vvEPA
United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EMB Report 79-CKO-18
September 1979
Air
Iron and Steel
(Coke Oven Battery Stack)
Emission Test Report
National Steel
Granite City, Illinois
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BY-PRODUCT COKE PLANT
Granite City Steel
Division of National Steel
Granite City, Illinois
Prepared for the
U.S. Environmental Protection Agency
Emission Measurement Branch
Research Triangle Park, North Carolina 27711
Prepared by
Clayton Environmental Consultants, Inc.
25711 Southfield Road
Southfield, Michigan 48075
EMB REPORT NO. 79-CKO-18
Work Assignment 17
Contract No. 68-02-2817
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FOREWARD
Two firms prepared this report under contract
to the U.S. Environmental Protection Agency, therefore,
it is presented in two sections. Section I was
prepared by Clayton Environmental Consultants, Inc.,
Southfield, Michigan and includes testing results
for particulate,sulfate, benzene, continuous CO
monitoring and 02, CO, C02, as well as visible
emission data for the battery stack exhaust.
Section II was prepared by TRW Energy Systems Group,
Durham, N.C. and contains benzo (a)pyrene (B(a)P)
sampling data only, and immediately follows Appendix
H of the Clayton report.
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TABLE OF CONTENTS
Page
SECTION I - CLAYTON REPORT
List of Figures i
List of Tables ii
1.0 Introduction 1
2.0 Summary and Discussion of Results 4
3.0 Process Description and Operation 23
4.0 Location of Sampling Points 28
5.0 Sampling and Analytical Procedures 32
APPENDICES
A. Project Participants
B. Field Data Sheets
B-l. Particulate Test
B-2. Sampling Summary Data
B-3. Visible Emissions
B-4. Summary of Visible Emissions
B-5. Process Data
B-6. Project Delays
C. Sulfate Weight by Fraction
D. Benzene Data
E. Carbon Monoxide Data
E-l. Carbon Monoxide Field Data
E-2. Summaries of Carbon Monoxide Data
F. Detailed Summary of Sampling and
Analytical Procedures
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TABLE OF CONTENTS (CONTINUED)
F-l. Determination of Benzene from
Stationary Sources - Method 110
F-2. Determination of Carbon Monoxide
Emissions from Stationary Sources -
Method 10
G. Example Calculations
H. Calibration Data
SECTION II - TRW REPORT
Page
1.0 Presentation of B(a)P Procedures and Data 1
APPENDICES
A. Field Data Sheets and Sampling Summary
Data
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SECTION I - CLAYTON REPORT
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LIST OF FIGURES
Figure Page
1.1 Plan View of Process/Control 3
System Layout
2.1 Relationship of CO Concentration, 16
Stack Opacity and Duct Temperature,
Run 1
2.2 Relationship of CO Concentration, 17
Stack Opacity and Duct Temperature,
Run 2
2.3 Relationship of CO Concentration, 18
Stack Opacity and Duct Temperature,
Run 3
4.1 Inlet Sampling Location 29
4.2 Outlet Sampling Location 31
5.1 Particulate Sampling Train 34
5.2 Sampling Train for Continuous 40
Monitoring of Carbon Monoxide
5.3 Integrated Bag Sampling Train 43
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LIST OF TABLES
Table Page
2.1 Particulate Weight by Fraction 5
2.2 Particulate Concentrations and 7
Emission Rates
2.3 Sulfate Concentrations and Emission 9
Rates
2.4 Sulfate as Percent of Particulate 10
by Weight
2.5 ESP Removal Efficiencies I2
2.6 Benzene Concentrations and Emission 20
Rates
2.7 Exhaust Gas Composition 22
3.1 Plant Design and Operation Record 25
ii
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1.0 INTRODUCTION
The U.S. Environmental Protection Agency (EPA)
retained Clayton Environmental Consultants, Inc. to
determine various gaseous and particulate emissions
on the C-battery at Granite City Steel, Division of
National Steel, in Granite City, Illinois. Sampling
was conducted at the inlet and outlet of a United-
McGill dry electrostatic precipitator (ESP) which
cleans the C-battery underfire flue waste gas. The
results of this study will be used in research and
development efforts for supporting New Source
Performance Standards for coke oven battery stacks in
the iron and steel industry. This study was commis-
sioned as EMB Project No. 79-CKO-18, Contract No.
68-02-2817, Work Assignment 17.
The testing program included the following:
(1) triplicate samples from the ESP inlet and
outlet for particulate and sulfate analyses;
(2) integrated bag samples from the inlet for
benzene and Orsat analyses;
(3) continuous carbon monoxide monitoring at
the inlet during the particulate runs (by
EPA-Method 10, NDIR analyzer); and,
(4) visible emission recordings for the duration
of each particulate sample run, read at the
battery stack exhaust.
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Auxiliary data included exhaust gas temperatures
and flowrates as determined from the traverses.
Figure 1.1 presents a plan view of the process/
control system layout as tested. A list of the proj-
ect participants is included as Appendix A.
- 2 -
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i
OJ
N 89.
Electrostatic Precipitator
Inlet from
C-b,attery
:underfire
waste-gas
flue
Outlet sampling
location
Inlet
sampling
location
tack
(Not to scale)
Figure 1.1. Plan view of process/control system layout,
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2.0 SUMMARY AND DISCUSSION OF RESULTS
Particulate weights, by fraction, are presented
in Table 2.1. Comparing the weight gain of the same
fraction for the different runs can be misleading since
stack flowrates, sampled gas volumes and possible
differences in process operations should also be
considered when comparing different runs.
Tables 2.2 and 2.3 present the filterable and
total concentrations and emission rates for particulate
and sulfate, respectively. TotaJ. particulate concentra-
tions were determined by weighing the impinger contents
and water and acetone rinses after evaporation, and
did not include an ether/chloroform extraction.
Concentrations are expressed as grains per dry
standard cubic foot (gr/dscf) and milligrams per dry
standard cubic meter (mg/dscm). Emission rates are ex-
pressed as pounds per hour (Ib/hr) and kilograms per hour
(kg/hr). Stack gas flowrates in dry standard cubic feet
per minute (dscfm) and temperature (F) are also presented.
Table 2.4 presents sulfate as a percent of particulate
based on the filterable and total emission rates. No
averaged data for Run 3 at the inlet were included in
the discussion because an undetermined amount of the
front acetone wash was spilled when the sample bottle
was accidentally broken in the field.
- 4 -
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TABLE- 2.1. PARTICULATE WEIGHT BY FRACTION, MILLIGRAMS
Sampling Sample
Location Number
1
Inlet
C 2
Ba ttery
3
1
Outlet
1 C 2
*" . Battery
3
Front
Acetone
Wash
1137.3
551.8
191. 2a
1040.7
927.8
329.5
38. 4b
127. lc
110-mm
Type A
Glass-Fiber
Filter
1145.9
341.6
383.6
1420.9
178.3
193.9
Filterable
Particulate
2283. 2
893.4
574.8
2461.6
1106. 1
688.9
Back
Ace tone
Wa sh
195.7
5.9
20.9
856.8
15. 1
3. 2
Impinger
Content s
and Water
Wa sh
235.7
57. 7
35. 7
674.9
23.0
14.6
Total
Particulate
2714.6
957.0
631.4
3993.3
1144. 2
706.7
An undetermined amount of the acetone wash was spilled when the sample bottle was accidentally
broken.
Methylene chloride rinse.
*
"Benzene rinse.
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PARTICULATE RESULTS
Inlet
Filterable particulate concentrations at the
inlet (Table 2.2) were 0.403 and 0.162 gr/dscf
(923 and 371 mg/dscm), respectively and averaged
0.283 gr/dscf (647 mg/dscm). Total particulate
concentrations were 0.479 and 0.173 gr/dscf (1100
and 398 mg/dscm, respectively) and averaged 0.326
gr/dscf (749 mg/dscm).
Filterable particulate emission rates were 141
and 55.2 Ib/hr (63.8 and 25.1 kg/hr), respectively,
and averaged 98.1 Ib/hr (44.5 kg/hr). Total particu-
late emission rates were 167 and 59.1 Ib/hr (75.9 and
26.8 kg/hr), respectively, averaging 113 Ib/hr (51.4
kg/hr).
Outlet
Concentrations of filterable particulate at the
outlet (Table 2.2) ranged from 0.105 to 0.370 gr/dscf
(240 to 847 mg/dscm) and averaged 0.213 gr/dscf (487
mg/dscm). Concentrations of total particulate ranged
from 0.107 to 0.601 gr/dscf (246 to 1370 mg/dscm)
and averaged 0.292 gr/dscf (668 mg/dscm).
Emission rates for filterable particulate ranged
from 42.0 to 155 Ib/hr (19.1 to 70.4 kg/hr) and aver-
aged 88.8 Ib/hr (40.3 kg/hr). Total particulate emis-
- 6 -
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TABLE 2.2. PARTICULATE CONCENTRATIONS "AND EMISSION" RATES
Sample
Number
and
Location
1979
Sample
Date
Stack Gas
Parameters
Flowrate
d s c f m
Temp
F
Concentration
Filterable
gr/dscf
mg/dscm
Total
gr/dsc f.
mg/dscm
Emission Rate
Filte
Ib/hr
rable
kg/hr
Total
Ib/hr
kg/hr
Inlet
1
2
3a
i
Outlet
1
2
3
7-
7-
7-
Average
7-
7-
26
27
28
26
27
7-28
Average
40,
39,
39,
39,
48,
49,
46,
48,
700
700
200
900
900
500
800
400
756
734
726
739
627
620
620
622
0
0
0
0
0
0
0
0
.403
.162
. 108
.283
.370
. 164
.105
. 213
923
371 .
