AIR POLLUTION CONTROL
IN THE
PRIMARY ALUMINUM INDUSTRY
VOLUME II OF II
APPENDICES
23 July 1973
SINGMASTER & BREYER
235 East 42nd Street
New York, N.Y. 10017
-------
AIR POLLUTION CONTROL
IN THE
PRIMARY ALUMINUM INDUSTRY
VOLUME II OF II
APPENDICES
23 July 1973
SINGMASTER & BREYER
235 East 42nd Street
New York, N.Y. 10017
-------
APPENDICES
TABLE OF CONTENTS
1A Data Acquisition Questionnaire
4A Particle Size Weight Distribution
5A Fractional Removal Efficiency Curves
6A Sampling and Analytical Technique
*6B Method 13 - Determination of Total Fluoride
Emissions
7A EPA Source Sampling
*8A Emission Flow Diagrams
8B Removal Equipment Purchase Costs
9A Sample Calculation of Industry Control
Improvement Costs
* EPA Sampling information contained in these sections,
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Appendix 1A
Data Acquisition Questionnaire
Most of the data from which the understanding
of the United States aluminum industry statistics and
control technology were derived came from responses to
a detailed and comprehensive questionnaire submitted
to all producers. In addition to general information
about each plant and its surroundings, the question-
naire asked detailed information about processes and
emission controls in 14 process areas which may be
associated with aluminum smelters. The first three of
these 15 sections are included in this appendix; they
are representative of questions in all process areas.
1A-1
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DATA ACQUISITION QUESTIONNAIRE
For
Engineering & Economic Study of Emissions Control
in The Primary Aluminum Smelting Industry
By.
SINGMASTER & BREYER
For
THE NATIONAL AIR POLLUTION CONTROL ADMINISTRATION
under
Contract No. CPA 70-21
Budget Bureau No. 85S-70012
Approval Expires May, 1971
1A-2
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PART I
1.0 Format
This questionnaire is designed to obtain pertinent data
on the emissions control practice and costs of the respondent
plants.
Part I of the questionnaire lists the data coding struc-
tures which are used to identify the plant elements reported
on, the collection/control systems utilized in these plant
elements, and the individual control units which make up -.the
various control systems.
Part II contains separate questionnaire sections applying
to the plant elements listed and coded in Section 2.0 below,
and utilizes the control system coding to reference the data,,
It is intended that only the sections applicable to a specific
plant be completed, and that other sections be disregarded.
Respondents are requested to carefully read the explanation
of the control system coding given in Part I, as its proper ap-
plication is very important in obtaining meaningful information
from Part II.
1A-3
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2.0 Process Emission Designation Codes
In primary aluminum smelter operation, effluents are
generated both by process operations and by physical materials
handling. To identify the process operations which may be
involved in a given reduction plant complex, including those
connected with support operations, the following check list
is presented.
To provide complete coverage of emission data for a given
plant, the respondent is requested to indicate, against the
appropriate process code, the processes carried out in his
plant; one section of Part II should be completed for each
plant element so checked, identified by the appropriate process
code designation.
1A-4
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Located at
Process Smelter
Code Site Process Designation
2.00 I | General Information
2.10 | | Primary Aluminum Smelting (Potlines)
2.20 [' | Carbon Anode Prebake
2.25 \__ | Prebake Carbon Anode Rodding
2.30 p" I Carbon Anode Mix - Soderberg Paste
2.40 | j carbon Cathode Mix - Monolithic
2.50 [" | Carbon Cathode Block - Prebake
2.55 I ( Calcining
2.60 r" I Aluminum Casting and Dross Reclaim
2.70 [" 1 Aluminum Fluoride Production
2.75 [ | Hydrogen Fluoride Production
2.80 [ ^ Cryolite Production
2.85 j i Pot Relining and Bath Reclaim
r*^"^"""*
2.90 I I Water Treatment Plant
2.95 1 I Steam and/or Energy Generation
1A-5
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3.0 Effluent Control System Codes
For the purpose of this questionnaire an effluent control
system is defined as the collection ducting gathering and
carrying effluents to a single or multistage arrangement of
equipment in which gaseous and/or particulate separations are
made from the conveying air stream. The effluent loading of
the system is taken at the inlet to the first control unit.
The emission from the system is the release to atmosphere of
the last control unit.
The control system code employed is a six-digit number
which can be used to uniquely designate the individual system
as a whole, the stage configuration of the control equipment,
and the type of equipment used in a given stage.
The first digit in the code is always 3, identifying the
code reference as a control system.
The second two digits identify the specific system for
which the data is given. These digits will be assigned by the
respondent, sequentially from 01, to the individual systems
used throughout the entire plant.
The fourth digit identifies the particular stage in the
unique system when the data refers to the control units, as
well as to the system as a whole. For collection systems without
1A-6
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control, as for example a building ventilation system
from which pollutants may be emitted, the fourth digit,
will be 0.
The final two digits designate the type of unit
(or parallel units) inithe stage.
Where the reference is made only to the system, th;
unused digit places are indicated by XX, e.g. 3.06.2.XX
.or 3.06.X.XX.
The listing following gives the fifth and sixth
digits assigned to various types of control unit.
To illustrate:
3.06.2.10 represents
unit - dry cyclone
stage - second
.sixth system
-^-control
1A-7
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4.0 Use of Available Data
The data requested by this questionnaire
is expected to be furnished if it;is available
from normal plant operating records (or design
criteria in the case of plants without an
operating history). Where data requires ex-
tensive measurement or analysis not normally
practiced, this fact should be noted on the
appropriate questionnaire sheets. Efforts to
make the data reporting as complete as possible
will be appreciated.
1A-8
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5.0 DEFINITIONS
CONTROL SYSTEM
EFFLUENT
EMISSION
Apparatus for gathering and treating effJ ,^'
or contaminants (usually dispersed in air
a gas stream) released from a process or
materials handling operation. Included ir.
a control system are:
i. Collection equipment consisting
of hoods, ductwork, instrumentation
and fans required to move the gaa
stream from its point of generation
and,
ii. Removal equipment such as cyclones,
scrubbers, etc. together with the
necessary auxilliary pumps, fans,
instrumentation, etc. required to
operate these units.
Pollutant in the form of gaseous compounds
or particulate matter (usually dispersed ir.
air or a gas stream) which is released from
a production or material handling process.
A pollutant which is released to the
atmosphere.
1A-9
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Plant Identification
Process Code 2.00 General
PART II
PRIMARY ALUMINUM SMELTER
General Information
1A-10
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Plant Identification
Process Code 2.00 General
This part of the questionnaire, designated by the code number
2.00, concerns general information about your smelter which char-
acterizes the plant as a whole and helps to put into perspective
the detailed information about the various effluents, controls,
and emissions which is asked in other sections of the question-
naire. Please answer the questions on form 2.00-1 with brief
statements or sketches as appropriate.
1A-11
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Plant Identification
Process Code 2.00 General
!„ Please describe briefly the smelter location and character-
istics of the immediate surroundings.
2. Please show on a sketch map the extent of owned or controlled
property, and location on the property of the major components
of the smelter.
3. what are the prevailing winds and frequency of temperature
inversions?
4. By what means is the bulk of your electric power generated and
where is the generation station?
5. By what means are alumina, cryolite, and aluminum fluoride de-
livered to the plantsite?
6. Are there any neighboring process industries which may emit
fluorides to the atmosphere?
7. Please prepare a brief statement on the money your company has
spent and.'is spending on research and development for air pol-
lution control techniques and equipment. If you can associate
1A-12
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Plant Identification
Process Code 2.00 General
an R & D cost with a specific device or process, please
point this out. Please differentiate between money spent
at the corporate level for the benefit of the vjhole com-
pany from that spent at the plant to solve local problems,
1A-13
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Plant Identification
Process Code 2.10 Potlines
PART II
PRIMARY ALUMINUM SMELTER
(Potlines)
1A-14
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Plant Identification
Process Code 2.10
PRIMARY ALUMINUM SMELTER
1.0 Description
The primary process is defined as the Hall Heroult Electroly-
tic reduction of alumina to aluminum. It includes the
buildings and equipment required to house and operate it
and to transport materials and energy to and from it. It
is carried out in the area enclosed by the gross perimeter
of the potline buildings, and is designated Process Code 2.10
in this questionnaire.
2.0 Physical Parameters - Plant Section
The intent of this section of the questionnaire is to ob-
tain information concerning equipment type and configura-
tion and building ventilation, insofar as these are
ooncerned with effluent generation, collection and control.
This information should be provided by filling in the bl'irik.
spaces on form 2.10-1. In plants where there are uncon-
trolled roof monitor emissions, please assign a control code
number to this system as well as to the controlled systerns.
In the last section of this part of the questionnaire,,
uncontrolled emission systems will be designated by a zero
in the third digit of the code number.
1A-15
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.....
1. Building Nos .
2. Air Flow into
bldgs . , scfm
3 . Avg . No . ope-
rating pots
per line
4. Type of pot
5. Control System
Codes*
"t
^
3. .XT. XX
3. .X.XX
3. .X.XX
3. .X.XX
'?
3.__.X.XX
3. .X.XX
3. .X.XX
3. .X.XX
POTLINE NUMBERS
3
3. .X.XX
3. .X.XX
3. .X.XX
3. .X.XX
4
3. .X.XX
3. .X.XX
3. .X.XX
3. .X.XX
5
3. .X.XX
3. .X.XX
3. .X.XX
3. .X.XX
6
3. .X.XX
•j • • X • XX
3. .X.XX
3. .X.XX
/
3. .X.XX
3. .X.XX
•3 • • X • XX
3. .X.XX
3
(D
M
Remarks
*1. The two-digit numbers to be entered identify the individual effluent control systems
2. If two potlines share a control system, enter the same number under each line.
3. Please assign a system code number to gases which leave the buildings without
emission control such as through roof monitors or a stack.
I
(ft
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Plant Identification
Process Code 2.10 Potlines
3^.0 Production
Objectives of this survey include the prorating of air
pollution control system costs to the output of primary
product, and the provision for some measure of the
future magnitude of control requirements and costs. The
intent of this section is to obtain actual past primary
aluminum production data and best estimates of expected
future output. This information may be provided by
filling in the blank spaces provided in the following
table.
