United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park, NC 27711
EMB Report 92-SLS-3
Volume 1
December 1992
Air
EPA
SECONDARY LEAD SMELTER
EMISSION TEST REPORT
EAST PENN MANUFACTURING
LYON STATION, PA
^/V^ *i +T-4
_ '** aad S^
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FINAL TEST REPORT
EAST PENN MANUFACTURING COMPANY
SECONDARY LEAD SMELTER
Volume I
Report and Appendices A & B
EPA Contract No. 68D20162
Work Assignment No. 1-16
Prepared for:
Mr. Robert McCrackan
Work Assignment Manager
US EPA, Emission Measurement Branch
OAQPS, TSD, MD-19
Research Triangle Park, NC 27711
September 30, 1994
L:\S116.005
Submitted by:
PACIFIC ENVIRONMENTAL SERVICES, INC.
5001 South Miami Blvd., Suite 300
PO Box 12077
Research Triangle Park, NC 27709-2077
(919) 941-0333
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DISCLAIMER
This report, submitted to U.S. Environmental Protection Agency (USEPA) Emission
Measurement Branch (EMB) was prepared from a Site-Specific Test Plan and data summaries
provided to Pacific Environmental Services, Inc. by the EMB. Raw field and analytical data,
calculations, and QA/QC procedures and results were not made available to PES. As a
result PES could not comment on the completeness and accuracy of the data or any
inconsistencies in the results.
Any mention of trade names or commercial products does not constitute endorsement
or recommendation for use by the U.S. EPA.
ii
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TABLE OF CONTENTS
Section
1 INTRODUCTION 1-1
1.1 Background 1-1
1.2 Test Program Organization 1-4
1.3 Program Objectives 1-4
2 SUMMARY AND DISCUSSION OF RESULTS 2-1
2.1 Total Paniculate Testing . . . 2-1
2.1.1 Blast Furnace Outlet 2-1
2.1.2 Blast/Reverb Furnaces Process 2-1
2.1.3 Ventilation/Hooding Baghouses 2-3
2.2 Filterable Paniculate, Particle Size
Distribution, and Condensible Paniculate
Testing 2-3
2.2.1 Blast Furnace Outlet 2-3
2.2.2 Blast/Reverb Furnaces Process 2-16
2.2.3 Ventilation/Hooding Baghouses 2-16
2.3 Metals Testing 2-30
2.3.1 Blast/Reverb Furnaces Baghouse
Inlet (Metals) . . . 2-30
2.3.2 Blast/Reverb Furnaces Process (Lead) 2-30
2.3.3 Ventilation/Hooding Baghouses (Lead) 2-43
2.4 Hydrochloric Acid/Chlorine Testing 2-43
2.5 Dioxins/Furans Testing 2-54
2.5.1 Scrubber Gas Stream 2-54
2.5.2 Process Baghouse Dust 2-54
iii
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TABLE OF CONTENTS (Continued)
Section Page
2.6 Aldehydes/Ketones Testing 2-54
2.7 Semi-Volatile Organics Testing 2-54
2.8 Volatile Organics Testing 2-93
2.9 Continuous Monitoring . . . 2-93
3 DESCRIPTION OF PROCESS AND AIR POLLUTION
CONTROL SYSTEMS 3-1
3.1 Process Description 3-1
3.1.1 Battery Breaking 3-1
3.1.2 Smelting Operations 3-3
3.1.3 Refining and Casting . 3-4
3.2 Air Pollution Control Equipment 3-4
3.3 Process and Air Pollution Control
Equipment Operating Data During Testing 3-7
3.3.1 Furnace Production Data 3-7
3.3.2 Refining and Casting Data 3-10
3.3.3 Control Device Data 3-10
3.4 Summary of Process Monitoring 3-11
4 SAMPLING LOCATIONS 4-1
4.1 Blast Furnace Outlet 4-1
4.2 Blast/Reverb Furnaces Baghouse Inlet 4-1
4.3 Blast/Reverb Furnaces Baghouse Outlet 4-3
4.4 Blast/Reverb Furnaces Wet Scrubber Outlet 4-3
4.5 Reverberatory Kettles Cyclone Inlet 4-6
4.6 Reverberatory Kettles Baghouse Outlet 4-6
4.7 Refiner Baghouse Inlet 4-6
4.8 Refiner Baghouse Outlet 4-6
4.9 No. 1 Baghouse Inlet 4-11
4.10 No. 1 Baghouse Outlet 4-11
4.11 No. 3 Baghouse Inlet 4-11
4.12 No. 3 Baghouse Outlet 4-11
iv
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TABLE OF CONTENTS (Continued)
Section
5 SAMPLING AND ANALYTICAL PROCEDURES . 5-1
5.1 Overview of Flue Gas Sampling, Testing,
and Analysis 5-1
5.2 Testing Equipment 5-2
5.2.1 Paniculate and Metallic HAP's 5-2
5.2.2 Paniculate and Lead 5-6
5.2.3 Semi-Volatile HAP's 5-8
5.2.4 PCDD/PCDF 5-10
5.2.5 Volatile Organic Sampling Train (VOST) 5-12
5.2.6 Aldehyde/Ketone Sampling Train 5-12
5.2.7 Particle Size Distribution and
Condensible Paniculate Sampling
Equipment 5-15
5.2.8 Hydrochloric Acid and Chlorine 5-17
5.2.9 THC Monitoring Equipment 5-17
5.2.10 Carbon Monoxide Monitoring
Equipment 5-19
5.3 Flue Gas Testing Procedures 5-19
5.3.1 Particulate and Metallic HAP's 5-19
5.3.2 Particulate and Lead 5-23
5.3.3 Semi-Volatile HAP's Testing and
Sample Recovery Procedures 5-23
5.3.4 Sampling Procedures for Volatile
Organics 5-23
5.3.5 Aldehyde/Ketone Sampling and Sample
Recovery Procedures 5-23
5.3.6 HC1 and C12 Sampling and Sample
Recovery 5-34
5.3.7 Particle Size Distribution
Sampling and Sample Recovery 5-34
5.4 Flue Gas Sample Analysis Procedures . . . 5-34
5.4.1 Particulate and Metallic HAP's
Procedures 5-44
5.4.2 Particulate and Lead Procedures 5-46
5.4.3 Analysis of Semi-Volatile HAP's 5-48
5.4.4 Analysis of PCDD/PCDF ..'... 5-50
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TABLE OF CONTENTS (Concluded)
Section Page
5.4.5 Analysis of Volatile Organics 5-54
5.4.6 Aldehyde/Ketone Analysis
Procedures 5-54
5.4.7 Analysis of Hydrochloric Acid
and Chlorine 5-54
5.4.8 Particle Size Distribution and
Condensible Particulate Analysis
Procedures 5-60
5.4.9 Continuous Emission Monitoring
Procedures . 5-60
5.4.10 Flue Gas Sample Analysis 5-63
5.4.11 Flue Dust Sample Analysis . 5-63
5.5 Process Data 5-63
6 QUALITY ASSURANCE 6-1
Appendix
A Summary Tables - Test Results and Sampling Data
B Description of Process and Air Pollution Control
Systems (Including Process Monitoring Data)
C Site-Specific Test Plan - Roy F. Weston, Inc.
D Sampling and Analytical Test Methods
vi
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LIST OF TABLES
Table Page
1-1 Test Locations and Methods 1-10
2-1 Summary of Particulate Emissions - Blast
Furnace Outlet (Sample Point A) 2-2
2-2 Summary of Particulate Emissions - Blast/
Reverb Furnaces Process 2-4
2-3 Summary of Particulate Emissions - Reverb
Kettles Baghouse 2-6
2-4 Summary of Particulate Emissions - Refiner
Baghouse 2-8
2-5 Summary of Particulate Emissions - No. 1
Sanitary Baghouse 2-10
2-6 Summary of Particulate Emissions - No. 3
Sanitary Baghouse 2-12
2-7 Summary of Filterable Particulate, PM10,
and Condensible Particulate Emissions -
Blast Furnace Outlet (Sample Point A) 2-14
2-8 Summary of Filterable Particulate, PM,0,
and Condensible Particulate Emissions -
Blast/Reverb Furnaces Baghouse 2-17
2-9 Summary of Filterable Particulate, PM10,
and Condensible Particulate Emissions -
Blast/Reverb Furnaces Scrubber Outlet
(Sample Point D) 2-20
2-10 Summary of Filterable Particulate, PMj0,
and Condensible Particulate Emissions -
Reverb Kettles Baghouse 2-22
2-11 Summary of Filterable Particulate, PM,0,
and Condensible Particulate Emissions -
Refiner Baghouse 2-26
2-12 Summary of Filterable Particulate, PM10,
and Condensible Particulate Emissions -
No. 1 Sanitary Baghouse 2-31
2-13 Summary of Filterable Particulate, PM,0,
and Condensible Particulate Emissions -
No. 3 Sanitary Baghouse 2-35
2-14 Summary of Metals Emissions - Blast/Reverb
Furnaces Baghouse Inlet (Sample Point B) 2-39
2-15 Summary of Lead Emissions - Blast Furnace
Outlet (Sample Point A) 2-42
2-16 Summary of Lead Emissions - Blast/Reverb
Furnaces Process 2-44
vii
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LIST OF TABLES (Concluded)
2-17 Summary of Lead Emissions - Reverb Kettles Baghouse 2-46
2-18 Summary of Lead Emissions - Refiner Baghouse 2-48
2-19 Summary of Lead Emissions - No. 1 Sanitary
Baghouse 2-50
2-20 Summary of Lead Emissions - No. 3 Sanitary
Baghouse 2-52
2-21 Summary of Hydrochloric Acid and Chlorine
Emissions - Blast/Reverb Furnaces Process 2-55
2-22 Summary of Dioxin and Furan Emissions - Blast/
Reverb Furnaces Baghouse Outlet (Sample Point C) 2-57
2-23 Summary of Dioxin and Furan Emissions - Blast/
Reverb Furnaces Scrubber Outlet (Sample Point D) 2-69
2-24 Summary of Aldehydes and Ketones Emissions -
Blast Furnace Outlet (Sample Point A) 2-80
2-25 Summary of Semi-Volatile Compounds Emissions -
Blast Furnace Outlet (Sample Point A) 2-85
2-26 Summary of Volatile Organic Compounds Emissions -
Blast Furnace Outlet (Sample Point A) 2-87
2-27 Summary of Total Hydrocarbon Emissions - Blast/
Reverb Furnaces Process 2-94
2-28 Summary of Carbon Monoxide Emissions - Blast/
Reverb Furnaces Process 2-95
2-29 Summary of Dioxins and Furans Analytical
Results - Blast/Reverb FurnaeeslBaghouse Dust
Samples (ppt) (Sample Point E) 2-96
3-1 Charge, Production, and Afterburner Fuel
Information 3-8
3-2 Summary of Control Device Operating Data 3-12
5-1 Sampling and Analytical Matrix 5-3
5-2 Semi-Volatile HAPs 5-51
5-3 PCDD/PCDF Compounds 5-53
5-4 Volatile HAPs 5-55
5-5 Aldehydes/Ketones 5-58
5-6 Holding Times For Samples 5-64
5-7 Approximate Detection Limits For Source
Samples 5-65
viii
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LIST OF FIGURES
Figure Page
1-1 Schematic of Blast/Reverberatory Furnaces and
Kettles/Hooding Processes with Sampling Points
Shown 1-3
1-2 Test Program Organization Chart 1-5
3-1 East Penn Process Flow Diagram 3-2
3-2 Emissions Control Flow Diagram 3-5
4-1 Blast Furnace Exhaust with Port and Traverse
Point Locations 4-2
4-2 Blast/Reverberatory Furnaces Baghouse Inlet
with Port and Traverse Point Locations 4-4
4-3 Blast/Reverberatory Furnaces Baghouse Outlet
with Port and Traverse Point Locations 4-5
4-4 Blast/Reverberatory Furnaces Scrubber Outlet
with Port and Traverse Point Locations 4-7
4-5 Reverberatory Kettles Cyclone Inlet with
Port and Traverse Point Locations 4-8
4-6 Reverberatory Kettles Baghouse Outlet with
Port and Traverse Point Locations Shown 4-9
4-7 Refiner Baghouse Inlet with Port and Traverse
Point Locations Shown . 4-10
4-8 Refiner Baghouse Outlet with Port and Traverse
Point Locations Shown 4-12
4-9 No. 1 Baghouse Inlet with Port and Traverse
Point Locations Shown 4-13
4-10 No. 1 Baghouse Outlet with Port and Traverse
Point Locations Shown . 4-14
4-11 No. 3 Baghouse Inlet with Port and Traverse
Point Locations Shown 4-15
4-12 No. 3 Baghouse Stack with Port and Traverse
Point Locations Shown 4-17
5-1 EPA Particulate and Metallic HAP's Sampling
Train 5-5
5-2 EPA Method 12 Particulate and Lead Sampling
Train 5-7
5-3 EPA Method 0010 Semi-Volatile Organic HAP's
Sampling Train 5-9
5-4 EPA Method 23 PCDD and PCDF Sampling Train 5-11
5-5 FJPA Method 0030 Volatile Organics Sampling
Train (VOST) 5-13
ix
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LIST OF FIGURES (Continued)
Figure Page
5-6 EPA Method 0011 Aldehyde/Ketone Sampling
Train 5-14
5-7 EPA Reference Methods 201A/202 Particle
Size Distribution and Condensible Particulate
Sampling Train 5-16
5-8 Draft EPA Method 26A Hydrogen Chloride
Sampling Train 5-18
5-9 Preparation Procedures for Particulate and
Metallic HAP's Sampling Train . . 5-20
5-10 Sampling Procedures for Particulate and
Metallic HAP's Sampling Train 5-21
5-11 Sample Recovery Procedures for Particulate
and Metallic HAP's 5-22
5-12 Preparation Procedures for Particulate and
Lead Sampling Trains 5-24
5-13 Sampling Procedures for Particulate and Lead 5-25
5-14 Sample Recovery Procedures for Particulate
and Lead 5-26
5-15 Preparation Procedures for Semi-Volatile HAP's
Sampling Train 5-27
5-16 Sampling Procedures for Semi-Volatile HAP's 5-28
5-17 Sample Recovery Procedures for Semi-Volatile
HAP's . . 5-29
5-18 Sample Recovery Procedures for Method 23 -
Dioxins and Furans 5-30
5-19 Preparation Procedures for Volatile Organics
Sampling Train 5-31
5-20 Sampling Procedures for Volatile Organics 5-32
5-21 Recovery Procedures for Volatile Organics 5-33
5-22 Preparation Procedures for Aldehydes/Ketones
Sampling Trains 5-35
5-23 Sampling Procedures for Aldehydes/Ketones 5-36
5-24 Sample Recovery Procedures for Aldehydes/Ketones
Sampling Trains 5-37
5-25 Preparation Procedures for HC1 and C12 Sampling
Trains 5-38
5-26 Sampling Procedures for HC1 5-39
5-27 Sample Recovery Procedures for HC1 Sampling Trains 5-40
5-28 Preparation Procedures for Particle Size
Distribution and Condensible Particulate Sampling
Train 5-41
5-29 Test Procedures for Particle Size Distribution
and Condensible Particulate Sampling Train 5-42
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LIST OF FIGURES (Concluded)
5-30 Sample Recovery Procedures for Particle Size
Distribution and Condensible Paniculate
Sampling Train 5-43
5-31 Paniculate and Multi-Metals Analytical
Scheme 5-45
5-32 Paniculate and Lead Analytical Scheme 5-47
5-33 Semi-Volatile HAP's Analysis Scheme 5-49
5-34 Analytical Scheme for Aldehydes/Ketones 5-57
5-35 Chloride Analysis Scheme : 5-59
5-36 Analysis Procedures for PM10 and Condensible
Paniculate Samples 5-61
xi
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SECTION 1
INTRODUCTION
1.1 BACKGROUND
Section 112 of the Clean Air Act (CAA), as amended November 1990, requires the
U.S. Environmental Protection Agency (EPA) to regulate categories of major and area
sources of hazardous air pollutants (HAP's) listed in section 112(b). The EPA has
determined that secondary lead smelters are anticipated to emit several of the 189 HAP's
listed (including lead compounds, hydrogen chloride, benzene, and toluene) in quantities
sufficient to designate these facilities as major sources. As a consequence, secondary lead
smelters are on the initial list of HAP-emitting source categories selected for regulation [57
FR 31576, My 16, 1992] and are in the group of categories for which final regulations
are expected to be promulgated by November 1994.
The Office of Air Quality Planning and Standards (OAQPS), through the Industrial
Studies Branch (ISB) of the Emission Standards Division (BSD), is responsible for the
development of the regulations for secondary lead smelters. Following a review of the
existing data, it was determined that insufficient information was available on HAP
emissions and control within this source category. A test program was developed for the
purpose of gathering the necessary data and involves emission testing at three facilities.
This emission report presents the test results from the third of the three facilities, East
Penn Manufacturing Company (East Penn), in Lyon Station, Pennsylvania.
The Emission Measurement Branch (EMB) coordinated the emission measurement
activities. Radian Corporation (Radian) was contracted by EPA/ISB to assist in the
process data collection activities. The Emission Inventory Branch (EIB) of OAQPS, which
intends to utilize the test data for emission factor development, also provided a portion of
the funding.
Roy F. Weston, Inc. (Weston) was contracted by EPA/EMB to plan and conduct
the emission testing program. At the initiation of the program, Weston was also going to
prepare the final test report describing the results of the sampling and analysis effort.
However, funding for this report preparation was exhausted before Weston could complete
a draft of the report. The EMB subsequently contracted Pacific Environmental Services,
Inc. (PES) under Contract No. 68D20162, Work Assignment 1-16, to prepare a test report
using the following materials: Western's tables summarizing the results of the testing
(Appendix A), Radian's draft process description and process monitoring data (Appendix
B), and Weston's site-specific test plan for East Penn (Appendix C).
1-1
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The East Penn, Lyon Station, Pennsylvania secondary lead smelting facility was
selected for investigation because:
• The facility operates both a reverberatory furnace and a blast furnace, which is one
of the basic smelting furnace configurations used at secondary lead smelters.
• The facility operates an afterburner followed by a baghouse and a wet scrubber.
This equipment mix is consistent with Maximum Achievable Control Technology
(MACT) floor determinations for secondary lead smelters that operate a
combination of furnaces. Test data collected from this facility may be used to
establish emission standards for both existing and new sources.
• The facility is equipped with state-of-the-art process and air pollution control
equipment.
• East Penn utilizes many innovative work practices and engineering controls to
suppress fugitive emissions.
Processes of interest under this testing effort included:
• Blast furnace exhaust (inlet to afterburner).
• Reverberatory and blast furnace
- afterburner outlet (baghouse inlet) and wet scrubber inlet and outlet.
• Reverberatory kettles
- baghouse inlet and outlet.
• Ventilation and hooding
- baghouse No. 1 inlet and outlet.
- baghouse No. 3 inlet and outlet.
- refiner baghouse inlet and outlet.
A schematic of the processes, identifying the sampling/measurement locations, is
shown in Figure 1-1.
The types of samples collected were dependent on the location being evaluated.
Pollutants measured under this program included:
Particulate matter
Condensible particulate matter
Semi-volatile organics
Volatile organics
Aldehydes/ketones
1-2
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East Penn Manufacturing Co.
Lyon Station, Pennsylvania
Blast
Furnace
Reverberatory
Furnace
Afterburner
Baghouse
we i ocniDDer
Reverbatory Kettles
'
Cyclone
Baghouse
Stack
Ventilation and
Local Hooding
'
Refiner Baghouse
Ventilation and
Local Hooding
No. 1 Baghouse
Ventilation and
Local Hooding
No. 3 Baghouse
1.
Stack j
A - Blast Furnace Outlet (Afterburner Inlet)
B - BlasL/Reverberatory Furnaces Baghouse Inlet
C - Blast/Reverberatory Furnaces Baghouse Outlet
D - Blast/Reverberatory Furnaces Wet Scrubber Outlet
E - Blast/Reverberatory Furnaces Baghouse Dust
F - Reverberatory Kettles Cyclone Inlet
G - Reverbatory Kettles Baghouse Outlet
H - Refiner Baghouse Inlet
I - Refiner Baghouse Outlet
J - No. 1 Baghouse Inlet
K - No. 1 Baghouse Outlet
L - No. 3 Baghouse Inlet
M - No. 3 Baghouse Outlet
Figure 1-1
Schematic of Blast/Reverberatory Furnaces and Kettles/Hooding Processes
with Sampling Points Shown
1-3
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Particle size distribution
Total hydrocarbons
Metals (arsenic, antimony, cadmium, total chromium, nickel, manganese, lead,
and mercury)
Dioxins/furans
Hydrochloric acid (HC1)
Chlorine (Clj)
Carbon monoxide (CO)
Sulfur dioxide (by facility CEM).
1.2 TEST PROGRAM ORGANIZATION
Figure 1.2 presents the organization and major lines of communication used in this
test program. Kevin Cavender and Rich Pelt from Radian and George Streit of ISB were
responsible for monitoring plant processes and control device operations during the tests.
Robert McCrackan of EMB was responsible for monitoring all sampling and analysis
activities. Mr. Rick Leiby, Manager, Metals Division of East Penn was the plant contact
person.
Weston was responsible for all field sampling and analytical activities, as well as
data reporting. Portions of the analyses were subcontracted to Triangle Laboratories, Inc.
(TLI) and Southwest Research Institute (SwRI).
1.3 PROGRAM OBJECTIVES
The main objective of this test effort was to gather emissions data from a secondary
lead smelter operating both a blast furnace and a reverberatory furnace.
The data were to be of sufficient quality to meet the following program objectives:
(1) establish the basis for emission standards for lead (Pb), particulate matter (PM),
hydrochloric acid (HC1), and total hydrocarbons (THC); (2) characterize control device
performance on Pb, PM, HC1, and THC; (3) approximate uncontrolled hazardous air
pollutant (HAP) emissions including metals and volatile and semi-volatile organic
compounds, aldehydes and ketones, and dioxins and furans; (4) develop emission factors
for particulate matter less than 10 microns in diameter (PM10); (5) establish the basis for
possible enhanced monitoring requirements for carbon monoxide (CO), sulfur dioxide
(SOj), and THC; and (6) monitor and record related process and operating information
suitable to support establishment of emission limits and development of emission factors.
The specific objectives for the field effort at this facility included:
• Collection of valid, representative samples during normal process operating
conditions of the sources to be evaluated.
1-4
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East Penn Manufacturing Co.
Lyon Station, Pennsylvania
EPA/Industrial Studies Branch
Technical Coordinator
George Slreit
(919)541-2364
EPA/Emission Measurement Branch
Work Assignment Manager
Robert McCrackan
(919)541-5137
Pacific Environmental Services
Final Report
Frank Meadows
(919)941-0333
East Penn Manufacturing
Test Coordinator
Rick Lciby
(215)682-6361
Weston
Test Director
Jeffrey O'Neill
(215)430-7201
Weston
Test Crew
Weston Analysis
Gravimetrics
Ray Siery
(215)524-6100
Radian Corporation
Process Monitor
Kevin Cavender/Rich Pelt
(919)541-9100
Weston
Project Director
Jim Seme
(919) 832-7042
Weston
QA/QC Officer
Paul Meeter
(215)430-7247
Triangle Laboratories
Volatiles and Semivolatiles
Gene Riley
(919)544-4664
Southwest Research Institute
Metals and Chlorides
Joe Brewer
(512)522-5168
Figure 1-2. Test Program Organization Chart
1-5
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• Measure simultaneously the emissions of total particulate matter, condensible
particulate matter, PM10, and lead at the inlet to the blast furnace afterburner,
inlet to the reverberatory and blast furnaces baghouse, outlet of the baghouse,
and outlet of the wet scrubber (exhaust stack).
• Measure the emissions of metallic HAP's at the reverberatory and blast furnaces
baghouse inlet.
• Measure total hydrocarbons sequentially at the blast furnace outlet, reverberatory
and blast furnaces baghouse inlet/outlet, and wet scrubber stack.
• Measure carbon monoxide at the blast furnace outlet and wet scrubber stack.
• Measure simultaneously the emissions of dioxins/furans, HC1, and C12 at the inlet
and outlet of the reverberatory and blast furnaces wet scrubber.
• Measure the emissions of volatile and semi-volatile organics, formaldehyde (plus
other aldehydes and ketones), total hydrocarbons, and CO at the outlet of the
blast furnace.
• Measure concentrations of dioxins/furans present in the blast and reverberatory
furnaces baghouse dust.
• Collect available sulfur dioxide data from the facility continuous emissions
monitor located on the wet scrubber exhaust stack.
• Measure simultaneously the emissions of total particulate matter, condensible
particulate, PM10, and lead at the inlet and outlet of the No. 1, No. 3, and refiner
baghouses.
• Measure simultaneously the emissions of total particulate matter, condensible
particulate, PM10, and lead at the inlet of the reverberatory kettles cyclone and
outlet of the reverberatory kettles baghouse.
In this testing effort, Weston followed standard EPA procedures for sampling and
analysis of the parameters of interest. The test program featured three runs for each
parameter plus the collection and analysis of quality control (QC) samples as required by
the methodologies employed.
Section 5 provides complete details on the sampling and analysis procedures that
were followed in this test program. These procedures can be summarized as follows:
• Filterable particulate and metals were determined by EPA Method 12 or multi-
metals test method procedures.
1-6
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• PM10 and condensible particulate were determined from a combination of
Reference Methods 201A and 202. The sampling system utilized an in-stack
cyclone to collect particulate matter > 10/tm. The impingers were analyzed
using Method 202 for condensible particulate matter.
• Metals (arsenic, antimony, cadmium, total chromium, nickel, manganese, lead,
and mercury) were determined utilizing the Methodology for the Determination
of Metals Emission in Exhaust Gases from Hazardous Waste Incineration and
Similar Combustion Processes procedures commonly known as multi-metals.
• Lead emissions were measured utilizing the procedures outlined in EPA Method
12.
• Total hydrocarbons were measured in accordance with Method 25A. Weston
used a J.U.M. Model VE-7 flame ionization analyzer for these measurements.
• Carbon monoxide was measured according to EPA Method 10 procedures. A
Thermo-Environmental Model 48 gas phase correlation filter nondispersive
infrared analyzer was used for these measurements.
• Aldehydes/ketones were determined by Method 0011. The sampling system
consists of a traversing isokinetic sample train with impingers containing 2,4-
dinitrophenylhydrazine to enhance collection of these compounds. The impingers
were rinsed with methylene chloride. Sample preparation included solvent
extraction followed by high performance liquid chromatography (HPLC)
analysis.
• Dioxins/furans were measured in accordance with EPA Method 23 procedures.
This system featured an XAD-2 resin trap to collect PCDD/PCDF. Sample
preparation included solvent extraction and analysis by high resolution GC/MS in
accordance with EPA Method 23.
• ,Semi-volatile organic compounds (boiling point > 150°C) were collected
utilizing a Modified Method 5 train as specified in SW-846, Method 0010. This
system also featured an XAD-2 resin trap to collect compounds of interest.
Sample preparation included solvent extraction and analysis by GC/MS in
accordance with SW-846, 8270.
• Volatile organic compounds (boiling point < 150°C) were collected utilizing
procedures detailed in SW-846 Method 0030. The compounds were collected on
Tenax and Tenax charcoal tubes, which were thermally desorbed and analyzed
by GC/MS in accordance with Methods 5040 and 8240.
• Hydrochloric acid and chlorine were collected utilizing proposed EPA Method
26A. The HC1 and C12 were collected in dilute sulfuric acid and sodium
hydroxide solution and analyzed by ion chromatography.
1-7
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• Dioxins/furans were measured in the baghouse dust. Sampling was conducted by
SW-846 S007 procedures utilizing a grab sampling technique with analysis by
SW-846 Method 8290 (high resolution GC/MS).
Table 1.1 provides a summary of the measured pollutants and gas stream parameters by
location, along with the associated test methods.
1-8
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TABLE 1.1
TEST LOCATIONS AND METHODS
LOCATION
POLLUTANT/PARAMETER
TEST METHOD
Blast/Reverberatory Furnaces
Baghouse Inlet
Paniculate and Metals
PM,0 and Condensible
Paniculate
Total Hydrocarbons
Gas Stream Composition (CO2
and 02)
Multi-Metals
Methods 201A and
202
Method 25A
Methods
Blast/Reverberatory Furnaces
Baghouse Outlet
(wet scrubber inlet)
Paniculate and Lead
Hydrochloric Acid/ Chlorine
PM10 and Condensible
Paniculate
PCDD/PCDF
Total Hydrocarbons
Gas Stream Composition (CO2
and
Method 12
Method 26A
Methods 201A and
202
Method 23
Method 25A
Methods
Blast/Reverberatory Furnaces
Wet Scrubber Outlet (stack)1
Paniculate and Lead
Hydrochloric Acid/Chlorine
PM10 and Condensible
Paniculate
PCDD/PCDF
Carbon Monoxide
Total Hydrocarbons
Gas Stream Composition (CO2
and
Method 12
Method 26A
Methods 201A and
202
Method 23
Method 10
Method 25A
Methods
1-9
-------
TABLE 1-1 (Concluded)
LOCATION
POLLUTANT/PARAMETER
TEST METHOD
Blast/Reverberatory Furnaces
Baghouse Dust
• Reverberatory Kettles
Cyclone Inlet
• Reverberatory Kettles
Baghouse Outlet
• Refiner Baghouse Inlet
• Refiner Baghouse Outlet
• No. 1 Baghouse Inlet
• No. 1 Baghouse Outlet
• No. 3 Baghouse Inlet
• No. 3 Baghouse Outlet
PCDD/PCDF
Paniculate and Lead
PM10 and Condensible
Particulate
Gas Stream Composition (CO2
Method S007
Method 12
Methods 201A and
202
Methods
1 The facility CEM system was utilized to monitor SO2 in the blast/reverberatory furnaces
system (scrubber) stack.
1-10
-------
SECTION 2
SUMMARY AND DISCUSSION OF RESULTS
This section contains tabulated results for all of the testing performed at the East
Penn facility. The results are presented by pollutant or parameter of interest with
subsections for the individual sources of concern. A discussion of the results and any
deviation from standard sampling procedures is provided. Detailed test data and test result
summaries are presented in Appendix A to this report.
2.1 TOTAL PARTICULATE TESTING
Testing was performed to determine the total paniculate concentrations and mass
flow rates at four test locations on the blast/reverberatory furnaces process and at the inlet
and outlet of the four ventilation and hooding baghouses (12 test locations). Table 5.1 in
Section 5 summarizes the sampling and analytical methods utilized at these locations.
Filterable particulate was determined from the multi-metals test train at the blast/reverb
furnaces baghouse inlet and from the EPA Method 12 sampling conducted at the blast
furnace outlet, blast/reverb furnaces baghouse outlet, scrubber outlet, and ventilation
baghouse inlet/outlets.
2.1.1 Blast Furnace Outlet
All three runs performed at the blast furnace outlet location yielded significant
amounts of particulate catch. An average concentration and mass rate of 11.5 gr/dscf and
376 Ib/hr, respectively, were measured on this uncontrolled process gas stream. Table 2.1
presents a summary of these test results.
2.1.2 Blast/Reverb Furnaces Process
A series of three test runs was made at three process locations: the blast/reverb
furnaces baghouse inlet (afterburner outlet), the baghouse outlet (scrubber inlet), and the
scrubber outlet (stack). These runs were performed simultaneously at the three locations
over 3 consecutive days. As expected, the concentration and mass rate at the baghouse
inlet were high, averaging 4.67 gr/dscf and 997 Ib/hr, respectively. At the outlets of the
baghouse and scrubber, the grain loading dropped to below 0.01 gr/dscf. The particulate
removal efficiency for the baghouse was calculated to be over 99.9 percent. The
particulate concentration at the scrubber outlet was actually measured as higher than at the
2-1
-------
TABLE 2-1. SUMMARY OF PARTICULATE EMISSIONS -
BLAST FURNACE OUTLET (SAMPLE POINT A)
Test run number
Test date
Average gas stream volumetric
flow, dscfm
1
12-10-92
3,700
2
12-11-92
4,400
3
12-12-92
3,500
Avg.
3,900
Paiticulate
Concentration, gr/wscf
Concentration, gr/dscf
Concentration, gr/dscf @ 15%
02
Concentration, mg/dscm
Mass emission rate, Ib/hr
Mass emission rate, kg/hr
13.0
14.6
21.9
33,400
460
209
8.56
9.17
12.0
21,000
345
157
9.75
10.9
12.5
25,000
. 321
146
10.4
11.5
15.5
26,500
376
170
2-2
-------
inlet, indicating a negative control efficiency. Table 2.2 shows the paniculate test results
for these three process sampling locations.
2.1.3 Ventilation/Hooding Baghouses
Total paniculate was measured simultaneously at the inlet and outlet of the four
ventilation baghouses: reverberatory kettles, refiner baghouse, and Nos. 1 and 3
"sanitary" baghouses. The Method 12 sampling train was used to collect these samples.
Table 2.3 presents the test results from the reverb kettles baghouse, where the average
concentration at the inlet was determined to be 0.05 gr/dscf and at the outlet was
8.4 x 10"* gr/dscf. The mass rate was reduced from 5.5 Ib/hr to 0.101 Ib/hr, for a
removal efficiency of 98.2 percent.
At the inlet of the refiner baghouse, the concentration averaged 0.037 gr/dscf and
the mass rate averaged 8.7 Ib/hr. At the outlet, a concentration of 7.0 x 1G4 gr/dscf and a
mass rate of 0.175 Ib/hr were measured, for a removal efficiency of 98.0 percent. Table
2.4 presents these test results.
At the inlet of the No. 1 sanitary baghouse, the paniculate concentration averaged
0.013 gr/dscf and the mass rate averaged 3.65 Ib/hr. Across the baghouse, these
parameters were reduced to 7.49 x 10"4 gr/dscf and 0.22 Ib/hr, for a removal efficiency of
93.9 percent. Table 2.5 presents a summary of these test results.
At the inlet of the No. 3 sanitary baghouse, the average paniculate concentration
was measured as 3.66 x 10"3 gr/dscf and the mass rate averaged 0.87 Ib/hr. At the outlet,
the concentration was reduced to 1.33 x 10"3 gr/dscf and the mass rate averaged 0.34
Ib/hr. The calculated removal efficiency for this baghouse is only 61.4 percent. Table
2.6 presents a summary of these test results.
2.2 FILTERABLE PARTICULATE, PM10 AND CONDENSIBLE PARTICULATE
TESTING
Testing to determine filterable and condensible particulate, and to allow
fractionation of the particulate catch into PM10 and non-PM10 segments, was performed at
all of the sampling locations described in Section 2.1 for total particulate. Table 5.1 in
Section 5 summarizes the sampling and analytical methods utilized for making these
determinations. Condensible particulate was determined using EPA Method 202 and PM10
was determined using Method 201A.
2.2.1 Blast Furnace Outlet
Filterable particulate made up the greatest portion of the particulate catch at the
blast furnace outlet, comprising about 98 percent of the total. The condensible fraction, of
which 80 percent was inorganic and 20 percent was organic, totaled only about 2 percent
of the total catch. PM10 amounted to 87.8 percent of all the particulate collected at this
location. Table 2.7 summarizes the results for this test location.
2-3
-------
TABLE 2-2. SUMMARY OF PARTICULATE EMISSIONS -
BLAST/REVERBERATORY FURNACES PROCESS
Baghouse Inlet (Point B)
Test run number
Test date
Average gas stream volumetric
flow, dscfm
1
12-10-92
24,700
2
12-11-92
24,900
3
12-12-92
25,100
Avg.
24,900
Particulate
Concentration, gr/wscf
Concentration, gr/dscf
Concentration, gr/dscf @ 15%
02
Concentration, mg/dscm
Mass emission rate, Ib/hr
Mass emission rate, kg/hr
4.09
4.87
146
11,200
1,030
467
3.42
4.21
126
9,640
899
408
4.05
4.94
5.48
11,300
1,061
481
3.85
4.67
92.7
10,700
997
452
Baghouse Outlet (Scrubber Inlet) (Point C)
Test run number
Test date
Average gas stream volumetric
flow, dscfm (total)
1
12-10-92
25,800
2
12-11-92
25,900
3
12-12-92
26,400
Avg.
26,000
Particulate
Concentration, gr/wscf
Concentration, gr/dscf
1.19E-03
1.37E-03
2.74E-04
3.22E-04
6.28E-04
7.30E-04
6.96E-04
8.09E-04
2-4
-------
TABLE 2-2. (Concluded)
Concentration, gr/dscf @ 15 %
02
Concentration, mg/dscm
Mass emission rate, Ib/hr
Mass emission rate, kg/hr
0.0412
3.14
0.304
0.138
3.87E-04
0.737
0.0716
0.0325
1.10E-03
1.67
0.165
0.0749
0.0142
1.85
0.180
0.0817
Baghouse Particulate Removal Efficiency 99.98
Wet Scrubber Outlet (Stack) (Point D)
Test run number
Test date
Average gas stream volumetric
flow, dscfm (total)
•
Concentration, gr/wscf
Concentration, gr/dscf
Concentration, gr/dscf @ 15%
02
Concentration, mg/dscm
Mass emission rate, Ib/hr
Mass emission rate, kg/hr
1
12-10-92
20,800
1.22E-03
1.39E-03
0.0416
3.18
0.247
0.112
2
12-11-92
18,200
6.60E-03
7.52E-03
0.0110
17.2
1.176
0.534
3
12-12-92
18,800
4.02E-03
4.63E-03
0.278
10.6
0.747
0.339
Avg.
19,300
3.49E-03
4.51E-03
0.110
10.3
0.723
0.328
Wet Scrubber Particulate Removal Efficiency -302
2-5
-------
TABLE 2-3. SUMMARY OF PARTICULATE EMISSIONS -
REVERBERATORY KETTLES BAGHOUSE
Cyclone Inlet (Point F)
Test run number
Test date
Average gas stream volumetric
flow, dscfm
Particulate
Concentration, gr/wscf
Concentration, gr/dscf
Concentration, gr/dscf @ 15%
02
Concentration, mg/dscm
Mass emission rate, Ib/hr
Mass emission rate, kg/hr
1
12-14-92
14,800
0.0238
0.0240
0.480
55.0
3.03
1.38
2
12-15-92
14,000
0.106
0.107
2.141
245
12.80
5.81
3
12-15-92
13,400
Avg.
14,100
5.79E-03
5.83E-03
0.117
13.4
0.669
0.304
0.0453
0.0456
0.912
104
5.50
2.50
Baghouse Outlet (Point G)
Test run number
Test date
Average gas stream volumetric
flow, dscfm
1
12-14-92
13,400
2
12-15-92
14,700
3
12-15-92
14,000
Avg.
14,000
Particulate
Concentration, gr/wscf
Concentration, gr/dscf
6.66E-04
6.75E-04
8.71E-04
8.78E-04
9.63E-04
9.69E-04
8.33E-04
8.41E-04
2-6
-------
TABLE 2-3. (Concluded)
Concentration, gr/dscf @ 15%
02
Concentration, mg/dscm
Mass emission rate, Ib/hr
Mass emission rate, kg/hr
0.0202
1.55
0.077
0.035
0.0263
2.01
0.110
0.050
0.0291
2.22
0.117
0.053
0.0252
1.93
0.101
0.046
Baghouse Particulate Removal Efficiency 98.2
2-7
-------
TABLE 2-4. SUMMARY OF PARTICULATE EMISSIONS -
REFINER BAGHOUSE
Baghouse Inlet (Point H)
Test run number
Test date
Average gas stream volumet-
ric flow, dscfm
1
12-14-92
27,000
2
12-15-92
26,700
Particulate
Concentration, gr/wscf
Concentration, gr/dscf
Concentration, gr/dscf @ 15%
02
Concentration, mg/dscm
Mass emission rate, Ib/hr
Mass emission rate, kg/hr
5.62E-03
5.66E-03
0.170
13.0
1.31
0.594
0.0424
0.0427
1.28
97.8
9.79
4.44
3
12-15-92
27,400
0.0625
0.0633
1.90
145
14.9
6.75
Avg.
27,000
0.0369
0.0372
1.12
85.3
8.66
3.93
Baghouse Outlet (Point I)
Test run number
Test date
Average gas stream volumet-
ric flow, dscfm
1
12-14-92
29,100
2
12-15-92
29,100
3
12-15-92
28,800
Avg.
29,000
Particulate
Concentration, gr/wscf
Concentration, gr/dscf
2.60E-04
2.63E-04
7.59E-04
7.63E-04
1.07E-03
1.09E-03
6.98E-04
7.04E-04
2-8
-------
TABLE 2-4. (Concluded)
Concentration, gr/dscf @ 15%
02
Concentration, mg/dscm
Mass emission rate, Ib/hr
Mass emission rate, kg/hr
7.89E-03
0.602
0.0656
0.0298
0.0229
1.75
0.191
0.086
0.0326
2.50
0.268
0.121
0.0211
1.62
0.175
0.0792
Baghouse Particulate Removal Efficiency 98.0
2-9
-------
TABLE 2-5. SUMMARY OF PARTICULATE EMISSIONS -
NO. 1 SANITARY BAGHOUSE
Baghouse Inlet (Point J)
Test run number
Test date
Average gas stream volumet-
ric flow, dscfm
1
12-16-92
32,400
2
12-16-92
32,200
3
12-17-92
31,600
Avg.
32,100
Particulate
Concentration, gr/wscf
Concentration, gr/dscf
Concentration, gr/dscf @ 15%
02
Concentration, mg/dscm
Mass emission rate, Ib/hr
Mass emission rate, kg/hr
0.0135
0.0137
0.410
31.4
3.80
1.72
0.0131
0.0132
0.396
30.2
3.65
1.65
0.0128
0.0130
0.398
29.8
3.51
1.59
Baghouse Outlet (Point K)
Test run number
Test date
Average gas stream volumet-
ric flow, dscfm
1
12-16-92
35,300
2
12-16-92
34,900
3
12-17-92
34,300
0.0131
0.0133
0.398
30.5
3.65
1.657
Avg.
34,800
Particulate
Concentration, gr/wscf
Concentration, gr/dscf
4.12E-04
4.15E-04
9.47E-04
9.55E-04
8.70E-04
8.78E-04
7.43E-04
7.49E-04
2-10
-------
TABLE 2-5. (Concluded)
Concentration, gr/dscf @ 15%
02
Concentration, mg/dscm
Mass emission rate, Ib/hr
Mass emission rate, kg/hr
0.0125
0.950
0.125
0.057
0.0286
2.19
0.286
0.130
0.0263
2.01
0.258
0.117
0.0225
1.72
0.223
0.101
Baghouse Particulate Removal Efficiency 93.9
2-11
-------
TABLE 2-6. SUMMARY OF PARTICULATE EMISSIONS -
NO. 3 SANITARY BAGHOUSE
Baghouse Inlet (Point L)
Test run number
Test date
Average gas stream volumetric
flow, dscfm
1
12-16-92
27,000
2
12-16-92
28,300
3
12-17-92
28,100
Avg.
27,800
Particulate
Concentration, gr/wscf
Concentration, gr/dscf
Concentration, gr/dscf @ 15%
02
Concentration, mg/dscm
Mass emission rate, Ib/hr
Mass emission rate, kg/hr
3.65E-03
3.70E-03
0.111
8.47
0.857
0.389
5.44E-03
5.50E-03
0.165
12.6
1.33
0.605
1.753-03
1.77E-03
0.053
4.05
0.427
0.194
3.61E-03
3.66E-03
0.0110
8.37
0.873
0.396
Baghouse Outlet (Point M)
Test run number
Test date
Average gas stream volumetric
flow, dscfm
1
12-16-92
29,400
2
12-16-92
30,100
3
12-17-92
29,000
Avg.
29,500
Particulate
Concentration, gr/wscf
Concentration, gr/dscf
5.56E-04
5.62E-04
1.63E-03
1.64E-03
1.76E-03
1.79E-03
1.32E-03
1.33E-03
2-12
-------
TABLE 2-6. (Concluded)
Concentration, gr/dscf @ 15%
02
Concentration, mg/dscm
Mass emission rate, Ib/hr
Mass emission rate, kg/hr
0.0112
1.29
0.141
0.0642
0.0329
3.76
0.424
0.192
0.0358
4.10
0.445
0.202
0.0266
3.05
0.337
0.153
Baghouse Particulate Removal Efficiency 61.4
2-13
-------
TABLE 2-7. SUMMARY OF FILTERABLE PARTICULATE, PM10, AND
CONDENSIBLE PARTICULATE EMISSIONS -
BLAST FURNACE OUTLET (SAMPLE POINT A)
Test run number
Test date
Average gas stream volumetric
flow, dscfm
1
12-10-92
3,180
2
12-11-92
3,720
3
12-12-92
3,470
Avg.
3,460
Filterable Paniculate >10jim
gr/dscf
Ib/hr
kg/hr
1.97
53.7
24.3
1.66
52.9
24.0
0.95
28.1
12.8
1.53
44.9
20.4
Filterable Paniculate <, 10/tm
gr/dscf
Ib/hr
kg/hr
12.3
334
151
Condensible Paniculate-Inorganic
gr/dscf
Ib/hr
kg/hr
0.306
8.34
3.78
9.05
288
131
10.5
313
142
10.6
312
141
0.193
6.15
2.79
0.135
4.02
1.82
0.211
6.17
2.80
2-14
-------
TABLE 2-7. (Concluded)
Condensible Paiticulate-Organic
gr/dscf
Ib/hr
kg/hr
0.049
1.34
0.609
0.066
2.10
0.951
0.041
1.21
0.549
0.052
1.55
0.703
Total Paniculate
gr/dscf
Ib/hr
kg/hr
Particulate Fractionation
PM10, % of total particulate
14.6
397
180
11.0
349
159
86.6
84.9
11.6
346
157
12.4
364
165
92.0
87.8
2-15
-------
2.2.2 Blast/Reverb Furnaces Process
A series of three test runs was performed at the inlet to the process baghouse
(afterburner outlet). At this location, filterable particulate made up approximately 97
percent of the total catch, while the condensible fraction was just over 3 percent. As
expected after a combustion control device, the organic portion was very low, comprising
less than 1 percent of all the condensible material collected. The particulate fraction
qualifying as PMio was about 65 percent. At the baghouse outlet, only one 4-hour run was
made (during the second run at the inlet) because of the extremely low particulate
concentration. At this location, filterable particulate made up approximately 10 percent of
all the particulate collected, and condensible particulate amounted to 90 percent (994-
percent of this being inorganic). The PM,0 fraction was approximately 96 percent. The
baghouse control efficiency measured for this inlet/outlet test was 97.2 percent. Table 2.8
presents these test results.
At the process stack (scrubber outlet), filterable particulate amounted to 27 percent
of the entire particulate catch. Condensible particulate was 73 percent of the total (98
percent inorganic, 2 percent organic). The PM10 fraction was 93.0 percent. As at
sampling point C, only one 4-hour test run was performed (simultaneous with the point C
testing) at this location. The particulate removal efficiency measured in this test was 92.7
percent. Table 2.9 presents the results for this test run.
2.2.3 Ventilation/Hooding Baghouses
The inlets and outlets of the four ventilation baghouses were also tested
simultaneously for filterable and condensible particulate, and to determine PMJO size
fractionation. As with the process baghouse and scrubber, the outlets were tested in only
one 4-hour test run simultaneous with the first test run at the inlet. Table 2.10 presents
the test results for the reverb kettles baghouse. At the inlet, filterable particulate
accounted for approximately 95 percent of the total catch (1.7 percent inorganic, 3.2
percent organic). The PM10 fraction was about 43.3 percent. At the baghouse outlet, the
filterable fraction decreased to approximately 49 percent, while the condensible portion
increased to about 51 percent (evenly split between inorganic and organic fractions). PMW
comprised about 81.1 percent of the particulate catch at the outlet. The baghouse
particulate removal efficiency was determined to be 97.5 percent.
At the inlet to the refiner baghouse, filterable particulate was measured as
approximately 85 percent of the total particulate catch. Condensible particulate was about
15 percent of the total catch, and was evenly divided into inorganic and organic fractions.
The PM10 fraction was about 42.5 percent. At the outlet, the filterable fraction increased
to about 70 percent of the total catch. Condensibles made up approximately 30 percent of
the catch (42 percent inorganic, 58 percent organic). The PM10 fraction increased across
the baghouse to 78.3 percent. The baghouse particulate removal efficiency was 93.7
percent. Table 2.11 summarizes the test results for this baghouse.
2-16
-------
TABLE 2-8. SUMMARY OF FILTERABLE PARTICULATE, PMi0, AND
CONDENSIBLE PARTICULATE EMISSIONS -
BLAST/REVERB FURNACES BAGHOUSE
Baghouse Inlet (Point B)
Test run number
Test date
Average gas stream volumetric
flow, dscfm
Run 1
12-10-92
28,900
Run 2
12-11-92
26,400
Run 3
12-12-92
27,700
Avg.
27,700
Filterable Paniculate > 10/im
gr/dscf
Ib/hr
kg/hr
1.79
445
202
2.78
630
286
0.64
152
69
1.74
409
186
Filterable Paniculate ^10/tm
gr/dscf
Ib/hr
kg/hr
2.39
594
269
4.15
940
426
1.79
425
193
2.78
653
296
Condensible Particulale-Inorganic
gr/dscf
Ib/hr
kg/hr
0.191
47.4
21.5
0.132
29.9
13.6
0.142
33.5
15.2
0.155
37.0
16.8
2-17
-------
TABLE 2-8. (Continued)
Condensible Particulate-Organic
gr/dscf
Ib/hr
kg/hr
1.07E-03
0.266
0.121
2.25E-03
0.511
0.232
6.93E-04
0.164
0.075
1.34E-03
0.314
0.142
Total Particulate
gr/dscf
Ib/hr
kg/hr
4.37
1087
473
7.6
1600
726
2.57
611
277
4.67
1099
499
Particulate Fractionation
PM10, % of total particulate
59.0
60.7
75.1
64.9
Baghouse Outlet (Point Q
Test run number
Test date
Average gas stream volumetric
flow, dscfm
12-11-92
26,967
Avg.
26,967
Filterable Particulate > 10pm
gr/dscf
Ib/hr
kg/hr
4.64E-03
1.07
0.487
4.64E-03
1.07
0.487
2-18
-------
TABLE 2-8. (Concluded)
Filterable Particulate <, 10/xm
gr/dscf
Ib/hr
kg/hr
8.81E-03
2.04
0.923
8.81E-03
2.04
0.923
Condensible Particulate-Inorganic
gr/dscf
Ib/hr
kg/hr
0.117
27.1
12.3
0.117
27.1
12.3
Condensible Particulate-Organic
gr/dscf
Ib/hr
kg/hr
6.75E-04
0.156
0.0708
6.75E-04
0.156
0.0708
Total Particulate
gr/dscf
Ib/hr
kg/hr
0.131
30.4
13.8
0.131
30.4
13.8
Particulate Fractionation
PM10, % of total particulate
96.4
96.4
Baghouse Particulate Removal Efficiency 97.2
Only one run performed due to low particulate loading.
2-19
-------
TABLE 2-9. SUMMARY OF FILTERABLE PARTICULATE, PM10, AND
CONDENSffiLE PARTICULATE EMISSIONS - BLAST/REVERB FURNACES
SCRUBBER OUTLET
(SAMPLE POINT D)
Test run number
Test date
Average gas stream volumetric
flow, dscfm
1
12-11-92
19,425
2
3
Avg.
19,425
Filterable Particulate > 10/im
gr/dscf
Ib/hr
kg/hr
9.38E-04
0.156
0.0708
9.38E-04
0.156
0.0708
Filterable Particulate <, 10/tm
gr/dscf
Ib/hr
kg/hr
2.73E-03
0.454
0.206
2.73E-03
0.454
0.206
Condensible Particulate-Inorganic
gr/dscf
Ib/hr
kg/hr
0.010
1.58
0.719
0.010
1.58
0.719
2-20
-------
TABLE 2-9. (Concluded)
Condensible Particulate-Organic
gr/dscf
Ib/hr
kg/hr
1.83E-04
0.0305
0.0138
1.83E-04
0.0305
0.0138
Total Particulate
gr/dscf
Ib/hr
kg/hr
0.014
2.22
1.01
0.014
2.22
1.01
Particulate Fiactionation
PM10, % of total participate
93.0
93.0
Scrubber Particulate Removal Efficiency 92.7
Only one run performed due to low paniculate loading.
2-21
-------
TABLE 2-10. SUMMARY OF FILTERABLE PARTICULATE, PM10, AND
CONDENSIBLE PARTICULATE EMISSIONS - REVERB KETTLES BAGHOUSE
Cyclone Inlet (Point F)
Test run number
Test date
Average gas stream volumetric
flow, dscfm
1
12-14-92
12,212
2
12-17-92
13,309
3
12-17-92
12,965
Filterable Paniculate > 10/zm
gr/dscf
Ib/hr
kg/hr
2.03E-03
0.213
0.0966
0.107
12.2
5.52
2.31E-03
0.257
0.117
Avg.
12,828
0.0371
4.22
1.91
Filterable Particulate < 10/im
gr/dscf
Ib/hr
kg/hr
1.57E-03
0.164
0.0744
5.65E-03
0.645
0.292
1.06E-03
0.118
0.0534
2.76E-03
0.309
0.140
CondensibleParticulate-Inorganic
gr/dscf
Ib/hr
kg/hr
7.58E-04
0.0794
0.0355
3.39E-04
0.0387
0.0176
1.07E-03
0.119
0.0540
7.22E-04
0.0790
0.0357
2-22
-------
TABLE 2-10. (Continued)
Condensible Particulate-Organic
gr/dscf
Ib/hr
kg/hr
3.27E-03
0.342
0.155
8.41E-04
0.0960
0.0435
2.20E-04
0.0244
0.0111
1.44E-03
0.154
0.0699
Total Particulate
gr/dscf
Ib/hr
kg/hr
7.63E-03
0.798
0.362
0.114
13.0
5.87
4.66E-03
0.518
0.236
4.21E-02
4.77
2.16
Particulate Fractionation
PM10, % of total particulate
73.4
6.0
50.5
43.31
'Run 2 not included in average
2-23
-------
TABLE 2-10. (Continued)
Baghouse Outlet (Point G)
Test run number
Test date
Average gas stream volumetric
flow, dscfm
1
12-14-92
14,019
Filterable Participate >10/im
gr/dscf
Ib/hr
kg/hr
1.91E-04
0.0229
0.0104
2
3
Avg.
14,019
1.91E-04
0.0229
0.0104
Filterable Particulate ^10/tm
gr/dscf
Ib/hr
kg/hr
3.00E-04
0.0360
0.0163
3.00E-04
0.0360
0.0163
Condensible Particulate-Inorganic
gr/dscf
Ib/hr
kg/hr
2.45E-04
0.0294
0.0134
2.45E-04
0.0294
0.0134
2-24
-------
TABLE 2-10. (Concluded)
Condensible Particulale-Organic
gr/dscf
Ib/hr
kg/hr
2.59E-04
0.0311
0.0141
2.59E-04
0.0311
0.0141
Total Particulate
gr/dscf
Ib/hr
kg/hr
9.95E-04
0.119
5.42E-02
9.95E-04
0.119
5.42E-02
Particulate Fractionation
PM10, % of total particulate
81.1
81.1
Cyclone/Baghouse Particulate Removal Efficiency 97.5
Only one run performed due to low particulate loading.
2-25
-------
TABLE 2-11. SUMMARY OF FILTERABLE PARTICULATE, PM10, AND
CONDENSIBLE PARTICULATE EMISSIONS - REFINER BAGHOUSE
Baghouse Inlet (Point H)
Test run number
Test date ,
Average gas stream volumetric
flow, dscfm
1
12-14-92
28,222
2
12-15-92
27,353
3
12-15-92
27,563
Avg.
27,713
Filterable Paniculate > 10/im
gr/dscf
Ib/hr
kg/hr
5.27E-03
1.27
0.578
1.77E-02
4.16
1.89
8.02E-03
1.90
0.860
1.03E-02
2.44
1.11
Filterable Paniculate < 10/im
gr/dscf
Ib/hr
kg/hr
2.38E-03
0.576
0.261
7.44E-03
1.74
0.791
5.87E-03
1.39
0.629
5.23E-03
1.24
0.560
Condensible Particulate-Inorganic
gr/dscf
Ib/hr
kg/hr
1.76E-04
0.0425
0.0193
4.33E-04
0.102
0.0460
3.48E-03
0.822
0.373
1.36E-03
0.322
0.146
2-26
-------
TABLE 2-11. (Continued)
Condensible Particulate-Organic
gr/dscf
Ib/hr
kg/hr
1.06E-04
2.58E-02
1.17E-02
3.96E-03
9.28E-01
4.21E-01
1.23E-05
2.91E-03
1.32E-03
1.36E-03
3.19E-01
1.45E-01
Total Particulate
gr/dscf
Ib/hr
kg/hr
7.93E-03
1.91
0.870
2.95E-02
6.93
3.15
1.74E-02
4.11
1.86
1.83E-02
4.32
1.96
Particulate Fractionation
PMj0, % of total particulate
33.7
40.0
53.9
42.5
2-27
-------
TABLE 2-11. (Continued)
Baghouse Outlet (Point I)
Test run number
Test date
Average gas stream volumetric
flow, dscfm
1
12-14-92
28,304
2
3
Avg.
28,304
Filterable Paniculate >10/tm
gr/dscf
Ib/hr
kg/hr
2.44E-04
0.0593
0.0269
2.44E-04
0.0593
0.0269
Filterable Particulate <10/xm
gr/dscf
Ib/hr
kg/hr
5.49E-04
0.133
0.0605
5.49E-04
0.133
0.0605
Condensible Particulate-Inorganic
gr/dscf
Ib/hr
kg/hr
1.40E-04
0.0340
0.0154
1.40E-04
0.0340
0.0154
2-28
-------
TABLE 2-11. (Concluded)
Condensible Particulale-Organic
gr/dscf
Ib/hr
kg/hr
1.96E-04
0.0476
0.0216
1.96E-04
0.0476
0.0216
Total Particulate
gr/dscf
Ib/hr
kg/hr
1.13E-03
0.274
0.124
1.13E-03
0.274
0.124
Particulate Fractionation
PM10, % of total participate
78.3
78.3
Baghouse Particulate Removal Efficiency 93.7
Only one run performed due to low paniculate loading.
2-29
-------
Filterable participate made up approximately 89 percent of the catch at the inlet to
the No. 1 sanitary baghouse. Condensible particulate at this location comprised about 11
percent (40 percent inorganic, 60 percent organic). Approximately 87.4 percent of the
total catch at the inlet qualified as PM10. At the outlet, filterable particulate was about 34
percent, while condensible particulate accounted for about 66 percent (47 percent
inorganic, 53 percent organic). The PM10 fraction was similar to the inlet, at 83.7
percent. The particulate removal efficiency measured for this baghouse was 93.5 percent.
These test results are summarized in Table 2.12.
At the No. 3 sanitary baghouse inlet, filterable particulate accounted for 80 percent
of the total particulate catch. The condensible portion was about 20 percent of the total
catch (67 percent inorganic, 33 percent organic). The PM10 fraction constituted about 83.3
percent of all the particulate collected. At the outlet to this baghouse, filterable particulate
was reduced to 38 percent of the total catch. Condensible particulate formed 62 percent of
all the particulate collected (96 percent inorganic, 4 percent organic). The PM,0 fraction
at the outlet was about 66.6 percent. The particulate removal efficiency of the No. 3
baghouse for the single inlet/outlet test was 37.8 percent. Table 2.13 presents a summary
of the test results for this baghouse.
2.3 METALS TESTING
Emissions of several metallic HAP's were measured at the inlet to the blast/reverb
furnaces baghouse. In addition, lead emissions were determined at several locations as
follows: blast furnace outlet, blast/reverb furnaces process, and ventilation/hooding
baghouse inlets and outlets. The EPA multi-metals sampling train was used to measure
the metals content in the process gas stream entering the baghouse. This testing was
performed simultaneously with the EPA Method 12 lead testing at the four sampling points
in the blast/reverb furnaces exhaust gas stream.
2.3.1 Blast/Reverb Furnaces Baghouse Inlet (Metals)
The concentrations and mass rates of eight metallic HAP's (including lead) were
measured in three test runs performed at the furnaces process baghouse (sampling point
B). The highest concentrations by far were found for lead and cadmium. The average
lead mass rate entering the baghouse was found to be 13.9 Ib/hr, and the average cadmium
mass rate was 24.3 Ib/hr. The next most prominent metals were antimony (2.6 Ib/hr),
arsenic, and mercury (both 1.3 Ib/hr). The other three metals averaged less than 0.01
Ib/hr at the baghouse inlet. Table 2.14 summarizes the test results for the multi-metals
testing.
2.3.2 Blast/Reverb Furnaces Process (Lead)
At the blast furnace outlet, the average lead concentration was measured as 1.62
gr/dscf and the average mass rate was 53.5 Ib/hr. Table 2.15 summarizes these test
results.
2-30
-------
TABLE 2-12. SUMMARY OF FILTERABLE PARTICULATE, PM10, AND
CONDENSIBLE PARTICULATE EMISSIONS - NO. 1 SANITARY BAGHOUSE
Baghouse Inlet (Point J)
Test run number
Test date
Average gas stream volumetric
flow, dscfm
1
12-16-92
32,370
2
12-17-92
31,383
Filterable Particulate > 10/im
gr/dscf
Ib/hr
kg/hr
4.64E-03
1.29
0.584
3.17E-04
0.09
0.0387
3
12-17-92
31,356
6.05E-04
0.16
0.0738
Avg.
31,703
1.86E-03
0.51
0.232
FUterable Particulate <, 10/im
gr/dscf
Ib/hr
kg/hr
1.06E-02
2.93
1.33
7.76E-03
2.09
0.95
Condensible Particulate-Inorganic
gr/dscf
Ib/hr
kg/hr
4.94E-04
0.137
0.0622
4.21E-04
0.113
0.0513
9.39E-03
2.52
1.15
9.24E-03
2.52
1.14
7.15E-04
0.192
0.0872
5.43E-04
0.147
0.0669
2-31
-------
TABLE 2-12. (Continued)
Condensible Particulale-Organic
gr/dscf
Ib/hr
kg/hr
8.97E-05
0.0249
0.0113
1.30E-03
0.349
0.158
1.03E-03
0.278
0.126
8.08E-04
0.217
0.0986
Total Paiticulate
gr/dscf
Ib/hr
kg/hr
1.58E-02
4.38
1.99
9.80E-03
2.64
1.20
1.17E-02
3.15
1.44
1.24E-02
3.39
1.54
Particulate Fractionation
PM10, % of total particulate
70.6
96.7
94.9
87.4
2-32
-------
TABLE 2-12. (Continued)
Baghouse Outlet (Point K)
Test run number
Test date
Average gas stream volumetric
flow, dscfm
1
12-16-92
36,858
2
3
Avg.
36,858
Filterable Particulate > 10/zm
gr/dscf
Ib/hr
kg/hr
1.15E-04
0.0364
0.0165
1.15E-04
0.0364
0.0165
Filterable Particulate <10/im
gr/dscf
Ib/hr
kg/hr
1.21E-04
0.0382
0.0173
1.21E-04
0.0382
0.0173
Condensible Particulate-Inorganic
gr/dscf
Ib/hr
kg/hr
2.19E-04
0.0691
0.0314
2.19E-04
0.0691
0.0314
2-33
-------
TABLE 2-12. (Concluded)
Condensible Paniculate-Organic
gr/dscf
Ib/hr
kg/hr
2.49E-04
0.0786
0.0356
2.49E-04
0.0786
0.0356
Total Particulate
gr/dscf
Ib/hr
kg/hr
7.04E-04
0.222
0.101
7.04E-04
0.222
0.101
Particulate Fractionation
PM10, % of total paniculate
83.7
83.7
Baghouse Particulate Removal Efficiency 93.5
Only one run performed due to low paniculate loading.
2-34
-------
TABLE 2-13. SUMMARY OF FILTERABLE PARTICULATE, PM10, AND
CONDENSIBLE PARTICULATE EMISSIONS - NO. 3 SANITARY BAGHOUSE
Baghouse Inlet (Point L)
Test run number
Test date
Average gas stream volumetric
flow, dscfm
Filterable Paniculate > 10/un
gr/dscf
Ib/hr
kg/hr
1
12-16-92
27,709
1.01E-03
0.240
0.109
2
12-17-92
28,309
1.75E-04
0.0425
0.0193
3
12-17-92
28,602
Avg.
28,207
2.28E-04
0.0559
0.0254
4.71E-04
0.113
0.0511
Filterable Paniculate < 10/xm
gr/dscf
Ib/hr
kg/hr
4.60E-02
1.09
0.495
5.14E-05
0.0125
5.66E-03
7.74E-04
0.190
0.0861
1.81E-03
0.431
0.196
Condensible Particulate-Inorganic
gr/dscf
Ib/hr
kg/hr
2.13E-04
0.0506
0.0229
3.18E-04
0.0772
0.0350
6.02E-04
0.148
0.0670
3.78E-04
0.0919
0.0416
2-35
-------
TABLE 2-13. (Continued)
Condensible Particulate-Organic
gr/dscf
Ib/hr
kg/hr
1.65E-04
0.0392
0.0178
3.62E-04
0.0878
0.0398
4.49E-05
0.0110
4.99E-03
1.91E-04
0.0460
0.0209
Total Particulate
gr/dscf
Ib/hr
kg/hr
4.74E-02
1.42
0.645
9.06E-04
0.220
0.100
1.65E-03
0.405
0.183
1.67E-02
0.682
0.309
Particulate Fractionation
PM,0, % of total paniculate
83.1
80.7
86.2
83.3
2-36
-------
TABLE 2-13. (Continued)
Baghouse Outlet (Point M)
Test run number
Test date
Average gas stream volumetric
flow, dscfm
1
12-16-92
29,369
2
3
Avg.
29,369
Filterable Paiticulate > 10/im
gr/dscf
Ib/hr
kg/hr
5.59E-04
0.141
0.0639
5.59E-04
0.141
0.0639
Filterable Particulate <, 10/un
gr/dscf
Ib/hr
kg/hr
7.92E-05
1.99E-02
9.04E-03
7.92E-05
1.99E-02
9.04E-03
Condensable Particulate-Inorganic
gr/dscf
Ib/hr
kg/hr
l.OOE-03
0.252
0.114
l.OOE-03
0.252
0.114
2-37
-------
TABLE 2-13. (Concluded)
Condensible Particulate-Organic
gr/dscf
Ib/hr
kg/hr
4.22E-05
1.06E-02
4.82E-03
4.22E-05
1.06E-02
4.82E-03
Total Particulate
gr/dscf
Ib/hr
kg/hr
1.68E-03
0.424
0.192
1.68E-03
0.424
0.192
Particulate Fractionation
PM10, % of total particulate
66.6
66.6
Baghouse Particulate Removal Efficiency 37.8
Only one run performed due to low particulate loading.
2-38
-------
TABLE 2-14. SUMMARY OF METALS EMISSIONS - BLAST/REVERB FURNACES
BAGHOUSE INLET (SAMPLE POINT B)
Test run number
Test date
Average gas stream
volumetric flow,
dscfm
i
12-10-92
24,700
2
12-11-92
24,900
3
12-12-92
25,100
Avg.