248
647
847
375
240
487
0.
0.
0.
0.
0.
0.
0.
0.
479
173
119
326
601
169
107
292
1100
398
272
74;9
1370
388
246
668
141
55. 2
36.4
98.1
155
69.5
42.0
88.8
63.
25.
16.
44.
70.
31.
19.
40.
8
1
5
5
4
5
1
3
167-
59. 1
40.0
113
252
71.9
43.1
122
75.9
26. 8
18. 1
51.4
114
32.6
19.6
55.4
An undetermined amount of the acetone wash was spilled when the sample bottle was accidentally
broken; results were not included in the average.
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sion rates ranged from 43.1 to 252 Ib/hr (19.6 to
114 kg/hr) and averaged 122 Ib/hr (55.4 kg/hr).
SULFATE RESULTS
Inlet
Filterable concentrations of sulfate at the inlet
(Table 2.3) were 0.015 and 0.055 gr/dscf (35.2
and 126 mg/dscm, respectively) and averaged 0.035
gr/dscf (80.6 mg/dscm). Total sulfate concentrations
were 0.045 and 0.062 (102 and 141 mg/dscm), respectively,
averaging 0.054 gr/dscf (122 mg/dscm).
Filterable sulfate emission rates were 5.36 and
18.7 Ib/hr (2.43 and 8.50 kg/hr, respectively) and
averaged 12.0 Ib/hr (5.47 kg/hr). Total sulfate
emission rates were 15.6 and 21.0 Ib/hr (7.07 and 9.54
kg/hr),respectively, and averaged 18.3 Ib/hr (8.31
kg/hr).
Sulfates as a percent (by emission rate) of.filter-
able particulate (Table 2.4) were 3.8 and 33.9 percent
and averaged 18.9 percent. Sulfates as a percent
of total particulate were 9.3 and 35.5 percent and
averaged 22.4 percent.
Aliquots of inlet Sample Nos. 1 and 2 liquid
fractions were analyzed for sulfate, whereas Sample No.
3 at the inlet and all outlet samples were analyzed
from dried residue remaining following the particulate
determination. The percentage sulfate retained was
- 8 -
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TABLE 2.3. SULFATE, CONCENTRATIONS AND EMISSION RATES
Sample
Number
and
Location
. 1979
Sample
Date
Stack Gas
Parameters
Flowrate
d s c f m
Temp
F
Concentration
Filterable
gr/dscf
mg/dscm
Total
gr/dscf mg/dscm
Emission Rate
Filte
Ib/hr
rable
kg/hr
Total
Ib/hr
kg/hr
Inlet
1
2a
3b
Outlet
1
2
3
7-26
7-27
7-28
Ave rage
7-26
7-27
7-28
Average
40,700
39, 700
39, 200
39, 900
48,900
49,500
46, 800
48,400
756
734
726
739
627
620
620
622
0.015
0.055
0.023
0.035
0.010
0.061
0.027
0.033
35.2
126
52. 2
80.6
22.4
141
60.9
74.8
0.0453
0.062
0.028
0.0 54
0.016
0.062
0.027
0.035
102a
141
63.0
12 2-
36.5
143
62.6
80. 7
5.36
18.7
7.66
12.0
4. 10
26. 1
10.7
13.6
2.43
8.50
3.48
5.47
1.86
11.8
4.84
6.17
15 .6a
21. 0
9. 25
18.3
6.68
26.4
11.0
14. 7
7.07a
9.54
4.20
8.31
3.03
12.0
4.98
6. 67
a An aliquot of the original sample was used for sulfate determinations; all. other determinations
were made on the residue, remaining after the sample was dried and weighed for the particulate
^determination.
An undetermined amount of the acetone wash was spilled when.the sample bottle was=accidentally
broken; results were not included in the average.
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TABLE 2.4. SULFATE AS PERCENT OF PARTICULATE
(Based on Emission Rates)
1
I1
o
1
Sample
Number
1
2
3
Average
Inlet
Filterable
Percent
3.8
33. 9a
21. Ob
18. 9
Total
Percent
a
9.3
35. 5a
23. lb
22.4
Outlet
Filterable
Percent
2.6
37.6
25.5
21.9
Total
Percent
2.7
36.7
25.5
21*6
aOriginal sample aliquot was used for sulfate determination, all other
determinations were made on the residue.
ฐAn undetermined.- amount of the acetone wash was spilled when the sample
bottle was accidentally broken; results were not included in the
average.
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much lower for Sample No. 1 (inlet and outlet) than
Sample Nos. 2 and 3. despite the different analytical
methods used for the determinations at each location.
Therefore, the reason for this difference may lie in
the process itself.
Outlet
Filterable concentrations of sulfate at
the outlet (Table 2.3) ranged from 0.010 to 0.061
gr/dscf (22.4 to 141 mg/dscm) and averaged 0.033
gr/dscf (74.8 mg/dscm). Total sulfate concentrations
ranged from 0.016 to 0.062 gr/dscf (36.5 to 143 mg/dscm)
and averaged 0.035 gr/dscf (80.7 mg/dscm).
Filterable sulfate emission rates ranged from
4.10 to 26.1 Ib/hr (1.86 to 11.8 kg/hr) and averaged
13.6 Ib/hr (6.17 kg/hr). Total sulfate emission rates
ranged from 6.68 to 26.4 Ib/hr (3.03 to 12.0 kg/hr)
and averaged 14.7 Ib/hr (6.67 kg/hr).
Sulfates as a percent (by emission rate) of filter-
able particulate at the outlet (Table 2.4) ranged from
2.6 to 37.6 percent and averaged 21.9 percent. Sulfates
as a percent of total particulate ranged from 2.7 to
36.7 percent and averaged 21.6 percent.
REMOVAL EFFICIENCY
The removal efficiencies for the filterable portion
of both particulate and sulfate are presented in Table
2.5. The filterable particulate efficiencies were
-9.9 and -25.9 percent and averaged - 17.9_percent,
- 11 -
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TABLE 2*5. ESP REMOVAL EFFICIENCIES
Sample
Number
1979
Sample
Date
.Percent Efficiency
Filterable
Particulate
1 7-26 - 9.9
2 7-27 - 25.9
3 7-28 a
.Average - 17.9
Filterable
Sulfate
23.5
- 39.6
a
- 8.1
An undetermined amount of the acetone probe wash at the inlet was spilled
when the sample bottle was accidentally broken making efficiency determination
unreliable.
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while filterable sulfate efficiencies were 23.5 and
-39.6 percent and averaged -8.1 percent.
In view of the unusual efficiency results, several
checks of all data were made including all calibrations,
field procedures, sampling methods and calculations.
It may be noted that the average percent isokinecity
at the inlet and outlet were 100.0 and 101.2, respec-
tively. Transfer procedures "were all performed in a
dust-free area. All sample log-in and analytical
procedures were also reviewed, which indicated no
inconsistancies. Calculations were reviewed by several
persons, again indicating consistent results. Further-
more, a TPvW test group sampled the same locations ,. ..'
simultaneously for benzene (a)pyrene (B(a)P). Results
from the TRW runs corroborated with the Clayton results.
It is highly unlikely that two source sampling firms
working independently of each other would achieve similar
results if sampling techniques were in error.
In light of these quality assurance reviews, the
test results appear to be valid. It is difficult to
draw conclusions with respect to the performance of the
ESP based on the data obtained, except that the ESP
removal efficiency of battery stack particulate is poor.
However, several observations are presented.
- 13 -
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The project was initially plagued with repeated
power failures, as evidenced by the disruptions in
sampling time, making correlations between CO data,
opacities, and stack temperatures sometimes impossible
for Run No. 1. These problems are noted in Appendix
B-6. All oven activity that occurred during each test
is also detailed in Appendix B-5.
When correlating the process operating data
with Figures 2.1, 2.2, and 2.3 on pages 16, 17, and
18, respectively, which illustrates all reversal
and charging activity times during each run, several
observations can be made.
The field data in Appendix B-l shows that when
an inlet filter would become suddenly blinded (plugged
or clogged), a charge had generally preceded this event
by several minutes. This may indicate poor conditions
of some oven walls in this battery. There were several
distinct temperature drops noted at the outlet sampling
points which were located closed to the stack wall (outer
points are cooler than the inner points). The largest
temperature drop generally appears on the last (bottom)
point of the vertical port. At this point, the temperature
is influenced by the cooler stack wall and also, the
convection of the hot stack gases which tend to rise
to the top of the -horizontal duct.
- 14 -
-------
The data reflect an average 21-percent increase
in the outlet flowrate over the inlet flowrate (dscfm),
which indicates possible air inleakage between the two
sampling locations. This leak could be a possible source
of particulate material being introduced into the ESP
system downstream of the inlet sampling location.
However, this leakage is not likely to contribute
to higher grain loadings at the outlet since ambient
particulate concentrations would have to be significantly
higher than those found in the inlet gas. Another
possible explanation for the higher outlet loadings
is reentrainment of particulate within the ESP itself.