PRODUCTION. ACTUAL & FORECAST
Short Tons, Net Aluminum*
YEAR
1967
1968
1969
1970
! 1971
1972
1973
1974
1975
1976
PRODUCTION
*Exclude Alloy Materials Additions.
Qualifying Remarks; (Use extra sheet if required)
1A-17
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Plant Identification
Process Code 2.10
4.0 Materials into Process
The intent of this section is to obtain a measure of the
quantities and forms in which materials must be handled.
This information also will serve as a basis for prorating
effluent control cost estimates on the basis of material
tonnages handled.
Please indicate the approximate annual tonnage of input
raw materials.
Annual Raw Material Input
Material
Alumina, Sandy
Alumina, Floury
"F" Content of Floury
Total "F" other Materials
[Anode Carbon, Prebake
Anode Soderberg Paste
Short Tons
1A-18
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plant Identification
process Code 2010 Potlines
IRIMARY ALUMINUM SMELTER
5.0 Materials Handling
The intent of this questionnaire section is to describe
the systems used to transport materials to and from the
potlines and to control effluents and emissions from such
transport, noting specifically:
a) Existence of separate or common control systems
at'these transfer points,
b) Efficiency of the specific control systems.
The material handling system is defined as the equipment
sequences used to transport materials to and from the
area bounded by the gross perimeter of the potlines. A
supplementary descriptive line flow diagram showing con-
trol references for each material handling system, as
illustrated in Fig* 1, is suggested for identification
and clarification.
The performances of the separate control systems serving
material handling transfer points are reported in forms
2.10-3,-4 and -5.
1A-19
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FIGURE 1
MATERIAL HANDLING SYSTEM
(EXAMPLE )
PROCESS CODE: 2.10
11
UNLOADING
12,13
PRIMARY
STORAGE
14,15
LINE STORAGE
16
CHARGING
EQUIPMENT
CONTROL
REFERENCE
1 1
1 2
13
14
15
16
POTS
1A-20
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Plant Identification
Process Code 2.10 Potlines
PRIMARY ALUMINUM SMELTER
5.0 Materials Handling (Cont'd)
For each material handled in your plant as noted in section 4.0
please use a separate sheet of form 2.10-2 to indicate the material
type, handling methods and the effluent control systems involved.
1A-21
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Plant Identification
Process Code Name
-2
of
Form
Materials Handling Transfer
Materials Handling Effluent Points
Name of Material
Material Form Bulk
Bagged
Pallets
Pieces
Liquid
Other specify
^Control Reference
Handling Method
Control Code
3 X.XX
3. .X.XX
3. .X.XX
3. .X.XX
3. .X.XX
•J * • J\. * ^Wx
3. .X.XX
Remarks:
*Please identify by number on a block flow diagram.
1A-22
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plant Identification
Process Code 2.10 Potlines
6.0 Effluent and Emission Parameters
To obtain a full description of the control systems, their per-
formance, and cost, a set of 3 data forms (-3, -4, and -5) is
requested to cover each separate control system used in this
process area.
The separate systems have been previously identified by code
on forms -l,and -2.
For each of these systems, please fill out a separate sheet of
form -3 giving the requested data on collected effluents enter-
ing the first control stage and, if available the data for in-
termediate control stages prior to final emission release.
(For Soderberg pot systems the burner is treated as the first
stage). Control units in parallel are to be considered as a
single stage. Forms are to be completed with available data
in units normally employed; where data is not available, the
fact should be noted.
For each of the control systems please fill out a separate
sheet of form -4 giving the requested data on emissions from
the last stage of control.
1A-23
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Plant Identification ______
Process Code 2.10 Potlines
6.0 Effluent and Emission Parameters
Where control systems discharge through a stack, the stack
should be treated as a separate system, perhaps in series with
others, and forms -4 and -5 should be completed for the stack.
For each stage in the separate control systems specific infor-
mation is requested concerning the operating parameters and
costs of the units or group of parallel units constituting
this control stage. You are requested to provide this data] by
completing a separate sheet of form -5 for each stage of each
control system specified.
1A-24
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plant Identification
process Code
Form
-3;
of
Name
Control System Input
Effluent Entering Control System
Control System Identification, Stage, and Type 3. ._.__
(Report data common to identical systems on one sheet and list
code numbers of identical systems.)
Effluent Parameter Units
Temperature, _
Gas Flow Rate, scfm
Nitrogen concentration, _
Oxygen concentration, _
Carbon Dioxide, _
Carbon Monoxide, _
Sulfur Dioxide, _
Sulfur Trioxide, _
Fluoride as F, _
Hydrocarbons , _
Pitch condensible at 32°F _
Total Particulates , _
Particulate composition,
A lumina _
Fluoride as F _
Carbon _
503 _
Range
Average
Size Distribution
< 5 />
< 10 ji
< 40 /i
<100 JU
> 100 H
Other identical control systems
Remarks :
1A-25
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Plant Identification Form -4; of
Process Code Name Control System Emission
Emission from Last Stage of Control
Control System Identification Stage and Type _!/ 3. .__. .
Effluent Parameter Units Range Average
Temperature,
Gas Flow Rate, scfm
Nitrogen concentration,
Oxygen concentration,
Carbon Dioxide,
Sulfur Dioxide,
Sulfur Trioxide,
Fluoride as F,
Hydrocarbons,
Pitch condensible at 32°F
Total Particulates,
Particulate Composition, w% Size Distribution, w%
Alumina _ < 5 p _
Fluoride as F _ < 10 u _
Carbon . < 40 i .
S03 _ < 100 JJL
>100 i
Emissions without control, such as may come from roof
monitors, should be designated 3. . O.XX
1A-26
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Plant Identification Form -5 of
Process Code Name Control Equipment
Operating Parameters and Costs for
Effluent Control Equipment
Control Unit Code Number: 3. ._.
Number of identical units in; parallel at this stage_
Manufacturer
Catalog number or other description
Total Gas Flow: Actual cfm Pressure Drop, in,
min
max
AVg
Total Fans: Number cfm HP
Liquor Flow, gpm Composition of Solvent
F concentration in discharge from control system,
Disposition of separated HF,
Total Pumps : Number gpm psi HP
Total Particulates Separated, Ib/hr.
Identification
Destination: Discard , Recycle , where?
Value of recovered fluorine, $ per ton of separated F.
* Ins tailed Cost of Collection Equipment, hoods, enclosures.
ductwork, etc. $ Year installed .
*Installed Cost of Removal Equipment, $ Year
Annual Operating Costs :
Power, $ Chemicals $ Parts $
Operating labor $ Maintenance labor $
Installed costs include purchase costs of all fans, pumps, drivers,
piping, structurals, ductwork, electrical accessories, instrumenta-
tion, etc,, installation labor costs, and engineering costs paid
directly by the smelter operator. Costs of collection and removal
equipment are additive to represent total costs of control systems.
1A-27
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Plant Identification ___^_
Process Code 2.20 Prebake Anodes
PART n
PREBAKE ANODES
1A-28
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Plant Identification
process code 2.20 Prebake Anodes
PREBAKE ANODES
1.0 Description
This process grouping comprises the buildings and equipment;
required to receive, prepare and store carboniferous
materials; to combine and form the materials into anodes;
to bake and clean the anodes.
2.0 Physical Parameters - Plant Section
The intent of this section is to obtain information on
equipment type and configuration, and unit operations, inso-
far as these affect effluent generation and collection.
Please enter the requested information in the blank spaces
on form 2.20-1.
1A-29
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Plant Identification Form 2.20-1 (cont'd)
Process Code 2.20 Prebake Anodes Physical Parameters
C. Pressing
Average number of presses in operation^
Average operating time per press, min/day
Press effluent control codes, 3. .X.XX, 3. .X.XX
D. Baking
Average number of furnaces in operation
Average operating time per furnace, hr/day
Average number of tunnel kilns in operation.
Average operating time per kiln,hr/day
Type of fuel: Natural gas , Fuel oil , Grade_
Fuel rate per ton of baked anodes,
Average sulfur content of fuel percent by weight.
Effluent control codes, 3. .X.XX, 3. .X.XX/ 3. .X.XX.
1A-30
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Plant Identification
process Code 2.20 Prebake Anodes
3.0 Production
The intent of this section is to provide an additional
measure of the cost effectiveness of effluent collection
and control systems in terms of the weight of carbon anode
product. Please enter the requested estimates in the blank
spaces of the following table:
ANNUAL SHORT TONS
YEAR
1967
1968
1969
1970
1971
1972
1973
1974
1975
1976
Green Anodes
Baked Anodes
1A-31
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Plant Identification
Process Code 2.20 Prebake Anodes
4.0 Raw Materials
The intent of this section is to obtain a measure of the
quantities and forms in which raw materials must be handled.
This information entered in the t;able below to provide a basis
for prorating collection and control costs estimates to tonn-
age of materials handled.
ANNUAL RAW MATERIALS
.MATERIAL
Green Petroleum Coke
Calcined Petroleum coke
Spent Anode Butts
Coal Tar Pitch H S P Solid
Liquid
Coal Tar Pitch L S P
Coal Tar
Pet. Base pitch H S P Solid
Liquid
SHORT TONS
Please furnish typical analyses for the above materials.
1A-32
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Plant Identification
Process Code 2.20 Prebake Anodes
5.0 Material Handling
The intent of this section is to describe the systems used to
transport materials to and from the carbon Anode Prebake Pro-
cess and to control effluents and emissions from such trans-
ports, noting specifically:
a) Existence of separate or common collection and
control systems at these transfer points.
b) Efficiency of the specific collection and contro1
systems.
The material handling system is defined as the equipment se-
quences used to transport materials to and from the areas
bounded by the gross perimeters of the carbon anode-prebake
operations. Excluded are products transfers between the
green mill and baking areas.
Separate and common collection and control systems serving
material handling transfer points are individually treated in
data sheets provided for their descriptions. A supplementary
descriptive line flow diagram showing control references for
each materials handling system, as illustrated in Fig. 2, is
&uggest;ed for identification and clarification.