24,900
CONCENTRATION, /*/m3
Antimony (Sb)
Arsenic (As)
Cadmium (Cd)
Chromium (Cr)
Lead(Pb)
Manganese (Mn)
Mercury (Hg)
Nickel (Ni)
24,700
19,800
254,100
< 56.1
135,900
< 9.67
10,800
< 130
17,894
18,351
292,200
53.9
174,000
7.30
15,000
89
40,573
< 12,787
237,500
85.9
137,600
< 1.83
15,200
< 223
27,700
< 14,800
261,300
< 65.3
149,200
< 4.35
13,700
< 88
CONCENTRATION, Ib/dscf
Antimony
Arsenic
Cadmium
Chromium
Lead
Manganese
Mercury
Nickel
1.54E-06
1.23E-06
1.59E-05
< 3.50E-09
8.49E-06
< 6.03E-10
6.72E-07
< 8.09E-09
1.12E-06
1.15E-06
1.82E-05
3.36E-09
1.09E-05
4.56E-10
9.39E-07
5.53E-09
2.53E-06
< 7.98E-07
1.48E-05
5.36E-09
8.59E-06
<1.14E-10
9.49E-07
<1.39E-08
1.73E-06
< 9.27E-07
1.63E-05
< 3.49E-09
9.32E-06
<2.72E-10
8.53E-07
< 5.51E-09
2-39
-------
TABLE 2-14. (Continued)
CONCENTRATION, Ib/dscf @ 15% C^
Antimony
Arsenic
Cadmium
Chromium
Lead
Manganese
Mercury
Nickel
4.62E-05
3.70E-05
4.76E-04
< 1.05E-07
2.55E-04
< 1.81E-08
2.01E-05
<2.43E07
3.35E-05
3.44E-05
5.47E-04
1.01E-07
3.26E-04
1.37E-08
2.82E-05
1.66E-07
2.81E-06
8.87E-07
1.65E-05
5.96E-09
9.55E-06
< 1.27E-10
1.05E-06
< 1.55E-08
2.75E-05
< 2.40E-05
3.47E-04
< 5.31E-08
1.97E-04
< 7.60E-09
1.65E-05
< 9.83E-08
EMISSION RATE, Ib/hr
Antimony
Arsenic
Cadmium
Chromium
Lead
Manganese
Mercury
Nickel
2.28
1.83
23.5
< 5.18E-03
12.6
< 8.93E-04
0.994
< 1.20E-02
1.67
1.71
27.2
5.02E-03
16.2
6.81E-04
1.40
8.26E-03
3.81
< 1.20
22.3
8.07E-03
12.9
< 1.72E-04
1.43
< 2.09E-02
2.59
< 1.38
24.3
< 5.23E-03
13.9
< 4.04E-04
1.27
< 8.24E-03
2-40
-------
TABLE 2-14. (Concluded)
EMISSION RATE, kg/hr
Antimony
Arsenic
Cadmium
Chromium
Lead
Manganese
Mercury
Nickel
1.03
0.829
10.6
< 2.35E-03
5.69
<4.05E04
0.451
< 5.43E-03
0.757
0.776
12.4
2.28E-03
7.36
3.09E-04
0.636
3.74E-03
1.73
< 0.545
10.1
3.66E-03
5.87
< 7.79E-05
0.648
< 9.50E-03
1.17
< 0.626
11.0
< 2.37E-03
6.31
< 1.83E-04
0.578
< 3.74E-03
2-41
-------
TABLE 2-15. SUMMARY OF LEAD EMISSIONS - BLAST FURNACE OUTLET
(SAMPLE POINT A)
Test run number
Test date
Average gas stream
volumetric flow, dscfm
1
12-10-92
3,700
2
12-11-92
4,400
3
12-12-92
3,500
Avg.
3,900
Lead
Concentration, Ib/dscf
Concentration, Ib/dscf @ 15%
02
Concentration, fig/m3
Mass emission rate, Ib/hr
Mass emission rate, kg/hr
2.19E-04
3.28E-04
3.51E+06
48.4
21.9
2.50E-04
3.26E-04
4.00E+06
65.8
29.9
2.23E-04
2.57E-04
3.57E+06
46.2
21.0
2.31E-04
3.04E-04
3.69E4-06
53.5
24.3
2-42
-------
At the process baghouse inlet (following the afterburner), the lead average
concentration and mass rate were reduced to 0.057 gr/dscf and 12.1 Ib/hr, respectively.
Further reductions to 0.0003 gr/dscf and 0.058 Ib/hr were effected across the baghouse.
The lead removal efficiency for the baghouse was determined to be 99.5 percent. The wet
scrubber had a minimal impact on the gas stream lead content, reducing the mass rate to
0.047 Ib/hr, for a lead removal efficiency of 18.6 percent. Table 2.16 summarizes these
test results.
2.3.3 Ventilation/Hooding Baghouses (Lead')
Gas stream lead content was measured at the four ventilation baghouses: the
reverberatory kettles baghouse, the refiner baghouse, and the Nos. 1 and 3 sanitary
baghouses.
At the inlet to the reverb kettles baghouse, the average lead concentration and mass
rate were 0.036 gr/dscf and 4.42 Ib/hr, respectively. At the outlet, the concentration was
reduced to 0.0003 gr/dscf and the mass rate to 0.039 Ib/hr, for a lead removal efficiency
of 99.1 percent. Table 2.17 summarizes the results of this test.
The inlet values of lead concentration and mass rate for the refiner baghouse were
0.028 gr/dscf and 6.57 Ib/hr, respectively. At the outlet, values of 0.0002 gr/dscf and
0.047 Ib/hr, respectively, were measured. The lead removal efficiency for this baghouse
was 99.3 percent. These test results are summarized in Table 2.18.
For the No. 1 sanitary baghouse, the lead concentration and mass rate measured at
the inlet were 0.007 gr/dscf and 1.96 Ib/hr, respectively. Across the baghouse, these
figures were reduced to 0.0001 gr/dscf and 0.044 Ib/hr. The lead removal efficiency for
this baghouse was determined to be 97.8 percent. Table 2.19 summarizes the test results
for this baghouse.
The lead concentration and mass rate at the inlet to the No. 3 sanitary baghouse
were 0.0027 gr/dscf and 0.65 Ib/hr, respectively. At the outlet, lead was measured at
0.0008 gr/dscf and 0.20 Ib/hr. The lead removal efficiency was only 69.1 percent. Table
2.20 summarizes these test results.
2.4 HYDROCHLORIC ACID/CHLORINE TESTING
Testing was performed at the furnaces process scrubber inlet (baghouse outlet) and
scrubber outlet (stack) to determine the hydrochloric acid (HC1) and chlorine (Cy content
of the process gas stream. The test team used Method 26A to make these measurements.
At the inlet to the scrubber, the average HC1 mass rate was measured as 26.2 Ib/hr.
The outlet value was 0.024 Ib/hr, for an HC1 removal efficiency of 99.9 percent. The
inlet C12 mass rate was 0.62 Ib/hr, and the outlet C12 mass rate was 0.015 Ib/hr. The
2-43
-------
TABLE 2-16. SUMMARY OF LEAD EMISSIONS -
BLAST/REVERBERATORY FURNACES PROCESS
Baghouse Inlet (Point B)
Test run number
Test date
Average gas stream
volumetric flow, dscfm
Lead
Concentration, Ib/dscf
Concentration, Ib/dscf @
15% O2
Concentration, /xg/m3
Mass emission rate, Ib/hr
Mass emission rate, kg/hr
1
12-10-92
24,700
8.45E-06
2.53E-04
1.35E+05
12.5
5.67
2
12-11-92
24,900
9.69E-06
2.91E-04
1.55E+05
14.5
6.56
3
12-12-92
25,100
6.27E-06
6.97E-06
l.OOE+05
9.44
4.28
Avg.
24,900
8.14E-06
1.84E-04
1.30E+05
12.1
5.51
Baghouse Outlet (Scrubber Inlet) (Point Q
Test run number
Test date
Average gas stream
volumetric flow, dscfm
1
12-10-92
25,800
2
12-11-92
25,900
3
12-12-92
26,400
Avg.
26,000
2-44
-------
TABLE 2-16. (Concluded)
Lead
Concentration, Ib/dscf
Concentration, Ib/dscf @
15% O2
Concentration, /ig/m3
Mass emission rate, Ib/hr
Mass emission rate, kg/hr
1.74E-08
5.23E-07
279
0.0270
0.0122
5.82E-08
6.98E-08
932
0.0905
0.0410
3.59E-08
5.38E-08
575
0.0568
0.0258
3.72E-08
2.16E-07
595
0.0581
0.0263
Baghouse Lead Removal Efficiency 99.5
Wet Scrubber Outlet (Stack) (Point D)
Test run number
Test date
Average gas stream
volumetric flow, dscfm
1
12-10-92
20,800
2
12-11-92
18,200
3
12-12-92
18,800
Avg.
19,300
Lead
Concentration, Ib/dscf
Concentration, Ib/dscf @
15% O2
Concentration, /*g/m3
Mass emission rate, Ib/hr
Mass emission rate, kg/hr
6.07E-08
1.82E-06
972
0.0756
0.0343
2.40E-08
3.51E-08
384
0.0262
0.0119
3.54E-08
2.12E-06
567
0.0399
0.0181
4.00E-08
1.33E-06
641
0.0473
0.0214
Wet scrubber Lead Removal Efficiency 18.6
2-45
-------
TABLE 2-17. SUMMARY OF LEAD EMISSIONS -
REVERBERATORY KETTLES BAGHOUSE
Cyclone Inlet (Point F)
Test run number
Test date
Average gas stream
volumetric flow, dscfm
1
12-14-92
• 14,800
2
12-15-92
14,000
3
12-15-92
13,400
Avg.
14,100
Lead
Concentration, Ib/dscf
Concentration, Ib/dscf @
15% O2
Concentration, /zg/m3
Mass emission rate, Ib/hr
Mass emission rate, kg/hr
5.07E-06
1.01E-04
8.11E+04
4.48
2.03
9.37E-06
1.87E-04
1.50E+05
7.84
3.56
1.17E-06
2.35E-05
1.88E+04
0.943
0.428
5.20E-06
1.04E-04
8.33E+04
4.42
2.01
Baghouse Outlet (Point G)
Test run number
Test date
Average gas stream
volumetric flow, dscfm
1
12-14-92
13,400
2
12-15-92
14,700
3
12-15-92
14,000
Avg.
14,000
2-46
-------
TABLE 2-17. (Concluded)
Lead
Concentration, Ib/dscf
Concentration, Ib/dscf @
15% O2
Concentration, /xg/m3
Mass emission rate, Ib/hr
Mass emission rate, kg/hr
6.46E-08
1.94E-06
1,035
0.0518
0.0235
4.94E-08
1.48E-06
792
0.0435
0.0197
2.63E-08
7.90E-07
422
0.0222
0.0101
4.68E-08
1.40E-06
749
0.0392
0.0178
Baghouse Lead Removal Efficiency 99.1
2-47
-------
TABLE 2-18. SUMMARY OF LEAD EMISSIONS -
REFINER BAGHOUSE
Baghouse Inlet (Point H)
Test run number
Test date
Average gas stream
volumetric flow, dscfm
1
12-14-92
27,000
2
12-15-92
26,700
3
12-15-92
27,400
Lead
Concentration, Ib/dscf
Concentration, Ib/dscf @
15% O2
Concentration, /ig/m3
Mass emission rate, Ib/hr
Mass emission rate, kg/hr
5.07E-07
1.52E-05
8.11E+03
0.820
0.372
4.96E-06
1.49E-04
7.95E+04
7.96
3.61
6.64E-06
1.99E-04
1.06E+05
10.9
4.96
Avg.
27,000
4.04E-06
1.21E-04
6.46E+04
6.57
2.98
Baghouse Outlet (Point I)
Test run number
Test date
Average gas stream
volumetric flow, dscfm
1
12-14-92
29,100
2
12-15-92
29,100
3
12-15-92
28,800
Avg.
29,000
2-48
-------
TABLE 2-18. (Concluded)
Lead
Concentration, Ib/dscf
Concentration, Ib/dscf @
15% O2
Concentration, /xg/m3
Mass emission rate, Ib/hr
Mass emission rate, kg/hr
2.50E-08
7.51E-07
401
0.0438
0.0199
2.64E-08
7.93E-07
424
0.0462
0.0210
3.05E-08
9.14E-07
488
0.0526
0.0239
2.73E-08
8.20E-07
438
0.0475
0.0216
Baghouse Lead Removal Efficiency 99.3
2-49
-------
TABLE 2-19. SUMMARY OF LEAD EMISSIONS -
NO.l SANITARY BAGHOUSE
Baghouse Inlet (Point J)
Test run number
Test date
Average gas stream
volumetric flow, dscfm
1
12-16-92
32,400
Lead
Concentration, Ib/dscf
Concentration, Ib/dscf @
15% O2
Concentration, /*g/m3
Mass emission rate, Ib/hr
Mass emission rate, kg/hr
9.56E-07
2.87E-05
15,309
1.86
0.843
2
12-16-92
32,200
3
12-17-92
31,600
Avg.
32,100
1.12E-06
3.36E-05
17,955
2.17
0.983
9.77E-07
2.93E-05
15,645
1.85
0.840
1.02E-06
3.05E-05
16,303
1.96
0.889
Baghouse Outlet (Point K)
Test run number
Test date
Average gas stream
volumetric flow, dscfm
1
12-16-92
35,300
2
12-16-92
34,900
3
12-17-92
34,300
Avg.
34,800
2-50
-------
TABLE 2-19. (Concluded)
Lead
Concentration, Ib/dscf
Concentration, Ib/dscf @
15% O2
Concentration, /xg/m3
Mass emission rate, Ib/hr
Mass emission rate, kg/hr
3.63E-08
1.09E-06
582
0.0768
0.0348
1.27E-08
3.81E-07
203
0.0266
0.0121
1.36E-08
4.07E-07
217
0.0279
0.0127
2.09E-08
6.26E-07
334
0.0438
0.0199
Baghouse Lead Removal Efficiency 97.8
2-51
-------
TABLE 2-20. SUMMARY OF LEAD EMISSIONS -
N0.3 SANITARY BAGHOUSE
Baghouse Inlet (Point L)
Test run number
Test date
Average gas stream
volumetric flow, dscfm
Lead
Concentration, Ib/dscf
Concentration, Ib/dscf @
15% O2
Concentration, ptg/m3
Mass emission rate, Ib/hr
Mass emission rate, kg/hr
1
12-16-92
27,000
3.95E-07
1.19E-05
6,328
0.640
0.290
2
12-16-92
28,300
6.41E-07
1.92E-05
10,259
1.087
0.493
3
12-17-92
28,100
1.33E-07
4.00E-06
2,134
0.225
0.102
Avg.
27,800
3.90E-07
1.17E-05
6,240
0.651
0.295
Baghouse Outlet (Point M)
Test run number
Test date
Average gas stream
volumetric flow, dscfm
1
12-16-92
29,400
2
12-16-92
30,100
3
12-17-92
29,000
Avg.
29,500
2-52
-------
TABLE 2-20. (Concluded)
Lead
Concentration, Ib/dscf
Concentration, Ib/dscf @
15% O2
Concentration, /tg/m3
Mass emission rate, Ib/hr
Mass emission rate, kg/hr
2.04E-07
4.08E-06
3,264
0.359
0.163
9.34E-08
1.87E-06
1,496
0.168
0.076
4.36E-08
8.73E-07
699
0.076
0.034
1.14E-07
2.27E-06
1,820
0.2012
0.0913
Baghouse Lead Removal Efficiency 69.1
2-53
-------
resulting C12 removal efficiency for the scrubber was 97.6 percent. Table 2.21 presents
the results of the HC1/C12 testing.
2.5 DIOXINS/FURANS TESTING
2.5.1 Scrubber Gas Stream
Testing to determine concentrations and mass rates of dioxins and furans
(PCDD/PCDF) was performed using EPA Method 23 procedures. Simultaneous sampling
was carried out at the same locations as the testing for HC1/C12, the inlet and outlet of the
furnaces process scrubber. Tables 2.22 and 2.23 summarize the test results by homologue
for the scrubber inlet and outlet, respectively.
The average total PCDD/PCDF mass rate measured at the scrubber inlet was
<3.07 x 10"7 Ib/hr, while the average mass rate at the scrubber outlet was 1.59 x 10"7
Ib/hr. The dioxin removal efficiency of the scrubber was found to be negative for each of
the three test runs. For furans, the removal efficiency was positive for all three runs and
averaged about 56.8 percent.
Toxic equivalent mass flow rates were also calculated for each test run at both
sampling locations. The average total toxic equivalent mass rates at the scrubber inlet and
outlet were 9.36 x 10"9 and 2.84 x 10'9 Ib/hr, respectively.
2.5.2 Process Baghouse Dust
Baghouse dust samples were collected during the PCDD/PCDF sampling at the
inlet and outlet of the process scrubber. A total of three composite samples (one per test
run) was obtained from the baghouse screw conveyor. Analysis for dioxin and furan
content was carried out using EPA Method 8290 procedures. Table 2.24 summarizes the
data in parts per trillion (ppt).
2.6 ALDEHYDES/KETONES TESTING
Testing for aldehydes/ketones was performed in accordance with EPA Method 0011
at the blast furnace outlet (sampling point A). All reported analytes, with the exception of
acetaldehyde and benzaldehyde, were measured at a mass rate of less than 0.10 Ib/hr. The
average mass rates for acetaldehyde and benzaldehyde were 0.17 and 0.11 Ib/hr,
respectively. Table 2.25 summarizes the test results for aldehydes/ketones.
2.7 SEMI-VOLATILE ORGANICS TESTING
Samples for semi-volatile organics analysis were collected only at the blast furnace
outlet (sampling point A), using EPA Method 0010. Table 2.26 summarizes the results of
2-54
-------
TABLE 2-21. SUMMARY OF HYDROCHLORIC ACID AND CHLORINE
EMISSIONS - BLAST/REVERB FURNACES PROCESS
Baghouse Outlet (Scrubber Inlet) (Point Q
Test run number
Test date
Average gas stream
volumetric flow, dscfm
1
12-8-92
24,800
2
12-8-92
28,000
3
12-9-92
24,900
Avg.
25,900
Hydrochloric Acid
ppm/v
ppm/v @ 15% O2
Mg/m3
Ib/hr
kg/hr
131
178
1.98E+05
18.4
8.34
235
214
3.57E+05
37.4
17.0
160
192
2.43E+05
22.7
10.3
175
195
2.66E+05
26.2
11.9
Chlorine
ppm/v
ppm/v @ 15% O2
/xg/m3
Ib/hr
kg/hr
6.72
9.16
19,804
1.84
0.834
9.24E-02
8.40E-02
272
2.86E-02
1.30E-02
0
0
0
0
0
2.27
3.08
6,692
0.622
0.282
2-55
-------
TABLE 2-21. (Concluded)
Scrubber Outlet (Point D)
Test run number
Test date
Average gas stream
volumetric flow, dscfm
1
12-8-92
19,400
2
12-8-92
21,200
3
12-9-92
18,700
Avg.
19,800
Hydrochloric Acid
ppm/v
ppm/v @ 15% O2
Mg/ni3
Ib/hr
kg/hr
0.192
0.274
291
0.0211
9.58E-03
0.200
0.317
304
0.0241
0.0109
0.252
0.419
381
0.0268
0.0121
0.215
0.337
325
0.0240
0.0109
Chlorine
ppm/v
ppm/v @ 15% O2
/ig/m3
Ib/hr
kg/hr
0.0820
0.117
242
0.0176
7.97E-03
ND
ND
ND
ND
ND
0.132
0.221
390
0.0274
1.24E-02
<7.15E-02
< 0.113
< 211
< 0.0150
<6.80E-03
Scrubber Hydrochloric Acid Removal Efficiency ^ 99.91
Scrubber Chlorine Removal Efficiency 97.6
2-56
-------
TABLE 2-22. SUMMARY OF DIOXIN AND FURAN EMISSIONS -
BLAST/REVERB FURNACES BAGHOUSE OUTLET
(SAMPLE POINT C)
Test run number
Test date
Average gas
stream volumetric
flow, dscfm
1
12-8-92
26,800
2
12-9-92
24,600
3
12-9-92
26,400
Avg.
25,900
DIOXIN CONCENTRATION, ppb/v
2,3,7,8-TCDD
1,2,3,7,8-PeCDD
1,2,3,4,7,8-
HxCDD
1,2,3,6,7,8-
HxCDD
1,2,3,7,8,9-
HxCDD
1,2,3,4,6,7,8-
HpCDD
Total TCDD
Total PeCDD
Total HxCDD
Total HpCDD
OCDD
Total PCDD
< 5.85E-07
< 5.29E-07
< 6.43E-07
< 4.82E-07
< 6.43E-07
1.33E-06
1.95E-06
2.11E-06
1.93E-06
1.33E-06
6.15E-06
1.35E-05
< 2.02E-07
< 3.65E-07
< 3.33E-07
< 1.66E-07
< 3.33E-07
1.07E-06
1.37E-05
1.46E-06
2.83E-06
1.07E-06
6.22E-06
2.53E-05
< 3.85E-07
< 3.48E-07
< 4.76E-07
< 3.17E-07
< 3.17E-07
1.17E-06
3.08E-05
2.79E-06
4.76E-07
5.84E-07
6.21E-06
4.09E-05
< 3.91E-07
< 4.14E-07
< 4.84E-07
< 3.22E-07
< 4.31E-07
1.19E-06
1.55E-05
2.12E-06
1.74E-06
9.94E-07
6.19E-06
2.66E-05
2-57
-------
TABLE 2-22. (Continued)
DIOXIN CONCENTRATION, ng/dscm
2,3,7,8-TCDD
1,2,3,7,8-PeCDD
1,2,3,4,7,8-
HxCDD
1,2,3,6,7,8-
HxCDD
1,2,3,7,8,9-
HxCDD
1,2,3,4,6,7,8-
HpCDD
Total TCDD
Total PeCDD
Total HxCDD
Total HpCDD
OCDD
Total PCDD
< 0.0078
< 0.0078
< 0.0104
< 0.0078
< 0.0104
0.0235
0.0261
0.0313
0.0313
0.0235
0.1175
0.2297
< 0.0027
< 0.0054
< 0.0054
< 0.0027
< 0.0054
0.0189
0.1838
0.0216
0.0460
0.0189
0.1189
0.3892
< 0.0052
< 0.0052
< 0.0077
< 0.0052
< 0.0052
0.0206
0.4126
0.0413
0.0077
0.0103
0.1186
0.5906
< 0.0052
< 0.0061
< 0.0079
< 0.0052
< 0.0070
0.0210
0.2075
0.0314
0.0283
0.0176
0.1183
0.4032
2-58
-------
TABLE 2-22. (Continued)
DIOXIN CONCENTRATION, ng/dscm @ 15% Oz
2,3,7,8-TCDD
1,2,3,7,8-PeCDD
1,2,3,4,7,8-
HxCDD
1,2,3,6,7,8-
HxCDD
1,2,3,7,8,9-
HxCDD
1,2,3,4,6,7,8-
HpCDD
Total TCDD
Total PeCDD
Total HxCDD
Total HpCDD
OCDD
Total PCDD
< 0.0107
< 0.0107
< 0.0142
< 0.0107
< 0.0142
0.0320
0.0356
0.0427
0.0427
0.0320
0.1602
0.3133
< 0.0045
< 0.0090
< 0.0090
< 0.0045
< 0.0090
0.0315
0.3063
0.0360
0.0766
0.0315
0.1982
0.6487
< 0.0063
< 0.0063
< 0.0095
< 0.0063
< 0.0063
0.0253
0.5052
0.0505
0.0095
0.0126
0.1453
0.7231
< 0.0072
< 0.0087
< 0.0109
< 0.0072
< 0.0099
0.0296
0.2824
0.0431
0.0429
0.0254
0.1679
0.5617
DIOXIN EMISSIONS, Ib/hr
2,3,7,8-TCDD
1,2,3,7,8-PeCDD
1,2,3,4,7,8-
HxCDD
1,2,3,6,7,8-
HxCDD
< 7.86E-10
< 7.86E-10
< 1.05E-09
< 7.86E-10
< 2.49E-10
< 4.99E-10
< 4.99E-10
< 2.49E-10
< 5.09E-10
< 5.09E-10
< 7.64E-10
< 5.09E-10
< 5.15E-10
< 5.98E-10
< 7.70E-10 •
< 5.15E-10
2-59
-------
TABLE 2-22. (Continued)
1,2,3,7,8,9-
HxCDD
1,2,3,4,6,7,8-
HpCDD
Total TCDD
Total PeCDD
Total HxCDD
Total HpCDD
OCDD
Total PCDD
< 1.05E-09
2.36E-09
2.62E-09
3.14E-09
3.14E-09
2.36E-09
1.18E-08
2.30E-08
< 4.99E-10
1.75E-09
1.70E-08
2.00E-09
4.24E-09
1.75E-09
1.10E-08
3.59E-08
< 5.09E-10
2.04E-09
4.08E-08
4.08E-09
7.64E-10
1.02E-09
1.17E-08
5.83E-08
< 6.85E-10
2.05E-09
2.01E-08
3.07E-09
2.72E-09
1.71E-09
1.15E-08
3.91E-08
DIOXIN EMISSIONS, kg/hr
2,3,7,8-TCDD
1,2,3,7,8-PeCDD
1,2,3,4,7,8-
HxCDD
1,2,3,6,7,8-
HxCDD
1,2,3,7,8,9-
HxCDD
1,2,3,4,6,7,8-
HpCDD
Total TCDD
Total PeCDD
Total HxCDD
< 3.56E-10
< 3.56E-10
< 4.75E-10
< 3.56E-10
< 4.75E-10
1.07E-09
1.19E-09
1.43E-09
1.43E-09
< 1.13E-10
< 2.26E-10
< 2.26E-10
< 1.13E-10
< 2.26E-10
7.92E-10
7.69E-09
9.05E-10
1.92E-09
< 2.31E-10
< 2.31E-10
< 3.47E-10
< 2.31E-10
< 2.31E-10
9.24E-10
1.85E-08
1.85E-09
3.47E-10
< 2.34E-10
< 2.71E-10
< 3.49E-10
< 2.34E-10
< 3.11E-10
9.28E-10
9.12E-09
1.39E-09
1.23E-09
2-60
-------
TABLE 2-22. (Continued)
Total HpCDD
OCDD
Total PCDD
1.07E-09
5.35E-09
1.05E-08
7.92E-10
4.98E-09
1.63E-08
4.62E-10
5.31E-09
2.65E-08
7.74E-10
5.21E-09
1.77E-08
DIOXIN TOXIC EQUIVALENT EMISSIONS, Ib/hr
2,3,7,8-TCDD
1,2,3,7,8-PeCDD
1,2,3,4,7,8-
HxCDD
1,2,3,6,7,8-
HxCDD
1,2,3,7,8,9-
HxCDD
1,2,3,4,6,7,8-
HpCDD
Other TCDD
Other PeCDD
Other HxCDD
Other HpCDD
OCDD
Total PCDD
< 7.86E-10
< 3.93E-10
< 1.05E-10
< 7.86E-11
< 1.05E-10
2.36E-11
0
0
0
0
1.18E-11
1.50E-09
< 2.49E-10
< 2.49E-10
< 4.99E-11
< 2.49E-11
< 4.99E-11
1.75E-11
0
0
0
0
1.10E-11
6.52E-10
< 5.09E-10
< 2.55E-10
< 7.64E-11
< 5.09E-11
< 5.09E-11
2.04E-11
0
0
0
0
1.17E-11
< 9.74E-10
< 5.15E-10
< 2.99E-10
< 7.70E-11
< 5.15E-11
< 6.85E-11
2.05E-11
0
0
0
0
1.15E-11
< 1.04E-09
2-61
-------
TABLE 2-22. (Continued)
FURAN CONCENTRATION, ppb/v
2,3,7,8-TCDF
1,2,3,7,8-PeCDF
2,3,4,7,8-PeCDF
1,2,3,4,7,8-
HxCDF
1,2,3,6,7,8-
HxCDF
2,3,4,6,7,8-
HxCDF
1,2,3,7,8,9-
HxCDF
1,2,3,4,6,7,8-
HpCDF
1,2,3,4,7,8,9-
HpCDF
Total TCDF
Total PeCDF
Total HxCDF
Total HpCDF
OCDF
Total PCDF
2.67E-05
3.69E-06
4.61E-06
8.21E-06
2.51E-06
2.01E-06
< 5.03E-07
4.60E-06
< 6.14E-07
1.64E-04
4.80E-05
1.29E-05
6.91E-06
1.84E-06
2.34E-04
2.55E-05
3.63E-06
4.78E-06
8.67E-06
2.78E-06
2.26E-06
< 3.47E-07
6.67E-06
< 7.94E-07
1.45E-04
4.97E-05
2.08E-05
9.69E-06
4.98E-06
2.30E-04
1.85E-05
3.10E-06
4.01E-06
7.94E-06
2.32E-06
1.66E-06
< 3.31E-07
6.52E-06
< 7.58E-07
8.72E-05
3.65E-05
1.22E-05
9.70E-06
3.36E-06
1.49E-04
2.35E-05
3.47E-06
4.47E-06
8.28E-06
2.54E-06
1.97E-06
< 3.94E-07
5.93E-06
< 7.22E-07
1.32E-04
4.47E-05
1.53E-05
8.77E-06
3.39E-06
2.04E-04
2-62
-------
TABLE 2-22. (Continued)
FURAN CONCENTRATION, ng/dscm
2,3,7,8-TCDF
1,2,3,7,8-PeCDF
2,3,4,7,8-PeCDF
1,2,3,4,7,8-
HxCDF
1,2,3,6,7,8-
HxCDF
2,3,4,6,7,8-
HxCDF
1,2,3,7,8,9-
HxCDF
1,2,3,4,6,7,8-
HpCDF
1,2,3,4,7,8,9-
HpCDF
Total TCDF
Total PeCDF
Total HxCDF
Total HpCDF
OCDF
Total PCDF
0.3394
0.0522
0.0653
0.1279
0.0392
0.0313
< 0.0078
0.0783
< 0.0104
2.0886
0.6788
0.2010
0.1175
0.0339
3.1199
0.3244
0.0514
0.0676
0.1352
0.0432
0.0351
< 0.0054
0.1135
< 0.0135
1.8381
0.7028
0.3244
0.1649
0.0919
3.1220
0.2347
0.0438
0.0567
0.1238
0.0361
0.0258
< 0.0052
0.1109
< 0.0129
1.1089
0.5158
0.1908
0.1650
0.0619
2.0424
0.2995
0.0491
0.0632
0.1290
0.0395
0.0308
< 0.0061
0.1009
< 0.0123
1.6785
0.6325
0.2387
0.1491
0.0626
2.7614
2-63
-------
TABLE 2-22. (Continued)
FURAN CONCENTRATION, ng/dscm @ 15% Oj
2,3,7,8-TCDF
1,2,3,7,8-PeCDF
2,3,4,7,8-PeCDF
1,2,3,4,7,8-
HxCDF
1,2,3,6,7,8-
HxCDF
2,3,4,6,7,8-
HxCDF
1,2,3,7,8,9-
HxCDF
1,2,3,4,6,7,8-
HpCDF
1234789-
1,Z.,J,*», 1 ,0,7
HpCDF
Total TCDF
Total PeCDF
Total HxCDF
Total HpCDF
OCDF
Total PCDF
0.4628
0.0712
0.0890
0.1744
0.0534
0.0427
< 0.0107
0.1068
< 0.0142
2.8481
0.9256
0.2741
0.1602
0.0463
4.2544
0.5406
0.0856
0.1126
0.2253
0.0721
0.0586
< 0.0090
0.1892
< 0.0225
3.0634
1.1713
0.5406
0.2748
0.1532
5.2033
0.2874
0.0537
0.0695
0.1516
0.0442
0.0316
< 0.0063
0.1358
< 0.0158
1.3578
0.6316
0.2337
0.2021
0.0758
2.5010
0.4303
0.0702
0.0904
0.1838
0.0566
0.0443
< 0.0087
0.1439
< 0.0175
2.4231
0.9095
0.3495
0.2124
0.0917
3.9862
2-64
-------
TABLE 2-22. (Continued)
FURAN EMISSIONS, Ib/hr
2,3,7,8-TCDF
1,2,3,7,8-PeCDF
2,3,4,7,8-PeCDF
1,2,3,4,7,8-
HxCDF
1,2,3,6,7,8-
HxCDF
2,3,4,6,7,8-
HxCDF
1,2,3,7,8,9-
HxCDF
1,2,3,4,6,7,8-
HpCDF
1,2,3,4,7,8,9-
HpCDF
Total TCDF
Total PeCDF
Total HxCDF
Total HpCDF
OCDF
Total PCDF
3.40E-08
5.24E-09
6.55E-09
1.28E-08
3.93E-09
3.14E-09
< 7.86E-10
7.86E-Q9
< 1.05E-09
2.10E-07
6.81E-08
2.02E-08
1.18E-08
3.40E-09
3.13E-07
2.99E-08
4.74E-09
6.24E-09
1.25E-08
3.99E-09
3.24E-09
< 4.99E-10
1.05E-08
< 1.25E-09
1.70E-07
6.49E-08
2.99E-08
1.52E-08
8.48E-09
2.88E-07
2.32E-08
4.33E-09
5.60E-09
1.22E-08
3.57E-09
2.55E-09
< 5.09E-10
1.10E-08
< 1.27E-09
1.10E-07
5.09E-08
1.88E-08
1.63E-08
6.11E-09
2.02E-07
2.91E-08
4.77E-09
6.13E-09
1.25E-08
3.83E-09
2.98E-09
< 5.98E-10
9.76E-09
< 1.19E-09
1.63E-07
6.13E-08
2.30E-08
1.44E-08
6.00E-09
2.68E-07
2-65
-------
TABLE 2-22. (Continued)
FURAN EMISSIONS, kg/hr
2,3,7,8-TCDF
1,2,3,7,8-PeCDF
2,3,4,7,8-PeCDF
1,2,3,4,7,8-
HxCDF
1,2,3,6,7,8-
HxCDF
2,3,4,6,7,8-
HxCDF
1,2,3,7,8,9-
HxCDF
1,2,3,4,6,7,8-
HpCDF
1,2,3,4,7,8,9-
HpCDF
Total TCDF
Total PeCDF
Total HxCDF
Total HpCDF
OCDF
Total PCDF
1.54E-08
2.38E-09
2.97E-09
5.82E-09
1.78E-09
1.43E-09
< 3.56E-10
3.56E-09
<4.75E-10
9.50E-08
3.09E-08
9.15E-09
5.35E-09
1.54E-09
1.42E-07
1.36E-08
2.15E-09
2.83E-09
5.66E-09
1.81E-09
1.47E-09
< 2.26E-10
4.75E-09
< 5.66E-10
7.69E-08
2.94E-08
1.36E-08
6.90E-09
3.85E-09
1.31E-07
1.05E-08
1.96E-09
2.54E-09
5.55E-09
1.62E-09
1.16E-09
< 2.31E-10
4.97E-09
< 5.78E-10
4.97E-08
2.31E-08
8.55E-09
7.39E-09
2.77E-09
9.15E-08
1.32E-08
2.16E-09
2.78E-09
5.67E-09
1.74E-09
1.35E-09
< 2.71E-10
4.43E-09
< 5.40E-10
7.39E-08
2.78E-08
1.04E-08
6.55E-09
2.72E-09
1.21E-07
2-66
-------
TABLE 2-22. (Continued)
FURAN TOXIC EQUIVALENT EMISSIONS, Ib/hr
2,3,7,8-TCDF
1,2,3,7,8-PeCDF
2,3,4,7,8-PeCDF
1,2,3,4,7,8-
HxCDF
1,2,3,6,7,8-
HxCDF
2,3,4,6,7,8-
HxCDF
1,2,3,7,8,9-
HxCDF
1,2,3,4,6,7,8-
HpCDF
1,2,3,4,7,8,9-
HpCDF
Other TCDF
Other PeCDF
Other HxCDF
Other HpCDF
OCDF
Total PCDF
3.40E-09
2.62E-10
3.27E-09
1.28E-09
3.93E-10
3.14E-10
< 7.86E-11
7.86E-11
< 1.05E-11
0
0
0
0
3.40E-12
9.10E-09
2.99E-09
2.37E-10
3.12E-09
1.25E-09
3.99E-10
3.24E-10
< 4.99E-11
1.05E-10
< 1.25E-11
0
0
0
0
8.43E-12
< 8.49E-09
232E-09
2.16E-10
2.80E-09
1.22E-09
3.57E-10
2.553-10
< 5.09E-11
1.10E-10
< 1.27E-11
0
0
0
0
6.11E-12
< 7.35E-09
2.91E-09
2.38E-10
3.06E-09
1.25E-09
3.83E-10
2.98E-10
< 5.98E-11
9.76E-11
< 1.19E-11
0
0
0
0
6.00E-12
< 8.32E-09
2-67
-------
TABLE 2-22. (Concluded)
TOTAL DIOXIN AND FURAN EMISSIONS
Total emissions,
kg/hr
Total emissions,
Ib/hr
< 1.52E-07
< 3.36E-07
< 1.47E-07
< 3.24E-07
< 1.18E-07
< 2.60E-07
< 1.39E-07
< 3.07E-07
TOTAL DIOXIN AND FURAN TOXIC EQUIVALENT EMISSIONS
Total emissions,
Ib/hr
1.06E-08
9.15E-09
8.32E-09
9.36E-09
DIOXIN REMOVAL EFFICIENCY, %
Total PCDD
-37.0%
-86.1%
14.1%
FURAN REMOVAL EFFICIENCY, %
Total PCDF
82.6%
43.0%
44.9%
A < symbol associated with the total should be interpreted as less than
or equal to the reported total, because one or more of the congener
totals was reported at the detection limit.
2-68
-------
TABLE 2-23. SUMMARY OF DIOXIN AND FURAN EMISSIONS -
BLAST/REVERB FURNACES SCRUBBER OUTLET
Test run number
Test date
Average gas stream
volumetric flow,
dscfm
1
12-8-92
20,300
2
12-9-92
18,700
3
12-9-92
19,700
Avg.
19,600
DIOXIN CONCENTRATION, ppb/v
2,3,7,8-TCDD
1,2,3,7,8-PeCDD
1,2,3,4,7,8-
HxCDD
1,2,3,6,7,8-
HxCDD
1,2,3,7,8,9-
HxCDD
1,2,3,4,6,7,8-
HpCDD
Total TCDD
Total PeCDD
Total HxCDD
Total HpCDD
OCDD
Total PCDD
< 4.06E-07
< 3.67E-07
< 5.02E-07
< 3.35E-07
< 5.02E-07
4.61E-07
1.93E-06
1.28E-06
< 5.02E-07
4.61E-07
6.40E-06
2.79E-05
< 6.50E-07
< 5.87E-07
< 8.92E-07
< 5.35E-07
< 7.14E-07
8.20E-07
5.63E-05
3.52E-06
8.92E-07
< 8.20E-07
6.22E-06
6.78E-05
< 8.14E-07
1.10E-07
< 1.34E-06
< 8.38E-07
< 1.17E-06
2.16E-06
2.44E-05
4.04E-06
< 1.01E-06
3.54E-06
1.11E-05
4.41E-05
< 6.23E-07
< 6.85E-07
< 9.11E-07
< 5.69E-07
< 7.96E-07
1.15E-06
3.33E-05
2.95E-06
< 8.00E-07
< 1.61E-06
7.91E-06
4.66E-05
DIOXIN CONCENTRATION, ng/dscm
2-69
-------
TABLE 2-23. (Continued)
2,3,7,8-TCDD
1,2,3,7,8-PeCDD
1,2,3,4,7,8-
HxCDD
1,2,3,6,7,8-
HxCDD
1,2,3,7,8,9-
HxCDD
1,2,3,4,6,7,8-
HpCDD
Total TCDD
Total PeCDD
Total HxCDD
Total HpCDD
OCDD
Total PCDD
< 0.0054
< 0.0054
< 0.0082
< 0.0054
< 0.0082
0.0082
0.2581
0.0190
< 0.0082
0.0082
0.1223
0.4157
< 0.0087
< 0.0087
< 0.0145
< 0.0087
< 0.0116
< 0.0145
0.7535
0.0522
0.0145
< 0.0145
0.1188
0.9535
< 0.0109
< 0.0163
< 0.0218
< 0.0136
< 0.0191
0.0381
0.3267
0.0599
< 0.0163
0.0626
0.2124
0.6779
< 0.0083
< 0.0102
< 0.0148
< 0.0092
< 0.0129
< 0.0203
0.4461
0.0437
< 0.0130
< 0.0284
0.1512
0.6824
DIOXIN CONCENTRATION, ng/dscm @ 15% Oj
2,3,7,8-TCDD
1,2,3,7,8-PeCDD
1,2,3,4,7,8-
HxCDD
1,2,3,6,7,8-
HxCDD
< 0.0086
< 0.0086
< 0.0129
< 0.0086
< 0.0145
< 0.0145
< 0.0242
< 0.0145
< 0.0172
< 0.0258
< 0.0344
< 0.0215
< 0.0134
< 0.0163
< 0.0238
< 0.0149
2-70
-------
TABLE 2-23. (Continued)
1,2,3,7,8,9-
HxCDD
1,2,3,4,6,7,8-
HpCDD
Total TCDD
Total PeCDD
Total HxCDD
Total HpCDD
OCDD
Total PCDD
< 0.0129
0.0129
0.4076
0.0300
< 0.0129
0.0129
0.1931
0.6564
< 0.0193
< 0.0242
1.2559
0.0869
0.0242
< 0.0242
0.1980
1.5892
< 0.0301
0.0602
0.5159
0.0946
< 0.0258
0.0989
0.3353
1.0704
< 0.0208
< 0.0324
0.7264
0.0705
<£ 0.0209
<. 0.0453
0.2421
1.1053
DIOXIN EMISSIONS, Ib/hr
2,3,7,8-TCDD
1,2,3,7,8-PeCDD
1,2,3,4,7,8-
HxCDD
1,2,3,6,7,8-
HxCDD
1,2,3,7,8,9-
HxCDD
1,2,3,4,6,7,8-
HpCDD
Total TCDD
Total PeCDD
< 4.13E-10
< 4.13E-10
< 6.19E-10
< 4.13E-10
< 6.19E-10
6.19E-10
1.96E-08
1.45E-09
6.10E-10
< 6.10E-10
< 1.02E-09
< 6.10E-10
< 8.13E-10
< 1.02E-09
5.28E-08
3.66E-09
< 8.04E-10
< 1.21E-09
< 1.71E-09
< 1.01E-09
< 1.41E-09
2.82E-09
2.41E-08
4.42E-09
< 6.09E-10
< 7.43E-10
< 1.08E-09
< 6.76E-10
< 9.47E-10
<, 1.48E-09
3.22E-08
3.18E-09
2-71
-------
TABLE 2-23. (Continued)
Total HxCDD
Total HpCDD
OCDD
Total PCDD
< 6.19E-10
6.19E-10
9.29E-09
3.16E-08
1.02E-09
< 1.02E-09
8.33E-09
6.68E-08
< 1.21E-09
4.63E-09
1.57E-08
5.01E-08
< 9.47E-10
< 2.09E-09
1.11E-08
4.95E-08
DIOXIN EMISSIONS, kg/hr
2,3,7,8-TCDD
1,2,3,7,8-PeCDD
1,2,3,4,7,8-
HxCDD
1,2,3,6,7,8-
HxCDD
1,2,3,7,8,9-
HxCDD
1,2,3,4,6,7,8-
HpCDD
Total TCDD
Total PeCDD
Total HxCDD
Total HpCDD
OCDD
Total PCDD
< 1.87E-10
< 1.87E-10
< 2.81E-10
< 1.87E-10
< 2.81E-10
2.81E-10
-•••"- —
8.90E-09
6.56E-10
< 2.81E-10
2.81E-10
4.21E-09
1.43E-08
< 2.76E-10
< 2.76E-10
< 4.61E-10
< 2.76E-10
< 3.69E-10
< 4.61E-10
2.40E-08
1.66E-09
4.61E-10
4.61E-10
3.78E-09
3.03E-08
< 3.65E-10
< 5.47E-10
< 7.30E-10
< 4.56E-10
< 6.39E-10
1.28E-09
1.09E-08
2.01E-09
< 5.47E-10
2.10E-09
7.11E-09
2.27E-08
< 2.76E-10
< 3.37E-10
< 4.90E-10
< 3.07E-10
< 4.29E-10
< 6.73E-10
— —
1.46E-08
1.44E-09
<, 4.30E-10
< 9.47E-10
5.04E-09
2.25E-08
2-72
-------
TABLE 2-23. (Continued)
DIOXIN TOXIC EQUIVALENT EMISSIONS, Ib/hr
2,3,7,8-TCDD
1,2,3,7,8-PeCDD
1,2,3,4,7,8-
HxCDD
1,2,3,6,7,8-
HxCDD
1,2,3,7,8,9-
HxCDD
1,2,3,4,6,7,8-
HpCDD
Other TCDD
Other PeCDD
Other HxCDD
Other HpCDD
OCDD
Total PCDD
< 4.13E-10
< 2.06E-10
< 6.19E-10
< 4.13E-11
< 6.19E-11
6.19E-12
0
0
< 0
0
9.29E-12
8.00E-10
< 6.10E-10
< 3.05E-10
< 1.02E-10
< 6.10-11
< 8.13E-11
< 1.02E-11
0
0
0
< 0
8.33E-12
1.18E-09
< 8.04E-10
< 6.03E-10
< 1.61E-10
< 1.01E-10
< 1.41E-10
2.82E-11
0
0
< 0
0
1.57E-11
< 1.85E-09
< 6.09E-10
< 3.72E-10
< 1.08E-10
< 6.76E-11
< 9.47E-11
< 1.48E-11
0
0
< 0
< 0
1.11E-11
< 1.28E-09
FURAN CONCENTRATIONS, ppb/v
2,3,7,8-TCDF
1,2,3,7,8-PeCDF
2,3,4,7,8-PeCDF
1,2,3,4,7,8-
HxCDF
5.56E-06
< 3.84E-07
< 3.84E-07
< 3.49E-07
1.64E-05
1.43E-06
< 4.10E-07
< 5.58E-07
1.07E-05
< 7.70E-07
< 5.77E-07
< 8.74E-07
1.09E-05
^ 8.63E-07
< 4.57E-07
< 5.93E-07
2-73
-------
TABLE 2-23. (Continued)
1,2,3,6,7,8-
HxCDF
2,3,4,6,7,8-
HxCDF
1,2,3,7,8,9-
HxCDF
1,2,3,4,6,7,8-
HpCDF
1,2,3,4,7,8,9-
HpCDF
Total TCDF
Total PeCDF
Total HxCDF
Total HpCDF
OCDF
Total PCDF
< 3.49E-07
< 3.49E-07
< 3.94E-07
< 3.19E-07
< 4.79E-07
5.13E-05
3.07E-06
3.49E-07
3.19E-07
< 5.89E-07
5.56E-05
< 3.72E-07
< 5.58E-07
< 7.44E-07
< 5.11E-07
< 6.81E-07
1.55E-04
1.25E-05
1.04E-05
< 5.11E-07
< 1.26E-06
1.80E-04
< 6.99E-07
< 6.99E-07
< 1.05E-06
< 6.40E-07
< 1.28E-06
1.07E-04
6.16E-06
< 8.74E-07
< 9.60E-07
< 1.48E-06
1.17E-04
< 4.73E-07
< 5.35E-07
< 7.14E-07
< 4.90E-07
< 8.14E-07
1.04E-04
7.24E-06
< 3.88E-06
< 5.97E-07
< 1.11E-06
1.17E-04
FURAN CONCENTRATIONS, ng/dscm
2,3,7,8-TCDF
1,2,3,7,8-PeCDF
2,3,4,7,8-PeCDF
1,2,3,4,7,8-
HxCDF
1,2,3,6,7,8-
HxCDF
0.0706
< 0.0054
< 0.0054
< 0.0054
< 0.0054
0.2087
0.0203
< 0.0058
< 0.0087
< 0.0058
0.1361
< 0.0109
< 0.0082
< 0.0136
< 0.0109
0.1385
< 0.0122
< 0.0065
< 0.0092
< 0.0074
2-74
-------
TABLE 2-23. (Continued)
2,3,4,6,7,8-
HxCDF
1,2,3,7,8,9-
HxCDF
1,2,3,4,6,7,8-
HpCDF
1,2,3,4,7,8,9-
HpGDF
Total TCDF
Total PeCDF
Total HxCDF
Total HpCDF
OCDF
Total PCDF
< 0.0054
< 0.0054
< 0.0054
< 0.0082
0.6521
0.0435
0.0054
0.0054
< 0.0109
0.7174
< 0.0087
< 0.0116
< 0.0087
< 0.0116
1.9708
0.1768
0.1623
< 0.0087
< 0.0232
2.3417
< 0.0109
< 0.0163
< 0.0109
< 0.0218
1.3613
0.0871
< 0.0136
< 0.0163
< 0.0272
1.5056
< 0,0083
< 0.0111
< 0.0083
< 0.0138
1.3281
0.1025
< 0.0604
^ 0.0102
< 0.0204
1.5216
FURAN CONCENTRATION, ng/dscm @ 15% O^
2,3,7,8-TCDF
6
1, 2,3,7, 8»PeCDF
2,3,4,7,8-PeCDF
1,2,3,4,7,8-
HxCDF
1,2,3,6,7,8-
HxCDF
2,3,4,6,7,8-
HxCDF
0.1115
< 0.0086
< 0.0086
< 0.0086
< 0.0086
< 0.0086
0.3478
0.0338
< 0.0097
< 0.0145
< 0.0097
< 0.0145
0.2149
< 0.0172
< 0.0129
< 0.0215
< 0.0172
< 0.0172
0.2248
<. 0.0199
< 0.0104
< 0.0149
< 0.0118
< 0.0134
2-75
-------
TABLE 2-23. (Continued)
1,2,3,7,8,9-
HxCDF
1,2,3,4,6,7,8-
HpCDF
1,2,3,4,7,8,9-
HpCDF
Total TCDF
Total PeCDF
Total HxCDF
Total HpCDF
OCDF
Total PCDF
< 0.0086
< 0.0086
< 0.0129
1.0297
0.0686
0.0086
0.0086
< 0.0172
1.1327
< 0.0193
< 0.0145
< 0.0193
3.2846
0.2947
0.2705
< 0.0145
< 0.0386
3.9029
< 0.0258
< 0.0172
< 0.0344
2.1494
0.1376
< 0.0258
< 0.0258
< 0.0430
2.3772
< 0.0179
< 0.0134
< 0.0222
2.1546
0.1670
< 0.1002
< 0.0163
< 0.0329
2.4709
FURAN EMISSIONS, Ib/hr
2,3,7,8-TCDF
1,2,3,7,8-PeCDF
2,3,4,7,8-PeCDF
1,2,3,4,7,8-
HxCDF
1,2,3,6,7,8-
HxCDF
2,3,4,6,7,8-
HxCDF
1,2,3,7,8,9-
HxCDF
5.37E-09
< 4.13E-10
< 4.13E-10
< 4.13E-10
< 4.13E-10
< 4.13E-10
< 4.13E-10
1.46E-08
1.42E-09
*
< 4.06E-10
< 6.10E-10
< 4.06E-10
< 6.10E-10
< 8.13E-10
1.01E-08
< 8.04E-10
< 6.03E-10
< 1.01E-09
< 8.04E-10
< 8.04E-10
< 1.21E-09
l.OOE-08
< 8.80E-10
< 4.74E-10
< 6.76E-10
< 5.41E-10
< 6.09E-10
< 1.01E-09
2-76
-------
TABLE 2-23. (Continued)
1,2,3,4,6,7,8-
HpCDF
1,2,3,4,7,8,9-
HpCDF
Total TCDF
Total PeCDF
Total HxCDF
Total HpCDF
OCDF
Total PCDF
< 4.13E-10
< 6.19E-10
4.95E-08
3.30E-09
4.13E-10
4.13E-10
< 8.26E-10
5.45E-08
< 6.10E-10
< 8.13E-10
1.38E-07
1.24E-08
1.14E-08
< 6.10E-10
< 1.63E-09
1.64E-07
< 8.04E-10
< 1.61E-09
1.01E-07
6.44E-09
< 1.01E-09
< 1.21E-09
< 2.01E-09
1.11E-07
< 6.09E-10
< 1.01E-09
9.61E-08
7.38E-09
< 4.27E-09
< 7.43E-10
< 1.49E-09
1.10E-07
FURAN EMISSIONS, kg/hr
2,3,7,8-TGDF
1,2,3,7,8-PeCDF
2,3,4,7,8-PeCDF
1,2,3,4,7,8-
HxCDF
1,2,3,6,7,8-
HxCDF
2,3,4,6,7,8-
HxCDF
1,2,3,7,8,9-
HxCDF
1,2,3,4,6,7,8-
HpCDF
2.43E-09
< 1.87E-10
< 1.87E-10
< 1.87E-10
< 1.87E-10
< 1.87E-10
< 1.87E-10
< 1.87E-10
6.64E-09
6.45E-10
< 1.84E-10
< 2.76E-10
< 1.84E-10
< 2.76E-10
< 3.69E-10
< 2.76-10
4.56E-09
< 3.65E-10
< 2.74E-10
< 4.56E-10
< 3.65E-10
< 5.47E-10
< 5.47E-10
< 3.65E-10
4.54E-09
<: 3.99E-10
< 2.15E-10
< 3.07E-10
< 2.45E-10
< 3.68E-10
< 3.68E-10
< 2.76E-10
2-77
-------
TABLE 2-23. (Continued)
1234789-
i,*,, jft, i to,y
HpCDF
Total TCDF
Total PeCDF
Total HxCDF
Total HpCDF
OCDF
Total PCDF
< 2.81E-10
2.25E-08
1.50E-09
1.87E-10
1.87E-10
< 3.75E-10
2.47E-08
< 3.69E-10
6.27E-08
5.62E-09
5.16E-09
< 2.76E-10
< 7.37E-10
7.45E-08
< 7.30E-10
4.56E-08
2.92E-09
< 4.56E-10
< 5.47E-10
< 9.12E-10
5.04E-08
< 4.60E-10
4.36E-08
3.35E-09
<, 1.93E-09
<. 3.37E-10
< 6.75E-10
4.99E-08
FURAN TOXIC EQUIVALENT EMISSIONS, Ib/hr
2,3,7,8-TCDF
1,2,3,7,8-PeCDF
2,3,4,7,8-PeCDF
1,2,3,4,7,8-
HxCDF
< 4.13E-118-
HxCDF
2,3,4,6,7,8-
HxCDF
1,2,3,7,8,9-
HxCDF
1,2,3,4,6,7,8-
HpCDF
1,2,3,4,7,8,9-
HpCDF
5.37E-10
< 2.06E-11
< 2.06E-10
< 4.13E-11
< 4.13E-11
< 4.13E-11
< 4.13E-11
< 4.13E-12
< 6.19E-12
1.46E-09
7.11E-11
< 2.03E-10
< 6.10E-11
< 4.06E-11
< 6.10E-11
< 8.13E-11
< 6.10E-12
< 8.13E-12
1.01E-09
< 4.02E-11
< 3.02E-10
< 1.01E-10
< 8.04E-11
< 8.04E-10
< 1.21E-10
< 8.04E-12
< 1.61E-11
l.OOE-09
^ 4.40E-11
< 2.37E-10
< 6.76E-11
< 5.41E-11
< 6.09E-11
< 8.11E-11
< 6.09E-12
< 1.01E-11
2-78
-------
TABLE 2-23. (Concluded)
Total TCDF
Total PeCDF
Total HxCDF
Total HpCDF
OCDF
Total PCDF
0
0
0
0
< 8.26E-13
9.40E-1013
0
0
0
< 0
< 1.63E-12
< 2.00E-09
0
0
< 0
< 0
< 2.01E-12
< 1.76E-09
0
0
< 0
< 0
< 1.49E-12
< 1.56E-09
TOTAL DIOXm AND FURAN EMISSIONS
Total emissions,
kg/hr
Total emissions,
Ib/hr
3.91E-08
8.61E-08
1.05E-07
2.31E-07
7.32E-08
1.61E-07
7.23E-08
1.59E-07
TOTAL DIOXIN AND FURAN TOXIC EQUIVALENT EMISSIONS
Total emissions,
Ib/hr
1.74E-09
3.17E-09
3.61E-09
2.84E-09
DIOXIN REMOVAL EFFICIENCY, %
Total PCDD
-37.0%
-86.1%
14.1%
FURAN REMOVAL EFFICIENCY, %
Total PCDF
82.6%
43.0%
44.9%
A < symbol associated with the total should be interpreted as less tan or equal to the
reported total, because one or more of the congener totals was reported at the detection
limit.
2-79
-------
TABLE 2-24. SUMMARY OF ALDEHYDES AND KETONES EMISSIONS-
BLAST FURNACE OUTLET (SAMPLE POINT A)
Test run number
Test date
Average gas stream
volumetric flow, dscfm
1
12-8-92
3,700
2
12-9-92
3,200
3
12-9-92
3,500
Avg.
Formaldehyde
ug/m3
Ib/dscf
lb/dscf@ 15% O2
Ib/hr
kg/hr
1,989
1.24E-07
8.87E-08
0.0274f
0.0124
3,363
2.10E-07
1.57E-07
0.0399
0.0181
4,098
2.56E-07
1.92E-07
0.0531
0.0241
3,150
1.97E-07
1.46E-07
0.0401
0.0182
Acetaldehyde
ug/m3
Ib/dscf
lb/dscf@ 15% O2
Ib/hr
kg/hr
16,36404
1.02E-06
7.30E-07
0.225
0.102
10,541
6.58E-07
4.94E-07
0.125
0.0567
12,100
7.55E-07
5.67E-07
0.157
0.0711
13,002
8.12E-07
5.97E-07
0.169
0.0767
Acrolein
ug/m3
Ib/dscf
Ib/dscf @ 15% 02
Ib/hr
kg/hr
6,392
3.99E-07
2.85E-07
0.0880
0.0399
5,156
3.22E-07
2.41E-07
0.0612
0.0277
3,365
2.10E-07
1.58E-07
0.0436
0.0198
4,971
3.10E-07
2.28E-07
0.0643
0.0291
2-80
-------
TABLE 2-24. (Continued)
Propanal
ug/m3
Ib/dscf
lb/dscf@ 15% 02
Ib/hr
kg/hr
3,077
1.92E-07
1.37E-07
0.0424
0.0192
2,194
1.37E-07
1.03E-07
0.0260
0.0118
2,253
1.41E-07
1.41E-07
0.0292
0.0132
2,508
1.57E-07
1.57E-07
0.0325
0.0148
Crotonaldehyde
ug/m3
Ib/dscf
lb/dscf@ 15% O2
Ib/hr
kg/hr
1,150
7.18E-08
5.13E-08
0.0158
7.19E-03
0.114
8.68E-08
6.51E-08
0.0165
7.48E-03
4.66E-03
6.69E-08
6.69E-08
0.0139
6.30E-03
4.19E-02
7.52E-08
7.52E-08
0.0154
6.99E-03
n-Butyxaldehyde
ug/m3
Ib/dscf
•Ib/dscf @ 15% O2
Ib/hr
kg/hr
7,454
4.65E-07
3.32E-07
0.103
0.0514
4,461
2.78E-07
2.09E-07
0.0529
0.0193
5,568
3.48E-07
2.61E-07
0.0721
0.0165
5,828
3.64E-07
2.67E-07
0.0759
0.0291
2-81
-------
TABLE 2-24. (Continued)
Methyl Ethyl Ketone
ug/m3
Ib/dscf
lb/dscf@ 15% O2
Ib/hr
kg/hr
8,227
5.14E-07
3.67E-07
0.113
0.0514
3,583
2.24E-07
1.68E-07
0.0425
0.0193
2,809
1.75E-07
1.32E-07
0.0364
0.0165
4,873
3.04E-07
2.22E-07
0.0641
0.0291
Benzaldehyde
ug/m3
Ib/dscf
lb/dscf@15% O2
Ib/hr
kg/hr
8,023
5.01E-07
3.58E-07
0.1100
0.0501
11,740
7.33E-07
5.50E-07
0.139
0.0632
6,957
4.34E-07
3.26E-07
0.090
0.0409
8,907
5.56E-07
4.11E-07
0.113
0.0514
Isovaleradehyde
ug/m3
Ib/dscf
Ib/dscf @ 15% O2
Ib/hr
kg/hr
1,834
1.15E-07
8.18E-08
0.0253
0.0115
179
1.12E-08
8.36E-09
2.12E-03
9.61E-04
294
1.84E-08
1.38E-08
3.81E-03
1.73E-03
769
4.80E-08
3.46E-08
0.0104
4.72E-03
2-82
-------
TABLE 2-24. (Continued)
Valeraldehyde
ug/m3
Ib/dscf
lb/dscf@ 15%O2
Ib/hr
kg/hr
4,286
2.68E-07
1.91E-07
0.0590
0.0268
2,216
1.38E-07
1.04E-07
0.026303
0.0119
1,783
1.11E-07
8.35E-08
0.023103
0.0105
2,762
1.72E-07
1.26E-07
0.0361
0.0164
O-Tolualdehyde
ug/m3
Ib/dscf
lb/dscf@ 15% O2
Ib/hr
kg/hr
2,666
1.66E-07
1.19E-07
0.0367
0.0167
2,828
1.77E-07
1.32E-07
0.0335
0.0152
222
1.39E-08
1.04E-08
2.88E-03
1.31E-03
1,905
1.19E-07
8.72E-08
0.0244
0.0111
m/p-Tolualdehyde
ug/m3
Ib/dscf
Ib/dscf @ 15% O2
Ib/hr
kg/hr
695
4.34E-08
3.10E-08
9.57E-03
4.34E-03
2,181
1.36E-07
1.02E-07
0.0259
0.0117
482
3.01E-08
2.26E-08
6.25E-03
2.83E-03
1,120
6.99E-08
5.19E-08
0.0139
6.30E-03
2-83
-------
TABLE 2-24. (Concluded)
Hexaldehyde
ug/m3
Ib/dscf
lb/dscf@ 15% O2
Ib/hr
kg/hr
1,736
1.08E-07
7.74E-08
0.0239
0.0108
1,009
6.30E-08
4.73E-08
0.0120
5.43E-03
965
6.03E-08
4.52E-08
0.0125
5.67E-03
1,237
7.72E-08
5.66E-08
0.0161
7.31E-03
2,5-Demethyl Benzaldehyde
ug/m3
Ib/dscf
lb/dscf@ 15% O2
Ib/hr
kg/hr
222
1.39E-08
9.90E-09
3.06E-03
1.39E-03
348
2.17E-08
1.63E-08
4.13E-03
1.87E-03
407
2.54E-08
1.91E-08
5.27E-03
2.39E-03
326
2.03E-08
1.51E-08
4.15E-03
1.88E-03
2-84
-------
TABLE 2-25. SUMMARY OF SEMI-VOLATILE COMPOUNDS EMISSIONS -
BLAST FURNACE OUTLET (SAMPLE POINT A)
Test run number
Test date
Average gas stream
volumetric flow, dscfm
1
12-8-92
3,700
2
12-9-92
3,200
3
12-9-92
3,400
Avg,
3,670
Phenol
/tg/m3
ppb/v
ppb/v @ 15% O2
Ib/hr
kg/hr
7,823
2,000
1,429
0.108
0.0490
6,248
1,597
1,198
0.0792
0.0359
13,734
3,511
2,633
0.200
0.0908
9,268
2,369
1,753
0.129
0.0586
Acetophenone
Mg/m3
ppb/v
ppb/v @ 15% O2
Ib/hr
kg/hr
2-Methylphenol
Mg/m3
ppb/v
ppb/v @ 15% O2
Ib/hr
kg/hr
1,712
343
245
0.0236
0.0107
1,800
360
270
0.0228
0.0103
3,587
718
539
0.0523
0.0237
2,366
474
351
0.0329
0.0149
< 1,496
< 333
< 238
< 0.0206
< 0.0094
< 1,489
< 331
< 248
< 0.0189
< 0.0086
2,061
459
344
0.0301
0.0136
< 1,185
< 264
< 196
< 0.0166
< 0.0075
Cumene
/ig/m3
< 1,496
< 1,489
3,325
< 1,606
2-85
-------
TABLE 2-25. (Concluded)
ppb/v
ppb/v @ 15% O2
Ib/hr
kg/hr
< 299
< 214
< 0.0206
< 9.36E-03
< 298
< 224
< 0.0189
< 8.56E-03
665
499
0.0485
2.20E-02
< 321
< 239
< 0.0227
< 0.0103
Naphthalene
M8/m3
ppb/v
ppb/v @ 15% 02
Ib/hr
kg/hr
13,783
2,399
1,713
0.190
0.863
16,035
2,791
2,093
0.203
0.0922
16,184
2,817
2,112
0.236
0.1070
15,334
2,669
1,973
0.210
0.0952
Biphenyl
fig/m3
ppb/v
ppb/v @ 15% O2
Ib/hr
kg/hr
7,135
1,113
795
0.0985
0.0447
7,164
1,118
838
0.0908
0.0412
9,931
1,549
1,162
0.145
0.0657
8,077
1,260
932
0.111
0.0505
bis(2-Ethylehexyl)phthalate
/tg/m3
ppb/v
ppb/v @ 15% O2
Ib/hr
kg/hr
5,709
352
251
0.0788
0.0357
4,860
299
225
0.0616
0.0279
3,699
228
171
0.0539
0.0245
4,756
293
216
0.0648
0.0294
2-86
-------
TABLE 2-26. SUMMARY OF VOLATILE ORGANIC COMPOUNDS EMISSIONS
BLAST FURNACE OUTLET (SAMPLE POINT A)
Blast Furnace Outlet
Test run
number
Average gas
stream
volumetric
flow, dscfm
1
3,700
2
3,500
3
4,000
Avg.
3,700
Chloromethane (Methyl Chloride)
Ib/dscf
Ib/dscf @
15% O2
Mg/m3
ppm/v
Ib/nr
kg/hr
5.35E-07
7.41E-07
8,562
4.08
0.119
0.054
1.21E-06
1.68E-06
19,399
9.24
0.254
0.115
< 6.90E-06
e
< 9.56E-06
e
< 110,512 e
< 52.7 e
< 1.66 e
< 0.751 e
< 2.88E-06
< 3.99E-06
< 46,158
< 22.0
< 0.676
< 0.307
Bromomethane (Methyl Bromide)
Ib/dscf
Ib/dscf @
15% 02
jig/m3
ppm/v
Ib/hr
kg/hr
< 9.25E-08
1.28E-07
< 1,481
< 0.375
< 0.0205
< 9.31E-03
2.49E-07
3.45E-07
3,991
1.01
0.0523
0.0237
1.61E-07
2.23E-07
2,582
0.654
0.0387
0.0176
< 1.68E-07
< 2.32E-07
< 2,685
< 0.680
< 0.0372
< 0.0169
2-87
-------
TABLE 2-26. (Continued)
Methylene Chloride
Ib/dscf
Ib/dscf @
15% O2
Mg/m3
ppm/v
Ib/hr
kg/hi
< 9.25E-08
< 1.28E-07
< 1,481
< 0.375
< 0.0205
<9.31E-03
2.49E-07
3.45E-07
3,991
1.01
0.0523
0.0237
1.61E-07
2.23E-07
2,582
0.654
0.0387
0.0176
< 1.68E-07
< 2.32E-07
< 2,685
< 0.680
< 0.0372
< 0.0169
Acetone
Ib/dscf
Ib/dscf @
15% O2
Mg/m3
ppm/v
Ib/hr
kg/hr
4.63E-07
6.42E-07
7,422
3.07
0.0467
0.0467
6.16E-07
8.54E-07
9,869
4.09
0.0587
0.0587
3.14E-07
4.35E-07
5,031
2.08
0.0342
0.0342
4.65E-07
6.44E-07
7,441
3.08
0.0465
0.0465
Carbon Bisulfide
Ib/dscf
Ib/dscf @
15% O2
Mg/m3
ppm/v
Ib/hr
kg/hr
< 4.39E-06 e
< 6.09E-06 e
< 70,367 e
< 22.2 e
< 0.975 e
< 0.442 e
4.70E-07
6.52E-07
7,533
2.383
0.0988
0.0448
< 7.11E-06
e
< 9.85E-06
e
< 113,875 e
< 360 e
< 1.71 e
< 0.774 e
< 3.99E-06
< 5.53E-06
< 63,925
< 20.2
< 0.927
< 0.420
2-8
-------
TABLE 2-26. (Continued)
Benzene
Ib/dscf
Ib/dscf @
15% 02
/*g/m3
ppm/v
Ib/hr
kg/hr
< 4.49E-06 e
< 6.22E-06 e
< 71,890 e
< 22.1 e
< 0.996 e
< 0.452 e
1.30E-07
1.80E-07
2,077
0.640
0.0272
0.0124
5.22E-06
7.23E-06
83,615
25.82
1.25
0.568
< 3.28E-06
< 4.54E-06
< 52,527
< 16.2
< 0.759
< 0.344
Toluene
Ib/dscf
Ib/dscf @
15% O2
/zg/m3
ppm/v
Ib/hr
kg/hr
1.69E-06
2.35E-06
27,148
7.09
0.376
0.171
< 2.24E-06 e
< 3.10E-06e
< 35,879 e
< 9.37 e
< 0.470 e
< 0.213 e
< 5.68E-06
< 7.87E-06
< 91,003
< 23.8
< 1.36
< 0.619
< 3.21E-06
< 4.44E-06
< 51,343
< 13.4
< 0.737
< 0.334
Chlorobenzene
Ib/dscf
Ib/dscf @
15% O2
/ig/m3
ppm/v
Ib/hr
kg/hr
< 9.25E-08
< 1.28E-07
< 1,481
< 0.317
< 0.0205
< 9.31E-03
< 1.01E-07
< 1.39E-07
< 1,611
< 0.344
< 0.0211
< 9.58E-03
1.40E-07
1.94E-07
2,245
0.480
0.0336
0.0153
< 1.11E-07
< 1.54E-07
< 1,779
< 0.380
< 0.0251
< 0.0114
2-89
-------
TABLE 2-26. (Continued)
Ethylbenzene
Ib/dscf
Ib/dscf @
15% 02
Mg/m3
ppm/v
Ib/hr
kg/hr
3.56E-07
4.93E-07
5,701
1.29
0.079
0.0358
6.81E-07
9.44E-07
10,907
2.47
0.143
0.0649
1.92E-06
2.66E-06
30,745
6.97
0.461
0.209
9.85E-07
1.37E-06
15,784
3.58
0.228
0.103
Styrene
Ib/dscf
Ib/dscf @
15% 02
/ig/m3
ppm/v
Ib/hr
kg/hr
1.75E-06
2.42E-06
27,975
6.46
0.388
0.176
< 2.36E-06 e
< 3.27E-06 e
< 37,809 e
< 8.73 e
< 0.496e
< 0.225 e
< 1.43E-05
e
< 1.99E-05
e
< 229,810 e
< 53.1 e
< 3.44 e
< 1.56 e
< 6.15E-06
< 8.52E-06
< 98,531
< 22.76
< 1.44
< 0.654
m-/p-xylene
Ib/dscf
Ib/dscf @
15% O2
Mg/m3
ppm/v
Ib/hr
kg/hr
4.61E-07
6.38E-07
7,377
1.67
0.102
0.0464
8.15E-07
1.13E-06
13,057
2.96
0.171
0.0776
1.01E-06
1.40E-06
16,136
3.66
0.242
0.110
7.61E-07
1.05E-06
12,190
2.76
0.172
0.0779
2-90
-------
TABLE 2-26. (Continued)
o-xylene
Ib/dscf
Ib/dscf @
15% 02
Mg/m3
ppm/v
Ib/hr
kg/hr
1.62E-07
2.24E-07
2,594
0.588
0.0360
0.0163
2.9E-07
4.10E-07
4,737
1.07
0.0621
0.0282
5.36E-07
7.43E-07
8,590
1.95
0.129
0.0115
3.31E-07
4.59E-07
5,307
1.20
0.0756
0.0186
n-Hexane
Ib/dscf
Ib/dscf @
15% O2
Mg/m3
ppm/v
Ib/hr
kg/hr
1.55E-07
2.14E-07
2,479
0.692
0.034
0.0156
5.68E-07
7.87E-07
9,095
2.54
0.119
0.0541
6.02E-07
8.34E-07
9,645
2.69
0.145
0.0656
4.42E-07
6.12E-07
7,073
1.97
0.0994
0.0451
1,3-Butadiene
Ib/dscf
Ib/dscf @
15% O2
fig/m3
ppm/v
Ib/hr
kg/hr
< 1.04E-05 e
< 1.45E-05 e
< 167,159 e
< 74.3 e
< 2.32 e
< 1.05 e
< 1. 14E-05 e
< 1.58E-05 e
< 182,946 e
< 81.4 e
< 2.40 e
< 1.09 e
< 1.44E-05
e
< 2.00E-05
e
< 230,840 e
< 103 e
< 3.46 e
< 1.57 e
< 1.21E-05
< 1.68E-05
< 193,648
< 86.1
< 2.72
< 1.24
2-91
-------
TABLE 2-26. (Concluded)
Cumene
Ib/dscf
Ib/dscf @
15% O2
/*g/m3
ppm/v
Ib/hr
kg/hr
< 9.25E-08
< 1.28E-07
< 1,481
< 0.296
< 0.0205
< 0.093
1.20E-07
1.66E-07
1,923
0.385
0.0252
0.0114
1.08E-07
1.50E-07
1,734
0.347
0.0260
0.0118
< 1.07E-07
< 1.48E-07
< 1.71E+03
< 0.343
< 0.0239
< 0.0108
2-92
-------
this testing. The most prevalent semi-organics (>0.10 Ib/hr) were found to be
naphthalene (0.21 Ib/hr), phenol (0.13 Ib/hr), and biphenyl (0.11 Ib/hr).