VISIBLE EMISSION AND CARBON MONOXIDE RESULTS
Visible emissions from the coke oven battery
stack were recorded for the duration of each particu-
late run, except Run 1, when visible emissions were
abbreviated due to darkness. The observations were
performed in accordance with EPA Method 9 by a
qualified visible emission observer. A graphic
summary of one minute average opacity readings is
presented in Figures 2.1, 2.2, and 2.3 for the three
test runs, respectively. Additional visible emission
data is included in Appendix B-4. Carbon monoxide
(CO) was monitored continuously during each of the
particulate runs. Linear recordings were averaged
- 15 -
-------
700.
600_
i
50(L
4oa
70GL
30-
cr>
3000-
aooor ;
1000
1517
I ' 1 I I 'I
....,.,,.-<;-:- I;;!:v1-!:
^^H^R-i^t1'!^
;:Lii.- Outlet temp, F H . |'
j,,-1 ' r '! p
; , . 11 I
-;i: -i,:-!ii.i !. iijih.
-,-.-ii..u..i-.i.,4M.-;>;_
ilii i;;i,.HH*t tp ITi
- ':-:n!"h-j.Tru-T rri-.;'
1 llnlettemp,
Opacity,, per cent \ '"-'_i....''_;
. . -/ I..;. ' . . !ป:..! .' . .. .._UL_ .--'.
/V |::!-i:iikH;:ii-i;:!;-i
\ T Charge [ ,
1600
I- : . ! . .I. , I. . . :. f ,1 ... J
. - I .::: In f.' :'::...
ill!] l.CO Concentration, ppm
iik) w
1630
: - J i4
1700
2000
I
2030
Figure 2.1. Relationship of CO concentrations, stack opacity, and duct temperature
Run 1
-------
: TOutlet temp, V .L::.
' - i '
Inlet temp, F
H,j;;:;i :< H;!}!^)-^ rTJ.^%-
^M?Wffn&-iฃ
Opacity, percent p ; -
I AReversalj.
-r!|ikiil'::;-h = !:|liii|ii:N:i|i|ii-n!!!'iA:': !| Mill = '!!:! jini.!;
T | T Charge
] CO Concent-rat-i-on-:, -ppm | . ;i ,!
1-' Ji.i_J.! :__:. :-iu^--:
1700
Figure 2.2. Relationship of CO concentrations, stack opacity and duct temperature
Run 2
-------
600_
co
i
Outlet temp, F
|lnlet Temp, F
[Opacity, percent!
A. Reve
'', '' 11'
.'! ", JlJl. .:. i
CO Concentration, ppm ;
3000^
2000 L
1000-
1300 1330 1610= 1630 1700 1730
Figure 2.3. Relationship of CO concentrations, stack opacity, and duct temperature
Run 3
-------
over one minute intervals and the results also
presented graphically in Figures 2.1, 2.2, and 2.3.
In addition to the above data, inlet and outlet stack
temperatures and charge and reversal cycles are also
presented on these graphs. Appendix E-2 presents 1-
minute averages of CO concentration.
In each test the rise and fall in CO concentra-
tions is generally preceded within a few minutes
by a corresponding rise or fall in stack opacity.
Since CO was monitored continuously and opacity was
read every 15-seconds, some fluctuations in CO
may not be correlated directly with opacity fluctua-
tions. However, a general trend seems to be apparent.
On Run 3, pump problems in the CO train were encountered
from 1235 to 1335, which invalidates the CO data for
this time period. Data for this period was not
displayed in Figure 2.3.
BENZENE RESULTS
Results of the benzene analyses are presented
in Table 2.6. Following the completion of Run 2,
the bag sample collected had developed a leak and
the sample was voided. Benzene concentrations were
0.11 and 0.16 ppm and averaged 0.14 ppm. Emission
rates were 0.05 and 0.08 Ib/hr (0.03 and 0.04 kg/hr),
respectively, and averaged 0.07 Ib/hr (0.04 kg/hr).
These results showed a high reproducibility although
they were lower than had been anticipated.
- 19 -
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TABLE 2.6. BENZENE CONCENTRATIONS AND EMISSION RATES
Sampling
Location
Sample
Number
Sample
Date
Concentration
ppm
Emission Rate
Ib/hr
kg/hr
Battery
C
Inlet
1
. a
2
3
Average
7/26/79
7/27/79
7/28/79
0.11
0.16
0.14
0.05
0.08
0.07
0.03
0.04
0.04
3 Inadequate sample collected for Run 2, therefore no data reported,
- 20 -
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Exhaust Gas Composition
Table 2.7 presents the results of the exhaust
gas composition and moisture content analyses.
Carbon dioxide, oxygen, and carbon monoxide concentra-
tions averaged 3.6, 13.8, and 0.3-percent, respectively,
over the three sample runs. The Orsat CO concentration
confirms the low continuous CO values.
- 21 -
-------
TABLE 2.7. EXHAUST GAS COMPOSITION (INLET)
Sample
Number
Moisture
Content
Pe rcent
Exhaust Gas Composition, Dry Basis
Pe rcent
Carbon
Dioxide
Oxygen
Carbon
Monoxide
Nitrogen
and Inerts
j
I
N>
1
2
3
Average
13.1
15.3
15.8
14.7
3.7
3.6
3.6
3.6
16.0
12.1
13.4
13.8
0.6
0.2
0.1
0.3
79.7
84.1
82.9
82.2
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3.0 PROCESS DESCRIPTION AND OPERATION
(supplied by Midwest Research Institute)
As part of the work being conducted for the
development of national emission standards for air
pollutants emitted from coke oven battery stacks,
emission tests are being performed on various well-
controlled sources. Such tests were conducted on .
Battery C at National Steel Corporation's Granite
City, Illinois facility because an electrostatic
precipitator (ESP) had recently been installed and
began operating in March 1979. With all three of the
parallel ESP modules on-line, the Granite City Steel
ESP has the highest specific collection area of any
ESP applied to coke oven battery stack emissions.
Therefore, the ESP serving Battery C at Granite City,
Illinois, was selected for these emission tests.
There are three coke oven batteries at Granite
City Steel's integrated steel plant, designated as
Batteries A,B, and C. Only Batteries B and C are
operating. Battery A was torn down and is presently
being completely rebuilt with 18 additional ovens.
Future plans include rebuilding Battery B with four less
ovens which is tentatively scheduled for June 1980.
After both reconstructed batteries are on-line, Battery
C will be shutdown and rebuilt with 14 less ovens.
- 23 -
-------
Battery C is a 61-oven Koppers-Becker gun-flue
battery, underfired with undesulfurized coke oven gas
supplied by the by-product plant. During the period
covering the emission tests, 36 coke ovens were
operating on a coking period of 17.5 hf with two ovens
(Nos. 155 and 163) on an extended coking cycle. The
other 25 ovens (Nos. 123-126, 131, 132, 144, 146, 147,
154, 157, 161, 162, 174-177, 181, and 193) were bricked-
up or out of service.
The C Battery started operating in 1961 and was
rehabilitated in 1976. This cold end--flue rehabilitation
included gun flue, crossover flue and end flue repairs.
Plant design and operational data for Battery C are
presented in Table 3,1. Maintenance techniques used
on Battery C were spray patching, cleaning steam aspira-
tors and stand pipes, and brushing gun-flue nozzles.
A hand-held slurry spraying gun is used to patch
the end flues and door jambs of the ovens. The spray
patching occurs after an oven has been pushed and before
the doors are replaced on the oven. This procedure
is employed more frequently to the coke side of the oven
than to the pusher side because more wear occurs on
that side.
An oxygen lance is used to decarbonize the steam
aspirators and coke oven standpipes. This procedure
will either burn the carbon deposits or just knock them
- 24 -
-------
TABLE 3.1. PLANT DESIGN AND OPERATION RECORD
Date
Plant Name Granite City Steel
Plant Location Granite City, IL.
Battery No. _C
Name of Plant Contact Dr. John Manda
Type of Ovens and Designer Gun Flue, Koppers-Becker
Date Built 1961
Date of Last Reh'abilitation 1976
Type of Last Rehabilitation End flue, Crossover Flue, and gun flue repairs
Number of Ovens Total 61 In Service 36
Size of Ovens Height 13' . Width 17" , Length 40'
Type of coke produced Blast furnace coke '
Normal coking time (hr) 20
Coal charged per oven (tons) 16.6
Reversal period (min) 30
Nozzle decarbonization method Air aspirated through open carbon caps
Is flue gas recirculated? no
Type of fuel gas coke oven Heating value 450 Btu/scf
Is fuel gas desulfurized? -no
Note use of stage charging, preheated coal, etc. stage charging is
used
Stack height and top diameter 261' 4" Ht. 10' diam.
Test location (stack or waste heat canal) inlet & outlet ESP(provide sketch)
' - *
Control method used electrostatic precipitator
Fuel gas analysis (1978 avg.) Coal analysis (April 1979)
^Component V o 1. % . Component Vol.%
C02 3.6 Ash 6.76
111. 1.3 S 1.25
1.6 HO ' Q.S3
VH ?s LI
53.0
WiซMIWM
19.3
O 3U
H22s :
- 25 -
-------
off. The other maintenance procedure uses a wire
brush on a 20-foot long rod which fits inside the
gun-flue nozzles and cleans any carbon build-up
on the nozzle which may restrict fuel gas flow.