1A-33
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FIGURE 2
CARBON ANODE PREBAKE
(EXAMPLE)
PROCESS CODE 2.20
CALCINED
HARD
PITCH
PREPARATION
COKE PREPARATION
CRUSHING
SCREENING
MILLING
COKE DUST
COLLECTION
' HOT LIQUID PITCH
COLLECTION
; ------- PITCH ,
PASTE MIXERS
I METER
I _____ I
PASTE COOLERS
ANODE PRESS
FUME
COLLECTION
SYSTEM
MATERIAL
BAKING FURNACES
ANODE CLEANING
DUST
COLLECTION
SYSTEM
ANODE RODDING
CONTROL
REFERENCE
1A-34
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Plant Identification _______
process Code 2o20 Prebake Anodes
5oO Material Handling (confd)
For each material used in your plant in this process area
please use a separate sheet of form 2*20-2 and indicate the
material type, handling methods,, and effluent control systems
involvedo
You are requested to complete these data sheets as completely
as possible, indicating where data is not available, if neces-
sary,,
1A-35
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Plant Identification
Process Code Name
-2
of
Form
Materials Handling Transfer
Materials Handling Effluent Points
Name of Material
%F
Material Form Bulk
Bagged
Pallets
Pieces_
Liquid_
Other "
Specify
^Control Reference
Handling Method
Control Code
3 X.XX
3. .X.XX
3. .X.XX
S.^.X.XX
3. .X.XX
3. .X.XX
3. .X.XX
Remarks:
*Please identify by number on a block flow diagram.
1A-36
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plant Identification
Process Code 2.20 Prebake Anodes
6.0 Process Effluent and Emission Parameters
The intent of this section is to obtain a full description of
the effluents generated in the green mill and baking opera-
tions, as distinguished from materials handling, of the ef-
fluent collection and control systems, and of the efficiency
of these systems and their costs.
Under the section 2.0 "Physical Parameters - Plant Section"
you were asked to reference code the collection control
systems by building and unit operation.
Please enter these codes again on forms 2.20-3, -4, and -5.
Use as many forms as are necessary to describe the different
effluent control systems used in conjunction with the unit
operations of your prebake carbon anode plant, following the
instructions given under section 6.0 of the potlines (2.10)
If ultimate discharge is from a stack, please complete the
following information.
Stack Height, ft
Exit gas velocity, ft/min ....
Exit gas temperature,°F ... '
Installed cost of stack, $
Year built
1A-37
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Plant Identification Form -3 ; of_
Process Code Name ' Control System Input
Effluent Entering Control System
Control System Identification, Stage, and Type 3. ._.__
(Report data common to identical systems on one sheet and list
code numbers of identical systems.)
Effluent Parameter Units Range Average
Temperature, _____
Gas Flow Rate, scfm
Nitrogen concentration,
Oxygen concentration,
Carbon Dioxide, ________
Carbon Monoxide,
Sulfur Dioxide,
Sulfur Trioxide,
Fluoride as F,
Hydrocarbons,
Pitch condensible at 32°F
Total Particulates,
Particulate composition, w% Size Distribution
Alumina < 5 C
Fluoride as F < 10 u
Carbon < 40 /i
303 < 100 p
> lOOyn
Other identical control systems
Remarks :
1A-38
-------
Plant Identification Form -4; of
Process Code Name Control System Emission
Emission from Last Stage of Control
Control System Identification Stage and Type _!/ 3. ._. .
Effluent Parameter Units Range Average
Temperature, ______
Gas Flow Rate, scfm
Nitrogen concentration,
Oxygen concentration,
Carbon Dioxide, _______
Sulfur Dioxide, _______
Sulfur Trioxide,
Fluoride as F,
Hydrocarbons, _______
Pitch condensible at 32°F
Total Particulates,
Particulate Composition, w% Size Distribution, w%
Alumina ____________ *• 5 u
Fluoride as F < 10 u
Carbon < 40 p.
303 < 100 ^i
>100 a
_!/ Emissions without control, such as may come from roof
monitors, should be designated 3. . O.XX
1A-39
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Plant Identification Form -5 of_
Process Code Name Control Equipment
Operating Parameters and Costs for
Effluent Control Equipment
Control Unit Code Number: 3. ._.
Number of identical units in; parallel at this stage_
Manufacturer
Catalog number or other description
Total Gas Flow: Actual cfm Pressure Drop, in.
min
max
AVg
Total Fans: Number cfm HP
Liquor Flow, gpm Composition of Solvent
F concentration in discharge from control system,
Disposition of separated HF,
Total Pumps : Number gpm psi HP
Total Particulates Separated, Ib/hr.
Identification
Destination: Discard , Recycle , where?
Value of recovered fluorine, $ per ton of separated F,
^Installed cost of Collection Equipment, hoods, enclosures.
ductwork, etc. $ Year installed ,
*lnstalled cost of Removal Equipment, $ Year
Annual Operating Costs:
Power, $ Chemicals $ Parts $
Operating labor $ Maintenance labor $
*Installed costs include purchase costs of all fans, pumps, drivers,
piping, structurals, ductwork, electrical accessories, instrumenta-
tion, etc., installation labor costs, and"engineering costs paid
directly by the smelter operator. Costs of collection and removal
equipment are additive to represent total costs of control systems.
1A-40
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Appendix 4A
Particle Size Weight Distribution
Figures 4A-1 through 4A-7 present data from
ten particle size vs weight fraction determinations
on several kinds of reduction plant effluents, de-
rived from aluminum industry sources.
The determination of aerodynamic particle
size distribution is inexact at best and these data
should be interpreted as indications of the diffi-
culty with which the dusts might be captured by re-
moval equipment rather than as precisely known
characteristics of the several dusts. If the size
distribution of a dust is determined by the same
techniques used to measure the fractional removal
efficiency of a control device, the two data may be
combined to estimate the total removal efficiency
for the device when working on the subject dust.
Details as to how the following data were obtained
are lacking.
4A-1
-------
FIGURE 4A-1
PARTICLE SIZE WEIGHT DISTRIBUTION
PREBAKE PRIMARY EFFLUENT
MULTIPLE CYCLONE CATCH
100
90
80
70
60
50
40
V-
30
20
10
9
8
7
6
5
4
100
1.0
0.9
0.8
0.7
I I I
T
T
0.6
0.5 f
0.4
6.3
0.2
0.1
0.01
I I
_L
1
1
10
10
0.1 12 5 10 20 30 40 SO 60 70 80 90 95 98 99 99.9
WEIGHT PERCENT SMALLER PARTICLES
4A-2 SOURCE-INDUSTRY DATA
0.1
99.99
-------
FIGURE 4A-2
PARTICLE SIZE WEIGHT DISTRIBUTION
PREBAKE POTROOM DUST
(NO PRIMARY COLLECTION)
100
0.3
0.2
0.1
0.01
11.0
I
0.1
5 10 20 30 40 50 60 70 80
WEIGHT PERCENT SMALLER
4A-3
90 95 98
PARTICLES
99
-I
99.9
O.I
99.W
-------
FIGURE 4A-3
PARTICLE SIZE WEIGHT DISTRIBUTION
ANODE PASTE MIXING FUME
100
90
80
70
60
SO
40
30
20
10
9
8
7
_ 4
5
3
1.0
0.9
0.8
0.7
0.6
0.5
0.4
6.3
0.2
0.1
0.01
100
10
I
I
I
1
1
I
JO.!
0.1
2 5 10 JO 30 40 50 60 70 80 90 95 98 99
WEIGHT PERCENT SMALLER PARTICLES
99.9
99.99
4A-4
SOURCE- INDUSTRY DATA
-------
FIGURE 4A-4
PARTICLE SIZE WEIGHT DISTRIBUTION
BAKE FURNACE EFFLUENT
(THREE INSTALLATIONS;
z
o
ce
100
90
80
70
60
SO
40
30
20
10
9
8
7
6
5
100
» 4
1.0
09
0.8
0.7
06
05
0.4
0.3
0.2
01
0.01
10
1.0
_L
J L
_L
-L
0.1
12 5 10' 20 30 40 50 60 70 80 90 95 98 99
WEIGHT PERCENT SMALLER PARTICLES
99.9
10.1
99.99
4A-5
SOURCE - INDUSTRY DATA
-------
FIGURE 4A-5
PARTICLE SIZE WEIGHT DISTRIBUTION
CAST HOUSE EFFLUENT
100
90
80
70
60
SO
40
30
10
9
8
7
6
5
— 4
100
1.0
0.9
0.8 [-
0.7 J-
T
o.s;—
0.6
0.4 r-
0.3
0.2
0.1
0.01
w
10
_L
_L
_L
0.1 |2 S 10 70 30 40 50 60 70 80 90 95 98 99
WEIGHT PERCENT SMALLER PARTICLES
4A-6
lo.i
99.99
SOURCE - INDUSTRY DATA
-------
FIGURE4A-6
PARTICLE SIZE WEIGHT DISTRIBUTION
EFFLUENT FROM SKIM RECLAMATION
ROTARY BARREL
Z
o
at
u
IU
N
100
90
80
70
60
50
40 -
30
20
10
9
8
7
6
5
4
Of
<
0.
2 -
T i r
0.4
0.3
02
0.1 —
0.01
I
100
10
uo
0.1
2 5 10
WEIGHT
70 30 40 SO 60 70 80
PERCENT SMALLER
4 A-7
99
99.9
90 95 98
PARTICLES
SOURCE INDUSTRY DATA
0.1
99-99
-------
FIGURE 4A-7
PARTICLE SIZE WEIGHT DISTRIBUTION
PREBAKE SECONDARY EFFLUENT
100
90
8Q
70
60
SO
40
30
20
10
9
8
7
6
5
4
-I 1 T
i.o
0.9
0.8
0.7
0.6
O.S
0.4
6.3
0.2
0.1
0.01
K>
I
100
1.0
0.1
99-99
0.1
)2 S 10 70 30 40 SO 60 70 80 90 95 98 99
WEIGHT PERCENT SMALLER PARTICLES
99.9
4A-8
SOURCE INDUSTRY DATA
-------
Appendix 5A
Fractional Removal Efficiency Curves
The performance of particulate removal equipment
can be described by a fractional removal efficiency curve,
a plot of a device's removal efficiency versus particle
size for a given set of operating parameters. The frac-
tional efficiency curve for a piece of equipment and the
weight distribution of particle sizes in an effluent
dust, measured with the same techniques, may be combined
to estimate the overall removal efficiency.
The following curves are presented:
5A-1 Self-Induced Spray operating at 3 in. and 10 in.
water gage pressure drop. Curve was supplied
by Western Precipitator Division, Joy Manufac-
turing Company.