2.8 VOLATILE ORGANICS TESTING
Volatile organic compounds (VOC) were also sampled only at the blast furnace
outlet, using the EPA Method 0030 (VOST) procedures. This sampling was performed in
conjunction with the aldehydes/ketones and semi-organics testing at this location. The
VOC concentrations and mass rates are summarized in Table 2.27.
The most prevalent of the 15 VOC's measured in the gas stream were 1,3-
Butadiene (2.72 Ib/hr), styrene (1.44 Ib/hr), carbon disulfide (0.93 Ib/hr), benzene (0.76
Ib/hr), and toluene (0.74 Ib/hr). Ten of the remaining 11 VOC's measured (excepting
toluene) also qualify as hazardous air pollutants.
2.9 CONTINUOUS MONITORING
Tables 2.28 and 2.29 summarize the results of the monitoring of total hydrocarbons
(THC) and carbon monoxide (CO) in the blast/reverb furnaces process (sampling points A,
B, C, and D). THC monitoring was performed using EPA Method 25A at these four
locations during the 2 days of sampling for aldehydes/ketones, HC1/C12, PCDD/PCDF,
semi-volatiles, and VOC.
2-93
-------
TABLE 2-27. SUMMARY OF TOTAL HYDROCARBON EMISSIONS - BLAST/REVERB FURNACES PROCESS
Run
1
2
3
Date
12-8-92
12-9-92
12-9-92
Tine
1030-1456
1235-1600
0928-1230
0948-1328
1435-1738
1520-1830
Afterburner Inlet
(Point A)
(ppi as
propane)
3,133
•-
2,412
•-
3,085
.--
(Ib/hr)"1
90.1
--
61.4
--
80.7
--
Afterburner Outlet (BH
inlet)
(Point B)
-------
TABLE 2-28. SUMMARY OF CARBON MONOXIDE EMISSIONS - BLAST/REVERB FURNACES PROCESS
Run
1
2
3
Date
1Z-8-92
12-9-92
12-9-92
Time
1030-1456
1235-1600
0928-1230
0948-1328
1435-1738
1520-1830
Afterburner Inlet
(Point A)
(ppi as
propane)
19,840
--
11,330
--
3,085
--
(lb/hr)"'
319
--
168
--
47.7
--
Afterburner Outlet (BH
inlet)
(Point B)
(ppmaS
propane)
28.1
. ..
--
--
--
'
(lb/hr)111
3.03
--
--
--
--
•-
Baghouse Outlet
(scrubber inlet)
(Point C)
(PP« «»
propane)
--
9.3
--
10
--
0.9
(lb/hr)111
.
1.09
--
1.11
--
0.104
Scrubber Outlet
(stack)
(Point D)
(ppa as
propane)
--
15.4
--
4.0
--
2.0
(lb/hr)"1
--
1.36
» •
0.327
-•
0.172
'"-Based on volunetric flow rates measured during isokinetic sampling.
Train Afterburner Intet Afterburner Outlet (BH inlet)
1 12-8-92 MM5-1 3,690 24,700 (12/10 metals run)
MM23-1
2 12-9-92 MM5-2 3,390 24,900 (12/11 metals run)
MH23-2 •- —
3 12-9-92 MM5-3 3,540 25,100 (12/12 metals run)
M23-3
Baghouse Outlet (scrubber inlet) Scrubber Outlet (stack)
26,800
24,600
26,400
20,300
18,700
19.700
2-95
-------
TABLE 2-29. SUMMARY OF DIOXINS AND FURANS ANALYTICAL RESULTS
BLAST FURNACE BAGHOUSE DUST SAMPLES (ppt)
(SAMPLE POINT E)
Analytes
2378-TCDD
12378-PeCDD
123478-HxCDD
123678-HxCDD
123789-HxCDD
1234678-HpCDD
OCDD
2378-TCDF
12378-PeCDF
23478-PeCDF
123478-HxCDF
123678-HxCDF
234678-HxCDF
123789-HxCDF
1234678-HpCDF
1234789-HpCDF
OCDF
TOTAL TCDD
TOTAL PeCDD
TOTAL HxCDD
TOTAL HpCDD
TLILab
Blank
Sample
(0.5)
(0.7)
(0.9)
(0.6)
(0.8)
1.5
33.0
(0.3)
(0.5)
(0.5)
(0.6)
(0.5)
(0.6)
(0.8)
(0.6)
(1.1)
(2.2)
(0.5)
(0.7)
(0.8)
1.5
Run-1
Composite
(0.8)
(1.0)
(1.2)
(0.8)
1.4
6.1
38.1
[6.0]
[3.0]
[4.5]
15.7
4.9
6.3
(1-0)
25.0
3.4
21.6
(0.8)
(1.0)
6.8
11.4
Run-2
Composite
(0.5)
(0.6)
(0.8)
0.25
0.66
3.9
34.6
1.9
[0.74]
1.3
5.2
1.8
1.8
(0.6)
10.3
1.7
13.3
[0.55]
(0.6)
2.2
7.6
Run-3
Composite
(0.8)
(1.3)
(1.3)
(0.9)
(1.1)
[3.3]
36.7
[2.0]
(0.9)
(0.8)
4.9
1.6
[2.6]
(1.1)
[9.7]
(1.5)
13.2
(0.8)
(1.3)
1.2
3.4
2-96
-------
TABLE 2-29. (Concluded)
TOTAL TCDF
TOTAL PeCDF
TOTAL HxCDF
TOTAL HpCDF
(0.3)
(0.5)
(0.6)
(0.8)
15.9
23.3
49.7
43.5
5.8
5.8
13.4
15.5
0.56
3.9
10.4
[14.2]
ppt-parts per trillion
[Estimated maximum possible concentration]
(Not detected-reported as Detection Limit)
2-97
-------
SECTION 3
DESCRIPTION OF PROCESS AND AIR POLLUTION CONTROL SYSTEMS
3.1 PROCESS DESCRIPTION
East penn Manufacturing Company operates a secondary lead smelting facility with
a production rate of approximately 45,000 tons of lead per year. The facility is collocated
with four battery production plants, also operated by East Penn. The raw material for the
smelter consists of approximately 80 percent automotive batteries, 15 percent industrial
batteries, and 5 percent plant scrap. The entire production of the smelter is used to supply
lead to the battery plants. Approximately 70 percent of the lead used by the battery plants
is supplied by the smelter.
Figure 3.1 illustrates the major process operations at the East Penn facility.
3.1.1 Battery Breaking
Spent lead-acid batteries are delivered to the plant by truck and broken on site.
Automotive and industrial batteries are disassembled in separate areas. The acid from
both areas is collected and sold for recycling. By the date of testing in December 1992,
acid reclamation had been operating fornine months. In December of 1993 90 percent of
acid from breaking operations was being recycled to battery manufacturing on site.
The steel casings of the industrial batteries are opened with a torch or plasma arc.
The battery plates and grids, with the acid and inside "jar" intact, are lifted with a small
overhead crane and moved to a conveyor, where the jar is cracked open with an ax and
the acid is allowed to drain out. The jars, plates, and grids are then conveyed into the
materials storage building, which is approximately 90 feet long and 60 feet wide.
Automotive batteries are placed on a conveyor and passed through one of two saws,
where the tops of the batteries are cut off and the acid is drained. The batteries then
proceed to a dumper, where the cases, plates, and remaining acid are separated. The
cases and tops are crushed and broken by a hammermill, and the lead, hard rubber, and
polypropylene are separated by flotation. The pieces of polypropylene are blown into a
trailer and the lead-bearing materials are conveyed into the materials storage room.
3-1
-------
j Acid Recovery |
Grids and Paste
Plastic Recovery I
Material
Storage Building.
Fluxes and
Reducing Agents
| Recycled DusT]
Reverberatory Lead
Furnace
Slag
Blast
Furnace
Slag
Lead
Landfill
Drosses
•j Refining | »j Casting j
Reagents [
Figure 3.1. East Penn Process Flow Diagram
3-2
-------
3.1.2 Smelting Operations
Lead smelting occurs in both a stationary reverberatory furnace and a blast furnace.
The reverberatory furnace uses the battery components as feed. The battery pieces are
transferred by a front-end loader to the furnace charging area, where the charge is
deposited into a bin and then fed with a vibratory conveyor to a weigh hopper. Weighed
lots of material are dumped into the ram feeder, which pushes the charge into the furnace.
Flue dust is screw-conveyed to the furnace and deposited directly ahead of the charge
material. When the furnace is charged, the flue dust is pushed into the furnace and the
track for the ram is cleared for another charge.
The reverberatory furnace is fired with propane and uses 50-percent oxygen
enrichment. The furnace has four burners: two at the end of the furnace and one on each
side. The combined heat input for the four burners is 16 MMBtu per hour. The
reverberatory furnace has a permitted capacity of 155 tons of lead product per day and
produces 62 tons of slag per day. It operates at a temperature of about 2,200°F. The
burner temperatures where smelting occurs are in excess of 2600°F. The lead
continuously over flows directly into one of two 75-ton receiving kettles. Slag is
continuously tapped into 1200-pound molds and is returned to the materials storage area to
be used as feed to the blast furnace.
The blast furnace feed consists of reverberatory furnace slag, re-run blast furnace
slag, and battery groups. The nonlead-bearing materials fed to the furnace as fuel and
reducing agents (coke, limestone, silica, and iron) are kept in conveying bins outside of
the materials storage area. The height of charge material in the furnace is monitored on a
closed-circuit television screen from inside the control room.
When the furnace needs a charge, the weigh hopper is moved along an overhead
monorail to each of the bins. The bins automatically feed the desired weight of the
material, which is also set from the control room. After each material is added, the
hopper is moved to the next bin, where the next material is automatically fed. The last
material to be fed into the hopper is the lead-bearing material. The weigh hopper transfers
the charge to a skip hoist bucket. The skip hoist carries the material to the top of the
furnace and charges it to the furnace.
The blast furnace is charged at a rate of approximately 117 tons per day of battery
scrap and slag. It uses coke as fuel and the blast air is 3-percent oxygen enriched. The
blast furnace has a permitted capacity of 90 tons of lead per day and produces about 25
tons of slag per day. Lead is tapped from the furnace into 2,600-pound ingots, which are
cooled and sent to the refining kettles after intermediate storage in a 15 by 15 foot, three-
sided structure outside the main smelting building.
The slag is periodically tapped into 1,200-pound pots. About one-half of the slag is
re-run through the blast furnace and the other half is disposed of as hazardous waste. The
slag resulting from a run using the re-run slag is not considered hazardous and is disposed
3-3
-------
of off-site. All of the blast furnace slag is not re-run because it is not cost-effective to run
all the slag twice.
3.1.3 Refining and Casting
Refining occurs in nine 75-ton kettles, each with a diameter of 8 feet. Two of the
kettles are used for refining hard lead from the blast furnace. The 2,600-pound ingots
from the blast furnace are loaded into these kettles by crane.
The other seven kettles are used to refine soft lead obtained from the reverberatory
furnace. Two of these kettles are receiving kettles for the reverberatory furnace. When
one of the receiving kettles is full, lead is tapped into the other receiving kettle. Lead in
the full receiving kettle is pumped to one of the other kettles for additional refining and
alloying. One kettle is used primarily as a backup.
When a kettle of lead has been refined to customer specifications, the lead is
pumped to an automatic casting machine. The casting machine fills 70-pound molds that
are water cooled as they transfer down the conveyor. The 70-pound ingots are then
stacked and taken to one of two lead product storage areas for subsequent travel to the
battery manufacturing plants. One of the final product storage areas is approximately 70
feet long and 50 feet wide, and the other is approximately 40 by 40 feet. The approximate
area in which smelting and refining operations take place is 100 by 100 feet.
3.2 AIR POLLUTION CONTROL EQUIPMENT
An air emissions control flow diagram for East Perm Manufacturing's smelting and
refining operations is presented in Figure 3.2. The process streams from the two furnaces
are combined and vented to an afterburner. The propane-fired afterburner has a retention
time of 2.5 seconds and is kept at a minimum temperature of 1,400°F. Typically, the
afterburner is idled to maintain this temperature because the reverberatory furnace exhaust
substantially heats the combined streams.
The combined streams pass through an evaporative cooler and then through six
cells of an eight-cell baghouse. The six shaker-type cells used to control the process gases
from the furnaces employ Gore-Tex membrane on Gore-Tex fabric. Just before the
process baghouse, approximately 8,000 cubic feet per minute of hygiene air from hoods
around the furnace is added through a dilution damper to further cool the exhaust before it
enters the six-cell process baghouse. An exhaust stream of approximately 40,000 acfm at
250°F is treated at an air-to-cloth ratio of 1.05 and a pressure drop of 3 to 5 inches of
water. The baghouse is inspected daily; the inspection includes a glass rod test. The
baghouse is equipped with a paniculate monitor and alarm to help detect leaks.
e After the baghouse, the process gases are exhausted to a wet scrubber to control
sulfur dioxide (SOj) emissions. The scrubber uses anhydrous ammonia that is
subsequently dissolved in water as the scrubbing fluid. The scrubber is a two-stage device
3-4
-------
Battery
Breaker
Reverberatory
Furnace
Blast
Furnace
Reverberatory
Furnace
Blast
Furnace
t
1
I
t
Material
Storage Building
Refining Kettles
and
Casting Machine
J Scrubber /....
7 andOemlster/
/Aftarfuimor / ...
.....
Slag Tap
Lead Top
SlagTap
SlrlnHoIet
Vibratory Feeder
Lead Tap
-.--• ' Hoods
/— _ . / ^^^BDrav Scrubber/
"~y Process uagnouse 7 •*•/ afjfj 5emteter /
Dagnouse no.a f .
""*f • isagnouse no. i *------•-----•--•
//
Baghouse No.3 /-•••—•••'•
/Refinery /..
Baghouse /
Figure 3.2. Emissions Control Flow Diagram
3-5
-------
in which fluid is injected horizontally into a horizontal duct (cross-current) by 10 injectors
in the first stage and 12 injectors in the second stage. A reaction chamber located after
each stage also acts as a settling chamber for the larger particles.
The treated gas then passes through a Monsanto Enviro-Chem mist eliminator,
which operates at a pressure drop of 4 to 8 inches of water. The mist eliminator is a two-
vessel unit that uses a total of 60 polyester "candle" elements. Each element is 12 feet
long and 24 inches in diameter, and uses a polypropylene prefilter. The solution collected
in the mist eliminator is recycled to the first stage of the scrubber. A solution containing
nitrogen and sulfur is produced and stored for sale to a fertilizer manufacturing plant.
Emissions from the six refining kettles (carried in a 16-inch duct), the casting area
where the molds are poured, general ventilation from the material storage area (carried in
a 20-inch duct), and the hooded dump door in the materials storage area (carried in a 14-
inch duct) are controlled by the refinery baghouse. The baghouse is a shaker-type, four-
cell carborundum dust collector baghouse that uses polyester or acrylic bags. It treats
40,000 acfm at an air-to-cloth ratio of 1.94 and has a pressure drop between 1 and 3
inches of water.
Emissions from the reverberatory furnace slag tap, lead tap, charging area, the area
where the slag molds are cooled, the two 75-ton receiving kettles, and the one 75-ton
spare kettle are controlled by the two additional compartments of the baghouse used to
treat the process gases. This two-cell baghouse (Baghouse No. 5) is a shaker-type
baghouse that uses woven polyester bags with a Gore-Tex membrane coating. It treats
20,000 acfm of exhaust gas at an air-to-cloth ratio of 1.57, and maintains a pressure drop
of between 1 and 3 inches of water.
Emissions from the blast furnace skip hoist (carried in a 30-inch duct), lead tap
(carried in a 12-inch duct), lead rotary table where the ingots are cooled (carried in a 12-
inch duct), and the vibratory feeder where the lead-bearing raw material is put into the
charge bucket (carried in a 12-inch duct) are controlled by Baghouse No. 3. This is a
shaker-type, six-cell carborundum dust collector baghouse that uses polyester or acrylic
bags. It treats 45,000 acfm of exhaust gas at an air-to-cloth ratio of 1.66.
The skip hoist and the vibratory feeder are located in the far corner of the materials
storage area. No physical barriers exist between them and the storage area. In order to
quantify emissions from the materials storage area, test data associated with just the
materials storage area must be obtained. Since the hoods for the skip hoist and the
vibratory feeder are in the far corner of the materials storage area, it is believed that a
small amount of the emissions associated with materials storage is collected by these
hoods. Therefore, it is believed that most of the emissions from the materials storage area
are collected by the general ventilation of the area and controlled by the refinery baghouse.
Emissions from the blast furnace slag tap (carried by a 15-inch duct) and the top of
the blast furnace where the charge is dumped by the skip hoist (carried by a 24-inch duct)
are controlled by Baghouse No. 1. This is a shaker-type six-cell carborundum dust
3-6
-------
collector baghouse that uses polyester or acrylic bags. It has a total cloth area of 12,600
ft2 and treats 22,500 acfm of exhaust
3.3 PROCESS AND AIR POLLUTION CONTROL EQUIPMENT OPERATING DATA
DURING TESTING
Emissions testing was performed on the two furnaces, as well as on various ventilation
and local hooding systems. Key process and pollution control data were collected during
the tests. Process data were collected in order to relate emissions to production, feed
characteristics, and process operation. Pollution control data were collected in order to
ensure proper operation during testing and to relate control performance to control device
operation.
3.3.1 Furnace Production Data
As discussed in Section 3.1, both the blast and reverberatory furnaces operate
continuously. The weights of raw material (grids and paste), coke, and fluxes were
recorded during all tests of furnaces or other sources in which charge could impact
emissions (i.e., lead tapping area, slag tapping area). Lead production and slag production
were also recorded.
The quantity of flue dust recycled from the baghouses to the reverberatory furnace is
10-12 percent of the total charge weight. However, since the system is a closed loop, it is
a constant, and therefore can be eliminated from the recordkeeping requirements of the
testing. Table 3.1 summarizes the charge, production, and afterburner fuel usage data
collected during testing.
Process information was collected during the time during which testing was occurring.
Additional readings were collected every time a test was begun or ended in order to
identify possible anomalies in the emissions data from each test. However, the production
data gathered during the short period of time of a particular test (2 to 4 hours) have
limited accuracy because of the methods by which measurements were taken. Therefore,
it is recommended that the average hourly charge and production rates for each individual
day of testing presented in Table 3.1 be used for the purpose of correlating production data
to the emissions measurements. This methodology will account for daily fluctuations in
charge and production, while minimizing potential inaccuracies due to the methods of
measuring these parameters.
Few plant operational problems occurred during the emissions testing. On December
12, the testing personnel communicated that grain loading at the blast furnace outlet
location appeared to be higher than during the previous tests. An investigations of the
process by Radian personnel and discussions with plant personnel revealed no process
changes from normal operation.
3-7
-------
TABLE 3.1
CHARGE, PRODUCTION, AND AFTERBURNER FUEL USAGE INFORMATION*
Tests
Performed
Date
First Test Start Time
Last Test End Time
Blast Furnace Information
Grids and Paste Charged
Coke Charged
Calcium Carbonate Charged
Silica Charged
Cast Iron Charged
Re- run Slag Charged
Lead Produced
Slag Produced
Reverberatory Furnace Information
Grids and Paste Charged
Propane Used (ftA3)
Lead Produced
Slag Produced
Vost #1
Semi-Vest #1
Ald/Ket #1
Oioxin #1
HCl #1 & #2
12/08/92
10:30 am
6:00 pm
Hourly
Total Average
During During
Testing Testing
(Ibs) (Ibs/hr)
77,461 10,328
4,451 593
1,783 238
1,027 137
7,121 949
2,931 391
57,200 7,627
20,400 2,720
132.088 17,612
49,273 6,570
83,270 11,103
21,600 2,880
Vost #2 & #3
Semi -Vost #2 & «
Ald/Ket #2 & #3
Dioxin #2 & #3
HCl #3
12/09/92
9:30 am
6:30 pm
Hourly
Total Average
During During
Testing Testing
(Ibs) (Ibs/hr)
85,549 9,505
5,920 658
2,131 237
1,255 139
8,588 954
3,560 396
59,800 6,644
27,600 3,067
176,682 19,631
57,633 6,404
127,080 14,120
28,800 3,200
PM/Pb/Mult-Met #1
PMIO-BFO, BHI #1
12/10/92
11:15 am
6:30 pm
Hourly
Total Average
During During
Testing Testing
(Ibs) (Ibs/hr)
79,441 10,957
4,525 624
2,163 298
1,243 171
8,201 1,131
3,129 432
54,600 7,531
22,800 3,145
134,931 18,611
47,253 6,518
NA" MA"
38,400 5,297
PM/Pb/Mult-Met #2
PM,,-BFO, BHI #2
PM10-BHO, SCO #1
12/11/92
9:15 am
4: 00pm
Hourly
Total Average
During During
Testing Testing
(Ibs) (Ibs/hr)
65,458 9,697
3,513 520
1,715 254
885 131
6,506 964
2,725 404
49,400 7,319
20,400 3,022
117,237 17,368
44,003 6,519
87,600 12,978
16,800 2,489
PM/Pb/Mult-Met #3
PM,0-BFO, BHI #3
12/12/92
8:45 am
11:45 am
Hourly
Total Average
During During
Testing Testing
(Ibs) (Ibs/hr)
27,576 9,192
1.635 545
566 189
342 114
2,634 878
1,079 360
26,000 8.667
9,600 3,200
62,377 20,792
19,696 6,565
39,950 13,317
9,600 3,200
Propane Used by Afterburner
(ft*3)
2,652
354
4,209
468
3,389
467
3,163
469
1,398
466
3-8
-------
TABLE 3.1 (Concluded)
Tests
Performed
Date
First Test Start Time
Last Test End Time
Blast Furnace Information
Grids and Paste Charged
Coke Charged
Calcium Carbonate Charged
Silica Charged
Cast Iron Charged
Re- run Slag Charged
Lead Produced
Slag Produced
Reverberator/ Furnace Information
Grids and Paste Charged
Propane Used (ftA3>
Lead Produced
Slag Produced
Propane Used by Afterburner
(ft*3)
Ref BH PN10 #1
Ref BH PM/Pb #1
BH#5 PH/Pb #1
BHff5 PM/Pb #1
12/14/92
1:45
7:45
Total
During
Testing
(Ibs)
MAb
PKA"
PDA"
PNA"
PNAC
PNA°
NAb
NAb
109,254
38,265
78,800
28,800
2,435
pm
pm
Hourly
Average
During
Testing
(Ibs/hr)
NA"
PNA"
PNA"
PNA"
PNAG
PNA"
NAb
NAb
18,209
6.378
13,133
4,800
406
Ref BH PH,0 #2 & #3
Ref BH PM/Pb #2 & #3
BH#5 PHIO #2 & *3
BH#5 PH/Pb #2 & US
12/15/92
8:30 am
6:30 pm
Total
During
Testing
-------
On December 14, testing personnel at the Baghouse No. 5 locations communicated
that the flow rate at their locations had increased substantially, and that testing could not
continue at the higher flow rate without significant equipment modifications. It was
determined by Radian personnel, through discussions with plant personnel, that one of the
reverberatory receiving kettles was being drossed and that normal operation was to
increase ventilation to ensure that the added dust from drossing was captured.
Dressing of one of the reverberatory kettles occurs about once every 24 hours for
about 2 hours. Emissions during this 2-hour period would represent only a small portion
of the total emissions being controlled by Baghouse No. 5, and would not significantly
affect the controlled emissions rate. However, testing was suspended for about 2 hours
during drossing and was continued only when the flow rate was back to normal.
On December 15, from 8:33 am to 8:48 am, no material was charged to the
reverberatory furnace so that minor maintenance could be conducted. This encompassed a
very small portion of the testing time that day and should not have a significant effect on
the emissions testing results. On December 17, a furnace was not charged for about 20
minutes. The electric power to the furnace was discontinued, causing the computer that
monitors the amount of charge to the furnace to be cleared. The time in which the furnace
was not charged appeared to be within the normal charge cycle of the furnace; therefore,
minimal effects on the emissions measurements were observed. Since the time of the
malfunction was so short, the total charge for the time of testing was extrapolated from the
readings taken earlier in the day.
3.3.2 Refining and Casting Data
The six refining kettles are operated in a "batch type" mode. Refining and casting
operations were monitored on December 14 and 15 during testing of the refinery
baghouse. During the December 14 testing, no casting operations occurred and only two
kettles contained lead at any time. During the December 14 testing, drossing occurred in
one of the kettles, and the lead in the two kettles was pumped to two other kettles.
During the December 15 tests, casting occurred only during the first set of tests
from 8:30 am to noon. During the first set of tests, lead from two kettles was pumped
into the casting machine, three kettles remained full of lead, and one kettle remained
empty. Also, drossing occurred during the first set of tests on one of the kettles.
During the second set of tests on December 15 from 2:30 pm to 6:30 pm, no
casting operations occurred. Also, three kettles remained full, drossing occurred on two
kettles, and lead was pumped from one kettle to another.
3.3.3 Control Device Data
The emission control devices at the facility were monitored by Radian personnel
and data on relevant parameters were collected in order to ensure proper operation of the
devices during testing and to relate control performance to control device operation.
3-10
-------
Table 3.2 summarizes the control data collected on the relevant parameters during the
emission tests.
Data on the afterburner, process baghouse, and scrubber were recorded during the
process testing. The afterburner inlet, operating, and outlet (after water spray)
temperatures were recorded. The inlet temperature, operating temperature, and outlet
temperature averaged 1,480°F, 1,731°F and 1,099°F, respectively. The average process
Pressure drop readings across each cell of the refinery baghouse, Baghouse No. 1,
Baghouse No. 3, and Baghouse No. 5 were collected during the testing of the systems that
are controlled by each baghouse. The average pressure drops for the refinery baghouse
and Baghouse No. 1 were 0.74 and 2.7 inches of water, respectively. Baghouse No. 3
and Baghouse No. 5 had average pressure drops of 0.8 and 0.7 inches of water,
respectively.
All control devices appeared to be operating properly during the testing period,
with one exception concerning the scrubber. On December 11, the facility had a problem
involving low ammonia flow to the scrubber; however, the outlet SO2 concentrations still
remained near the 200 ppm permitted limit. This problem was corrected by plant
personnel before emissions testing was begun at the scrubber stack location.
3.4 SUMMARY OF PROCESS MONITORING
The process and control devices appeared to be operating normally during the
emissions testing, with the following exceptions:
• The problem with the ammonia flow to the scrubber on December 11, which
was corrected before testing was begun at the scrubber test locations, should
have no impact on the testing;
• The break in charging to the reverberatory furnace for 15 minutes on December
15, which encompassed a very small portion of the testing time that day, should
have an insignificant effect on the results of the testing; and
• The 20-minute repair of the blast furnace skip hoist on December 17, which
appeared to be within the normal charge cycle of the furnace, should have an
insignificant impact on the testing.
3-11
-------
TABLE 3.2. SUMMARY OF CONTROL DEVICE OPERATING DATA
Device
Afterburner
Process Baghouse
Process Scrubber
Refinery Baghouse
Baghouse No. 1
Baghouse No. 3
Baghouse No. 5
Parameter
Inlet temperature (°F)
Operating temperature (°F)
Outlet temperature (°F)*
Pressure drop (in. H2O)
PH
Inlet temperature (°F)
Outlet SO2 concentration (ppm)
Pressure drop (in. H2O)
Pressure drop (in. H2O)
Pressure drop (in. H2O)
Pressure drop (in. H2O)
Operating Data
Minimum Maximum
1,278
1,559
1,060
0
5.76
170
2
0
0
0
0
1,563
1,866
1,150
4.9
6.70
240
355
0.9
4.2
1.2
1.5
Average
1,480
1,731
1,099
2.7
6.51
225
132
0.74
2.7
0.8
0.7
' After evaporative cooling.
3-12
-------
SECTION 4
SAMPLING LOCATIONS
Emission sampling was conducted at (1) the blast furnace outlet, (2) the
reverberatory and blast furnaces baghouse inlet and outlet, (3) the reverberatory and blast
furnaces wet scrubber outlet (stack), (4) the reverberatory kettles cyclone inlet and
baghouse outlet, and (S) the Nos. 1 and 3 and refiner baghouses inlets and outlets. The
following subsections describe the sampling locations in detail, and include a schematic of
each location. Since the raw field data were not made available, PES assumed the
dimensional data from Weston's site-specific test plan to be correct.
4.1 BLAST FURNACE OUTLET
Since the reverberatory and blast furnace exhaust gases merge at the base of the
afterburner, no acceptable location existed at which to sample the uncontrolled combined
gas stream. Only the exhaust gases exiting the blast furnace upstream of the afterburner
inlet could be sampled.
Two 6"-diameter (dia.) test ports were placed in a straight section of the metal 24"
inside diameter (I.D.) duct. These twotest ports (A/B) were utilized to obtain all
isokinetic samples. The ports were placed 90° apart at a location >70'(> 8 diameters)
downstream and 60" (2.5 diameters) upstream from the nearest flow disturbances. The
test location was just upstream from where the duct makes a 45° bend (at roof level) to
combine with the reverberatory furnace exhaust at the afterburner inlet.
A single 4"-dia. port (C) was already in place approximately 24" upstream of the
45° bend. That port was used for THC, CO, and VOST measurements. Access to the
test ports was from the roof, so no platform was required. Figure 4.1 illustrates the test
port placement and traverse point locations.
4.2 BLAST/REVERB FURNACES BAGHOUSE INLET
Two 6"-dia. test ports were placed in a straight section of the metal 48"-I.D. duct.
These two test ports (A/B) were utilized to obtain all isokinetic samples. The ports were
4-1
-------
East Penn Manufacturing, Co.
Lyon Station, Pennsylvania
PortA/B
Side View
PottC
Roof
Line
24"
Traverse
Point
Number
1
2
3
4
S
6
Distance from
Inside Near Wall
(inches)
1
31/2
7
17
201/2
23
PortC
Port A
PortB
Drawing Not to Scale
RGURE4-1
BLAST FURNACE EXHAUST WITH PORT
AND TRAVERSE POINT LOCATIONS
4-2
-------
placed 90° apart at a location approximately 9.5' (2.4 diameters) downstream and 36" (0.8
diameter) upstream from the nearest flow disturbances.
A single 3"-dia. port (C) was placed 1.5' upstream (offset 45°) of ports A and B.
This port was utilized for total hydrocarbons monitoring. Figure 4.2 illustrates the test
port and traverse point locations.
It was necessary to position test port A 36" upstream from where the duct changes
configuration from circular to square. This centered the port at a location where two I-
beams cross and access could be obtained between the I-beams. The existing walkway
was sufficient for access to both ports A and C.
A 6' x 6' platform was constructed in order to access test port B. This platform
was constructed on the lower roof on the opposite side of the duct and provided sufficient
clearance between the port and the platform.
4.3 BLAST/REVERB FURNACES BAGHOUSE OUTLET
Two 6"-dia. test ports were placed in a straight section of the 60" I.D. metal duct.
The two test ports (A/B) were placed 90° apart at a location 60" downstream from the
existing single test port C. This placed test ports A/B 60' (12 diameters) downstream and
70' (14 diameters) upstream from the nearest gas flow disturbances. Test port B was
placed 45° offset of test port C. Test ports A/B were used for all isokinetic sampling, and
port C was used for CEM monitoring. Figure 4.3 depicts the port and traverse point
locations.
In addition to the port placement, a scaffold with safety railing was erected in order
to access test ports A/B and C. The 6' x 6' platform was centered to allow access to all
three ports.
4.4 BLAST/REVERB FURNACES WET SCRUBBER OUTLET
A total of four 6"-dia. test ports were located 90° apart on the 60"-I.D. fiberglass
stack. The test ports were placed 37' (7.4 diameters) downstream from the scrubber exit
and 114" (1.9 diameters) upstream of the stack exit point.
Test ports B/C were used for all isokinetic sampling. Port A was used for the
Weston CEM probe. Test port D was dedicated to the facility SO2 monitor.
The existing test port and platform proved suitable for sampling. A 24" wide
section of the platform kickplate and lower hand railing needed to be removed to allow use
4-3
-------
East Penn Manufacturing, Co.
Lyon Station, Pennsylvania
Baghouse
Inlet
Duct
48"
Afieibuiuei
Exhaust
Ports Port
A/B C
y
Beam
Support
36"
9'6"
Side View
Travene
Point
Number
1
2
3
4
5
6
7
8
9
10
11
12
Distance fitom
Inside Near W»ll
(inches)
1
31/4
55/8
81/2
12
17
31
36
391/2
421/3
443/4
47
PonC
PortA
Walkway
PortB
Front View '
Platfonn
Drawing Not to Scale
FIGURE 4-2
BLAST/REVERBERATORY FURNACES BAGHOUSE INLET
WITH PORT AND TRAVERSE POINT LOCATIONS
4-4
-------
East Penn Manufacturing, Co.
Lyon Station, Pennsylvania
TO-
PonC
Ports A/B Cj O
Platform
Traverse
Point
Number
1
2
3
4
S
6
Distance from
Inside Near Wall
(inches)
25/8
83/4
173M
421/4
511/4
573/8
PortA
PonC
PoitB'
Ports A/B
Drawing Not to Scale
FIGURE 4-3
BLAST/REVERBERATORY FURNACES BAGHOUSE OUTLET
WITH PORT AND TRAVERSE POINT LOCATIONS
4-5
-------
of the sampling monorails. The 24" wide cut was centered directly behind ports B and C
as shown in Figure 4.4.
4.5 REVERBERATORY KETTLES CYCLONE INLET
Two 6"-dia. test ports were placed in a straight section of the 40"-I.D. duct. The
ports were placed 90° apart at a location approximately 17' (5.1 diameters) downstream
and 80" (2.0 diameters upstream from the nearest flow disturbances. Figure 4.5 illustrates
the test port and traverse point locations.
A 6' x 6' test platform with railings was required at this location. The platform
was centered to allow equal access to both test ports.
4.6 REVERBERATORY KETTLES BAGHOUSE OUTLET
Two 4"-dia. test ports were already located on the 60"-I.D. metal stack. These
two 4"-dia. ports required replacement with 6"-dia. ports to allow insertion of the particle
size distribution sampler. The ports were located 23' (4.6 diameters) downstream and 48"
(0.8 diameter) upstream from the nearest gas flow disturbances.
The existing port locations met the minimum requirement for use of the monorail
system. See Figure 4.6 for test port and traverse point locations.
4.7 REFINER BAGHOUSE INLET
Two 6"-dia. test ports were installed on the 40"-I.D. metal duct. The test ports
were positioned 12' (3.6 diameters) downstream and 5' (1.5 diameters) upstream from the
nearest gas flow disturbances. See Figure 4.7 for test port and traverse point locations.
The upper port (B) was placed 90° above port A and was accessible from the
existing walkway. No platform or safety railing was required at this test port.
4.8 REFINER BAGHOUSE OUTLET
A total of four 4"-dia. ports were already in position on the 60"-I.D. outlet stack.
Two of the four test ports needed to be replaced with 6"-dia. ports to allow insertion of
the particle size distribution sampler.
The existing ports were 30' (6 diameters) downstream and 40' (8 diameters)
upstream from the nearest gas flow disturbances. The existing platform and safety railing
4-6
-------
East Penn Manufacturing, Co.
Lyon Station, Pennsylvania
114"
37'
£
\
Ports
A.B.C
O
]
|
V
Plaifonn
Side View
Traverse
Point1
N amber
1
2
3
4
S
6
Distance fiom
Inside Near Wan
(inches)
25/8
83/4
173/4
421/4
511/4
573/8
24"
Port B
Port A
PonC
SOzCEMPon
Top View
60"
Port B
PonA
PonC
Top View
Drawing Not to Scale
FIGURE 4-4
BLAST/REVERBERATORY FURNACES SCRUBBER OUTLET
WITH PORT AND TRAVERSE POINT LOCATIONS
4-7
-------
East Penn Manufacturing, Co.
Lyon Station, Pennsylvania
208-
80"
T U
Ports A/B
Cyclone
X
Platform
Traverse
Point
Number
1
2
3
4
5
6
7
8
9
10
Inside Near Will
(inches)
1
31/4
57/8
9
135/8
261/4
31
341/8
363/4
39
Port A
PoitB
Platform
Drawing Not to Scale
FIGURE 4-5
REVERBERATORY KETTLES CYCLONE INLET
WITH PORT AND TRAVERSE POINT LOCATIONS
4-8
-------
East Penn Manufacturing, Co.
Lyon Station, Pennsylvania
Existing
ffctfonn
Ports
A/B
48"
Port A
Port B
23*
Top View
Traverse
Point
Number
1
2
3
4
5
6
7
8
9
10
n
12
Inside Near Wall
(inches)
11/4
4
7
105/8
15
213/8
385/8
45
493/8
S3
56
583/4
Side View
Drawing Not to Scale
FIGURE 4-6
REVERBERATORY KETTLES BAGHOUSE OUTLET
WITH PORT AND TRAVERSE POINT LOCATIONS SHOWN
4-9
-------
East Penn Manufacturing, Co.
Lyon Station, Pennsylvania
PonA
Tnvenc
Point
Number
1
2
3
4
5
6
7
8
9
10
11
12
Piff^WI1^ FT"1*11
Inside Near Wall
(inches)
1
25/8
43/4
7
10
141/4
253/4
30
33
351/4
373/8
39
Top View
Drawing Not to Scale
FIGURE 4-7
REFINER B AGHOUSE INLET
WITH PORT AND TRAVERSE POINT LOCATIONS SHOWN
4-10
-------
were sufficient, but no access ladder was available. Access to the test location was
provided by hydraulic lift truck. See Figure 4.8 for test port and traverse point locations.
4.9 NO. 1 BAGHOUSE INLET
Two 6"-dia. test ports needed to be installed on the 30"-I.D. inlet duct. The test
ports were placed at a location IS' (6 diameters) downstream and 60" (2 diameters)
upstream from the nearest gas flow disturbances. Test port A was placed on the side of
the duct nearest the existing walkway, while port B was placed 90° offset from port A on
the bottom of the duct. A 6' x 6' platform with safety railings was constructed in order to
access port B. The existing walkway was sufficient to access port A. See Figure 4.9 for
test port and traverse point locations.
4.10 NO. 1 BAGHOUSE OUTLET
Two 6"-dia. test ports were required on a straight section of the metal 32"-I.D.
exhaust duct. The ports were positioned 10' (3.75 diameters) downstream and 17" (0.5
diameter) upstream from the nearest gas flow disturbances, and were located upstream
from the baghouse ID fan. This location was selected to minimize extensive platform
requirements that would be necessary to access the exhaust stack. Placement of the test
ports at this location enabled access from ground level. See Figure 4.10 for test port and
traverse point locations.
4.11 NO. 3 BAGHOUSE INLET
Two 6"-dia. test ports were placed in a straight section of the metal 48"-I.D. duct.
The test ports were positioned ~23' (5.8 diameters) downstream and 7' (1.75 diameters)
upstream from the nearest gas flow disturbances. The test ports were at the same location
as an existing test port; however, the newly installed ports were placed 45° offset above
and below the previously installed port. This allowed access to ports A/B by means of a
scaffold and platform placed alongside the duct. Figure 4.11 illustrates the test port and
traverse point locations.
4.12 NO. 3 BAGHOUSE OUTLET
A total of four 4"-dia. ports were already in position on the outlet stack. Two of
the four test ports were replaced with 6"-dia. ports to allow insertion of the particle size
distribution sampler.
4-11
-------
East Penn Manufacturing, Co.
Lyon Station, Pennsylvania
Platform
60"
48"
Fjcisong Pom
A.B.C.D
30'
Traverse
Point
i
2
3
4
5
6
7
8
Distance from
Inside Near Wall
finches)
2
63/8
115/8
193/8
405/8
483/8
533/4
58
Side View
Drawing Not to Scale
FIGURE 4-8
REFINER BAGHOUSE OUTLET
WITH PORT AND TRAVERSE POINT LOCATIONS SHOWN
4-12
-------
East Penn Manufacturing, Co.
Lyon Station, Pennsylvania
Side View
Platfonn
Tnveisc
Point
Number
i
2
3
4
5
6
7
8
Inside Nor Wall
(inches)
1
31/8
57/8
95/8
203/8
241/4
267/8
29
Front View
Drawing Not to Scale
FIGURE 4-9
NO. 1 BAGHOUSE INLET
WITH PORT AND TRAVERSE POINT LOCATIONS SHOWN
4-13
-------
East Penn Manufacturing, Co.
Lyon Station, Pennsylvania
Baghonse
Wall
10'
Seam
\
Ground
Level
ID
Fan
ToEDFan
Top View
Side View
Traverse
Point
Number
1
2
3
4
5
6
7
8
9
10
11
12
OlStSOCC uOffl
Inside Near Wall
(inches)
1
21/8
33/4
55/8
8
113/8
205/8
24
263/8
281/4
297/8
31
Drawing Not to Scale
FIGURE 4-10
NO. 1BAGHOUSE OUTLET
WITH PORT AND TRAVERSE POINT LOCATIONS SHOWN
4-14
-------
East Penn Manufacturing, Co.
Lyon Station, Pennsylvania
PonC
—O
. Ports A/B
u
23'
To
Btghousc
Side View
PonA
PonC
PonB
48"
Tnvcnc
Point
1
2
3
4
5
6
7
8
9
10
bade Near Wall
(inches)
11/4
4
7
107/8
161/2
311/2
371/8
41
44
463/4
Front View
Drawing Not to Scale
FIGURE 4-11
NO. 3 BAGHOUSE INLET
WITH PORT AND TRAVERSE POINT LOCATIONS SHOWN
4-15
-------
The existing ports were 14' (3.1 diameters) downstream and 40' to 45' (8.7
diameters) upstream from gas flow disturbances. The existing platform and safety railing
were sufficient; however, no access ladder was available. Access to the test location was
provided by hydraulic lift truck. See Figure 4.12 for test port and traverse point locations.
4-16
-------
East Penn Manufacturing, Co.
Lyon Station, Pennsylvania
55"
Platform
Ports
A/B/C/D
PonA
40'
PonC
Port B
PortD
Top View
14'
Traverse
Point
1
2
3
4
5
6
7
8
9
10
11
12
Inside Near Wan
(inches)
1
35/8
51/2
93/4
133/4
195/8
353/8
411/4
451/4
481/2
511/3
54
Side View
Drawing Not to Scale
FIGURE 4-12
NO. 3 BAGHOUSE STACK
WITH PORT AND TRAVERSE POINT LOCATIONS SHOWN
4-17
-------
SECTION 5
SAMPLING AND ANALYTICAL PROCEDURES
The sampling, testing, and analysis procedures that were used in this test program
are described in detail in this section following overviews presented in Subsections 5.1 and
5.2. The following information is provided in this section.
Subsection Description
5.1 Overview of Flue Gas Sampling, Testing, and Analysis Procedures
5.2 Testing Equipment
5.3 Flue Gas Testing Procedures
5.4 Flue Gas Sample Analysis Procedures
The full text of each test method is included in Appendix D.
5.1 OVERVIEW OF FLUE GAS SAMPLING, TESTING, AND ANALYSIS
PROCEDURES
Following equipment setup, preliminary test data were compiled at each of the 13
test locations to determine nozzle sizes and to calculate isokinetic sampling rates. Test site
geometric measurements were rechecked and sampling point distances were recalculated as
a QA step on the pretest survey data. A pitot traverse was performed to determine
velocity profiles and to check for the presence of cyclonic flow at each location. Flue gas
temperature, dry gas composition, and moisture content were also determined by EPA
Reference Methods 2, 3, and 4, respectively.
Flue gas sampling was conducted simultaneously, by parameter type (with the
exception of total hydrocarbons and carbon monoxide), at all test locations during each of
three test runs. Individual test runs lasted 1 to 6 hours depending on the parameter and
the circumstances of the test.
Testing on the reverberatory and blast furnaces process occurred over 5 consecutive
days. Testing at the eight test locations on the four ventilation and hooding baghouses
(No. 5, refiner, No. 1, and No. 3) was conducted over a 4-day period.
5-1
-------
The parameters determined and corresponding measurement mechanisms are
shown, by test location, in Table 5.1. Triplicate tests for each parameter were generally
performed. Analysis protocols are also summarized by location in Table 5.1.
5.2 TESTING EQUIPMENT
Various sampling trains were used to sample the flue gases during the testing.
Each type of train is described in detail in the following paragraphs. The manual test
trains were prepared and recovered on-site in a Weston transportable laboratory trailer.
5.2.1 Paniculate and Metallic HAP's
Paniculate, metallic HAP's, and moisture present in the reverberatory and blast
furnaces baghouse inlet were collected utilizing the methodology for the Determination of
Metals Emissions in Exhaust Gases from Hazardous Waste Incineration and Similar
Combustion Processes, EPA/530-SW-91-0101, December 1990 (see Figure 5.1). The
sampling train consisted of the following components:
• A borosilicate nozzle with an inside diameter sized to sample isokinetically.
• A heated, borosilicate-lined probe, equipped with a calibrated thermocouple to
measure flue gas temperature and a calibrated S-type pitot tube to measure flue
gas velocity pressure.
• A heated oven containing a section of borosilicate tubing followed by a
borosilicate filter holder with a preweighed 9-cm quartz fiber filter.
• A section of borosilicate tubing to connect the outlet of the filter holder to the
first impinger.
• An impinger train containing seven impingers (No. 1 -dry; No. 2 - 100 ml nitric
acid/hydrogen peroxide; No. 3 - 100 ml nitric acid/hydrogen peroxide; No. 4 -
dry; No. 5 - 100 ml potassium permanganate/sulfuric acid; No. 6 - 100 ml
potassium permanganate/sulfuric acid; No. 7 - 300 gm silica gel).
• A vacuum hose with adapter to connect the outlet of the impinger train to a
control module.
• A control module containing a 3-cfm carbon vane vacuum pump (sample gas
mover), a calibrated dry gas meter (sample gas volume measurement device), a
calibrated orifice (sample gas flow rate monitor), and inclined manometers
(orifice and gas stream pressure indicators).
5-2
-------
TABLE 5.1. SAMPLING AND ANALYTICAL MATRIX
Sampling
Location
Bint Pumice
Outlet
Blast/
Reverbenuory
Baghouie Inlet
Total *> of
Samples Per
Location
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
Sample Type
Semi-VoUiik HAPs
Volatile HAP«
Aldehydes/Ketones
PMlo/Condeniib!e»
Particulate/Pb
Toul Hydrocaifaont
Carbon Monoxide
CM Stream Velocity
Volumetric Flow
Moisture
Oat Stream Composition
(CO, and O,)
Paniculate/ Metallic
HAPs'
PMu/Condensibles
Total Hydrocarbons
Gai Stream Velocity
Volumetric Row
Moisture
Gas Stream Composition
(CO, and 0,)
Sampling Method1
SW-84S Method 0010
SW-846
Method 0030
Method 0011
Method 201A/202
Method 12
Method 25A
Method 10
Method!
(pilot tube)
Method 4 (Condensing)
Method 3
Multi-Meuls
Method 201A/202
Method 2SA
Method 2
(pilot tube)
Method 4 (Condensing)
Melhod3
Sample
collected
By
WBSTON
WBSTON
WBSTON
WBSTON
WBSTON
WBSTON
WBSTON
WBSTON
WBSTON
WBSTON
WBSTON
WBSTON
WBSTON
WBSTON
WBSTON
WBSTON
Minimum
Volume
Sampled*
1.9 M1 (70 Ft1)
5-10 liter* per
lube pair
1.4 M' (50 ft')
0.85 M' (30 ft')
1.4 M1 (50 A')
N/A
N/A
N/A
0.85 to 3 M1 (30
to 106 ft?)
SOIiten
1.4 M1 (50 ft1)
0.85 M' (30 ft1)
N/A
N/A
a8S to 3 M* (30
to 106 ft*)
SOIiten
On-Sile Analysis
Type'
FID
NORA
Flow dscfm
Moisture %
Gas Stream
Composition %
FID
Flow dscfm
Moisture %
Gas Stream
Composition %
Method
CHM
CBM
Pressure
differential
Gravimetric
Onat
CBM
Pressure
differential
Gravimetric
Onat
By
WBSTON
WBSTON
WBSTON
WBSTON
WBSTON
WBSTON
WBSTON
WBSTON
WBSTON
Remote Lab Analysis
Type
Soni-Volstile
Organics
Volatile
Organics
Aldehydes/
Ketones
PM«/
CondenslNes
Paiticulale/Pb
Paniculate/
Metals
PMJ
Condensibles
Method4
HRGC LRMS Method
8270
HRGC LRMS Methods
5040 and 8240
HPLC
Gravimetric Methods
201 A and 202
Method 5 and 12
Gravimetric SW-846
7000 series
Gravimetric Methods
201A and 202
By*
TLI
TL1
TLI
W
SwRI
SwRI
W
5-3
-------
TABLE 5.1. (Concluded)
Sampling
Locali on
Bill!/
Reveiberaioiy
Bighouse
Outlet (Wet
Scrubber Inlet)
Bltil/
Reveibentoiy
Fumicci Wet
Scmbber
Outlet
Toul » of
Samples Per
Location
a
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
Sample Type
Particuhte/Pb
Hydrochloric
Acid/Chlorine
PCDD/PCDP
Toul Hydrocarbon
PMle/Condeniiblet
Gn Sueam Velocity
Volumetric Row
Moiilure
On Stream Compoiiiion
(CO, and O,)
Piniculite/Pb
Hydrochloric
Acid/Chlorine
PCDD/PCDP
Toul Hydrocarbon
PM,,/Coodeniiblei
Cirbon Monoxide
CM Sueam Velocity
Volumetric Flow
Moinuie
Gil Sueam Compoiitiofi
(CO, and 0,)
Sampling Method1
Method 12
Method 26A
Method 23
Method 2SA
Method 20IA/202
Method 2
(Pilot Tube)
Method 4 (Condeniing)
Melhod3
Method 12
Method 26A
Method 23
Method 2SA
Method 201 A/ 202
Method 10
Method!
(Pilot Tube)
Method 4 (Condeniing)
Method 3
Sample
collected
By
WESTON
WBSTON
WESTON
WBSTON
WBSTON
WESTON
WBSTON
WBSTON
WBSTON
WESTON
WBSTON
WBSTON
WBSTON
WBSTON
WBSTON
Minimum
Volume
Sampled*
1.9 M1 (70 ft')
1.4 M» (50 ft')
3 M1 (106 ft')
N/A
0.85 M' (30 ft')
N/A
0.85 to 3 M1
(30 ft1)
50 liter*
1.9 M' (70 ft5)
1.4 M' (50 ft')
3 M' (106 ft')
N/A
0.85 M' (30 ft')
N/A
N/A
0.85 to 3 M1
(30ft1)
SOliten
On-Site Analyiii
Type'
FID
Flow dicim
Moiiture %
Gai Stream
Compoiition %
FID
NDIRA
Flowdscfm
Moinuie %
Git Stream
Method
CBM
Preiture
Differential
Gravimetric
Onat
CBM
CBM
Pieiiuie
Differential
Gravimetric
Onal
By
WESTON
WBSTON
WBSTON
WESTON
WESTON
WBSTON
WBSTON
WBSTON
WBSTON
Remote Lab Analysis
Type
Parti culile/Pb
Hydrochloric
Acid/Chlorine
PCDD/PCDP
PM10/
Condeniiblei
P«ticulaie/Pb
Hydrochloric
Acid/Chlorine
PCDD/PCDP
PM,o/
Condemibtes
Method4
Method. 5 and 12
Method 26A
HRGC/HRMS Method
23
Gravimetric Methods
201A and 202
Melhodi 5 and 12
Method 26A
HRGC/HRMS Method
23
Gravimetric Melhodi
201 A and 202
By"
SwRI
SwRI
TU
W
SwRI
SwRI
TU
W
5-4
-------
THERMOMETER
T
fVl
ALL GLASS SAMPLE EXPOSED SURFACE TO HERB.
(EXCEPT WHEN TEFLON FILTER SUPPORT IS USED.)
CHECK
VALVE
THERMOCOUPLE
GLASS
PROBE
TIP
/
REVERSE-TYPE
PITOTTUBB
GLASS
FILTER
'HOLDER
THERMOCOUPLE
IMPINGBRSWITH
ABSORBING SOLUTIONS
GLASS PROBE LINER
PITOT MANOMETER
EMPTY (OPTIONAL KNOCKOUT)
5% HN03/IO%H,q,
TEMPERATURE
SENSORS
BY-PASS VALVE
MAIN VACUUM LINE
VALVE
ORIFICE
MANOMETER
FIGURE 5-1
EPA PARTICULATE AND METALLIC HAPs SAMPLING TRAIN
5-5
-------
• A switchable calibrated digital pyrometer to monitor flue and sample gas
temperatures.
5.2.2 Particulate and Lead
Paniculate, lead, and moisture present in the reverberatory and blast furnaces
baghouse outlet, wet scrubber outlet, and the four ventilation and hooding baghouse inlet
and outlet gas streams were measured using an EPA Method 12 sampling train (see
Figure 5.2). This sampling train consisted of the following components:
• A borosilicate nozzle with an inside diameter sized to sample isokineticaUy.
• A heated, borosilicate-lined probe equipped with a calibrated thermocouple to
measure flue gas temperature and an S-type pilot tube to measure the flue gas
velocity pressure.
• A heated oven containing a borosilicate connector and filter holder with a
preweighed 9-cm quartz fiber filter.
• A section of borosilicate tubing to connect the outlet of the filter holder to the
first impinger.
• An impinger train containing four impingers (No. 1 - 100 ml 0.1 N nitric acid
(HN03); No. 2 - 100 ml 0.1 HNO3; No. 3 - dry; No. 4 - 300 gm silica gel).
• A vacuum hose with adapter to connect the outlet of the impinger train to a
control module.
• A control module containing a 3-cfm carbon vane vacuum pump (sample gas
mover), a calibrated dry gas meter (sample gas volume measurement device), a
calibrated orifice (sample gas flow rate monitor), and inclined manometers
(orifice and gas stream pressure indicators).
• A switchable calibrated digital pyrometer to monitor
flue and sample gas temperatures.
The material collected in the nozzle, in the probe, in the flask or connector, in the
front-half of the filter holder, and on the quartz fiber filter were considered to be
paniculate. Water vapor was collected in the impinger portion.
5-6
-------
THERMOCOUPLE
THERMOCOUPLE
CLASS
PROBE
TIP
REVERSE TYPE
PITOTTUBB
ALL GLASS SAMPLE EXPOSED SURFACE
GLASS FILTER TO HERB. (EXCEPT TEFLON FILTER SUPPORT)
HOLDER WITH
y TEFLON
Z. FILTER SUPPORT
THERMOCOUPLE
CHECK
VALVE
IMPINGERSWrm
ABSORBING SOLUTIONS
ORIFICE
MANOMETER
FIGURE 5-2
EPA METHOD 12
PARTICULATE AND LEAD SAMPLING TRAIN
5-7
-------
5.2.3 Semi-Volatile HAP's
The semi-volatile HAP's sampling train (Figure 5.3) consisted of the following
components:
• A borosilicate nozzle with an inside diameter sized to sample isokinetically.
• A heated, borosilicate-lined probe equipped with a calibrated thermocouple to
measure flue gas temperature and an S-type pilot tube to measure the flue gas
velocity pressure.
• A heated oven containing a borosilicate connector, cyclone/flask, and filter
holder with a Soxhlet-extracted glass fiber filter.
• A borosilicate connector to join the outlet of the filter holder to the inlet of the
impinger train.
• An impinger train consisting of a Graham (spiral) type ice-water cooled
condenser, a temperature sensor (thermocouple), an iced-water jacketed module
containing 40 gm of 30/60 mesh Amberlite™ XAD-2 main (pre-extracted), a 1-
liter condensate trap, one standard and one modified Greenburg-Smith impinger
each containing 100 ml high purity (HPLC grade) water, and a final impinger
containing 300 gm of dry preweighed silica gel with a thermocouple to detect
sample gas exit temperature.
• A vacuum line (umbilical cord) with adapter to connect the outlet of the
impinger train to a control module.
• A control module containing a 3-cfm carbon vane vacuum pump, a calibrated
dry gas meter, a calibrated orifice, and inclined manometers.
• A switchable calibrated digital pyrometer to monitor flue and sample gas
temperatures.
The material collected in the nozzle, in the probe, in the connector or
cyclone/flask, in the front-half filter holder, and on the glass fiber filter was combined
with the rinses/extract of the connectors, condenser, and XAD-2 sorbent for the
determination of semi-volatile HAP's. Moisture content of the flue gases was determined
by measuring the increase in weight/ volume of the impinger contents.
5-8
-------
HEATED ABBA
STACK
WALL | |
FILTER HOLDER
TEMPERATURE
SENSOR
TEMPERATURE
SENSOR
HEATED
PROBE/
BUTTONHOOK
NOZZLE
e
TEMPERATURE
SENSOR
REVERSE-TYPE
PITOTTUBB
CHECK
VALVE
PITOT MANOMETER
TEMPERATURE
^"SENSOR
BY-PASS VALVE
-1X1-
ICE WATER RBCIRCULATION PUMP
TEMPERATURE
SENSORS
VACUUM LINE
ORIFICE
MANOMETER
DRY GAS METER
AIR-TIGHT PUMP
FIGURE 5-3
EPA METHOD 0010
SEMI-VOLATILE ORGANIC HAPS SAMPLING TRAIN
5-9
-------
5.2.4 PCDD/PCDF
The EPA Method 23 sampling train (Figure 5.4) used to measure PCDD/PCDF at
the inlet and outlet of the reverberatory and blast furnaces wet scrubber consisted of the
following components.
• A borosilicate nozzle with an inside diameter sized to sample isokinetically.
• A heated, borosilicate-lined probe equipped with a calibrated thermocouple to
measure flue gas temperature and an S-type pilot tube to measure the flue gas
velocity pressure.
• A heated oven containing a borosilicate connector and filter holder with a
Soxhlet extracted glass fiber filter.
• A borosilicate connector to join the outlet of the filter holder to the inlet of the
impinger train.
• An impinger train consisting of a Graham (spiral) type ice-water cooled
condenser, a temperature sensor (thermocouple), an ice-water jacketed module
containing 40 grams of 30/60 mesh Amberlite™ XAD-2 (pre-extracted), a 1-liter
condensate trap, one standard and one modified Greenburg-Smith impinger each
containing 100 ml high purity (HPLC grade) water, and a final impinger
containing 300 grams of dry preweighed silica gel plus a thermocouple to detect
sample gas exit temperature.
• A vacuum line (umbilical cord) with adapter to connect the outlet of the
impinger train to a control module.
• A control module containing a 3-cfm carbon vane vacuum pump, a calibrated
dry gas meter, a calibrated orifice, and inclined manometers.
• A switchable calibrated digital pyrometer to monitor flue and sample gas
temperatures.
The material collected in the nozzle, in the probe, in the connector or
cyclone/flask, in the front-half filter holder, and on the glass fiber filter was combined
with the solvent rinses/extract of the connectors, condenser, and XAD-2 sorbent for the
determination of PCDD/PCDF. Moisture content of the flue gases was determined by
measuring the increase in weight/volume of the impinger contents. A minimum of 3 cubic
meters of gas was collected per sample.
5-10
-------
STACK T
WALL | I
HEATED AREA
FILTER HOLDER
TEMPERATURE
SENSOR
TEMPERATURE
SENSOR
HEATED
PROBE/
BOTTONIIOOK!
NOZZLE
TEMPERATURE
SENSOR
RBVBRSB.TYPB
PITOTTUBB
CHECK
VALVE
PITOT MANOMETER
ICBWATBRRECIRCDLATIONPUMP CONDENSATE TRAP
TEMPERATURE
SENSORS
BY-PASS VALVE
VACUUM LINE
ORIFICE
MANOMETER
DRY GAS METER
AIR-TIGHT PUMP
FIGURE 5-4
EPA METHOD 23
PCDD AND PCDF SAMPLING TRAIN
5-11
-------
5.2.5 Volatile Organic Sampling Train (VOST)
The volatile organics at the blast furnace outlet were determined by VOST. This
sampling train (see Figure 5.5) consisted of the following components connected in series:
• A heated quartz-lined probe, 3 ft. in length, containing a glass wool paniculate
filter.
• The probe was connected to an ice water-cooled condenser followed by a
temperature sensor, an adsorption cartridge containing 1.6 gm of Tenax-GC, and
a condensate trap.
• A section of Teflon tubing was used to connect the outlet of the condensate trap
to a second condenser which was followed by a back-up sorbent trap containing
1 gm of Tenax-GC and 1 gm of activated charcoal, a second condensate
collector, and a tube containing an unweighed amount of dry silica gel.
• The tube of silica gel was connected, via an umbilical cable, to a control console
containing flow controllers, a calibrated 1-liter-per-minute dry gas meter, a
sample pump, a temperature indicator, and other components.
A total of four tube pairs per run were collected. Sample time and sample rate
were varied depending on total hydrocarbon measurement. Each individual tube pair was
collected over a 10 to 20-minute period sampling at a rate of 0.25 to 0.5 liter per minute.
The volatile organics were determined by analyzing the pairs of traps from each
test run by purge-trap-desorb GC/MS.
5.2.6 Aldehyde/Ketone Sampling Train
The aldehydes and ketones in the blast furnace outlet gas stream were determined
by EPA Method 0011. The sampling train (see Figure 5.6) consisted of the following
components connected in series:
• A calibrated borosilicate-lined nozzle attached to a borosilicate-lined probe.
• A rigid borosilicate connector to join the outlet of the sample probe to the inlet
of the impinger train.
• An impinger train consisting of five impingers. The first, second, third, and
fourth impingers each contained 100 ml of cleaned 2,4-dinitrophenylhydrazine
(DNPH) solution. The fifth impinger contained 300 grams of dry preweighed
silica gel. The second impinger was a Greenburg-Smith type; all other
5-12
-------
GLASS WOOL
PARTICULATB FILTER
ORIFICE
MANOMETER
FIGURE 5-5
EPA METHOD 0030
VOLATILE ORGANIC SAMPLING TRAIN (VOST)
5-13
-------
STACK
WALL
TEMPERATURE
SENSOR
1HBRMOCOUPL8
HEATED
PROBE/
BOTTONIIOOK
NOZZLE
REVERSE-TYPE
mOTTUBB
PITOT MANOMETER
N '/
DNP1I SOLUTION
TEMPERATURE
SENSORS
BY-PASS VALVE
VACUUM
GAUGE
ORIFICE
VACUUM LINE
ORIFICE
MANOMETER
FIGURE 5-6
EPA METHOD 0011
ALDEHYDE/KETONE SAMPLING TRAIN
SIUCACBL
5-14
-------
impingers were of a modified design. All impingers were maintained in a
crushed ice bath.
• A vacuum line (umbilical cord) with adapter to connect the outlet of the
impinger train to a control module.
• A control module containing a 3-cfm carbon vane vacuum pump, a calibrated
dry gas meter, a calibrated orifice, and inclined manometers.
• A switchable calibrated digital pyrometer to monitor flue and sample gas
temperatures.
5.2.7 PM10 and Condensible Particulate Sampling Equipment
PM10 and condensible particulate in the blast furnace outlet, reverberatory and blast
furnaces baghouse inlet/outlet, wet scrubber outlet, and four ventilation and hooding
baghouses inlet/outlet gas streams were determined using combined EPA Methods 201A
and 202 (see; Figure 5.7). The sampling train consisted of the following components:
• A stainless steel nozzle with an inside diameter sized to sample isokinetically
connected to a pre-separator.
• A PM10 cyclone.
• A heated, borosilicate-lined probe equipped with a calibrated thermocouple to
measure flue gas temperature and calibrated S-type pilot tube to measure flue gas
velocity pressure.
• A section of borosilicate tubing to connect the outlet of the probe to the first
irnpinger.
• An impinger train consisting of four impingers. The first two impingers
contained 100 ml of water, the third impinger was dry, and the fourth contained
300 gm of dry preweighed silica gel.
• A vacuum hose with adapter to connect the outlet of the impinger train to a
control module.
• A control module containing a 3-cfm carbon vane vacuum pump, a calibrated
dry gas meter, a calibrated orifice, and inclined manometers.
• A switchable calibrated digital pyrometer to monitor flue and sample gas
temperatures.
5-15
-------
THERMOCOUPLE
8-STAGE IMPACTOR \ |_
HOUSING^
NOZZLE
REVERSETYPE
PITOTTUBB
ALL GLASS SAMPLE EXPOSED SURFACE
TO HERB. (EXCEPT TEFLON FILTER SUPPORT)
CHECK
THERMOCOUPLE VALVE
IMPINGBRSWITH
ABSORBING SOLUTIONS
VACUUM
BY-PASS VALVB GAUGE
ORIFICE
MANOMETER
FIGURES-?
EPA REFERENCE METHODS 201 A/202
PARTICLE SIZE DISTRIBUTION AND CONDENSIBLE PARTICULATE SAMPLING TRAIN
5-16
-------
5.2.8 Hydrochloric Acid and Chlorine
The sampling train used to measure hydrochloric acid and chlorine emissions at the
reverberatory and blast furnaces wet scrubber inlet and outlet was operated in accordance
with proposed EPA Method 26A procedures (see Figure 5.8).