The new ESP on Battery C stack began operating
in March 1979. The ESP was built by United McGill
using a point-to-plane design. The ESP is divided
into three units operating in parallel. Each unit
has four separate sets of electrical fields, numbered
1, 2, 3, and 4. For each unit two electrical controls
serve fields 1 and 3 together and fields 2 and 4
together.
The ESP installed on Battery C was designed for
a total gas flow rate of 2,600 actual cubic meters per
minute (92,000 acfm). It has three parallel modules
and the design gas velocity, with two modules on-line,
was 0.88 m/sec (2.9 ft/sec). Each module has a
collection area of 2,550 m2 (27,440 ft2) and all three
modules together have a collection area of 7,650 m2
o
(82,320 ft ). Therefore, the design specific collection
ey
area, with all three modules in service, was 2,942 m /1,000
acm/min (895 ft2/!,000 acfm).
In June 1979 United McGill made minor adjustments
to all three units to prevent reentrainment during the
cleaning mode. Instead of cleaning fields 1 and 2
together, United McGill staggered the fields being rapped.
- 26 -
-------
This new arrangement of rapping fields 1 and 3 and
fields 2 and 4 maintains a collecting field in operation
at all times during the cleaning mode. A United McGill
field engineer was present during the testing to
monitor the performance of the ESP. However, no
adjustments were made to the ESP while sampling
activities were being conducted.
During each test day, process operating data were
obtained at approximately 1-hour intervals. The time
that each oven was pushed and charged was recorded
whenever possible. All process operating logs and
charts are included in Appendix Br-5a. The Battery C
oven push and charge log sheets and ESP log sheets
are also presented in Appendix B-5.
Granite City Steel's personnel, who provided
assistance during the testing were Dr. Manda, Mr. Hoffman,
Mr. Piatt and Mr. Siebenberger. Mr. MacDonald from
United McGill monitored the ESP performance.
aNote: Process operating data and copies of operating
charts have not been included, since National
Steel has claimed them to be confidential.
- 27 -
-------
4.0 LOCATION OF SAMPLING POINTS
Inlet
The ESP inlet sampling location was a 59.4-inch
(150.1-cm) I.D. duct from the battery-C waste heat
flue, located approximately 50 feet (15.2 meters)
above ground, and 10 feet (3.0 meters) upstream of
a 90-degree bend, which provided adequate upstream/
downstream distances to disturbances. The duct was
accessed through two three-inch ports located at a
90-degree separation about the stack circumference.
Each traverse (two) consisted of 12
points. Velocity pressures and temperatures were
measured at each of the 24 sampling points. Figure
4.1 is a diagram of the inlet sampling location
showing each of the traverse points and their
respective distances from the duct wall.
The inlet sampling site was located very close
to the battery and coke oven quench car, exposing
sampling personnel to major hazards, i.e., heat,
smoke, and flames. To minimize these hazards, a
sheet steel platform with three walls was erected
at the inlet duct, along with an insulation pad
on the platform floor. Additionally, a steel catwalk
connecting the precipitator outlet site to the
inlet location was constructed. This allowed the
sampling crew a quick evacuation of the inlet area,
and also permitted a safe location for the sampling
equipment.
- 28 -
-------
f i~-+-+
j
i
1
6 f
+
+
i-
+
_1 1
| |
South port
59.4" I.D.
To ESP
Catwalk
to ESP
Sampling
platform
, I
West port
To
ESP
Point
1
2
3
4
5
6
7
8
9
10
11
12
Distance
(Inches )
1.3
4.0
7.0
10.5
14.9
21.1
38.3
44.5
48.9
52.4
55.4
58.1
10' '
'
50'
I
r i
, ( Catwalk to
1 l
i * ;
i
ESP
1 1
Protective wal
and
Is
sampling platform
Inlet from C,
underfire was
flue
-
bat t
te-gฃ
Figure 4.1. Inlet sampling location.
-------
Outlet
At the ESP oulet sampling location, two three-
inch ports were used to gain access to the 59.5inch
(151.1-cm) I.D. duct which extends horizontally from
the ESP to the battery stack. The port located at
the top of the duct did not provide sufficient verti-
cal clearance to maneuver the probe. Thus, an addi-
tional port was installed at the bottom of the duct.
Scaffolding was used to gain access to this port
location. Each traverse (two) consisted of 20 points.
Velocity pressures and temperatures were measured at
each of the 40 sampling points. Figure 4.2 is a
diagram of the outlet sampling location showing each
of the traverse points and their respective distances
from the duct wall.
- 30 -
-------
Horizontal
port
Electrostatic
Precipitator
To C battery
stack
59.5" I.D,
Outlet
sampling
location
Electrostatic Precipitator
Vertical port
Point
1
2
3
4
5
6
7
8
9
10
Distance
(inches )
0.8
2.3
4.0
5.8
7.7
9.8
12.1
14.9 .
18.2
23.1
Point
11
12
13
14
15
16
17
18
19
20
Di stance
(inches )
36.4
41.3
44.6
47.4
49.7
51.8
53.7
55.5
57.2
58.7
Platform
A A A A
19 1/2'
-H*
31
Figure 4.2. Outlet sampling location.
-------
5.0 SAMPLING AND ANALYTICAL PROCEDURES
Triplicate two-hour particulate samples were
extracted isokinetically and simultaneously at
both inlet and outlet locations of the ESP.
Twenty-four points were sampled at the inlet
location for five minutes per point while forty
points were sampled at the outlet location for
three minutes per point. During each run, the
probe, Pitot tube, and thermocouple assembly were
moved to each sampling point, the velocity pressure
and temperatures of the exhaust gas were measured,
and isokinetic sampling flowrates were adjusted
accordingly using an orifice-type meter to indicate
instantaneous flowrates.
Proper nozzle alignment with the flue-gas
stream was maintained throughout the test at both
testing locations without difficulty. The bottom
port at the outlet sampling location required a
special vertical support system which was construc-
ted by Clayton Environmental Consultants, Inc. The
impinger assembly was moved as required at the outlet
location to gain access to the bottom port. All field
data sheets are included in Appendix B.
- 32 -
-------
The sampling train was checked for leaks before
and after each sample run in accordance with the
requirement that the initial leak rate shall not
exceed 0.02 cfm at 15-inches of mercury vacuum.
The final leak rate shall not exceed 0.02 cfm at
the greatest vacuum occurring during the test.
A modified EPA Method 5 sampling train was used
at both locations (Figure 5.1). The sampling train
consisted of a sharp, tapered, stainless steel sam-
pling nozzle; an unheated glass probe assembly (Method
5 modification); flexible unheated Teflonฎ tubing
(Method 5 modification) leading to a heated cyclone
assembly (Method 5 modification) including a 110-mm
glass-fiber filter; two Greenburg-Smith impingers,
the first modified, the second standard, each contain-
ing 100-ml of distilled water; an empty modified
Greenburg-Smith impinger; a modified Greenburg-Smith
impinger containing approximately 300-grams of silica
gel; a leakless pump with vacuum gauge; a calibrated
dry gas meter equipped with bimetallic inlet and outlet
thermometers; and, a calibrated orifice-type flowmeter
that was connected to a O-to-10-inch range inclined
(water gauge) manometer.
For the first half of Run 1 at the inlet and the
entire first run at the outlet, the cyclone was not
- 33 -
-------
Nozzle
Thermometer
Unheated
glass probe
Unheated
Teflonฎ line
IT*
S-type
Pitot
Inclined
manometer
oc
Heated
cyclone
Inclined
manometer
Heate'd"
lllO-mra filter
Dry 300 g
trap silica gel
Thermometers
Bypas s
valve
Vacuum
line
Main
valve
Vacuum
gauge
ff ^
(J
Leakless
pump
Dry gas
meter
Figure 5.1. Particulate sampling train.
-------
used. Due to the unusual resinous character of the
particulate in the exhaust gas, which caused the
filters to blind (plug or clog), difficulty in
maintaining the sampling rate was experienced.
It was decided by the Clayton project leader and the
EPA Technical Manager that modifying the train by
adding a cyclone upstream of the filter would prevent
this situation. An unheated probe and Teflonฎ flex-
line was used because of the extremely hot stack
gas (740F inlet and 620F outlet).
/
The impinger train was immersed in an ice bath
to maintain the temperature in the last impinger at
70F or less. All of the sampling train glassware was
connected by ground glass joints, sealed with stop-
cock grease, and clamped to prevent leakage. A
calibrated S-type Pitot tube was connected to the
sampling probe and velocity pressures were read on
the inclined manometer. An iron-constantan (I/C)
thermocouple, attached to the Pitot-probe assembly,
was connected to a calibrated pyrometer. During
the course of testing, the average filter and cyclone
temperature was kept at 250 + 25F.
Following the leak check at the end of each
120-minute test period, the sampling trains were
transferred to a sheltered clean-up area. Any conden-
- 35 -
-------
sate in the cyclone and impingers was measured and
volume increases recorded. The solutions were then
placed in separate glass sample bottles and sealed with
(fi)
TefIon -lined caps. The silica gel was weighed to
determine the weight gain. Only acetone was used for
rinses of the probe, nozzle, and Teflonฎ flex-line
on approval of the EPA Technical Manager because
water had no observable effect on the accumulation of
the unusual particulate matter. An undetermined
amount of sample was lost in the field on Run 3 of the
inlet when a front-half acetone rinse sample bottle
was accidentally broken.