5A-2 Venturi Scrubber from Dickie, L. "Air Pollution
Control Equipment Operation, Application, Cost,
and Effectiveness". Presented at a meeting of
N.Y.A.S.H.R.A.E., October, 1969.
5A-3 Centrifugal Wet Scrubber. Data received from
Vibro Dynamics Company.
5A-4 Wet Impingement Scrubber curve taken from
Stairmand, C.J. "The Design of Modern Gas Clean-
ing Equipment", Jour. Inst. Fuel, London
(February 1956).
5A-1
-------
99.99
U
te.
X
o
u
z
o
99.9
9 9.8
9 9.5
9 9
98
9 5
90
8 0
70
6 0
S 0
4 0
3 0
10
1 0
0.01
FIGURE 5A-1
FRACTIONAL REMOVAL EFFICIENCY
ORIFICE TYPE SCRUBBER
i r
i 1 1 .1 1 M I
i i r
TT
PRESSURE DROP
10 IN.
3 IN.
I I I 11
0.05 0.1
0.5 1
1 0
so 100
PARTICLE SIZE, MICRONS
Source: Joy Manufacturing Co.
5A-2
-------
99.99
u
te.
99.9
9 98
9 95
99
98
95
O 90
u
z
o
•s.
8 0
70
6 0
S 0
4 0
3 0
20
1 0
1 1 | 1 1 1 1
FIGURE 5A-2
FRACTIONAL REMOVAL EFFICIENCY
VENTURI SCRUBBER
I 1 1 1 1 1 1
X
T
r
7
1 1 1 1 1 1
o.oi
0.05 O.I
0.5 1
5 10
50 100
PARTICLE SIZE, MICRONS
Source: L. Dickie
5 A-3
-------
0.01
FIGURE 5A-3
FRACTIONAL REMOVAL EFFICIENCY
CENTRIFUGAL WET SCRUBBER
9 »• » t
99.9
998
99.5
99
98
>-
Z
Ul
U
£ 95
O.
t-
X
O 90
Ul
U 80
Z
ut
y 70
u.
u.
Ul
_j «0
O so
Ul
* 40
3 0
20
1 0
1 1 1 | 1 1 1 1
1 1 ' 1 ' M '
1 I l | I i 1 1
.
/
//
/
l/i I 1 t i U
1 1 i | I i I"
s*
/
i
i
'
1 1 1 1 1 1 11
1 1 1 1 1 1 1 1
^ ^ — —
V
1 1 1 1 1 1 I.I
0.05 0.1
0.5 1
10
so 100
PARTICLE SIZE, MICRONS
Source: Vibro Dynamics Co.
5A-4
-------
99.99
z
IU
U
oc
IU
X
o
U
z
tu
U
99.9
998
9 9.5
99
9 8
95
90
8 0
7 0
-t 60
<
O 50
in
* 40
3 0
2 0
1 0
0.01
FIGURE 5A-4
FRACTIONAL REMOVAL EFFICIENCY
WET IMPINGEMENT SCRUBBER TOWER
i r i f i n r
till
T i1 fTTI
L
0.05 0.1
0.5 1
5 1 0
PARTICLE SIZE, MICRONS
I I I I I i IT
I i I I I I I i
50 100
Source: C. J. Stairmand
5A-5
-------
Appendix 6A
Pollutant Sampling and Analysis Techniques
6A.1 Procedures Reported
Several aluminum producers have supplied
descriptions of procedures followed in obtaining rep-
resentative samples of potline effluents and in ana-
lyzing the samples for particulates, soluble solid
fluoride, insoluble solid fluoride, gaseous fluoride,
tars, and sulfur oxides.
Although similar, the sampling and analytical
procedures differ in details of equipment and method
developed by the individual organizations to meet
their specific needs. It is beyond the scope of this
study to evaluate one procedure with respect to an-
other or to critically assess the applications. They
are presented in this appendix as illustrative refer-
ences.
6A-1
-------
6A.2 Source Scrubber Sampling and Analytical
Procedures at a Prebake Reduction Plant
Velocity determinations are made at a point
where the gas flow is as uniform as possible. An ac-
curate gas flow is needed for sampling at isokinetic
conditions. A standard pitot tube and differential
pressure gauge are used to take a traverse across the
duct. The gas temperature is measured and the pres-
sure readings from the traverse are converted to ve-
locity by the basic formula:
Vs = 3.90 2992
V
Ps Gd
where
Vs is the velocity of the gas in feet per second.
Ps is the absolute pressure of the gas in inches of
mercury in the duct.
Gd is the specific gravity of the gas referred to air.
H is the gauge readings in inches of water.
Ts is the absolute temperature of the gas (degrees C
+ 273).
The gas sample is drawn through a sampling train
consisting of a sample probe, an alundum or paper fil-
ter, a membrane back-up filter, an impinger train con-
sisting of one impinger filled with 200 mis of IN NaOH
solution for removal of gaseous fluorides and one im-
pinger filled with 200 grams of silica gel for water
removal, a gas flow meter, a vacuum pump, and a dry
gas meter. The samples are taken from the inlet and
outlet ducts of the scrubber simultaneously at isoki-
netic rates. Sampling time is a minimum of three
hours.
The sampling train for the electrostatic precip-
itators is the same except a glass probe packed with
fiber glass followed by a membrane back-up filter is
used to collect tars and particulates.
The collected samples are carefully transported
to the chemical laboratory for analysis. The filters
are dried, desiccated and weighed to the nearest 0.1
mg on an analytical balance and the original weights
6A-2
-------
of the filters are subtracted, thus yielding the total
weights of the particulates collected. To determine
the particulate fluoride, the fluoride in the filters
is fixed with CaO, then fused with NaOH and finally
the fluoride content is determined by the "Semi-
Automated Method for the Determination of Fluoride"
using a Technicon Auto-Analyzer. The gaseous fluoride
collected in the impinger bottle containing NaOH solu-
tion is determined by either the "Semi-Automated Meth-
od" or by use of a fluoride "specific ion" electrode.
The total volume of air sampled is converted to
standard conditions and is divided into the weights of
particulate fluoride and HF gas as determined above in
order to report the analytical results as milligrams
of constituent per standard cubic foot of gas.
6A-3
-------
6A.3 Source Sampling Procedure for a
Prebake Potline Using Dry Scrubbers
Sampling is carried out isokinetically in the
inlet duct and/or outlet stack. It may be done either
at a single, average-velocity point, as determined by
a preliminary pitot-tube traverse, or by continuous
traverse, depending upon the purpose of the test. The
sampling train consists of the following parts:
a) Entry Nozzle, L-shaped. Aluminum tubes of
1/4" or 3/8" I.D.., 4" total length, bent in a smooth
curve of about 1-1/2" radius. Entry is tapered to a
sharp edge and the tube is coated (internally) with
epoxy en ame1.
b) Thimble Holder, Alcoa design. Similar to
Western Precipitation Corporation's paper thimble
holder, cat. no. D1012, and internally coated with
methyl methacrylate ("Krylon"). The Alcoa design
holder accepts a 33 x 94 mm thimble (Whatman Extrac-
tion Thimble, cellulose, single thickness).
c) Connecting Pipe. Aluminum pipe (1/2" I.D.
electrical conduit) of convenient length, internally
coated with epoxy enamel, and attached to outlet of
thimble.
d) Connecting Tubing. Viton tubing, 1/2" I.D.
and of minimum length, is used to connect the sampling
probe to inlet of an impinger train, and to make all
connections up to the mist trap.
e) Impinger Train. Two Greenburg-Smith stand-
ard impingers, in series, each containing 125 ml of
0.1N NaOH solution. Impingers are followed by a mist
trap (e.g., empty impinger, Erlenmeyer flask, or bot-
tle).
f) Gas Metering Device. Sprague dry gas meter,
or equivalent, with pressure gauge and thermometer.
Must be calibrated before use.
6A-4
-------
g) Suction Source. Electrically-driven air
pump or compressed air aspirator may be used, but must
be of sufficient capacity to draw air at a minimum
rate of 1 cfm through the assembled train.
Paper thimbles are numbered (with pencil) dried
overnight at 105°C in tared weighing bottles, and
cooled in a desiccator for 1 hour. The bottle stop-
pers are quickly replaced, and each bottle-plus-thimble
is weighed. Care must be exercised in cleaning and
charging collection devices in the laboratory, and in
assembling trains at the sampling site. Where pos-
sible, the entire train (up to the gas meter) is as-
sembled and sealed in the laboratory, and transported
as a unit. Masking tape is a convenient sealant and
should also be applied to cover ground joints of the
impingers. After assembly, each train is checked for
leakage by blocking the nozzle and applying about 10
in. mercury vacuum. If the vacuum holds with pump hose
clamped shut, sampling may be started.
The sampling probe should be inserted in the duct
with the entry nozzle looking downstream (upward, in a
stack) to prevent premature entrance of particles. The
sampling probe is rotated into the stream as the suc-
tion device is turned on. A similar precaution is
taken at shut-down; probe is rotated 180° to prevent
loss of collected solids from the entry nozzle.
Throughout the sampling period, readings of gas
meter temperature, pressure drop, indicated gas volume,
and rate are recorded at regular intervals. Sampling
rate may require occasional adjustment as loading of
the filter increases. It may be necessary to add dis-
tilled water to the first impinger during prolonged
sampling; immersion of impingers in an ice bath will
reduce the rate of evaporation.
On removal of the probe from the stack, the entry
is again sealed with masking tape, and the probe car-
ried to the laboratory with nozzle upward. All outer
surfaces of the probe, connecting hoses, impingers,
and trap are cleaned before disassembly and recovery
of the sample. Solids from inside the entry nozzle
are added to the thimble, which is then dried and
weighed as before. Inside surfaces of thimble holder,
6A-5
-------
connecting pipe, hoses, and mist trap are rinsed with
distilled water and rinsings added to the combined im-
pinger liquids.
Determined blanks are deducted from sample re-
sults: a clean thimble is dried, weighed, and analyzed
in the same fashion as sample thimbles; sodium hydrox-
ide solution and make-up water (if required), in vol-
umes equal to those used in sampling, are also carried
through the entire analytical procedure.
6A-6
-------
6A.4 Source Sampling and Analytical Pro.cedures
at a Smelter Using Secondary Control Only
Scope of Determinations
This process of analysis comprises the following
directions and determinations:
6A.4.1 Principle of the "Standard" method for
analyzing flue gases.