• A borosilicate nozzle with an inside diameter sized to sample isokinetically.
• A heated, borosilicate-lined probe, equipped with a calibrated thermocouple to
measure flue gas temperature and a calibrated S-type pilot tube to measure flue
gas velocity pressure.
• A heated oven containing a section of borosilicate tubing followed by a
borosilicate filter holder with a 9-cm Teflon/quartz filter.
• A section of borosilicate tubing to connect the outlet of the filter holder to the
first impinger.
• An impinger train containing six impingers (No. 1 - 50 ml 0.1 N sulruric acid;
No. 2 - 100 ml 0.1 N sulruric acid; No. 3 - 100 ml 0.1 N sulfuric acid; No. 4 -
100 ml 0.1 N sodium hydroxide; No. 5 - 100 ml 0.1 N sodium hydroxide; No.
6 - 300 gm silica gel).
• A vacuum hose with adapter to connect the outlet of the impinger train to a
control module.
• A control module containing a 3-cfm carbon vane vacuum pump, a calibrated
dry gas meter, a calibrated orifice, and inclined manometers.
• A switchable calibrated digital pyrometer to monitor flue and sample gas
temperatures.
At the locations upstream of the baghouse, Weston placed a cyclone with drop-out
flask ahead of the paniculate filter. This served to reduce the particulate buildup on the
filter and minimize filter changes. Flexible unheated Teflon lines were also utilized
between the filter exit and the first impinger. The flexible lines were treated similar to the
rigid connector between the back half of the filter holder and first impinger and recovered
as per the procedure used for that connector.
5.2.9 THC Monitoring Equipment
At the reverberatory and blast furnaces baghouse inlet/outlet and wet scrubber
outlet, THC was monitored by EPA Method 25A flame ionization analyzer (FIA)
technique using a heated J.U.M. Model VE-7 analyzer.
5-17
-------
STACK
WALL
THERMOCOUPLE
GLASS
PROBE
TIP
THERMOCOUPLE
REVERSETYPE
prrOTTUBB
GAS FLOW
DIRECTION
GLASS FILTER HOLDER WITH
QUARTZ-FIBER FILTER
THERMOCOUPLE
CHECK
VALVE
1MPINGERS WITH
ABSORBING SOLUTIONS
PITOT
MANOMETER
50,100,100ml
0.1 N Hj SO4
RESPECTIVELY
V
100 ml EACH
0.1 N N«OH
3001
SILICA GEL
TEMPERATURE
SENSORS
BY-PASS VALVE
VACUUM
GAUGE
VACUUM LINE
ORIFICE
MANOMETER
FIGURE 5-8
DRAFT EPA METHOD 26A
HYDROGEN CHLORIDE SAMPLING TRAIN
5-18
-------
5.2.10 Carbon Monoxide Monitoring Equipment
Carbon monoxide (CO) concentrations were determined using EPA Method 10
procedures. The carbon monoxide analyzer utilized was a Thermo-Envkonmental Model
48, gas phase correlation filter nondispersive infrared analyzer, which is not affected by
carbon dioxide in the sample gas. Therefore, no COj scrubber was necessary.
Sampling with a single total hydrocarbon analyzer was conducted at each of the
blast and reverberatory furnaces' four process sampling locations. Sampling was
conducted over a 3-to-6-hour period per day on 2 days. The total hydrocarbon monitoring
at the blast furnace outlet and blast/reverberatory furnaces wet scrubber stack was
simultaneous with carbon monoxide monitoring at those locations.
Total hydrocarbon monitoring at the blast/reverberatory furnaces afterburner inlet
was conducted simultaneous with the YOST sampling for the purpose of determining
VOST sample times and volumes. A second total hydrocarbon analyzer was used for this
purpose.
The Method 3 Tedlar bag samples obtained at each location for gas stream
composition analysis were retained and analyzed for total hydrocarbons. This served to
provide total hydrocarbon measurements for locations on days when the continuous
monitoring technique was not being utilized.
SO2 monitoring of the wet scrubber exhaust stack was conducted utilizing the East
Perm CEM system. These data were collected in conjunction with each test period.
5.3 FLUE GAS TESTING PROCEDURES
The following paragraphs and flow charts summarize the procedures used to sample
the flue gases.
5.3.1 Particulate and Metallic HAP's
Figures 5.9, 5.10, and 5.11 illustrate the procedures used to prepare the particulate
and metallic HAP's sampling trains prior to each test, to sample the stack gases, and to
recover the samples from the train, respectively. Preparation, testing, and sample
recovery techniques conformed to those specified in the multi-metals test procedure. Each
test performed on the reverberatory and blast furnaces baghouse inlet was 72 minutes in
length. Sample volume for each run was between 35 and 40 dscf and the sampling rate
was +. 10 percent of isokinetic or better.
5-19
-------
GLASSWARE, PROBE FILTER
HOLDER, IMHNGERS, CONNECTORS
QUARTZ FIBER FILTERS
REMOVE SURFACE RESIDUE WITH HOT
SOAPY WATER. RINSE WITH TAP
WATER FOLLOWED BY RINSES OF
DISTILLED WATER. SOAK IN 10% NITRIC
ACID, RINSE WITH DISTILLED
WATER, ACETONE, AND AIR DRY
TRANSPORT TO TEST SITE
CHARGE IMPINGER TRAIN
PLACE TARED FILTER
INTO FILTER HOLDER
INLET AND OUTLET OF
SAMPLING NOZZLE, PROBE
SEAL SAMPLING TRAIN COMPONENTS
WITH SEPTUMS AND/OR GROUND
GLASS PLUGS OR CAPS TO
PREVENT CONTAMINATION
IMPNGERNO. 1:
DRY
IMPINGER NO. 2:
100 ml 5% HNOj /10% H202
IMPINGER NO. 3:
100 ml 5% HNOj /10% H2O2
IMPINGER NO. 4:
DRY
IMPINGER NO. 5:
100 ml ACIDIFIED 4% KMaCU
IMPINGER NO. &
100 ml ACIDIFIED 4% KMnO4
IMPINGER NO. 7:
300 g SILICA GEL INLET TO
IMPINGER NO. 1 AND OUTLET
TO IMPINGER NO. 7
TRANSPORT SAMPLING TRAIN
COMPONENTS TO SAMPLING
SITE
Figure 5.9. Preparation Procedures for
Particulate and Metallic HAP's Sampling Train
5-20
-------
ATTACH NOZZLE TO PROBE
AND PROBE TO CONNECTOR
TO FILTER HOLDER.
ATTACH IMPINGER TRAIN TO
FILTER HOLDER WITH
BOROSELICATE TUBING
ATTACH SAMPLING
TRAIN COMPONENTS AT
SAMPLING SITE
ZERO INCLINED MANOMETERS
CONNECT UMBILICAL TO
CONTROL MODULE AND TO
IMPINGER NO. 7 OUTLET
LEAK CHECK ASSEMBLED SAMPLING
TRAIN AT IS" He. LEAK CHECK
PITOT / LINES PER METHOD 2
PROBE AND OVEN
HEATERS 250*F
RECORD LEAK RATE
ON FIELD DATA SHEET
TURN ON PROBE AND OVEN
HEATERS AND ADD ICE TO
IMPINGER TRAIN
TEAM LEADER CHECK
WITH PROCESS OBSERVER
FOR START TIME
PROCESS OBSERVER CHECK
THAT PROCESS
IS OPERATING NORMALLY
PROBE POSITIONED IN
STACK AT FIRST
SAMPLING POINT
RECORD CLOCK TIME, INITIAL
DRY GAS METER, AP,TS,AND>&|
VALUES. FOR ISOKINETIC SAMPLING
DETERMINE AH. SET AH AT ORIFICE
METER. READ REMAINING
GAUGES.
REMOVE SAMPLE PORT CAP.
INSERT PROBE THROUGH PORT.
SEAL PORT.
START TEST
AT DESIGNATED
START TIME
RECORD DATA ON FIELD
DATA SHEET AT EACH
POINT
PROCESS OBSERVER
CHECKING
THROUGHOUT THE TEST
SAMPLE
EACH POINT ON
TRAVERSE
STOP SAMPLING AFTER COMPLETING
TRAVERSE AND REMOVE PROBE
FROM STACK
RECORD FINAL DRY
GAS METER READING
AND LEAK CHECK
TRANSFER SAMPLING TRAIN
TO NEXT SAMPLE PORT
AND REPEAT PROCEDURE
AT COMPLETION OF TEST, LEAK
CHECK TRAIN AND PITOT LINES
AS PREVIOUSLY INDICATED AND
RECORD VALUES. SEAL OPENINGS
AND TRANSPORT TO FD2LD
LABORATORY FOR RECOVERY.
Figure 5.10. Sampling Procedures for
Particulate and Metallic HAP's Sampling Train
5-21
-------
NOZZLE. PRODB. AND
FRONT-HALF FILTER
HOLDER
NOZZLB. PROBE. AND
FRONT-HALF FILTER
HOIJ3ER
RINSE WITH 100 ml
ACETONE WHILE
BRUSHING THREE
TIMES
FILTER
IMPINaBRNOS.
1.2. AND 3
1
RINSE wrm too mi
O.I NORMAL HNOj
CUSTODY SEAL
WASHINGS IN LABELED
BOROSUJCATB
BOTTLB. MARK LIQUID
LEVEL, COMPLETE
CUSTODY FORM.
SECURE SAMPLE
CUSTODY SEAL
WASHINGS IN LABELED
BOROSOJCATB
BOT1LB. MARK LIQUID
LEVEL, COMPLETE
CUSTODY FORM,
SECURE SAMPLE
CUSTODY SEAL IN
LABELED GLASS PETRI
DISH. COMPLETE
CUSTODY FORM.
SECURE SAMPLE
IMPINOHRNO.4
MEASURE VOLUME
OP LIQUID AND
RECORD
MPDtQBR NOS.
5 AND 6
'
MEASURE VOLUME
OF LIQUID AND
RECORD
TRANSFER SOLUTION
TO LABELED
BOROSDJCATB
BOTTLE
IMPDKJBRNOS.S
AND 6 (IF VISIBLE
DEPOSITS REMAIN)
MEASURE VOLUME
OF LIQUID AND
RECORD
TRANSFER SOLUTION
TO LABELED
BOROSDJCATB
BOTTLE
i
WASHIMPmOBR
AN CONNECTORS
WITH 100 ml O.I
NORMAL UNO j
ADD WASHINGS TO
BOTTLE AND CUSTODY
SEAL. MARK LIQUID
LEVEL. COMPLETE
CUSTODY FORM.
SECURE SAMPLE
IMPINGER NO. 7
SQ.ICA GBL
|
WASH TUB TWO
IMPINGBRSWrTHA
TOTAL OF2S ml SNHQ
TRANSFER SOLUTION
TO LABELED
BOROSDJCATB
BOTTLE
WASH DUPDSOER WITH
100 ml 0.1
NORMAL UNO]
ADD WASHINGS TO
DOTTLE AND CUSTODY
SEAL. MARK LIQUID
LEVEL. COMPUBTB
CUSTODY FORM,
SECURE SAMPLE
WASH IMPUMGERS AND
CONNECTORS WITH
100mlKMnO]AND
100 ml DISTILLED
WATER
ADD WASHINGS TO
BOTTLE AND CUSTODY
SEAL. MARK LIQUID
IJWBL. COMPLETE
CUSTODY FORM,
SECURE SAMPLE
TRANSFER Hd
SOLUTION TO LABELED
BOROSUJCATB BOTTLE
CONTAINING 200 ml
DISTILLED WATER
(CAUTION: VENTING
REQUIRED. SEE
ADVISORY NOTE
IN METHOD)
1
CUSTODY SEAI,
MARK LIQUID LEVEL.
COMF1 KIB CUSTODY
FORM. SECURE
SAMPLE
WEIGH. RECORD.
INDICATE
REGENERATION
REQUIRED
Figure 5.11. Sample Recovery Procedures for
Paniculate and Metallic HAP's
5-22
-------
5.3.2 Particulate and Lead
Figures 5.12, 5.13, and 5.14 depict the preparation, sampling, and recovery
procedures, respectively, used for the particulate and lead sampling train. All 12 gas
sampling locations were tested for total particulate and lead content. The sampling rate
during most of the tests was isokinetic jh 10% and did not exceed a maximum rate of 0.75
cfm. A minimum of 70 dscf was collected per run, except at the blast furnace outlet and
baghouse inlet. Lower volumes were collected at these two locations due to the high
particulate loadings. The duration of these test runs was 120 minutes, except at the two
locations mentioned above.
5.3.3 Semi-volatile HAP's Testing and Sample Recovery Procedures
Figures 5.15, 5.16, and 5.17 depict the preparation, sampling, and recovery
procedures, respectively, used for the semi-volatile sampling train. The sampling rate
during two of the runs performed at the blast furnace outlet was isokinetic _+ 10% and
never exceeded the maximum rate of 0.75 cfm specified by the test method. Test time
was 120 minutes. Due to the high particulate grain loading, multiple filter changes were
necessary. Approximately 50 dscf sample volume was collected during each 2-hour test
period. A summary of the detection limits by parameter for this test program is presented
at the end of this section. A blank train was set up, leak checked, and sealed for the
duration of one of the tests, and recovered as indicated in Figure 5.17. The purpose of
this train blank was to determine whether or not contamination occurred during the
preparation, setup, recovery, or analysis steps as a QC check.
The preparation and sampling procedures for the EPA Method 23 sampling train
for PCDD/PCDF were identical to those outlined in Figures 5.15 and 5.16 except that the
sampling was 3 hours in duration, collecting > 106 dscf sample volume. The sample
recovery procedures for the EPA Method 23 test train are illustrated in Figure 5.18.
5.3.4 Sampling Procedures for Volatile Organics
Figures 5.19, 5.20, and 5.21 outline the preparation, sampling, and recovery
procedures used to determine the volatile organic HAP's at all locations during the
program. Each of the four tube pairs per test were collected over a 10 to 20-minute
period at a sample rate of 0.25 to 0.5 liter per minute. All four tube pairs for each test
were subjected to analysis.
5.3.5 Aldehyde/Ketone Sampling and Sample Recovery Procedures
The preparation, sampling, and recovery procedures used for determination of
formaldehyde, aldehydes, and ketones conformed to those specified in EPA Method 0011.
Tests were 42 or 60 minutes in duration, > 30 dscf in sample volume, and approximately
200 percent isokinetic. A small nozzle diameter was selected to reduce sample flow
5-23
-------
GLASSWARE, PROBE FILTER
HOLDER, IMPINGERS, CONNECTROS
QUARTZ FIBER FILTERS
REMOVE SURFACE RESIDUE WITH HOT
SOAPY WATER, RINSE WITH TAP
WATER FOLLOWED BY RINSES OF
DISTILLED WATER. SOAK IN 10% NITRIC
ACID, RINSE WITH DISTILLED
WATER, ACETONE, AND AIR DRY
TRANSPORT TO TEST SITE
CHARGE IMPINGER TRAIN
PLACE FILTER .
INTO FILTER HOLDER
INLET AND OUTLET OF
SAMPLING NOZZLE, PROBE
SEAL SAMPLING TRAIN COMPONENTS
WITH SEPTUMS ANDA3R GROUND
GLASS PLUGS OR CAPS TO
PREVENT CONTAMINATION
IMPINGER NO. 1:
lOOmlfXlNHNOj
IMPINGER NO. 2:
lOOmiaiNHNOj
IMPINGER NO. 3:
DRY
IMPINGER NO. 4:
300 G SILICA GEL
TRANSPORT SAMPLING TRAIN
COMPONENTS TO SAMPLING
SITE
Figure 5-12. Preparation Procedures for
Particulate and Lead Sampling Trains
5-24
-------
ATTACH NOZZLE TO PROBE
AND PROBE TO CONNECTOR
TO FILTER HOLDER.
ATTACH IMPINGER TRAIN TO
FILTER HOLDER WITH
BOROSILICATE TUBING
ATTACH SAMPLING
TRAIN COMPONENTS AT
SAMPLING SITE
CONNECT UMBILICAL TO
CONTROL MODULE AND TO
IMPINGER NO. 7 OUTLET
ZERO INCLINED MANOMETERS
LEAK CHECK ASSEMBLED SAMPLING
TRAIN AT IS" Hg. LEAK CHECK
PTTOT / LINES PER METHOD 2
PROBE AND OVEN
HEATERS 250 *F
RECORD LEAK RATE
ON FIELD DATA SHEET
TURN ON PROBE AND OVEN
HEATERS AND ADD ICE TO
IMPINGER TRAIN
TEAM LEADER CHECK
WITH PROCESS OBSERVER
FOR START TIME
PROCESS OBSERVER CHECK
THATPROCESS
IS OPERATING NORMALLY
PROBE POSITIONED IN
STACK AT FIRST
SAMPLING POINT
RECORD CLOCK TIME, INITIAL
DRY GAS METER, APTTs.AND'&i
VALUES. FOR ISOK2NETIC SAMPLING
DETERMINE AH. SET AH AT ORIFICE
METER. READREMAINING
GAUGES.
REMOVE SAMPLE PORT CAP.
INSERT PROBE THROUGH PORT.
SEAL PORT.
START TEST
AT DESIGNATED
START TIME
RECORD DATA ON FIELD
DATA SHEET AT EACH
POINT
PROCESS OBSERVER
CHECKING
THROUGHOUT THE TEST
SAMPLE
EACH POINT ON
TRAVERSE
STOP SAMPLING AFTER COMPLETING
TRAVERSE AND REMOVE PROBE
FROM STACK
RECORD FINAL DRY
GAS METER READING
AND LEAK CHECK
TRANSFER SAMPLING TRAIN
TO NEXT SAMPLE PORT
AND REPEAT PROCEDURE
AT COMPLETION OF TEST, LEAK
CHECK TRAIN AND PITOT LINES
AS PREVIOUSLY INDICATED AND
RECORD VALUES. SEAL OPENINGS
AND TRANSPORT TO FD2LD
LABORATORY FOR RECOVERY.
Figure 5.13. Sampling Procedures for Paniculate and Lead
5-25
-------
NOZZLE, PROBE, AND
FRONT-HALF FILTER
HOLDER
RINSE WHILE BRUSHING WITH
100 ml ACETONE
SEAL WASHINGS IN LABELED
BOROSILICATE BOTTLE MARK
LIQUID LEVEL. COMPLETE CUSTODY
FORM. SECURE SAMPLE
NOZZLE, PROBE, AND
FRONT-HALF FILTER
HOLDER
RINSE WHILE BRUSHING WITH
100 ml 0.1 NORMAL HNOj
SEAL WASHINGS IN LABELED
BOROSILICATE BOTTLE MARK
LIQUID LEVEL, COMPLETE CUSTODY
FORM. SECURE SAMPLE
FILTER
SEAL IN LABELED GLASS PETRI
DISH. COMPLETE CUSTODY
FORM. SECURE SAMPLE
IMPINGER NOS. L 2, AND 3
SILICA GEL
(MOISTURE CATCH)
MEASURE VOLUME OF LIQUID
AND RECORD.
WEIGH AND RECORD WEIGHT.
INDICATE REGENERATION
REQUIRED.
TRANSFER SOLUTION TO
LABELED BOROSILICATE BOTTLE
WASH IMPINGERS AND CONNECTORS
WITH 100 ml 0.1 NORMAL HNO3
ADD WASHINGS TO BOTTLE AND SEAL.
MARK LIQUID LEVEL. COMPLETE
CUSTODY FORM. SECURE SAMPLE
Figure 5.14. Sample Recovery Procedures for
Particulate and Lead
5-26
-------
GLASSWARE: PROBE;
FILTER HOLDER, CONOENSATB
TRAP. IMPINCERS, CONNECTORS
GLASS FIIBR FILTERS
•OROSILICATE NOZZLE
GLASSWARE: IAD-J
SORDBNT MODULES AND CAPS
XAD-2
REMOVE SURFACE RESIDUALS
AND SILICONS ORBASBS BY
SOAKING IN HOT CHROMIC ACID
CI.HANINO SOLUTION, RINSB
WITH TAP WATER. WASH IN SOAP
AND WATER. RINSE Wmi
DISTILLED WATER. RINSB WHH
NANOGRADB MBTHYLBNB
CIILORIDB
WASH IN SOAP AND WATER. RINSB
WITH DISTILLED WATER. RINSB
WITH NANOORADB ACBTONB,
RINSB Wim NANOORADB
MBTIIYLBNB CHLORIDE
SOXHLBT EXTRACT WITH
TOLUENE FOR 16 HOURS.
NI DRY. SEAL Wmi GLASS
CAPS OR WRAP ALL EXPOSED
ENDS WITH ALUMINUM FOIL
WASH IN SOAP AND WATER. RINSB
WITH DISTILLED WATER. RINSB
WITH NANOORADB ACBTONB.
RINSB WITH NANOORADB
MBTHYLBNB CHLORIDE MUFFLE
AT 450% FOR 4 HOURS
TRANSPORTTO JOB SITE
RETAIN SAMPLES OF
DISTILLED WATER FOR BLANK
DETERMINATIONS
CLEAN IN SOXHLBT WH1I
DISTILLED WATER IX.
PESTICIDE GRADE MBTHANOL.
AND NANOORADB METHYLBNB
CHLORIDE 2X FOR 24 HOURS
PACK MODULES WITH XAD-2. PUT
END CAPS ON CONTAINER AND
COVER WITH ALUMINUM FOIL
CHAROBIMPINOBR TRAIN
COMPLETE ASSEMBLY OF TRAIN
SEAL OPEN ENDS OF
IMPINOERS AND NOZZLE WITH
OLASS PLUGS AND ALUMINUM
FOIL. RESPECTIVELY
CONDBNSATB TRAP EMPTY,
IMPINOBR NO. 1 AND NO. 2 WITH
100 ml BACH OF DISTILLED WATER;
DUPINOER NO. 3 DRY. IMP1NOER
NO. 4 300 ORAMS DRY SILICA DEL
RINSB CONDBNSATB TRAP AND
FIRST TWO IMPINOERS WITH
DISTILLED WATER
TRANSPORT TO TEST POINT
Figure 5.15. Preparation Procedures for Semi-Volatile HAP's Sampling Train
5-27
-------
ATTACH NOZZLE TO PROBE
AND PROBE TO FILTER HOLDER.
ATTACH IMPINGER TRAIN TO FILTER
HOLDER WITH BOROSILICATE TUBING.
(ATTACH XAD TUBE TO
SEMrVOLATILE TRAIN)
ASSEMBLE SAMPLING
TRAIN COMPONENTS AT
SAMPLING SITE
ZERO INCLINED MANOMETERS
PROBE AND OVEN
HEATERS 2SO°F
RECORD CLOCK TIME, INITIAL
DRY GAS METER, AP,TS,ANDTM
VALUES. FOR ISOKINETIC SAMPLING
DETERMINE AH. SET AH AT ORIFICE
METER. READREMAINING
GAUGES.
RECORD DATA ON FIELD
DATA SHEET AT EACH
POINT
LEAK CHECK ASSEMBLED SAMPLING
TRAIN AT IS" Hg. LEAK CHECK
PFTOT / LINES PER METHOD 2
•—
•—
TURN ON PROBE AND OVEN
HEATERS AND ADD ICE TO
IMPINGER TRAIN. START
CONDENSER / XAD COOLANT WATER.
1
TEAM LEADER CHECK
WITH PROCESS OBSERVER
FOR START TIME
1
PROBE POSITIONED IN
STACK AT FIRST
SAMPLING POINT
STAR!
AT DESK
START
1
•TEST
3NATED
TIME
SAMPLE
EACH POINT ON
TRAVERSE
\
STOP SAMPLING AFTER COMPLETING
TRAVERSE AND REMOVE PROBE
FROM STACK
•—
-»
CONNECT UMBILICAL TO
CONTROL MODULE AND TO
IMPINGER NO. 4 OUTLET
RECORD LEAK RATE
ON FIELD DATA SHEET;
MUST BE <= 0.02 dm
PROCESS OBSERVER CHECK
THAT PROCESS
IS OPERATING NORMALLY
REMOVE SAMPLE PORT CAP.
INSERT PROBE THROUGH PORT.
SEAL PORT.
PROCESS OBSERVER
CHECKING
THROUGHOUT THE TEST
RECORD FINAL DRY
GAS METER READING
AND LEAK CHECK
1
TRANSFER SAMPLING TRAIN
TO NEXT SAMPLE PORT
AND REPEAT PROCEDURE
— »
AT COMPLETION OF TEST, LEAK
CHECK TRAIN AND PTTOT/ LINES AS
PREVIOUSLY INDICATED AND
RECORD VALUE. SEAL OPENINGS
AND TRANSPORT TO FIELD
LABORATORY FOR RECOVERY.
Figure 5.16. Sampling Procedures for Semi-Volatile HAP's
5-28
-------
NOZZLE, PROBE, AND
FRONT-HALF FILTER
HOLDER
FILTER
CONNECTORS
AND
CONDENSER
XAD-2 MODULE
WASH WHILE BRUSHING
WITH NANOGRADB
METHANOL / METIIYUiNB CHLORIDB
SEAL IN I.ABRLED GLASS BOTTLE OR
PETRIDISH. COMPLETE CUSTODY
FORM. SECURE SAMPLE
WASH WITH NANOGRADB
MBTHYLENE CHLORIDE/MBTIIANOL
REMOVE FROM
IMPINGER TRAIN
SEAL WASHINGS IN LABELED
BOROSILICATB BOTTLE MARK
LIQUID LEVEL. tOMPLBTE CUSTODY
FORM. SECURE SAMPLE
i.
TRANSFER WASHINGS TO
BOROSILICATB BOTTLE; LABEL, SEAL
AND MARK LIQUID LEVEL, COMPLETE
CUSTODY FORM*. SECURE SAMPLE.
SEAL ENDS WITH GLASS
CAPS. COVER WITH FOIL. LABEL.
COMPLETE CUSTODY FORM.
SECURE SAMPLE
CONDENSATETRAP
IMPINGER NO. 1,2, AND 3
IMPINGER NO. 4
(SILICA GEL)
MEASURE VOLUME OF LIQUID
AND RECORD.
J_
MEASURE VOLUME OF LIQUID
AND RECORD.
_L
WEIGH AND RECORD
TRANSFER SOLUTION TO
LABELED BOROSILICATB BOTTLE
TRANSFER SOLUTION TO
LABELED BOROSILICATB BOTTLE
WASH WITH DISTILLED WATER
AND METHYLENE CHLORIDE/
MBTHANOL*.
J_
WASH WITH DISTILLED WATER
AND METHYLONB CHLORIDE/
MBTHANOL*.
ADD WASHINGS TO BOTTLE AND
SEAL. MARK LIQUID LEVEL.
COMPLETE CUSTODY FORM,
SECURE SAMPLE.
_L
• OONDENSATE AND SOLVENT RINSE SAMPLES FOR BACK
HALF OF TRAIN WERE MAINTAINED SEPARATELY.
ADD WASHINGS TO BOTTLE AND
SEAL. MARK LIQUID LEVEL.
COMPLETE CUSTODY FORM,
SECURE SAMPLE
Figure 5.17. Sample Recovery frocedures for Semi-Volatile HAP's
5-29
-------
NOZZLE, PROBE. AND
FRONT-HALF FILTER
HOLDER
FILTER
^_
WASH WITH
NANOORADO
ACETONE
•
WASIIWmi
NANOGRADB
METHYLENB CHLORIDE
SP.AI.WASI1INOSIN
SEPARATE LABELED
BOROSOJCATB
BOTTLES. MARK LIQUID
LEVELS, COMPLETE
CUSTODY FORM.
SECURE SAMPLES
XAD-1 MODULE
(
SEAL IN LABELED
GLASS BOTTLE OR
PBTRI DISH.
COMPLBTB CUSTODY
FORM. SECURE
SAMPLE
•
CONDENSATE
TRAr
RBMOVBFROM
IMPINOBR TRAIN
IMPINGER NOS.
1,1 AND 3
(
MEASURE VOLUME
OP LIQUID AND
RECORD
SEAL BNDS WITH
GLASS CAPS. COVER
WITH FOIL. LABEL,
COMPLETE CUSTODY
FORM, SECURE
SAMPLE
BACK- HALF FILTER
HOLDER, CONNECTORS
AND CONDENSER
MEASURE VOLUME
OF LIQUID AND
RECORD
DISCARD
LIQUID
DISCARD
LIQUID
ALL TEST TRAIN
COMPONENTS (EXCEPT
CONDENSATE TRAP
ANDIMriNGERS)
IMPINGER NO. 6
(SILICA GEL)
1
WASH WITH
NANOORADB ACETONE
ANDMBTHYLBNB
CHLORIDE
i
TRANSFER WASHINGS
TOBOROSILICATB
BOTTLE; LABEL. SEAL,
AND MARK LIQUID
LEVEL, COMPLETE
CUSTODY FORM*,
. SECURE SAMPLE
WASH WTIH TOLUENE
ADD WASHINGS
TO BOTTLE AND SEAL,
MARK LIQUID LEVEL,
COMPLBTB CUSTODY
FORM, SECURE
SAMPLE
WEIGH AND RECORD
Figure 5.18. Sample Recovery Procedures for Method 23 -
Dioxins and Furans
5-30
-------
GLASSWARE AND
TEFLON* TUBING
TENAXGC
RINSE WITH NANOCRAOE
ACETONE. RINSE WITH
PESTICIDE GRADE HEXAKE
ACTIVATED CHARCOAL
EXTRACT IN SOXHLETFOR
It HOURS WITH METHANOL
SILICA GEL
FIREAT600%FOR
1HOUR
DRYAT17SeCPOR
2 HOURS
DRY FOR 1 HOUR IN OVEN
AT 103 - JOS t SEAL ENDS
WITH CLASS. TEFLON, OR
STAINLESS STEEL CAPS
AND/OR FOIL
DRY FOR 3-5 HOURS IN
120*COVEN
PACE SORBENT TUBES WITH
TENAXGC
PACK SORBENT TUBES
WITH CHARCOAL
1.6 GRAMS INTO
TUBE TYPE 1
U> GRAM INTO
TUBETYPB2
PACK DRYING TUBE WITH
20 GRAMS OF SILICA GEL
1 GRAM INTO BACK-UP SECTION
OFTUBETYPE2
CAP ENDS
CONDITION ATZTOtWTIH
PURIFIED HELIUM FLOW OF
30 odAoa FOR 120 MINUTES
CAP ENDS WITH TEFLON OR
STAINLESS STEEL PLUGS,
PLACE DJ TRANSPORT TUBES,
COVER WITH ALUMINUM FOIL
PLACED) AMBER JAR CONTAINING
ACTIVATED CHARCOAL. SEAL
JAR WITH TEFLON-UNED LID.
STORE AT 4°C-
TRANSPORT TO TEST SITE
ASSEMBLE COMPONENTS
SEAL OPEN ENDS OF TRAIN
WITH GLASS FOB. AND/OR FOB,
TRANSPORTTO TESTP01NT
Figure 5.19. Preparation Procedures for
Volatile Organics Sampling Train
5-31
-------
ATTACH IN SERIES: PROBE
CONDENSER. TUBE THE 1,
CONDENSATE TRAP. TEFLON TUBING,
SECOND CONDENSER. TUBE TYPE 2,
SECOND CONDENSATE TRAP. TUBING.
AND SILICA GEL TUBE
ASSEMBLE SAMPLING TRAIN
COMPONENTS AT TEST POINT
CONNECT UMBILICAL TO OUTLET 0
SILICA GEL TUBE AND TO
CONTROL CONSOLE
LEAK CHECK ASSEMBLED
SAMPLING TRAIN AT IS IN. HG
AT FRONT END OF PROBE
PROBE HEATER AT25°F
RECORD LEAK CHECK ON FIELD
DATASHEET
TURN ON PROBE HEATER AND
COOLANT PUMP
TEAM LEADER CHECK WITH
PROCESS OBSERVER FOR
START TIME
PROCESS OBSERVER
ENSURES THATPROCESS IS
OPERATING NORMALLY
PROBE POSITIONED AT SAMPLING
POINT IN STACK
REMOVE SAMPLE PORT AND PROBE
CAPS. INSERT PROBE THROUGH
PORT. SEAL PORT
RECORD CLOCK TIME. RECORD
DOTIAL DRY GAS METER READING
AND COMPONENT TEMPERATURES.
SET SAMPLING RATE ON ROTAMETER
AND READ REMAINING GAUGES
START TEST ATDESIGNATED
TIME
PROCESS OBSERVER TAKE DATA
THROUGHOUT TEST
RECORD DATA ON FIELD DATA SHEET
EVERY 5 MINUTES
SINGLE POINT. CONSTANT RATE
SAMPLING AT 0 J UTER/MIN FOR
29 MINUTES
SHUT OFF TRAIN. RECORD
VOLUME READING. REMOVE
PROBE FROM STACK. LEAK
CHECK TRAIN AND RECORD
LEAK RATE
CHANGE TRAP PAIRS EVERY.
20 MINUTES THROUGHOUTTHE
« HOUR TEST. SEAL ENDS
WITH TEFLON OR STAINLESS
STEEL CAPS
RECORD FINAL DRY GAS METER
READING AND LEAK CHECK AT
END OF 4-6 HOUR TEST
Figure 5.20. Sampling Procedures for Volatile Organics
5-32
-------
PROBE AND CONDENSER
SORBENTTUBES
WASH WITH DISTILLED WATER
CONDENS ATE TRAPS
REMOVE FROM TRAIN
DISCARD LIQUID
SILICA GEL
MEASURE VOLUME OF LIQUID
AND RECORD
SEAL ENDS WITH TEFLON
CAPPED TRANSPORT TUBES
OR STAINLESS STEEL CAPS
AND INSERT IN TEFLON
WEICR RECORD VOLUME,
INDICATE REGENERATION
REQUIRED
PLACE LIQUID IN 4ftnd VGA
VIAL, TOP WITH WATER.
SEPTUM SEAL
PLACE IN LABELED AMBER
JAR CONTAINING ACTIVATED
CHARCOAL, SEAL JAR WITH
TEFLON LINED UD, STORE AT
WATER ICE TEMPERATURE (4 ^Q.
COMPLETER CUSTODY FORM.
SECURE SAMPLES FOR SHIPMENT
Figure 5.21. Recovery Procedures for Volatile Organics
5-33
-------
through the train in order to minimize degradation and overloading of the DNPH impinger
solution. Figures 5.22, 5.23, and 5.24 illustrate the EPA Method 0011 preparation,
sampling, and recovery procedures, respectively.
The preparation and recovery of the EPA Method 0011 test train were performed in
an area isolated from the preparation and recovery activities for the other test trains. This
was done to minimize the potential for contamination of the Method 0011 samples with
acetone.
A blank train (identical to the EPA Method 0011 sample train) was charged, leak
checked, and recovered during one of the three test runs performed at the blast furnace
outlet. The blank train was analyzed as a QC check to determine whether or not
contamination occurred during preparation, setup, recovery, or analysis. Acetone
contamination was found in each impinger of each run including the train blank. It was
determined that the acetone was not native to the samples, and the values reported
represent the analytical detection limit.
5.3.6 HC1 and C1-; Sampling and Sample Recovery
Figures 5.25, 5.26, and 5.27 outline the preparation, sampling, and recovery
procedures used to prepare, sample, and recover the EPA 26A test trains at the
reverberatory and blast furnaces wet scrubber inlet/outlet test locations.
Test length was 2 hours in duration and a minimum of 50 dscf sample volume was
collected at both locations. Sampling at both locations was isokinetic +. 10 percent or
better.
5.3.7 PM Samlin and Samle Recover
Figures 5.28, 5.29, and 5.30 outline the preparation, sampling, and recovery
procedures used to determine PM10 at all locations during the program.
The PM10 concentrations at all stack locations were quite low. This dictated very
long sample runs, approximately 4 hours.
5.4 FLUE GAS SAMPLE ANALYSIS PROCEDURES
Paniculate, metals, PM10, condensible particulate, semi-volatiles (including
PCDD/PCDF), aldehydes/ketones, volatile organics, HCL, and C12 samples were
recovered on-site at the field laboratory. The field laboratory was located in the
environmental laboratory trailer parked nearthe testing locations. The aldehyde/ketone and
volatile organics samples along with the Method 0010 and Method 23 XAD traps were
5-34
-------
GLASSWARE
REMOVE SURFACE RESIDUE
WITH HOT SOAPY WATER, RINSE
WITH TAP WATER FOLLOWED
BY DISTILLED WATER.
RINSE WTIH NANOGRADE
METHYLENE CHLORIDE
DRY FOR 1 HOUR IN OVEN AT
lOSt. SEALENDSWTTH
GLASS. TEFLON OR FOIL
TRANSPORTTO TEST SITE
CHARGE IMPINGER TRAIN
INLET AND OUTLET OF
SAMPLING NOZZLE PROBE
100 ml DNPH SOLUTION
lOOmlDNPHSOLimON
IMPINGER Na 2:
100ml DNPHSOLUTION
IMPINGER Na 3:
100 ml DNPHSOLUTION
IMPINGER Na 4:
100ml DNPHSOLUTION
IMPINGER NO. 5:
300 g SILICA GEL
SEAL SAMPLING TRAIN COMPONENTS
WITH GROUND GLASS PLUGS OR
CAPS TO PREVENT CONTAMINATION
INLET TO IMPINGER NO. 1
AND OUTLET TO IMPINGER NO. 5
TRANSPORT SAMPLING TRAIN
COMPONENTS TO SAMPLING
SITE
Figure 5.22. Preparation Procedures for
Aldehydes/Ketones Sampling Trains
5-35
-------
ATTACH NOZZLE TO PROBE
AND PROBE TO MINCER
TRAIN WITH
BOROSILICATE TUBING
ATTACH SAMPLING
TRAIN COMPONENTS AT
SAMPLING SITE
ZERO INCLINED MANOMETERS
CONNECT UMBILICAL TO
CONTROL MODULE AND TO
IMPINGER NO. S OUTLET
LEAK CHECK ASSEMBLED SAMPLING
TRAIN AT IS" Hg. LEAK CHECK
mOT; LINES PER METHOD 2
PROBE AND OVEN
HEATERS 250 *F
RECORD LEAK RATE ON FIELD
DATA SHEET; MUST BES&02 eta.
TURN ON PROBE AND OVEN
HEATERS AND ADD ICE TO
IMPINGER TRAIN
TEAM LEADER CHECK
WITH PROCESS OBSERVER
FOR START TME
PROCESS OBSERVER CHECK
THAT PROCESS
IS OPERATING NORMALLY
PROBE POSITIONED IN
STACK AT FIRST
SAMPLING POINT
RECORD CLOCK TIME, INITIAL
DRY GAS METER, AP.Ts .ANDTw
VALUES. FOR ISOK3NETIC SAMPLING
DETERMINE AH. SET AH AT ORIFICE
METER. READ REMAINING
GAUGES.
REMOVE SAMPLE PORT CAP.
INSERT PROBE THROUGH PORT
SEAL PORT.
START TEST
AT DESIGNATED
START TIME
RECORD DATA ON FIELD
DATA SHEET AT EACH
POINT
PROCESS OBSERVER
CHECKING
THROUGHOUT THE TEST
SAMPLE
BACH POINT ON
TRAVERSE
STOP SAMPLING AFTER COMPLETING
TRAVERSE AND REMOVE PROBE
FROM STACK
RECORD FINAL DRY
GAS METER READING
AND LEAK CHECK
TRANSFER SAMPLING TRAIN
TO NEXT SAMPLE PORT
AND REPEATPROCEDURE
AT COMPLETION OF TEST,
LEAK CHECK TRAIN AS
PREVIOUSLY INDICATED AND
RECORD VALUE. SEAL OPENINGS
AND TRANSPORT TO FIELD
LABORATORY FOR RECOVERY.
Figure 5.23. Sampling Procedures for Aldehydes/Ketones
5-36
-------
NOZZLE. PROBE
CONNECTORS, IMPINGERS
NO. 1.2,3 AND*
DRAIN ANY CONDENSATE INTO
NO. 1IMPINGER
CONNECTORS, IMPINGERS
NO. 1.2,3 AND 4
MEASURE VOLUME AND RECORD
RINSE WHILE BRUSHING WITH
METHYLENE CHLORIDE
RINSE WHILE BRUSHING WITH
METHYLENE CHLORIDE AND
HPLC WATER
TRANSFER SOLUTION TO LABELED
BOTTLE PROBE WASH
ADD WASHINGS TO LABELED AMBER
BOROSmCATEBOTTLE
MAKE FINAL RINSE OF CONNECTORS
WITH METHYLENE CHLORIDE AND
WATER
WASH IMPINGERS AND
CONNECTORS WITH
METHYLENE CHLORIDE
ADD WASHINGS TO PROBE/
IMPINGERS SAMPLE BOTTLE
ADD WASHINGS TO BOTTLE AND SEAL
SEAL BOTTLE. MARK LIQUID LEVEL,
COMPLETE CUSTODY FORM.
SECURE SAMPLE
NOTE: IMPINGERS 1,2, 3, AND 4 WERE MAINTAINED SEPARATELY.
Figure 5.24. Sample Recovery Procedures for
Aldehydes/Ketones Sampling Trains
5-37
-------
ACETONE WASH OF
SAMPLING NOZZLE,
PROBE, FILTER HOLDER
THOROUGHLY CLEAN
SAMPLING TRAIN COMPONENTS
IN LABORATORY
TRANSPORT
TO
TEST SITE
CHARGE
IMPINGER
TRAIN
MOD. IMPINGER NO. 1:
SOmiaiNH2SO4
STD. IMPINGER NOS. 2 AND 3:
100mlEA.0.1NH2SO4
MOD. IMPINGER NOS 4 AND 5:
100mlEA.OJNN»OH
IMPINGER NO. 6:
300gSniCAGEL
EXAMINE TEFLON FILTER
FOR FLAWS AND PLACE
INTO FILTER HOLDER
INLET AND OUTLET OF
SAMPLING NOZZLE,
PROBE
SEAL SAMPLING TRAIN
COMPONENTS WITH
SEPTUMS AND/OR
GROUND GLASS PLUGS
OR CAPS TO PREVENT
CONTAMINATION
INLET TO IMPINGER NO. 1
AND OUTLET TO
IMPINGER NO. 6
TRANSPORT SAMPLING
TRAIN COMPONENTS TO
SAMPLING SITE
Figure 5.25. Preparation Procedures for
HC1 and C12 Sampling Trains
5-38
-------
ATTACH NOZZLE TO PROBE AND
PROBE TO CONNECTOR OR
rvn fMVJfi ^A.CIC xn FII TTT* HOLDER.
ATTACH IMPINGER TRAIN TO
FILTER HOLDER WITH
BOROSILICATE TUBING
ZERO INCLINED MANOMETERS.
248 * 25*F
RECORD CLOCK TIME. RECORD INITIAL
DRY GAS METER. READ AP,TS,TM.
FOR ISOKJNETIC SAMPLING
DETERMINE AH. SET AH AT ORIFICE
METER, READ REMAINING
GAUGES.
RECORD DATA ON FIELD DATA
SHEET AT EACH POINT EVERY
5 MINUTES
ASSEMBLE!
TRAIN COMP
SAMPLES
SAMPLING
ONENTS AT
GSITE
1
TURN ON PROBE AND OVEN
HEATERS AND ADD
ICE TO IMPINGER TRAIN
i
LEAK CHECK ASSF"
TRAIN AT IS" Hj
PTTOT LINES F
i
TEAM LEAD
Wl'lH PROCE!
FORSTA1
MBLED SAMPLING
{« i w AIT I'uLi'ic
ER METHOD 2.
IER CHECK
IT TIME
PROBE POSITIONED IN
DUCT/STACK AT FIRST
SAMPLING POINT
STAR!
START
SAM
TRAV
i
STOP SAMPLING AI
TRAVERSE, RECO
REMOVE PROBE Fl
LEAK'
I
•TEST
5NATED
TIME
PLE
)DJTON
rpgR
TER COMPLETING
EU> VOLUME, AND
KOM DUCT/STACK.
•mnr.
I
TRANSFER SAMPLING TRAIN
TO NEXT SAMPLE PORT,
LEAK CHECK, AND REPEAT
TRAVERSE PROCEDURE.
•
CONNECTUMBILICAL TO
CONTROL MODULE AND TO
IMPINGER NO. 6 OUTLET
RECORD LEAK RATE ON FIELD
DATA SHEET; TRAIN LEAK
MUST BE < OjUcftn
PROCESS OBSERVER CHECK
THAT PROCESS
IS OPERATING NORMALLY
REMOVE SAMPLE PORT CAP.
INSERT PROBE THROUGH PORT.
SEAL PORT.
PROCESS OBSERVER
THROUGHOUT THE TEST
RECORD FINAL DRY
GAS METER READING
AMH IPAK rmtntr
AT COMPLETION OF TEST,
LEAK CHECK TRAIN AND PITOT LINES
AS PREVIOUSLY INDICATED AND
RECORD VALUES. SEAL OPENINGS
AND TRANSPORT TO FIELD
LABORATORY FOR RECOVERY.
Figure 5.26. Sampling Procedures for HC1
5-39
-------
NOZZLE, PROBE, CONNECTOR OR
CYCLONE/FLASK, FRONT-HALF
FILTER HOLDER
FILTER
WASH AND BRUSH WITH
ACETONE. MINIMUM 3 TIMES
UNTIL CLEAN. DISCARD WASHES.
DISCARD
CONNECTORS
DMPINCER NOS. 1, 2, AND 3.
(HO AND MOISTURE CATCH)
CONNECTORS
CMPINGERS NOS. 4 AND S.
-------
ACETONE WASH OF SAMPLING
NOZZLE, CYCLONE,
IMPACTOR, PROBE, AND
FILTER HOLDER
THOROUGHLY CLEAN
SAMPLING TRAIN COMPONENTS
IN LABORATORY
TRANSPORT
TO
TEST SITE
CHARGE
IMPINGER
TRAIN
MOD. IMPINGER NO. 1:
100 ml H2 O
STD. IMPINGER NO. 2s
100ml H20
MOD. IMPINGER NO. 3:
DRY
IMPINGER NO. 4:
300 « SILICA GEL
EXAMINE TARED FILTERS
FOR FLAWS AND PLACE
INTO IMPACTOR
INLET AND OUTLET OF
SAMPLING NOZZLE,
PROBE
SEAL SAMPLING TRAIN
COMPONENTS WITH
SEPTUMS AND/OR
GROUND GLASS PLUGS
OR CAPS TO PREVENT
CONTAMINATION
INLET TO IMPINGER NO. 1
AND OUTLET TO
IMPINGER NO. 4
TRANSPORT SAMPLING
TRAIN COMPONENTS TO
SAMPLING SITE
Figure 5.28. Preparation Procedures for Particle Size Distribution and Condensible
Particulate Sampling Train
5-41
-------
ATTACH NOZZLE, CYCLONE, AND
IMPACTOR TO PROBE.
ATTACH IMPINGER TRAIN TO
PROBE WITH
BOROSILICATE TUBING
ASSEMBLE SAMPLING
TRAIN COMPONENTS AT
SAMPLING SITE
J
ZERO INCLINED MANOMETERS.
PROBE AND OVEN HEATERS
248 t 25*F
-
RECORD CLOCK TIME. RECORD INITIAL
DRY GAS METER. READ AP,TS,TM.
FOR ISOHNETIC SAMPLING
DETERMINE AH. SET AH AT ORIFICE
METER. READ REMAINING
GAUGES.
•
•—
RECORD DATA ON FIELD DATA
SHEET AT EACH POINT
TURN ON PROBE AND OVEN
HEATERS AND ADD
ICE TO IMPINGER TRAIN
LEAK CHECK ASSEMBLED SAMPLING
TRAIN AT IS" Hg; LEAK CHECK
PITOT LINES PER METHOD 2.
TEAM LEADER CHECK
WITH PROCESS OBSERVER
FOR START TIME
PROBE POSITIONED IN
DUCT/STACK AT FIRST
SAMPLING POINT
START TEST
AT DESIGNATED
START TIME
SAMPLER/
rtV TO A VPPCT? PU
TOTHEAV
^CH POINT
.OPORTIONALLY
ERAGEAP
•
CONNECT UMBILICAL TO
CONTROL MODULE AND TO
IMPINGER NO. 4 OUTLET
—
•—
m —
STOP SAMPLING AFTER COMPLETING
TRAVERSE, RECORD VOLUME, AND
REMOVE PROBE FROM DUCT/STACK.
LEAK CHECK.
_-•
RECORD LEAK RATE ON FIELD
DATA SHEET; TRAIN LEAK
MUST BE s 0.02 cftn
PROCESS OBSERVER CHECK
THAT PROCESS
IS OPERATING NORMALLY
REMOVE SAMPLE PORT CAP.
INSERT PROBE THROUGH PORT.
SEAL PORT.
PROCESS OBSERVER
CHECKING
THROUGHOUT THE TEST
RECORD FINAL DRY
GAS METER READING
AND LEAK CHECK.
'
TRANSFER SAMPLING TRAIN
TO NEXT SAMPLE PORT,
LEAK CHECK, AND REPEAT
TRAVERSE PROCEDURE.
_— •
AT COMPLETION OF TEST, LEAK
CHECK TRAIN AND PTTOT LINES AS
PREVIOUSLY INDICATED AND RECORD
VALUES. PURGE TRAIN. SEAL
OPENINGS AND TRANSPORT TO FIELD
LABORATORY FOR RECOVERY.
Figure 5.29. Test Procedures for Particle Size Distribution
and Condensible Particulate Sampling Train
5-42
-------
IMP ACTOR, CYCLONE
AND NOZZLE
PARTICLE SIZE FILTERS
WASH AND BRUSH WITH
ACETONE A MINIMUM OF
THREE TIMES UNTO. CLEAN
CUSTODY SEAL FILTERS IN
LABELED PETRI DISHES.
COMPLETE CUSTODY FORM.
SECURE SAMPLE FOR SHIPMENT.
CUSTODY SEAL WASHINGS IN
LABELED BOROSILICATE BOTTLE.
COMPLETE CUSTODY FORM.
SECURE SAMPLE FOR SHIPMENT.
PROBE, CONNECTORS, IMPINGER NO&
L 2, AND 3. (CONDENSIBLE
PARTICULATE AND MOISTURE CATCH)
PROBE, CONNECTORS, IMPINGER NOS.
L 2, AND 3. (CONDENSIBLE
CONDENSIBLE AND MOISTURE CATCH)
SELICAGEL
(MOISTURE CATCH)
MEASURE WEIGHT AND RECORD.
RINSE WITH METHYLENE CHLORIDE
INTEGRITY SEAL SAMPLE AND
WASHINGS IN LABELED BOROSILICATE
BOTTLE. MARK LIQUID LEVEL.
WEIGH. RECORD,
INDICATE REGENERATION
REQUIRED.
INTEGRITY SEAL SAMPLE AND
WASHINGS IN LABELED BOROSILICATE
BOTTLE MARK LIQUID LEVEL.
COMPLETE CUSTODY FORM.
SECURE SAMPLE FOR SHIPMENT.
COMPLETE CUSTODY FORM.
SECURE SAMPLE FOR SHIPMENT.
Figure 5.30. Sample Recovery Procedures for Particle
Size Distribution and Condensible Paniculate Sampling Train
5-43
-------
stored at 4°C until analyses were performed. The participate, metals, condensible
particulate, HC1, CI^, and particle size distribution samples did not require refrigeration
or other special preservation steps. Consistent procedures were employed for sample
analysis. Sample integrity was assured by maintaining strict chain-of-custody records
during all analyses proceedings. Samples from each run were shipped via overnight air
carrier to Triangle Labs or SwRI laboratories for prompt analysis.
5.4.1 Particulate and Metallic HAP's Procedures
Samples collected for paniculate metals analysis were contained in seven different
media:
Front half acetone (paniculate) - Container No. 2.
Front half nitric acid - Container No. 3
Filter (paniculate) - Container No. 1
Back half nitric acid - Container No. 4
Impinger 4 condensate - Container No. 5A.
Potassium permanganate solution (acidified) - Container No. SB.
Impinger 5 and 6 HC1 rinse - Container No. 5C.
Analytical procedures and calculations for particulate determination were performed as
specified in Sections 4 and 6 of Method 5. The particulate analysis procedure is described
below:
• The filter and any loose fragments are desiccated for 24 hours and weighed on a
calibrated analytical balance to the nearest 0.1 mg to a constant weight.
"Constant weight" means a difference of no more than 0.5 mg or 1% of total
weight less tare weight, whichever is greater, between two consecutive
weighings, with no less than 6 hours of desiccation time between weighings.
• The front-half acetone wash samples and corresponding acetone blank are
evaporated at ambient temperature and pressure in tared beakers, and then
desiccated to constant weight to the nearest 0.1 mg.
The total weight of material measured in the front-half wash fraction plus the
weight of material collected on the glass fiber filter, represents the EPA Method 5
particulate catch for each run. Acetone and filter blank corrections were made on all
sample weights.
The metals analytical procedures are outlined below. A flow diagram for the
multi-metals analysis scheme is presented in Figure 5.31. The detailed procedures are
specified in the reference method.
5-44
-------
CONTAINER 3
ACID PROBE RINSE
(LABELED FH)
CONTAINER >
ICBTONR PROBE RINSE
(LABELED AR)
CONTAINER 1
FILTER
(LABELED F)
REDUCE TO DRYNESS
INATAREDBBAKER
CONTAINER 4 (HNOj/HjO,)
IMFINGERS
(LABELED BH)
(INCLUDES CONDENSATB
IMPINGERIFUSED)
_L
CONTAINER
5A,SB,ANDSC
DESICCATE TO
CONSTANT WEIGHT
ALIQUOT TAKEN FOR
CVAAS FOR Hg ANALYSIS
FRACTION 2B
DRTERMINH RESIDUE
WBIOirr IN BEAKER
DETERMINE FILTER
PARTICULATB WEIGHT
'TOpH2
NCHNOj
OLUMBTO
NESS AND
rilHPAND
HNO3
SOLUBIUZB RESIDUE
wmtcoNCHNO}
i^_^_«J
DIVIDBOJg SECTIONS
AND DIGEST BACH
SECTION WITH CONG
HPANDHNQi
DIGEST WITH ACID AND
PERMANGANATE AT 9S°C
FOR 2 HOURS AND
ANALYZE BY CVAAS
FORHg
J_
FILTER AND DILUTE TO
KNOWN VOLUME
FRACTION I
REMOVE 50 TO
100 ml ALIQUOT FOR
Hg ANALYSIS
FRACTION IB
DIGEST WITH ACID
AND PERMANGANATE AT
95"C IN A WATER BATH
FOR 2 HOURS
ANALYZE BY ICAP
FOR TARGET METALS
FRACTION IA
ANALYZE BY GPAAS
FOR METALS
FRACTION IA
ANALYZE ALIQUOT BY
CVAASFOR Hg
ACIDITY REMAINING
SAMPLE TO pll 2 WITH
CON. HNOj FRACTION 2A
REDUCE VOLUME TO
NEAR DRYNESS AND
DIGEST WITH HNOj
AND HjOj
INDIVIDUALLY. THREE
SEPARATE DIGESTIONS
AND ANALYSIS:
DIOEST WITH ACID AND
PERMANGANATE AT
93% FOR 2 HOURS
AND ANALYZE BY
CVAAS FOR Hg
FRACTION 3A.3B.3C
ANALYZE BY ICAP
FOR IS TARGET
METALS
ANALYZE BY
GPAASFOR
METALS
Figure 5.31. Paniculate and Multi-Metals Analytical Scheme
5-45
-------
• The front-half acetone residue, front-half nitric acid, and filter samples were
combined in the laboratory for analysis.
• The back-half nitric acid impingers were treated as a separate sample as was the
acidified potassium permanganate sample.
• After the front-half nitric acid and filter samples were combined, the metals
were solubilized by the addition of nitric acid and 30% hydrogen peroxide.
Sample volume was reduced to 50 ml on a hot plate. The sample was then
brought to 250-ml final volume and an aliquot removed for Hg analysis by cold
vapor atomic absorption spectroscopy (CVAAS).
• The back-half impinger solution was treated similarly to the front half
combination. The sample was solubilized in nitric acid and 30% hydrogen
peroxide and reduced to SO ml final volume. The sample was then diluted to
250 ml and an aliquot analyzed for mercury using CVAAS.
The combined front-half nitric acid/filter and the back-half nitric acid was analyzed
for Sb, As, Cd, Cr, Pb, Mn, and Ni using inductively coupled plasma atomic emission
spectroscopy (ICP) and atomic absorption spectroscopy (AAS).
The acidified potassium permanganate and rinse samples and impinger 4 sample
were analyzed for mercury only. The volume of these samples was reduced to 100 ml and
analyzed directly for mercury. Mercury results were quantified by CVAAS with results
reported in micrograms.
5.4.2 Particulate and Lead Procedures
The analysis procedures for lead are summarized below. The analytical procedures
for paniculate are identical to those described in Section 5.4.1. A flow diagram for the
paniculate and lead analysis scheme is presented in Figure 5.32. The lead analysis of the
EPA Method 12 samples was carried out as follows:
• The front-half acetone residue, front-half 0.1 N HNO3 wash, and impinger
contents were combined in the laboratory for analysis. The combined samples
were then taken to dryness on a hot plate.
• The residue was combined with the filter (cut into strips) in an Erlenmeyer flask.
A total of 30 ml of 50% HNQ, was used to resolubilize the residue to aid in
transfer to the flask. The sample was taken to near boiling, maintaining a
minimum 15 ml volume with addition of 50% HNOj. A 10 ml aliquot of 3%
hydrogen peroxide was added while heating.
5-46
-------
CONTAINER 3
ACID PROBE RINSE
(LABELED FH)
ACIDITY TO pH 2
Wmi CONC. HNOj
REDUCE VOLUME TO
NEAR DRYNESS AND
DIGEST WITH
CONC. HNOj
CONTAINER!
tCBTONE PROBE RINSE
(LABELED AR)
CONTAINER 1
FILTER
(LABELED P)
CONTAINER 4 (HNOj)
IMPINGBRS
(LABELED BH)
REDUCE TO DRYNESS
IN A TARED BEAKER
DESICCATE TO
CONSTANT WEIGHT
ACIDITY SAMPLE
TO pH 2 WITH
CONC IINO3
DETERMINE RESIDUE
WEIGHT IN BEAKER
DETERMINE FILTER
PARTICULATB WEIGHT
REDUCE VOLUME TO
NEAR DRYNESS AND
DIGEST WITH UNO]
AND HjOj
SOLUBIUZB RESIDUE
WfTHCONC. HNOj
— ___ —J
DIVIDE O.Sg SECTIONS
AND DIGEST BACH
SECTION WITH
CONC. HNOj
ANALYZE FOR
LEAD
BYOFAAS
FILTER AND
DILUTE TO
KNOWN VOLUME
ANALYZEFOR
LEAD
BYGPAAS
Figure 5.32. Particulate and Lead Analytical Scheme
5-47
-------
• The resultant sample was cooled, filtered, and diluted to a 250 ml volume with
distilled water.
• The samples were analyzed for lead by atomic absorption spectrometry using an
air acetylene flame. Blank samples of filter and 0.1 N HNO3 were analyzed in
like manner.
Lead results were reported in total micrograms per train.
5.4.3 Analysis of Semi-Volatile HAP's
The analysis procedure for semi-volatile HAP's is summarized below. See EPA
Method 8270 for detailed specification of the analysis procedures.
• Each front-half wash sample was concentrated to 1-5 ml using a rotary
evaporator apparatus. The sample container was rinsed three times with
methylene chloride, added to concentrated solution, and concentrated further to
near dryness.
• The above concentrate was added to the filter and XAD-2 resin in a soxhlet
apparatus that contained a precleaned glass extraction thimble and silica gel. A
semi-volatile internal standard was added. The apparatus was covered with a
plug of precleaned glass wool. The sample was refluxed with toluene for 16
hours. The extract was transferred using three 10 ml rinses of toluene to a
rotary evaporator and concentrated to approximately 8 ml. It was then reduce to
1 ml under a nitrogen stream. The sample was split in half. One split was
analyzed, while the other was stored.
• The back-half impinger solvent rinse was concentrated to 2 ml using a rotary
evaporator, then added to the impinger water/condensate sample. Following
solvent addition, the sample was spiked with the appropriate semi-volatile
internal standards. A liquid extraction was conducted using methylene chloride.
The extract was then combined with the front-half soxhlet extract for cleanup
and analysis.
• The remaining extract was analyzed for the semi-volatile HAP compounds
utilizing EPA Method 8270 procedures for high-resolution GC with low-
resolution mass spectrometry.
Figure 5.33 presents the analytical scheme for the EPA Method 8270 procedures.
Field, trip, and laboratory blanks, and an EPA-supplied audit sample were analyzed
with each group of source samples using the above procedure as QC contamination or
performance checks, as appropriate.
5-48
-------
MeOH/MtCJj FH RINSES
XADPRESPIKEDWITH
100 ug
TERPHENYL-D14
ROTOVAPTO2ml
FILTER
IMPINGER WATER
ADDTOSOXLET
ADD TO SOX FOR
MeQ, EXTRACTION
ADDTOSOXLET
SPIKE WITH
ORGANICSSS
SPnOES-I.ni AND V
SOXHLETIN
MeCh-2ND
MeOH MeCIj BH RINSES
ROTOVAPTOZml
SPIKE WITH
ORGANICSSS
SPIKES-HANDY
SOXHLETIN
MeQj-lST
ADD TO IMPINGER
WATER
UQ-LIQ
EXTRACT-MeCU
50«MeQi
EXTRACT TO ARCHIVE
COMBINE
ORGANICSSS SPKE-I
D5-PHENOL 100 ug
1.4-DIBROMOBENZENE-D4 100 ug
ORGANICS SS SPKE-n
DS-NIIROBENZENE 100 ug
2-FLUOROBIPHENYL 100 ug
U.5-TR1CHLOROBENZENE-D3 100 ug
ORGANICS SSSPiKE-m
Z4.6-TJUBROMOPHENOL 100 ug
ORGANICS SS SPKE-IV
ANTHRACENE-D10 100 ug
ORGANICS SSSPKE-V
PYRENE-D10 100 ug
50%Mea2
EXTRACT TO ORGANICS
ANALYZEFOR
SEMTVOL COMP DS 8270
TARGETUSTPLUS 10TICS
Figure 5.33. Semi-Volatile HAP's Analysis Scheme
5-49
-------
The semi-volatile HAP's results are reported as ng for each compound. A list of
all the semi-volatile HAP's analyzed for is provided in Table 5.2.
5.4.4 Analysis of PCDD/PCDF
The analysis procedure for PCDD/PCDF is summarized below. See EPA Method
23 for detailed specification of the analysis procedures.
• Each front-half wash sample was concentrated to 1-5 ml using a rotary
evaporator apparatus. The sample container was rinsed three times with
methylene chloride, added to concentrated solution, and concentrated further to
near dryness.
• The above concentrate was added to the filter and XAD-2 resin in a soxhlet
apparatus that contained a precleaned glass extraction thimble and silica gel. A
PCDD/PCDF internal standard was then added. The apparatus was covered
with a plug of precleaned glass wool. The sample was refluxed with toluene for
16 hours. The extract was transferred using three 10 ml rinses of toluene to a
rotary evaporator and concentrated to approximately 8 ml. It was then reduced
to 1 ml under a nitrogen stream. The sample was split in half. One split was
analyzed, while the other was stored.
• The back-half solvent rinse was concentrated to 2 ml using a rotary evaporator.
• Following solvent addition, the sample was spiked with the appropriate
PCDD/PCDF internal standards. A liquid extraction was conducted using
methylene chloride. The extract was combined with the front-half soxhlet
extract for cleanup and analysis.
• The extract was analyzed by EPA Method 23 using high-resolution gas
chromatography (HRGC) and high-resolution mass spectrometry (HRMS) for
PCDD/PCDF.
Field, trip, and laboratory blanks, and an EPA-supplied audit sample were analyzed
with each group of source samples using the above procedure as QC or performance
checks, as appropriate.
Results were reported as ng of total PCDD/PCDF and each 2,3,7,8 isomer per test
Weights of each dioxin identified were provided. Table 5.3 presents a list of all
PCDD/PCDF homologues that were quantified.
5-50
-------
TABLE 5.2. SEMI-VOLATILE HAP's
N-Nitrosodimethylamine
Cumene
a-Pinene
b-Pinene
Aniline
1 ,2,4-Trimethylbenzene
Phenol
Benzyl Chloride
Bis-(2-Chloroethyl)Ether
n-Nitrosomorpholine
1 ,4-Dichlorobenzene
p-Cymene
Acetophenone
1 ,2-Dibromo-3-Chloropropane
Hexachloroethane
o-Toluidine
2-Methylphenol
Nitrobenzene
n,n-Dimethylaniline
Isophorone
3,4-Methylphenol
1 ,2,4-Trichlorobenzene
a-Terpineol
Pentachloronitrobenzene
4-Nitrobiphenyl
Di-n-Butylphthalate
Naphthalene
o-Anisidine
Hexachlorobutadiene
2-Chloroacetaphenone
a,a,a-trichlorotoluene
n,n-Diethylaniline
1 ,4-Phenylenediamine
Hydroquinone
Pentamethylbenzene
Hexachlorocyclopentadiene
2,4,6-Trichlorphenol
2,4,5-Trichlorphenol
2,4-Dichlorophenol
2,3-Dichlorophenol
2,6-Dichlorophenol
3,5-Dichlorophenol
3,4-Dichlorophenol
Biphenyl
Dimethylphthalate
2,4-Dinitrotoluene
2,4-Dinitrophenol
4,6-Dinitro-2-Methylphenol
Dibenzofuran
4-Nitrophenol
Trifluralin
Hexachlorobenzene
5-51
-------
TABLE 5-2. (Concluded)
Pyrene
Benzidine
4,4'-Methylenedianiline
Dimethylaminolazobenzene
Butylbenzylphthalate
3,3'-Dimethylbenzidine
Methylene Bis-Chloroaniline
Chrysene
3,3'-Dichlorobenzidene
Bis-(2-Ethylhexyl)Phthalate
3,3'-Dimethoxybenzidine
4-Aminobiphenyl
Pentachlorophenol
Phenol-dS*
Nitrobenzene-d5*
1 ,3 ,5-Trichlorobenzene-d3*
1 ,4-Dibromobenzene-d4*
2-Fluorobiphenyl
2,4,6-Tribromophenol
Anthracene-dlO*
Pyrene-dlO*
Terphenyl-dl4'
* Surrogate standards.
5-52
-------
TABLE 5.3. PCDD/PCDF COMPOUNDS
2378-TCDD
Total TCDD
12378-PeCDD
Total PeCDD
123478-HxCDD
123678-HxCDD
123789-HxCDD
Total HxCDDD
1234678-HpCDD
Total HpCDDD
Total OCDD
2378-TCDF
Total TCDF
12378-PeCDF
23478-PeCDF
Total PeCDF
123678-HxCDF
234678-HxCDF
123489-HxCDF
Total HxCDF
1234678-HpCDF
1234789-HpCDF
Total HpCDF
Total OCDF
5-53
-------
5.4.5 Analysis of Volatile Organics
The EPA Method 5040 purge-trap-desorb (P-T-D) GC/MS procedure was utilized
to identify and quantify volatile organics in the VOST tube samples. EPA Method 8240
was utilized to analyze for volatiles in the condensate samples.
Each sorbent tube sample analyzed was spiked with internal standards, then
thermally desorbed in a tube oven onto the Tenax analytical adsorbent trap. This
procedure is described in Section 7 of the reference method and in the QA/QC plan. Each
sample was then desorbed from the analytical adsorbent trap into the GC/MS system per
EPA Method 5040. Analysis of the condensate samples was conducted as specified in
EPA Method 624, P-T-D GC/MS.
Laboratory results were reported as total ng of each volatile organic in the samples.
Volatile organic concentration and mass rate results were developed via computer using
validated equations. A list of the volatile organic compounds is provided in Table 5.4.
5.4.6 Aldehyde/Ketone Analysis Procedures
The analytical procedures for the quantification of aldehydes and ketones were
performed as specified in EPA Methods 0011 and 0011A utilizing high-performance liquid
chromatography (HPLC). The compound list was extended to include other aldehydes and
ketones by application of Method IP-6A (indoor air procedure).
Each of the four DNPH impingers was recovered and maintained separately.
Analysis of the fourth impinger solution was performed initially to determine if
breakthrough occurred.
Figure 5.34 illustrates the Method 0011-A/IP-6-A analysis steps for the
determination of aldehydes and ketones. A list of the aldehydes and ketones is presented
in Table 5.5.
5.4.7 Analysis of Hydrochloric Acid and Chlorine
Each sample (types 1 and 2) was analyzed for d'anions by the procedures outlined
in EPA SW-846 Method 9056. The chloride content of each sample type 1 was analyzed
by ion chromatography and reported as HC1. The chloride content of the sample type 2
(0.1 N NaOH impingers) was reported as chlorine. A schematic depicting the analysis
scheme for EPA Method 9056 is provided in Figure 5.35.
