
analyzed by
NAA, g
0.2971
0.2649
0.3278
0.3149
0.5200
0.3971
0.0068
0.0001
0.0002
0.0000
0.0007
0.0024
0.0028
0.0063
0.0902
0.0139
0.0011
0.0009
0.0006
0.0009
0.0007
0.0014
0.0037
0.0567
0.1039
0.1254
0.1144
Total Crc
results by
NAA, ug
52.1
50.0
67.8
47.1
142.9
58.1
9.95
7.79
9.36
6.72
9.61
8.59
8.28
10.56
14.12
20.29
8.62
8.98
9.26
7.39
6.85
9.60
10.67
14.19
45.7
89.5
60.6
Total Crd
concen-
tration
by NAA,
ug/g
175.4
188.8
206.8
149.6
274.8
146.3
f
f
f
f
f
f
f
f
f
801.4
f
f
f
f
f
f
f
f
439.8
713.7
529.7
Total Cre
content
of sample,
"9
52.1
50.0
67.8
47.1
142.9
58.1
f
f
f
f
f
f
f
f
f
11.14
f
f
f
f
f
f
f
f
_
-
-
Total Cr
concentration,
ug/dNm3 _
31.5
22.7
28.1
11.4
24.5
12.2
f
f
f
f
f
f
f
f
f
12.88
f
f
f
f
f
f
f
f
_
-
-
Total Cr mass
emission rate,
kg/h
0.0017
0.0015
0.0018
0.0008
0.0019
0.0010
Total particulate (acetone rinse residue and filter) collected during sample run.
ug Cr for filter/acetone blank). Particle-size data are uncor-
Particulate weight analyzed by NAA.
c Total Cr results by NAA. Run Nos. PCI and PCO are blank corrected values
rected. (=8 ug Cr for filter stage blank.)
Total Cr(C) divided by particulate weight analyzed by NAA(b).
Total Cr concentration (ug/g) multiplied by total particulate weight collected(a).
Assumed tn bo below the detection limit since sample values are less than two times the stnadard deviation nf the blank values.
-------
The total Cr content of the inlet samples on a yg/g basis ranged between
175.4 and 206.8 yg/g. Total Cr concentrations on a yg/dNm basis ranged
3
between 22.7 and 31.5 yg/dNm with corresponding mass emission rates ranging
between 0.0015 kg/h (0.0033 Ib/h) and 0.0018 kg/h (0.0040 Ib/h).
The total Cr content of the outlet samples on a yg/g basis ranged be-
tween 146.3 and 274.8 yg/g. The total Cr concentration on a yg/dNm basis
3
ranged between 11.4 and 24.5 yg/dNm with corresponding mass emission rates
of 0.0008 kg/h (0.0018 Ib/h) and 0.0019 kg/h (0.0042 Ib/h), respectively.
All inlet and outlet total Cr data have been corrected for a filter/acetone
Cr blank level of 21 yg, which is reasonable considering the levels of Cr
detected in these samples.
Total Cr in the ESP fly ash samples ranged from 439.8 yg/g to 713.7
yg/g. The data were determined from samples obtained during each test.
Particle size samples from each location were analyzed by individual
stages in an attempt to characterize total Cr by size fraction. As reported
in Table 2-8, the total Cr content of individually-loaded stages ranged from
6.7 to 14.1 yg for the inlet sample, and 6.9 to 20.3 yg for the outlet sam-
ple. Filter blank Cr levels ranged from 6.3 to 14 yg and averaged about 8 yg
per filter for a set of eight filters (see Section 3). Because the filter
blank levels of total Cr are similar to measured Cr values on each stage and
the sample values are less than two times the standard deviation of the blank
values, no reasonable conclusions can be drawn regarding total Cr size distri-
bution. The uncorrected data reported in Table 2-8 indicate that some Cr is
present in the sample fractions of Stage 7 and the backup filter, which
represent particle sizes of less than 2 ym.
2-21
-------
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: 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 ESP hopper catch w$s obtained during the April
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 could be collected.
0 Calibration of all field sampling equipment.
0 Checks of train configuration and calculations.
3-1
-------
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, field audits were 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.
Emission and process samples were analyzed in two separate batches.
Table 3-3 summarizes the linear regression data of the spectrophotometer
calibration for the two days.
3-2
-------
TABLE 3-1. FIELD EQUIPMENT CALIBRATION
Equipment
Meter box
Pi tot tube
Digital indicator
Stack thermocou-
ple
Orsat analyzer
Impinger
thermocouple
Balance
Barometer
Dry gas
thermometer
Probe nozzle
ID
No.
FB-3
FB-8
FB-11
FB-12
020
516
220
262
139
206
141
1-1
1-5
Hettler
No. 743985
227
FB-3
FB-8
FB-11
FB-12
2-120
4-101
5-108
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
Call per
Allowable
error
AH P iO.15
(Y ±0.5% V post-test)
Cp +0.01
+0.5%
±1.5*
(±2% saturated)
±0.5%
±2°F
±0.5 g
±0.10 in.Hg
(0.20 post-test)
±5°F
On ±0.004 In.