6A.4.2 Arrangement of the sampling stations.
6A.4.3 Sampling position and location of the
probe aperture in the stream of gas.
6A.4.4 The selection of the type of probe
according to the flue gas.
6A.4.5 Fundamentals for sampling final gases
after washing installations.
6A.4.6 Choice of the diameter of the probe
aperture.
6A.4.7 Directions for measuring rate of flow
of gases and amounts of gas.
6A.4.8 The sampling apparatus.
6A.4.9 The preparation of the apparatus for
sampling.
6A.4.10 Carrying out sampling.
6A.4.11 Dismantling and emptying the sampling
apparatus.
6A.4.12 Determination of tar.
6A.4.13 Determination of dust.
6A.4.14 Determination of S (gaseous).
6A-7
-------
6.4.15 Determination of F content.
6.4.16 Processing the contents of the droplet
separating bottle.
6A. 4.1 Principle of the "Standard" Method
for Analyzing Flue Gases
a) Sampling
The gas to be analyzed is taken from the
stream of gas by means of a probe adapted to the na-
ture of the flue gas. The solid constituents, dust
and tar, are separated in a heated filtering apparatus,
the temperature of which is kept at 85°C by means of a
thermostat, by filtering the gas to be analyzed through
a filter thimble. The heating of the filtering appa-
ratus serves to evaporate any droplets of spray water
which may be present, so as thereby to avoid any ab-
sorption of gaseous HF in the filter thimble.
The gaseous constituents, HF and SO2/ are ab-
sorbed in three absorption washing bottles connected
in series, which are filled with glass beads. Five
percent soda solution is used as absorption solution.
The washing bottles and accessories are combined in
an absorption apparatus.
The suction pump and the gas-measuring equip-
ment are combined in a separate pump station.
b) Working up the Sample in the
Analytical Laboratory
The filter thimbles are extracted with "tri"
in a Soxhlett apparatus to separate the tar.
After the "tri" has been distilled off, the
flasks are dried at 80°C and the tar content is weighed
out.
The filter thimbles are dried at >105°C and the
dust content is weighed out.
6A-8
-------
The dust in the filter sleeves is washed with
H20; by determining the fluorine in the solution (dis-
tillation and titration), the content of water-soluble
fluorine is obtained. The dust is thereafter boiled
out with 5% NaOH; by determining the fluorine in the
solution, the content of insoluble fluorine in the
dust is obtained.
The gaseous fluorine in the absorption solu-
tions is obtained by determination (F determination -
distillation and titration with Th(NC>3)4). The gas-
eous S is obtained by precipitating it gravimetrically
with BaCl2 as BaS04.
6A.4.2 Arrangement of the
Sampling Stations
The sampling stations must be accessible with-
out danger. Steps must be taken to see that the sam-
pling apparatus can be fixed or set up without any
difficulty. It should be possible to fit up the con-
nections to the pump station (suction pipe, electric
cables) without any great expenditure of work, or
permanent installations should be arranged.
Measuring flanges (for sampling and measuring
the amounts of gas) having an inside diameter of at
least 100 mm are to be installed in pipe lines and
flues at the sampling stations.
Pipe lines should have as large a cross-section
as possible at the sampling station so that the gas
velocities become as small as possible. Wide probe
apertures can then be used, whereby the danger of
blocking thereof is reduced and also the aerodynamic
conditions for satisfactory sampling are improved.
There should be no bends and inlets in the pipe line
for a distance of five times the diameter in front of
the sampling station.
If the speed of flow exceeds 8 m/s, special
measuring sections are to be installed in the pipe
line. The following table contains the dimensions of
the measuring sections, calculated for a speed of the
gas of 7.5 m/s. These dimensions permit the use of
probe apertures with a diameter of 4.0-4.5 mm.
6 A-9
-------
Length of
Volume Pipe Measuring
of Gas Diameter Section
0.2 cu.m/s 20 cm 2.0 m
0.5 cu.m/s 30 cm 3.0 m
1.0 cu.m/s 40 cm 4.0 m
2.0 cu.m/s 60 cm 6.0 m
3.0 cu.m/s 70 cm 7.0 m
4.0 cu.m/s 80 cm 8.0 m
5.0 cu.m/s 90 cm 9.0 m
6A.4.3 Sampling Position and Location
of the Probe Aperture
in the Stream of Gas
In crude gas lines of Soderberg S4 and VS8 in-
stallations the sampling stations are installed in
front of the cyclones and in front of the washing ap-
paratus.
In waste-gas chimneys of Soderberg installa-
tions, the sampling station should, if possible, be
located 1-3 meters below the mouth. Where conditions
are unfavorable, the sampling may also be carried out
at the foot of the chimney (at a height above the in-
let corresponding to five times the diameter), provid-
ed that there are no spray nozzles above the sampling
station. The droplet separating bottle connected to
the outlet end of the probe simulates the processes
taking place in the chimney.
In sampling in waste-air chimneys of shop spray
plants having a rectangular cross-section, the probe
is located in the central axis. If possible, the probe
should be shifted twice a day along this axis, so that
the entire length of the spray field is covered during
the sampling period.
In shop air final gas analyses, care should
moreover be taken that no air infiltrates from the at-
mosphere into the probe aperture. To this end, the
probe is introduced into a sheet-metal jacket through
a slot therein. The jacket has a diameter of 40 cm
6 A-10
-------
and a height of 50 cm, and is placed directly on the
droplet-collecting layer (brushwood or p.v.c. mesh).
The probe aperture should be located about 15 cm above
the droplet-collecting layer.
In sampling from pipe lines, the probe aperture
should be arranged as far as possible towards the cen-
ter of the pipe.
The general rule is that the probe aperture
must always be directed against the stream of gas.
6A.4.4 The Selection of the Type of Probe
According to the (Furnace) Flue Gas
a) Shop Air Before Reaching
the Roof Spray Plant
1 The rate of flow is small; the gas for analysis
only contains the finest of particles in the form of an
aerosol; the moisture content is low.
A simple probe consisting of a tube with an
internal diameter of 8 - 9 mm bent at right angles is
used. The probe is placed immediately at the inlet to
the filtering apparatus.
b) Shop Air After the Roof
Spray Plant
The rate of flow is small; apart from very
finely divided spray water in aerosol form, the gas for
analysis also contains some individual large droplets
which have penetrated through the drop catching screen;
it is saturated with moisture.
The probe is a special probe having drop pro-
tection plates. The probe is placed directly at the
inlet of the filtering apparatus. By means of this
special probe only the aerosol particles are caught
during sampling, while the coarse spray water droplets,
mostly retained in the spray field, are.excluded.
6A-11
-------
c) Crude Gas in the Suction Lines
of Soderberg Installations
The rate of flow is high; the gas for analysis
contains particles of various sizes and a great deal of
moisture.
A probe with an aerodynamically shaped tip is
used whose opening diameter is adapted to the velocity
of flow of the gas stream. The probe tube is insulated
against heat loss where it lies outside the pipe line,
so that there is no condensation of water vapor and it
is connected by the shortest path to the filtering ap-
paratus.
d) Final Gas in the Waste Gas Chimneys
of Soderberg Installations
The rate of flow is high; the gas for analysis
contains particles of various sizes and spray water
droplets; it is saturated with moisture.
A probe with an aerodynamically shaped tip is
used whose opening diameter is adapted to the velocity
of flow of the gas stream. A thermally insulated drop-
let collecting bottle is placed between the probe and
the filtering apparatus for separating spray water
droplets.
6A.4.5 Fundamentals for Sampling Final Gases
After Washing Installations
a) The Nature of the Final Gas
The waste gases in the final gas lines after
the washing installations entrain more or less large
amounts of spray water droplets with them, depending
on the efficiency of the droplet separating devices.
In the final chimneys, a considerable part of the spray
water droplets is deposited. Mainly the fine and aer-
osol type of droplet pass to the atmosphere.
6A-12
-------
b) The Application of the Droplet
Separating Bottle
It is very important to measure the droplet
water content in final gas analysis (control of the
efficiency of the droplet separators). For this pur-
pose, a thermally insulated droplet separating bottle
is placed between the probe and the inlet of the fil-
tering apparatus. By slowing down and reversing the
flow of the gas stream, the droplets of spray water
are separated in the bottle. Only the fine and aero-
sol type droplets reach the filtering apparatus and
then enter the final gas analysis.
For the droplet water that is separated, meas-
urements are made of:
a) the amount separated,
b) the pH value,
c) the amount of:
F (soluble and in the dust),
S, tar and dust.
If sampling takes place at.the foot of the
final chimney, then sufficiently satisfactory final
gas analysis results are obtained, since the droplet
separating bottle reproduces the separation processes
of the final gas chimney. The content of F, S, tar
and dust in the droplet water are stated separately
and are not counted in the final gas analysis results.
If the sampling takes place 1-3 meters below
the mouth of the final chimney, then the amount of F,
S, tar and dust in the droplet water are similarly
stated separately, but are taken into consideration
in assessing the final gas analysis results by adding
the constituents of the droplet water to the results
of the final gas analysis.
With roof spray plants, control of the effi-
ciency of the droplet separating devices is carried
out by using a normal probe instead of the special
6A-13
-------
probe with droplet baffles to sample the final gas (as
used for sampling shop air) a droplet separating bot-
tle being connected after the probe.
The dimensions of the droplet separating bot-
tle can influence the droplet separation process.
Therefore, the droplet separating bottles should all
be the same throughout the concern.
c) Use of a Heated Probe
If, for control purposes, the composition of a
final gas after the washing plant is to be determined
as satisfactorily as possible, then a heated probe is
used for sampling. The probe is heated electrically
to a temperature of 60-80°C. The probe has a length
of about 80 cm and is connected to the inlet of the
filtering apparatus by the shortest possible path.
The spray water droplets that are present in
the final gas are evaporated in the probe. The con-
stituents of the spray water F, S, tar and dust there-
fore enter into the results of the final gas analysis.
Thus by using a heated probe, the composition of the
final gas at the sampling point (= sum of the portion
in the final gas + portion of the spray water) is ob-
tained. Additional separation processes taking place
in the final chimneys are not considered in this sam-
pling method. Similarly, no conclusions can be drawn
as to the amount and composition of the spray water
from the analysis results.