5-54
-------
TABLE 5.4. VOLATILE HAP's
Bromochloromethane
Chloromethane
Bromomethane
Vinyl Chloride
Methylene Chloride
Acetone
Carbon Disulfide
1 , 1-Dichloroethane
Chloroform
1 ,2-Dichloroethane
1 ,4-Difluorobenzene
2-Butanone
1,1, 1-Trichloroethane
Carbon Tetrachloride
Vinyl Acetate
Bromodichloromethane
1 ,2-Dichloropropane
Trans- 1 , 3-Dichloropropene
Trichloroethene
1 , 1 ,2-Trichloroethane
Benzene
Cis-1 , 3-Dichloropropene
Bromoform
Chlorobenzene-d5
4-Methyl-2-Pentanone
Tetrachloroethene
Chlorobenzene
Ethylbenzene
Styrene
n-/p-Xylene
o-Xylene
Acrolein
Acrylonitrile
lodomethane
1 ,4-Dichloro-2-Butene
n-Hexane
Methyl Tert-Butyl Ether
1,3-Butadiene
Dibromomethane
Vinyl Bromide
Isooctane
AUyl Chloride
Cumene (Isopropylbenzene)
Dimethyl Sulfide
Dimethyl Disulfide
A-Pinene
B-Pinene
p-Cymeme
1 ,2-Dichloroethane-d4*
4-Bromofluorobenzene'
Toluene-dS*
Benzene-d6*
5-55
-------
TABLE 5-4. (Concluded)
1 , 1 ,2,2-Tetrachloroethane
Toluene
o-Xylene-dlO*
5-56
-------
7JJ
EXTRACTION:
SOLID SORBBNT OR
MBTHYLBNH
CHLORIDET
7.1.1
ENSURE SAMPLE
HOMOGENEITY. PERFORM
* SOLID DETERMINATION.
IF APPROPRIATE
7.1.1
WEIOHSAMPLBINTO
BOTTLE; ADD EXTRACTION
FLUID; EXTRACT II HOURS;
FILTER
73.1
PERFORM CLEANUP. 1
NECESSARY
7.12
CENTRIFUGE SAMPLE, IP
NECESSARY
7.3
DBRIVAITZATION: MEASURE
ALIQUOT FOR LIQUID SAMPLE
OR LIQUID EXTRACT OF SOLID
SAMPLE; DILUTE TO TOTAL
VOLUME OF 100 ml
MBTHYLBNB CHLORIDE
SOLID
8ORBENTJ
73.4.1
ADD ACETATE BUFFER AND
ADJUST pH WITH ACETIC ACID
OR SODIUM HYDROXIDE; ADD
DNPH REAGENT, SEAL
CONTAINER; SHAKE 30 MINUTES
7J.43
ASSEMBLE VACUUM MANIFOLD
AND CONNECT TO PUMP;
ASSEMBLE CARTRIDGES;
ATTACH SORBBNT TRAD) TO
MANIFOLD; CONDITION
CARTRIDGE
7J.4J
REMOVE REACTION VESSELS
FROM SHAKER; ADD SODIUM
CHLORIDE SOLUTION
7.3.44
ADD THE REACTION SOLUTION
TO SORBBNT TRAD); ELUTD
UNDERVACUUM
7.3.4.5
BLUTB TRAM WITH BTHANOL,
DILUTE TO VOLUME WITH
BTHANOL; MIX
7.3J.I
ADD ACETATE BUFFER AND
ADJUST pH WITH ACETIC ACID
OR SODIUM HYDROXIDE; ADD
DNPH REAGENT; SEAL
CONTAINER; SHAKE 2 MINUTES
7J.S.1
EXTRACT SOLUTION WITH 330-al
PORTIONS OF MBTHYLBNB
CHLORIDE; COMBINE
MBTHYLBNB CHLORIDE LAYERS
7J.SJ
ASSEMBLE A KUDBRNA-DANISH
(K-D) REDUCE TO EXTRACT
CONCENTRATE LAYERS OP
MBTHYLBNB CHLORIDE
7.35.4
ADD BOILING CHIPS TO
EVAPORATION FLASK AND
ATTACH A THREE-BAIL SN YDER
COLUMN TO THE K-D ASSEMBLY;
IMMERSE APPARATUS IN HOT
WATER BATH; ADJUST
POSITIONING TO FINISH
CONCENTRATION IN 10-15 MM.
7.3.5.5
EXCHANGE SOLVENT TO
MBTHANOL USING K-D ASSEMBLY
7.4
ESTABLISH LC OPERATING
PARAMETER
7J.1.I.I
PREPARB CALIBRATION
STANDARDS
7J.1.1.2
DBRIVATIZB STANDARD
SOLUTIONS
7J.I3.1
ANALYZE STANDARDS AND
TABULATE PEAK AREA AGAINST
CONCENTRATION INJECTED
7.5.133
VERIFY WORKING CAUBRATION
CURVE DAILY WHIII OR MORE
STANDARDS
7.6.1
ANALYZE BY HPLC USING
SPECIFIED CONDITIONS; OTHER
CONDITIONS OR HARDWARE MAY
BE USED IF QC REQUIREMENTS
ARE MET
7.6.2
USB RETENTION TIMES TO
INTERPRET CHROMATOGRAMS
7.6.3
IF PEAK AREA EXCEEDS LINEAR
WORKING RANGE, USB A
SMALLER SAMPLE VOLUME OR
THE FINAL SOLUTION MAY BE
DILUTED WITH BTHANOL AND
REANALYZED
7.6.4
IP PEAK AREA MEASUREMENT IS
PREVENTED BY INTERFERENCES,
FURTHER CLEANUP IS NEEDED
7.7.1
CALCULATE RESPONSE
FACTORS FOR ANALYTBS
7.73
CALCULATE CONCENTRATIONS
OP ALDEHYDES IN SAMPLE,
NOTING DILUTION FACTOR FOR
SAMPLES
Figure 5.34. Analytical Scheme for Aldehydes/Ketones
5-57
-------
TABLE 5.5. ALDEHYDES/KETONES
Formaldehyde
Acetaldehyde
Acrolein
Acetone
Methyl ethyl ketone
Propionaldehyde
Crononaldehyde
Butyraldehyde
Benzaldehyde
Isovaleraldehyde
Valeraldehyde
o-tolualdehyde
m-tolualdehyde
p-tolualdehyde
hexanaldehyde
2 ,5-dimethylbenzaldehyde
This list includes the IP-6A extended list of compounds.
5-58
-------
7.L1
ESTABLISH ION
CHROMATOGRAPHIC
OPERATING PARAMETERS
COMPARE RESULTS TO
CALIBRATION CURVES. IF
RESULTS EXCEED CENTRAL
LIMITS IDENTIFY PROBLEM
BEFORE PROCEEDING
7.1.2
PREPARE CALIBRATION
STANDARDS AT A MINIMUM
OF THREE CONCENTRATION
LEVELS AND A BLANK
INSPECT A SPIKED SAMPLE
OF KNOWN CONC; CALCULATE
THE CONC FROM THE
CALIBRATION CURVE IF
RESULT EXCEEDS CONTROL
LIMITS. FIND PROBLEM
BEFORE PROCEEDING
7.13
PREPARE
CALIBRATION
CURVES
±
BEGIN
SAMPLE
ANALYSIS
7.1.4
VERIFY THE CALIBRATION
CURVES EACH WORKING DAY
OR WHENEVER THE ANION
ELUENT IS CHANGED. AND FOR
EVERY BATCH OF SAMPLES
7Z18
ANALYZE ALL
SAMPLES IN THE
SAME MANNER
YES
YES
IF A DILUTION IS NECESSARY
THE DILUTION SHOULD
BE MADE WITH ELU AB-
SOLUTION
NO
722
ANALYZE STANDARDS
BEGINNING WITH THE HIGHEST
CONCENTRATION AND
DECREASING IN
CONCENTRATION
7.12.10
DILUTE SAMPLE
WITH REAGENT
WATER
722
ADD CONCENTRATED ELUANT
TO ALL SAMPLES AND
STANDARDS TO REMOVE
WATER DIP
73.1
PREPARE SAMPLE
CALIBRATION CURVES FOR
EACH ANION OF INTEREST
AND COMPUTE SAMPLE
CONCENTRATION
733
CALCULATE CONCENTRATIONS
FROM INSTRUMENTAL
RESPONSE
Figure 5.35. Chloride Analysis Scheme
5-59
-------
5.4.8 PM10 and Condensible Particulate Analysis Procedures
Analytical procedures and calculations for particulate determination were performed
as specified in Sections 4 and 6 of Method 5, and Section 5 of Method 202. The analysis
procedure is described below:
• The filter and any loose fragments are desiccated for 24 hours and weighed on a
calibrated analytical balance to the nearest 0.1 mg to a constant weight.
"Constant weight" means a difference of no more than 0.5 mg or 1% of total
weight less tare weight, whichever is greater, between two consecutive
weighings with no less than 6 hours of desiccation time between weighings.
• The front-half acetone wash sample (cyclone exit to filter) is evaporated at
ambient temperature and pressure in tared beakers, and then desiccated to
constant weight to the nearest 0.1 mg.
• The back-half water is evaporated at ambient temperature and pressure in tared
beakers and then desiccated to a constant weight to the nearest 0.1 mg.
The total weight of material measured in the front-half wash fraction plus the
weight of material collected on the glass fiber filter, and PMi0 cyclone represents filterable
particulate matter. Acetone blank corrections were made on all wash sample weights.
The total weight measured in the back-half wash fraction represents the EPA
Method 202 condensible particulate catch for each run. Figure 5.36 depicts the particulate
analysis scheme.
5.4.9 Continuous Emission Monitoring Procedures
The Weston portable CEM system was used to continuously monitor the
concentrations of THC at the blast furnace outlet, blast/reverberatory furnaces baghouse
inlet/outlet, and wet scrubber outlet. Additionally, CO was monitored at the blast furnace
outlet and wet scrubber outlet.
The portable CEM system is a self-contained unit capable of measuring the gaseous
emission stream and plant signals simultaneously, as well as providing computer-generated
display and reports. Both sets of measurements are accepted on a real-time basis. This
capability allows the analyst to understand how parametric variations in plant operating
conditions affect plant emissions.
The CEM system contained an instrument rack, a data acquisition system, and a
microcomputer. The instrument rack contained continuous emission analyzers and
conditioning units, recorders, and a data acquisition system. The following procedures
were used to perform emission testing in accordance with EPA methodology:
5-60
-------
TYPES1-9 (FILTERS)
DESICCATE EACH FILTER
TO CONSTANT WEIGHT
SAMPLE TYPE I
FRONT HALF ACETONE
SAMPLE TYPE 3
BACK HALF WATER
TRANSFER CONTENTS TO
TARED BEAKER
DETERMINE TOTAL SAMPLE
VOLUME
EVAPORATE TO DRYNESS
TRANSFER CONTENTS TO
TAREDBEAKER
DESICCATE TO CONSTANT WEIGHT
EVAPORATE TO DRYNESS
SAMPLE TYPES.
BACK HALF METHYLENE CHLORIDE
DESICCATE TO CONSTANT WEIGHT
DETERMINE TOTAL SAMPLE
VOLUME
TRANSFER CONTENTS TO
TAREDBEAKER
EVAPORATE TO DRYNESS
DESICCATE TO CONSTANT WEIGHT
Figure 5.36. Analysis Procedures for
PM,0 and Condensible Particulate Samples
5-61
-------
• Total hydrocarbons (EPA Method 25A).
• Carbon monoxide (EPA Method 10).
Stack samples were collected through a heated stainless steel probe and heated
Teflon line and sent to the portable GEM. The total hydrocarbon and carbon monoxide
samples were drawn directly from this heated line. The heated sample line pressure was
monitored and the sampling rate was controlled by a needle valve on the pump outlet in
order to maintain excess conditioned sample flow. The excess sample was released to the
atmosphere to maintain a constant sample pressure.
The carbon monoxide sample was drawn through the heated Teflon sample line and
into a sample conditioner. The sample conditioner consists of a two-pass refrigerative
cooler with a Teflon heated pump, and sample system pressure is monitored immediately
before the sample pump. The dried sample was directed to the analyzer.
The data from the CEM train were processed through a Molytek Model 2702 chart
recorder. This unit had the capacity to handle up to 32 channels of data from instruments,
thermocouples, and other process instrumentation. The Model 2702 can also create virtual
channels through the combination of any two channels. All active channels can be
displayed on a single strip chart. The Model 2702 also scales and converts the analog
input signals to digital (ASCII) format, and transmits the data to a computer for data
logging. The Weston data logging program read the digital output from the Molytek 2702
approximately once per second. The speed varied depending upon the number of active
channels, microprocessor speed, and the baud rate for transmission. The data logger
calculated a 1-min average from the simultaneous readings and stored this average on a
hard disk. The data logger displayed the instantaneous channel values in real time, with
updates every 5 sec. The 1-min. average and rolling 60-min. average values were also
displayed.
At the close of each test period, the CEM data stored on the hard disk drive were
downloaded to a Lotus 1-2-3 spreadsheet to calculate discreet time periods and to correct
for calibration drift.
The analyzers used for this evaluation of the emissions included the following:
Parameter Manufacturer and Model Detection Method
THC J.U.M. Model VE-7 FIA
CO TECOModeUS NDIR
The analyzers were calibrated at the start and end of each test day and/or test
series. Analyses of calibration gases from NTIS traceable cylinders were performed along
with zero checks. Three-point calibrations (low, mid, and high range) were performed
5-62
-------
directly for each analyzer. Bias checks were performed by introducing the calibration
standard that was closest to the observed concentration in the sample gas at a three-way
valve on the probe. Bias checks performed at the intervals between each test repetition
were averaged to correct for instrument drift. The bias calibration gases were sent to the
probe valve through a separate Teflon line and back through the heated sample line and
sample conditioning system to the instrument to determine the entire sampling system
calibration bias. Bias calibration gas flow is regulated to maintain sample line pressure.
All calibrations, zero and calibration drift tests, and QA procedures followed the specific
requirements in the EPA reference methods. The calibration drift correction described in
EPA Method 6C was used for all analyzers unless otherwise specified.
5.4.10 Flue Gas Sample Analysis
All other parameters not measured continuously by instrumental techniques
including semi-volatile HAP's, volatile organic HAP's, metals, HC1, C12, particle size
distribution particulate, and condensible paniculate were transported via overnight air
carrier to either Weston, Triangle Labs, or SwRI for analysis. All samples were run
within the holding times indicated in Table 5.6. Table 5.7 presents a listing of the
detection limits by parameter for this program.
5.4.11 Flue Dust Sample Analysis
The dioxin and furan content of the composited reverberatory and blast furnaces
baghouse dust sample from each of the three test runs was determined. Analysis was
performed utilizing EPA Method 8290 procedures.
5.5 PROCESS DATA
The specific process parameters monitored during the testing were discussed in
Section 3. Monitoring began a minimum of 30 minutes prior to the start of each test
period.
5-63
-------
TABLE 5.6. HOLDING TIMES FOR SAMPLES
POLLUTANT
Semi-Volatile HAP's
Volatile HAP's
Particulate
Aldehydes/Ketones
HC1/C12
Metals
MATRIX
Solids and Liquids
Solids and Liquids
Solids and Liquids
Liquids
Liquid
Solids and Liquids
HOLDING TIME (DAYS)
14
14
28
14
28
28
5-64
-------
TABLE 5.7. APPROXIMATE DETECTION LIMITS FOR SOURCE SAMPLES
POLLUTANT
HC1
CL,
Particulate
Pb
As
Sb
Cd
Cr
Ni
Mn
Hg
Volatile Organics
(per analyte)
Semi-volatile Organics
(per analyte
PCDD/PCDFb
(per isomer)
Aldehyde6
(per analyte)
PM10d
TRAIN TOTAL
DETECTION LIMITS
(units as noted)
2.0 mg
0.5 mg
0.1 mg
1 - 5 Mg
l-5/*g
l-5Mg
1 - 10 /ig
1 - 10 Mg
1-20/xg
1 - 10 /xg
l-5Mg
25 - 50 ng
25 - 50 Mg
0.050 ng
0.8 - 5.0 Mg
0.1 mg
IN-STACK DETECTION
LIMITS
(units as noted)
1.4 mg/m3
0.4 mg/m3
0.05 mg/m3
0.5 - 2.6 Mg/m3
0.5 - 2.6 Mg/m3
0.5 - 2.6 Mg/m3
0.5 - 5.3 Mg/m3
0.5 - 5.3 Mg/m3
0.5 - 10.5 Mg/m3
0.5 - 5.3 Mg/m3
0.45 - 2.6 Mg/m3
2.5 - 5.0 Mg/m3
13 - 26 Mg/m3
17 x 1CT6 Mg/m3
2.4 - 16 Mg/m3
0.12 mg/m3
1 Based on the minimum anticipated sample volumes.
b The detection limit for the PCDD/PCDF analysis of the baghouse dust is 5.0 Mg/kg per
analyte.
* Ranges shown are the minimum detection limits for the various aldehydes/ketones.
* Detection limit for PMi0 cyclone separator.
5-65
-------
SECTION 6
QUALITY ASSURANCE
Raw field data, analytical data, and calibration data were not made available to
PES. Therefore, the results of Westons' quality assurance/quality control activities for this
project could not be incorporated into this report.
6-1
-------
APPENDIX A
SUMMARY TABLES - TEST RESULTS AND SAMPLING DATA
-------
TABLE A-l.
SUMMARY OF PARTICULATE AND LEAD INPUT DATA
(SAMPLE POINT A)
TEST DATA
Run number
Location
Date
Time period
BLAST FURNACE OUTLET
l(HDec-92 ll-Oec-92 12-Dec-92
1112-4357 1253-1400 0850-1145
INPUTS FOR CALCULATIONS
Sq.rt. delta P
Delta H
Stack temp. (deg.F)
Meter temp. (degP)
Sample volume (act)
Barometric press. (in.Hg)
Volume l^O imp. (ml)
Weight chngesil. gel (g)
%O2
%CO
Area of stack (sq.ft.)
Sample time (min.)
Static pressure (i
Nozzle dia. (in.)
Meter boreal.
CpOfpitottube
PARTICULATE LABORATORY REPORT DATA
Total paniculate catch, g
Total Lead (Pb) catch, mg
0.2779
0.68
2103
47.1
30.877
29.87
54.2
27.1
4.1
17.0
0.0
78.9
4.91
72
-1.00
0329
1.003
0.84
30.4480
3200.00
0.3141
1.00
169.5
51.7
24.488
29.10
30.4
7.0
4.7
16.4
0.0
79.0
4.91
48
-0.80
0329
1.003
0.84
14.6857
2800.00
0.2623
0.55
216.1
61.7
18.734
29.51
28.0
16.8
5.2
ISA
0.0
79.0
4.91
48
-0.80
0329
1.003
0.84
135004
1900.00
A-l
-------
TABLE A-2.
SUMMARY OF PARTICULATE AND LEAD TEST DATA
AND RESULTS (SAMPLE POINT A)
TEST DATA
Tett run number
Test location
Test dale
Test time period
SAMPLING DATA
Sampling duration, min.
Nozzle diameter, in.
Barometric pressure, in. Hg
Avg. orifice press, diff., in Hf>
Avg. dry gas meter temp., deg F
Avg. abs. dry gas meter temp., deg. R
Total liquid collected by train, ml
Std. vol. of H2O vapor coll. cu.ft.
Dry gas meter calibration {actor
Sample vol. at meter cond., dcf
Sample vol. at std. cond., dscf (1)
Percent of isokinetic sampling
GAS STREAM COMPOSITION DATA
OC>2, % by volume, dry basis
Oj, % by volume, dry basis
GO, % by volume, dry basis
N2,% by volume, dry basis
Molecular wt of dry gas, Ib/Ib mote
HjOvaporingassueam. prop. byvoL
Mole fraction of dry gas
Molecular wt. of wet gas, Ib/lb mole
1
10-Dec-92
1112-1357
72
0.329
29.87
0.68
47.10
507
81.3
3.83
1.0030
30.877
32333
101.1
4.1
17.0
0.0
78.9
29.3
0.106
0.894
28.1
2
BLAST FURNACE OLTTIET
ll-Oec-92
1253-1400
48
0.329
29.10
1.00
51.70
512
37.4
1.76
1.0030
24.488
24.702
97.5
4.7
16.4
0.0
79.0
29.4
0.067
0.933
28.6
3
12-Dec-92
0850-1145
48
0.329
29.51
0.55
61.70
522
44.8
2.11
1.0030
18.734
18.775
94.3
52
ISA
0.0
79.0
29.5
0.101
0.899
283
GAS STREAM VELOCITY AND VOLUMETRIC FLOW DATA
Cross sectional nozzle area, sq.ft.
Static pressure, in. H£)
Static pressure, in. Hg
Absolute pressure, in. Hg
Avg. temperature, deg. F
Avg. absolute temperature, deg.R
Pilot tube coefficient
total number of traverse points
Avg. gas stream velocity, fL/sec.
Stack/duct cross sectional area, sq.ft.
Avg. gas stream volumetric flow, wacC/min.
Avg. gas stream volumetric flow, dscfmin (l)
LABORATORY REPORT DATA
Total paniculate catch, g
Total Lead (Pb) catch, rag
PARTICUIATB EMISSIONS DATA
Pa*ttmtflt£ enncmtralkm nrhstBcf
fUlUlfUUUK WHmBHUrtlHlli, JJ»/wa»/l
Particulate concentration Kr/dscf
Paniculate concentration, gr/dsef @ 15% O2
Paniculate mass emission rate, to/hr
Paniculate mass emission rate, kg/hr
LEAD (Pb) EMISSIONS DATA
Lead (Pb) concentration, Ib/dscf
Lead (Pb) concentration, Ib/dscf @ 15% Oj
Lead (Pb) concentration, ug/nv5
Lead (Pb) mass emission rate, Ib/hr
Lead (Pb) mass emission rate, kg/hr
0.000590
HI
-0.074
29.80
210
670
0.84
30
17.8
4.91
5300
3700
30.4480
3200.00
13.0
14.6
21.9
460
209
2.19&04
3.28&04
3.51EH)6
48.4
21.9
0.000590
-0.8
-0.059
29.04
170
630
0.84
30
19.6
4.91
5800
4400
14.6857
2800.00
8.56
9.17
12.0
345
157
150E-04
3.26B-04
4.00EHJ6
65.8
29.9
0.000590
-0.8
-0.059
29.45
216
676
0.84
30
17.0
4.91
5000
3500
13.2004
1900.00
9.73
10.9
12.5
321
146
2.23E04
2.57B04
3.S7E406
46.2
21.0
0) Standard conditions = 68 deg. F. (20 deg. C.) and 29.92 in Hg (760 mm Hg)
A-2
-------
TABLE A-3.
SUMMARY OF PARTICULATE AND METALS (LEAD) INPUT DATA
(SAMPLE POINT B)
TEST DATA
Run number
Location
Date
Tune period
1 2
Blast/Reverb Furnace Baghouse Inlet
lO-Dec-92
11104346
ll-Dec-92
1253-1551
12-Dec-92
0851-1149
INPUTS FOR CALCULATIONS
Sq.rt. delta P
Delta H
Stack temp. (deg.F)
Meter temp. (deg.F)
Sample volume (act.)
Barometric press. (in.Hg)
Volume H2O imp. (ml)
Weight chnge sil. gel (g)
%CO
%N2
Area of stack (sq.ft.)
Sample time (min.)
Static pressure (inHfS)
Nozzle dia. (in.)
Meter box cal.
Cp of pilot tube
PARTICULATfi LABORATORY REPORT DATA
Total paniculate catch, g
Total Lead (Pb) catch, mg
0.6802
0.99
276.9
42.4
34.983
29.85
141.7
6.5
0.0
20.8
0.0
79.2
14.75
72
-3.20
0.235
0.994
0.84
11.5333
165
0.7175
1.14
282.2
51.5
38.660
29.10
1803
93
0.0
20.8
0.0
79.2
14.75
72
-3.50
0.235
0.994
0.84
10.5612
150
0.7260
1.18
301.4
51.8
38.126
29.51
169.9
9.6
4.2
15.6
0.0
80.2
14.75
72
-2.90
0.235
0.994
0.84
123628
110
A-3
-------
TABLE A-4.
SUMMARY OF PARTICULATE AND METALS (LEAD) TEST
DATA AND RESULTS (SAMPLE POINT B)
TEST DATA
Test run number
Test location
Test dale
Test time period
1 2 3
Blast/Reverb Furnace Baghouse Inlet
lO-Dec-92 ll-Dec-92 12-Oec-92
11KH346 1253-1551 085M149
SAMPLING DATA
Sampling duration, min. 72
Nozzle diameter, in. 0.235
Barometric pressure, in. Hg 29.85
Avg. orifice press, diff., in H2O 0.99
Avg. dry gas meter temp., degF 42.39
Avg. abs. dry gas meter temp., deg.R 502
Total liquid collected by train, ml 148.2
Std.vol. of HjO vapor colUcu.ft. 6.98
Dry gas meter calibration factor 0.9940
Sample vol. at meter cond., dcf 34.983
Sample vol. at std.cond.dscf(l) 36.534
Percent of isokinetic sampling 100.8
GAS STREAM COMPOSITION DATA
GOj. % by volume, dry basis 0.0
C>2,% by volume, dry basis 20.8
OO,% by volume, dry basis 0.0
N2, % by volume, dry basis 79.2
Molecular WL of dry gas, Ib/lb mole 28.8
Hf> vapor in gas stream; prop, by vol. 0.160
Mole fraction of dry gas 0.840
Molecular WL of wet gas, Ib/Ib mole 27.1
GAS STREAM VELOCITY AND VOLUMETRIC FLOW DATA
Cross sectional nozzle area, sq.ft.
Static pressure, in. HjO
Static pressure, in. Hg
Absolute pressure, in. Hg
Avg. temperature, deg. F
Avg. absolute temperature, degR
Pilot lube coefficient
Total number of traverse points
Avg. gas stream velocity, fl/sec.
Stack/duct cross sectional area, sq.ft.
Avg. gas stream volumetric flow, wacf/min.
Avg. gas stream volumetric Dow, dscfAnin O
LABORATORY REPORT DATA
Total paniculate catch, g 11.5333
Total Lead (Pb) catch, mg 165.00
PARTICULATE EMISSIONS DATA
Paniculate concentration, gr/wscf 4.09
Paniculate concentration, gr/dscf 4.87
Paniculate concentration, gr/dscf @ 15% O2 146.15
Paniculate mass emission rate, Ib/hr 1029.697
Paniculate mass emission rate, kg/hr 467.060
LEAD (Pb) EMISSIONS DATA
Lead (Pb) concentration, Ib/dscf 9.96E-06
Lead (Pb) concentration, Ib/Uscf @ 15% O, 2.99E-04
Lead (Pb) concentration, ug/m3 I. 59E+O5
Lead (Pb) mass emission rate. Ib/hr 14.731
Leod(Pb) mass emission rate, kg/hr 6.682
72
0.235
29.10
1.14
51.50
512
189.6
8.93
0.9940
38.660
38.676
105.7
0.0
20.8
0.0
79.2
28.8
0.187
0.813
26.8
10.5612
150.00
3.42
4.21
126.42
898.890
407.728
8.55E06
2.57&04
1.37E+05
12.767
5.791
72
0.235
29.51
1.18
51.80
512
179.5
8.45
0.9940
38.126
38.659
104.8
4.2
15.6
0.0
80.2
29.3
0.179
0.821
27.3
0.000301
-3.2
-0.235
29.61
277
737
0.84
30
46.8
14.75
41.400
24,700
0.000301
-3.5
-0.257
28.84
282
742
0.84
30
50.5
14.75
44.700
24,900
0.000301
-2.9
-0.213
29.30
301
761
0.84
30
50.9
14.75
45,000
25.100
12.3628
110.00
4.05
4.94
5.48
1061.269
481.381
6.27E06
6.97E-06
l.OOE+05
9.443
4.283
O Standard conditions= 68 deg. F. (20 deg. C) and 29.92 in Hg (760 mm Hg)
A-4
-------
TABLE A-5.
SUMMARY OF PARTICULATE AND LEAD INPUT DATA
(SAMPLE POINT C)
TEST DATA
Run number
Location
Date
Time period
Operator
INPUTS FOR CALCULATIONS
Sq. it delta P
Delta H
Stack temp. (deg.F)
Meter temp. (deg.F)
Sample volume (act.)
Barometric press. (in.Hg)
Volume I^O imp. (ml)
. Weight chnge sil. gel (g)
%OD2
%O2
%CO
%N2
Area of stack (sq.ft.)
Sample time (min.)
Static pressure (in.H2O)
Nozzle dia. (in.)
Meter box cal.
Cp of pilot tube
PARTICULATE LABORATORY REPORT DATA
Total paniculate catch, g
Total Lead (Pb) catch, mg
1 2 3
Blast/Reverb Furnace Baghouse Outlet
lO-Dec-92 ll-Dec-92 12-DeoS2
1110-1345 1230-1535 0845-1150
0.5760
1.98
214.9
35.2
84.989
29.87
277.3
27.6
0.0
20.8
0.0
79.2
17.10
120
-7.25
0300
1.001
0.84
0.0081
0.72
0.5963
2.17
206.8
48.8
89.473
29.10
314.8
23.5
5.0
16.0
0.0
79.0
17.10
120
-7.50
0300
1.002
0.84
0.0019
2.40
0.6036
2.16
222.6
47.3
89.127
29.51
289.2
29.5
4.0
17.0
0.0
79.0
17.10
120
-7.50
0.300
1.002
0.84
0.0044
1JO
A-5
-------
TABLE A-6.
SUMMARY OF PARTICULATE AND LEAD TEST DATA AND RESULTS
(SAMPLE POINT C)
TEST DATA
Test tun number
Test location
Test date
Test time period
SAMPLING DATA
Sampling duration, min.
Nozzle diameter, in.
Barometric pressure, in. Hg
Avg. orifice press, diff., in HjO
Avg. dry gas meter temp., deg F
Avg. abs. dry gas meter temp., deg. R
Total liquid collected by train, ml
Std. vol. of H2O vapor coll.. cu.fL
Dry gas meter calibration {actor
Sample vol. at meter cond.. dcf
Sample vol. at std. cond, dscf (1)
Percent of isokinetic sampling
GAS STREAM COMPOSITION DATA
OO2, % by volume, dry basis
02, % by volume, dry basis
OO, % by volume, dry basis
N2. % by volume, dry basis
Molecular wt of dry gas, Ib/Ib mole
H2O vapor in gas stream, prop, by vol.
Mole fraction of dry gas
Molecular wt. of wet gas. Ib/Ib mole
1
lO-Dec-92
1110-1346
120
0.300
29.87
1.98
33.17
495
304.9
14.35
1.0010
84.989
90.969
102J
0.0
20.8
0.0
79.2
28.8
0.136
0.864
27.4
2
Blast/Reverb Furnace Baghouse Outlet
ll-Oeo-92
123CH535
120
0300
29.10
2.17
48.80
509
3383
15.93
1.0020
89.473
90.945
101.9
5.0
16.0
0.0
79.0
29.4
0.149
0.851
27.7
3
12-Dec-92
0845-1150
120
0300
29.51
2.16
47.30
507
318.7
15.00
1.0020
89.127
92.132
101.4
4.0
17.0
0.0
79.0
29.3
0.140
0.860
27.7
GAS STREAM VELOCITY AND VOLUMETRIC FLOW DATA
Cross sectional nozzle area, sq.ft.
Static pressure, in. H2O
Static pressure, in. Hg
Absolute pressure, in. Hg
Avg. temperature, deg. F
Avg. absolute temperature, deg.R
Pilot tube coefficient
Total number of traverse points
Avg. gas stream velocity, ftVsec.
Stack/duct cross sectional area, sq.ft.
Avg. gas stream volumetric flow, wacf/min.
Avg. gas stream volumetric flow.dscf/min W
LABORATORY REPORT DATA
Total paniculate catch, g
Total Lead (Pb) catch, mg
PARTICULATE EMISSIONS DATA
Paniculate concentration, gr/wscf
Paniculate concentration, gr/dscf
Paniculate concentration, gr/dscf @ 15% O2
Paniculate mass emission rate, Ib/hr
Paniculate mass emission rate, kg/hr
LEAD (Pb) EMISSIONS DATA
Lead (Pb) concentration. Ib/dscf
Lead (Pb) concentration. Ib/dscf @ 15% O2
Lead (Pb) concentration, ug/m3
Lead (Pb) mass emission fate, Ib/hr
Lead (Pb) mass emission rate, kg/hr
0.000491
-7.25
-0533
2934
215
675
0.84
30
37.9
17.10
38,900
25300
0.0081
0.72
1.19E-03
1.37E03
4.12&02
0304
0.138
1.74608
5.23E07
2.79E+02
0.027
0.012
0.000491
-7.5
-0.551
28.55
207
667
0.84
30
393
17.10
40300
25500
0.0019
2.40
2.74E-04
3.22B04
3.87&04
0.072
0.032
5.82E-08
6.98E-08
932E+02
0.090
0.041
0.000491
-7.5
-0.551
28.96
223
683
0.84
30
40.0
17.10
41,000
26.400
0.0044
1J>0
6.28E-04
730&04
1.10E-03
0.16S
0.073
3.59B-08
5.38&08
5.75E+02
0.057
0.026
(M Standard conditions = 68 deg. F. (20 deg. C.) and 29.92 in Hg (760 mm Hg)
A-6
-------
TABLE A-7.
SUMMARY OF PARTICULATE AND LEAD INPUT DATA
(SAMPLE POINT D)
TEST DATA
Run number
Location
Date
Time period
Operator
INPUTS FOR CALCULATIONS
Sq. it delta P
Delta H
Stack temp. (deg.F)
Meter temp. (deg.F)
Sample volume (act)
Barometric press. (in.Hg)
Volume Hf> imp. (ml)
Weight chnge sil. gel (g)
%CO
%N2
Area of stack (sq.ft.)
Sample time (min.)
Static pressure (in.H2O)
Nozzle dia. (in.)
Meter box cal.
Cp of pilot tube
PARTICULATE LABORATORY REPORT DATA
Total paniculate catch, g
Total Lead (Pb) catch, tng
Blast/Reverb Furnace Scrubber Outlet
lO-Deo-92 ll-Dec-92 12-Oec-92
11KH345 1231-1535 0845-1143
0.3676 0.3309 0.3394
1.60 1.64 1.72
125.5 1263 128.0
47.1 74.1 57.0
81.647 85.521 81.661
29.87 29.10 29.51
223.1 227.7 244.1
19.1 14.0 17.4
0.0 4.1 0.0
20.8 16.9 20.9
0.0 0.0 0.0
79.2 79.0 79.0
19.63 19.63 19.63
120 120 120
-0.06 -0.06 -0.06
0.367 0373 0.373
0.981 0.981 0.981
0.84 0.84 0.84
0.0075 0.0395 0.0243
230 0.88 1.30
A-7
-------
TABLE A-8.
SUMMARY OF PARTICULATE AND LEAD TEST DATA AND RESULTS
(SAMPLE POINT D)
TEST DATA
Test run number
Test location
Test date
Test time period
SAMPLING DATA
Sampling duration, min.
Nozzle diameter, in.
Barometric pressure, in. Hg
Avg. orifice press, diff.. in H2O
Avg. dry gas meter temp., deg F
Avg. abs. dry gas meter temp., deg. R
Total liquid collected by train, ml
Std. vol. of H^ vapor coll.. cu.fl.
Dry gas meter calibration (actor
Sample vol. at meter cond., dcf
Sample vol. at std. cond. dscf (1)
Percent of isokinetic sampling
GAS STREAM COMPOSITION DATA
COj, % by volume, dry basis
Oj,% by volume, dry basis
CO, % by volume, dry basis
N2, % by volume, dry basis
Molecular wt. of dry gas, Ib/lb mole
H2O vapor in gas stream, prop, by vol.
Mole fraction of dry gas
Molecular wt of wet gas, Ib/lb mote
1
l(H>ec-92
1110-1345
120
. 0.367
29.87
1.60
47.10
507
242.2
11.40 •
0.9811
81.647
83.560
89.6
0.0
20.8
0.0
79.2
28.8
0.120
0.880
27.5
2
Blast/Reverb Furnace Scrubber Outlet
ll-Dec-92
1231-1535
120
0.373
29.10
1.64
74.10
534
241.7
11.38
0.9811
85.521
80.975
95.7
4.1
16.9
0.0
79.0
293
0.123
0.877
27.9
3
12-Dec-92
0845-1143
120
0373
29.51
1.72
57.00
517
261.5
1231
0.9811
81.661
81.014
92.8
0.0
20.9
0.0
79.0
28.8
0.132
0.868
27.4
GAS STREAM VELOCITY AND VOLUMETRIC FLOW DATA
Cross sectional nozzle area, sq.ft.
Static pressure, in. H£)
Static pressure, in. Hg
Absolute pressure, in. Hg
Avg. temperature, deg. F
Avg. absolute temperature, deg.R
Pilot tube coefficient
Tblal number of traverse points
Avg. gas stream velocity, fUsec.
Slack/duct cross sectional area, sq.ft.
Avg. gas stream volumetric flow, wacf/min.
Avg. gas stream volumetric flow, dscf/min I1)
LABORATORY REPORT DATA
Total paniculate catch, g
Total Lead (Fb) catch, mg
PARTICULATE EMISSIONS DATA
Paniculate concentration, gr/wscf
Paniculate concentration, gr/dscf
Paniculate concentration, gr/dscf @ 15% O2
Paniculate mass emission rate. Ib/hr
Paniculate mass emission rate, kg/hr
LEAD (Pb) EMISSIONS DATA
Lead (Pb) concentration. Ib/dscf
Lead (Pb) concentration. Ib/dscf @ 15% O2
Lead (Pb) concentration, ug/m3
Lead (Pb) mass emission rate, Ib/hr
Lead (Fb) mass emission rate, kg/hr
0.000735
-0.06
-0.004
29.87
126
586
' 0.84
30
22.3
19.63
26.200
20.800
0.0075
230
1.22E-03
U9E-03
4.16E-02
0.247
0.112
6.07E-08
1.82E-06
9.72EW2
0.076
0.034
0.000759
-0.06
-0.004
29.10
126
586
0.84
30
20.2
19.63
23300
18.200
0.0395
0.88
6.60E-03
7.52B-03
1.10B-02
1.176
0.534
2..40E-08
3.5 IE-OS
3.84&02
0.026
0.012
0.000759
-0.06
-0.004
29.51
128
588
0.84
30
20.8
19.63
24,500
18.800
0.0243
130
4.02E-03
4.63E-03
2.78E-01
0.747
0339
3J4&08
2.12E-06
5.67E+02
0.040
0.018
''' Standard conditions = 68 deg. F. (20 deg. C) and 29.92 in Hg (760 mm Hg)
A-8
-------
TABLE A-9. SUMMARY OF PARTICULATE AND LEAD INPUT DATA
(SAMPLE POINT F)
TEST DATA
Run number 12 3
Location Reverb Kettles Cyclone Inlet
Date 14-Dec-92 15-Deo-92 15-Dec-92
Tune period 1504-1714 0835-1150 1435-1709
INPUTS FOR CALCULATIONS
Sq.rt delta P 0.4843 0.4595 0.4382
Delta H 2.08 1.72 1.55
Stack temp. (degJ) 91.3 93.0 85.4
Meter temp. (deg.F) 76.0 55.2 57.0
Sample volume (act.) 92.295 79.994 79.232
Barometric press. (inUg) 30.09 29.95 29.92
Volume HjO imp. (ml) 0.0 1 1.1
Weight chngesil. gel (g) 14.2 10.4 10.1
%O>2 0.0 0.0 0.0
%O2 20.7 20.7 20.7
%CO 0.0 0.0 0.0
%N2 79.3 79.3 79.3
Area of stack (sq.ft.) 9.28 9.28 9.28
Sample time (min.) 120 120 120
Static pressure (in.K^O) -1.05 -1.00 -4.00
Nozzle dia. Cm.) 0.303 0.303 0.303
Meter box cal. 1.003 1.003 1.003
Cp of pilot tube 0.84 0.84 0.84
PARTICULATE LABORATORY REPORT DATA
Total paniculate catch, g 0.1432 0.5730 0.0308
Total Lead (Pb) catch, mg 211.70 351.00 43.33
A-9
-------
TABLE A-10. SUMMARY OF PARTICULATE AND LEAD TEST
DATA AND RESULTS (SAMPLE POINT F)
TEST DATA
Test run number
Test location
list date
Test time period
SAMPLING DATA
Sampling duration, min.
Nozzle diameter, in.
Barometric pressure, in. Hg
Avg. orifice press, diff.. in Hf)
Avg. dry gas meter temp., deg F
Avg. abs. dry gas meter temp., deg. R
Total liquid collected by train, ml
Std. vol. of HjO vapor coll., cu.ft.
Dry gas meter calibration factor
Sample vol. at meter cond., dcf
Sample voL at std. cond. dscf (1)
Percent of isokinetic sampling
GAS STREAM COMPOSITION DATA
CO}. % by volume, dry basis
Oj,% by volume, dry basis
CO. % by volume, dry basis
N2,% by volume, dry basis
Molecular WL of dry gas, Ib/Ib mole
H^ vapor in gas stream, prop, by vol.
Mole fraction of dry gas
Molecular wl of wet gas, Ib/lb mole
1
2
3
Reverb Kettles Cyclone Inlet
14-Dec-92
13044714
120
0303
30.09
2.08
75.98
336
14.2
0.67
1.0030
92.293
92.141
96.5
0.0
20.7
0.0
793
28.8
0.007
0.993
28.7
lS-Dec-92
0835-1150
120
0303
29.95
1.72
55.20
515
11.4
0.54
1.0030
79.994
82.624
91.4
0.0
20.7
0.0
79.3
28.8
0.006
0.994
28.8
15-Dec-92
1435-1709
120
0303
29.92
1.55
57.00
517
11.2
0.53
1.0030
79.232
81.437
93.9
0.0
20.7
0.0
793
28.8
0.006
0.994
28.8
GAS STREAM VELOCITY AND VOLUMETRIC FLOW DATA
Cross sectional nozzle area, sq.ft.
Static pressure, in. HjO
Static pressure, in. Hg •
Absolute pressure, in. Hg
Avg. temperature, deg. F
Avg. absolute temperature, degjl
Pilot tube coefficient
Total number of traverse points
Avg. gas stream velocity, fUsec.
Stack/duct cross sectional area, sq.ft.
Avg. gas stream volumetric flow, wacf/min.
Avg. gas stream volumetric flow, dscf/min (1'
LABORATORY REPORT DATA
Total paniculate catch, g
Total Lead (Pb) catch, mg
PARTICULATE EMISSIONS DATA
Paniculate concentration, gr/wscf
Paniculate concentration, gr/dscf
Paniculate concentration, gr/dscf @ 15% O2
Paniculate mass emission rate, Ib/hr
Paniculate mass emission rate, kg/hr
LEAD (Pb) EMISSIONS DATA
Lead (Pb) concentration, Ib/dscf
Lead (Pb) concentration, Ib/dscf @ 13% O2
Lead (Pb) concentration, ug/m3
Lead (Pb) mass emission rate, Ib/hr
Lead (Pb) mass emission rate, kg/hr
0.000501
-1.05
-0.077
30.01
91
351
0.84
30
27.8
9.28
13,500
14,800
0.1432
211.70
238&02
2.40&02
4.80&01
3.035
1.376
5.07&06
1.01&04
8.11Ef04
4.485
2.034
0.000501
^
-0.074
29.88
93
553
0.84
30
26.5
928
14,700
14,000
0.5730
351.00
1.06E01
1.07B01
2.14E+00
12.804
5.808
937E-06
1.87E-04
1.50E+05
7.843
3.557
0.000501
-1
-0.074
29.85
85
545
0.84
30
25.1
9.28
14,000
13,400
0.0308
4333
5.79&03
5.83&03
1.17&01
0.669
0304
1.17&06
235EOS
1.88EHM
0.943
0.428
(l) Standard conditions = 68 deg. F. (20 deg. C) and 29.92 in Hg (760 mm Hg)
A-10
-------
TABLE A-ll.
SUMMARY OF PARTICULATE AND LEAD INPUT DATA
(SAMPLE POINT G)
TEST DATA
Run number
Location
Date
Tune period
Operator
INPUTS FOR CALCULATIONS
Sq.rt delta P
Delta H
Stack temp. (deg.F)
Meier temp. (degJF)
Sample volume (act)
Barometric press. (m.Hg)
Volume H2O imp. (ml)
Weight chngesil. gel (g)
%CO
%N2
Area of stack (sq.ft.)
Sample time (min.)
Static pressure (in.H2O) .
Nozzle dia. (in.)
Meter box cat.
Cp of pilot tube
PARTICULATE LABORATORY REPORT DATA
Total paniculate catch, g
Total Lead (Pb) catch, mg
Reveib Kettles Baghouse Outlet
14-Dec-92 15-Oec-92 15-Dec-92
1501-1859 0835-1150 1435-1709
0.2125 02313 0.2205
1.62 2.56 1.75
96.5 89.4 85.0
56.1 41.0 41.3
76.450 79.994 79.232
30.09 29.95 29.95
6.9 -1.4 -0.7
13.8 14.2 13.3
0.0 0.0 0.0
20.8 20.8 20.8
0.0 0.0 0.0
792 79.2 79.2
19.31 1931 19.31
120 120 120
-0.03 -0.03 -0.03
0.421 0.432 ' 0.432
0.994 0.999 0.999
0.84 0.84 0.84
0.0034 0.0048 0.0053
' 2.30 1.90 1.00
A-ll
-------
TABLE A-12. SUMMARY OF PARTICULATE AND LEAD TEST
DATA AND RESULTS (SAMPLE POINT G)
TEST DATA
Test run number
Test location
Test date
lest time period
SAMPLING DATA
Sampling duration, min.
Nozzle diameter, in.
Barometric pressure, in. Hg
Avg. orifice press, difl., in Hfl
Avg. dry gas meter temp., deg F
Avg. abs. dry gas meter temp., deg. R
Total liquid collected by train, ml
Std. vol. of HjO vapor coll., cu.ft.
Dry gas meter calibration {actor
Sample vol. at meter cond., dcf
Sample vol. at std. cond., dscf(l)
Percent of isokinetic sampling
GAS STREAM COMPOSITION DATA
CC>2, % by volume, dry basis
O2, % by volume, dry basis
CO, % by volume, dry basis
Nj, % by volume, dry basis
Molecular wt of dry gas. to/lb mole
HjO vapor in gas stream, prop, by vol.
Mole fraction of dry gas
Molecular wu of wet gas, Ib/to mole
1
14-Dec-92
1501-1859
120
0.421
30.09
1.62
56.10
516
20.7
0.98
0.9940
76.450
78.463
97.7
0.0
20.8
0.0
79.2
28.8
0.012
0.988
28.7
2
Reverb Kettles Baghouse Outlet
15-Dec-92
0835-4150
120
0.432
29.95
2.56
41.00
501
12.8
0.60
0.9985
79.994
84.759
91.3
0.0
20.8
0.0
79.2
28.8
0.007
0.993
28.8
3
15-Dec-92
1435-1709
120
0.432
29.95
1.75
41.30
501
12.6
0.59
0.9983
79.232
83.735
94.3
0.0
20.8
0.0
79.2
28.8
0.007
0.993
28.8
GAS STREAM VELOCITY AND VOLUMETRIC FLOW DATA
Cross sectional nozzle area, sq.ft.
Static pressure, in. HjO
Static pressure, in. Hg
Absolute pressure, in. Hg
Avg. temperature, deg. F
Avg. absolute temperature, deg.R
Pilot tube coefficient
Total number of traverse points
Avg. gas stream velocity, fL/sec.
Stack/duct cross sectional area, sq.ft.
Avg. gas stream volumetric flow, wacf/min.
Avg. gas stream volumetric flow, dscf/min '*'
LABORATORY REPORT DATA
Total paniculate catch, g
Total Lead (Pb) catch, mg
PARTICULATE EMISSIONS DATA
Paniculate concentration, gr/wscf
Paniculate concentration, gr/dscf
Paniculate concentration, gr/dscf @ 15% O2
Paniculate mass emission rate, tb/hr
Paniculate mass emission rale, kg/hr
LEAD (Pb) EMISSIONS DATA
Lead (Pb) concentration, Ib/dscf
Lead (Pb) concentration, Ib/dscf @ 15% Oj
Lead (Pb) concentration, ug/m3
Lead (Pb) mass emission rate. Ib/hr
Lead (Pb) mass emission rate, kg/hr
0.000967
-0.03
-0.002
30.09
97
557
0.84
30
12.3
19.31
14.200
13.400
0.0034
230
6.66E-04
6.75E-04
2.02B-02
0.077
0.035
6.46B08
1.94E-05
1.04E+03
0.052
0.024
0.001018
-0.03
-0.002
29.95
89
549
0.84
30
13.3
19.31
15.400
14,700
0.0048
1.90
8.71E-04
8.78E-04
2.63B02
0.110
0.050
4.94E-08
1.48E-06
7.92E+02
0.044
0.020
0.001018
-0.03
-0.002
29.95
85
545
0.84
30
12.6
19.31
14.600
14,000
0.0053
1.00
9.63E-04
9.69E-04
2.91&02
0.117
0.053
2.63608
7.90&07
4.22Et02
0.022
0.010
(l) Standard conditions = 68 deg. F. (20 deg. C.) and 29.92 in Hg (760 mm Hg)
A-12
-------
TABLE A-13. SUMMARY OF PARTICULATE AND LEAD INPUT DATA
(SAMPLE POINT H)
TEST DATA
Run number 123
Location Refiner Baghouse Inlet
Date 14-Dec-92 15-Dec-92 15-Dec-92
T.me period 1605-1855 0835-1120 142M650
INPUTS FOR CALCULATIONS
Sq. it delta P 0.7461 0.7417 07587
Delta H 2.31 1.79 190
Stack temp. (deg.F) 92.6 94.4 855
Meter temp. (deg.F) 63.0 43.9 473
Sample volume (act.) 93.640 79.994 79.232
Barometric press. (in.Hg) 30.09 29.95 29.94
Volume H;,O imp. (ml) 1.1 2.3 9.4
Weight chngesil. gel (g) 13.7 10'0 125
%OO2 0.0 0.0 00
%02 20.8 20.8 20.8
9&CO 0.0 0.0 00
%N2 79.2 79.2 79.2
Area of stack (sq.ft.) 11.04 11.04 n.04
Sample time (min.) 120 120 120
Static pressure (in.H2O) -2.00 -2.00 -2.00
Nozzle dia. (in.) 0.250 0.235 0.235
Meter box cat. 1.002 1.002 1.002
Cp of pilot tube 0.84 0.84 0.84
PARTICULATE LABORATORY REPORT DATA
Total paniculate catch, g 0.0351 0.2337 0.3407
TotalLead (Pb) catch, mg 22.00 190.00 250.00
A-13
-------
TABLE A-14. SUMMARY OF PARTICULATE AND LEAD TEST
DATA AND RESULTS (SAMPLE POINT H)
TEST DATA
Test run number
Test location
Test dale
Test time period
SAMPLING DATA
Sampling duration, min.
Nozzle diameter, in.
Barometric pressure, in. Hg
Avg. orifice press, dift.. in H2O
Avg. dry gas meter temp., deg F
Avg. abs. dry gas meter temp., deg. R
Total liquid collected by train, ml
Std. vol. of H2O vapor coll.. cu.fl.
Dry gas meter calibration factor
Sample vol. at meter cond., dcf
Sample vol. at std. cond. dscf (1)
Percent of isokinetic sampling
GAS STREAM CX)MPOSrnON DATA
CO2. % by volume, dry basis
02- % by volume, dry basis
CO. % by volume, dry basis
N2, % by volume, dry basis
Molecular wt of dry gas. Ib/lb mole
H2O vapor in gas stream, prop, by vol.
Mole fraction of dry gas
Molecular wt of wet gas, Ib/lb mole
1
14-Oec-92
1605-1855
120
0.250
30.09
Z31
63.04
323
14.8
0.70
1.0020
93.640
95.755
95.8
0.0
20.8
0.0
79.2
28.8
0.007
0.993
28.8
2
Refiner Baghouse Inlet
15-Oec-92
0835-1120
120
0.235
29.95
1.79
43.90
504
12.3
0.58
1.0020
79.994
84.407
96.5
0.0
20.8
0.0
79.2
28.8
0.007
0.993
28.8
3
15-Dec-92
142M650
120
0.235
29.94
1.90
47.30
507
21.9
1.03
1.0020
79.232
83.038
92.5
0.0
20.8
0.0
79.2
28.8
0.012
0.988
28.7
GAS STREAM VELOCITY AND VOLUMETRIC FLOW DATA
Cross sectional nozzle area, sq.ft.
Static pressure, in. t^O
Static pressure, in. Hg
Absolute pressure, in. Hg
Avg. temperature, deg. F
Avg. absolute temperature, deg.R
Pilot tube coefficient
Total number of traverse points
Avg. gas stream velocity, ft/sec.
Stack/duct cross sectional area, sq.ft.
Avg. gas stream volumetric flow, wacf/min.
Avg. gas stream volumetric flow, dscf/min (1'
LABORATORY REPORT DATA
Total naniculatc catch, ff
• WUM p»* "*"*T ilT- ••* O
Total Lead (Pb) catch, mg
PARTICULATE EMISSIONS DATA
Paniculate concentration, gr/wscf
Paniculate concentration, gr/dscf
Paniculate concentration, gr/dscf @ 15% O2
Paniculate mass emission rate, Ib/hr
Paniculate mass emission rate, kg/hr
LEAD (Pb) EMISSIONS DATA
Lead (Pb) concentration. Ib/dscf
Lead (Pb) concentration, Ib/dscf @ 15% O2
Lead (Pb) concentration, ug/m3
Lead (Pb) mass emission rate, Ib/hr
Lead (Pb) mass emission rate, kg/hr
0.000341
-2
-0.147
29.94
93
553
0.84
30
42.9
11.04
28.400
27.000
0.0351
22.00
5.62E-03
5.66&03
1.70EK11
1.310
0.594
5.07E07
1.52&05
8.11E+03
0.820
0.372
0.000301
-2
-0.147
29.80
94
554
0.84
30
4i8
11.04
28,400
26.700
0.2337
190.00
4.24E-02
4.27E-02
1.28E+00
9.788
4.440
4.96E-06
1.49E-04
7.95EHM
7.957
3.609
0.000301
•2
-0.147
29.79
86 .
546
0.84
30
43.5
11.04
28300
27,400
0.3407
250.00
6.25E-02
6J3B02
t.90E*00
14.889
6.754
6.64E-06
1.99E-04
1.06Ef05
10.924
4.955
11 > Standard conditions •= 68 deg. F. (20 deg. C.) and 29.92 in Hg (760 mm Hg)
A-14
-------
TABLE A-15.
SUMMARY OF PARTICULATE AND LEAD INPUT DATA
(SAMPLE POINT I)
TEST DATA
Run number
Location
Date
Tune period
Refiner Baghouse Outlet
14-Dec-92 15-Deo-92 15-Dec-92
1605-1855 0835-1120 1425-1650
INPUTS FOR CALCULATIONS
Sq.rt delta P
Delta H
Stack temp. (deg.F)
Meter temp, (degp)
Sample volume (act)
Barometric press. (in.Hg)
Volume I^O imp. (ml)
Weight chngesil. gel (g)
%CO
%N2
Area of stack (sq.ft.)
Sample time (min.)
Static pressure (in.H2O)
Nozzle dia. (in.)
Meter box cal.
Cp of pilot tube
PARTICULATE LABORATORY REPORT DATA
Total paniculate catch, g
Total Lead (Pb) catch, mg
0.5766
1.65
84.5
65.7
88.137
30.09
6.3
15.4
0.0
20.8
0.0
79.2
15.32
120
0.24
0.270
0.985
0.84
0.0015
1.00
0.5738
1.61
813
54.8
79.994
29.95
-3.4
13.8
0.0
20.8
0.0
79.2
15.32
120
0.24
0.270
0.981
0.84
0.0040
97.00
0.5679
1.75
79.4
58.2
79.232
29.95
1.0
17.2
0.0
20.8
0.0
79.2
15.32
120
0.24
0.270
0.981
0.84
0.0056
1.10
A-15
-------
TABLE A-16. SUMMARY OF PARTICULATE AND LEAD TEST
DATA AND RESULTS (SAMPLE POINT I)
TEST DATA
Test run number
Test location
Test date
Test time period
SAMPLING DATA •
Sampling duration, min.
Nozzle diameter, in.
Barometric pressure, in. Hg
Avg. orifice press, ditt. in H2O
Avg. dry gas meter temp., deg F
Avg. abs. dry gai meter temp., deg. R
Total liquid collected by train, ml
Std. vol. of RjO vapor coll.. cu.ft.
Dry gas meter calibration factor
Sample vol. at meter cond.. dcf
Sample vol. at std. cond, dscf (1)
Percent of isokinetic sampling
GAS STREAM COMPOSITION DATA
G02. % by volume, dry basis
Oj. % by volume, dry basis
CD. % by volume, dry basis
N2, % by volume, dry basis
Molecular WL of dry gas, tb/Ib mole
HjO vapor in gas stream, prop, by vol.
Mole fraction of dry gas
Molecular WL of wet gas, Ib/lb mole
1
14-D&C-92
1605-1855
120
0.270
30.09
1.65
65.70
526
21.7
1.02
0.9853
88.137
88.035
97.1
0.0
20.8
0.0
79.2
28.8
0.011
0.989
28.7
2
Refiner Baghouse Outlet
lS-Dec-92
0835-1120
120
0.270
29.95
1.61
54.80
515
10.4
0.49
0.9811
79.994
80.861
89.1
0.0
20.8
0.0
79.2
28.8
0.006
0.994
28.8
3
15-Dec-92
1425-1650
120
0.270
29.95
1.75
58.20
518
182
0.86
0.9811
79.232
79.593
88.8
0.0
20.8
0.0
79.2
28.8
0.011
0.989
28.7
GAS STREAM VELOCITY AND VOLUMETRIC FLOW DATA
Cross sectional nozzle area, sq.ft.
Static pressure, in. HjO
Static pressure, in. Hg
Absolute pressure, in. Hg
Avg. temperature, deg. F
Avg. absolute temperature. degJl
Pilot tube coefficient
Total number of traverse points
Avg. gas stream velocity, ft./sec.
Stack/duct cross sectional area, sq.ft.
Avg. gas stream volumetric flow, wacf/min.
Avg. gas stream volumetric flow, dscf/min l n
LABORATORY REPORT DATA
Total paniculate catch, g
Total Lead (Pb) catch, mg
PARTICULATE EMISSIONS DATA
Paniculate concentration, gr/wscf
Paniculate concentration, gr/dscf
Paniculate concentration, gr/dscf @ 15% O2
Paniculate mass emission rate, Ib/hr
Paniculate mass emission rate, kg/hr
LEAD (Pb) EMISSIONS DATA
Lead (Pb) concentration. Ib/dscf
Lead (Pb) concentration, Ib/dscf @ 15% O2
Lead (Pb) concentration, ug/m3
Lead (Pb) mass emission rate. Ib/hr
Lead (Pb) mass emission rate, kg/hr
0.000398
024
0.018
30.11
85
545
0.84
30
32.9
15.32
30200
29,100
0.0015
1.00
2.60&O4
2.63&04
7.89B03
0.066
0.030
230&08
7.51&07
4.01Ef02
0.044
0.020
0.000398
024
0.018
29.97
81
541
0.84
30
32.7
15.32
30,000
29.100
0.0040
0.97
7.59&04
7.63E-04
2.29B02
0.191
0.086
2.64&08
7.93E-07
4.24EW2
0.046
0.021
0.000398
024
0.018
29.97
79
539
0.84
30
323
15J2
29,700
28300
0.0056
1.10
1.07E03
1.09E-03
3.26&02
0.268
0.121
3.05E08
9.14B-07
4.88E+02
0.053
0.024
< l> Standard conditions = 68 deg. F. (20 deg. C) and 29.92 in Hg (760 mm Hg)
A-16
-------
TABLE A-17. SUMMARY OF PARTICULATE AND LEAD INPUT DATA
(SAMPLE POINT J)
TEST DATA
Run number 123
Location No. 1 Sanitary Baghouse Inlet
Date lWDec-92 16-Dec-92 17-Dec-92
Time period 1235-1512 1654-1906 0810-1012
INPUTS FOR CALCULATIONS
Sq.rt. delta P 1.6813 1.6603 1.6396
Delta H 1.74 1.67 1.63
Stack temp. (deg.F) 47.6 45.0 48.5
Meter temp. (deg.F) 56.9 52.6 56.0
Sample volume (act.) 81.840 79.994. 79.232
Barometric press. (in.Hg) 29.88 29.85 29.64
Volume H2O imp. (ml) 1.9 4.4 2.6
Weight chngesil. gel (g) 23.8 12.2 14.3
%CO2 0.0 0.0 0.0
%O2 20.8 20.8 20.8
%CO 0.0 0.0 0.0
%N2 79.2 79.2 79.2
Area of stack (sq.ft.) 5.73 5.73 5.73
Sample time (min.) 120 120 120
Static pressure (in.H2O) -6.40 -6.40 -6.40
Nozzle dia. (in.) 0.150 0.150 0.150
Meter box cal. 1.002 0.992 0.992
C,, of pilot tube 0.84 0.84 0.84
PARTICULATE LABORATORY REPORT DATA
Total paniculate catch, g 0.0743 0.0700 0.0672
Total Lead (Pb) catch, mg 36.41 41.62 35.43
A-17
-------
TABLE A-18. SUMMARY OF PARTICULATE AND LEAD TEST
DATA AND RESULTS (SAMPLE POINT J)
TEST DATA
Test ran number
Test location
Test date
Test time period
SAMPLING DATA
Sampling duration, min.
Nozzle diameter, in.
Barometric pressure, in. Hg
Avg. orifice press, diff.. in H2O
Avg. dry gas meter temp., deg F
Avg. abs. dry gas meter temp., deg. R
Total liquid collected by train, ml
Std. vol. of H2O vapor coll.. cu.ft.
. Dry gas meter calibration (actor
Sample vol. at meter cond., dcf
Sample vol. at std. cond, dscf (1)
Percent of isokinetic sampling
GAS STREAM COMPOSITION DATA
GO2, % by volume, dry basis
Oj. % by volume, dry basis
CO. % by volume, dry basis
N2. % by volume, dry basis
Molecular wt of dry gas. Ib/lb mole
H2O vapor in gas stream, prop, by vol.
Mole fraction of dry gas
Molecular wt of wet gas, Ib/lb mole
1
No. 1
16-Dcc-92
1235-1512
120
0.150
29.88
1.74
S6.88
517
25.7
1.21
1.0020
81.840
83.981
100.7
0.0
20.8
0.0
79.2
28.8
0.014
0.986
'28.7
2
Sanitary Baghousc Inlet
16-Dec-92
1654-4906
120
0.150
29.85
1.67
52.60
513
16.6
0.78
0.9920
79.994
81.850
98.8
0.0
20.8
0.0
79.2
28.8
0.009
0.991
28.7
3
17-Dec-92
0810-1012
120
0.150
29.64
1.63
56.00
516
16.9
0.80
0.9920
79.232
79.964
98.5
0.0
20.8
0.0
79.2
28.8
0.010
0.990
28.7
GAS STREAM VELOCITY AND VOLUMETRIC FLOW DATA
Cross sectional nozzle area, sq.ft.
Static pressure, in. H2O
Static pressure, in. Hg
Absolute pressure, in. Hg
Avg. temperature, deg. F
Avg. absolute temperature. deg.R
Pilot tube coefficient
Total number of traverse points
Avg. gas stream velocity, ft./sec.
Stack/duct cross sectional area, sq.ft.
Avg. gas stream volumetric flow, wacf/min.
Avg. gas stream volumetric flow, dscf/min (1)
LABORATORY REPORT DATA
Total paniculate catch, g
Total Lead (Pb) catch, mg
PARTICULATE EMISSIONS DATA
Paniculate concentration, gr/wscf
Paniculate concentration, gr/dscf
Paniculate concentration, gr/dscf @ 15% O,
Paniculate mass emission rate. Ib/hr
Paniculate mass emission rate, kg/hr
LEAD (Pb) EMISSIONS DATA
Lead (Pb) concentration. Ib/dscf
Lead (Pb) concentration. lb/dscf@ 15%O,
Lead (Pb) concentration, ug/m3
Lead (Pb) mass emission rate. Ib/hr
Lead (Pb) mass emission rate, kg/hr
0.000123
-6.4
-0.471
29.41
48
508
0.84
30
93.7
5.73
32.200
32.400
0.0743
36.41
1.35&02
1.37E-02
4.10&01
3.796
1.722
9.56E-07
2.87&OS
1.53E+04
1.859
0.843
. 0.000123
-6.4
-0.471
29.38
45
505
0.84
30
92.2
5.73
31.700
32.200
0.0700
41.62
U1&02
1.32&02
3.96&01
3.648
1.655
1.12E06
3.36E-05
1.80E+04
2.168
0.983
0.000123
-6.4
-0.471
29.17
49
509
0.84
30
91.7
5.73
31.500
31.600
0.0672
35.43
1.28E02
1.30&02
3.89B01
3.514
1.194
9.77R-07
2.93&05
IJ6E404
1.852
0.840
11' Standard conditions = 68 deg. F. (20 deg. C.) and 29.92 in Hg (760 mm 1 le)
A-18
-------
TABLE A-19. SUMMARY OF PARTICULATE AND LEAD INPUT DATA
(SAMPLE POINT K)
TEST DATA
Run number 1 2 3
Location No. 1 SANITARY BAGHOUSE OUTLET
Date 16-Deo-92 16-Dec-42 17-Oec-92
Time period 1235-1512 1654-1906 08KH012
Operator
INPUTS FOR CALCULATIONS
Sq.rt delta P 1.8311 1.8102 1.7833
Delta H 1.91 2.01 1.94
Slack temp. (degJF) 48.9 47.4 50.3
Meter temp. (deg.F) 62.4 64.4 62.1
Sample volume (act) 89.549 92.616 90.242
Barometric press. (in.Hg) 29.88 29.85 29.64
Volume H2O imp. (ml) -2.2 -3.9 -1.9
Weight chngesil. gel (g) 19.6 19.5 19.7
S&COj 0.0 0.0 0.0
. %02 20.8 20.8 20.8
%CO 0.0 0.0 0.0
%N2 79.2 79.2 79.2
Area of stack (sq.ft) 5.76 5.76 5.76
Sample time (min.) 120 120 120
Static pressure (in.H2O) -14.90 -14.30 -11.00
Nozzle dia. (in.) 0.150 0.152 0.152
Meter box cal. 1.003 1.003 1.003
Cp of pilot lube 0.84 0.84 0.84
PARTICULATE LABORATORY REPORT DATA
Total paniculate calch.g 0.0025 0.0058 0.0052
Total Lead (Pb)calch.mg 1.50 0.54 0.56
A-19
-------
TABLE A-20. SUMMARY OF PARTICULATE AND LEAD TEST
DATA AND RESULTS (SAMPLE POINT K)
TEST DATA
Test run number
Test location
lest date
lest time period
SAMPLING DATA
Sampling duration, min.
Nozzle diameter, in.
Barometric pressure, in. Hg
Avg. orifice press, diff.. in H2O
Avg. dry gas meter temp., deg F
Avg. abs. dry gas meter temp., deg. R
Total liquid collected by train, ml
Std. vol. of Hf> vapor coll.. cu.fl
Dry gas meter calibration factor
Sample vol. at meter cond.. dcf
Sample vol. at std. cond. dscf (1)
Percent of isokinetic sampling
GAS STREAM COMPOSITION DATA
OX % by volume, dry basis
Oj, % by volume, dry basts
CO, % by volume, dry basis
N2. % by volume, dry basis
Molecular wi. of dry gas, Ib/Ib mole
H,O vapor in gas stream, prop, by vol.
Mole fraction of dry gas
Molecular wt. of wet gas. Ib/Ib mole
1
No. 1
16-Dec-92
1235-1512
120
0.150
29.88
1.91
6238
522
17.4
0.82
1.0030
89.549
91.053
101.1
0.0
20.8
0.0
79.2
28.8
0.009
0.991
28.7
2
SANrTARY BAGHOUSE
16-Dec-92
1654-1906
120
0.152
29.85
Z01
64.42
524
15.6
0.74
1.0030
92.616
93.734
102.2
0.0
20.8
0.0
79.2
28.8
0.008
0.992
28.7
3
OUTLET
lT-Dcc-92
0810-1012
120
0.152
29.64
1.94
62.10
522
17.8
0.84
1.0030
90.242
91.079
101.2
0.0
20.8
0.0
79.2
28.8
0.009
0.991
28.7
GAS STREAM VELOCITY AND VOLUMETRIC FLOW DATA
Cross sectional nozzle area, sq.ft.