Actual
error
AHP: -0.02; Y: -0.007%
AHQ: -0.06; Y: -0.010%
6H0: -0.04; Y: -0.014%
AH0: 0.0; Y: .0.017%
-
-0.4%
+0.4%
+0.2%
+0.3%
-0.4* (CO,)
0.0% (02)
+ 1°F
+ 1°F
0.0 g
+0.02 In.Hg
In: -2°F; Out: -2°F
In: -4°F: Out: -3°F
In: -1°F; Out: -4°F
In: -1°F; Out: 0°F
0.000 in.
0.000 in.
0.000 in.
0.002 in.
0.002 in.
0.001 in.
0.001 in.
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
X
X
X
Comments
Y = 0.029; Audit AH9 0.08
Y = 0.019; Audit AHP 0.01
Y = 0.014; Audit AHP 0.01
Not performed
(Field audit results)
Visually inspected on site
Visually inspected on site
Field audit results: 0.2*
Field audit results: 0.3*
Audit value
C02 and Or * 5.2%
Inlet
Inlet
Inlet
Outlet
Outlet
Inlet
Outlet
CO
CO
-------
TABLE 3-2. EXAMPLE FILTER AND REAGENT BLANK
ANALYSIS FOR PARTICULATE
Sample type and
filter number
Participate - 8510139
Reeve Angel 934 AH
Acetone blank3
Original tare
weight, mg
363.3
102,545.1
Blank
weight, mg
363.8
102,547.1
Blank
value
0.5 mg
0.013 mg/gb
188 ml evaporated and desiccated before weighing.
'Exceeds blank value limitations (0.01 mg/g used in calculations).
TABLE 3-3. LINEAR REGRESSION DATA SPECTROPHOTOMETER CALIBRATION
Sample
description
Process,
duplicates,
plus spike
Inlet and
blank
Date
(1985)
6/5
6/11
Cr+6
standard
concen-
tration,
yg/ml
0.0
0.1
0.2
0.3
0.4
0.5
0.0
0.1
0.2
0.3
0.4
0.5
Absorb-
ance
0.000
0.130
0.262
0.390
0.522
0.656
0.000
0.130
0.262
0.386
0.513
0.636
Y-Intercept
-0.0008
0.0039
Slope
1.3097
1.2666
Correlation
coefficient
0.99998
0.99986
3-4
-------
The analytical detection limit established for the two days was less
than 0.004 yg/ml for an absorbance of 0.005 above the linear regression
intercept. This detection limit corresponds to the same total micrograms of
chromium VI as in previous reports. The established detection limit for the
inlet particulate samples was 1.7 yg/g because of the small amount of par-
ticulate collected on these filters.
Because the concentrations 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
to cover the volume of material being extracted. This physical requirement
increased the detection limit.
The filter/acetone blank contained 0.87 yg of Cr . This value was used
to correct the inlet particulate values. Duplicate and spike analyses were
performed on the ESP fly ash sample taken on May 23, 1985. The results of
the duplicate analyses were 0.14 and 0.13 pg/g, which is just above the
detection limit of 0.1 ug/g for process samples having a large quantity of
loose particulate available for analysis and requiring no reagent or filter
blank correction. The spike recovery was 103 percent.
One problem was encountered with the analysis of the inlet particulate
samples. After the alkaline extract was filtered, the samples were slightly
cloudy (white opaqueness). This interfered with the colorimetric determina-
tion, and the absorbance of an aliquot not containing the color reagent was
subtracted from the absorbance of the sample to correct for this interferent.
*U.S. EPA SW846, 2nd ed., July 1982.
3-5
-------
Arsenic samples were analyzed on June 4, 1985. The least-squares fit of
the data to quadratic equations for the graphite furnace atomic absorption
calibration gave a correlation coefficient of 0.9990. The results of blank
analyses were 9.60 yg for the filter and <0.006 mg/liter (detection limit)
for the rinse and impinger samples. The filter blank value is typical for
glass fiber filters. Duplicate analysis of the impinger fraction for the
outlet runs gave 6.22 and 5.27 yg, respectively. Spike recoveries were 95.4,
92.1, 101.9, and 0 percent for the filter, rinse, impingers, and bomb frac-
tions, respectively.
Table 3-4 presents QC data relative to the total Cr analysis by NAA.
Duplicate, audit, and blank data are presented.
As discussed in Section 2.8, a filter/acetone Cr blank level of 21 yg is
reported. Total Cr results for the inlet and outlet particulate emission
samples were corrected for blank levels since the measured Cr content ranged
between two and four times the blank values. Particle size Cr data were not
corrected for filter blank Cr levels since measured Cr values were less than
two times the blank Cr values for the majority of the stages analyzed. This
seems prudent considering the low levels of total Cr observed in the samples.
3-6
-------
TABLE 3-4. QC DATA FOR TOTAL CHROMIUM BY NAA
Lab No.
ESP fly ash - Run 1
EL 566
ESP fly ash - Run 3
EL 568
NB5 fly ash
Alkaline extract
Type I H20
Method 5 filter/
acetone
Particle size filter -
Stage 0
Particle size filter -
Stage 1
Particle size filter -
Stage 2
Particle size filter -
Stage 3
Particle size filter -
Stage 4
Particle size filter -
Stage 5
Particle size filter -
Stage 6
Particle size filter -
Stage 7
Particles size filter -
Backup
Sample type
Duplicate analysis
Duplicate analysis
Audit
Blank
Blank
Blank
Blank
Blank
Blank
Blank
Blank
Blank
Blank
Blank
Blank
Results total Cr,
ug (except as noted)
45.7; 44.0
60.6; 36.6
201 yg (196 ug/g
accepted)
Not detected
Not detected
21.0
9.40
7.78
14.09
6.67
6.75
. 5.76
6.36
8.11
9.68
3-7
-------
SECTION 4
SAMPLING LOCATIONS AND TEST PROCEDURES
This section describes the sampling sites and the test methods used to
characterize participate, chromium, and arsenic emissions.