6A.4.6 Choice of the Diamater
of the Probe Aperture
a) Sampling in Waste Gas Lines
of Soderberg Installations
The basic rule for sampling waste gases which
contain dust and spray water droplets is that the
velocity of the partial gas stream in the probe aper-
ture should be equal to that of the gas stream at the
point of sampling. Only when this rule is obeyed
does no change occur by the sampling, in the partial
gas stream, in the concentration of the particles and
6A-14
-------
the particle size distribution.
To fulfill this rule, the diameter of the probe
aperture must be selected according to the velocity of
gas flow at the sampling point and according to the
amount of gas drawn off through the apparatus for anal-
ysis. The following formula is valid:
d = diameter of the prob: mm
M = volume of analysis gas drawn off: 1/h
v = gas velocity at point of sampling: m/sec.
This formula is only strictly true for aero-
dynamically ideal conditions, in which there is no con
gestion zone in front of the probe aperture. To avoid
a congestion zone as far as possible, the probe should
have the shape of the tip of a lead pencil (angle of
cone 11.5°, d/1 = 0.20) and care must be taken to en-
sure that the gas velocity at the point of sampling
does not exceed about 8-10 m/sec. (installation of
analysis sections) .
Exchangeable probe tips of stainless steel are
kept in stock with the following calibers, these cor-
responding to the following maximum gas velocities for
a maximum sample withdrawal of 420 1/h:
d = ( 3.0; 3.5) 4.0; 4.5; 5.0; 6.0; 7.0 mm
v = (16.8; 12.3) 9.5; 7.5; 6.0; 4.2; 3.1 m/sec
b) Sampling of Shop Air
The velocity of gas flow is so small that no
congestion zone can be formed in front of the probe
aperture. The solid particles are present as aerosols
and behave practically as a gas component. The suc-
tion velocity and the shape of the probe can therefore
be chosen freely.
6 A-15
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6A.4.7 Directions for Measuring Rate of Flow
of Gases and Amounts of Gas
a) Flow Velocities
Pipe Lines
Use of a "Prandtl pressure tube" with "Askania
Minimeter" as differential pressure meter.
(The formula is valid for air,
density = 1.293 kg/Ncu.m.)
" R (at 0°C and 760 mm Hg)
v _ ./15..17 XAP
Exhaust Air Chimney
Use of a vane anemometer, measureing range
0.2-20 m/sec, type 119 y of R.Fuess. Calculation of
the velocity from the measured wind path over 1 min.
v = W (;Lmin) (m/sec)
60
b) Measurement of the Amount of Gas
Pipe Lines (circular cross-section)
Use of a "Prandtl pressure tube" with "Askania
Minimeter" as differential pressure meter.
In four equiplanar rings of radius 0.1; 0.2;
0.4; 1.0 the differential pressure is measured and
the arithmetic mean of the pressure difference formed
from them.
M = 2- D2 A/19'62 x R x Ap(m) (m3/sec)
(s = density of the gas in kg/Ncu.m.
For air, s = 1.293 kg/Ncu.m.)
6A-16
-------
Exhaust Air Chimneys (rectangular cross-section)
An integrating measurement of the wind path over
the whole cross-section of the waste air chimney is
made. A Fuess vane anemometer, type 119 y, is used. The
cross-section of the waste air chimney is divided ac-
cording to the scheme shown below into 9 rectangular
sections similar in shape to the complete cross-section.
The wind path is integrated continuously for
half a minute in the center of each of these component
sections. In this way, the sum of the average wind path
of the amount of waste air for 4% mins. is obtained.
M =
R
x w(4Jg min) , m'-prl
x y^cu.m/oec;.
c) The Symbols Used in t
•
•
•
•
•
•
he Formulae
and What They Stand For
•
*
•
v = gas velocity: m/sec.
M = gas volume: cu. m/sec.
W( ) = wind (gas) path during the period of measure-
ment: m.
p = differential pressure: mm H20
p (m) = arithmetical mean of several differential
pressure measurements: mm I^O
R = reduction factor for N.T.P. (0°C, 760 mm Hg)
= 0.359 x P(k) ( p(b) = barometer level in
273 + t mm Hg,
t = temperature of the
gas in 0°C ) .
D = diameter of the pipe line in m.
Q = cross-section of the exhaust air chimney in
sq.m.
6A-17
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6A.4.8 The Sampling Apparatus
a) The Probe Tube
The probe tube of the normal probe for sam-
pling pipe lines and final chimneys consists of copper
tubing; diameter 14/8 mm. It is bent at right angles
at the front, so that the probe aperture can be directed
against the gas stream. The length of the probe tube
depends on the diameter of the pipe lines in which sam-
pling is to be carried out. The front mouth is thread-
ed and the probe tips can be screwed into the thread.
The rear end is turned to about 10 mm, so that a hose
with an internal diameter of 8 mm can be put on.
In the insulated probe, the insulation consists
of asbestos string wound crosswise with 2 layers of
glass silk tape, or of a vacuum hose with an internal
diameter of 14 mm.
In the heated probe a low voltage heating coil
for 36 V is applied over an insulating layer and the
same insulation as is used in the insulated probe is
applied over it.
b) The Droplet Separating Bottle
This consists completely of plastic. Droplet
separation takes place in a chamber 48 mm in diameter
and 100 mm in height. The bottle is installed within
an insulating casing, so that as far as possible the
bottle remains at the temperature of the analysis gas.
The separated water droplets are collected in a 30 ml
Plexiglas measuring cylinder attached by a thread con-
nection. The amount of droplet water separated can
therefore be checked easily.
c) The Filtering Apparatus
The filtering apparatus consists of Anticorodal
coated with a protective layer of "Araldit" resin. The
filtering apparatus is made by turning from a 80 mm
diameter pressed bar. The gas inlet and gas exit tubes
are welded in and similarly protected with "Araldit".
6A-18
-------
The sealing of the unit and the fixing of the
filter thimbles is effected jointly by means of an
0-ring seal. The seal is so constructed that the
flanges can be screwed together metal on metal. This
construction gives a constantly safe seal that cannot
come loose during sampling.
The filtering apparatus is inserted in an
electric oven. The temperature of the oven is held
constant at 85° by means of a thermostat ("Fenval").
A rod heating element giving 150 Watt and 36 V is used
for heating. The electric oven is built to the small-
est possible weight, but is nevertheless proof against
rain water.
A filter thimble with a simple sealed insert
(Schleicher and Schull No. 603) is placed in the fil-
tering unit. Filter thimbles with the following dimen-
sions are used for the various analysis gases:
Crude gas VS8, S4 : dia. 38 mm, length 200 mm
Final gas VS8, S4 : dia. 38 mm, length 85 mm (if
the content of dust lies below
50 mg/Ncu.m. and tar below
20 mg/Ncu.m.)
Shop air, crude
and final gas : dia. 25 mm, length 70 mm
For the filter thimbles with an internal dia-
meter of 38 mm the same filtering apparatus is used.
A special filtering apparatus is required for filter
thimbles with an internal diameter of 25 mm.
d) The Absorption Apparatus for the
Gaseous F and S Constituents
The gaseous F and S constituents are absorbed
in three glass bead absorbers connected in series
(dia. 50 mm, height 450 mm). The absorbers are half-
filled with glass beads of 5 mm diameter. Each con-
tains 150 ml Na2CC>3 solution for absorption.
6A-19
-------
The absorbers are built into an Anticorodal
box which has a transparent front window of Plexiglas.
The box itself has a coating of paint to protect it
against corrosion.
The following items are also built into the
box of the absorption apparatus:
1. A non-return valve at the inlet to the
first absorber bottle. This is intended
to prevent absorption alkali rising back
into the filtering apparatus.
2. A plastic safety bottle attached to the
outlet of the third absorber bottle to
prevent impurities from the suction line
to the pump station entering the absorber
bottle.
3. A 90 watt, 36 v heating unit to adjust the
temperature of the absorber box when the
external temperature falls below 0°C.
4. An electrical distribution box for con-
necting the various heating units and
optionally a hand lamp.
The gas inlet and exit tubes consist of p.v.c.
pipes dia. 10/8. The connections are made with trans-
parent plastic hose resistant to HF and SO2/ dia. 12/8
mm.
The connecting line between the filtering and
the absorption units is also made of the same plastic
hose; this should be kept as short as possible and in
no case exceed 1 m.
e) The Pump Station
The pump station consists of a weatherproof
box which has a transparent window. In this there
are: the suction pump, the instruments for gas
measurement, a 220/36 v, 500 watt cut-off transformer
for the heating units for the filtering and absorp-
tion units, heating and lighting means for the pump
6A-20
-------
station, as well as the electrical distribution box.
The electrical installation of the pump station is to
be so designed that several pump stations can be cou-
pled together easily.
The pump station is placed on a bench at ground
level. It is connected to the apparatus at the sampling
point by the suction line, which is made of not too
soft, transparent plastic hose, and by an electric
cable. There is no limit to the length of the con-
necting line (e.g. 25 m). The excess lengths of line
are stored on a holder at the pump station.
The instruments for gas measurement are con-
nected in series as follows:
Suction pump, "Rota" flow meter, gas meter,
thermometer, vacuum gauge, safety bottle,
connection from the suction line to the ab-
sorption apparatus.
The hose connections in the pump station con-
sist of transparent plastic hose 12/8 mm in diameter.
The connecting nozzles should have an external diam-
eter. The connecting nozzles should have an external
diameter of 10 mm.
A Pfeiffer (Wetzlar) "Medvak" pump, type MB
1000, is used as the suction pump. This pump is cou-
pled directly to a single phase motor and is therefore
very reliable in operation. Maintenance of the pump
is limited to an occasional oil change (about every
2-3 months) .
The rate of suction is regulated by means of
a speed governor on the motor (coarse regulation) and
by allowing ballast air to enter the suction side of
the pump (fine-regulation). The ballast air is freed
from dust by means of filtration through a filter
thimble (e.g. dia. 38 mm, length 85 mm).
The rate of suction is controlled by using a
"Rota" meter with a measuring range of up to 500 1/h
(up to 8 1/min). The regulation of the suction rate
with thie aid of the gas meter and a stop watch is
laborious and time-consuming.
6 A-21
-------
The volume of gas sucked through the sampling
apparatus is measured by a gas meter. Dry gas meters
should be used since they have a long life and require
very little maintenance. (Type MB 2.4 Elster Mainz).