Static pressure, in. H2O
Static pressure, in. Hg
Absolute pressure, in. Hg
Avg. temperature, deg. F
Avg. absolute temperature. deg.R
Pilot tube coefficient
Total number of traverse points
Avg. gas stream velocity, ft/sec.
Stack/duct cross sectional area, sq.ft.
Avg. gas stream volumetric flow, wacf/min.
Avg. gas stream volumetric flow, dscf/min ^'
LABORATORY REPORT DATA
Total paniculate catch, g
Total I earl (Pb) catch, mg
PARTICULATE EMISSIONS DATA
Paniculate concentration, gr/wscf
Paniculate concentration, gr/dscf
Paniculate concentration, gr/dscf @ 15% Oj
Paniculate mass emission rate, Ib/hr
Paniculate mass emission rate, kg/hr
IJiAD (Pb) EMISSIONS DATA
Lead (Pb) concentration. Ib/dscf
Lead (Pb) concentration. Ib/dscf @ 15% O2
Lead (Pb) concentration, ug/m3
Lead (Pb) mass emission rate, Ib/hr
Lead (Pb) mass emission rate, kg/hr
0.000123
-14.9
-1.096
28.78
49
509
0.84
30
103.1
5.76
35,700
35.300
0.0025
1.50
4.12E-04
4.15&04
1.25B02
0.125
0.057
3.63E-08
1.09&06
5.82E+02
0.077
0.035
0.000126
-143
-1.051
28.80
47
507
0.84
30
101.8
5.76
35200
34.900
0.0058
OJS4
9.47&04
9.55B04
2.86E-02
0.286
0.130
1.27E-08
3.81E-07
2.03E402
0.027
0.012
0.000126
-11
-0.809
28.83
50
510
0.84
30
100.5
5.76
34.700
34300
0.0052
6.56
8.70G-04
8.78E-04
2.63&02
0.258
0.117
136R-08
4.07&07
2.17Et02
0.028
0.013
11! Standard conditions = 68 deg. F. (20 deg. C.) and 29.92 in Hg (760 mm Hg)
A-20
-------
TABLE A-21. SUMMARY OF PARTICULATE AND LEAD INPUT DATA
(SAMPLE POINT L)
TEST DATA
Run number 12 3
Location No. 3 Sanitary Baghouse Intel
Date 16-Dec-92 16-Oec-92 17-Dec-92
Time period 123CH500 1645-1857 0855-1105
INPUTS FOR CALCULATIONS
Sq.rt delta P 0.6592 0.6915 0.6872
Delia H 1.83 2.00 1.94
Stack temp. (deg.F) 60.7 60.4 59.6
Meter temp. (deg.F) 70.9 65.7 65.9
Sample volume (act.) 91.288 95.646 94.558
Barometric press. (in.Hg) 29.85 29.64 29.64
Volume H20 imp. (ml) 5.90 2.9 3.5
Weight chngesil. gel (g) 20.0 18.8 21.2
%ca, 0.0 0.0 o.o
%O2" 20.8 20.8 20.8
%CO 0.0 0.0 0.0
%N2 79-2 79-2 79-2
Area of stack (sq.ft.) 12.44 12.44 12.44
Sample time (min.) 120 120 120
Static pressure (in-Hp) -14.10 -14.10 -14.10
Nozzle dia. (in.) 0.249 0.249 0.249
Meter box cal. 0.981 0.981 0.981
Cp of pilot tube 0.84 0.84 0.84
PARTICULATE LABORATORY REPORT DATA
Total paniculate catch, g 0.0214 0.0334 0.0106
Total Lead (Pb) catch, mg 15.99 27.25 5.60
A-21
-------
TABLE A-22. SUMMARY OF PARTICULATE AND LEAD TEST
DATA AND RESULTS (SAMPLE POINT L)
TEST DATA
Test run number
Test location
Test date .
Test time period
SAMPLING DATA
Sampling duration, min.
Nozzle diameter, in.
Barometric pressure, in. Hg
Avg. orifice press, diff.. in lt>O
Avg. dry gas meter temp., deg F
Avg. abs. dry gas meter temp., deg. R
Total liquid collected by train, ml
Sid. vol. of H2O vapor coll.. cu.ft.
Dry gas meter calibration factor
Sample vol. at meter cond., dcf
Sample vol. at std. cond. dscf (1)
Percent of isokinetic sampling
GAS STREAM COMPOSITION DATA
002. % by volume, dry basis
Oj, % by volume, dry basis
CO, % by volume, dry basis
Nj.% by volume, dry basis
Molecular wL of dry gas, Ib/Ib mole
HjO vapor in gas stream, prop, by vol.
Mole fraction of dry gas
Molecular WL of wet gas. Ib/Ib mole
1
No.
16-Dec-92
1230-1500
120
0.249
29.85
1.83
70.93
531
25.9
1.22
0.9811
91.288
89.226
101,3
0.0
20.8
0.0
79.2
28.8
0.013
0.987
28.7
2
3 Sanitary Baghouse
16-Dec-92
1645-1857
120
0.249
29.64
2.00
65.70
526
21.7
1.02
0.9811
95.646
93.793
101.6
0.0
20.8
0.0
79.2
28.8
0.011
0.989
28.7
3
Inlet
lT-Occ-92
0855-1105
120
Oi49
29.64
1.94
65.90
526
24.7
1.16
0.9811
94.558
92.677
101.1
0.0
20.8
0.0
79.2
28.8
0.012
0.988
28.7
GAS STREAM VELOCITY AND VOLUMETRIC FLOW DATA
Cross sectional nozzle area, sq.ft.
Static pressure, in. H2O
Static pressure, in. Hg
Absolute pressure, in. Hg
Avg. temperature, deg. F
Avg. absolute temperature. deg.R
Pilot tube coefficient
Total number of traverse points
Avg. gas stream velocity. fUsec.
Slack/duct cross sectional area, sq.ft.
Avg. gas stream volumetric flow, wacf/min.
Avg. gas stream volumetric flow, dscf/min (1'
LABORATORY REPORT DATA
Total paniculate catch, g
Total Lead (Pb) catch, mg
P ARTICULATE EMISSIONS DATA
Paniculate concentration, gr/wscf
Paniculate concentration, gr/dscf
Paniculate concentration, gr/dscf @ 15% O,
Paniculate mass emission rate. Ib/hr
Paniculate mass emission rate, kg/hr
LEAD (Pb) EMISSIONS DATA
Lead (Pb) concentration. Ib/dscf
Lead (Pb) concentration, Ib/dscf @ 15% Cs
Lead (Pb) concentration, ug/m3
Lead (Pb) mass emission rate. Ib/hr
Lead (Pb) mass emission rate, kg/hr
0.000338
-14.1
-1.037
28.81
61
521
0.84
30
37.6
12.44
28.000
27,000
0.0214
15.99
3.65&03
3.70E-03
1.11EO1
0.857
0.389
3.95E-07
1.19E-05
6.33EHO
0.640
0.290
0,000338
-14.1
-1.037
28.60
60
520
0.84
30
39.5
12.44
29,500
28300
0.0334
27.25
5.44E-03
5.50E-03
1.65E-01
1334
0.605
6.41G-07
1.92&05
1.03EHM
1.087
0.493
0.000338
-14.1
-1.037
28.60
60
520
0.84
30
39.3
12.44
29300
28.100
0.0106
5.60
I.75&03
1.77E-03
5.32E-02
0.427
0.194
1.33&07
4.00&06
2.13EKJ3
0.225
0.102
-------
TABLE A-23. SUMMARY OF PARTICULATE AND LEAD INPUT DATA
(SAMPLE POINT M)
TEST DATA
Run number 1 2 3
Location No. 3 Sanitary Baghouse Outlet
Date 16-Dsc-92 16-Oec-92 lT-ttec-42
Time period 1235-1512 1647-1857 0855-1105
Operator
INPUTS FOR CALCULATIONS
Sq. rt delta P . 0.5737 0.5851 0.5684
Delta H 1.34 1.42 1.35
Stack temp. (deg.F) 65.6 62.3 62.7
Meter temp. (deg.F) 63.3 64.4 63.6
Sample volume (act) 71.137 73.069 71.022
Barometric press. (in.Hg) 29.85 29.85 29.64
Volume HjO imp. (ml) 3.2 2.2 7.7
Weight chngesil. gel (g) 14.1 14.3 12.9
0.0 0.0 0.0
20.7 20.7 20.7
%CO 0.0 0.0 0.0
%N2 79.3 79.3 79.3
Area of stack (sq.ft.) 15.32 15.32 15.32
Sample time (min.) 120 120 120
Static pressure (in-HjO) -0.20 -0.19 -0.19
Nozzle dia. (in.) 0.237 0.237 0.237
Meter box cat. 0.994 0.994 0.994
Cp of pitot tube 0.84 0.84 0.84
PARTICULATE LABORATORY REPORT DATA
TbtaJ paniculate catch, g 0.0026 0.0078 0.0082
Total Lead (Pb) catch, mg 6.60 3.10 1.40
A-23
-------
TABLE A-24. SUMMARY OF PARTICULATE AND LEAD TEST
DATA AND RESULTS (SAMPLE POINT M)
TEST DATA
Test run number
Test location
Test date
Test time period
SAMPLING DATA
Sampling duration, min.
Nozzle diameter, in.
Barometric pressure, in. Hg
Avg. orifice press, diff., in H2O
Avg. dry gas meter temp., deg F
Avg. abs. dry gas meter temp., deg. R
Total liquid collected by train, ml
Sid. vol. of H2O vapor coll., cu.fl.
Dry gas meter calibration factor
Sample vol. at meter cond., dcf .
Sample vol. at std. cond, dscf (1)
Percent of isokinetic sampling
GAS STREAM COMPOSITION DATA
CO2, % by volume, dry basis
O2, % by volume, dry basis
CO, % by volume, dry basis
N2, % by volume, dry basis
Molecular WL of dry gas, Ib/lb mole
HjO vapor in gas stream, prop, by vol.
Mole fraction of dry gas
Molecular wt. of wet gas. Ib/lb mole
1
16-Dec-42
1235-1512
120
0.237
29.85
134
63.25
523
113
0.82
0.9940
71.137
71.392
1013
0.0
20.7
0.0
79.3
28.8
0.011
0.9S9
28.7
2
No. 3 Sanitary Baghouse Outlet
16-Deo-92
1647-1857
120
0.237
29.85
1.42
64.42
524
16.5
0.78
0.9940
73.069
73.181
101.4
0.0
20.7
0.0
79.3
28.8
6.011
0.989
28.7
3
17-Dec-92
0855-1105
120
0.237
29.64
135
63.60
524
20.6
0.97
0.9940
71.022
70.731
101.6
0.0
20.7
0.0
793
28.8
0.014
0.986
28.7
GAS STREAM VELOCITY AND VOLUMETRIC FLOW DATA
Gross sectional nozzle area, sq.ft.
Static pressure, in. H2O
•Static pressure, in. Hg
Absolute pressure, in. Hg
Avg. temperature, deg. F
Avg. absolute temperature, deg.R
Pilot tube coefficient
Total number of traverse points
Avg. gas stream velocity, fu/sec.
Stack/duct cross sectional area, sq.ft
Avg. gas stream volumetric flow, wacf/min.
Avg. gas stream volumetric How, dscf/min l ' '
LABORATORY REPORT DATA
Total paniculate catch, g
Total Lead (Pb) catch, mg
PARTICULATE EMISSIONS DATA
Paniculate concentration, gr/wscf
Paniculate concentration, gr/dscf
Paniculate conccniration. gr/dscf @ 15% O2
Paniculate mass emission rate. Ib/hr
Paniculate mass emission rale, kg/hr
LEAD (Pb) EMISSIONS DATA
Lead (Pb) concentration, Ib/dscf
Lead (Pb) concentration. Ib/dscf @ 15% Oj
Lead (Pb) concentration, ug/hr5
Lead (Pb) mass emission rate. Ib/hr
Lead (Pb) mass emission rate, kg/hr
0.000306
-0.2
-0.015
29.84
66
526
0.84
30
323
15.32
29.700
29,400
0.0026
6.60
5.56&04
5.62E-04
1.12E-02
0.141
0.064
2.04E-07
4.08B-06
3.26EHJ3
0.359
0.163
0.000306
-0.185
-0.014
29.84
62
522
0.84
30
32.8
1532.
30^00
30.100
0.0078
3.10
1.63E-03
1.64&03
3.29E02
0.424
0.192
9.34E-08
1.87B06
1.50Ef03
0.168
0.076
0.000306
-0.185
-0.014
29.63
63
523
0.84
30
32.0
15.32
29,400
29.000
0.0082
1.40
1.76E-03
1.79&03
3.58&02
0.445
0.202
4.36&08
8.73&07
6.99Et02
0.076
0.034
'" Standard conditions = 68 deg. F. (20 deg. C.) and 29.92 in Hg (760 mm I Ig)
A-24
-------
TABLE A-25. SUMMARY OF PM10 AND CONDENSIBLE PARTICULATE
TEST DATA AND RESULTS (SAMPLE POINT A)
Test Data
Test Run Number
Test Location
Test Date
Test time period
Measured Data
Meter Box Y
Avg Delta H, inches H2O
Barometric Pressure, inches Hg
Meter Volume, cu.ft
Avg Meter Temp, deg F
Static Pressure, inches H2O
Avg Stack Temp, deg F
Water Collected, g
Carbon dioxide, %
Oxygea %
Avg Sqrt Delta P. sqrt(inches H2O)
Sample Time, min
Nozzle Diameter, inches
Stack Area, sq. ft.
PM10
Paniculate Collected (PM cyclone), g
Calculated Data
Standard Meter Volume, cu.ft
Stack Pressure, inches Hg
Moisture. %
Molecular Weight-wet, Ib/lb-mole
Velocity, ft/s
Stack Area, sq.ft
Volumetric flow, acfm
Volumetric flow, dscfm
Isokinctic Rate, %
Cyclone flowrate (actual), cfm
Cyclone flowrate (target), cfm
Panicle Diam. with 50% penetration, urn
Run 1
12-1 092
1620-1825
0.992
0.50
29.87
21.253
63.7
-4.00
219.5
52.4
10.0
13.3
0.244
60.25
0.341
4.9
1.2582
15.5996
0.4210
0.0678
2.7092
21.237
29.80
10.4
28.9
15.6
4.91
4,589
3.180
85.8
0.509
0.558
10.68
Run 2
Blast Furnace Outlet
12-11-92
0937-1310
0.992
0.49
29.10
25.310
54.5
-1.00
152.2
44.7
8.4
13.1
0.267
87.25
0.341
4.9
1.0082
13.6992
03137
0.1069
2.6993
25.080
29.03
7.7
28.9
16.4
4.91
4.818
3.718
59.9
0.372
0.491
12.16
Run 3
12-12-92
0850-1141
0.992
0.49
29.51 .
26.823
67.8
-0.92
209.3
35.4
5.2
15.8
0.253
71.50
0.341
4.9
1.4376
16.4992
0.2300
0.0693
1.6095
26.277
29.44
6.0
28.8
16.1
4.91
4,755
3.470
82.0
0.504
0.551
10.66
A-25
-------
TABLE A-26. SUMMARY OF PM1Q AND CONDENSIBLE PARTICULATE
TEST DATA AND RESULTS (SAMPLE POINT B)
Test Data
Test Run Number
Test Location
Test Date
Test time period
Measured Data
Meter Box Y
Avg Delta H. inches H2O
Barometric Pressure, inches Hg
Meter Volume, cu.ft
Avg Meter Temp, deg F
Static Pressure, inches H2O
Avg Stack Temp, deg F
Water Collected, g
Carbon dioxide, %
Oxygen. %
Avg Sqrt Delta P. sqrt(inches H2O)
Sample Time, min
Nozzle Diameter, inches
Stack Area, sq.ft.
PM10
Paniculate Collected (PM cyclone), g
Calculated Data
Standard Meter Volume, cu.ft
Stack Pressure, inches Hg
Moisture, %
Molecular Weight-wet, Ib/lb-mole
Velocity, ft/s
Stack Area, sq.ft
Volumetric flow, acfm
Volumetric flow, dscfm
IsokineticRate,%
Cyclone flowrate (actual), cfm
Cyclone flowrate (target), cfm
Panicle Diam. with 50% penetration, um
Run 1 Run 2 Run 3
Blast/Reverb Furnaces Baghouse Inlet
12-10-92 12-11-S2 12-12-92
1620-1827 09354300 0850-1143
1.001 1.001 0.999
0.62 0.48 0.43
29.87 29.10 29.51
32.379 24.841 24.047
50.0 43.0 46.4
-2.80 -2.80 -2.80
267.0 266.0 279.4
111.0 127.8 80.0
0.0 0.0 4.2
21.0 20.8 15.6
0.773 . 0.756 0.753
77.00 67.75 -69.00
0.197 0.197 0.197
14.8 14.8 14.8
0.2330 0.4985 0.1831
4.9698 63297 2.6899
0.4156 0.2171 0.2266
0.0023 0.0037 0.0011
3.8992 4.5791 1.0290
33.537 25.407 24.707
29.66 28.89 29.30
13.5 19.1 13.2
27.4 26.8 ' 27.8
52.5 52.6 51.5
14.75 14.75 14.75
46.463 46.579 45,581
28,937 26,443 27,653
104.9 98.8 90.3
0.699 0.661 0.590
0.619 0.607 0.602
9.17 9.42 10.14
A-26
-------
TABLE A-27. SUMMARY OF PM10 AND CONDENSIBLE PARTICULATE
TEST DATA AND RESULTS (SAMPLE POINT C)
Test Data
Test Run Number
Test Location
Test Date
Test time period
Measured Data
Meter Box Y
Avg Delta H, inches H2O
Barometric Pressure, inches Hg
Meter Volume, cu.ft
Avg Meter Temp, deg F
Static Pressure, inches H2O
Avg Stack Temp, deg F
Water Collected, g
Carbon dioxide, %
Oxygen. %
Avg Sqrt Delta P. sqrt(inches H2O)
Sample Time, min
Nozzle Diameter, inches
Stack Area, sq. ft.
PM10
Paniculate Collected (PM cyclone), g
Calculated Data
Standard Meter Volume, cu.ft
Stack Pressure, inches Hg
Moisture, %
Molecular Weight-wet. Ib/lb-mole
Velocity, ft/s
Stack Area, sq.ft
Volumetric flow, acfm
Volumetric now, dscfm
Isokinetic Rate. %
Cyclone flowrate (actual), cfm
Cyclone flowrate (target), cfm
Panicle Diam. with 50% penetration, urn
Only one run performed due to low paniculate loading.
Run 1
Baghouse Outlet(Scrubber Inlet)
12-11-92
0915-1355
1.002
0.43
29.10
91.425
51.2
-7.70
198.8
366.3
5.0
16.0
0.622
251.25
0.215
17.1
6.0525
0.0000
0.6999
0.0040
0.0277
92.080
28.53
15.8
27.6
40.8
17.10
41,905
26,967
92.2
0.569
0.540
9.63
Run 2
Run 3
A-27
-------
TABLE A-28. SUMMARY OF PM10 AND CONDENSIBLE PARTICULATE
TEST DATA AND RESULTS (SAMPLE POINT D)
Test Data
Test Run Number Run 1
Test Location Scrubber Outlet
Test Date 12-11-92
Test time period 0915-1340
Measured Data
Meter Box Y 0.985
Avg Delta H, inches H2O 0.42
Barometric Pressure, inches Hg 29.10
Meter Volume, cu.ft 86.990
Avg Meter Temp, degF 52.9
Static Pressure, inches H2O -0.06
Avg Stack Temp, degF 125.7
Water Collected, g 261.7
Carbon dioxide, % 4.1
Oxygen, % 16-9
Avg Sqrt Delta P, sqrt(inches H2O) 0.353
Sample Time, min 233.25
Nozzle Diameter, inches 0.262
Stack Area, sq.ft. 19.6
PM10
Paniculate Collected (PM cyclone), g 0.0052
Calculated Data
Standard Meter Volume, cu.ft 85.879
Stack Pressure, inches Hg 29.10
Moisture. % 12.5
Molecular Weight-wet, Ib/Ib-mole 27.9
Velocity, ft/s 21.5
Stack Area, sq.ft 19.63
Volumetric flow, acfm 25344
Volumetric now, dscfm 19.425
Isokinetic Rate, % 99.4
Cyclone flowrate (actual), cfm 0.480
Cyclone flowrate (target), cfm 0.482
Particle Diam. with 50% penetration, urn 10.03
Only one run per fanned due to low paniculate loading.
Run 2
Run 3
A-28
-------
TABLE A-29. SUMMARY OF PM10 AND CONDENSIBLE PARTICULATE
TEST DATA AND RESULTS (SAMPLE POINT F)
Test Data
Test Run Number
Test Location
Test Date
Test time period
Measured Data
Meter Box Y
Avg Delta H. inches H2O
Barometric Pressure, inches Hg
Meter Volume, cu.ft
Avg Meter Temp, deg F
Static Pressure, inches H2O
Avg Stack Temp, deg F
Water Collected, g
•. Carbon dioxide, %
Oxygen. %
Avg Sqrt Delta P, sqrt(inches H2O)
Sample Tune, min
Nozzle Diameter, inches
Stack Area. sq. ft.
PM10
Paniculate Collected (PM cyclone), g
Calculated Data
Standard Meter Volume, cu.ft
Stack Pressure, inches Hg
Moisture. %
Molecular Weight-wet, Ib/lb-mole
Velocity, ft/s
Stack Area, sq.ft
Volumetric flow, acfm
Volumetric flow, dscfm
Isokinetic Rate. %
Cyclone flowrate (actual), cfm
Cyclone flowrate (target), cfm
Particle Diam. with 50% penetration, um
Run 1
12-14-92
1345-1945
0.992
0.60
30.09
76.820
77.8
-1.10
94.6
3.9
0.0
20.8
0.400
171.25
0.231
9.3
0.0077
0.0000
0.0037
0.0160
0.0099
75.320
30.01
0.2
28.8
23.0
9.28
12,826
12212
114.9
0.462
0.459
9.95
Run 2
Reverb Kettles Cyclone Inlet
12-17-92
0805-1115
0.992
0.58
29.95
82.993
55.1
-0.90
91.1
9.7
0.0
20.8
0.437
196.00
0.231
9.3
0.0131
0.0179
0.0019
0.0046
0.5847
84.554
29.88
0.5
28.8
25.1
9.29
13.988
13309
103.4
0.453
0.459
10.09
Run 3
12-17-92
1200-1530
0.992
0.58
29.92
50.069
59.1
-1.05
85.0
0.7
0.0
21.0
0.422
116.25
0.231
93
0.0035
0.0000
0.0035
0.0007
0.0076
50.574
29.84
0.1
28.8
24.1
9.28
13,430
12,965
107.0
0.451
0.459
10.14
A-29
-------
TABLE A-30. SUMMARY OF PM10 AND CONDENSIBLE PARTICULATE
TEST DATA AND RESULTS (SAMPLE POINT G)
Test Data
Test Run Number Run 1 Run 2 Run 3
Test Location Reverb Kettle Baghouse Outlet
Test Date 12-14-92
Test time period 1345-1956
Measured Data
Meter Box Y 0.999
Avg Delta H. inches H2O 0.59
Barometric Pressure, inches Hg 30.10
Meter Volume, cu.ft 97.971
Avg Meter Temp, degF 49.9
Static Pressure, inches H2O -0.03
Avg Slack Temp. degF 96.2
Water Collected, g 13.7
Carbon dioxide, % 0.0
Oxygen, % 20.8
Avg Sqrt Delta P, sqrt(inches H2O) 0.222
Sample Time, min 236.00
Nozzle Diameter, inches 0.341
Stack Area, sq.ft. 19.3
PM10
Paniculate Collected (PM cyclone), g 0.0013
Calculated Data
Standard Meter Volume, cu.ft 102.018
Stack Pressure, inches Hg 30.10
Moisture. % 0.6
Molecular Weight-wet. Ib/lb-mole 28.8
Velocity, fl/s 12.8
Slack Area, sq.ft 19.31
Volumetric flow, acfm 14,778
Volumetric flow, dscfm 14,019
Isokinetic Rate. % 93.9
Cyclone flowrate (actual), cfm 0.456
Cyclone flowrate (target), cfm 0.465
Particle Diam. with 50% penetration, urn 10.15
Only one run per fanned due to low paniculate loading.
A-30
-------
TABLE A-31. SUMMARY OF PM10 AND CONDENSIBLE PARTICULATE
TEST DATA AND RESULTS (SAMPLE POINT H)
Test Data
Test Run Number
Test Location
Test Date
Test lime period
Measured Data
Meter Box Y
Avg Delta H, inches H2O
Barometric Pressure, inches Hg
Meter Volume, cu.ft
Avg Meter Temp, deg F
Static Pressure, inches H2O
Avg Stack Temp, deg F
Water Collected, g
Carbon dioxide. %
Oxygen, %
Avg Sqrt Delia P, sqrt(inches ICO)
Sample Time, min
Nozzle Diameter, inches
Stack Area, sq.ft.
PM10
Paniculate Collected (PM cyclone), g
Calculated Data
Standard Meter Volume, cu.ft
Stack Pressure , inches Hg
Moisture, %
Molecular Weight-wet, Ib/Ib-mole
Velocity, ft/s
Stack Area, sq.ft
Volumetric flow, acfm
Volumetric flow, dscfm
Isokinetic Rate, %
Cyclone flowrate (actual), cfm
Cyclone flowrate (target), cfm
Particle Diam. with 50% penetration, urn
Run 1
12-14-92
1500-2028
1.002
0.57
30.09
126.333
79.8
-1.80
93.2
16.6
0.0
20.8
0.780
290.75
0.195
11.0
0.0091
0.0101
0.0014
0.0009
0.0426
124.652
29.96
0.6
28.8
44.9
11.04
29.729
28.222
80.9
0.452
0.467
10.24
Run 2
Refiner Baghouse Inlet
12-15^2
1040-1642
1.002
0.55
29.95
87.644
65.6
-2.00
89.4
7.5
0.0
20.8
0.754
208.00
0.181
11.0
0.0126
0.0300
0.0025
0.0227
0.1017
88.390
29.80
0.4
28.8
43.3
11.04
28.701
27,353
96.0
0.446
0.473
10.43
Run 3
12-15-92
1616-1817
1.002
0.56
29.95
37.475
69.3
-2.00
88.9
12.9
0.0
20.8
0.767
88.00
0.181
11.0
0.0115
0.0028
0.0085
0.0000
0.0195
37.532
29.80
1.6
28.7
44.1
11.04
29.245
27,563
95.6
0.453
0.473
10.32
A-31
-------
TABLE A-32. SUMMARY OF PM10 AND CONDENSIBLE PARTICULATE
TEST DATA AND RESULTS (SAMPLE POINT I)
Test Data
Test Run Number
Test Location
Test Date
Test time period
Run 1
Refiner Baghouse Outlet
12-14-92
1500-1945
Run 2
Run 3
Measured Data
Meter Box Y 0.981
Avg Delta a inches H2O 0.54
Barometric Pressure, inches Hg 30.09
Meter Volume, cu.ft 99.365
Avg Meter Temp, deg F 62.5
Static Pressure, inches ICO 0.25
Avg Stack Temp, deg F 81.1
Water Collected, g 8.7
Carbon dioxide, % 0.0
Oxygen. % 20.8
Avg Sqrt Delta P, sqrt(inches H2O) 0.555
Sample Tune, min 232.75
Nozzle Diameter, inches 0.215
Stack Area. sq. ft 30.6
PM10
Paniculate Collected (PM cyclone), g 0.0016
Calculated Data
Standard Meter Volume, cu.ft 99.158
Stack Pressure, inches Hg 30.11
Moisture. % 0.4
Molecular Weighi-wet, Ib/Ib-mole ' 28,8
Velocity, ft/s 31.5
Stack Area, sq.ft 15.32
Volumetric flow, acfm 28.954
Volumetric flow, dscfm 28.304
IsokineticRate.% 91.5
Cyclone flow/rate (actual), cfm 0.436
Cyclone flowrate (target), cfm 0.448
Panicle Diam. with 50% penetration, um 10.20
Only one run per fanned due to low paniculate loading.
A-32
-------
TABLE A-33. SUMMARY OF PM10 AND CONDENSIBLE PARTICULATE
TEST DATA AND RESULTS (SAMPLE POINT J)
Test Data
Test Run Number
Test Location
Test Date
Test time period
Measured Data
Meter Box Y
Avg Delta H, inches H2O
Barometric Pressure, inches Hg
Meter Volume, cu.ft
Avg Meter Temp, deg F
Static Pressure, inches H2O
Avg Stack Temp, deg F
Water Collected, g
Carbon dioxide, %
Oxygen, %
Avg Sqrt Delta P, sqrt(inches H2O)
Sample Time, min
Nozzle Diameter, inches
Stack Area, sq. ft
PM10
Paniculate Collected (PM cyclone), g
Calculated Data
Standard Meter Volume, cu.ft
Stack Pressure, inches Hg
Moisture, %
Molecular Weight-wet. Ib/lb-mole
Velocity, ft/s
Stack Area, sq.ft
Volumetric flow, acfm
Volumetric flow, dscfm
Isokinetic Rate, %
Cyclone flowrate (actual), cfm
Cyclone flowrate (target), cfm
Particle Diam. with 50% penetration, urn
Run 1
12-16-92
1137-1512
1.002
0.60
29.88
110.536
63.0
-6.50
48.1
19.8
0.0
20.8
1.714
251.75
0.132
5.6
0.0040
0.0726
0.0036
0.0007
0.0336
111.779
29.40
0.8
28.7
95.4
5.59
31,973
32370
80.6
0.439
0.425
9.77
Run 2
No. 1 Sanitary Baghouse Inlet
12-17-92
0805-1115
1.002
0.60
29.64
73.987
61.1
•-6.00
49.8
8.9
0.0
20.8
1.666
169.00
0.132
5.6
0.0018
0.0357
0.0020
0.0063
0.0015
74.499
29.20
0.6
28.8
93.2
5.59
31,237
31.383
82.6
0.439
0.430
9.85
Run 3
12-17-92
1200-1530
1.002
0.61
29.56
77.753
66.5
-6.00
52.2
15.3
0.0
20.8
1.676
174.50
0.132
5.6
0.0037
0.0433
0.0036
0.0052
0.0030
77.271
29.12
0.9
28.7
94.2
5.59
31.561
31356
83.0
0.446
0.430
9.75
A-33
-------
TABLE A-34. SUMMARY OF PM1Q AND CONDENSIBLE PARTICULATE
TEST DATA AND RESULTS (SAMPLE POINT K)
Test Data
Test Run Number Run 1 Run 2 Run 3
Test Location No. 1 Sanitaiy Baghouse Outlet
Test Date 12-16-92
Test time period 1137-1607
Measured Data
Meter Box Y 0.992
AvgDelta H, inches H2O 0.57
Barometric Pressure, inches Hg 29.88
Meter Volume, cu.ft 108.951
Avg Meter Temp, degF 65.3
Static Pressure, inches H2O -14.10
Avg Stack Temp, degF 47.2
Water Collected, g 17.3
Carbon dioxide. % 0.0
Oxygen. % 20.8
AvgSqrtDeltaP.sqrt(inchesH2O) 1.907
Sample Time, min 248.50
Nozzle Diameter, inches 0.131
Stack Area. sq. ft 5.8
PM10
Paniculate Collected (PM cyclone), g 0.0008
Calculated Data
Standard Meter Volume, cu.ft 108.602
Stack Pressure, inches Hg 28.84
Moisture, % 0.7
Molecular Weight-wet, fc/lb-mole 28.8
Velocity, ft/s 107.1
Stack Area, sq.ft 5.76
Volumetric flow, acfm 37,021
Volumetric flow, dscfm 36358
IsokineticRate,% . 73.0
Cyclone flowrate (actual), cfm • 0.439
Cyclone flowrate (target), cfm 0.426
Panicle Diam. with 50% penetration, urn 9.79
Only one ran performed due to low paniculate loading.
A-34
-------
TABLE A-35. SUMMARY OF PM10 AND CONDENSIBLE PARTICULATE
TEST DATA AND RESULTS (SAMPLE POINT L)
Test Data
Test Run Number
Test Location
Test Date
Test time period
Measured Data
Meter Box Y
Avg Delta H, inches H2O
Barometric Pressure, inches Hg
Meter Volume, cu.ft
Avg Meter Temp, deg F
Static Pressure, inches H2O
Avg Stack Temp, deg F
Water Collected, g
Carbon dioxide, %
Oxygea %
Avg Sqrt Delta P, sqrt(inches H2O)
Sample Time, min
Nozzle Diameter, inches
Stack Area. sq. ft
PM10
Paniculate Collected (PM cyclone), g
Calculated Data
Standard Meter Volume, cu.ft
Stack Pressure, inches Hg
Moisture. %
Molecular Weight-wet, Ib/lb-mole
Velocity, ft/s
Stack Area, sq.ft
Volumetric flow, acfm
Volumetric flow, 'dscfm
Isokinetic Rate, %
Cyclone flowrate (actual), cfm
Cyclone flowrate (target), cfm
Panicle Diam. with 50% penetration, urn
Run 1
12-16-92
1142-1604
0.985
0.55
29.85
107.000
61.8
-14.10
63.4
22.2
0.0
20.8
0.676
242.50
0.181
12.4
0.0138
0.0179
0.0015
0.0011
0.0070
106.530
28.81
1.0
28.7
38.6
12.44
28,813
27,709
110.4
0.457
0.435
9.66
Run 2
No. 3 Sanitary Baghouse Inlet
12-17-92
0806-1143
0.985
0.54
29.64
81.602
59.5
-14.10
62.8
17.5
0.0
20.8
0.693
184.50
0.181
12.4
0.0003
0.0000
0.0017
0.0019
0.0009
81.023
28.60
1.0
28.7
39.7
12.44
29.632
28309
108.0
0.460
0.440
9.70
Run 3
12-17-92
1230-1550
0.985
0.55
29.64
83.702
63.3
-14.15
63.7
22.7
0.0
20.8
0.702
188.50
0.181
12.4
0.0037
0.0004
0.0032
0.0002
0.0012
82.512
28.60
1.3
28.7
40.3
12.44
30.076
28.602
106.6
0.460
0.440
9.69
A-35
-------
TABLE A-36. SUMMARY OF PM1Q AND CONDENSIBLE PARTICULATE
TEST DATA AND RESULTS (SAMPLE POINT M)
Test Data
Test Run Number Run 1 Run 2 Run 3
Test Location No. 3 Sanitary Baghouse Outlet
Test Date 12-16-92
Test time period 1141-1546
Measured Data
Meter Box Y 0.999
Avg Delta H, inches mo 0.62
Barometric Pressure, inches Hg 29.85
Meter Volume, cu.ft 86318
Avg Meter Temp, deg F 58.1
Static Pressure, inches ICO -0.19
Avg Stack Temp, deg F 65.4
Water Collected, g 17.3
Carbon dioxide, % 0.0
Oxygen, % 20.8
Avg Sqrt Delta P, sqrt(inches H2O) 0.573
Sample Time, min 218.50
Nozzle Diameter, inches 0.181
Stack Area, sq. ft. 15.3
PM10
Paniculate Collected (PM cyclone), g 0.0032
Calculated Data
Standard Meter Volume, cu.ft ' 87.736
Stack Pressure, inches Hg 29.84
Moisture, % 0.9
Molecular Weight-wet, Ib/lb-mole 28.7
Velocity, ft/s 32.2
Stack Area, sq.ft 15.32
Volumetric flow, acfm 29,588
Volumetric flow, dscfm 29,369
IsokineticRate,% 117.2
Cyclone flowrate (actual), cfm 0.405
Cyclone flowrate (target), cfm 0.440
Particle Diam. with 50% penetration, um 10.61
Only one run performed due to low paniculate loading.
A-36
-------
TABLE A-37.
SUMMARY OF PARTICULATE AND METALS (LEAD)
INPUT DATA (SAMPLE POINT B)
TEST DATA
Run number
Location
Date
Time period
INPUTS FOR CALCULATIONS
Sq. rt. delta P
Delta H
Stack temp. (deg.F)
Meter temp. (deg.F)
Sample volume (act)
Barometric press. (in.Hg)
Volume H2O imp. (ml)
Weight chnge sil. gel (g)
%C02
%02
%CO
%N2
Area of stack (sq.ft.)
Sample time (min.)
Static pressure (in.H2O)
Nozzle dia. (in.)
Meter box cal.
Cp of pilot tube
1
10-Dec-92
1110-1346
0.6802
0.99
276.9
42.4
34.983
29.85
141.7
6.5
0.0
20.8
0.0
79.2
14.75
72
-3.20
0.235
0.994
0.84
2
Blast/Reverb Furnace Baghouse Inlet
ll-Oec-92
1253-1551
0.7175
1.14
282.2
51.5
38.660
29.10
180.3
9.3
0.0
20.8
0.0
79.2
14.75
72
-3.50
0.235
0.994
0.84
3
12-Dec-92
0851-1149
0.7260
1.18
301.4
51.8
38.126
29.51
169.9
9.6
4.2
15.6
0.0
80.2
14.75
72
-2.90
0.235
0.994
0.84
PARTICULATE LABORATORY REPORT DATA, g
Total paniculate catch
11.533
10.561
12363
METALS LABORATORY REPORT DATA, ug
Antimony (Sb) 25,535
Arsenic (As) 20,460
Cadmium (Cd) 262,950
Chromium (Cr) < 58
Lead(Pb) 140.620
Manganese (Mn) < 10
Mercury (Hg) 11,130
Nickel (Ni) < 134
19.600
20.100
320,000
59
190,630
8
16,470
97
44,420
14,000
260,020
94
150,700
2
16,650
244
A-37
-------
TABLE A-38. SUMMARY OF PARTICULATE AND METALS (LEAD)
TEST DATA AND RESULTS (SAMPLE POINT B)
TEST DATA
Test run number
Test location
Test date
Test time period
SAMPLING DATA
Sampling duration, min.
Nozzle diameter, in.
Barometric pressure, in. Hg
Avg. orifice press, diff., in H2O
Avg. dry gas meter temp., deg F
Avg. abs. dry gas meter temp., deg. R
Total liquid collected by train, ml
Std. vol. of H2O vapor coll., cu.ft.
Dry gas meter calibration factor
Sample vol. at meter cond., dcf
Sample vol. at std. cond., dscf W
Percent of isokinetic sampling
GAS STREAM COMPOSITION DATA
CC>2, 96 by volume, dry basis
O2, % by volume, dry basis
CO, % by volume, dry basis
N2, % by volume, dry basis
Molecular wt. of dry gas, Ib/Ib mole
H2O vapor in gas stream, prop, by vol.
Mole fraction of dry gas
Molecular wt of wet gas, Ib/Ib mole
1
lO-Oec-92
1110-1346
72
0.235
29.85
0.99
42.39
502
148.2
6.98
0.9940
34.983
36.534
100.8
0.0
20.8
0.0
79.2
28.8
0.160
0.840
27.1
2
Blast/Reverb Furnace Baghousc Inlet
ll-Oec-92~
1253-1551
72
0.235
29.10
1.14
51.50
512
189.6
8.93
0.9940
38.660
38.676
105.7
0.0
20.8
0.0
79.2
28.8
0.187
0.813
26.8
3
12-Dee-92
0851-1149
72
0.235
29,51
1.18
51.80
512
179.5
8.45
0.9940
38.126
38.659
104.8
4.2
15.6
0.0
80.2
29.3
0.179
0.821
27.3
GAS STREAM VELOCITY AND VOLUMETRIC FLOW DATA
Cross sectional nozzle area, sq.ft.
Static pressure, in. H2O
Static pressure, in. Hg
Absolute pressure, in. Hg
Avg. temperature, deg. F
Avg. absolute temperature, deg.R
Pitot tube coefficient
Total number of traverse points
Avg. gas stream velocity. ft./sec.
Stack/duct cross sectional area, sq.ft.
Avg. gas stream volumetric flow, wacf/min.
Avg. gas stream volumetric flow, dscf/min. (1'
0.000301
-3.2
-0.235
29.61
277
737
0.84
16
46.8
14.75
41400
24700
0.000301
-3.5
-0.257
28.84
282
742
0.84
16
50.5
14.75
44700
24900
0.000301
-2.9
-0.213
29.30
301
761
0.84
16
50.9
14.75
45000
25100
PARTICULATE LABORATORY REPORT DATA
Total paniculate catch, g
PARTICULATE EMISSIONS DATA
Paniculate concentration, gr/wscf
Paniculate concentration, gr/dscf
Paniculate concentration, gr/dscf @ 15% O2
Paniculate mass emission rate, kg/hr
Paniculate mass emission rate, Ib/hr
11.533
4:091
4.872
146.149
467.1
1029.7
10.561
3.424
4.214
126.419
407.7
898.9
12.363
4.050
4.935
5.483
481.4
1061.3
A-38
-------
TABLE A-38. (Concluded)
TEST DATA
Test run number
Test location
Test date
Test lime period
METALS LABORATORY REPORT DATA, ug
Antimony (Sb)
Arsenic (As)
Cadmium (Cd)
Chromium (Cr)
Lead (Pb)
Manganese (Mo)
Mercury (Hg)
Nickel (Ni)
METALS CONCENTRATIONS. Ib/dtcf C1)
Antimony
Arsenic
Cadmium
Chromium
Lead
Manganese
Mercury
Nickel
METALS CONCENTRATIONS. Ib/dicf @ 15% O2 W
Antimony
Arsenic
Cadmium
Chromium
Lead
.Manganese
Mercury
Nickel
METALS CONCENTRATIONS, ug/m3
Antimony
Arsenic
Cadmium
Chromium
Lead
Manganese
Mercury
Nickel
METALS EMISSION RATES, Ib/br C1)
Antimony
Arsenic
Cadmium
Chromium
Lead
Manganese
Mercury
Nickel
METALS EMISSION RATES, kg/br 0)
Antimony
Arsenic
Cadmium
Chromium
Lead
Manganese
Mercury
Nickel
1
10-Dec-92
1110-1346
25535
20460
262950
< 58
140620
< 10
11130
< 134
1.S4E-06
1.23E-06
1.S9E-05
< 3.50E-09
8.49E-06
< 6.03E-10
6.72E-07
< 8.09E-O9
4.62B-05
3.70E-05
4.76E-04
< 1.05E-07
2.55E-04
< 1.81E-08
2.01E-05
< 2.43E-07
2.47E-KM
1.98E+04
2.54E+05
< 5.61E+01
1.36E405
< 9.67E+00
1.08E404
< 1.30E+02
2.28E+00
1.83E+00
2.35E401
< 5.18E-03
1.26E+01
< 8.93E-04
9.94E-01
< 1.20E-02
1.03E+00
8.29E-01
l.OGE+01
< 2.35E-03
S.69E-KK)
< 4.05E-04
4.51E-01
< 5.43E-03
2
Blast/Reverb Furnace Baghouse Inlet
UHDec-92
1253H551
19600
20100 <
320000
59
190630
8 <
16470
97 <
1.12E-06
1.15E-06 <
1.82E-05
3.36E-09
1.09E-05
4.56E-10 <
9.39E-07
5J3E-09 <
3J5E-05
3.44E-05 <
5.47E-04
1.01E-07
3.26E-04
1.37E-08 <
2.82E-05
1.66E-07 <
1.79E+04
1.84E+04 <
2.92E+05
5.39E+01
1.74E405
7.30E+00 <
1.50E+04
8.86E+01 <
1.67E+00
1.71E+00 <
2.72E+01
5.02E-03
1.62EWI
6.81E-04 <
1.40E+00
8.26E-03 <
7.57E-01
7.76&01 <
1.24E+01
2.28E-03
7.36E+00
3.09E-04 <
6.36B-01
3.74R-03 <
3
12-Oec-92
0851-1149
44420
14000
260020
94
150700
2
16650
244
2J3E-06
7.98E-07
1.48E-05
5.36E-09
8.59E-06
1.14E-10
9.49E-07
1.39E-08
2.81E-06
8.87E-07
1.65E-OS
5.96E-09
9.55E-06
1.27E-10
1.05E-06
1.55E-08
4.06E+04
1.2SE+04
2.37EW5
8-S9E+01
1.38E+OS
1.83E+00
U2E+04
2J3E402
3.81E-MO
1.20E+00
2.23E+01
8.07E-03
1^9E-H)1
1.72E-04
1.43H+00
2.09E-02
1.73E+00
5.45E-01
1.0tE+01
3.66E-03
5.87E+00
7.79E-05
6.48E-01
9.50E-03
m Standard conditions = 68 dcg. F. (20 dcg. C.) and 29.92 in Hg (760 mm Hg)
A-39
-------
TABLE A-39.
SUMMARY OF HCL AND CHLORINE INPUT DATA
(SAMPLE POINT C)
Test Data
Run number
Location
Date
Time period
Operator
Inputs For Calcs.
Sq. rt. delta P
Delta H (in H2O)
Stack temp. (deg.F)
Meter temp. (deg.F)
Sample volume (act.)
Barometric press. (in.Hg)
Volume H2O imp. (ml)
Weight chngesil. gel (g)
% CO2
%O
1 23
Blast/Reverberatory Furnaces Baghouse Outlet
Area of stack (sq.ft.)
Sample time (min.)
Static pressure (in.H2O)
Nozzle dia. (in.)
Meter box cat.
C0 of pilot tube
LABORATORY REPORT DATA
Total catch C12, mg
Total catch HC1. mg
12-08-92
1045-1310
RB
0.5774
1.93
220.3
47.8
84.650
29.81
352.20
12.70
5.60
16.60
77.80
17.1042
120.00
-7.20
0.300
1.002
0.84
49.5
495
12-08-92
1550-1808
RB
0.6086
2.16
229.6
46.3
88.023
29.81
172.80
14.20
3.60
14.40
82.00
17.1042
120.00
-7.20
0.300
1.002
0.84
0.710
930
12-09-92
952-1302
RB
0.5565
1.84
219.7
47.4
82.438
30.00
238.10
22.80
5.00
16.00
79.00
17.1042
120.00
-7.40
0.300
1.002
0.84
NA
595
A-40
-------
TABLE A-40.
SUMMARY OF HYDROGEN CHLORIDE AND CHLORINE TEST
DATA AND RESULTS (SAMPLE POINT C)
1 2 3
Blast/Reverberatory Furnaces Baghouse Outlet
12-08-92 12-08-92 12-09-92
1045-1310 1550-1808 952-1302
SAMPLING DATA
Sampfing duration, min.
Nozzle diameter, in.
Cross sectional nozzle area, sq.ft.
Barometric pressure, in. Hg
Avg. orifice press, diff., in HjO
Avg. dry gas meter temp., deg F
Avg. ate. dry gas meter temp., deg. R
Total liquid collected by train, ml
Std. vol. of H,O vapor coll., cu.ft.
Dry gas meter calibration factor
Sample vol. at meter cond., dcf
Sample vol. at std. cond., dscf(1)
Percent of isokineuc sampling
GAS STREAM COMPOSITION DATA
COj, % by volume, dry basis
O2, % by volume, dry basis
Nj. % by volume, dry basis
Molecular wt. of dry gas, Ib/lb mole
H:O vapor in gas stream, prop, by vol.
Mole fraction of dry gas
Molecular wt. of wet gas, Ib/lb mole
GAS STREAM VELOCITY AND VOLUMETRIC FLOW
Static pressure, in. H2O
Static pressure, in. Hg
Absolute pressure, in. Hg
Avg. temperature, deg. F
Avg. absolute temperature, deg.R
Pilot tube coefficient
Total number of traverse points
Avg. gas stream velocity, ft/sec.
Stack/duct cross sectional area, sq.ft.
Avg. gas stream volumetric flow, wacf/min.
Avg. gas stream volumetric flow, dscf/min.
LABORATORY REPORT DATA
Total catch Cl,. mg
Total catch HCI. mg
CHLORINE EMISSIONS
C12 concentration, ppm/v
C12 concentration, ppm/v @15% O2
Q2 concentration. ug/mj
Cl, mass rate. Ib/hr
Clj mass rate, kg/hr
Chlorine removal efficiency, %
120.0
0.300
0.000491
29.81
1.93
48
508
364.9
17.177
1.002
84.650
88.257
103.4
5.60
16.60
77.80
29.56
0.163
0.837
27.68
DATA
-7.20
-0.529
29.28
220
680
0.84
20
38.0
17.104
39000
24800
49.5
495
6.72
9.16
19304
1.84
0.834
99.04
HYDROGEN CHLORIDE EMISSIONS
HCI Gaseous concentration. ppm/V
Clj concentration, ppm/v @15% O2
HCI Gaseous concentration, ug/m3.
HCI mass rate. Ib/hr
HCI mass rate, kg/hr
1 lydrogen Chloride removal efficiency, %
"> Standard conditions = 68 deg. F. (20 deg. C.) and 29.92 inches Hg (760 mm Hg)
131
178
1.98E+05
18.4
8.34
99.89
120.0
0.300
0.000491
29.81
2.16
46
506
187.0
8.803
1.002
88.023
92.086
95.4
3.60
14.40
8100
29.15
0.087
0.913
28.18
-7.20
-0.529
29.28
230
690
0.84
20
40.0
17.104
41000
28000
0.710
930
9.24E-02
8.40E-02
2.72ti+02
2.86E-02
130E-02
47.24
235
214
3.57E+05
37.4
17.0
99.94
120.0
0.300
0.000491
30.00
1.84
47
507
260.9
12^82
1.002
82.438
86.533
100.9
5.00
16.00
79.00
29.44
0.124
0.876
28.02
-7.40
-0.544
29.46
220
680
0.84
20
36.3
17.104
37200
24900
NA
595
O.OOE+00
O.OOE+00
O.OOE+00
O.OOE+00
O.OOE+00
NA
160
192
2.43E+05
22.7
10.3
99.88
A-41
-------
TABLE A-41.
SUMMARY OF HCL AND CHLORINE INPUT DATA
(SAMPLE POINT D)
Test Data
Run number
Location
Date
Time period
Operator
Inputs For Calcs.
Sq.itdeliaP
Delta H (in H,O)
Stack temp. (deg.F)
Meter temp. (deg.F)
Sample volume (act.)
Barometric press. (in.Hg)
Volume HjO imp. (ml)
Weight chngesil. gel (g)
%C02
%02
%N2
Area of stack (sq.ft.)
Sample time (rnin.)
Static pressure (in.H.O)
Nozzle dia. (in.)
Meter box cat.
Cp of pilot tube
LABORATORY REPORT DATA
Total catch Cl,. mg
Total catch HC1. mg
1 2 3
Blasi/Reverbcratory Furnaces Scrubber Outlet
12-08-92 12-08-92 12-09-92
1045-1310 1550-1808 1052-1302
DA/KA/RB DA/KA/RB DA/KA/RB
0.3447
1.60
127.0
57.5
83.167
29.81
211.10
15.70
4.20
16.80
79.00
19.6350
120.00
-0.06
0366
0.981
0.84
0.570
0.685
0.3677
1.93
120.3
48.6
91.235
29.81
188.00
17.00
3.80
17.20
79.00
19.6350
120.00
-0.06
0.366
0.981
0.84
ND@1.0
0.800
0.3377
1.47
132.5
47.8
78.499
30.00
242.70
15.40
2.40
17.40
80.20
19.6350
120.00
-0.06
0366
0.981
0.84
0.890
0.870
A-42
-------
TABLE A-42. SUMMARY OF HCL AND CHLORINE TEST DATA
AND RESULTS (SAMPLE POINT D)
TEST DATA
Test run number
Test location
Test date
Test time period
SAMPLING DATA
Sampling duration, min.
Nozzle diameter, in.
Crass sectional nozzle area, sq.ft.
Barometric pressure, in. Hg
Avg. orifice press, diff.. in HjO
Avg. dry gas meter temp., deg F
Avg. abs. dry gas meter temp., deg. R
Total liquid collected by train, ml
Sid. vol. of Hp vapor coll., cu.fL
Dry gas meter calibration factor
Sample vol. at meter cond, dcf
Sample vol. at std. cond, dscf <*'
Percent of isokinettc sampling
GAS STREAM COMPOSITION DATA
CO2, % by volume, dry basis
O2, % by volume, dry basis
Ny % by volume, dry basis
Molecular WL of dry gas. Ib/lb mole
Rp vapor in gas stream, prop, by vol.
Mole fraction of dry gas
Molecular wt of wet gas. Ib/lb mole
1
2
3
Blast/Reverberatory Furnaces Scrubber Outlet
10-10-92
1136-1604
120.0
0.366
0.000731
29.81
1.60
58
518
226.8
10.677
0.981
83.167
83.238
96.1
4.20
16.80
79.00
29.34
0.114
0.886
28.05
10-1 Ir92
10-12-92
1239-1739 1245-1709
120.0
0366
0.000731
29.81
1.93
49
509
205.0
9.651
0.981
91.235
92.983
98.2
3.80
1720
79.00
29.30
0.094
0.906
2823
120.0
0.366
0.000731
30.00
1.47
48
508
258.1
12.150
0.981
78.499
80.557
96.3
2.40
17.40
80.20
29.08
0.131
0.869
27.63
GAS STREAM VELOCITY AND VOLUMETRIC FLOW DATA
Static pressure, in. Hp
Static pressure, in. Hg
Absolute pressure, in. Hg
Avg. temperature, deg. F
Avg. absolute temperature, degJR
Pilot tube coefficient
Total number of traverse points
Avg. gas stream velocity, fUsec.
Stack/duct cross sectional area, sq.ft.
Avg. gas stream volumetric flow.wacf/min.
Avg. gas stream volumetric flow, dscf/min.
LABORATORY REPORT DATA
Total catch Cj, mg
Total catch HO. mg
CHLORINE EMISSIONS
O2 concentration, ppm/v
dj concentration, ppm/v @15% O2
a, concentration, ug/m3
O2 mass rate. Ib/hr
Qj mass rale, kg/hr
Chlorine removal efficiency, %
HYDROGEN CHLORIDE EMISSIONS
HO Gaseous concentration, ppm/v
HO Gaseous concentration, ppm/v @15% O2
HO Gaseous concentration, ug/m3
HO mass rate. Ib/hr
HO mass rate, kg/hr
-0.06
-0.004
29.81
127
587
0.84
20
20.7
19.635
24400
19400
0.570
0.685
0.082
0.117
242
1.76E-02
7.97E-03
99.04
0.192
0.274
291
2.11E-02
9.58&03
. -0.06
-0.004
29.81
120
580
0.84
20
21.9
19.635
25800
21200
< ND@1.0
0.800
47.24
0200
0317
304
2.41E-02
1.09&02
-0.06
-0.004
30.00
132
592
0.84
20
20.5
19.635
24200
18700
0.890
0.870
0.132
0.221
390
2.74E-02
1.24E-02
NA
0.252
0.419
381
2.68E-02
1.21EO2
Hydrogen Chloride removal efficiency. %
99.89
99.94
99.88
Standard conditions = 68 deg. P. (20 deg. C.) and 29.92 inches Hg(760 mm Hg)
A-43
-------
TABLE A-43.
SUMMARY OF DIOXIN AND FURAN INPUT DATA
(SAMPLE POINT C)
TEST DATA
Run number
Location
Date
Time period
Operator
INPUTS FOR CALCULATIONS
Sq.rt. delta P
Delta H
Stack temp. (deg.F)
Meter temp. (deg.F)
Sample volume (act.)
Barometric press. (in.Hg)
Volume H2O imp. (ml)
Weight chnge sil. gel (g)
1 2 3
BLAST/REVERB FURNACES BAGHOUSE OUTLET
12-08-92 12-09-92 12-09-92
1235-1600 0948-1325 1520-1838
KH ARB ARB
%CO
%N2
Area of stack (sq.ft.)
Sample time (min.)
Static pressure (in-HjO)
Nozzle dia. (in.)
Meter box cat.
Cp of pilot tube
MEFs/89 TOXIC EQUIVALENCE FACTORS
2,3,7,8-TCDD
1,2.3.7,8-PeCDD
1,2.3.4,7,8-HxCDD
U.3.6.7,8-HxCDD
U3,7,8.9-«xCDD
1,2,3,4,6,7,8-HpCDD
Other TCDD
Other PeCDD
Other HxCDD
Other HpCDD
OCDD
1
0.5
0.1
0.1
0.1
0.01
0
0
0
0
0.001
0.588150
1.87861
229.00
50.40
129.116
30.11
282.8
32.6
5.6
16.6
0.0
77.8
17.104
180.0
-7.20
0.301
1.002
0.840
0.563250
1.82167
220.90
51.30
125.404
30.00
455.5
35.0
3.6
17.4
0.0
79.0
17.104
180.0
-7.70
0301
1.002
0.840
0.585670
1.97800
223.92
50.88
131.283
30.00
346.5
41.5
4.0
16.1
0.0
79.9
17.104
180.0
-7.50
0.301
1.002
0.840
2,3.7,8-TCDF
U.3,7.8-PeCDF
2,3.4,7,8-PeCDF
1.23,4,7,8-HxCDF
1,2.3,6.7.8-HxCDF
2.3,4,6.7,8-HxCDF
U3.7.8,9-HxCDF
U3.4.6,7.8-HpCDF
UJ.4,7.8.9-HpCDF
OlherTCDF
Other PcCDF
Other HxCDF
Other HpCDF
OODF
0.1
0.05
0.5
0.1
0.1
0.1
0.1
0.01
0.01
0
0
0
0
0.001
A-44
-------
TABLE A-43. (Concluded)
TEST DATA
Run number
Location
Date
Time period
1 2 3
BLAST/REVERB FURNACES BAGHOUSE OUTLET
12-08-92 12-09-92 12-O9-92
12354600 0948-1325 1520-1838
Diozin Laboratory Report Data, ng
23.7,8-TCDD
1,2,3,7,8-PeCDD
U,3,6,7,8-HxCDD
1.23.7,8.9-HxCDD
Total TCDD
Total PeCDD
Total HxCDD
Total HpCDD
OCDD
Total PCDD
Furan Laboratory Report Data, ng
2,3,7,8-TCDF
2,3,4,7,8-PeCDF
U3,4,7,8-HxCDF
U3,6,7.8-HxCDF
2,3,4,6,7,8-HxCDF
1,23,4,6,7,8-HpCDF
Total TCDF
Total PeCDF
Total HxCDF
OCDF
Total PCDF
0.030
0.030
0.040
0.030
0.040
0.090
0.100
0.120
0.120
0.090
0.450
0.880
1.300
0.200
0.250
0.490
0.150
0.120
0.030
0.300
0.040
8.000
2.600
0.770
0.450
0.130
11.950
0.010
0.020
0.020
0.010
0.020
0.070
0.680
0.080
0.170
0.070
0.440
1.440
1.200
0.190
0.250
0.500
0.160
0.130
0.020
0.420
0.050
6.800
2.600
1.200
0.610
0.340
11.550
0.020
0.020
0.030
0.020
0.020
0.080
1.600
0.160
0.030
0.040
0.460
2.290
0.910
0.170
0.220
0.480
0.140
0.100
0.020
0.430
0.050
4.300
2.000
0.740
0.640
0.240
7.920
A-45
-------
TABLE A-44. SUMMARY OF DIOXIN AND FURAN TEST DATA
AND RESULTS (SAMPLE POINT C)
TEST DATA
Test run number
Test location
Test date
Test time period
SAMPLING DATA
Sampling duration, min.
Nozzle diameter, in.
Cross sectional nozzle area, sq.ft.
Barometric pressure, in. Hg
Avg. orifice press, diff., in H2O
Avg. dry gas meter temp., deg F
Avg. abs. dry gas meter temp., deg. R
Total liquid collected by train, ml
Std. vol. of H2O vapor coll., cu.fL
Dry gas meter calibration factor
Sample vol. at meter cond., dcf
Sample vol. at std. cond, dscf (1)
Percent of isokinetic sampling
GAS STREAM COMPOSITION DATA
CO2. % by volume, dry basis
O2, % by volume, dry basis
CO, % by volume dry basis
N2, % by volume, dry basis
Molecular wt of dry gas, Ib/lb mole
HjO vapor in gas stream, prop, by vol.
Mole fraction of dry gas
Molecular wt of wet gas, Ib/lb mole
1
BLAST/REVERB
12-08-92
1235-1600
180.0
0.301
0.000494
30.11
1.88
50
510
315.4
14.8
1.002
129.116
135.249
97.1
5.6
16.6
0.0
77.8
29.56
0.099
0.901
28.4
2
3
FURNACES BAGHOUSE OUTLET
12-09-92
0948-1325
180.0
0.301
0.000494
30.00
1.82
51
511
490.5
23.1
1.002
125.404
130.635
102.0
3.6
17.4
0.0
79.0
29.27
0.150
0.850
27.6
12-09-92
1520-1838
180.0
0.301
. 0.000494
30.00
1.98
51
511
388.0
18.3
1.002
131.283
136.925
99.9
4.0
16.1
0.0
79.9
29.28
0.118
0.882
28.0
GAS STREAM VELOCITY AND VOLUMETRIC FLOW DATA
Static pressure, in. H2O
Static pressure, in. Hg
Absolute pressure, in. Hg
Avg. temperature, deg. F
Avg. absolute temperature, deg.R
Pilot tube coefficient
Total number of traverse points
Avg. gas stream velocity, ft/sec.
Stack/duct cross sectional area, sq.ft.
Avg. gas stream volumetric flow, wacf/min.
Avg. gas stream volumetric flow, dscf/min.
-7.20
-0.529
29.58
229
689
0.84
30
38.2
17.10
39200
26800
-7.70
-0.566
29.43
221
681
0.84
30
37.0
17.10
38000
24600
-7.50
-0351
29.45
224
684
0.84
30
38.3
17.10
39300
26400
(1) Standard conditions = 68 degrees F. (20 deg. C) and 29.92 in Hg (760 mm Hg)
A-46
-------
TABLE A-44. (Continued)
TEST DATA
Test run number
Test location
' Test date
Test time period
DIOXIN LABORATORY REPORT DATA, ng
23,7.8-TCDD
U,3,7.8-PeCDD
1,23,4,7,8-HxCDD
1,2,3,6,7,8-HxCDD
U3.7,8,9-HxCDD
U,3.4.6.7,8-HpCDD
Total TCDD
Total PeCDD
Total IfaCDD
Total HpCDD
OCDD
Total PCDD
DIOXIN CONCENTRATION, ppb/v
23,7,8-TCDD
1,2,3.7,8-PeCDD
12,3,4,7,8-HxCDD
lZ3,6,7,8-HxCDD
1,2,3,7,8,9-HxCDD
1,2,3.4,6.7.8-HpCDD
TbtalTCDD
Total PeCDD
Total HxCDD
Total HpCDD
OCDD
Total PCDD
DIOXIN CONCENTRATION, ppm/v
23,7,8-TCDD
1.2,3,7,8-PeCDD
U,3,4,7,8HtfeCDD
1,2.3,6.7,8-HxCDD
U.3.7,8,9-HxCDD
U3.4,6,7,8-^pCDD
Total TCDD
Total PeCDD
Total HxCDD
Total HpCDD
OCDD
Total PCDD
1 2 3
BLAST/REVERB FURNACES BAGHOUSE OUTLET
12-08-92 12-09-92 12-09-92
1235-1600 0948-1325 1520-1838
0.030
0.030
0.040
0.030
0.040
0.090
0.100
0.120
0.120
0.090
0.450
0.880
< 5.85B-07
< 5.29E-07
< 6.43&07
< 4.82E-07
< 6.43E-07
1.33E-06
1.95&06
2.11E-06
1.93E-06
1.33E-06
6.15E-06
1.35E-05
< 5.85E-10
< 5.29E-40
< 6.43E-10
< 4.82E-10
< 6.43E-10
1.33E-09
1.95E-09
2.11E-09
1.93E-09
133E-09
6.15E-09
135E-08
0.010
0.020
0.020
0.010
0.020
0.070
0.680
0.080
0.170
0.070
0.440
1.440
< 2.02E-07
< 3.65&07
< 333&07
< 1.66E-07
< 3.33&07
1.07E-06
137&05
1.46E-06
2.83E-06
1.07&O6
6.22&O6
2.53&05
6.67&O9
3.65E-10
333E-10
1.66E-10
333E-10
1.07E-09
137E-08
1.46E-09
2.83E-09
1.07E-09
0.020
0.020
0.030
0.020
0.020
0.080
1.600
0.160
0.030
0.040
0.460
2.290
3.85E-07
3.48E-07
4.76E07
3.17E-07
3.17B07
1.17E-06
3.08&05
2.79E06
4.76B07
5.84&07
6.21BO6
4.09&05
3.85E-10
3.48E-10
4.76E-10
3.17E-10
3.17E-10
1.17E-09
3.08E-08
2.79E-09
4.76E-10
5.84E-10
6.21E-09
4.09E-08
A-47
-------
TABLE A-44. (Continued)
TEST DATA:
Test run number
Test location
Test date
lest time period
DIOXIN CONCENTRATION, ng/dscm
23,7.8-TCDD
UJ.73-PeCDD
U,3.4,7,8-HxCDD
1.2,3,6,7,8-HxCDD
1.2.3,7.8,9-HxCDD
1,2,3.4.6.7,8-ffcCDD
Total TCDD
Total PeCDD
Total HxCDD
Total HpCDD
OCDD
Total PCDD
DIOXIN EMISSIONS, ng/dscm @ 15% O2
2,3,7,8-TCDD
U,3,7.8-PeCDD
U,3,4.7.8-HxCDD
U.3,6,7,8-HxCDD
1,2.3,7.8.9-HxCDD
UJ.4,6.73-HpCDD
Total TCDD
Total PeCDD
Total HxCDD
Total HpCDD
OCDD
Total PCDD
DIOXIN EMISSIONS, Ib/hr
2.3,7.8-TCDD
1,2.3.7.8-PeCDD
U3.4.7.8-HXCDD
1,23,6,7,8-HxCDD
U.3.7,8.9-HxCDD
U3,4,6.7.8-HpCDD
Total TCDD
Total PeCDD
Total HxCDD
Total HpCDD
OCDD
Total PCDD
1 2 3
BLAST/REVERB FURNACES BAGHOUSE OUTLET
12-08-92 12-09-92 12-09-92
1235-1600 0948-1325 1520-1838
0.0078
0.0078
0.0104
0.0078
0.0104
0.0235
0.0261
0.0313
0.0313
0.0235
0.1175
0.2297
0.0107
0.0107
0.0142
0.0107
0.0142
0.0320
0.0356
0.0427
0.0427
0.0320
0.1602
0.3133
7.86E-10
7.86E-10
1.05E-09
7.86&40
1.05E-09
236E-09
2.62E-09
3.14&09
3.14E-09
2.36E-09
1.18E-08
2.30E-08
<
<
<
<
<
0.0027
0.0054
0.0054
0.0027
0.0054
0.0189
0.1838
0.0216
0.0460
0.0189
0.1189
03892
0.0045
0.0090
0.0090
0.0045
0.0090
0.0315
03063
0.0360
0.0766
0.0315
0.1982
0.6487
2.49E-10
4.99E-10
4.99E-10
2.49E-10
4.99E-10
1.75E-09
1.70E-08
2.00E-09
4.24&09
1.75E-09
1.10E-08
0.0052
0.0052
0.0077
0.0052
0.0052
0.0206
0.4126
0.0413
0.0077
0.0103
0.1186
0.5906
0.0063
0.0063
0.0095
0.0063
0.0063
0.0253
0.5052
0.0505
0.0095
0.0126
0.1453
0.7231
5.09E-10
5.09E-10
7.64E-10
5.09E-10
5.09E-10
2.04E-09
4.08E-08
4.08E-09
7.64E-10
1.02E-09
1.17E-08
5.83E-08
A-48
-------
TABLE A-44. (Continued)
TEST DATA:
Test run number
Test location
Test date
Test time period
DIOXIN EMISSIONS, kg/hr
2,3,7,8-TCDD
1,2,3.7,8-PeCDD
U,3,4,7,8-HxCDD
U.3,6.7,8-HxCDD
1,2.3.7.8,9-HxCDD
1.23.4,6,7.8-HpCDD
Total TCDD
Total PeCDD
Total HxCDD
Total HpCDD
OOSD
Total PCDD
DIOXIN TOXIC EQUIVALENTEMISSIONS, Ib/hr W
23J.8-TCDD
1.23,7,8-PeCDD .