4.1 SAMPLING LOCATIONS
Flue gas samples were extracted simultaneously from the inlet duct and
outlet stack of the ESP. Figures 4-1 and 4-2 show the sampling locations.
At the ESP inlet, two 10.2-cm (4-in.) i.d. sampling ports were located
approximately 5.9 duct diameters downstream and 1.7 duct diameters upstream
from the nearest flow disturbances in the 1.8-m (5-ft 11-in.) i.d. duct. At
the ESP outlet, two 10.2-cm (4-in.) i.d. sampling ports were located approxi-
mately 5.7 stack diameters downstream and 2.1 stack diameters upstream from
the nearest flow disturbances in the 1.6-m (5-ft 3i-in.) i.d. stack. Both
locations conformed to the minimum requirements for sampling port locations
specified in EPA Reference Method 1.*
4.2 PARTICIPATE AND HEXAVALENT CHROMIUM SAMPLE EXTRACTION AND ANALYSIS
Flue gas samples were simultaneously collected at the ESP 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 1984.
4-1
-------
*35 ft
10 ft
FLOW
DUCT
TO ESP
I
ro
~ ^.
t
HEAT RECOVERY
BOILER EXHAUST
JS25 ft
UNIT NO. 1
II
TWO 10.2 cm (4 in.) i.d.
SAMPLING PORTS
CROSS-SECTION
(LOOKING TOWARDS ESP)
»1.8 m (5 ft 11 in.) i.d.
WALL
GRADE
Figure 4-1. ESP inlet sampling location.
-------
«3.4 m(ll ft)
PORTS'
/J
1
^9.1 m (
«5.5 m
\
^
Q
1
^^^^
30 ft)
18 ft)
'
en
n
l-l
NO SAMPLE
X
LOCATION
r
i
i
I
i
•~~
—
—
—
^^^m
^^•B
MH^
^^^
••^H
^^^m
+
1
J
SAMPLING PLATFORM
CROSS-SECTION
i S*" " """"X.
/ 31/4 in .Yi
V 1
TWO 10.2 cm (4 in.)
SAMPLING PORTS
^ FLUE GAS FROM
I.D. FAN
RRAOF
Figure 4-2. ESP outlet sampling location.
4-3
-------
Initially, the collected samples were analyzed gravimetrically by Method
5 to determine particulate concentration and mass emission rates. At the
completion of the gravimetric analysis, the samples were prepared and ana-
lyzed for Cr according to procedures described in a draft EPA method en-
titled "Determination 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 20 sampling points were used to traverse the cross-sectional
areas of the ducts. At each site, each point was to be sampled for 15 min-
utes, thus yielding a total test time of 300 minutes. However, the first
test was abbreviated due to adverse weather, and the second inlet test was
also abbreviated due to an excessive leak rate following the first half of
the test. This second test (PSI-2) was run at a higher sampling rate for 150
minutes.
The testing and analytical procedures used are described briefly here,
and detailed procedures are presented in Appendix D.
4.2.1 Velocity and Gas Temperature
A Type-S pitot 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 EPA Reference
Method 2.* The temperature at each sampling point was measured with a ther-
mocouple and digital readout.
4.2.2 Molecular Weight
Flue gas composition was determined in accordance with the basic proce-
dures described in EPA Reference Method 3.* Grab samples were collected
prior to the start of 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 reasonably consistent throughout the
test series.
40 CFR 60, Appendix A, Reference Methods 2 and 3, July 1984.
4-5
-------
4.2.3 Particu1ate/Cr+6
Samples of particulate, Cr, and total Cr were collected as specified
in EPA Reference Method 5.* All tests were conducted isokinetically by
regulating the sample flow rate relative to the gas velocity in the duct (as
measured 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
test. The acetone rinse and particulate caught on the filter media were
dried at room temperature, desiccated to a constant weight, and weighed on an
analytical balance. Total filterable particulate matter was determined by
adding these two values.
Upon completion of the gravimetric analysis, the inlet sample fractions
were prepared and analyzed for Cr according to procedures recently devel-
oped 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.
40 CFR 60, Appendix A, Reference Method 5, July 1984.
**
Test Methods for Evaluating Solid Waste. U.S. Environmental Protection
Agency, SW-846, 2nd ed., July 1982.
4-6
-------
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. These samples are being held for
further analysis if desired.
4.3 PARTICLE SIZE DISTRIBUTION
Samples for particle-size distribution measurements were collected at
the ESP inlet and outlet by an Andersen Mark III impactor. This in-stack
impactor consists of eight cut-point stages and a backup filter. The impac-
tor was preceded by a 15-pm cyclone precutter. The sampled gas stream enters
the system through the precutter. Particles with sufficient inertia are
impacted against the sides of the cyclone. Smaller particles flow with the
gas stream and exit the cyclone and into the main impactor. Then, particles
with sufficient inertia are impacted on the first stage filter with smaller
particles passing onto the second stage, and similarly to each succeeding
stage. Finally, a glass fiber filter removes all particles remaining in the
gas stream downstream of the final stage.