All rinsings were collected in glass sample
(ft\
bottles with Teflon^-lined caps. Initial probe
rinses appeared deep black in color. The particu-
late collected on the filters at both locations had a
black, oily appearance throughout the testing program.
The impinger assembly was thoroughly rinsed with water,
and these water rinsings were placed in the impinger
solution bottles. Following the water wash of the
impingers, the entire impinger assembly was then
rinsed with acetone. The impinger catch at the out-
let location for Run 2 had a cloudy, milky appearance
and the impinger catch for Run 3 attained an amber
appearance. Run 1 at the outlet and all runs at the
inlet displayed no unusual colors in the impinger
- 36 -
-------
catch. Benzene and methylene chloride rinses were
required on the probe, nozzle, Teflonฎ flex-line,
cyclone and front-half of the filter assembly for
Run 3 at the outlet. Acetone rinses had failed to
totally clean the assembly.
Thus, at the end of each run, the following
.four-fractions had been collected from both the
inlet and outlet for particulate and sulfate
analyses :
(1) a,cetone rinsings of the nozzle, probe,
Teflonฎ tubing, cyclone and front-half
of the glass-filter holder. For Run 3,
at the outlet only, methylene chloride
and benzene rinses were performed in
addition to the acetone on these same
component s;
(2) 110-mm glass-fiber filter;
(3) impinger contents and water rinsings of
the back-half of the filter holder,
impingers, and connecting glassware; and,
(4) acetone rinsings of the back-half of the
filter holder, impingers, and the connect-
ing glassware.
- 37 -
-------
In the laboratory, the liquid fractions were
measured volumetrically and these fractions were
then placed in beakers. The water fractions were
evaporated to residue at 105C and the particulate
weight determined (ether/chloroform extractions were
not performed on impinger water). The acetone,
methylene chloride, and benzene fractions were
evaporated at room temperature and weighed until
constant. Filters were desiccated at room temperature
for 24-hours and weighed, with at least 6-hours
of desiccation time between weighings, until constant.
All weight determinations ware performed on an analyt-
ical balance having a sensitivity of 0.1 milligrams.
Sulfates were determined from the residues of
each liquid fraction. These residues were brought
up to 100-ml with 80-percent isopropanol, and a
30-ml aliquot was taken from each. ! Due to inters
ferences from the residues of Fraction 3 from Run 1
at the inlet and Fraction 1 from Run 2 at the inlet,
a 5-ml aliquot from the original sample was taken
and brought up to 25-ml with 100-percent isopropanol.
The filters were also combined with 80-percent
isopropanol.
Each of these samples was adjusted with perchloric
acid to a pH of between 2.5 and 4.0. Three to five
drops of thorin indicator were then added and the
- 38 -
-------
solution titrated with standardized barium perchlorate.
The results are reported as sulfuric acid (including
sulfur trioxide), and as percent of the filterable and
total emission rates.
Carbon Monoxide Sampling
A sample of flue-gas was drawn through a stainless
steel probe, Teflonฎ tubing, and then through a
particulate and condensate trap containing a glass
wool plug, to a 3-way valve. This valve was used to
divide the gas sample into two streams; one for the
continuous analysis of carbon monoxide and one to
provide an integrated bag sample for the determinations
of benzene content (by GC analysis) and exhaust gas
composition (by the Orsat method).
The gas stream used for carbon monoxide monitoring
was then passed through two modified Greenburg-Smith
impingers, the first containing approximately 250-
grams of silica gel and the second containing approx-
imately 500-grams of Ascariteฎ, for moisture and carbon
dioxide removal, respectively. Finally, a leak-free
diaphragm pump forced the sample through a needle valve
to a rotameter and the Beckman, Model 865, NDIR analyzer.
At the sample interface, a flowrate of approximately
1.5 scfh with a delivery pressure of 10 psig was maintained
for the duration of the continuous sampling. An analog
strip chart recorder was used to record all Instrument
outputs. This sampling system is depicted in Figure 5.2.
- 39 _
-------
Stainless steel probe
Teflon sampling line
-
Three-way valve
u
pj|
A"
&
&
J)
0
A
<&l
*y
* 0
f. C\
A .j
A
6
f
^~
4 *
o
e&
Of
^
A
ซ\
\
250g 500g
silica Ascarite^
gel
Needle
valve
Calibration
gases
Valve
Leakless
Diaphragm
Pump
A
Flowrate
Meter
Output to
strip chart
recorde r
Beckraan Model
. 865 NDIR
analyzer
Ranges 0-10,000 ppm
Figure 5.2. Sampling train for continuous monitoring of carbon monoxide.
-------
The daily calibration sequence included passing
a certified standard zero gas (dry nitrogen) and a
certified standard span gas concentration (9900 ppra
carbon monoxide in .nitrogen) through the analyzer.
The instrument output was calibrated for the antici-
pated range of 0-10,000 ppm carbon monoxide by adjust-
ment of the zero and gain settings to the appropriate
signal, as indicated on a calibration curve. The
instrument, which operates by the Luft principle as
specified by Reference Method 10, was equipped with
a 4-position valve to ..allow introduction of sample
gas or any of the required standard calibration gases,
as depicted in Figure 5.2.
The measured CO concentrations were determined
by adjusting the recorded strip chart values with
the factory calibration curve for the 16-mm cell,
which was adjusted to the standard gas concentrations
used in the field. The data was then reduced to one-
minute intervals.
Integrated Bag Sampling (Benzene and Orsat)
An integrated bag sample was withdrawn from the
ESP inlet duct simultaneously with each particulate
sampling run utilizing the train depicted in Figure
5.3 (described previously under Carbon Monoxide
/Ov
Sampling). An evacuated Sarart^bag, especially
treated to reduce permeability, with a volume
- 41 -
-------
of 96-liters was placed inside an insulated steel
drum. The drum was then gradually evacuated, ;' . r
filling the Saranฉ bag at a controlled flowrate, using
a rotameter and valve assembly,as shown in Figure 5.3.
When the bag was filled, it was removed and transferred
to a' field laboratory for immediate gas chromatographic
(GC) analysis for benzene content and later, Orsat
analysis for gaseous composition.
The method used for the determination of benzene
concentrations is in accordance with EPA Method 110,
^'Determination of Benzene from Stationary Sources",
delineated in Appendix F-l. Gas chromatographic
field analyses were performed utilizing an Analytical
Instrument Development (AID) Model 511, portable gas
chromatograph with a flame ionization detector and a
6' x 1/8" stainless steel column packed with 1.75-
percent Bentone and 5-percent SP1200 on 100/120 mesh
Supelcoport. The following operating conditions were
maintained for all analyses: 85C oven, 105C detector,
99C gas sampling loop with 1-ml capacity, and 15-ml/min
zero nitrogen carrier gas. The samples were analyzed
for benzene on the same day they were collected. Peak
areas were measured using a compensating polar plani-
meter. The sample chromatograms had three apparent
peaks, which were completely resolved.
- '42 -
-------
Stainless steel sampling line
Stainless
steel
probe
Teflor^tubing
Dry trap
with glass
wool plug
Needle
valve
Pump
Insulated steel drum
f~
Figure 5.3. Integrated bag sampling train.
-------
Following the GC analyses, each integrated bag
sample was analyzed by the Orsat method for carbon
dioxide, oxygen, and carbon monoxide concentrations,
as specified in EPA Method 3. These results were
used to calculate the molecular weight and the percent
excess air of the process gas.
Visible Emissions
Visible emissions from the C battery stack
exhaust .were recorded for the duration of each
sample run. The observations were performed in
accordance with EPA Method 9 by a qualified visible
emissions observer. A summary of the visible emission
data is presented in Appendix B-4.
- 44 -
-------
SECTION II - TRW REPORT
-------
1.0 PRESENTATION OF B(a)P PROCEDURES AND DATA
The B(a)P train is a modified Method 5 train, having
an adsorbent trap placed between the heated filter box and
the impingers. The adsorbent trap is water-cooled to 127F
and as a result, condensation will take place in the trap
prior to the impingers. For this reason, the moisture content
determined from the impinger water and silica gel is not
accurate since all the water collected in the train is not
measured. For B(a)P data reduction, the moisture content
from the Clayton particulate train was used for the B(a)P
trains.
-------
APPENDIX A
FIELD DATA SHEETS AND
SAMPLING SUMMARY DATA
-------
Granite Citv
RUN
DATE
Meter Volume
Hater Volume
Stack Volume
Stack Volume
Stack Volume
%Isokinetic
mg/Filter
me/Rinse
mg/X/VD-2
mg/lmplngsrs
nig/Total
mg/DSCn
kg/Hour
Ibs/DSCF
Ibs/Hour
lbs/24 Hour Day
lbs/365 Days
(DSCF)
(CSCH)
(ACFM)
(DSCFM)
(DSCMiM)
lay
BCV-P
1
7-26-79
68.5
1.94
117,720
44,003
1246.2
81.9
<0.001
1.128
0.925
0.722
2.775
0.0014
0.0001
8.74 x ID"1!
2.308 x 10" o
5.538 x 10
2.02
- Inlet Test Results
7
7-27-79
52.3
1.48
124,655
' 45,914
1300.3
106.2
<0.001
4.114
0.500
Not Done
4.614
O.C031
0.0002 .