The gas temperature is read from a thermometer
placed at the inlet of the gas meter.
The vacuum produced by the vacuum pump is
measured by means of a U-tube manometer. This has a
measuring range up to 200 mm Hg.
A safety bottle is placed in the suction line
at its entry in the pump station. The object of the
safety bottle is to separate out any condensation water
formed in the connecting line to the absorption appa-
ratus.
6A.4.9 The Preparation of the Apparatus
for Sampling
a) The sampling apparatus consisting of probe,
filtering apparatus and absorption apparatus is pre-
pared in the analytical laboratory for sampling. Probe
tube, droplet separating bottle, filtering apparatus,
absorber and hoses are thoroughly cleaned. (Short con-
necting lengths of hose are boiled in distilled water,
washed with distilled water and dried free from dust).
b) The apparatus is then assembled as follows:
A prepared filter thimble is placed on the cone of the
filtering apparatus cover, an aluminum foil strip is
wrapped round the thimble and the "0" ring pushed over
it. Then the filtering apparatus is screwed together
until the flanges are metal-to-metal with some pressure
on them.
The absorbers are filled up to half their height
with well cleaned and dried glass beads and closed with
the rubber stoppers which are fitted with inlet and
outlet tubes. 150 ml 5% Na2C03 solution are introduced
by means of a pipette (Na2CO3 anal. Merck). At least
once a week, a blank sample is taken from each batch of
for F and S determination.
6A-22
-------
After filling with soda solution, the assembly
of the absorber unit is completed. Then the probe (and
possibly the droplet separating bottle, which has been
placed in the insulating box) is mounted on the filter-
ing apparatus and this is connected to the absorption
apparatus. The probe aperture and the exit of the ab-
sorption apparatus are sealed with a rubber cap.
c) The filter thimbles are prepared as fol-
lows: The filter thimbles are washed with distilled
water, dried and extracted with "tri". They are dried
overnight on an open weighing glass in a drying cab-
inet at 105°C. The weighing glass is closed, allowed
to cool in a desiccator and the filter thimbles are
weighed in the closed weighing glass. The constant
weight obtained should be better than i 0.5 mg.
6A.4.10 Carrying Out Sampling
a) Preparations at the
Sampling Station
The sampling apparatus is brought into posi-
tion. The outlet of the absorber unit is connected to
the hose line from the pump station. The flow velocity
of the gas is now measured at the sampling point and
the diameter of the probe aperture .is determined. The
corresponding probe tip is then screwed in and, with
the probe aperture closed, the pump station is used
carefully to provide suction for testing the sampling
apparatus for leaks. If this check is positive, then
the probe is placed in the gas stream and sampling can
begin.
The rate of suction is adjusted to 360-420 1/h
=6-7 1/min.
b) The Sampling Procedure
To obtain a sufficient average, samples are
taken for 2 days, if possible, for VS8 and S4 crude and
final gases. This amounts to about 4 Ncu.mr for shop
air, samples are taken for 3 days. This amounts to
about 8 Ncu.m.
6A-23
-------
During sampling, the following hourly readings
are entered on a recording sheet:
Time, temperature of the gas at the gas meter,
vacuum, reading of the gas meter. Every hour the con-
ditions in the furnace shop are also recorded:
Number of ignitions, number of crust breakings,
number of burners in operation in the case of
VS8.
At least three times a day, the temperature
of the gas at the withdrawal point is noted.
For the entire duration of analysis, the op-
erating conditions in the shop are also entered on the
recording sheet, such as: number of furnaces in opera-
tion, kg of anode mass added, kg of fluorides stirred
in and, if necessary, the degree of comminution of the
alumina.
c) Conclusion of Sampling
The probe is taken out of the gas stream. A
few liters of air are sucked through the apparatus (so
that no condensation of moisture occurs in the filter
thimbles on cooling), the heating is switched off and
the suction line to the pump station is clipped at the
outlet of the absorption unit. After the pressure in-
side the sampling apparatus has equalized itself, the
connecting line between the filter and absorption units
is well clipped and the sampling apparatus is then sep-
arated from the suction line. After opening the clamp-
ing screw of the suction line, the suction pump in the
pump station can be switched off. The probe aperture
and the outlet of the absorber unit are sealed with
rubber caps and the sampling apparatus taken to the
analytical laboratory for attention.
6A.4.11 Dismantling and Emptying
the Sampling Apparatus
First the whole apparatus is very carefully
cleaned to remove adherent dirt and dust, so that when
it is dismantled the analysis is not contaminated.
6 A-2 4
-------
Then the apparatus is separated into the constituent
parts - probe, possibly the droplet separating bottle,
filtering apparatus and absorption unit - and the sep-
arate units are carefully sealed at the points of sep-
aration.
First the filtering apparatus is brought into
a vertical position and the loose dust and tar brought
into the filter thimble by tapping. Next, the filter-
ing apparatus is unscrewed and the thimble separated
from the cone and placed in a Soxhlet apparatus.
The dust and tar is washed out of the inlet
tube of the filtering apparatus into a beaker using
"tri". If a droplet separating bottle was used in
sampling, then the contents of the probe belong to the
droplet water. A weighed pad moistened with "tri" is
used to clean the probe tube and the inlet tube of the
filtering apparatus. The pad is prepared in precisely
the same way as the filter thimbles, dried and weighed
in a closed weighing glass. The "tri" that is obtain-
ed on washing the dried glass bead absorber and the
glass beads is added to the quantity of "tri" in the
beaker. ("tri" = trichloroethylene)
In the absorption unit the connections be-
tween the glass bead absorbers are opened and the con-
tents of each absorber poured, together with the glass
beads, into a cylindrical separating funnel of about
500 ml capacity. In this the glass beads are washed
until free from alkali with wash water containing
phenolphthalein. The same wash water is also used to
wash the p.v.c. tubes, the connecting hose between the
absorption and filter units and the non-return valve.
The absorption solutions of all three absorbers and
the washing solutions are collected in a 2 liter beak-
er, concentrated and transferred to a 1 liter grad-
uated flask. The absorbers are inverted for drying.
The glass beads are dried in a drying cabinet at 80°C.
When the whole of the absorption unit is dry, it is
washed with "tri" and the latter added to the "tri"
washing solution in the beaker.
6 A-2 5
-------
6A.4.12 Determination of the Tar
The combined "tri" washing solutions are
filtered through the filter thimble in the Soxhlet ap-
paratus and the beaker washed well with "tri". Then
the filter thimbles, together with cleaning pad, are
extracted to exhaustion in the Soxhlet apparatus. The
"tri" is carefully distilled off in a previously tared
100 ml flask except for a few ml of solution. Over-
heating of the contents of the flask is to be avoided,
so that no loss of tar occurs. The last ml of "tri"
are evaporated on a water bath and the flask is dried
in a drying cabinet at 80°C. Then the tar can be
weighed.
The Use of Trichloroethylene
as Tar Extracting Solvent
The "tri" is used instead of CS2 as extracting
agent. According to experiments made in the Rheinfelden
Laboratory, the same results are obtained with "tri" as
with CS2- The "tri" is obtained directly from the man-
ufacturer in carboys. It is predistilled over CaCl2
just before use in the laboratory. This is the only
certain way of obtaining anhydrous "tri" without a res-
idue.
From time to time, the predistilled "tri"
should be examined by a blank test to ensure freedom
from any residue. The "tri" is used only once for ex-
traction. The "tri" distilled off is collected and
can be used in the works for degreasing purposes.
6A.4.13 Determination of the Dust
The extracted filter thimble, together with
the cleaning pad, is dried in the accompanying weigh-
ing glass in a drying cabinet at 105°C. The sealed
weighing glass is allowed to cool in a desiccator and
the dust weight found by difference.
6 A-2 6
-------
6A.4.14 Determination of S (Gaseous)
100 ml of the absorption solution filtrate
from the 1 liter graduated flask are mixed with a few
drops of hydrogen perioxide and boiled to oxidize any
sulphite that may be present. Hydrochloric acid is
then added until methyl red changes color and then a
further 5 drops excess. The mixture is now boiled
until the CC>2 has completely escaped. 3 g A1C13-6H2O
are added and the sulphate precipitated at the boiling
temperature with an excess of 0.1 M barium chloride
solution. After standing for six hours, the barium
sulphate precipitate is filtered off through a blue
band filter, this is ignited at 800°C and the barium
sulphate weighed.
6A.4.15 Determination of the F Content
a) F (Gaseous)
10 - 100 ml of the absorption solution fil-
trate from the 1 liter graduated flask are pipetted
into a 250 ml Claisen flask. The F is distilled over
with perchloric acid to 250 ml by the Fellenberg method
and determined by microtitration with 0.01-n. thorium
nitrate solution.
b) F (Water-soluble) in the Dust
After weighing the dust, the filter thimble
is washed with 500 ml of distilled water. The F con-
tent of an aliquot part is determined by distillation
and titration with 0.01-n. thorium nitrate.
c) F (Insoluble in Water) in the Dust
Determination of the F Soluble
in the Dust
The filter thimble washed with water is added
to 200 ml of 5% NaOH and boiled for 15 mins. The slur-
ry is filtered with suction and washed with hot dis-
tilled water containing phenolphthalein until an alkali-
free reaction is obtained. The filtrate is made up to
6 A-2 7
-------
1 liter. The F content is determined in 10 - 100 ml
by the Fellenberg method. This method gives 95% of
the F (insoluble in water) in the dust.
Control Method
The filter thimble washed with water is dried
at 105°C and ashed in a covered Pt dish in a muffle
furnace at 600°C. The ash is decomposed with 2 g NaOH
in a Pt crucible and the F distilled over, by distilla-
tion with perchloric acid, to 250 ml and the F deter-
mined by titration with thorium nitrate solution.
6A.4.16 Processing the Contents
of the Droplet Separating Bottle
The amount of the separated droplet water is
measured.
The pH value of the droplet water is deter-
mined (indicator method).
The separated droplet water is filtered
through a prepared (as with the filter thimbles) and
tared blue band filter into a 100 ml graduated flask;
the separating bottle is washed; the flask is made up
to the mark.
The probe tube with probe tip and connecting
hose to the droplet separator are cleaned with "tri"
and a weighed pad. The separating bottle is washed
with "tri" after it has been allowed to dry. The
amounts of "tri" used for washing and cleaning are
collected in a beaker and filtered through the blue
band filter - which has been dried - used for filter-
ing the droplet water, in which there is also the used
cleaning pad. The filter is washed with "tri". The
"tri" filtrate is preferably collected directly in a
100 ml flask.