This type of impactor was used at both sites since the particulate
concentrations were low at both sites.
Three samples were collected at the ESP inlet and outlet from single
points in the ducts that represented average velocities and temperatures. At
the inlet, Tests PSI-2 and -3 were run for 120 minutes, with Test PSI-4
running for 90 minutes. At the outlet, Test PSO-1 was conducted for 120
minutes, and Tests PSO-2 and -3 were conducted for 180 minutes. Isokinetic
4-7
-------
sampling rates were set initially, and constant cut-point characteristics
were maintained throughout the sampling period.
At the completion of each test, the impactor samples were recovered
according to procedures described in the Mark III operations manual.
Each recovered fraction was subjected to a gravimetric analysis using
EPA Method 5 procedures. Size distribution curves were established repre-
senting the total weight percent of particulate matter smaller than the
indicated aerodynamic particle diameter in micrometers.
Cut-points for the eight Mark III impactor stages were calculated by
computer programs contained in "A Computer-Based Cascade Impactor Data Reduc-
tion System" (CIDRS) developed for EPA by Southern Research Institute (SRI).*
All particle size results are based on a particle density of 1 g/cm3. Data
reduction and intermediate results calculations for both types of impactors
were performed by the CIDRS program, with moisture contents obtained from the
particulate tests.
Samples from Runs PSI-4 and PSO-3 were analyzed for total Cr by NAA.
4.4 PROCESS SAMPLES
Grab samples of ESP hopper ash were collected periodically during each
particulate/chromium test. The samples from each test were composited so
that one representative sample per test was available for analysis. The
samples were extracted and analyzed for Cr in accordance with procedures
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.
4-8
-------
similar to those used for the Cr analysis of the particulate samples. An
aliquot of each sample was also analyzed for total Cr.
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 pi tot 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.
4-9
-------
SECTION 5
PROCESS OPERATION
The following process description was prepared by Midwest Research
Institute (MRI), the EPA New Source Performance Standards (NSPS) contractor.
Personnel from MRI were on site during the test program to monitor and record
all pertinent incinerator and ESP data.
5.1 PROCESS DESCRIPTION
Tuscaloosa Energy Recovery incinerator facility consists of four modular
municipal refuse incinerators manufactured by Consumat Systems, Incorporated,
and installed in 1984. Each incinerator has a rated capacity of 80 Mg/day
(90 tons/day) and typically operates 24 hours per day, 5 days a week. During
the month preceding testing, each incinerator burned an average of 56 Mg/day
(63 tons/day). Exhaust from the four incinerators is fed through two heat
recovery boilers to produce 24,900 kg (55,000 Ib) of steam per hour. Ap-
proximately 99 percent of the refuse incinerated is supplied by residential
sources in eight nearby municipalities. The remaining 1 percent [4.5 Mg/day
(5 tons/day)] consists of scrap tires from the nearby B.F. Goodrich plant
that purchases the steam produced. Large metal items are manually sorted
from the refuse prior to incineration.
Figure 5-1 shows a cross section of a typical modular incinerator con-
sisting of a primary and a secondary chamber. During startup, natural gas is
introduced via one burner in each chamber. Refuse is loaded into the primary
chamber and is partially oxidized under starved air, or substoichiometric,
5-1
-------
Figure 5-1. Cross section of typical modular incinerator.
5-2
-------
conditions. (Primary chambers of modular starved air incinerators typically
operate at 25 to 50 percent below stoichiometry.) The combustible gases and
particulates generated in the primary chamber flow into the secondary chamber
where combustion is completed under excess air conditions, typically 50 to
100 percent above stoichiometry. Temperature in the primary chamber of each
incinerator is maintained between 540° and 760°C (1000° and 1400°F). Sec-
ondary chamber temperatures are typically 1150°C (2100°F). No auxiliary fuel
is used during normal operation.
5.2 AIR POLLUTION CONTROL SYSTEM
Particulate emissions are controlled by an electrostatic precipitator
(ESP) manufactured by Precipitair Pollution Control Company of Longview,
Texas. Exhaust from the four incinerators is routed through the ESP prior to
exiting through a single stack. An induced draft (ID) fan is located after
the ESP and before the stack. Design specifications for the ESP are pre-
sented in Table 5-1.