19.35 x 10" I1
5.331 x IQy
1.279 x 10"
4.67
3
7-28-79
43.4
1.23
121,392
44,476
1259.5
104.1
<0.001
28.112
0.462
Not Done
28.574
0.0232
0.0018
144.83 x lO;11
3.865 x 10" ซ
9.276 x 10
33.85
Average
54.7
1.55
121,255
44,793
1263.7
97.4
<0.001
11.118
0.629
11.988
0.0092
0.0007
57.43 x 10
1.542 "x 10
3.701 x 10
13.51
-11
-3
-2
-------
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'FIELD DATA
PLANTฃ^
DATE '
. SA"?LiilG LC
:','^iA}// /* (~~ / / f
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c-^xio.S1 ~T~s! )>L.(r"'?*~
SAV.PLF TYPE -A'^/P ' : .
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OPERATOR _
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. pc~> o --O t^r^-- ^ frit. ^'OiOC
-,
A.V.51ENT TFttPFRATUSE ' '' "
TRAVERSE
POINT
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HEAD
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/, 2-
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PRODE LEK
NOZZLE I.D
ASS'JN'IO ,V.C
SA.VPLE BO
.'.ETER BOX
METER AH,
C FACTOR
GTH AND TYf
JlSTUP.E.'i _
X NU:Y,QER
>r ^~ 'tZCSr^ S
-r-^
''ซ7^
NUMBER
PROSE HEATER SETTING
"... . HEATER BOX SETTING .
.:' . REFERENCE
ATIC OF TRAVERSE ?0,riT LAYOUT
ORO ALL DATA EVERY __J.'2_ MINUTES
ORIFICE PRESSURE
OlFFEREHTiAL
(iH), in. H20)
DESIRED
/ Of
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2.. 3
ACTUAL
/.*7
/, 9
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2.J
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TEMPERATURE
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&&
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PUMP
VACUUM,
in. H2
IV
/ฃ>
/~3_
/ "7
2-3
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/Or/,
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2 1
11
27
'
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SAMPLE. BOX
TEMPERATURE.
"% 'S^
^ So
-2^
9%
75
9\-
- -
COMMENTS:
-------
FIELD DATA
CAT'7 "? / ."- -i'/ / '/
SA:,'rLi!w LOCATION _JT .'Jc(r f~L
TRAVERSE'
PO'.ST '
t'.UKBER
' / 1
"2-
3
"r
^
/,
^
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7 .
/i-''
SAXrlE TYP
RUN NUY.GEfi
' OPERATOR .
AMBIENT TE
CAr.OKETRIC
' . STATIC PRES
FILTER NUM
"X. CLOCK TIME
S^f|PcU^ \vCLOCM
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ฃ :'^..-'-t -y
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^'RP. !PS) - ,U
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NOZZLE 1.0
ASSUMED V.C
S;V,'PLฃ BO
METES SOX
METER AH.
C FACTOR1
USTURF.'i C/7C>
< fiU.V.BER
NUMBER
. PROBE HEATER SETTING
2_ ^ 7 HEATER BOX SETTING
SCHEV.ATIC OF TRAVERSE P
READ AND RECORD ALL DATA EVERY
GAS V.ETER READING
ivraj. it3
T ^ C/ r'l. c/
:;?~ ?jY'^I oq's^TcoO
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ORIFICE PRESSURE
DIFFERENTIAL
(AH;, in. H,0)
DESIRED
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TEMPERATURE
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REFERENCE
ES
A n
TEMPERATURE
INLET
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9s"
c^j
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~T-/4G
"yi.- o
"77, 'D
2^ } \ 7^,0
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^7^
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ฐl 9)
7 z.
rv-
^'o.tftf
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in. Kj
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2- 3
23
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.23
i-~>
1 1
2 5'
21
2.3
2^5
/o^.ofc
SAMPLE BOX
TEMPERATURE,
<2-ฃT?
2-4"~?J>
2 5"
2.S"o
3L..^o
^.^o
2.S"o>
2^^
7- Tc -,
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2.S-0
,
TEMPERATURE,
&o
^r^
Ac3
g"D
^(3
^Cj)
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go
f3c i
^ซ^i
5?r>
ซfo
1
1
*.
ป
I*
%'
5*
COK-.'.ENTS:
&
-------
' FIELD DATA
\
PLANT ฃ-
DATE
:i^l^a^sayt_ '.
' ' SA:,.PL!;SG LO:>{TICN ! '..W./.iT
TRAVERSE
POINT
KU'.'.BER
/
SAMPLE TYP
'' -RUIi :v_
-/ i-V-l^' I^rr^r
1 r / I (~~
{ ' 1 ' ' *->
x /;' /-<} ^.o
* .'-^i"' t
,-i
ip.-.~
p'/r.-.rr.pf J?. '). ^"
SliRP..^,).,. , P ' ..
IFSW.V. : '
SCtiEi.
READ AND REC
CAS, METER REAOiNG
^.'/^--^r/^V-^/'A
VELOCITY
HEAD
(ip_), in. H'/O
X7
LlLil, ~> ^J<"'
/'{/$/?
^-L^S'I
yifX/'j
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72-vx?
747
767
7^2^
7
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TEH SETTING
X SETTING
DRYGASKETGR
TEMPERATURE
INLET
/ s-\ /. t
/<5 v'
! !t>
7.^ -a {. // 2,"
7yo
V "3 '-^ '
/^6
a ">~
m-
OUTLET
9ฃ,
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^0
Clo
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9 /5
7o
ฃ~t e
ฃj j
5f
I'i
<7'/
^ ^
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^'2-
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e"2^
9^
PUV.P
VACUUM.
in. Hg
6"c?
S". c
5-^-
- 7.0
2?'$""
9.'^-
SAMPLE BOX
TEMPERATURE.
. ฐF
ZS~D
Z S""c.
7 j"o
? -ro
ZLji'o
^Jo>
^ .!To
5?. o 2- sTo
<^ซ o
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if. 2-
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l^
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zr -.
f'O
^s-*
'
2-T"o
j f S ^ *"* i "^ " ^^
/ *^' ' v^
Z3'.o
2i"&
2.s7c5-
V i
IMPINCER
TEMPERATURE,
"F
iL~2-
d, 2-
4 i
/. p^
6 ^'
6 2L-"
6^-
/<6
ฃo
6 ฐ
C^ 2?
r~2 C^
\
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(?o "
"** ?-*
/J-
^^
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/, V
6 ^
6V
/z.7
/2"Z 1
f^ \
Ay
/^7
/2-7
CO.V.V.ESTS:
-------
TRAVERSE
PCIilT
NU.V.OER
//
1 h.
.
^v CLOCK TtV.E
TIME, ir M X^OCr-'
CAS METER READING
- . j v"y/. 7
v.->6 ^"
Lj ; cj / ฃ O
V^/^,/7
^-/-IS^D?
*
VELOCITY
HEAD
l.\p,l. r.. HoO
/' i'>
ORIFICE PHESS'JIiE
CiFf ESENTIAL
I.iHi. in HjO'.
' /"/.-?
/ ' ?T i i 7 >
ACTUAL
A/cS
d ^ ซ-|c
STACK
TEMPERATURE
7 w-
7 <"o
... *
j
1
"
t
i
i
/o r~i
^ .. ~
]-<. \i A-O-ป,
j .'2.ฃ>8>
i 1 "V '-"
1 1 1 .*.->
i
"
,-1>Si-
, .ซ
- "7 7^>
OHY GAS METER
TEMI'ERATUKE
lTmiK>.'F
//S"
ic?
^3
OUTLET
7<;r
cjt 5f
PUKP
VACUU.Vi.
in HE
Lb
2'v
SAMPLE BOX
TEMPERATURE.
Op
2 To
.
;
ft 7
. , .
IMPlNCER
TEMPERATURE.
ฐF
77F"
Lฃ-
.\
~
r
I
-------
FIELD DATA
(I \ :>-r-9:r_ !^ฑy:',_Jr_
SAMPLE TYPE .
OPERATOR tju.^^
A!v.3if.M TEMPERATURE
BAROMETRIC PRESSURE
STATIC PRESSURE, (p )
FILTER Kl'.V,3ฃR(s)
PROBE LENGTH AfiO TYPE___ฃ>___
NOZZLE i.D- . (^' )& j
ASSU.Y.ฃ0 MOISTURE,', LQ.
SA-ViPLE BOX NUMBER ..... l^ - 2. ^
METEP. BOX NUMBER _
METER iH, L
cFACTOR:
PROBE HEATER SETTING
HEATER BOX Sฃ7TmG__32LSd.
REFERENCE 4p^___
SCHEMATIC OF TRAVERSE POIHT LAYOUT
RF.AD AMD RECORD ALL DATA P'.-'FRY.. ,
-------
\ . L . ,.
'I. BH* ^ > ^^M
^^^^flป?ปป. ^^^^^^B _ ^H^^^^B
TRAVERSE
PCIHT
NU.Y.CE3
. -
/ /
i
I
"N. CLOCK Ti.V.E
~~ - . :
r- 5 3
.