U,3.4.7,8-HxCDD
U3,6.7,8-HxCDD
1.23,7,8,9-HxCDD
1,23.4,6,7,8-HpCDD
Other TCDD
Other PeCDD
Other HxCDD
Other HpCDD
OCDD
Total PCDD
1 2 3
BLAST/REVERB FURNACES BAGHOUSE OUTLET
12-08-92 12-09-92 12-09-92
1235-1600 0948-1325 1520-1838
3.56E-10
3.56E-10
4.75E-10
3.56E-10
4.75E-10
1.07E-09
1.19E-09
1.43E-09
1.43E-09
1.07E-09
5J5E-09
1.05&08
1.13E-10
2.26E-10
2.26E-10
1.13E-10
2.26E-10
7.92E-10
7.69E-09
9.05E-10
1.92E-09
7.92E-10
4.98E-09
1.63E-08
< 7.86E-10
< 3.93E-10
< 1.05E-10
< 7.86E-11
< 1.05E-10
236E-41
O.OOE+00
O.OOE+00
O.OOE+00
O.OOE+00
1.18E-11
1.50E-09
<
<
<
<
<
2.49E-10
2.49E-10
4.99E-11
2.49E-11
4.99E-11
1.75E-11
O.OOE+00
O.OOE+00
O.OOE+00
O.OOE+00
1.10E-11
6.52E-10
2.31E-10
2.31E-10
3.47E-10
2.31E-10
2.31E-10
9.24E40
1.85E-08
1.85E09
3.47E-10
4.62E-10
5.31E-09
2.65E-08
5.09E40
2.55E-10
7.64E-11
5.09E-11
5.09E-U
2.04&41
O.OOE+00
O.OOE+00
O.OOE+00
O.OOE+00
1.17E-11
9.74E-10
A-49
-------
TABLE A-44. (Continued)
TEST DATA
Test run number
Test location
Test date
Test time period
FURAN LABORATORY REPORT DATA, ng
23.7.8-TCDF
U3.7.8-PeCDF
2J,4,7.8-PeCDF
1,23.4,7.8-HxCDF
1.23.6.7,8-HxCDF
23,4,6.7,8-HxCDF
1,23,7.8.9-HxCDF
1,2.3,4.6.7,8-HpCDF
1,23.4,7.8,9-HpCDF
TbtalTCDF
Total PeCDF
Total HxCDF
Total HpCDF
OCDF
Total PCDF
FURAN CONCENTRATION, ppb/v
23,7.8-TCDF
123,7,8-PeCDF
23.4,7.8-PeCDF
U3.4.7.8-HXCDF
1.23.6.7,8-HxCDF
23,4.6,7,8-HxCDF
U3.7,8,9-HxCDF
U3.4.6.7.8-HpCDF
1.23,4,73.9-HpCDF
Total TCDF
Total PeCDF
Total HxCDF
Total HpCDF
OCDF
Total PCDF
FURAN CONCENTRATION, ppm/v
23.7.8-TCDF
153,73-PeCDF
23,4,7.8-PeCDF
1.23.4,7.8-HxCDF
U3*,7,8-HxCDF
23.4,6,7.8-«xCDF
1 23
BLAST/REVERB FURNACES BAGHOUSE OUTLET
12-08-92 12-09-92 12-09-92
1235-1600 0948-1325 1520-1838
130
0.20
0.25
0.49
0.15
0.12
< 0.03
0.30
< 0.04
8.00
2.60
0.77
0.45
0.13
11.95
1.20
0.19
0.25
0.50
0.16
0.13
< 0.02
0.42
< 0.05
6.80
2.60
1.20
0.61
034
11.55
0.91
0.17
0.22
0.48
0.14
0.10
< 0.02
0.43
< 0.05
4.30
ZOO
0.74
0.64
024
7.92
Total TCDF
Total PeCDF
Total HxCDF
Total HpCDF
OCDF
Total PCDF
2.67E-05
3.69E06
4.61&O6
8.21E-06
2J1B06
2.01E-06
S.03&07
4.60&06
6.14B-07
1.64&04
4.80&05
1.29BO5
6.91E-06
1.84E-06
234&04
2.67&08
3.69E-09
4.61E-09
8.21E-09
2J1E-09
2.01E-09
5.03B-10
4.60&09
6.14B-10
1.64&07
4.80E-08
1.29E-08
6.91B09
1.84E-09
2.34&07
2J5E-05
3.63E-06
4.78&06
8.67E06
2.7SB06
U6B06
3.47B07
6.67&06
7.94E-07
1.45E-04
4.97E05
2.08E-05
9.69B06
4.98E-06
230&04
135&W
3.63E-09
4.78E-09
8.67E09
2.78E09
< 3.47E-10
6.67E-09
< 7.94E-10
1.45E-07
4.97E-08
2.08&08
9.69E-09
4.98E-09
2.30E07
1.85E05
3.10E-06
4.01&06
7.94E-06
2J2E06
1.66&06
3-31&07
6.52&06
7J8E-07
8.72&05
3.65E-05
1.22&05
9.70B06
3J6E-06
1.49&04
UJE08
3.10E-09
4.01E-09
7.94&09
2J2E09
1.66E09
3.31E-10
6.52&09
7.58E-10
8.72B08
3.65E08
1.22&08
9.70&09
3.36&09
1.49E-07
A-50
-------
TABLE A-44. (Continued)
TEST DATA:
Test run number
Test location
Test dale
Test time period
FURAN CONCENTRATIONS, ng/dscm
23.7,8-TCDF
1.2.3.7,8-PeCDF
2,3,4.7,8-PeCDF
U,3,4.7.8-HxCDF
1A3.6.73-HXCDF
2.3.4,6.7,8-HxCDF
li3,4,6,73-HpCDF
Total TCDF
Total PeCDF
Total HxCDF
Total IIpCDF
OCDF
Total PCDF
Fnran Emissions, ng/dscm @ 15% O2
2,3,7.8-TCDF
2,3,4,7,8-PeCDF
1.23.4.73-HxCDF
U.3.6,7.8-HxCDF
lA3.73,9-HxCDF
lA3A6.7,8-HpCDF
Total TCDF
Total PeCDF
Total HxCDF
Total HpCDF
OCDF
Total PCDF
FURAN EMISSIONS, Ib/hr
2J.7.8-TCDF
U,3.7,8-PeCDF
2,3,4,7,8-PeCDF
23,4,6,7^-HxCDF
1.2J,4.6.7,&«pCDF
U3,4,7,8,9-HpCDF
Total TCDF
Total PeCDF
Total HxCDF
Total HpCDF
OCDF
Total PCDF
1 2 3
BLAST/REVERB FURNACES BAGHOUSE OUTLET
12-OW2 12-OW2 12-09-92
1235-1600 094S-1325 152CH838
0.3394
0.0522
0.0653
0.1279
0.0392
0.0313
0.0078
0.0783
0.0104
2.0886
0.6788
0.2010
0.1175
0.0339
3.1199
3.40E-08
5.24609
6.55B09
U8E-08
3.93B-09
3.14EO9
7.86E-10
7.86B09
1.05E-09
2.10&07
6.81&08
2.02E-08
1.18E08
3.40&09
3.13E07
0.3244
0.0514
0.0676
0.1352
0.0432
0.0351
0.0054
0.1135
0.0135
1.8381
0.7028
0.3244
0.1649
0.0919
3.1220
0.4628
0.0712
0.0890
0.1744
0.0534
0.0427
0.0107
0.1068
0.0142
2.84S1
0.9256
0.2741
0.1602
0.0463
4.2544
0.5406
0.0856
0.1126
.0.2253
0.0721
0.0586
< 0.0090
0.1892
< 0.0225
3.0634
1.1713
0.5406
0.2748
0.1532
5.2033
2.99BO8
4.74&09
6.24E-09
1.25&08
3.99BO9
3.24&09
4.99E-10
1.05E08
1.25&09
1.70&07
6.49&08
2.99E-08
1.52E-08
8.48&09
2.88&07
0.2347
0.0438
0.0567
0.1238
0.0361
0.0258
0.0052
0.1109
0.0129
1.1089
0.5158
0.1908
0.1650
0.0619
2.0424.
0.2874
0.0537
0.0695
0.1516
0.0442
0.0316
0.0063'
0.13S8
0.0158
1.3578
0.6316
0.2337
0.2021
0.0758
2.5010
2.32&08
4.33E-09
5.60E-09
1.22&08
3.57&09
2.55E09
5.09B-10
1.10&08
1.27E-09
1.10&07
5.09E-OS
1.88E-08
1.63&08
6.-11E-09
2.02SO7
A-51
-------
TABLE A-44. (Concluded)
TEST DATA:
Test run number
Test location
Test date
Test time period
FURAN EMISSIONS, kg/hr
2,3,7,8-TCDF
1,2,3,7.8-feCDF
23.4,7.8-PeCDF
lZ3,4,7.8-HxCDF
1.2,3,6,7,8-HxCDF
23,4,6,7,8-HxCDF
1,2,3.7,8.9-HxCDF
1,2,3,4,6.7,8-HpCDF
1.2.3.4,7,8.9-HpCDF
Total TCDF
Tbtal PeCDF
Total HxCDF
Total HpCDF
OCDF
Tbtal PCDF
FURAN TOXIC EQUIVALENT EMISSIONS, Ib/hr W
2,3.7,8-TCDF
1,2,3,7.8-PeCDF
2,3,4,7,8-PeCDF
U,3.4,7,84feCDF
1,2,3,6,7,8-HxCDF
23,4.6.7.8-HxCDF
1,2,3.7.8,9-HxCDF
1.2.3,4.6,7,8-HpCDF
U,3,4,7,8.9-HpCDF
Other TCDF
Other PeCDF
Other HxCDF
Other HpCDF
OCDF
Total PCDF
TOTAL DIOXIN AND FURAN EMISSIONS
Total emission, kg/hr
Total emission. Ib/hr
1 2 3
BLAST/REVERB FURNACES BAGHOUSE OUTLET
12-08-92 12-09-92 12-09-92
1235-1600 0948-1325 1520-1838
1.54E-08
2.38E-09
2.97E-09
5.82E-09
1.78E-09
1.43E-09
3.56E-10
3.56E-09
4.75E-10
3.09E-08
9.15E-09
5.35&09
U4E-09
1.42&07
1.52E-07
336E-07
U6E-08
2.15E-09
2.83&09
5.66E-09
1.81E-09
1.47E-09
2.26E-10
4.75E-09
5.66E-10
7.69E-08
2.94E-08
1J6E-08
6.90E-09
3.85E-09
U1E-07
3.40E-09
2.62E-10
3^7E-09
1.28E-09
3.93E-10
3.14BHIO
7.86B41
7.86E-11
1.05E-11
O.OOE+00
O.OOE+00
O.OOE400
O.OOE+00
3.40E-42
9.10E-09
2.99E-09
2J7E-10
3.12E-09
1.25&09
3.99E-10
3.24E-10
< 4.99&41
1.05E-10
< 1.25EH11
O.OOE+00
O.OOE+00
O.OOE+00
O.OOE+00
8.48E-12
< 8.49E-09
TOTAL DIOXIN AND FURAN TOXIC EQUIVALENT EMISSIONS C1)
Total emission, Ib/hr 1.06E-08
1.47E-07
3.24E-07
< 9.15E-09
1.05E-08
1.96E-09
2.54E-09
5.55E-09
1.62E-09
1.16&09
2.31E-10
4.97E-09
5.78E-10
4.97E-08
2.31E-08
8.55E-09
7.39E-09
2.77E-09
9.15E-08
2.32E-09
2.16E-10
2.80E-09
1.22E-09
3.57E-10
2J5E-10
5.09E-11
l.lOE-10
1.27E-11
O.OOE+00
O.OOE+00
O.OOE+00
O.OOE+00
6.11E-12
7.35E-09
1.18E-07
2.60E-07
< 8.32E-09
(1)
Based on MEFs/89.
A-52
-------
TABLE A-45.
SUMMARY OF DIOXIN AND FURAN INPUT DATA
(SAMPLE POINT D)
TEST DATA
Run number
Location
Date
Time period
Operator
INPUTS FOR CALCULATIONS
Sq. rt. delta P
Delta H
Stack temp. (deg.F)
Meter temp. (deg.F)
Sample volume (act.)
Barometric press. (in.Hg)
Volume H2O imp. (ml)
Weight chnge sil. gel (g)
%O2
%OO
%N2
Area of stack (sq.ft.)
Sample time (min.)
Static pressure (in.H2O)
Nozzle dia. (in.)
Meter box cal.
Cp of pilot tube
I-TEFs/89 TOXIC EQUIVALENCE FACTORS
2,3,7.8-TCDD
1.23,73-PeCDD
1.2,3.4,7,8-HxCDD
U,3.6,7,8-HxCDD
1,2,3,7,8,9-HxCDD
U3,4,6,7,8-HpCDD
Other TCDD
Other PeCDD
Other HxCDD
Other HpCDD
OCDD
1
0.5
0.1
0.1
0.1
0.01
0
0
0
0
0.001
12 3
BLAST/REVERB FURNACES SCRUBBER OUTLET
12-8-92 12-9-92 12-9-92
1235-1560 0948-1325 1520-1838
ALMENDINGER ALMEND1NGER ALMENDINCER
0.354700
1.66840
124.83
58.19
129.436
29.81
282.5
21.0
3.8
17.2
0.0
79.0
19.635
180.0
-0.06
0.367
0.985
0.840
0.339600
1.46080
133.56
53.78
119.623
30.00
376.4
36.9
2.4
17.4
0.0
80.2
19.635
180.0
-0.06
0.367
0.985
0.840
0.348800
1.65420
127.08
50.97
126.583
30.00
328.9
23.7
3.6
17.2
0.0
79.2
19.635
180.0
-O.06
0.367
0.985
0.840
2,3,7.8-TCDF
UJ,7.8-PeCDF
2,3,4,7,8-PeCDF
UJ,4,7,8-«xCDF
1,2,3,6,7,8-HxCDF
2,3.4,6.7,8-HxCDF
U,3.7.8.9-HxCDF
UJ.4,6,7.8-HpCDF
UJ.4,7,8,9-HpCDF
Other TCDF
Other PeCDF
Other HxCDF
Other HpCDF
OCDF
0.1
0.05
0.5
0.1
0.1
0.1
0.1
0.01
0.01
0
0
0
0
0.001
A-53
-------
TABLE A-45. (Concluded)
TEST DATA
Run number
Location
Date
Time period
1 2 3
BLAST/REVERB FURNACES SCRUBBER OUTLET
12-S-92 12-9-92 12-9-92
1235-1560 0948-1325 1520-1838
Diozin Laboratory Report Data, og
23.7,8-TCDD
1,2,3,7,8-PeCDD
U,3,4J,8-HxCDD
U.3.6J,8-HxCDD
1.2J,7,8,9-HxCDD
Total TCDD
Total PeCDD
Total HxCDD
Total HpCDD
OCDD
Total PCDD
Furan Laboratory Report Data, ng
23,7.8-TCDF
UJ.7.8-PeCDF
2,3,4.7,8-feCDF
U.3.4,7,8-HxCDF
U,3.6.7.8-HxCDF
23,4.6,7.8-HxCDF
U.3.7,8,9-HxCDF
U,3.4,6.7,8-HpCDF
1,2.3.4,7,8,9-HpCDF
Total TCDF
Total PeCDF
Total HxCDF
Total HpCDF
OCDF
Total PCDF
< 0.020
< 0.020
< 0.030
< 0.020
< 0.030
0.030
0.950
0.070
< 0.030
0.030
0.450
1.530
0.260
0.020
0.020
0.020
0.020
0.020
0.020
0.020
0.030
2.400
0.160
0.020
0.020
0.040
2.640
< 0.030
< 0.030
< 0.050
< 0.030
< 0.040
< 0.050
2.600
0.180
0.050
< 0.050
0.410
3.290
0.720
0.070
< 0.020
< 0.030
< 0.020
< 0.030
< 0.040
< 0.030
< 0.040
6.800
0.610
0.560
< 0.030
< 0.080
8.080
< 0.040
< 0.060
< 0.080
< 0.050
< 0.070
0.140
1.200
0.220
< 0.060
0.230
0.780
2.490
0.500
< 0.040
< 0.030
< 0.050
< 0.040
< 0.040
< 0.060
< 0.040
< 0.080
5.000
0.320
< 0.050
< 0.060
< 0.100
5.530
A-54
-------
TABLE A-46. SUMMARY OF DIOXIN AND FURAN TEST DATA
AND RESULTS (SAMPLE POINT D)
TEST DATA
Test run number
Test location
Test date
Test time period
SAMPLING DATA
Sampling duration, min.
Nozzle diameter, in.
Cross sectional nozzle area, sq.ft.
Barometric pressure, in. Hg
Avg. orifice press, diff., in H2O
Avg. dry gas meter temp., deg F
Avg. abs. dry gas meter temp., deg. R
Total liquid collected by train, ml
Std. vol. of H2O vapor coll., cu.ft
Dry gas meter calibration factor
Sample vol. at meter cond.. dcf
Sample vol. at std. cond. dscf (1)
Percent of isokinetic sampling
GAS STREAM COMPOSITION DATA
OO2, % by volume, dry basis
C^, % by volume, dry basis
CO. % by volume dry basis
N2, % by volume, dry basis
Molecular wt. of dry gas, Ib/Ib mole
H2O vapor in gas stream, prop, by vol.
Mole fraction of dry gas
Molecular wt of wet gas. Ib/Ib mole
1 2 3
BLAST/REVERB FURNACES SCRUBBER OUTLET
12-8-92 12-9-92 12-9-92
1235-1560 0948-1325 1520-1838
180.0
0367
0.000735
29.81
1.67
58
518
303.5
14.3
0.985
129.436
129.951
95.2
3.8
17.2
0.0
79.0
29.30
0.099
0.901
28.2
GAS STREAM VELOCITY AND VOLUMETRIC FLOW DATA
: pressure, in. Hg) -0.06
Static pressure, in. Hg -0.004
Absolute pressure, in. Hg 29.81
Avg. temperature, deg. F 125
Avg. absolute temperature, deg.R 585
Pilot tube coefficient 0.84
Total number of traverse points 30
Avg. gas stream velocity, fu/sec. 21.3
Stack/duct cross sectional area, sq.ft. 19.63
Avg. gas stream volumetric flow, wacf/min. 25000
Avg. gas stream volumetric flow, dscf/min. 20300
180.0
0.367
0.000735
30.00
1.46
54
514
413.3
19.5
0.985
119.623
121.837
96.7
2.4
17.4
0.0
80.2
29.08
0.138
0.862
27.6
-0.06
-0.004
30.00
134
594
0.84
30
20.7
19.63
24300
18700
180.0
0.367
0.000735
30.00
1.65
51
511
352.6
16.6
0.985
126.583
129.696
97.7
3.6
17.2
0.0
79.2
29.26
0.113
0.887
28.0
-0.06
-0.004
30.00
127
587
0.84
30
20.9
19.63
24700
19700
(1) Standard conditions = 68 degrees F. (20 deg. C.) and 29.92 in Hg (760 mm Hg)
A-55
-------
TABLE A-46. (Continued)
TEST DATA
Test run number
Test location
Test date
Test time period
DIOXJN LABORATORY REPORT DATA, ng
2.3,7,8-TCDD
UJ.7,8-PeCDD
1.2,3,4.7,8-HxCDD
U3.6,7,8-HxCDD
U,3,7.8,9-HxCDD
U.3.4,6,7.8-HpCDD
Total TCDD
Total PeCDD
Total HxCDD
Total HpCDD
OCDD
Total PCDD
DIOXIN CONCENTRATION, ppb/v
23,7,8-TCDD
U3.7,8-PeCDD
lZ3,4.7,8-«xCDD
UJ,6,7,8-HxCDD
U3,7,8,9-HxCDD
1,2,3.4.6.7,8-HpCDD
Total TCDD
Total PeCDD
Total HxCDD
Total HpCDD
OCDD
Total PCDD
DIOXIN CONCENTRATION, ppm/v
2,3,7,8-TCDD
UJ,7,8-PeCDD
UJ,4.7,8-HxCDD
1.23,6.7.8-HxCDD
U,3,7.8.9-HxCDD
U.3.4.6.7.8-HpCDD
Total TCDD
Total PeCDD
Total HxCDD
Total HpCDD
OCDD
Total PCDD
1 2 3
BLAST/REVERB FURNACES SCRUBBER OUTLET
12-8-92 12-9-92 12-9-92
1235-1560 0948-1325 1520-1838
0.020
0.020
0.030
0.020
0.030
0.030
0!950
0.070
0.030
0.030
0.450
1.530
4.06E-07
3.67E-07
5.02EO7
3.35E-07
5.02E-07
4.61E-07
1.93E-05
1.28E-06
5.02E-07
4.61E-07
6.40E-06
2.79E-05
4.06E-10
3.67E-10
5.02E-10
3.35E40
5.02E-10
4.61E-10
1.93E-08
1.28E-09
5.02E-10
6.40E-09
2.79E-08
0.030
0.030
0.050
0.030
0.040
0.050
2.600
0.180
0.050
0.050
0.410
3.290
6.50E-07
5.87E-07
8.92E-0?
5.35E07
7.14E-07
8.20&07
5.63E-05
3.52&06
8.92E-07
8.20E-07
6.22E-06
6.78E-05
6.67E-09
5.87E-10
8.92E-10
5.35E-10
7.14E-10
8.20E-10
5.63E-08
3.52E-09
8.92E-10
8.20E-10
6.22E-09
6.78E-08
0.040
0.060
0.080
0.050
0.070
0.140
1.200
0.220
0.060
0.230
0.780
2.490
8.14E-07
1.10B-06
1.34E-06
838E-07
1.17E-06
2.16B06
2.44E-05
4.04EO6
1.01E-06
1.11E-05
4.41E-05
8.14E-10
1.10E-09
134&09
8.38E-10
1.17E-09
2.16&09
2.44&08
4.04E-09
1.01E-09
3.54E-09
1.11E-08
4.41E-08
A-56
-------
TABLE A-46. (Continued)
TEST DATA:
Test nin number
Test location
Test date
Test time period
DIOXIN CONCENTRATION, ng/dscm
2,3,7.8-TCDD
U3,7.8-PeCDD
U.3,4J.8-HxCDD
U,3.6,7.8-«xCDD
lZ3.7,8.9-HxCDD
U3,4,6.7.8-HpCDD
TolalTCDD
Total PeCDD
Total HxCDD
Total HpCDD
OCDD
Total PCDD
DIOXIN EMISSIONS, ng/dscm @ 15% O2
23.7,8-TCDD .
lZ3.7.8-PeCDp
U,3,4.7.8-HxCbD
1,2,3,6,7,8-HxCDD
U.3,7,8.9-HxCDD
1,2,3.4.6.7,8-HpCDD
Total TCDD
"Baal PeCDD
Total HxCDD
Total HpCDD
OCDD
Total PCDD
DIOXIN EMISSIONS, Ib/hr
2.3.7,8-TCDD
UJJ,8-PeCDD
U,3,4.7.8-HxCDD
U3,6.7.8-HxCDD
U.3,7.8.9-«xCDD
U.3.4,6.7.8-HpCDD
Total TCDD
Total PeCDD
Total HxCDD
Total HpCDD
OCDD .
Total PCDD
0.0054
0.0054
0.0082
0.0054
0.0082
0.0082
0.2581
0.0190
0.0082
0.0082
0.1223
0.4157
< 0.0087
< 0.0087
< 0.0145
< 0.0087
< 0.0116
< 0.0145
0.7535
0.0522
0.0145
< 0.0145
0.1188
0.9535
1 2 3
BLAST/REVERB FURNACES SCRUBBER OUTLET
12-W2 12-9-92 12-9-92
1235-1560 0948-1325 1520-1838
0.0109
0.0163
0.0218
0.0136
0.0191
0.0381
0.3267
0.0599
0.0163
0.0626
0.2124
0.6779
< 0.0172
< 0.0258
< 0.0344
< 0.0215
< 0.0301
0.0602
0.5159
0.0946
< 0.0129 0.0242 < 0.0258
0.0989
0.3353
1.0704
4.13E-10 < 6.10E-10 < 8.04E-10
4.13E-10 < 6.10E-10 < 1.21E-09
6.19E-10 < 1.02E-09 < 1.61E-09
4.13E40 < 6.10E-10 < 1.01E-09
6.19E-10 < 8.13E-10 < 1.41E-09
6.19E-10 < 1.02E-09 2.82E-09
1.96E-08 5.28E-08 2.41E-08
1.45E-09 3.66E-09 4.42E-09
6.19E-10 1.02E-09 < 1.21E-09
6.19E-40 < 1.02E-09 4.63&09
9.29E-09 8.33E-09 1.57E-08
3.16E-08 6.68E-08 5.01E-08
0.0086
0.0086
0.0129
0.0086
0.0129
0.0129
0.4076
0.0300
0.0129
0.0129
0.1931
0.6564
< 0.0145
< 0.0145
< 0.0242
< 0.0145
< 0.0193
< 0.0242
1.2559
0.0869
0.0242
< 0.0242
0.1980
1.5892
A-57
-------
TABLE A-46. (Continued)
TEST DATA:
Test run number
Test location
Test date
Test time period
DIOXIN EMISSIONS, kg/far
2.3.7,8-TCDD
1,23,7.8-PeCDD
1,23.4.7.8-HxCDD
U3,6,7,8-HxCDD
U3.7.8,9-HxCDD
1.23,4.6,7.8-HpCDD
Total TCDD
Total PeCDD
Total HxCDD
Total HpCDD
OCDD
Total PCDD
DIOXIN TOXIC EQUTVAUENT EMISSIONS, Ib/hr C1)
23.7,8-TCDD
1,23.7,8-PeCDD
U3,4J.8-HxCDD
1.23.6.7,8-HxCDD
1,23,73,9-HxCDD
Other TCDD
Other PeCDD
Other HxCDD
Other HpCDD
OCDD
Total PCDD
1 2-3
BLAST/REVERB FURNACES SCRUBBER OUTLET
12-S-92 12-9-92 12-9-92
123M560 0948-1325 1520-1838
1.87E-10
1.87E-10
2.81E-10
1.87E-10
2.81E-10
2.81E-10
8.90E-09
6.56E-10
2.81E-10
2.81E-40
4.21E-09
1.43E-08
2.76E-10
2.76E-10
4.61E-10
2.76E-10
3.69E-10
4.61E-10
2.40E-08
1.66E-09
4.61E-10
4.61E-10
3.78E-09
3.03E-08
4.13E-10
2.06E-10
6.19E-11
4.13E-11
6.19E-11
6.19E-12
O.OOE+00
O.OOE+00
O.OOE+00
O.OOE+00
9.29E-12
8.00E-10
< 6.10E-10
< 3.05E-10
< 1.02E-10
< 6.10E-11
< 8.13E-11
< 1.02E-11
.O.OOE+00
O.OOE+00
O.OOE+00
< O.OOE+00
8.33E-12
1.18E-09
3.65E-10
5.47E-10
7.30E-10
4.56E-10
6.39&40
1.28&09
1.09&08
2.01E-09
5.47E-10
2.10E-09
7.11E-09
8.04E-10
6.03E-10
1.61E-10
1.01E-10
1.41E-10
2.82E-11
O.OOE+00
O.OOE+00
O.OOE+00
O.OOE+00
1.57E-11
1.85E-09
A-58
-------
TABLE A-46. (Continued)
TEST DATA
Test ran number
Test location
Test dale
Test time period
FURAN LABORATORY REPORT DATA, ng
2J.7.8-TCDF
UJ,7,8-PeCDF
23.4,7,8-PeCDF
li3.4,73-HxCDF
lZ3,6,7,8-HxCDF
2.3,4,6.7.8-HxCDF
U3,7,8,9-HxCDF
1,2,3.4.6,7,8-HpCDF
12.3.4,7,8,9-HpCDF
Total TCDF
TbtalPeCDF
Total HxCDF
Total HpCDF
OODF
Total PCDF
FURAN CONCENTRATION, ppb/v
W.73-TCDF
lZ3.73H?eCDF
2.3,4,7,8-PeCDF
U,3.4.7.8-HxCDF
1A3.6.73-HXCDF
23.4,6.7,8-HxCDF
U.3.7.8,9-HxCDF
1,2.3.4,6,7,8-HpCDF
1,2,3,4.7,8,9-HpCDF
TbtalTCDF .
Total PeCDF
Total HxCDF
Total HpCDF
OCDF
Total PCDF
FURAN CONCENTRATION, ppm/v
23.7,8-TCDF
U.3.7,8-PeCnF
23.4,73HPeCDF
li3,4,7,8-HxCDF
UJ.6,73-HxCDF
2,3.4,6.7.8-HicCDF
1,2.3,7,8.9-HxCDF
1,2,3.4.6,7,8-HpCDF
U.3.4.7,8.941pCDF
Total TCDF
Total PeCDF
Total IhCDF
Tbtal HpCDF
OCDF
Total PCDF
1 2 3
BLAST/REVERB FURNACES SCRUBBER OUTLET
12-8-92 12-9-92 12-M2
12354560 0948-1325 1520-1838
0.26
0.02
0.02
0.02
0.02
0.02
0.02
0.02
0.03
2.40
0.16
0.02
0.02
0.04
2.64
5.56E-06
3.84E-07
3.84E07
3.49E07
3.49&07
3.49B07
3.49B07
3.19&07
4.79&07
5.13E05
3.07E-06
3.49EO7
3.19&07
5.89E-07
5.56&09
3.84EHO
3.84E-10
3.49B40
3.49E40
3.49E-10
3.49B-10
3.19E-10
4.79E-10
5.13E08
3.07E09
3.49E-10
3.19E40
5.89E-10
5.56E08
0.72
0.07
0.02
0.03
0.02
003
0.04
0.03
0.04
6.80
0.61
0.56
0.03
0.08
8.08
1.64E05
1.43E06
4.10E07
5.58B07
3.72B07
5J8E07
7.44E07
5.11B07
6.81&07
1.55E04
1.2SB05
1.04E05
5.11E07
126B06
1.80B04
1.64&08
1.43E09
4.10640
SJ8E40
3.72E40
5.58E40
7.44B40
5.11E40
0.50
0.04
0.03
0.05
0.04
0.04
0.06
0.04
0.08
5.00
032
0.05
0.06
0.10
5.53
1.07&05
7.70E07
5.77E-07
8.74E-07
6.99E-07
6.99E-07
1.05E-06
6.40&O7
1.55B07
1.25E08
1.04&08
5.11E-10
1.26D09
1.80&07
1.07&04
6.16E-06
8.74E-07
9.60E-07
1.48E-06
1.17&04
1.07&08
7.70E-10
5.77E-10
8.74E40
6.99E40
6.99E-10
1.05&09
6.40E40
1.28&09
1.07E-07
6.16EO9
8.74E-10
9.60E-10
1.48&09
1.17&07
A-59
-------
TABLE A-46. (Continued)
TEST DATA:
Test run number
Test location
Test date
Test time period
FURAN CONCENTRATIONS, ng/dscm
23.7.8-TCDF
U3,7,8-PeCDF
23.4.73-PeCDF
U3,4,7,8-HxCDF
U3,6,7,8-HxCDF
23.4.6,7.8-HxCDF
1,23.7,8,9-HxCDF
133.4,6.7,8-HpCDF
U3.4.7,8,9-HpCDF
TbtalTCDF
Tblal PeCDF
Total HxCDF
Tola! HpCDF
OCDF
Total PCDF
Fnran Emissions, ng/dscm @ 15% 02
23,7.8-TCDF
U3.7.8-PeCDF
2,3,4,7,&-PcCDF
U3,4.7,8-HxCDF
1.23.6.7,8"«xCDF
23.4.6,7.8-HxCDF
1.23.7,8.9-HxCDF
1.23.4.6J.8-HPCDF
U3.4.7,8.9-HpCDF
Total TCDF
Total PeCDF
Total HxCDF
Total HpCDF
OCDF
Total PCDF
FURAN EMISSIONS, Ib/hr
23.7.8-TCDF
1.23.7,8-PeCDF
23.4.7.8-PeCDF
1,23,4,7,8-HxCDF
1,23.6,7,8-HxCDF
23,4.6,7,8-HxCDF
1.23.7,8.9-HxCDF
1.23,4,6,7,8-HpCDF
U3.4.7.8.9-HpCDF
Total TCDF
Total PeCDF
Total HxCDF
Total HpCDF
OCDF
Total PCDF
1 2 3
BLAST/REVERB FURNACES SCRUBBER OUTLET
12-8-92 12-9-92 12-9-92
1235-1560 0948-1325 1520-1838
0.0706
0.0054
0.0054
0.0054
0.0054
0.0054
0.0054
0.0054
0.0082
0.6521
0.0435
0.0054
0.0054
0.0109
0.7174
0.1115
0.0086
0.0086
0.0086
0.0086
0.0086
0.0086
0.0086
0.0129
1.0297
0.0686
0.0086
0.0086
0.0172
1.1327
537E09
4.13E-10
4.13E-10
4.13E-10
4.13E-10
4.13E-10
4.13E-10
4.13B-10
6.19E-10
4.95E08
3.30E09
4.13FMO
4.13E-10
8.26E-10
5.45&08
0.2087
0.0203
0.0058
0.0087
0.0058
0.0087
0.0116
0.0087
0.0116
1.9708
0.1768
0.1623
0.0087
0.0232
23417
03478
0.0338
0.0097
0.0145
0.0097
0.0145
0.0193
0.0145
0.0193
3.2846
0.2947
0.2705
0.0145
0.0386
3.9029
1.46E-08
1.42E-09
4.06E-10
6.10E-10
4.06EHO
6.10E-10
8.13E-10
6.10E-10
8.13E-10
1.38E07
1.24&08
1.14&Q8
6.10E40
1.63E09
1.64&07
0.1361
0.0109
0.0082
0.0136
0.0109
0.0109
0.0163
0.0109
0.0218
1.3613
0.0871
0.0136
0.0163
0.0272
IJ056
0.2149
0.0172
0.0129
0.0215
0.0172
0.0172
0.0258
0.0172
0.0344
2.1494
0.1376
0.0215
0.0258
0.0430
23772
1.01E08
8.04E-10
6.03E40
1.01E09
8.04E-10
8.04E-10
1.21&09
8.04R-10
1.61DO9
• 1.01E-07
6.44G-09
1.01E-09
1.21B09
2.01&09
1.11E-07
A-60
-------
TABLE.A-46. (Concluded)
TEST DATA:
Test run number
Test location
Test date
Test time period
FURAN EMISSIONS, kg/hr
2,3,7,8-TCDF
U,3.7,8-PeCDF
2,3,4,7,8-PeCDF
1,2,3,4,7.8-HtCDF
1,2,3,6,7,8-HxCDF
23,4,6,7.8-HxCDF
1,2,3,7,8,9-HxCDF
U,3,4,6,7,8-HpCDF
1,2,3,4,7,8,9-HpCDF
Total TCDF
Total PeCDF
Total HxCDF
OCDF
Total PCDF
FURAN TOXIC EQUIVALENT EMISSIONS, Ib/hr (l)
1 2 3
BLAST/REVERB FURNACES SCRUBBER OUTLET
12-8-92 12-9-92 12r9-92
1235-1560 0948-1325 1520-1838
2.43E-09
1.87E-10
1.87E-10
1.87E-10
1.87E-10
1.87E-10
1.87E-10
1.87E-10
2.81E-10
2.25E-08
1.50E-09
1.87E-10
1.87E-10
3.75E-10
2.47E-08
6.64E-09
6.45E-10
1.84E-10
2.76E-10
1.84E-10
2.76E-10
3.69E-10
2.76E-10
3.69E-10
6.27E-08
5.62E-09
5.16E09
2.76E-10
7.37E-10
7.45E-08
4.56E-09
3.65E-10
2.74E-10
4.56E-10
3.65E-10
3.65E-10
5.47E40
3.65E-10
7.30E-10
4.56&08
2.92E-09
4.56E-10
5.47E-10
9.12E-10
5.04E-08
2,3,7,8-TCDF
23.4,7,8HPeCDF
U,3,4,7,8-H)tCDF
1.2.3,6,7,8-HjcCDF
23.4,6,73-HxCDF
1,2.3,7,8,9-HxCDF
U,3,4.6.7.&-HpCDF
1,2,3,4,7.8.9-HpCDF
Other TCDF
Other PeCDF
Other HxCDF
Other HpCDF
OCDF
Total PCDF
TOTAL DIOXIN AND FURAN EMISSIONS
Total emission, kg/hr
Total emission, Ib/hr
5.37E-10
2.06E-11
2.06E-10
4.13E-11
4.13E-11
4.13E-11
4.13E-11
4.13E-12
6.19E-12
O.OOE+00
O.OOE+00
O.OOE+00
O.OOE+00
8.26E-13
9.40E-10
3.91BO8
8.61E-08
TOTAL DIOXIN AND FURAN TOXIC EQUIVALENT EMISSIONS (*>
Total emission, Ib/hr 1.74E-09
1.46E-09
7.11E-11
2.03E-10
6.10E-11
4.06E-11
6.10E-11
8.13E-11
6.10E-12
8.13E-12
O.OOE+00
O.OOE+00
O.OOE+00
O.OOE+00
1.63E-12
2.00E-09
1.05&07
231&07
< 3.17E-09
1.01E-09
4.02E-11
3.02E-10
1.01E-10
8.04E-11
8.04E-11
1.21E-40
8.04E-12
1.61E-11
O.OOE+00
O.OOE+00
O.OOE+00
O.OOE+00
2.01E-12
1.76E-09
7.32E-08
1.61E-07
< 3.61E-09
Based on MEFs/89.
A-61
-------
TABLE A-47.
SUMMARY OF ALDEHYDES/KETONES INPUT DATA
(SAMPLE POINT A)
TEST DATA
Run number
Location
Date
Time period
Operator
INPUTS FOR CALCULATIONS
Sq.rt. delta P
Delta H
Stack temp. (deg.F)
Meter temp. (deg.F)
Sample volume (act)
Barometric press. (in.Hg)
Volume Hp imp. (ml)
Weight chnge sil. gel (g)
%O2
%CO
%N2
Area of stack (sq.ft.)
Sample time (tnin.)
Static pressure (in.HjO)
Nozzle dia. (in.)
Meter box cal. • .
Cp of pilot tube
LABORATORY REPORT DATA, ug.
Formaldehyde
Acetaldehyde
Acrolein
Acetone O
Propanal
Crotonaldehyde
n-Butyraldehyde
Methyl Ethyl Ketone
Benzaldehyde
Isovaleradehyde
Valeraldchyde
O-Tolualdchyde
m/p-Tolualdehyde
Hexaldehyde
2.5-ttemethyl Benzaldehyde
1 2 3
BLAST FURNACE OUTLET
1M-92 12-9-92 12-3-92
1030-1456 0928-1157 1435-1738
AM AM AM
0.2827 0.2419 0.2582
0.75 0.53 0.60
257.2 253.0 249.7
65.6 61.5 55.4
53.198 32.016 34.511
29.50 30.06 30.06
71.3 37.1 38.8
14.5 22.7 13.2
9.8 8.8 5.2
12.6 13.0 15.8
0.0 0.0 0.0
77.6 78.2 79.0
4.909 4.909 4.909
60.0 42.0 42.0
-0.10 -0.80 -0.80
0.329 0329 0.329
1.003 1.003 1.003
0.84 0.84 0.84
2981.3 3113.6 4139.2
24527.9 9759.8 12221.8
9580.9 4774.2 3398.5
15539.9 5048.6 11887.9
4612.4 2031.0 2275.6
1724.3 1287.0 1083.1
11171.9 4130.1 5624.6
12330.7 3317.4 2837.0
12025.3 10870.3 7027.3
2749.6 • 165.4 297.1
6424.4 2051.9 1800.6
3995.6 2618.2 224.7
1041.6 2019.8 487.1
2601.9 934.3 975.1
332.7 322.5 411.1
('' Acetone contamination was found in each impinger of each run including the train blank. It was determined that
the acetone was not native to the samples and the reported value represents the analytical detection limit.
A-62
-------
TABLE A-48. SUMMARY OF ALDEHYDES/KETONES TEST DATA
AND RESULTS (SAMPLE POINT A)
TEST DATA
Test run number
Test location
Test date
Test time period
SAMPLING DATA
Sampling duration, min.
Nozzle diameter, in.
Cross sectional nozzle area, sq.ft.
Barometric pressure, in. Hg
Avg. orifice press, diff.. in H2O
Avg. dry gas meter temp., deg F
Avg. abs. dry gas meter temp., deg. R
Total liquid collected by train, ml
Std. vol. of Hp vapor coll., cu.ft.
Dry gas meter calibration factor
Sample vol. at meter cond., dcf
Sample vol. at std. cond. dscf (I)
fercem of isokinetic sampling
STACK GAS STREAM COMPOSITION DATA
CO2, % by volume, dry basis
O2, % by volume, dry basts
CO. % by volume, dry basis
N2, % by volume, dry basis
Molecular wL of dry gas, Ib/lb mole
HjO vapor in gas stream, prop, by vol.
Mole fraction of dry gas
Molecular WL of wet gas, Ib/lb mole
1
12-8-92
1030-1456
60.0
0.329
0.000590
29.50
0.75
66
526
85.8
4.0
1.003
53.198
52.926
199.5
9.8
12.6
0.0
77.6
30.1
0.071
0.929
29.2
2
BLAST FURNACE OUTLET
12-9-92
0928-1157
42.0
0.329
0.000590
30.06
0.53
62
522
59.8
2.8
1.003
32.016
32.694
204.5
8.8
13.0
0.0
78.2
29.9
0.079
0.921
29.0
GAS STREAM VELOCITY AND VOLUMETRIC FLOW DATA
Static pressure, in. Hf>
Static pressure, in. Hg
Absolute pressure, in. Hg
Avg, temperature, deg. F
Avg, absolute temperature, ileg.R
Pilot tube coefficient
Total number of traverse points
Avg. gas stream velocity, fUsec.
Slack/duct cross sectional area, sq.ft.
Avg. gas stream volumetric flow, wacf/min.
Avg, gas stream volumetric flow, dscf/min. (1'
LABORATORY REPORT DATA, ug.
Formaldehyde
Acetaldehyde
Acrolein
Acetone^
Propanal
Crotonaldehyde
n-Butyraldehyde
Methyl Ethyl Ketonc
Benzaldehyde
Isovalcradehyde
Valeraldehyde
O-Tolualdehyde
m/p-Tolualdchydc
Hexaldehyde
2,5-Demahyl Benzaldehyde
-0.10
-0.007
29.49
257
717
0.84
12
18.5
4.91
5500
3700
2981.3
24527.9
9580.9
15539.9
4612.4
17243
11171.9
12330.7
12025.3
2749.6
6424.4
3995.6
1041.6
2601.9
332.7
-0.80
-0.059
30.00
253
713
0.84
12
15.7
4.91
4600
3200
3113.6
9759.8
4774.2
5048.6
2031.0
1287.0
4130.1
3317.4
10870.3
165.4
2051.9
2618.2
2019.8
934.3
322.5
3
12-9-92
1435-1738
42.0
0.329
0.000590
30.06
0.60
55
515
52.0
2.4
1.003
34.511
35.667
204.3
5.2
• CD
15.8
n ft
0.0
79.0
29.5
0.064
0.936
28.7
-0.80
-0.059
30.00
250
710
0.84
12
16.8
A fll
4.91
5000
3500
4139.2
12221.8
3398J
11887.9
2275.6
1083.1
5624.6
2837.0
7027.3
297.1
1800.6
224.7
487.1
975.1
411.1
(') Standard conditions = 68 deg. F. (20 deg. C) and 29.92 in Hg (760 mrnHg)
<2> Acetone contamination was found in each impinocr of each run including the train blank. It was determined that
the acetone was not native to the samples and the reported value represents the analytical detection limit.
A-63
-------
TABLE A-48. (Continued)
TEST DATA
Test run number
Test location
Test date
Test time period
ALDEHYDES/KEYTONES CONCENTRATIONS,
Formaldehyde
Acetaldehyde
Acrolein
Acetone
Propanal
Crotonaldehyde
n-Butyraldehyde
Methyl Ethyl Ketone
Benzaldehyde
Isovaleradehyde
Valeraldehyde
OTolualdehyde
m/p-Tolualdehyde
Hexaldehyde
2>Oemethyl Benzaldehyde
ALDEHYDES/KEyrONES CONCENTRATIONS,
Formaldehyde
Acetaldehyde
Acrolein
Acetone
Propanal
Crotonaldehyde
n-Butyraldehyde
Methyl Ethyl Ketone
Benzaldehyde
Isovaleradehyde
Valeraldehyde
OTolualdehyde
m/p-Tolualdehyde
Hexaldehyde
2,5-Demethyl Benzaldehyde
ALDEHYDES/KEYTONES CONCENTRATIONS,
Formaldehyde
Acetaldehyde
Acrolein
Acetone •
Propanal
Crotonaldehyde
n-Butyraldehyde
Methyl Ethyl Ketone
Benzaldehyde
Isovaleradehyde
Valeraldehyde
O-Tolualdehyde
m/p-Tolualdehyde
Hexaldehyde
2,5-Demethyl Benzaldehyde
1
12-S-92
103CH456
ug/dscm
1,989
16364
6392
10368
3,077
1,150
7,454
8,227
8.023
1,834
4286
2.666
695
1,736
222
Ib/dscf
1.24E07
1.02E-06
3.99E-07
6.47E-07
1.92E-07
7.18E-08
4.65E-07
5.14&07
5.01E-07
1.15E-07
2.68E-07
1.66E-07
4.34E-08
1.08E-07
139E-08
Ib/dscf @15% 02
8.87E-08
730E-07
2.85&07
4.62&07
137&07
5.13E-08
332E-07
3.67&07
3.58&07
8.18E-08
1.91E-07
1.19&O7
3.10&08
7.74E-08
9.90&09
2
BIASTFURNACEOUTLET
12-9-92
0928-1157
3363
10.541
5,156
5.453
2,194
1390
4,461
3,583
11.740
179
2316
2,828
2,181
1.009
348
2.10&07
6.58B07
3.22E-07
3.40E-07
137&07
8.68E-08
2.78E-07
2.24E-07
733E-07
1.12E-08
138EK17
1.77E-07
136E-07
630E-08
2.17&08
1.57&07
4.94&07
2.4\&n
2.55E-07
1.03E-07
6.51E-08
2.09E-07
1.68E-07
5.50EK17
836&09
1.04E-07
132E-07
1.02EK)7
4.73E^)8
1.63&08
3
12-9-92
1435-1738
4.098
12.100
3365
11.769
2353
1.072
5,568
2309
6,957
294
1.783
222
482
965
407
2.56E-07
7.55E-07
2.10E-07
735E-07
1.41E-07
6.69E-08
3.48E-07
1.75&07
434E-07
1.84E-08
1.11&07
139E^)8
3.01E-08
6.03E-08
2J4E-08
2.95E-07
8.72EO7
2.42E-07
8.48B07
1.62E07
7.72E-08
4.01E-07
2.02E-07
5.01E-07
2.12E-08
1.28E-07
1.60E-08
3.47E-08
6.95E-08
2.93E-08
A-64
-------
TABLE A-48. (Concluded)
TEST DATA '
Test run number
Test location
Test date
1
12-S-92
Test time period 1030-1456
ALDEHYDES/KEYTONES MASS EMISSION RATES, kg/hr
Formaldehyde . 1.24E-02
Acetaldehyde
Acrolein
Acetone
Propanal
Crotonaldehyde
n-Butyraldehyde
Methyl Ethyl Ketone
Benzaldehyde
Isovaleradehyde
Valeraldehyde
O-Tolualdehyde
m/p-Tolualdehyde
Hexaldehyde
2,5-Demethyl Benzaldehyde
AIDEHYDES/KEyrONES MASS EMISSION RATES, Ib/hr
Formaldehyde
Acetaldehyde
Acrolein
Acetone
Propanal
Crotonaldehyde
n-Butyraldehyde
Methyl Ethyl Ketone
Benzaldehyde
Isovaleradehyde
Valeraldehyde
O-ToIualdehyde
m/p-Tolualdehyde
Hexaldehyde
2,5-Demethyl Benzaldehyde
1.02E-01
3.99&02
6.48E-02
1.92E-02
7.19E-03
4.66E-02
5.14E-02
5.01E-02
1.15E-02
2.68E-02
1.67E-02
4.34E-03
1.08E-02
1.39E-03
2.74E-02
2.25E-01
8.80E-02
1.43E-01
4.24E-02
1J8E-02
1.03E-01
1.13E-01
1.10E-01
2.53E-02
5.90E-02
3.67E-02
9.57E-03
2.39E-02
3.06E-03
2
BLASTFURNACE OUnET
12-9-92
0928-1157
1.81E-02
5.67E-02
2.77E-02
2.93E-02
1.18E-02
7.48&03
2.40E-02
1.93E-02
6.32E-02
9.61&04
1.19E02
1.52E02
1.17E-02
5.43E-03
1.87E-03
3.99E02
1.25E-01
6.12E-02
6.47E-02
2.60E02
1.65E-02
5.29E-02
4.25E-02
1J9&01
2.12EK53
2.63E02
3.35FKJ2
2.59E-02
1.20&02
4.13E-03
3
12-9-92
1435-1738
2.41E-02
7.11E-02
1.98E-02
6.91E-02
1.32E-02
6.30E-03
3.27E-02
1.65E-02
4.09E-02
1.73E-03
1.05E-02
1.31E-03
2.83E-03
5.67E-03
2J9E-03
5.31E-02
1J7E-01
4.36E-02
1.52EKJ1
2.92E-02
139E-02
7.21E^)2
3.64E-02
9.01&02
3.81&03
2.31E-02
2.88E-03
6.25&O3
1.25E-02
5.27E-03
A-65
-------
TABLE A-49.
SUMMARY OF SEMI-VOLATILE ORGANICS INPUT DATA
(SAMPLE POINT A)
TEST DATA
Run number .
Location
Date
Time period •
Operator
INPUTS FOR CALCULATIONS
Sq. rt. delta P
Delta H
Stack temp. (deg.F)
Meter temp. (deg.F).
Sample volume (act.)
Barometric press. (in.Hg)
Volume H2O imp. (ml)
Weight chnge sil. gel (g)
%O2
%CO
%N2
Area of stack (sq.ft.)
Sample time (min.)
Static pressure (in.H2O)
Nozzle dia. (in.)
Meter box cal.
C,, of pilot tube
1 2 3
BLAST FURNACE OUTLET
08-Dec-92 09-Dec-92 09-Dec-92
1030-1434 0928-1230 1445-1740
AW AW AW
0.2988 0.2591 0.2948
0.92 0.65 0.59
278.3 246.0 251.5
64.5 62.4 58.6
46.982 47.033 51.096
29.81 30.06 30.06
112.8 73.2 70.2
22.4 23.6 13.2
9.8 8.8 8.8
12.6 13.0 13.0
0.0 0.0 0.0
77.6 78.2 78.2
4.91 4.91 4.91
120 120 120
-1.00 -1.00 -1.00
0.331 0.331 0.331
1.000 0.992 0.992
0.84 0.84 0.84
A-66
-------
TABLE A-49. (Concluded)
TEST DATA
Run number 123
Location BLAST FURNACE OUTLET
Date . 08-Dec-92 09-Dec-92 09-De2
Tune period ' 10m434 0928-1230 1445-1740
SEMI-VOLATILE ORQANICS LABORATORY REPORT DATA, ng
1.2.4-TrinKthylbenzene < 2400 < 2,000 < 2.000
Phenol 10,459 8.393 ' 20.187
Benzyl Chloride < 2.000 < 2400 < 2.000
Bis (2-chIorocthyl) ether < 2400 < 2400 < 2.000
n-Nitrosomorpholine < 2,000 < 2.000 < 2.000
1.4-Diehlorobenzene < 2400 • < 2.000 < 2.000
p-Cymene < 2,000 < 2.000 < 2.000
Acetophenone 2.289 2.418 5.272
< 2.000 < 2.000 < 2.000
Hexachloroanane < 2.000 < 2.000 < 2.000
o-Tohiidtne < 2.000 < 2.000 < 2,000
2-MethylphenoI < 2.000 < 2.000 3.030
n-Nitrosodimethylamuie < 2.000 < 2.000 < 2.000
Cumene < 2.000 < 2,000 4.887
a-Pinene < 2.000 < 2.000 < 2.000
b-Pinene < 2.000 < 2400 < 2,000
Aniline < 2400 < 2400 < 2.000
Naphthalene . 11.427 21.540 23.788
o-Anisidine < 2400 < 2400 < 2400
Henchlorobutadiene < 2400 < 2400 < 2400
2-CttonBcetophencne < 2400 < 2400 < 2400
aAa-Trichlarotoluene < 2400 < 2,000 < 2.000
N.NDieihylaiiiline < 2400 < 2400 < 2.000
1.4-Pbenvknedianune < 2400 .< 2.000 < 2.000
Hydroquinone < 2.000 < 2.000 < 2.000
Pentamethylbenzene < 2.000 < 2.000 < 2.000
Nitrobenzene < 2.000 < 2,000 < 2.000
KNOimelhylaiiilme < 2.000 < 2.000 < 2400
Isophorone < 2.000 < 2.000 < 2.000
3.4-Methylphenol < 2.000 < 2.000 < 2400
1.14-Triehlorobeiizene < 2.000 < 2,000 < 2400
a-Terpineol < 2.000 < 2.000 < 2.000
trinitrotoluene < 2.000 < 2.000 < 2400
2.4-Dininophenol < 2.000 < 2.000 < 2.000
4.5-Dinitro-trothylphenol < 2.000 < 2.000 < 2.000
Dibcnzofunn < 2400 < 2.000 < 2.000
4-Nitrophenol < 2.000 < 2.000 < 2.000
Trifluralin < 2.000 . < 2400 < 2.000
Hexachlonxydopentadiene < 2.000 < 2.000 < 2.000
2.4.Wrichlorophenol < 2.000 . < 2.000 < 2.000
Z4.5-Trichlorophenol < 2.000 < 2,000 < 2.000
2.4-Dichlorophenol < 2.000 < 2,000 < 2.000
2.3-Dkhlorophenol < 1000 < 2400 < 2.000
2.6-Dichlorophenol < 2.000 ' < 1000 < 2.000
3.5-Dichlorophenol < 1000 < 2.000 < 1000
3.4-Oichlorophenol < 1000 < 2.000 < 1000
Biphenyl 9J40 9.623 14.597
Dimethylphthalatc < 2.000 < 2.000 < 2.000
Penuchlorophenol < 2400 < 1000 < 2.000
PcnttchlaranitTobenzene < ' 2.000 < 2.000 < 2.000
4-Nitrobiphenyl < 2.000 < 1000 < 2.000
DHHutylphthalate < 2.000 - < 2.000 < 2.000
Hexachlorobenzene . < 2.000 < 2.000 < 2.000
4-Aminobiphenyl < 2.000 < 1000 < 1000
3.3'-T>im«hoxyben2idine < 2.000 < 1000 < 1000
Pyrene < 2.000 < 2.000 < 2.000
Bcnzidine < 2.000 < 1000 < 1000
4.4>-*tethylenedianiline < 2.000 < 1000 < 1000
Dimethylaminoazobenzene < 2.000 < 1000 < 2.000
ButylbenzylphthaUte < 2.000 < 2.000 < 2.000
3.3M3imethylbenzidine < 2.000 < 1000 < 2.000
Methylene bis-chloramiline < 2.000 < 2.000 < 2.000
Chrysene < 2.000 < 2.000 < 2.000
3.3'-Oichlorohiaradine < 2.000 < 2.000 < 2.000
bis(2-ahylhcxyl)phth>l«c 7.633 6.528 5.437
A-67
-------
TABLE A-50.
SUMMARY OF SEMI-VOLATILE ORGANICS TEST DATA
AND RESULTS (SAMPLE POINT A)
TEST DATA
Test run number 1
Test location
Test date 08-Dec-92
Test time period 1030-1434
SAMPLING DATA
Sampling duration, min. 120.0
Nozzle diameter, in. 0.331
Cross sectional nozzle area, sq.ft. 0.000598
Barometric pressure, in. Hg 29.81
Avg. orifice press, diff., in H2O 0.92
Avg. dry gas meter temp., deg F 65
Avg. abs. dry gas meter temp., deg. R 525
Total liquid collected by train, ml 135.2
Std. vol. of H2O vapor coll., cu.ft. 6.4
Dry gas meter calibration factor 1.000
Sample vol. at meter cond. dcf 46.982
Sample vol. at std. cond.,dscf(l) 47.210
Isokinetic.% 87.7
GAS STREAM COMPOSITION DATA
CO2,% by volume, dry basis 9.8
O2-% by volume, dry basis 12.6
CO, % by volume dry basis 0.0
N2,% by volume, dry basis 77.6
Molecular wt. of dry gas, Ib/lb mole 30.07
H2O vapor in gas stream, prop, by vol. 0.119
Mole fraction of dry gas 0.881
Molecular WL of wet gas. Ib/lb mole 28.6
GAS STREAM VELOCITY AND VOLUMETRIC FLOW DATA
Static pressure, in. H2O -1.00
Static pressure, in. Hg -0.074
Absolute pressure, in. Hg 29.74
Avg. temperature, deg. F 278
Avg. absolute temperature, deg.R 738
Pilot tube coefficient 0.84
Total number of traverse points 1
Avg. gas stream velocity, ft/sec. 20.0
Stack/duct cross sectional area, sq.ft. 4.909
Avg. gas stream volumetric flow, wacf/min. 5,900
Avg. gas stream volumetric flow, dscf/min. 3,700
BLAST FURNACE OUTLET
09-Dec-92 09-Dec-92
0928-1230 1445-1740
120.0 . 120.0
0.331 0.331
0.000598 0.000598
30.06 30.06
0.65 0.59
62 59
522 519
96.8 83.4
4.6 3.9
0.992 0.992
47.033 51.096
47.434 51.902
96.0 91.3
8.8 8.8
13.0 13.0
0.0 0.0
78.2 78.2
29.93 29.93
0.088 0.070
0.912 0.930
28.9 29.1
-4.00 -1.00
-0.074 -0.074
29.99 29.99
246 . 252
706 712
0.84 0.84
1 1
16.8 19.1
4.909 4.909
4.900 5.600
3,400 3.900
(1) Standard conditions = 68 degrees F. (20 deg. C.) and 29.92 inches Hg (760 mm Hg)
A-68
-------
TABLE A-50. (Continued)
TEST DATA
Test run number
Test location
Test date
Test time period
SEMI-VOLATILE ORGANICS EMISSION RESULTS, ug/m
1.2,4-Trimelhylbenzene <
Phenol
Benzyl Chloride <
Bis (2-cbloroethyl) ether <
1,4-DkhIorobenzene <
p-Cymene <
Acetopbenone
l>Dibromo-3-chloropropane <
Henchlorccthine <
o-Tohiidine <
2-Methylphenol <
n-NitrojodoDelhylamine <
Cumene <
a-Pinene <
b~PuiGne ^
Aniline <
Naphthalene
o-Aniiidine <
Henchlorobutadiene <
2-CbJoroaoetophenone *
*A»-Trichloraloliiene <
N.N-Diethylaniline <
1.4-fhenylenedianiine ' ^
Hydroouinone . ^
Pentamethylbenzene <
Nitrobenzene *
N.N-DimethylmUine <
Iiophorone <
3,4 Mdhirtphcnol ^
1^,4-lrichlorobenzene <
a^Terpineol ' <
2,4-Dinitrotohiene <
2.4-Oinitrophenol ' ^
4,6-Dinitro-2methylphenol <
Dibenzofuran ^
4-Nitrophenol <
Triiluralin *
Henchlcrocydopentadiene <
2.4.6-Trichlorephenol <
2,4.5-Trichlorophenol <
2.4-Dichlorophenol <
2,3-Dichloropbenol <
2.6-Dichlorophenol <
3.5-Dichlarophenol <
3.4-Dichlorophenol <
Biphenyl
DimethylphthnUte <
PentachloroDnenol ^
Pentacnloranitrobenzene <
4-Nitrobiphenyl <
Drn-butylphthalate <
HenchlorobenzEnc <
4-Aminobiphcnyl <
3.3'-Oimelhoxybenzidine <
Pyrene <
Benzidine <
4.4<-Methylenedianiline <
Dirnethylaminoazobenzene <
Bulylbenzylphthalate <
3,3'-Oimeihylbenzidinc *
Methytene bis-chloroanilinc <
Chrysene <
3.3'-Dichlorobenzidine <
bis(2-£lhylhexyi)phthaUte
1
08HDec-92
1030-1434
3
1.496
7.823
1,496
1.496
1,496
1.496
M96
1.712
1,496
1,496
1.496
1.496
1,496
1.496
1.496
1,496
1.496
13.783
1.496
1.496
1.496
1.496
1.496
1.496
1.496
1.496
1,496
1.496
1.496
1.496
1.496
1.496
1.496
1.496
1.496
1.496
1,496
1.496
1,496
1,496
1.496
1.496
1.496
1.496
1.496
1.496
7.135
1.496
1.496
1.496
1.496
1.496
1.496
1.496
1.496
1.496
1.496
1.496
1.496
1.496
1.496
1.496
1.496
1.496
5.709
2
BLAST FURNACE OUTLET
09-Oec-92
0928-1230
< 1.489
6,248
< 1.489
< 1.489
< 1.489 <
< 1.489
< 1.489
1.800
< 1,489
< 1.489
< 1.489
< 1,489
< 1.489
< 1,489
< 1.489
< 1.489
< 1.489
16.035
< 1.489
< 1.489
< 1.489
< 1.489
< 1,489
< 1,489
< 1.489
< 1.489
< 1.489
< 1.489
. < 1.489
< 1,489
< 1.489
< 1.489
< 1.489
< 1.489
< 1,489
<. 1.489
< 1,489
< 1.489
< 1.489
< 1.489
< 1.489
< 1.489 .
< 1.489
< 1.489
< 1.489
< 1.489
7.164
< 1.489
< 1.489
< 1.489
< 1.489
< 1.489
< 1.489
< 1.489
< 1.489
< 1.489
< 1.489
< 1.489
< 1.489
< 1.489
< 1.489
< 1.489
< 1.489
< 1.489
4.860
3
09-DM-92
1445-1740
: 1.361
13.734
! 1.361
e 1.361
e 1,361
c 1.361
c 1.361
3.587
<: 1.361
c 1.361
e 1.361
2.061
c 1.361
3.325
« 1.361
c 1.361
< 1.361
16.184
c 1.361
< 1.361
< 1.361
< 1J61
< 1.361
< 1.361
< 1.361
< 1.361
< 1.361
< 1.361
< 1.361
< 1,361
< 1,361
< 1.361
< 1.361
< 1.361
< 1.361
< 1.361
< 1.361
< 1.361
< 1.361
< 1.361
< 1.361
< 1.361
< 1,361
< 1.351
< 1.361
< 1.361
9.931
< 1.361
< 1.361
< 1.361
< 1.361
< 1.361
< 1.361
< 1.361
< 1.361
< 1.361
< 1.361
< 1.361
< 1.361
< 1.361
< 1.361
< 1.361
< 1.361
< 1.361
3.699
AVERAGE
< 1.448
9.268
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
• 2J66
< 1.448
< 1.448
< 1.448
2.061
< 1.448
3.325
< 1.448
< 1.448
< 1.448
15.334
< ' 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
8.077
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
< 1.448
4.756
A-69
-------
TABLE A-50. (Continued)
TEST DATA
Test run number
Test location
Test date
Test time period
SEMI-VOLATILE ORGANICS EMISSION RESULTS,
1.2.4-Trimethylbenzene!
Phenol
Benzyl Chloride
Bis (2-chloraethyl) ether
D-NHrosomorDholiDe
1.4-Oknlorobouene
p-Cymene
Acetophenone
l>Dibromo-3-chloropropane
Hcxachlorocthane
c-Toluidine
2-Methylphenol
ft-Nitmodimcthvlainino
QQDCDB
ti PiTiJitiai
Q*rHmtB
Aniline
Nipbthikne
o-Anisidine
Hexachlorobutadiene
S-ChlOfOBOC.tophcnonc
MJfr-TKchlorotohiene
N^HDiethylnniline
Hydroquinooc
Penlamelhylbenzene
Nitrobenzene
N,N€>imohylaniline
3>Memylphenol
1.2.4-THchlarobenzEDe
a-Terpineol
2.4-Dinimxoluene
2.4-DimlJOpheiiol
4.6-Dinitio-i-roelhylphenol
Dibenzofuran
4-Nitrophenol
Trifluralin
Hexachlorocyclopentadicnc
2.4.6-Trichlorophenol
2.4.5-Trichloropbenol
2.4-Oichloropbenol
2.3-Dfchloropbenol
2.6-DicUorophenol
3.5-Dichtorophenoi
3 4-DictUoroDbeool
Bipheiiyi
Dimethylpnthabte
Pentachloropbenol
PcntafhKjiuiiitrolMMWgiie
4-Nitrobrphenyl
Dhn-butylphlhalaie
Hexachlorobcnzcne
4-Aminobiphcnyl
3.3'-DimeIhoxybenzidinc
Pyrene
Benzidine
4.4'-Melhylenedianiline
Dimethylaminoazobenzene
Butylbenzylphthalale
3.3'-Dimethylbcrmdine
Methytene bis-chloroaniline
Chrysene
3.3'-Dichlorobenzidine
bis(2-Ethylhcxyl)phthal»te
1
OS-Dec-92
1030-1434
ppb/v
< 299
2.000
< 284
< 252
< 310
< 245
< 268
343
< 152
< 152
< 336
< 333
< . 486
< 299
< 264
< 264
< 386
2.399
< 292
< 138
< 233
< 184
< 241
< 333
< 327
< 243
< 292
< 295
< 260
< 333
< 198
< 233
< 198
< 195
< 182
< 214
< 259
< 107
< 132
< 182
< 182
< 221
< 221
< 221
< 221
< 221
1.113
< 185
< 135
< 122
< 181
< 129
< 126
< 213
< 147
< 178
< 195
< 182
< 160
< 115
< 170
< 135
< 158
< 142
352
2
BLAST FURNACE OUTLET
09-Dec-42
0928-1230
< 298
1.597
< 283
< 250
< 309
< 244
< 267
360
< 152
< 151
< 334
< 331
< 483
< 298
< 263
< 263
< 385
2.791
< 291
< 137
< 232
< 183
< 240
< 331
< 325
< 242
< 291
< 293
< 259
< 331
< 197
< 232
< 197
< 195
< 181
< 213
< 257
< 107
< 131
< 181
< 181
< 220
< 220
< 220
< 220
< 220
1.118
< 184
< 135
< 121
< 180
< 129
< 126
< 212
< 147
< 177
< 194
< 181
< 159
< 115
< 169
< 134
< 157
< 142
299
3
09-OCC-92
1445-1740
< 272
3.511
< 259
< 229
< 282
< 223
< 244
718
< 139
< 138
< 305
459
< 442
665
< 240
< 240
< 352
2.817
< 266
< 126
< 212
< 167
< 219
< 303
< 297
< 221
< 266
< 268
< 237
< 303
< 180
< 212
< 180
< 178
< 165
< 195
< 235
< 98
< 120
< 166
< 166
< 201
< 201
< 201
< 201
< 201
1.549
< 169
< 123
< 111
< 164
< 118
< 115
< 193
< 134
< 162
< 178
< 165
< 145
< 105
< 154
< 123
< 143
< 129
228
AVERAGE
< 290
1369
< 275
< 244
< 300
< 237
< 260
474
< 147
< 147
< 325
459
< 470
665
< 256 .
< 256
< 374
2.669
< 283
< 134
< 225
< 178
< 234
< 322
< 316
< 235
< 283
< 285
< 252
< 322
< 192
< 226
< 191
< 189
< 176
< 207
< 250
< 104
< 128
< 176
< 176
< 214
< 214
< 214
< 214
< 214
1.260
< 179
< 131 •
< 118
< 175
< 125
< .122
< 206
< 143
< 172
< 189
< 176
< 155
< 112
< 164
< 130
< 153
< 138
293
A-70
-------
TABLE A-50. (Continued)
TEST DATA
Test run number
Test location
Test date
Test time period
SEMI-VOLATILE ORGANICS EMISSION RESULTS.