5.3 PROCESS CONDITIONS DURING TESTING
All tests were conducted while the four incinerator modules were opera-
ting normally at approximately 320 tons of refuse per day (90 percent of
capacity). Table 5-2 outlines the tests conducted on the incinerator. The
lower chamber temperatures and upper chamber temperatures were monitored and
controlled to operate in the typical ranges of 980° to 1200°F and 2080° to
2120°F, respectively. The following incinerator process parameters were
recorded every 15 minutes during testing: lower chamber and upper chamber
temperatures for each of the four modules (Nos. 1 through 4), steam flow,
5-3
-------
TABLE 5-1. TUSCALOOSA ENERGY RECOVERY INCINERATOR
ESP DESIGN SPECIFICATIONS
Collection efficiency, % 50
Inlet dust loading, gr/dscf 0.06
Outlet dust loading, gr/dscf 0.03
Gas volume, acfm 76,000
Gas temperature, °F 350
No. of fields 2
Collection plate area, ft2 10,617
Specific collection area, ft2/!,000 acfm 140
Collection plate height, ft 28
Collection plate length, ft 7.3
Aspect ratio 0.52
Gas velocity, ft/s 4.18
Gas passage spacing, 1n. 10
No. of gas passages 13
No. of plates 28
Secondary voltage, kV 45
Secondary current, mA 300
ESP power, kVA 27
5-4
-------
TABLE 5-2. SUMMARY OF TESTS CONDUCTED ON THE TUSCALOOSA ENERGY RECOVERY
INCINERATOR, TUSCALOOSA, ALABAMA3
Sampling point
ESP inlet
ESP outlet
Outside observa-
Test type
Particulate concentration
Particle size
Particulate concentration
Particle size
NO concentration
A
Visible emissions
Test Method
EPA Method 5
Anderson Mark III
EPA Method 5
Anderson Mark III
EPA Method 7
EPA Method 9
No.
per
run
1
1
1
1
~4b
tion point
ESP dust hopper Fly ash
Grab
•10
Tests consisted of one run per day on May 21, 22, and 23, 1985. Method 5
samples on the first day were gathered for arsenic analyses. A116other
samples to be analyzed for particulate, total chromium, chromium , and
cadmium.
Each observation period was 6 minutes in duration. These data were
collected to support transmissometer data.
5-5
-------
steam temperature, steam pressure, ID fan amps, carbon monoxide concentra-
tion, and stack gas opacity. Integrated steam flow values were recorded
daily at the beginning and end of the test period. Tables 5-3, 5-4, and 5-5
present the process parameters recorded during Runs 1, 2, and 3, respec-
tively. Appendix J contains charts of the opacity and steam parameters
recorded during the test period.
A local power outage during a thunderstorm stopped the inlet Method 5
and particle sizing sampling at 6:20 p.m. during Run 1. During the temporary
power loss, the emergency venting system was engaged to allow the incinerator
exhaust to bypass the ESP and stack. Sampling during Run 2 was interrupted
due to circuit overload from the sampling equipment. Sampling resumed after
an additional electrical circuit was used to power the sampling equipment.
Air inleakage at the ID fan flange was discovered and sealed during Run 3.
The ESP operation did not remain steady during the three-day test period,
although it was operating as usual according to plant personnel. Prior to
Run 1, plant personnel adjusted the electronic controls to obtain the maximum
secondary voltages to both ESP fields and to frequent a short in the inter-
nals. Plant personnel also questioned the accuracy of the voltage and cur-
rent meters. During Run 1, power to the ESP inlet field was interrupted
several times because the transformer-rectifier tripped off. Primary and
secondary current meters both registered a zero value during Runs 1 and 2
even when the inlet field was apparently operating. The averge power level
to the ESP during Run 1 was estimated to be 1.70 kVA, representing 6 percent
of the design power level of 27 kVA. During Run 2, from 8:00 to 11:45 a.m.,
the inlet field tripped off occasionally and then stayed off after 11:45 a.m.
5-6
-------
TABLE 5-3. PROCESS DATA FOR RUN 1—TUSCALOOSA ENERGY RECOVERY
May 21, 1985
en
--J
Time
a.m.
7:30
8:00
8:15
8:30
8:36
8:45
9:00
9:15
9:30
9:45
10:00
10:15
10:30
10:45
11:00
11:15
11:27
11:30
p.m.
12:45
12:46
12:47
1:00
1:15
1:30
1:45
2:00
2:15
Unit No. 1
Unit
Lower Upper Lower
chamber chamber chamber
temp., temp., temp.,
'F *C *F
1194 1143
1210 1150
1223 1153
1195 1146
MS inlet and outlet
1166 1146
1152 1149
1131 1150
1130 1148
1104 1148
1095 1146
1043 1146
1034 1153
1014 1144
985 1 1 55
986 1145
H5 inlet and outlet
986 1148
966 1 1 50
M5 outlet started
M5 inlet started
970 1146
981 1147
985 1149
994 1 1 53
1010 1150
1031 1148
1400
1253
1172
1171
test
1144
1079
1058
1054
1063
1081
1046
1036
1039
1031
1055
test
1083
1054
990
982
969
958
952
948
No. 2
Unit No. 3
Upper Lower Upper
chamber chamber chamber
temp., temp., temp.,
•C *F 'C
1140
1134
1140
1142
for arsenic
1138
1132
1142
1143
1146
1149
1142
1138
1140
1140
1141
for arsenic
1141
1144
1142
1143
1142
1140
1141
1142
1106
1137
1188
1215
started
1188
1145
1091
1090
1091
1076
1054
1054
1052
1041
1044
ended
1045
1067
1061
1052
1045
1038
1035
1030
1146
1147
1147
1150
1148
1120
1153
1145
1145
1144
1146
1138
1144
1142
1148
1127
1146
1145
1143
1144
1145
1147
1150
Unit No. 4
Lower
chamber
temp.,
•F
1178
1197
1236
1220
1218
1145
1151
1138
1075
1036
1067
1072
1123
1125
1126
1123
1069
1062
1066
1075
1089
1084
1080
Upper
chamber
temp.,
•c
1146
1140
1146
1149
1148
1165
1152
1147
1148
1146
1147
1145
1142
1145
1148
1165
1142
1144
1147
1148
1150
1150
1148
Steam
temp.,
•F
435
435
435
435
435
430
430
430
435
435
435
435
435
435
435
435
430
430
430
430
430
430
430
Steam Steam
pressure, flow,
psi Ib/h
355
355
355
355
350
350
355
355
355
360
360
360
360
360
355
355
350
350
350
350
355
355
355
65.000
66,000
65,000
64,000
62,000
62,500
63,000
63,000
63,000
68,000
67,500
67,500
65,000
66,000
63.000
62,500
62,000
63.000
62,000
63,000
64,000
64,000
63,500
I.D.