GAS METER READING
' V- "3
VELOCITY
HcAO
li? 1. in. HjO
ORIFICE PRESSURE
DIFFERENTIAL
UlHl. in. K?0)
DESIRED
ACTUAL
STACK
TEV.PERATUP.E
lTri.ฐr
-/ci^-.f A3 of' Ai?;^ ^^Vl 74^
/^/'/' yp'o
r
V'TI ~^\
| , 0 '^
/) &G
*j ? , 25 7
i
(
' U) L(
V
In'-)'
) '
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1 .1
1
I
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1
fi :(->()
I
I .
i
i
"
i
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.
i
-.
-T^'Ah"
DRY GAS METER
TEMPERATURE
INLET ^
1 ? -^
' /
/5i3*cป
OUTLET
/2.o
i ; U 3.
, f vi
}l'fl~!-
PUMP
VACUUM.
in H?
P-7N
SAMPLE BOX
TEMPEFUYfUFiE.
ฐ?
"2,^0
i
IWINGER
TEMPERATURE.
ฐF
^72- "
... . .
.
, -
-
'
L.
.
e
-------
TRAVERSE POINT LOCATION FOR CIRCULAR DUCTS
I
I
'LAHT.
ATE _
r c ,
2 -3
(^ 9-
^3 - -*
^3.3
^").^
STACK I.D.
-
.
,
- PRODUCT OF
' COLUMNS 2 AHD 3 .
(TO MEAREST 1/8 ItiCH)
DISTANCE B
i
TRAVERSE POINT LOCATl'Oi;
FROM OUTSIDE OF KIPPLE
(SIKiVOF COIJjWHS t, & 5}
' //o.?(o
A/ o i
* /
/>S-2-
2./.5T9
2^-r4 -
33", 6C"
^T3. >r>
^&, 9.6
^.r. ^^
P^ ฃ3 1
?vrV .1
"7 C . ' C C7
/ .
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1
.
1
EPA fn-j.-! 23?
-------
GRANITE CITY
BaP - OUTLET TEST RESULTS.
RUN
AVERAGE
DATE
Meter
Meter
Stack
Stack
Stack
Volume
Volume
Volume
Volume
Volume
% Isokinetic
mg/Filter
mg/Rinse
mg/XAD-2
mg/Impingers
mg/Total
mg/DSCM
kg/Hour
Ibs/DSCF
Ibs/Kour
lbs/24 Hour Day
lbs/365 Days
(DSCF)
(DSCM)
(ACFM)
(DSCFM)
(DSCMM)
7-26-79
69.21
1.96
160,635
68,241
1931
115.9
7.500
0.644
1.085
0.908
10.137
.0052
.0006
7-27-79
7-28-79
32.46 x 10
1.305 x 10
3.133 x 10
11.43
-n
-3
-2
87
3.
8.
31
16.374/14.554 .
.467.41
164,837/155,169 .
70.381/66,313
1992/1877 '' .
116.5/50.2
9.500
8.922
5.000 : -"
Not Done .'
23.422 -
.051/.057
.0029/.0029
.51 x 10"V/77-79 x 10"11
547 x 10 p/3.153 x 10"^ .
513 x 10 V7.567 x 10"^
..07/27.62 ' : '
60.49
1.71
150.168
64,421
1823
107.3
0.175
4.099
0.450
Not Done
4.724 .
.0028
.0003
17.51 x.lO"],1
6.640 x 10 7
1.593 x 10"^
5.81
53.55
1.51
156,935
67,003
1896
102.2
5.725
4.555
2.178
12.761
. 0085
.0017
53.82 x
2.167 x
5.201 x
18.98
10
10
10
-n
-3
-2
-------
: ; . , ;|
Fdi.N sau5trป :'.'. V -.'' . ' '..:"
\V ;.. ' . ,; '. _'..; ' .
?st - S-tillc Prcss'jrp, "Hg (nrilg) ' ' '.',.''.' "''' -, ':'''. ', ''-'
Ps - Sl-scV Css Pressure, "Hg Absoluts, (mrflj) ...-. - :'. .. . .":
1 COj - YoK-rv: I Cry . '-. ' :,.;.,',' '.'';'.'.
I Oj - Yolunc I Dry . '".''.'
t CO - Yolurซ i Dry ' ;" '.'' ''"'-.' ' ' ..
I H. - YoUr.-e i; Dry ' ' .; ' ... : " ' .(;'; '.
Ts - Average Slock Tcrrpcroturc ฐF (ฐC) . '.. .-.';" ' ' . ' :.'.' '
1 H,0 - I Koisl-jre In Stick Gss, 3y YoK^s ' '.'.'.'.'' - ';..'
2 7,7 .-'..'.'.. :
As - Stack Arei, ftc (?V) . -..'..'.. . . ,
hi - t'.'olcculir ซc!g!it or Stjck Gts, Dry Bisls /;; , '.. ''"'''.' '
f,i - H.alecuUr Height of Stsck Csj, Wet Eisis ' .' '.' ' ' '. .
Ys - Siack Gas Ycicclty, ft/sec , (r./scc) '.; .-.';' '"'
Qi'- Slick Gas YoU-.clrlc Ficx ซt SttcV. Conditions, ACm (Ka /win.)
Qi - SUch Gis Yol'jrctric fiw st StandirdiCoivljtlons, OSCFo (!!s>3/ai'.n')
J UA - Percent Cxcess Air . _. . . . '.'.'.. . ''.-.' V' ';-.''... ...' '".
"TCST CO.'IOH IONS' '.; '..' ;'/:;. '/; ;. '>:;;'.'- x'v .;-'. ;/.,.
Fb - Bsrc.T.clrlc Pressure,' 'Hg (mila) ' ...:''.'.' V. /''.' ' '. ./'.
, '''''*.. l - ."'
On - SjrpMr.o !>r:z'i2 OUxctcr, In, (sr.) '' . ." . ' .',.-;, .' .'
T - SJ'pHr.1; Tlr?, riln ' . '' .. '
- Y.I - S-J-?U Yolume, ACF (n3) . . ' . ;;. ''',.'. : '".
Up - li?t SarpUrj Points . .. ' ''',... ' '"
Cf - Pilot Tube Coernclcnt ' , .-. . .;. .;.';.: ;.','. ;'
Tn . Averaijc' Meter Ter.pcrjture ฐF (ฐC) ; ';.." . . '' ";''.'''.
Pra -'Avcrsoc Orifice' Pressure Drip, '.'iUO (nriUO) ' / ''.'. .'.' ;.\."'^ , '
Ylc - Cs-rfenjjte Collected' (Irplngcrj jnd Gcl),mli ' .' ;'" .."':'".'
. . . .
. ' ' .
>:GLISII UMTS
, o 7
r2?A A /
3.7V
../V-^r-
i&i:L.SJL
1 '? -7 ~'^>
^^7
i
:
( *! f' -*_O
i '/:?<* $~
f TIST C.i!.cuuiio:is '....\.. . :..-.;: |
Y*,r. Cc.iiersed Kotcr Yjpor, SOCF (Hi } _ ' . 1 ' /' ~"
Yrr-'iYolore of Gas Ssrpled at Stand;,-;; Ccndlt^n: , OSCF (iV) '. | -'' /'.':.'--
-* ' : 'M V f
JH,,Q . Percent Hols tyre . Dy Yolur-2 ..'..'. f ' ~-t--
Hs - H.olccuUr Weight of Stzck GJJ, Wet Eisi?' :.''..-"..'.!. I ** % ' ' [_ -.-
YJ - Stick Yclocltv, ft/sec (r./jcc) . '..''' .' , _ _ | /<5 3- 7-
J 1 - Perctr.t Iso^lncllc . ' ' ' - |- Jf$"--7
- 1
MHR1C UNITS
: ^fo 6
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METRIC UH1TS
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FIELD DATA
PLAN:^.
/ly././i;.y_V ...//",-:_ _ . PRC3F. LENGTH ,'.KO TYPE !.-> ^x^tS.^
SA.Y:?LL7YPE 'A//"-*
. OPERATOR .
? /
1 f^'f**. C^rf 'l^ti/
/.P'nAT'J'JL '' i -S
, PrtCSiL1;-:^
STATIC FซHS5'Ji5ฑ, {P ' _- . \ .Oj^lV. _O
TRAVERSE
PCi.M
KINDER
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(V,).U3
/^.i oy ^ '' """^
/ > < y*' /
TT^^-. ! (C">xi;/oT-ic/"vv
3 -53 JT
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METER i!i
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> NUKGCR ^ / 6^''C7
PROBE HEATF.R SETTIKC
. ' ' HEATER OCX SETTING
REFF.RESC
tAT.'C CF TRAVERSE P^-KT LAYOUT
C:iO ALL DATA EVERY.^c^_ ISlK'JTtS
C-FIIFICE PRESSURE STACK
OiFFEREI-.TIAL TEMPERATURE
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TEMPERATURE.
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TEKPERATURE.
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i
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:!CCi'!'.r.v:u;-:E | STACK
l''r 0 i ACTUA1 '
*-s~! .(>.""! f/->.s~"s
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DM CAS METER
TEMPERATURE
l?iLET
- "Vf^5
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TEMPERATURE.