1.2.4-Trimethylbcnzene
Phenol
Benzyl Chloride
Bis (2-chloroethyl) ether
D-Nitrosomorpholine . •
1.4-Dichlorobenzcne
p-Cymenc
Aoetophenooe
Hexachloraethaoe
o-ToluidiDe
2-Methylphenol
n-NhrosodiroethyUmine
fltm^tw
fn . ,
a i lueiK
b"Pujeu€
Aniline
Naphthalene
o-Anotdine
Hexachlofobuladiene
2~Qilafoacetaibenone
ajLt-Trichkrololittne
N.NCiethyhniline
l,4-Pbenylenedi«mine
Hydro^uiDonc
PentamethylbauEnc
Nitrobenzene
liNOioKthytaniline
Z&QphorottB
3.4-Metbylphenol
li.4-Trichloeobenitne
t-Terpineol
2.4-Dinimnohiene
2.4-DinitraphenoI
4.6-Oinilro 2 mahylphenol
Dibenzonuun
4-Nhrophenot
Triflnnlin
Kexachlorocyclopentadiene
2,4.6-TOchlorophenol
2.4.5-TOcnloropbenol
2.4-Diehlorophenol
2.3-Dichlorophenol
2.6-Dkhlorophenol
3^-DicbJoropbenol
3.4-Dkhloroahenol
Biphenjrl
Dimethylphlhalate
Pentachlorapheool
Pentachloraoitrobeniene
4-Nttrobrphenyl
DHi-butylphthabte
Hexachlorobenzene
4-Aminobiphenyl
3.3'-DimethCHCybcnzidine
Pyrene
Benzidine
4.4'-Melhylmedianiline
Dimelhylaminoazobenzcne
ButylbenzylphthaUte
3.3'-4}imethylbenzidine
Methyfene bij-chlorcamline
Qtrysene
3.3'-43khlarobcnzidinc
bjs(2-ahylhexyl)phthal*te
1
OS-Dec-92
1030-1434
ppb/v @ 15% O2
< 214
1.429
< 203
< 180
< 221
< 175
< 192
245
< 109
< 109
< 240
< 238
< 347
< 214
< 189
< 189
< 276
1.713
< 209
< 99
< 166
< 132
< 172
< 238
< 233
< 173
< 209
< 210
< 186
< 238
< 142
< 167
< 141
< 140
< 130
< 153
< 185
< 77
< 94
< 130
< 130
< 158
< 158
< 158
< 158
< 158
795
< 132
< 97
< 87
< 129
< 92
< 90
< 152
< 105
< 127
< 140
< 130
< 114
< 82
< 121
< 96
< 113
< 102
251
2
BLAST FURNACE OUTLET
09-Deo-92
0928-1230
< 224 «
1.198
< 212 «
< 188 •
< 231
< 183
< 200 •
270
< 114 •
< 113
< 251
< 248
< 363
< 224
< 197
< 197
< 288 •
2.093
< 218
< 103
< 174
< 137
< 180
< 248
< 244
< 181
< 218
< 220
< 194
< 248
< 148
< 174
< 147
< 146
< 136
< 160
< 193
< 80
< 98
< 136
< 136
< 165
< 165
< 165
< 165
< 165
838
< 138
< 101
< 91
< 135
< 97
< 94
< 159
< 110
< 133
< 146
< 136
< 119
< 86
< 127
< 101
< 118
< 106
225
3
09-Dec-02
1445-1740
: 204
2.633
: 194
: 172
: 211
: 167
c 183
539
: 104
c 104
: 229
344
C 331
499
C 180
c 180
c 264
2.112
c 199
c 94
£ 159
e 126
c 165
C 227
C 223
e 166
e 199
e 201
« 178
< 227
c 135
< 159 •
e 135
e 133
< 124
< 146
< 176
< 73
< 90
< 124
< 124
< 151
< 151
< 151
< 151
< 151
1.162
< 126
< 92
< 83
< 123
< 88
< 86
< 145
< 101
< 121
< 133
< 124
< 109
< 79
< 116
< 92
< 108
< 97
171
AVERAGE
< 214
1.753
< 203
< 180
< 221
< 175
< 192
351
< 109
< 109
< 240
344
< 347
499
< 189
< 189
< 276
1.973
< 209
< 99
< 166
< 132
< 172
< 238
< 233
< 173
< 209
< 210
< 186
< 238
< 142
< 167
< 141
< 140
< 130
< 133
< 185
< 77
< 94
< 130
< 130
< 158
< 158
< 158
< 158
< 158
932
< 132
< 97
< 87
< 129
< 92
< 90
< 152
< 105
< 127
< 140
< 130
< 114
< 82
< 121
< 96
< 113
< 102
216
A-71
-------
TABLE A-50. (Continued)
TEST DATA
Test run number
Test location
Test date
Test time period
SEMI-VOLATILE ORQANICS EMISSION RESULTS, Ib/hr
1.2.4-Trimethylbenzene <
Phenol
Benzyl Chloride <
Bii(2-coloroethyl) ether <
fr"N ttrosomorpholtnc ^
1.4-Dichlorobenzene <
pCymene <
AcctoplMiiouc-
1.2-Dibrorao-J-chloropropane <
Herachloroethiine <
o-Toluidine <
2-Methylpbenol <
n-Nitrojodunethylaminc <
rhim-mi • . <
• Pl.i«nn *»
• ji i uienB ^
Winene <
Aniline <
Nxpbtbuene
o-Annidine <
HexBChlorobut&dieDe <
2-CUorouetophenone <
ajurfrichlorotouiene <
N.NCiethyl»nilinc <
1.4-Phenylenediamine <
Hydroqnmone <
Penttmethylbenrrne <
Nitrobenzene <
N.r+Oimethylanilme <
IsophoroDB <
3,4-Methylphenol <
L2.4-Trichlorobenzene <
irTerpiiieol <
2.4-Dinitrotoliiene <
2.4-Dinitrophenol <
4.6-Dinitro-a-mcthylphenol <
Dibenzofuran <
4-Nitrophenol <
TriQunlin <
Hexachlorocyclopenudiene <
2.4.6-Trichlorophcnol <
2,4.5-Tridilorophenol <
2.4-Dichlorophenol <
2,3-Dichkrophenol <
2.6-Dichlcrophenol <
3.5-Dichkrophenol <
3,4-Dicalarophenol <
Biphenyl
Dimethylphthalite <
Pent&cbloropbenol <
PeDt&chloronilrobenzene <
4-NttroDiphenyl . ^
DHriwrylphlhalate <
Hexachlorobenzene <
4-Aminobipbenyl <
3.3'-Oimelhoxybenzidine <
Pyrene <
Benzidine <
4.4'-Methylcncdi«iiline <
Dimethylaminoazobenzene <
Butylbenzylphthalate <
3.3'-Oimethylbenzidine <
Melhylene bis-chlorraniline <
Chrysene <
3.3'-Dichlorobenzidinc ' <
bis(2-£lhylhexyl)phihalate
1
OS-Oec-92
10304434
0.0206
0.1080
0.0206
0.0206
0.0206
0.0206
0.0206
0.0236
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.1902
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0X1206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0985
0/1206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0206
0.0788
2
BLAST FURNACE OUTLET
09-Oec-92
0928-1230
< 0.0189
0.0792
< 0.0189
< 0.0189
< 0.0189 <
< 0.0189
< 0.0189
0.0228
< 0.0189
< 0.0189 <
< 0.0189 •
< 0.0189
< 0.0189 •
< 0.0189
< 0.0189 . •
< 0.0189
< 0.0189 <
0.2032
< 0.0189
< 0.0189 «
< 0.0189
< • 0.0189
< 0.0189 •
< 0.0189
< 0.0189 •
< 0.0189 •
< 0.0189 «
< 0.0189
< 0.0189
< 0.0189
< 0.0189
< 0.0189 <
< 0.0189 <
< 0.0189
< 0.0189
< 0.0189
< 0.0189
< 0.0189
< 0.0189
< 0.0189
< 0.0189
< 0.0189
< 0.0189
< 0.0189
< 0.0189
< 0X1189
0.0908
< 0.0189
< 0.0189
< 0.0189
< 0.0189
< 0.0189
< 0.0189
< 0.0189
< 0.0189
< 0.0189
< 0.0189
< 0.0189
< 0.0189
< 0.0189
< 0.0189
< 0.0189
< 0.0189
< 0.0189
0.0616
3
09^^e
-------
TABLE A-50. (Concluded)
TEST DATA
Test run number
Test location
Test date
Test time period
SEMI-VOLATILE ORGANICS EMISSION RESULTS.
Ii4-Trimethylbenzene
Pfaeool
Benzyl Chloride
Bis (2-chloroethyl) ether
D-Nitrosuuiui pnolme
1.4-Dichlorobenzene
p-Cymene
Acetophenooe
1 ** "'liliiruim-'l-i litiiiiMMjIIUlM:
l,^Wlifl«mrycUluiu|*wpaW.
Hexacblcroeth&ne
o-Toluidine
2-MethyrpbencJ
n-NitrosodimethyUmine
CutDeoe
a-Pinene
Irfinene
Aniline
o-Aniiidine
HejDchlorobutadiens
2-Chlccoicetophenooe
lAft-IrichlofotolueDe
N,N-Diethyliniline
l,4-Pbenylrae-Trichlorophenol
2,4-DichIorophenol
2J-Dichlorophenol
2.6-Dichlorophenol
33-DicUorophenol
3.4-Dichlorophenol
oiphcoyt
Dimetfaylphthafcie
PMilBfhtfgTinirmhfji tfrtf
conicmmii miiu micozcne
4-Nitrobiphenyl
Di-n-butylphthalato
HencblorobernBne
4-Aminobipbenyl
3,3'-DimeIhoxybcnzidine
Bcnzidine
4.4'-MethylenedUniline
Dimethylam moazobenzene
Butylbenzylphthalate
3.3'-Dimelhylbenadine
Melhylene bij-chloroaniline
Chrysene
3.3'-Dichlorobenzidine
bis(2-Bhylhcxyl)phth>late
1
OS-Dec-92
1030-1434
kg/hi
< 0.00936
0.04897
< 0.00936
< 0.00936
< 0.00936
< 0.00936
< 0.00936
0.01072
< 0.00936
< 0.00936
< 0X0936
< 0.00936
< 0X0936
< 0.00936
< 0X0936
< 0.00936
< 0X0936
0.08628
< 0.00936
< 0.00936
< 0.00936
< 0.00936
< 0.00936
< 0.00936
< 0.00936
< 0.00936
< 0.00936
< 0.00936
< 0.00936
< 0.00936
< 0.00936
< 0.00936
< 0X0936
< 0X0936
< 0.00936
< 0X0936
< 0.00936
< 0.00936
< 0X0936
< 0.00936
< 0.00936
< 0X0936
< 0.00936
< 0.00936
< 0.00936
< 0.00936
0X4467
< 0.00936
< 0.00936
< 0.00936
< 0.00936
< 0.00936
< 0.00936
< 0.00936
< 0.00936
< 0.00936
< 0.00936
< 0.00936
< 0.00936
< 0.00936
< 0.00936
< 0.00936
< 0.00936
< 0.00936
0.03574
2
BLAST FURNACE OUTLET
09-Dec-92
09284230
< 0.00856 •
0X3591
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.00856 ' •
0.01034
< 0.00856 •
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< O.C0856
< 0X0856
< 0.00856 .
0.09215
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.0085:. ._
< 0.0085.
< OXOS56
< 0.00856
< 0X0856
0.04117
< 0.00856
< 0.00856
< 0.00856
< 0X0856
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.00856
< 0.00856
0.02793
3
09-Dec-92
1445-1740
c 0.00900
0.09083
c 0.00900
c 0.00900
c 0.00900
c 0.00900
£ 0.00900
0.02372
< 0.00900
S 0.00900
e 0.00900
0.01363
e 0.00900
0.02199
C 0.00900
c 0.00900
c 0.00900
0.10704
c 0.00900
c 0X0900
< 0.00900
< 0.00900
c 0.00900
< 0.00900
f 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
0.06568
< 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
< 0.00900
0.02446
AVERAGE
< 0.00897
0.05857
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
0.01493
< 0.00897
< 0.00897
< 0.00897
0.01363
< 0.00897
0X2199
< 0.00897
< 0X0897
< 0.00897
0.09516
< 0X0897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
. < 0.00897
< 0.00897
0.05051
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
< 0.00897
0.02938
A-73
-------
APPENDIX B
DESCRIPTION OF PROCESS AND AIR POLLUTION
CONTROL SYSTEMS (INCLUDING PROCESS MONITORING DATA) -
RADIAN
-------
SECTION 3.0
DESCRIPTION OF PROCESS AND AIR POLLUTION CONTROL SYSTEMS
3.1 PROCESS DESCRIPTION
East Penn Manufacturing Company operates a secondary lead
smelting facility with a production rate of approximately
45,000 tons of lead per year. The facility is collocated with
four battery production plants, also operated by East Penn.
The raw material for the smelter consists of approximately
80 percent automotive batteries, 15 percent industrial
batteries, and 5 percent plant scrap. The entire production
of the smelter is used to supply lead to the battery plants.
Approximately 70 percent of the lead used by the battery
plants is supplied by the smelter.
Figure 3-1 illustrates the major process operations at
the East Penn facility.
3.1.1 Battery Breaking
Spent lead-acid batteries are delivered to the plant by
truck and are broken on site. Automotive batteries and
industrial batteries are disassembled in separate areas. The
acid from both areas is collected and sold for recycling.
Between 10,000 and 15,000 automotive batteries are processed
per day. East Penn is currently installing a facility to
recycle the acid for use in the on-site battery plants.
The steel casings of the industrial batteries are opened
with a torch or plasma arc. The battery plates and grids, .
with the acid and inside "jar" intact, are lifted with a small
overhead crane and moved to a conveyor, where the jar is
cracked with an ax and the acid is allowed to drain. The
jars, plates, and grids are then conveyed into the materials
storage building, which is approximately 90 feet long and 60
feet wide.
Automotive batteries are placed on a conveyor and passed
through one of two saws, where the tops of the batteries are
-------
to
Acid Recovery I
Battery
Breaker
Grids and Paste
Plastic Recovery
Fluxes and
Reducing Agents
Landfill
Figure 3-1. Process Flow Diagram
East Penn Manufacturing, Lyon Station, Pennsylvania
-------
cut off and the acid is drained. The batteries then proceed
to a dumper, where the cases, plates and remaining acid are
separated. The cases and tops are crushed and broken by a
hammermill, and the lead, hard rubber, and polypropylene are
separated by flotation. The pieces of polypropylene are blown
into a trailer and the lead-bearing materials are conveyed..
into the materials storage room.
3.1.2 Smelting Operations ^
Lead smelting occurs in both a stationary reverberatory
furnace and a blast furnace. The reverberatory furnace uses
the battery components as feed. The battery pieces are
transferred by a front-end loader to the furnace charging
area, where the charge is deposited into a bin and then fed
with a vibratory conveyor to a weigh hopper. Weighed lots of
material are dumped into the ram feeder, which pushes the
charge into the furnace. Flue dust is screw-conveyed to the
furnace and is deposited directly ahead of the charge
material. When the furnace is charged, the flue dust is
pushed into the furnace and the track for the ram is cleared
for another charge.
The reverberatory furnace is fired with propane and uses
50- ..-cent oxygen enrichment. The furnace has four burners:
twc c he end of the furnace and one on each side. The
combined heat input for the four burners is 16 MMBtu per hour.
The reverberatory furnace has a permitted capacity of 155 tons
of lead product per day and produces about 78 tons of slag per
day. It operates at a temperature of about 2,200° F. The
lead is tapped directly into one of two 75-ton receiving
kettles. Slag is continuously tapped into 1200-pound molds
and is returned to the materials storage area to be used as
feed to the blast furnace.
The blast furnace feed consists of reverberatory furnace
slag, re-run blast furnace slag, and battery groups. The
non-lead-bearing materials fed to the furnace as fuel and
reducing agents (coke, limestone, silica, and iron) are kept
-------
in conveying bins outside of the materials storage area. The
height of charge material in the furnace is monitored on a
closed-circuit television screen from inside the control room.
When the furnace needs a charge, the weigh hopper is
moved along an overhead monorail to each of the bins. The
bins automatically feed the desired weight of the material,
which is also set from the control room,. After each material
is added, the hopper is moved to the next bin, where the next
material is automatically fed. The last material to be fed
into the hopper is the lead-bearing material. The weigh
hopper transfers the charge to a skip hoist bucket. The skip
hoist carries the material to the top of the furnace and
charges it to the furnace.
The blast furnace is charged at a rate of approximately
117 tons per day of battery scrap and slag. It uses coke as
fuel and the blast air is 3-percent oxygen enriched. The
blast furnace has a permitted capacity of 90 tons of lead per
day and produces about 25 tons of slag per day. Lead is
tapped from the furnace into 2,600-pound ingots, which are
cooled and sent to the refining kettles after intermediate
storage in a 15 by 15 foot, three-sided structure outside the
main smelting building.
The slag is periodically tapped into 1,200-pound pots.
About one-half of the slag is re-run through the blast furnace
and the other half is disposed of as hazardous waste. The
slag resulting from a run using the re-run slag is not
considered hazardous and is disposed of off-site. All of the
blast furnace slag is not re-run because it is not cost-
effective to run all the slag twice.
3.1.3 Refining and Casting
Refining occurs in nine 75-ton kettles, each with a
diameter of 8 feet. Two of the kettles are used for refining
hard lead from the blast furnace. The 2,600-pound ingots from
the blast furnace are loaded into these kettles by crane.
-------
The other seven kettles are used to refine soft lead
obtained from the reverberatory furnace. Two of these kettles
are receiving kettles for the reverberatory furnace. When one
of the receiving kettles is full, lead is tapped into the
other receiving kettle. Lead in the full receiving kettle is
pumped to one of the other kettles for additional refining and
alloying. One kettle is used primarily as a backup.
When a kettle of lead has been refined to customer
specifications, the lead is pumped to an automatic casting
machine. The casting machine fills 70-pound molds that are
water-cooled as they transfer down the conveyor. The 70-pound
ingots are then stacked and taken to one of two lead product
storage areas for subsequent travel to the battery
manufacturing plants. One of the final product storage areas
is approximately 70 feet long and 50 feet wide, and the other
is approximately 40 by 40 feet. The approximate area in which
smelting and refining operations take place is 100 by
100 feet.
3.2 AIR POLLUTION CONTROL EQUIPMENT
An air emissions control flow diagram- for East Penn
Manufacturing's smelting and refining operations is presented
in Figure 3-2. The process streams from the two furnaces are
combined and vented to an afterburner. The propane-fired
afterburner has a retention time of 2.5 seconds and is kept at
a minimum temperature of 1,400° F. Typically, the afterburner
is idled to maintain this temperature because the
reverberatory furnace exhaust substantially heats the combined
streams.
The combined streams pass through an evaporative cooler
and then through six cells of an eight-cell baghouse. The six
shaker-type cells used to control the process gases from the
furnaces employ Gore-Tex membrane on Gore-Tex fabric. Just
before the process baghouse, approximately 8,000 cubic feet
per minute of ambient air are added through a dilution damper
to further cool the exhaust before it enters the six-cell
-------
Battery
Breaker
Reverberatory
Furnace
Blast
Furnace
Reverberatory
Furnace
Blast
Furnace
;
i
i
Material
Storage Building
Refining Kettles
and
Casting Machine
/ Scrubber /
/ andDemister/
/ /
t . ...... +j Afterburner /• ~
Slag Tap
Lead Tap
SlagTap
Oifln Lfaist
Vibratory Feeder
Lead Tap
General Ventilation
Hoods
T
/^••••K^—^ • .
>r/w«Aeo Ranh/M tea / * «j^^P^®¥ SCfXIDDSr /_ .... ...
IU(*O«»«I UoyilUUao / "7 ortfj riomiet^r /
/ / olio Uoiiiiaioi /
/ / /
/ 7
---------Hy DagnOUse NO. 1 f
Baghouse No.3 /
/Refinery /
Baghouse /
Figure 3-2. Emissions Control Flow Diagram
East Penn Manufacturing, Lyon Station, Pennsylvania
-------
process baghouse. An exhaust stream of approximately
40,000 acfm at 250°F is treated at an air-to-cloth ratio of
1.05 and a pressure drop of 3 to 5 inches of water. The
baghouse is inspected daily; the inspection includes a glass
rod test. The baghouse is equipped with a particulate monitor
and alarm to help detect leaks.
After the baghouse, the process exhausts go to a wet-_•
scrubber to control sulfur dioxide (802) emissions. The ^..
scrubber uses anhydrous ammonia that is subsequently dissolved
in water as the scrubbing fluid. The scrubber is a two-stage
scrubber in which fluid is injected horizontally into a
horizontal duct (cross-current) by 10 injectors in the first
stage and 12 injectors in the second stage. A reaction
chamber located after each stage also acts as a settling
chamber for the larger particles.
The treated gas then passes through a Monsanto Enviro-
Chem mist eliminator, which operates at a pressure drop of 4
to 8 inches of water. The mist eliminator is a two-vessel
unit that uses a total of 60 polyester "candle" elements.
*
Each element is 12 feet long and 24 inches in diameter, and
uses a polypropylene prefilter. The solution collected in the
mist eliminator is recycled to the first stage'of the
scrubber. Ammonium bisulfate is produced and stored for sale
to a fertilizer manufacturing plant.
Emissions from the six refining kettles (carried in a
16-inch duct), the casting area where the molds are poured,
general ventilation from the material storage area (carried in
a 20-inch duct), and the hooded dump door in the material
storage area (carried in a 14-inch duct) are controlled by the
refinery baghouse. The baghouse is a shaker-type, four-cell
carborundum dust collector baghouse that uses polyester or
acrylic bags. It treats 40,000 acfm at an air-to-cloth ratio
of 1.94 and has a pressure drop between 1 and 3 inches of
water.
-------
Emissions from the reverberatory furnace slag tap, lead
• tap, charging area, the area where the slag molds are cooled,
the two 75-ton receiving kettles, and the one 75-ton spare
kettle are controlled by the two additional compartments of
the baghouse used to treat the process gases. This two-cell
baghouse (Baghouse No. 5) is a shaker-type baghouse that uses
woven polyester bags with a Gore-Tex membrane coating. It
treats 20,000 acfm of exhaust gas at an air-to-cloth ratio of
1.57, and maintains a pressure drop of between 1 and 3 inches
of water.
Emissions from the blast furnace skip hoist (carried in a
30-inch duct), lead tap (carried in a 12-inch duct), lead
rotary table where the ingots are cooled (carried in a 12-inch
duct), and the vibratory feeder where the lead-bearing raw
material is put into the charge bucket (carried in a 12-inch
duct) are controlled by Baghouse No. 3. This is a
shaker-type, six-cell carborundum dust collector baghouse that
uses polyester or acrylic bags. It treats 45,000 acfm of
exhaust gas at an air-to-cloth ratio of 1.66.
The skip hoist and the vibratory feeder are located in
the far corner of the materials storage area. No physical
barriers exist between them and the storage area. In order to
quantify emissions from the materials storage area, test data
associated with just the material storage area must be
obtained. Because the hoods for the skip hoist and the
vibratory feeder are in the far corner of the materials
storage area, it is believed that a small amount of the
emissions associated with materials storage will be collected
by these hoods. Therefore, Radian personnel believe that most
of the emissions from the materials storage area are collected
by the general ventilation of the area and are controlled by
the refinery baghouse.
Emissions from the blast furnace slag tap (carried by a
15-inch duct) and the top of the blast furnace where the
charge is dumped by the skip hoist (carried by a 24-inch duct)
8
-------
are controlled by Baghouse No. 1. This is a shaker-type,
six-cell carborundum dust collector baghouse that uses
polyester or acrylic bags. It has a total cloth area of
12,600 ft2 and treats 22,500 acfm of exhaust.
3.3 PROCESS AND AIR POLLUTION CONTROL EQUIPMENT OPERATING
DATA DURING TESTING
Emissions testing was performed on the two furnaces, as
well as on various ventilation and local hooding systems. Key
process and pollution control data were collected during the
tests. Process data were collected in order to relate
emissions to production, to feed characteristics, and to
process operation. Pollution control data were collected in
order to ensure proper operation during testing and to relate
control performance to control device operation.
3.3.1 . Furnace Production Data
As discussed in Section 3.1, both the blast and the
reverberatory furnaces operate continuously. The weights of
raw material (grids and paste), coke, and fluxes were recorded
during all tests of furnaces or other sources in which charge
could impact emissions (i.e., lead tapping area, slag tapping
area). Lead production and slag production were also
recorded.
The quantity of flue dust recycled from the baghouses to
the reverberatory furnace is not measured at the facility;
however, Radian personnel believe that the dust is only a
small part of the total charge to the furnace and can be
considered negligible. Table 3-1 summarizes the charge,
production, and afterburner fuel usage data collected during
testing.
Process information was collected during the time in
which testing was occurring. Additional readings were
collected every time a test was begun or ended in order to
identify possible anomalies in the emissions data from each
test. However, the production data gathered during the short
period of time of a particular test (2 to 4 hours) have
-------
TABLE 3-1. CHARGE, PRODUCTION, AND AFTERBURNER FUEL USAGE INFORMATION3
Vost 01
Semi-Vost 01
Aid/Key 01
Tests
Performed
Date
First Test Start Time
Last Test End Time
Blast Furnace Information
Grids and Paste Charged
Coke Charged
Calcium Carbonate Charged
Silica Charged
Cast Iron Charged
Rerun Slag Charged
Lead Produced
Slag Produced
Dioxin 01
HCl
01 I 02
12/08/92
10
6
Total
During
Testing
(Ibs)
77,461
4,451
1,783
1,027
7,121
2.931
57,200
20,400 .
:30 am
:00 pm
Hourly
Average
During
Testing
(Ibs/hr)
10,328
593
238
137
949
391
7,627
2,720
Vost 02 & 03
Semi-Vost 02 & 03
Aid/Key 02 I 03
Dioxin 02 A 03
HCl
03
12/09/92
9:30
6:30
Total
During
Testing
(Ibs)
85.549
5,920
2,131
1.255
8.588
3,560
59,800
27.600
am
pm
Hourly
Average
During
Testing
(Ibs/hr)
9.505
658
237
139
954
396
6,644
3.067
PM/Pb/Mult-Met 01
PM10-BFO.
BHI 01
12/10/92
11:15
6:30
Total
During
Testing
(Ibs)
79,441
4.525
2.163
1,243
8,201
3,129
54.600
22.800
am
pm
Hourly
Average
During
Testing
(Ibs/hr)
10,957
624
298
171
1,131
432
7,531
3.145
PM/Pb/Mult-Met 02
PM10-8FO, BHI 02
PH10-BHO. SCO 01
PM/Pb/Mult-Met 03
PM10-BFO.
12/11/92
9:
4:
Total
During
Testing
(Ibs)
65,458
3.513
1.715
885
6,506
2,725
49.400
20.400
15 an
00 pm
Hourly
Average
During
Testing
(Ibs/hr)
9.697
520
254
131
964
404
7.319
3.022
BHI 03
12/12/92
8:45
11:45
Total
During
Testing
27.
1.
2.
1,
26.
9.
(Ibs)
576
635
566
342
634
079
000
600
am
am
Hourly
Average
During
Testing
(Ibs/hr)
9.192
545
189
114
878
360
8.667
3.200
Reverberatory Furnace Information
Grids and Paste Charged
Propane Used (ftA3)
Lead Produced
Slag Produced
Propane Used by Afterburner
(ft*3)
132.088
49.273
83,270
21,600
2,652
17,612
6.570
11.103
2,880
354
176,682
57.633
127,080
28,800
4,209
19.631
6,404
14.120
3,200
468
134.931
<7.253
MAb
38,400
3.389
18,611
6,518
NAb
5,297
467
117,237
44,003
87,600
16,800
3,163
17.368
6.519
12.978
2.489
469
62.
19.
39.
9.
1.
377
696
950
600
398
20,792
6,565
13.317
3,200
466
-------
TABLE 3-1.
CHARGE, PRODUCTION, AND AFTERBURNER FUEL USAGE INFORMATION3
(Concluded)
Test
Performed
Date
First Test Start Tine
Last Test End Time
Blast Furnace Information
Grids and Paste Charged
Coke Charged
Calciui Carbonate Charged
Silica Charged
Cast Iron Charged
Rerun Slag Charged
Lead Produced
Slag Produced
Reverberatory Furnace Information
Grids and Paste Charged
Propane Used (ft*3)
Lead Produced
Slag Produced
Propane Used by Afterburner
(ftA3)
8 All data are provided in units of
b Hot available.
c P*raiMters not Ami i cable for test
Ref BH PN10 #1
Ref BH PN/Pb *1
BH*5 PN/Pb #1
BH«5 PN/Pb #1
12/U/92
1:45 pm
7:45 pro
Hourly
Total Average
During During
Testing Testing
(Ibs) (Ibs/hr)
HAb HAb
PHAC PMAC
PNAC PHAC
PHAC PHAC
PHAC PNAC
PHAC PNAC
NAb NAb
NAb HAb
109.254 18.209
38,265 6.378
78,800 13,133
28,800 4,800
2,435 ^Op
f^~^
pounds except propane
ts conducted.
Ref BH PN10 *2 & «
Ref BH PN/Pb #2 ft «
BH«5 PN10 02 & #3
BH*5 PH/Pb #2 & *3
12/15/92
8:30
6:30
Total
During
Testing
(Ibs)
94.566
PNAC
PNAC
PHAC
PHAC
PHAC
70.200
22,800
175,914
6,390
97,410
31,200
4.557
am
pm
Hourly
Average
During
Testing
(Ibs/hr)
9,457
PMAb
PHAb
PMAb
PNAb
PNAb
7,020
2,280
17,591
639
9,741
3.120
456
usage, which is in units
8H#1 PN10 #1
BH01 PN/Pb #1 & #2
BH« PN10 *1
BH*3 PN/Pb *1 & #2
12/16/92
11:45
7:00
Total
During
Testing
(Ibs)
69.651
4,049
1,852
992
7,175
2.589
52,000
18,000
NAb
HA?
HAb
MAb
HAb
of cubic feet.
am
pro .
Hourly
Average
During
Testing
(Ibs/hr)
9,607
558
255
137
990
357
7.172
2,483
HAb
MAb
NAb
NAb
NAb
BH«1 PH10 02 & #3
BH*1 PN/Pb #3
BH« PH10 #2 & «
BH« PN/Pb «3
Bl Slag Tap #1 & #2
12/17/92
8:15
3:45
Total
During
Testing
(Ibs)
63,754
3,626
1.540
900
6,664
2.534
49.400
22,800
NAb
NAb
HAb
MAb
HAb
am
pm
Hourly
Average
During
Testing
(Ibs/hr)
8,501
483
205
120
889
338
6.587
3,040
HAb
HAb
HAb
NAb
MAb
)•
-------
period of time of a particular test (2 to 4 hours) have
limited accuracy because of the methods in which measurements
were taken. Therefore, it is recommended that the average
hourly charge and production rates for each individual day of
testing presented in Table 3-1 be used for the purpose of
correlating production data to the emissions measurements.
This methodology will account for daily fluctuations in charge
and production, while minimizing potential inaccuracies due to
the methods of measuring these parameters.
Few plant operational problems occurred during the
emissions testing. On December 12, the testing personnel
communicated that grain loading at the blast furnace outlet
location appeared to be higher than during the previous tests.
An investigation of the process by Radian personnel and
discussions with plant personnel revealed no process changes
from normal operation.
On December 14, testing personnel at the Baghouse No. 5
locations communicated that the flow rate at their locations
had increased substantially, and that testing could not
continue at the higher flow rate without significant equipment
modifications. It was determined by Radian personnel, through
discussions with plant personnel, that one of the
reverberatory receiving kettles was being drossed and that
normal operation was to increase ventilation to ensure that
the added dust from dressing was captured.
Dressing of one of the reverberatory kettles occurs about
once every 24 hours for about 2 hours. Emissions during this
two-hour period would only represent a small portion of the
total emissions being controlled by Baghouse No. 5, and would
not significantly affect the controlled emissions rate.
However, testing was suspended for about 2 hours during
dressing and was continued only when the flow rate was back to
normal.
On December 15, from 8:33 am to 8:48 am, no material was
charged to the reverberatory furnace so that minor maintenance
12
-------
could be conducted. "his encompassed a very small portion of
the testing time that day and should not have a significant
effect on the emissions testing results. On December 17, a
malfunction occurred on the blast furnace skip hoist and the
furnace was not charged for about 20 minutes. The electric
power to the furnace was discontinued, causing the computer
that monitors the amount of charge to the furnace to be *.
cleared. The time in which the furnace was not charged
appeared to be within the normal charge cycle of the furnace;
therefore, minimal effects on the emission measurements were
observed. Because the time of the malfunction was so short,
the total charge for the time of testing was extrapolated from
the readings taken earlier in the day.
3.3.2 Refining and Casting Data
The six refining kettles are operated in a "batch type"
mode. Refining and casting operations were monitored on
December 14 and 15 during testing of the refinery baghouse.
During the December 14 testing, no casting operations occurred
and only two kettles contained lead at any time. During the
December 14 testing, dressing occurred in one of the kettles,
and the lead in the two kettles was pumped to two other
kettles.
During the December 15 tests, casting occurred only
during the first set of tests from 8:30 am to 12:00 noon.
During the f--st set of tests, lead from two kettles was
pumped into the casting machine, three kettles remained full
of lead, and one kettle remained empty. Also, drossing
occurred during the first set of tests on one of the kettles.
During the second set of tests on December 15 from 2:30
pm to 6:30 pm, no casting operations occurred. Also, three
kettles remained full, drossing occurred on two kettles, and
lead was pumped from one kettle to another.
13
-------
3.3.3 Control Device Data
The emissions control devices at the facility were
monitored by Radian personnel and data on relevant parameters
were collected in order to ensure proper operation of the
devices during testing and to relate control performance to
control device operation. Table 3-2 summarizes the control
data collected on the relevant parameters during the emission
tests.
Data on the afterburner, process baghouse, and scrubber
were recorded during the process testing. The afterburner
inlet, operating, and outlet (after water spray) temperatures
were recorded. The inlet temperature, operating temperature,
and outlet temperature averaged 1,480°F, 1,731°F and 1,099°F,
respectively. The average process baghouse pressure drop
across each cell was 2.7 inches of water. The acidity (pH) of
the scrubber solution, the inlet gas temperature to the
scrubber, and the outlet SO2 concentration were also recorded.
The pH averaged 6.51, the inlet gas temperature was 225°F, and
the outlet S02 concentration averaged 132 ppm. During the
first three days of testing, the anhydrous ammonia level in
the 30,000-gallon tank was monitored. Over the 72-hour
period, the scrubber used approximately 6,600 gallons of
anhydrous ammonia.
Pressure drop readings across each cell of the refinery
baghouse, Baghouse No. 1, Baghouse No. 3, and Baghouse No. 5
were collected during the testing of the systems that are
controlled by each baghouse. The average pressure drop for
the refinery baghouse and Baghouse No. 1 was 0.74 and
2.7 inches of water, respectively. Baghouse No. 3 and
Baghouse No. 5 had average pressure drops of 0.8 and
0.7 inches of water, respectively.
All control devices appeared to be operating properly
during the testing period, with one exception concerning the
scrubber. On December 11, the facility had a problem
14
-------
TABLE 3-2. SUMMARY OF CONTROL DEVICE OPERATING DATA
Device
Afterburner
Process Baghouse
Process Scrubber
Refinery Baghouse
Baghoi.be No. 1
Baghouse No. 3
Baghouse No. 5
Parameter
Inlet temperature (°F)
Operating temperature (°F)
Outlet temperature (°F)a
Pressure drop (in.i^O)
PH
Inlet temperature (°F)
Outlet SO£ concentration (ppm)
Pressure drop (in.H2O)
Pressure drop (in.I^O)
Pressure drop (in.H2O)
Pressure drop (in.H?O)
Operating Data
Minimum Maximum
1,278
1,559
1,060
0
5.76
170
2
0
0
0
0
1,563
1,866
1,150
4.9
6.70
240
355
0.9
4.2
1.2
1.5
Average
1,480
1,731
1,099
2.7
6.51
225
132
0.74
2.7
0.8
0.7
After evaporative cooling.
-------
involving low ammonia flow to the scrubber; however, the
outlet SO2 concentrations still remained near the 200 ppm
permitted limit. This problem was corrected by plant
personnel before emissions testing was begun at the scrubber
stack location.
3.4 SUMMARY OF PROCESS MONITORING
The process and control devices appeared to be operating
normally during the emissions testing, with the following
exceptions:
• The problem with the ammonia flow to the scrubber on
December 11, which was corrected before testing was
begun at the scrubber test locations, should have no
impact on the testing;
• The break in charging to the reverberatory furnace
for 15 minutes on December 15, which encompassed a
very small portion of the testing time that day,
should have an insignificant effect on the results
of the testing; and
• The 20-minute repair of the blast furnace skip hoist
on December 17, which appeared to be within the
normal charge cycle of the furnace, should have an
insignificant impact on the testing.
16
-------
BLAST AND REVERBERATORY FURNACE PROCESS CONTROL MONITORING SHEET - EAST PENN MANUFACTURING
Date: 12/8/92 Tests Conducted: VOST *1: SEMI-VOST #\. ALP/KEY »1; DIOXIN 01; HCL »1; HCL
First Test Start Time: 10:30 AM
Last Test End Time: 6:00 PM
Afterburner Information
Temp. Temp, of
of Exhaust Operating Exhaust
Before Temp, of After
A burner A burner A burner8
rime >F) ~rn ~rn
10:30
10:45
11:00
11:15
11:30
11:45
12:00
12:15
12:30
12:45
1:00
1:15
1:30
1:45
2:00
2:15
2:30
2:45
3:00
3:15
3:30
3:45
4:00
4:15
4:30
4:45
5:00
5:15
5:30
5:45
6:00
Average:
Maximum
Minimum:
1530
1559
1553
1545
1546
1538
1515
1511
1513
1525
1540
1542
1512
1512
1515
1531
1545
1563
1559
1529
1502
1500
1516
1527
1532
1524
1515
1491
1459
1433
1466
1521
1563
1433
1779
1798
1752
1758
1764
1785
1744
1740
1763
1717
1695
1649
1759
1772
1789
1797
1723
1749
1675
1723
1714
1728
1751
1752
1788
1781
1747
1717
1714
1707
1727
1744
1798
1649
1105
1085
1112
1096
1089
1104
1107
1086
1113
1103
1076
1093
1126
1099
1078
1103
1118
1082
1079
1111
1113
1067
1090
1150
1101
1070
1101
1101
1084
1077
1076
1097
1150
1070
Baghouse Pressure Drops (in. H,O)
Cell
1
3.2
0.2
2.3
2.5
2.7
2.7
3.0
3.2
3.0
2.4
2.2
2.4
2.5
2.5
3.2
0.2
Cell
2
3.6
3.3
2.9
2.9
3.1
3.0
3.4
3.6
3.7
3.0
2.6
2.8
3.0
3.1
3.7
2.6
Cell
3
.3.1
2.5
2.4
2.5
2.6
2.6
2.9
3.0
3.1
2.4
2.1
2.3
2.4
.
2.6
3.1
2.1
Cell
4
2.7
3.2
2.0
2.2
2.3
2.4
2.6
2.9
2.9
0.0
1.8
2.0
2.2
2.2
3.2
0.0
Cell
5
3.2
3.7
2.5
2.5
2.7
2.7
3.0
3.2
3.2
3.5
2.2
2.4
2.6
2.9
3.7
2.2
Cell
8
2.6
3.0
0.1
2.0
1.9
2.1
2.4
2.4
2.6
2.7
2.3
1.9
1.9
2.1
3.0
0.1
Scrubber Data
Temp.
at SO2
Entrance Concentration
pH (*F) (ppm) Comments
6.64
6.61
6.64
6.65
6.64
6.57
6.64
6.62
6.62
6.62
6.63
6.60
6.60
6.63
6.63
6.61
6.67
6.62
6.58
6.60
6.64
6.64
6.62
6.61
6.61
6.62
6.67
6.57
225
230
230
230
230
230
230
235
240
230
230
230
235
240
235
240
235
235
235
235
235
235
235
235
235
233
240
225
50
230
180
200
90
120
120
60
70
60
65
95
110
125
135
133
135
160
190
70
120
140
110
95
140
190
195
125
230
50
• After evaporative cooling.
-------
03
BLAST AND REVERBERATORY FURNACE PROCESS CONTROL MONITORNG SHEET - EAST PENN MANUFACTURING
Date: 12/9/92 Tests Conducted: VOST #2 & »3: SEMI-VOST »2 & »3. ALP/KEY *2 & »3: DIOXM if 2 & *3: HCL
first Test Start Time: 10:00 AM
Last Test End Tone: 6:30 PM
Afterburner Information
Temp. Temp, of
of Exhaust Operating Exhaust
Before Temp, of After
A_burner A burner AJmrner*
Time
10:00
10:15
10:30
10:45
11:00
11:15
11:30
11:45
12:00
12:15
12:30
12:45
1:00
1:15
1:30
1:45
2:00
2:15
230
2:45
3:00
3:15
3:30
3:45
4:00
4:15
4:30
4:45
5:00
5:15
5:30
5:45
6:00
6:15
6:30
Average:
Maximum:
Minimum:
rn
1354
1374
1387
1406
1426
1416
1438
1414
1378
1403
1431
1462
1460
1461
1454
1452
1428
1431
1441
1465
1467
1469
1479
1475
1479
1509
1506
1497
1508
1499
1496
1483
1492
1493
1480
1452
1509
1354
f R
1633
1700
1709
1708
1715
1711
1703
1688
1711
1717
1702
1713
1707
1711
1726
1712
1714
1680
1711
1746
1729
1723
1716
1720
1711
1731
1724
1740
1719
1710
1705
1706
1712
1710
1707
1711
1746
1633
rn
1079
1090
1107
1088
1094
1098
1105
1095
1108
1113
1089
1090
1098
1102
1108
1094
1103
1100
1095
1101
1103
1080
1117
1101
1082
1106
1116
1098
1082
1111
1113
1079
1097
1121
1108
1099
1121
1079
Baghouse Pressure Drops (in. H2O)
Cell
1
1.8
1.9
2.1
2.3
2.5
2.6
2.7
0.0
1.9
2.1
2.3
2.5
2.7
2.9
3.1
2.4
2.5
3.0
3.3
3.3
3.9
2.1
2.2
2.2
2.3
2.5
2.8
2.9
3.0
1.9
2.5
3.9
0.0
Cell
2
2.1
2.3
2.5
2.6
2.8 .
2.9
3.0
2.6
2.2
2.3
2.7
2.8
2.9
3.2
3.2
2.6
2.8
3.2
3.5
3.5
0.0
2.6
2.4
2.4
2.6
2.8
3.0
3.1
3.2
2.3
2.7
3.5
0.0
Cell
3
1.8
2.0
2.1
2.3
2.4
2.6
1.8
2.2
1.9
2.1
2.4
2.5
2.7
3.0
3.0
2.3
2.5
2.9
3.2
3.2
4.0
2.2
2.2
2.1
2.4
2.6
2.7
2.8
2.9
2.2
2.5
4.0
1.8
Cell
4
1.6
1.7
1.9
2.1
2.2
2.3
2.6
2.8
1.7
1.9
2.1
2.3
2.5
2.7
2.8
2.2
2.3
2.7
3.0
3.0
3.8
1.5
1.9
2.0
2.1
2.3
2.5
2.6
2.7
1.9
2.3
3.8
1.5
Cell
5
1.9
2.1
2.3
2.4
2.6
2.7
2.8
3.2
1.9
2.2
2.4
2.7
2.8
3.0
3.0
2.6
2.6
3.1
3.3
3.4
3.7
2.7
2.3
2.2
2.5
2.6
2.8
2.9
3.0
0.0
2.6
3.7
0.0
Cell
8
* 2.0
1.5
1.7
2.0
2.1
2.3
2.3
2.3
2.1
1.6
1.9
2.0
2.1
2.3
2.5
2.0
2.0
2.3
2.7
2.7
3.3
2.5
0.0
1.6
1.8
2.0
2.2
2.2
2.3
2.2
2.1
3.3
0.0
Scrubber Data
Temp.
at S02
Entrance Concentration
PH
6.62
6.56
6.61
6.61
6.59
6.58
6.58
6.58
6.61
6.59
6.58
6.57
6.58
6.62
6.63
6.59
6.58
6.56
6.54
6.57
6.58
6.57
6.55
6.56
6.52
6.51
6.57
6.51
6.57
6.61
6.58
6.63
6.51
rn
225
230
230
225
225
225
225
225
230
230
235
230
230
235
235
240
235
235
235
240
235
235
240
235
230
235
235
235
230
230
232
240
225
(ppm) Comments
35
90
70
80
115
150
150
225
150
140
170
225
210
160
140
40
85
105
160
260
220
240
355
160
130
160
130
195
190
140
156
355
35
-------
BLAST AND REVERBERATORY FURNACE PROCESS CONTROL MONITORING SHEET - EAST PENN MANUFACTURING
Date: 12/10/92 Tests Conducted: PM/Pb/MULTI-METALS if 1: PM10 - BFO. BHI *1
First Test Start Time: 11:15AM
Last Test End Time: 6:30 PM
H
vo
Afterburner Information
Temp. Temp, of
of Exhaust Operating Exhaust
Before Temp, of After
A_burner A_burner A_burner*
Time
11:15
11:30
11:45
12:00
12:15
12:30
12:45
1:00
1:15
1:30
1:45
2:00
2:15
2:30
2:45
3:00
3:15 .
3:30
3:45
4:00
4:15
4:30
4:45
Average:
Maximum:
Minimum:
rn
1420
1422
1430
1435
1438
1443
1447
1441
1444
1439
1450
1456
1456
1464
1471
1461
1466
1469
1466
1474
1477
1483
1481
1454
1483
1420
m
1707
1707
1712
1711
1713
1717
1707
1709
1719
1702
1710
1710
1712
1707
1710
1707
1713
1712
1721
1705
1709
1705
1705
1710
1721
1702
rn
1104
1097
1106
1089
1099
1103
1110
1093
1095
1104
1102
1105
1100
1093
1092
1103
1109
1100
1081
1106
1119
1102
1083
1100
1119
1081
Baghouse Pressure Drops (in. H.O)
Cell
1
2.5
2.7
3.1
1.8
2.1
2.3
2.5
2.7
2.9
3.2
3.1
4.0
2.0
2.7
4.0
1.8
Cell
2
2.8
3.0
2.5
2.3
2.5
2.6
2.8
3.0
3.1
2.6
3.3
0.0
2.4
2.5
3.3
0.0
Cell
3
2.4
2.6
0.0
1.8
2.1
2.2
2.5
2.6
2.8
0.0
3.0
4.0
2.0
2.2
4.0
0.0
Cell
4
2.3
2.5
2.8
1.5
1.9
2.1
2.6
2.4
2.6
3.0
2.7
3.8
1.6
2.4
3.8
1.5
Cell
5
2.7
2.3
3.3
2.5
2.3
2.4
2.6
2.7
2.9
3.5
3.0
'.
4.1
2.9
2.9
4.1
2.3
Cell
8
2.5
2.4
3.3
2.7
2.3
2.3
2.7
2.8
2.9
3.5
3.1
4.3
3.1
2.9
4.3
2.3
Scrubber Data
Temp.
at SO2
Entrance Concentration
pH
6.56
6.54
6.44
6.41
6.51
6.56
6.42
6.44
6.49
6.54
6.51
6.49
6.56
6.41
(*F) (ppm). Comments
230
230
220
220
220
220
220
225
225
225
235
225
235
220
70
80
120
210
195
Discussing slag tap test
110
200
310
280
220
20
165
310
20
After evaporative cooling.
-------
to
o
BLAST AND REVERBERATORY FURNACE PROCESS CONTROL MONITORING SHEET - EAST PENN MANUFACTURING
Date: 12/11/92 Tests Conducted: PM/Pb/MULTI-METALS *2: PM10 - BFO. BHI02: PM10 - BHO. SCO
First Test Start Time: 9:15 AM
Last Test End Time: 4:00 PM
Afterburner Information
Temp. Temp, of
of Exhaust Operating Exhaust
Before Temp, of After
A_burner A_bumer AJximer*
Time PR (*R PR .
9:15
9:30
9:45
10:00
10:15
10:30
10:45
11:00
11:15
11:30
11:45
1200
1215
12:30
1245
1:00
1:15
1:30
1:45
2:00
2:15
2:30
2:45
3:00
3:15
3:30
4:45
Average:
Maximum:
Minimum:
1278
1322
1351
1396
1429
1455
1445
1474
1488
1498
1508
1477
1474
1460
1458
1454
1461
1463
1457
1449
1443
.1452
1424
1407*
1427
1423
1427
1437
1508
1278
1559
1627
1650
1702^
1704
1701
1715
1702
1716
1713
1715
1704
1711
1714
1706
1711
1723
1714
1705
1713
1705
1706
1696
1658
1678
1682
1705
1694
1723
1559
1074
1119
1110
1118
1067
1103
1100
1101
1090
1060
1085
1143
1101
1083
1101
1118
1103
1074
1098
1101
1098
1107
1095
1095
1105
1108
1103
1098
1143
1060
BaghouM Pressure Drops (in. H,O)
Cell
1
2.5
2.7
2.9
3.1
3.1
3.1
2.2
2.1
2.3
2.4
2.5
2.8
3.0
3.3
1.7
2.2
2.3
2.5
2.5
2.8
3.1
3.6
1.9
2.0
2.3
2.5
2.9
2.6
3.6
1.7
Cell
2
3.7
4.1
4.5
4.6
4.8
3.3
3.7
3.8
3.8
3.1
3.6
4.3
4.4
3.4
3.3
3.1
3.5
4.0
3.9
3.9
4.2
1.0
3.5
3.0
3.8
4.1
4.0
3.7
4.8
1.0
Cell
3
2.6
2.7
3.0
3.0
3.2
3.0
2.3
2.2
2.2
2.4
2.4
2.7
3.0
0.0
2.0
2.2
2.2
2.4
2.6
2.8
3.0
3.6
2.0
2.0
2.4
2.6
2.6
2.5
3.6
0.0
Cell
4
2.1
1.9
2.0
2.7
2.5
2.8
1.2
1.3
1.3
2.2
1.4
2.0
2.5
2.6
2.2
1.1
1.5
2.6
2.0
1.8
2.0
2.6
1.4
1.8
1.8
2.2
2.0
2.0
2.8
1.1
Cell
5
2.6
2.7
3.0
2.6
3.3
3.2
0.0
2.3
2.4
2.5
2.5
2.8
3.0
3.6
2.7
2.3
2.3
2.5
2.7
2.9
3.1
3.9
2.7
2.1
2.4
2.6
2.7
2.6
3.9
0.0
Cell
8
2.5
2.7
2.9
3.1
3.2
3.3
3.3
3.0
2.3
2.5
2.5
2.9
3.1
3.6
2.4
2.9
2.3
2.5
2.6
2.8
3:i
3.7
2.9
2.9
2.3
2.6
2.7
2.8
3.7
2.3
Scrubber Data
Temp.
at SO2
Entrance Concentration
pH • PR (ppm) Comments
6.34
6.28
6.13.
6.02
6.01
5.87
5.87
5.62
5.76
5.79
5.92
6.14
6.34
6.56
6.69
6.70
6.59
6.52
6.49
6.56
6.63
6.66
6.66
6.64
6.61
6.57
6.31
6.70
5.76
200
200
195
195
190
200
205
205
160
170
180
195
200
200
205
205
205 .
205
205
210
210
210
215
215
225
225
202
225
170
110
130
80
140
160
200
210
220
250
220
180
135
80
30
80
20
10
120
310
120
220
20
10
5
Scrubber calibration at 200 ppm
2
122
310
2
* After evaporative cooling.
-------
BLAST AND REVERBERATORY FURNACE PROCESS CONTROL MONITORING SHEET - EAST PENN MANUFACTURING
Date: 12/12/92 Tests Conducted: PM/Pb/MULTI-METALS *3: PM10 - BFO: BHI »3
First Test Start Time: 8:45 AM
Last Test End Time: 11:45 AM
to
H
Afterburner Information
Temp. Temp, of
of Exhaust Operating Exhaust
Before .Temp, of After
A burner A burner A burner*
Time
9:00
9:15
9:30
9:45
10:00
10:15
10:30
10:45
11:00
11:15
11:30
11:45
Average:
Maximum:
Minimum:
rn
1543
1534
1520
1519
1529
1565
1535
1506
1516
1523
1574
1582
1537
1582
1506
rn
1817
1812
1749
1756
1727
1826
1785
1779
1817
1783
1832
1866
1796
1866
1727
rn
1117
1085
1084
1122
1083
1126
1078
1095
1114
1081
1113
1099
1100
1126
1078
Baghouse Pressure Drops (in. H2O)
Cell
1
3.1
3.3
3.4
3.5
3.8
2.1
2.2
2.5
2.7
2.8
3.0
3.1
3.0
3.8
2.1
Cell
2
4.4
4.5
4.8
4.9
4.2
3.5
3.8
3.9
4.0
4.2
4.4
4.2
4.2
4.9
3.5
Cell
3
3.0
3.2
3.4
3.6
0.0
2.2
2.2
2.4
2.6
2.8
3.0
3.0
2.6
3.6
0.0
Cell
4
2.4
2.6
2.6
3.0
3.0
1.8
2.0
2.0
2.4
2.4
2.6
2.6
2.5
3.0
1.8
Cell
5
3.1
3.3
3.4
3.5
4.0
2.1
2.3
2.6
2.8
2.8
3.0
3.2
3.0
4.0
2.1
Cell
8
3.0
3.2
3.3
3.5
3.9
2.9
2.0
2.3
2.5
2.7
2.9
3.1
2.9
3.9
2.0
Scrubber Data
Temp.
at SO2
Entrance Concentration
pH
6.53
6.52
6.54
6.58
6.60
6.57
6.54
6.53
6.58
6.55
6.59
6.55
6.56
6.60
6.52
rn
230
230
230
230
230
230
230
235
235
235
235
235
232
235
230
(ppm) Comments
15
40
80
80
60
50
80
280
185
90
70
85
93
280
15
• After evaporative cooling.
-------
to
REFINING KETTLES PROCESS AND REFINERY BAGHOUSE MONITORING SHEET - EAST PENN MANUFACTURING
Date: 12/14/92 Tests Conducted: REF. BHPMlO»1:REFBHPM/Pb*1:BH*5PMlO*1:BH»5PM/Pb»1
First Test Start Time:
1:45 PM
Last Test End Time: 7:45 PM
Kettle Information
Time
3:00
3:15
3:30
3:45
4:00
4:15
4:30
4:45
5.00
5:15
5:30
5:45
6:00
6:15
6:30
6:45
7:00
7:15
7:30
7:45
Kettle 1
Activity
Seraph
Melted"
Full
Dressing
Full
Full
Full
Kettle 2
Activity
FuH
Full
Empty
Empty
Empty
Empty
Empty
Kettle 3
Activity
Empty
Empty
Empty
Empty
Full
Full
Dressing
Kettle 4
Activity
Empty
Empty
Empty
Empty
Empty
Empty
Empty
Kettles
Activity
Full
Dressing
Dressing
Dressing
Empty
Empty
Empty
Kettle 6
Activity
Empty
Empty
Empty
Empty
Empty
Empty
Empty
Average:
Maximum:
Minimum:
Baghouse Pressure Drops fin. K»O)
Cell
1
0.75
0.75
0.75
0.90
0.75
0.75
0.75
0.75
0.75
0.90
0.90
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.76
0.90
0.75
Cell
2
0.75
0.75
0.75
0.90
0.75
0.75
0.75
0.75
0.75
0.00
0.90
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.73
0.90
0.00
Cell
. 3
0.75
0.75
0.75
0.00
0.75
0.75
0.75
0.75
0.75
0.90
0.00
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.68
0.90
0.00
Cell
4
0.75
0.75
0.75
0.90
0.75
0.75
0.75
075
0.75
0.90
0.90
0.75
0.75
0.75
0.75
0.75
0.75
0:75
0.78
0.90
0.75
Comments
No casting occuring during tests
Discussing increased flow on BH #5
Transferred lead from #2 to #1
Transferred lead from #5 to #3
• Filled with unmetted scrap.
b Scrap melted.
-------
FUGITIVE EMISSIONS CONTROL MONITORING SHEET (BAGHOUSE #5) - EASTPENN MANUFACTURING
Date: 12/14/92
Tests Conducted: REF BH PM10 »1: REFBH PM/Pb *1: BH »5 PM10 »l: BH #5 PM/Pb #1
First Test Start Time: 1:45 PM
Last Test End Time: 7:45 PM
Baghouse Pressure Drops
fin. H,0)
Time
Cell
6
Cell
7
Comments
to
Began dressing kettle #8 — facility increases flow to BH #5 during dressing
suspended testing during dressing
Resumed Testing
Average:
Maximum:
Minimum:
0.8
1.3
0.6
0.9
1.5
0.3
-------
to
REFINING KETILES PROCESS AND REFINERY BAGHOUSE MONITORING SHEET - EAST PENN MANUFACTURING
Dais: 12/15/92 Test* Conducted: BH PM10 02 & 03: BH »5 PM/Pb »2 & »3: BH *5 PM10 02 & 03: BH »5 PM/Pb 02 & »3
FinrtTert Start Time: 8:30 AM Last Test End Time: 8:30 PM
Katie Information
Time
8:30
8:45
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
12:15
12:30
12:45
1:00
1:15
1:30
1:45
2:00
2:15
2:30
2:45
3:00
3:15
3:30
3:45
4:00
4:15
4:30
4:45
5.00
5:15
5:30
5:45
8:00
6:15
6:30
Kettel Katta2
Acttvty Actrvty
Caring 3/4 Ful
Casting 3/4 Ful
Caring 3/4 Ful
Empty Adding*
Empty Dressing
Empty Dressing
.
Empty Fufl
Empty Ful
Empty Ful
Ful Empty
KatleS Katie 4 KetteS
Actfvty Actrvty Activtv
Ful Ful Empty
Ful Dressing Empty
Ful Dressing Empty
Ca.»ilnj Dressing Empty
Empty Full Empty
Ful Empty Empty
FuU Empty Empty
Ful Empty . Empty
Fufl Empty Empty
Ful Empty Empty
Kettee
Actrvty
Fufl
Dressing
Dressing
Fufl
Dressing
Fufl
Full
Dressing
Dressing
Dressing
Average:
Maximum:
Minimum:
Baqhouae Pressure Drabs fin. HjOl
Col
1
0.75
0.75
0.75
0.75
0.75
0.90
0.00
0.75
0.75
0.75
0.75
0.75
0.75
0.00
.0.90
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.90
0.75
0.75
0.75
0.75
0.00
0.90
0.75
'0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.71
0.90
0.00
Cal
2
0.75
0.75
0.75
0.75
0.75
0.90
0.90
0.75
0.75
0.75
0.75
0.75
0.75
0.90
0.00
0.75
0.75
0.75
0.75
0.75
0.75
0.75
O.OQ
0.75
0.75
0.75
0.75
0.90
0.90
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.73
0.90
0.00
CeU
3
0.75
0.75
0.75
0.75
0.75
0.90
0.90
0.75
0.75
0.75
0.75
0.75
0.75
0.90
0.90
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.90
0.75
0.75
0.75
0.75
0.90
0.00
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.90
0.00
CaU
4
0.75
0.75
0.75
0.75
0.75
0.00
0.90
0.75
0.75
0.75
0.75
0.75
0.75
0.90
0.90
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.90
0.75
0.75
0.75
0.75
0.90
0.90
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.90
0.00
Comments
No more casting during tests
Asking about process sheets
Transferred lead from *4 to *3
Transferred lead from #2 to *\
Getting process sheets
• Adding blast lead ingots.
-------
FUGITIVE EMISSIONS CONTROL MONITORING SHEET (BAGHOUSE *5) - EAST PENN MANUFACTURING
C&1± 12/15/92
Tests Conducted: REF BH PM10 »2 & 03: REF BH PM/Pb »2 & »3: BH »5 PM10 02 & »3: BH »5 PM/Pb »2 &
First Test Start Time: 8:30 AM Last Te«t End Time: 6:30 PM
Baghoiae Pressure Drops
(in.HgO)
Tim*
Cell
Cell
7
Comments
Ul
8:30
8:45
9:00
0:15
8:30
9:45
10:00
10:15
10:30
10:45
11:00
11:15
11:30
11:45
12:OO
12:15
12:30
12:45
1:00
2:45
3:00
3:15
3:30
3:45
4:00
4:15
4:30
4:45
5:00
5:15
5:30
0.5
0.6
0.6
0.6
0.5
0.5
0.5
1.0
0.5
0.6
0.6
0.6
0.6
0.6
0.6
0.0
0.2
0.4
0.5
0.5
0.6
0.7
0.4
0.7
0.7
0.7
0.6
0.7
0.6
0.7
0.4
0.5
0.4
0.5
0.3
0.3
0.5
0.3
0.5
0.7
0.5
0.5
0.3
0.5
0.5
0.6
0.0
0.3
0.3
0.4
0.5
0.7
0.0
0.7
0.6
0.5
0.3
0.6
0.3
0.5
No testing on this baghouse from 1:15 to 2:30
Extra kettle filled with unmelted scrap
Average:
Maximum:
Minimum:
0.6
1.0
0.0
0.4
0.8
0.0
-------
FUGITIVE EMISSIONS CONTROL MONITORING SHEET (BAGHOUSE #3) - EAST PENN MANUFACTURING
Date: 12/16/92
Tests Conducted: BH *1 PM10 *1: BH »1 PM/Pb »1 & *2: BH »3 PM10 *1: BH *3 PM/Pb »1 &
First Test Start Time: 11:45 AM Last Test End Time: 7.00PM
to
o\
Baghouse Pressure Drops
Cell
Time 1
12:00 0.7
12
:15 0.7
12:30 0.8
12:45 0.8
1
1
1
1
:00 0.8
:15 0.8
-.30
:45 0.8
2:00 0.9
2
:15 1.0
2:30 0.8
2
:45 1.0
Cell
2
0.3
0.4
0.4
0.6
0.4
0.4
0.5
0.6
0.7
0.4
0.6
(in. H,0)
Cell Cell Cell
3
0.4
0.6
0.6
0.6
0.6
0.6
0.6
0.5
0.6
0.6
0.6
4 5
Cell
6 Comments
0.9 1.0 1.0
0.9 1
0.9 1
0 1.0
0 1.0
1.0 0.0 1.1
0.8 1.0 0.9
0.8 1.
1.0 1.
0 1.0
Discussing material storage area ventilation
1 O.O
1.0 1.0 1.1
1.0 0.0 1.1
0.9 1.0 1.0
1.0 0.0 1.1
3:00
3
.15 0.0
3:30 0.8
3:45 0.8
4
'
11
5
5
5
00 0.8
:00 0.8
:15 0.8
.30 0.8
5:45 0.6
6:00 0.8
6
6
:15 0.8
30 0.8
7:45 0.8
7:00 1.0
Average: 0.6
Maximum: 1 .0
Minimum: 0.0
0.6
0.4
0.4
0.4
%$i$$l!i$$$is&
:ssss?««ga8!8s
liiliiliii
0.4
0.4
0.4
0.6
0.4
0.4
0.4
0.4
0.6
0.5
0.7
0.3
0.6
0.6
O.6
0.6
EESfiQMaGScCB&HWHHfi
iii^iiiiigiiiii«i
Pppj^P^
0.6
0.6
0.6
0.6
0.6
0.6
0.6
0.6
0.6
0.6
0.6
0.4
Recording process data
0.9 1.0 1.1
0.8 1.0 1.0
0.8 1.0 1.0
0.9 1.0 1.0
Bftg&SHftMgftftMgaaiVjfiflMfttf
Blilllii
0.9 1.
No testing 4:15 to 4:45
III
0 1.0
0.9 1.0 1.0
0.9 1.0 0.9
1.0 1.
1 0.0
0.9 1.0 1.0
0.9 1.0 1.0
0.9 1.0 1.0
0.9 1.0 1.0
1.1 1.2 1.1
0.9 0.9 0.9
1.1 1.2 1.1 •
0.8 0.0 0.0
-------
FUGITIVE EMISSIONS CONTROL MONITORING SHEET (BAGHOUSE #1) - EAST PENN MANUFACTURING
Date: 12/16/92
Tests Conducted: BH *1 PM10 *1: BH #\ PM/Pb »1 & *2: BH #3 PM10 »1: BH »3 PM/Pb *1 &
First Test Start Time: 11:45 AM Last Test End Tune: 7:00 PM
to
Baghouse Pressure Drops
Cell
Time 1
12:00 2.0
t 1.1
12:30 2.0
12:45 2.0
1:00 1.7
1:15 2.0
1:30
1:45 2.0
2:00 2.0
2:15 2.0
2:30 2.0
2:45 2.0
3:00
3:15 2.0
3:30 1.8
3:45 2.0
4:00 2.0
5:00 0.7
5:15 2.0
5:30 1.9
5:45 2.1
6:00 2.0
6:15 1.8
6:30 1.9
7:45 1.9
7:00 2.0
Average: 1.9
Maximum: 2.1
Minimum: 0.7
(in. H,0)
Cell Cell
2 3
0.0 3.5
3.3 3.2
. 3.1 3.0
2.9 3.1
2.7 2.9
3.2 3.8
2.8 3.1
2.0 3.0
3.1 3.0
2.5 3.0
2.9 3.0
3.1 3.1
3.0 3.0
3.1 3.1 .
3.1 3.0
mm
2.8 3.3
2.6 3.2
0.3 3.3
3.2 3.2
0.0 3.0
2.8 3.0
2.6 3.0
2.7 3.0
2.9 3.0
2.5 3.1
3.3 3.8
0.0 2.9
Cell
4
3.3
0.4
2.8
0.4
2.7
2.6
2.9
2.5
2.8
2.7
2.9
2.9
3.0
2.9
2.8
•
3.1
0.3
3.4
3.2
3.4
2.8
2.9
2.9
3.0
2.6
3.4
0.3
Cell
5
2.0
2.0
2.0
2.2
1.8
2.0
2.0
1.8
2.0
2.0
2.0
2.0
2.0
2.0
2.0
m
2.0
2.1
2.0
1.0
2.0
1.9
2.0
2.0
2.0
2.0
2.2
1.0
Cell
b
3.6
3.4
3.4
3.7
3.1
3.3
3.3
3.4
3.5
3.5
3.5
3.6
3.6
3.6
3.6
3.4 .
3.8
3.4
3.8
3.4
3.4
3.5
3.5
3.5
3.5
3.8
3.1
Comments
Discussing process with blast furnace operator
Recording process data
No testing 4:15 to 4:45
-------
FUGITIVE EMISSIONS CONTROL MONITORING SHEET (BAGHOUSE *3) - EAST PENN MANUFACTURING
Date: 12/17/92
Tests Conducted: BH »1 PM10 »2 & *3: BH »1 PM/Pb »3: BH *3 PM10 *2 & »3: BH »3 PM/Pb #3; BLAST SLAG
00
First Test Start Time: 8:15 AM
TAP #1 & *2
Last Test End Time: 3:45 PM
Baghouse Pressure Drops
(in. H,O)
Time
9:00
9:15
9:30
9:45
10:00
10:15
10:30
10:45
11:00
Average:
Maximum:
Minimum:
Cell
1
0.6
0.8
0.6
0.8
0.8
0.8
1.0
0.0
0.8
0.7
1.0
0.0
Cell
2
0.4
0.4
0.4
0.4
0.4
0.4
0.6
0.6
0.4
0.4
0.6
0.4
Cell
3
0.6
0.6
0.6
0.6
0.6
0.6
0.6
6.6
0.6
0.6
0.6
0.6
Cell
4
0.9
0.9
0.9
0.9
0.8
0.8
0.2
1.0
6.8
0.8
1.0
0.2
Cell
5
1.0
1.0
1.0
1.0
1.0
1.0
.1
.1
.0
.0
.1
1.0
Cell
6 Comments
1.0
1.0
1.0
1.0
1.0
1.0
1.1
1.1
1 .0 All outlet locations done
1.0
1.1
1.0
-------
FUGITIVE EMISSIONS CONTROL MONITORING SHEET (BAGHOUSE #1) - EAST PENN MANUFACTURING
Date: 12/17/92
Tests Conducted: BH »1 PM10 #2 & *3: BH #\ PM/Pb *3: BH *3 PM10 #2 & #3: BH #3 PM/Pb »3: BLAST SLAG
vo
TAP #1 & #2
First Test Start Time: 8:15 AM
Last
Test End Time: 3:45 PM
Baghouse Pressure Drops
(in. H,O)
Time
8:30
8:45
9:00
9:15
9:30
9:45
10:00
10:15
10:30
10:45
Average:
Maximum:
Minimum:
Cell
1
1.9
2.1
2.1
1.9
2.1
2.1
2.0
2.0
2.0
2.0
2.1
1.9
Cell
2
2.6
2.4
3.1
3.3
2.6
3.3
2.9
3.1
3.0
2.9
3.3
2.4
Cell
3
3.1
3.3
3.4
3.0
3.3
3.3
3.3
3.1
3.3
3.2
3.4
3.0
Cell
4
2.9
0.5
3.3
3.1
3.1
3.0
2.9
3.1
3.3
2.8
3.3
0.5
Cell
5
2.0
2.3
2.3
2.2
2.2
2.0
2.1
2.0
2.2
2.1
2.3
2.0
Cell
6
3.8
4.2
2.0
3.8
3.8
3.8 .
3.9
3.6
4.0
3.7
4.2
2.0
Comments
Discussing process with reverb operator
All outlet locations done
------- |