fan,
amps
210
205
200
200
200
200
200
200
200
205
200
200
200
200
200
200
195
200
200
200
200
200
200
Opac i t}
%
4
6
7
6
5
4
5
5
5
4
3
3
4
4
6
7
6
5
4
4
4
4
5
Steam
total
I, xlO Ib/
h
123,040
128,980
156,150
(continued)
-------
TABLE 5-3. (continued)
en
i
oo
Time
2:30
2:45
3:00
3:15
3:30
3:30
3:45
4:00
4:07
4:15
4:30
4:45
5:00
5:15
5:30
5:30
5:35
5:45
6:00
6:15
6:20
6:20
Unit No. 1
Lower Upper
chamber chamber
temp., temp.,
•F 'C
1065 1155
1023 1148
1029 1148
1056 1147
Particle sizing
1107 1144
1120 1151
1115 1 1 50
Particle sizing
1102 1151
1091 1148
1072 1146
1057 1142
1056 1143
1038 1146
Particle sizing
M5 outlet ended
1041 1148
1047 1150
1031 1150
Unit No. 2
Lower Upper
chamber chamber
temp., temp.,
•F 'C
961 1143
993 1137
1000 1138
1034 1150
outlet started
1045 1151
1050 1149
1095 1142
inlet started
1148 1134
1102 1138
1052 1140
1018 1144
1019 1143
1026 1150
outlet ended
1012 1146
996 1142
1010 1138
Power outage; inlet H5 and particle
NOTE: at 6:20
p.m. power off due to
Unit No. 3
Lower Upper
chamber chamber
temp., temp.,
•F 'C
1012
1028
1029
1072
1135
1162
1121
1074
1061
1149
1035
1037
1014
1025
1034
1008
sizing
storm,
1148
1150
1143
1150
1143
1145
1142
1140
1144
1143
1144
1145
1141
1143
1145
1148
ended .
ft
Unit No. 4
Lower
chamber
temp.,
•F
1046
1026
1047
1073
1134
1164
1121
1085
1097
1099
1103
1104
1088
1102
1121
1080
Upper
chamber
temp.,
•c
1149
1136
1137
1148
1148
1143
1142
1142
1144
1143
1141
1140
1146
1145
1146
1145
Steam
temp.,
•F
430
435
430
430
430
430
430
430
430
430
430
430
430
430
430
430
Steam Steam
pressure, flow,
psl Ib/h
355
360
355
355
355
355
355
355
350
350
350
350
350
350
350
350
63,000
65,000
64,000
64,000
64,000
63,000
64,000
64,000
61,000
61,000
61,000
61,000
62,000
61,000
62,000
62,000
1.0.
fan,
amps
200
200
200
200
200
200
200
200
200
200
200
200
200
200
200
200
Steam
total
Opacity, xlO Ib/
% h
4
3
3
4
4
4
5
5
5
4
3
3
3
3
3
3 190,656
-------
TABLE 5-4.
en
i
PROCESS DATA FOR RUN 2— TUSCALOOSA ENERGY RECOVERY
22, 1985
Time
a.m.
8:30
8:45
9:00
9:10
9:15
9:30
9:45
10:00
10:15
10:30
10:45
11:00
11:15
11:30
Unit No. 1
Lower Upper
chamber chamber
temp., temp.,
•F "C
1110 1150
1095 1148
1073 1148
Unit No. 2
Lower Upper
chamber chamber
temp., temp.,
•F 'C
1074 1140
1062 1152
1046 1159
Unit No,
. 3
Unit No,
. 4
Lower Upper Lower Upper
chamber chamber chamber chamber Steam
temp., temp., temp., temp., temp.,
•F 'C *F *C *F
1030
1028
1024
1144
1145
1146
1072
1092
1114
1155
1151
1148
355
355
355
Steam Steam
pressure, flow,
psi Ib/h
435
435
430
65,500
64,000
62,500
I.D.
fan,
amps
200
200
200
Steam
total
Opacity, xlO Ib/
% h
1 279,160
2
2
M5 inlet and outlet started
1063 1154
1061 1150
1071 1148
1108 1150
1097 1151
1077 1148
1064 1147
1033 1152
1046 1148
1032 1154
1102 1141
1086 1153
1052 1131
1035 1141
1054 1142
999 1142
1014 1143
1084 1140
1115 1150
1023 1142
Port change at 11:40 a.m.; cracked
11:45
p.m.