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FIELD DATA
PROQE LENGTH AND TYPE ฃ?.'jZฃ_gL
T r-.rs'v t.f. j -
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SCHEMATIC CF TRAVERSE POiXT LAYOUT
. . : .READ AซD RECORD ALL DATA ฃVERY_=4_ f.'.-NUT
GAS :fฃTER READING VELOCITY ORIFICE PRESSURE STACK
i.Vm!,i>.3 HcAO DlrrERENTiAL TEMPERATURE
(ipj. in. H,0 UK), in. K,0) (TJ,ฐF
> *. L 5
V 7..^ /S'"" DESWEO (ACTUAL
8^1(^0 |. /j,/-2^ i./. ?._ ^^T2^
ASSUMED f.:
SA.V.PL.E BO
.V.ETER BOX
KETER iH
C FACTOR
PROSE KEA
HEATER BC
REFf.RE.NC
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JISTURE '. V' J"'''--
fiUI.'.OER "7 /" 8 H>
TER SETTING
X SETT (NO
'Tฃ.V.?ฃRATU?.E
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C'JTLET
(Tm ,)' "F
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TEMPERATURE,
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TRAVERSE
CLOCK T-.V.E
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CLOCKi
CASKETER R?.AO:SC
.VBi. !l3
VELOCITY [ ORIFICE PRESSURE
QIFFEP.EKIiAL-
i. m
STACK
TEMPERATURE
...._, /_-_- j I DESIRED'I ACTUAL
-i:^, 1
'; ,-\t \ ฑL-
DRY CAS METER
TEMPERATURE
.45-0
ฑLi
CUTLET
PUMP
VACUUM.
ฃ,7.5
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SAMPLE DOX
TEMPERATURE.
JL^L
I.V.PI.NCER
TEMPERATURE.
ฐF
JLt
! *5
.3 :.57,,
l.V
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FIELD DATA
pi A'iTj^/'f/"i>'v/<^ ^ ^L/JL.''^,
'
PR03E LC'NCTH AffD'TYPE__r2
CAVE :L
3A:.l.PLi?.S Li.
SA.V.PLE7YP
' OPERATOR _
--*'. -L,/-'-? '? :
rATic;,1 '"'.'^ >"-:'._>." x~
/-?>-; ,.-.'>
/-'/ -',
S^/S-r /*/S~-. dS/l'-l
. A.v.r.SESTTFV.FrSAT'JSE o
.
. . ' SCKKATIO OF TRAVERSE PCiMT LAYOUT _. '
' . _ READ AND RECOSO ALL DATA -ฃVERY__3_ KiNUTES . , ' ' .
CAS:,;.'ฃTuR READING
(Vnl. It3
7~~~ ^2.^?jj_^jfe(D , >.r:r"
3 \:L3o
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H 6.7. 64
M- /,'<:;', ^ 1?
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Cfa^ -
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OUTLET .
'T ' ฐF
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77 1 70
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SAMPLE BOX
TEMPERATURE,
ฐF
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L^.r>
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? sn
?,r)ti
? ฃ/)
'J.5K
SSQ
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ฃ5,-o
2.5O
2.?>o
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IMPINGER
TEMPERATURE,
ฐF
-74
if
ID
1 -.(
AS-
Afr)
65
?.^D t ฃ5>
^..n/O
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7 I ' r-'.^o '
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-------
in. x.- ;ป.
-------
TRAVERSE POINT LOCATION FOR CIRCULAR DUCTS
PLANT
DATE
SAMPLING LOCATION
INSIDE OF FAR WALL TO
OUTSIDE OF NIPPLE, (DISTANCE A) _
INSIDE OF NEAR WALL TO
OUTSIDE OF fiiP.PLE, (DISTANCE S3) _
STACK I.O., (DISTANCE A - DISTANCE B},-
NEAREST UPSTREAM DISTURBANCE
NEAREST DOWNSTREAM DISTURBANCE _
CALCULATOR _ ___ ___
- &oo
SCHEiV,ATiC OF SAMPLING LOCATION
v
\
t
\
1
TRAVERSE
POINT
NUMBER
. /..
"2~-r '
?
3'^T< G
' ฃ y- ^.
"7'3~, ^
,F2 . ^
ปx '~*>
<^\^ . i
^o . >- - -
7.7.3
" (?-?- ^
/ .
.
.X
.
1 i
STACK I.D.
6z'ป
ฃ2-"
<
^- -. ^
PRODUCT OF
"COLUMNS 2 AND-3'-
(TO NEAREST 1/3 INCH)
-. , . - '
. '
*
DISTANCES
4 "
- -
TRAVERSE- PO!HT LOCATION
FROiil OUTSIDE OF NIPPLE
(SUM OF. COLUMNS 4 ง5) |
' '
5:3 ^ __.
B , /;v-
//^^ .
/ฅ. ^-^.
/?.*-%> . B
2, ^. - <) J" 1
V3 ^y"
5"^-ro 1
^\ -Of
. ^;^. ^ '$>. i
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_J&ฃ%^ I
.
. ' . '
-
.: 'Jut) 232
-v
-------
a"t'..Nail Qtfvo^. 3.1*ee,\
SAMPLING SUMMARY SHEET
y ' Location
( ฃ'
Sampled source1 $v -Prod^ ; C^fe^. G.O
/ 7-V.-7- 4
ฃ 2-cx 7- ;?' /:/' | o
C 3. A 7-' i-7 ; /";). c
-~> ;7.-.P.,V -vj . 4
Run MWd f
S 23.25 28
< 2 a .1 9 2 O .3. 8
( 2 'b 2320 3#
3 23 2. (p 2L?
sp. -m MX ;... ' m ..... m mstd . . w . wqcs . - ' 'd
O ,g? A. 9'; 6 8 7:5.^D.<;-. !)/a-?| 49.ai .^^^"- ,.....-- -"
i o f^^ , ฃ ^ ;-^4 / 7 .. fr 3 $ ! / Pฃ 3 [ 16,374 ^ - - ' " - "
?o /ซ^ c?^.q4- iฃ,y>'V ! ?5"/t> H.^^4 ^. ' """ "" ! ,.---
0 /S^f ^^ ^^ 61 ^- ^^^ !/>$?.ฃ> (5?<9.4^ ..-""""" -"
fW P ' P C V Ap x fj +4t&0 ' ' V '.''.' T
S L. S (. ' S , S'* ' . .> S
. H- :- .'oi_j%.9 . fej 1__ 34 \ 4^7^ ( ^3L'3' . 'fe^7 |/^
. 1b-,0? ri9_GJ T~^f J_jf2. --iSฃ_ 1-6?. ^4. f^5> <
^;)/ --ฃ,7 2^-5$ 5^ j 3ฃ,&5 \ 5 6^*5 6#'^ 1^
17 f,/l xV (F + Pm V ; ICO x Vu N Total No. 'of Sampling Pol its ' .'Vw . . '^uno of Vatcg Vipor Co',:octeซ5
i / ซu r mo vv /-I ' n^c - ' P ' ?** "' j'^, our
- .- 13.6; * u .,.- ..fl'V, - '
ra . , ซ ( [_ t wj)
$td ra
Std*'Vw ' "?' Av-racc Orifice >n'ssu-9 ' ' * X Xolstyrc by Volume '.' '-.. .
'''"' Oreo. In. KjO. ': y^ . Me^e' Fraction of Dry Sas '
' \ai "_'P47 !__ Vw ' Hd ' ISO^LJl / " Pb '8arป*ir10o?rcssure, in. !?.. .' ' _ K?. _ Voluii S Cry ' ' , ; ;:','
".. .
vu tv.rn *^ > fปn 32 \
. t
1
y u u
P * P t P ' :
s b - st
.
Vs-5IZ9.4Cp x / ifs ;< (is t <
1 ,032 x (Ts ซ 460) x V_
.-XI ^d.
V . Volnw of Dry Gas at Keter ฃ On -VpluTC-X Dry ~v.
f ft) + I1' 1 '" Conditions, OC" . * : . . . -
" .''-Z M5ฐ' ' ' TT Average Kcter Tenpersturj,' "' S C0^._ Volano S Dry .-
" ฐF '. ' . S f!2 -. Volume X Dry
' ' " : Htd'-Vฐ^srSf ฐfy C" ^ STI>' " ' ซ"ซ." Holwuhr Weight of Stack 8ซ/''
' ' 5 ฐ . . . Dry Basis
. V Total M.O CoUectsd In Is pin- ' . ' '
r . ^ 1/2 ' sen jni Silica Gel, si . .. i^ ' Xalccular-Wolght of StscS -
rwy .1?' i jy j - -. ua->is
a Ory standard cubic foci. stBS'^i <^.92 In- !)9- ' . :
*' . b. Standard conditions u^g'FT^ZS.SZ 1n., Kg, - . . .-'' ' '- . '
. ' ' '
- -" ' { . s\
\ !ฃ>ฃ> ,y
94 96&
3 -4 .906
_ -
i n, i .mi
Tt pn %I
?* "/^5" //-S,^
ฃ>'^ //^^ //^,5^
6>7- 2
PJt Static Pressure of Stack
Gas, 1n. 1(9
P. Stack Cas Pressure, 1n. Hg
' ; Absolute
C ' Pltct Tube Crjcrflclcnt
V ' Stack Cas Velocity at Stack
Conditions, fpm.
.T, Average Stack Temperature
5 : ' "t
Tt (lot Tiro of Test, Kin.'
0 S 11 T N '1 01
. n c ?. " anx. eri i
S I . Percent Isoldnctlc
/. * '
x Tt x
.
pmduct of the velocity head (4?s) and the
st,id< tcuipcraturc ?r
------- |