12:08
12:30
12:38
12:45
12:54
1:00
1:15
1:30
1:45
2:00
2:15
2:30
2:38
1076 1150
Particle sizing
1100 1148
Particle sizing
1029 1159
H5 inlet started
977 1145
977 1148
962 1150
962 1 161
955 1 1 50
974 1140
992 1 1 50
Particle sizing
1086 1148
outlet started
980 1139
inlet started
960 1139
932 1144
913 1141
892 1138
903 1142
929 1141
927 1145
932 1142
inlet ended
1042
1046
1114
1148
1148
1066
1048
1030
1043
1082
probe noted
1052
1017
1020
1013
1002
991
986
969
961
971
1124
1147
1146
1143
1144
1144
1148
1144
1143
1156
on inlet;
1144
1148
1151
1143
1143
1142
1149
1142
1143
1147
1084
1100
1080
1070
1072
1089
1090
1108
1128
1102
samp 1 i ng
1101
1040
1027
1058
1051
1047
1064
1059
1078
1111
1142
1156
1145
1159
1148
1148
1146
1145
1155
1150
stopped
1150
1151
1144
1147
1163
1179
1152
1146
1146
1146
350
350
350
350
350
350
350
350
350
350
355
360
360
360
360
360
360
360
355
355
430
430
430
430
430
430
430
430
430
430
430
435
435
435
435
435
435
435
435
435
58,000
60,000
61,000
62,000
58,000
60,000
58,000
58,000
57,000
59,000
64,000
66,000
64,500
65,000
66,500
67,500
67,500
66,500
65,500
62,500
190
195
195
195
205
200
200
195
200
200
200
205
210
215
215
215
215
215
215
220
2
3
3
3
3
3
2
3
3
4
4
1
1
2
2
1
1
1
2
2
(continued)
-------
en
O
TABLE 5-4. (continued)
Time
2:45
3:00
3:08
3:15
3:20
3:30
3:45
4:00
4:02
Unit No. 1
Lower Upper
chamber chamber
temp., temp.,
•F "C
1023 1150
1069 1151
Particle sizing
1047 1150
M5 outlet ended
1043 1151
1025 1148
1061 1152
M5 inlet ended
Unit No.
2
Lower Upper
chamber chamber
temp., temp..
*F
958
987
outlet ended
1017
1018
1029
1062
•c
1146
1150
1143
1150
1142
1134
Unit No. 3
Lower
chamber
temp.,
•F
1010
1035
1090
1065
1020
1039
Upper
chamber
temp.,
•c
1145
1144
1146
1145
1141
1143
Unit No. 4
Lower
chamber
temp..
•F
1185
1256
1204
1037
1114
1124
Upper
chamber
temp.,
•c
1145
1140
1147
1146
1149
1144
Steam
temp..
•F
355
355
355
350
350
350
Steam
Steam
pressure, flow,
psi
435
435
435
430
430
430
Ib/h
63,500
63,500
61,000
58,000
58,000
58,000
I.D.
Steam
total
fan, Opacity, xlO Ib/
amps
210
205
200
200
200
195
%
3
3
3
3
4
3
h
321 ,790
-------
TABLE 5-5. PROCESS DATA FOR RUN 3—TUSCALOOSA ENERGY RECOVERY
May 23, 1985
Time
a.m.
8:00
8:30
8:40
8:41
8:45
9:00
9:30
10:00
10:15
10:30
10:40
10:45
:00
:15
:30
:40
:45
:58
p.m.
12:00
12:15
12:30
12:45
:00
:15
:30
:40
:45
2:00
2:15
2:27
Unit No. 1 Unit No. 2
Lower Upper Lower Upper
chamber chamber chamber chamber
temp., temp., temp., temp.,
•F *C *F "C
1109 1146 1001 1136
1078 1149 1037 1126
M5 outlet started
M5 inlet started
1092 1147 1050 1143
1105 1146 1063 1133
1119 1150 1034 1143
1066 1150 1064 1139
1052 1141 1054 1140
1036 1150 1038 1138
Particle sizing outlet started
1003 1151 1082 1137
1001 1150 1131 1139
993 1150 1163 1142
1043 1148 1117 1150
M5 outlet ended
1068 1147 1110 1142
Particle sizing Inlet started
1085 1153 1103 1139
1173 1147 1057 1142
1192 1146 1088 1143
1214 1146 1124 1142
1169 1148 1085 1143
1094 1150 1033 1140
1078 1148 1018 1143
Particle sizing outlet ended
1054 1152 971 1139
1037 1149 1020 1125
1006 1149 1011 1149
M5 inlet ended
Unit
Lower
chamber
temp.,
•F
1087
1031
1019
1009
1004
996
996
1003
987
982
975
986
1003
1007
1152
1122
1084
1043
998
995
983
1015
973
No. 3
Upper
chamber
temp.,
•c
1144
1144
1144
1144
1143
1148
1146
1150
1145
1146
1145
1143
1147
1147
1145
1144
1142
1144
1146
1141
1147
1135
1148
Unit
Lower
chamber
temp.,
•F
1014
1051
1126
1090
1126
1092
1080
1063
1034
1025
1015
1023
1022
991
1094
1081
1063
1018
1006
1036
1015
1012
1052
No. 4
Upper
chamber
temp.,
•c
1152
1157
1155
1145
1150
1142
1148
1142
1150
1152
1155
1142
1144
1146
1144
1142
1142
1152
1146
1148
1146
1148
1146
Steam
temp.,
•F
435
435
435
435
435
435
435
435
435
435
435
435
435
435
435
435
435
430
430
430
430
430
430
Steam
pressure,
PSl
355
355
355
350
350
355
355
360
360
360
360
360
360
360
350
350
350
350
350
350
350
350
350
Steam
flow,
Ib/h
65,000
64,500
64,500
63,000
62,000
65,000
65,000
66,50p
66,000
66,000
66,500
65,000
65,000
65,500
62,000
62,000
62,000
58.000
54,500
56,000
57,000
58,500
60,500
I.D.
fan,
amps
215
215
215
215
215
215
215
215
215
215
215
215
215
215
215
215
215
205
200
200
195
195
195
Opacity,
1
2
2
2
2
3
4
3
7
5
2
2
2
3
3
3
7
Steam
total
xlO Ib/
h
419,700
457,450
(continued)
-------
TABLE 5-5. (continued)
C71
ro
Unit No. 1 Unit No. 2
Time
2:30
2:45
3:00
3:12
3:15
3:30
3:45
4:00
4:15
4:30
4:42
5:00
Lower Upper Lower
chamber chamber chamber
temp., temp., temp..
*F 'C "F
1007 1148 1023
1009 1147 1037
1025 1148 1005
Upper
chamber
temp..
•c
1146
1142
1142
Unit No. 3
Lower
chamber
temp.,
•F
989
1008
996
Upper
chamber
temp.,
•c
1147
1148
1149
Unit No. 4
Lower
chamber
temp..
•F
1050
1048
1079
Upper
chamber
temp..
•c
1146
1145
1148
Steam
temp.,
•F
430
430
430
Steam
pressure
psi
350
350
350
Steam
, flow.
Ib/h
58,500
57,000
56,500
I.D.
Steam
total
fan. Opacity, xlO Ib/
amps
195
195
205
%
5
4
5
h
Particle sizing inlet started
1035 1151 1013
1034 1147 1054
1019 1146 1034
996 1146 1018
1007 1150 1046
1029 1151 1030
1137
1139
1144
1147
1145
1144
1025
1101
1082
1066
1057
1067
1142
1143
1145
1147
1142
1145
1064
1098
1077
1059
1012
1020
1147
1147
1148
1149
1145
1131
430
430
430
430
430
430
350
350
350
350
350
350
55,000
58,000
58,000
58,000
58,000
58,500
200
195
195
195
195
195
6
5
3
3
3
4
Particle sizing inlet stopped
474,873
-------
The average ESP power level during Run 2 was estimated to be 2.0 kVA, repre-
senting 7 percent of the design power level. During Run 3, the outlet field
tripped off from 11:00 to 11:30 a.m., and was restarted at 11:30 a.m. The
average ESP power level during Run 3 was estimated to be 5.7 kVA, repre-
senting 21 percent of the design level. Tables J.3-1, J.3-2, and J.3-3 in
Appendix J present the recorded values of the monitored ESP parameters during
Runs 1, 2, and 3, respectively.
5.4 SUMMARY OF PROCESS OPERATIONS DURING TESTING
The incinerator modules were operated under steady and normal conditions
at approximately 90 percent of capacity throughout the tests. It is expected
that the inlet sampling data are representative for uncontrolled emission
levels. (Approximately 90 percent of all modular plants are uncontrolled.)
The ESP operation was not steady and the ESP power levels represent only a
small fraction of the design power level. (This ESP as well as the control
devices on the modular plants with controls has a design removal efficiency
of only approximately 50 percent.) Air inleakage at the ID fan flange
occurred throughout most of the test period. It is expected that the outlet
sampling results do not reflect representative conditions for controlled
emission levels.
The inlet chromium emission levels will be used to represent the 90
percent of the modular facilities without controls. By applying a removal
efficiency of 50 percent to the inlet chromium emission levels, typical
chromium emissions for the uncontrolled facilities can be estimated; thus,
the suspect outlet data from the Tuscaloosa facility will not have to be used
to represent current controlled emission levels.
5-13
-------
The temperature .in the primary chamber of each incinerator is maintained
between 540° and 760°C (1000° and 1400°F). Secondary chamber temperatures
are typically 1150°C (2100°F). No auxiliary fuel is used during normal
operation.
Approximately 99 percent of the refuse incinerated at the Tuscaloosa
facility is supplied by residential sources in eight nearby municipalities.
The remaining 1 percent [4.5 Mg/day (5 tons/day)] consists of scrap tires
from the nearby tire plant. Large metal items are sorted from the refuse
prior to incineration and sent to a landfill.
Exhaust from the incinerators is routed through a common ESP for par-
ticulate emission control prior to exiting through a single stack. The ESP
was manufactured by the PPC Company of Longview, Texas. It has two fields
with 14 plates in each field. The plates are spaced approximately 25 cm (10
in.) apart and are 7.6 m (25 ft) long and 2.4 m (8 ft) wide. The applied
voltages to the first and second fields are 31 and 30 kV, respectively. The
specific collection area is estimated to be 400 m2/1000 acmm (120 ft2/1000
acfm). The ESP has a design removal efficiency of 50 percent and collects
approximately 320 kg (700 Ib) of fly ash per day.
All tests were conducted while the incinerators were operating under
normal conditions. However, the ESP experienced some operational difficul-
ties at various times throughout the test program.
5-14
------- |