Determination of the dust: the blue band filter is
dried at 105°C and weighed.
Determination of the tar: the "tri" is evaporated,
the flask is dried at 80°C
and then weighed.
6 A-2 8
-------
Determination of the F; aliquot part of the water
filtrate, perchloric acid
distillation, titration with
0.01-n. thorium nitrate solu-
tion.
Possible determination
of F in the dust: after the dust determination,
the filter is boiled with 5%
NaOH solution and F deter-
mined in the filtrate.
Determination of the S: aliquot part of the aqueous
filtrate, precipitation with
BaCl2, weighing as barium
sulphate.
6 A-2 9
-------
6A.5 Source Sampling and Analytical
Techniques at a HS Soderberg Plant
The following report describes sampling and
analytical techniques practiced at a United States
HS Soderberg Plant.
The report was first prepared in 1968 and re-
vised in April 1972.
6 A-30
-------
TABLE OF CONTENTS
Section Page
6A.5.1 Introduction 6A-32
6A.5.2 Definition of Problem 6A-32
6A.5.3 Conclusion 6A-32
6A.5.4 Discussion 6A-33
6A.5.5 Sampling System 6A-34
6A.5.6 Analysis System 6A-38
6A.5.7 Comments on Innovations to System 6A-42
6A.5.8 Calculations System 6A-43
Appendixes
A. Analysis of Air Effluent Sample on
47mm Glass Fiber Filter Paper 6A-51
B. Carbon Determination Using Gasometer 6A-54
C. Determination of Fluoride by
Technicon Autoanalyzer 6A-56
D. Analysis of Air Effluent Sample in
Glass-Wool Filled Sampling Head 6A-57
E. Analysis of Smith-Greenberg Impinger
Bottles (Gaseous Fluoride) 6A-58
(S02) 6A-59
6 A-31
-------
Improvement Tests on Air Control Scrubbers
Sampling and Analysis
6A.5.1 Introduction
The development of a satisfactory system for
sampling and analyzing Soderberg pot gas required a
major portion of the effort in testing air cleaning
equipment.
This second report on the overall project
covers this phase of the investigation.
6A.5.2 Definition of Problem
Sampling and analysis for the air control de-
velopment work previously performed during 1952-1955
concerned itself primarily with indications of gaseous
and particulate fluorides, and to a lesser extent with
total solids and tar fog. The system usually attempted
to evaluate one or two contaminants at a time, rather
than examining total pollution.
It was felt necessary to develop a sampling
and analysis system which would define the complex
Soderberg contamination as a whole and as a sum of
its parts as continuing outplant problems on solid
and liquid fallout placed more emphasis on the solid
contaminants.
6A.5.3 Conclusion
A sampling and analysis system was developed
which provided a practical method in the field and in
the laboratory, covered the broad range of the pollu-
tants simultaneously, and permitted some cross checks
and material balances to verify general trends in the
testing. It provides definitive accounting for all
important contaminants without large omissions or
duplications in the categories involved.
6 A-3 2
-------
6A.5.4 Discussion
Standard procedures for measurement of effici-
ency and performance of air cleaning equipment call
for "determination of the average dust concentration
at the inlet of the scrubber and at the outlet of the
scrubber... It is....essential that the respective
dust concentration be expressed in terms of weight of
dust per dry standard volume or weight unit of gas".
(Paragraph 4.5, "Test Procedures for Gas Scrubbers",
Industrial Gas Cleaning Institute Publication No. 2).
This method was used during the 1952-1955 period and
was adopted for use again with the concentrations ex-
pressed in the English Engineering Units of grains per
standard cubic foot of dry air.
The ideal approach to an air cleaning test
would be to batchwise segregate a given mass of dirty
air, weigh it, determine the amount of each impurity,
clean it as the test equipment does, and then deter-
mine the residual impurities. Collection efficiencies
on each impurity could be calculated and checked thru
a material balance approach.
Since this is impractical, the best approxima-
tion is secured by careful sampling of inlet and outlet
gas. The constant base unit for such calculations is
standard cubic foot of dry air. The cross checks pos-
sible in calculating material balances force the estab-
lishment of a sound sampling and analysis system.
Soderberg pot gas exhaust contains many sub-
stances. A comprehensive list includes:
Substance Physical State
1. Air, Bone Dry Gaseous
2. Water Vapor Gaseous
3. Water, Entrained Liquid
4. Fluoride, Gaseous Gaseous
5. Fluoride, Particulate Solid
6. Inorganic Fume Solid Particulate
Aerosol
7. S02 Gaseous
8. Inorganic & Miscella-
neous Gases (CO, CC-2,
CF4, CS, etc.) Gaseous
6 A-3 3
-------
9. Alumina, Particulate Solid
10. River Sand, Particulate Solid
11. Carbon Soot & Smoke Solid Particulate
Aerosol
12. Tar Fog Liquid Aerosol
13. Gaseous Hydrocarbon Gaseous
Numbers 8 and 10 did not enter into the con-
siderations of these tests.
6A.5.5 Sampling System
The equipment for sampling pot gas in the in-
lets to the scrubbers is shown schematically in Figure
1.
#1 - A Gelman No. 1235 Inline aluminum filter
holder is positioned in the duct so that the inlet
right-angled glass or metal probe is located at a
selected sampling point. The probe is sized for iso-
kinetic sampling. This filter holder contains a 47 mm
Gelman Type E glass fiber paper. This paper is used
in high-volume samplers as it combines low pressure
drop when dry with extremely fine particle retention.
Type E contains an acrylic binder to give it high wet
strength and will withstand temperatures to 900°F.
The minimum retention efficiency for particles larger
than 0.3 is 99.7% measured by Dioctyl Phthalate Pen-
etration (DOP) Test. The efficiency is greater than
98% for particles as small as 0.05 micron.
The filter holder is mounted on the end
of a 1" x 2" wood pole which can be clamped to the
jig previously developed for positioning a pitot in
the ducts. The jig contains 3" IPS threads which
fasten into 3" pipe fittings welded to the duct. The
wood strip can be positioned with a pair of vise grip
pliers. Leakage is eliminated by stuffing with a rag.
The inlet duct gas normally runs about
200°F and the filter holder rises to and operates at
this temperature.
#2 - As soon as possible, after the filtered
gas enters tubing surrounded by atmospheric tempera-
ture, it is routed into a 27 mm ID Pyrex filter tube
6 A-34
-------
en
>
u>
©
FIGURE 1
SCHEMATIC - INLET GAS SAMPLING EQUIPMENT
1 - Gelman Head and Isokinetic Glass Probe Inserted in Gas Stream
2 - Glass Head (Packed with glass wool) in ice-brine solution
3 - Two Smith-Greenberg Impingers
4 - Filter Flask
5 - F & P Flowrator
fi - Spragus Meter
7 -- Tct.ary Vacuum Pump
-------
packed tightly with 4.0 grains of Corning glass wool.
The tube is surrounded by an ice-brine bath at
26°F_^ 2°F and the gas cooled. A space is left be-
tween the small glass entrance tube and the glass
wool packing. The condensible hydrocarbons deposit
either on the inside of the 27 mm tube or on the
glass wool packing as indicated by a yellow coloration.
#3 - The gaseous fluoride is caught in the
first of two series Pyrex Smith-Greenberg impingers.
The first holds 250 ml distilled water as the absorp-
tion liquid.
S02 is caught in the second S-G impinger.
It is filled with 250 ml of 1-2% NaOH and Phenolphtha-
lein to insure causticity.
#4 - A 50 ml filter flask trap prevents any
liquid from the impingers being carried forward in
the sampling train.
#5 - The instantaneous rate of sample flow is
measured by a Fisher-Porter Model 10A 1027A Flowrator
with a capacity of 1.2 SCFM. The normal sampling rate
is either 1.0 or 0.75 CFM controlled by the valves on
the Sprague Meter or Gast Pump.
#6 - The total volume of sample collected is
measured with a Sprague #1A Dry Gas Test Meter with
cumulating reset dials. A vacuum gauge and metal ther-
mometer installed in the meter outlet indicate the
absolute pressure and temperature of the gas as it is
being measured, permitting conversion to SCF.
#7 - The air mover is a Gast pressure-vacuum
pump.
The sampling equipment of Figure 1 worked well
on the substantially dry inlet gas. A sample could
be taken effectively with a reasonable change in pres-
sure drop across the glass fiber filter in the Gelman
Head.
Outlet sampling presented a major problem un-
til the use of a preheater was suggested to dry the
gas before filtering.
6A-36
-------
Figure 2 shows the inclusion of a %" OD x 4"8"
long copper or stainless steel sampling tube ahead of
the Gelman Head. The tube is wrapped with an electric
Briskeat flexible heating tape over most of its length.
The heating element is wrapped with asbestos paper and
glass tape to keep the moisture out. This 768 watt
unit was operated at approximately 75 volts through a
Variac which brings the gas to a temperature of about
60°C _/ 5°.
Heating of the outlet gas apparently converted
any liquid water to the vapor state. (The Gelman glass
fiber filter paper will pass air at a rate 61 times
as fast as it will pass liquid water). The output
from the Gelman Head was then fed into the glass wool
packed condensing head with as short a connection as
possible.
The lack of isokinetic sampling on the fine
particle size of the outlet gas is a common practice
and not considered significant.
Vibration snubbers were used to protect the
sampling equipment whenever necessary.
Most sample runs were 90-120 minutes duration.
All tubing joints must be tight - glass tub-
ing was used as much as possible.
Samples are taken simultaneously in inlet and
outlet positions.
6A.5.6 Analysis System
The total air contaminant removed from a sam-
ple of either inlet or outlet scrubber gas was for-
warded to the laboratory in three distinct physical
parts:
a) Contained on the 47 mm glass fiber filter
paper.
b) Contained on glass wool in a glass sampling
head, and
6 A-3 7
-------
i
(jO
oo
FIGURE 2
SCHEMATIC - OUTLET GAS SAMPLING EQUIPMENT
1 - Copper Tube with Electric Heater attached to Gelman Head
2 - Glass Head (packed with glass wool) in Ice-brine Solution
3 - Two Smith-Greenberg Impingers
4 - Filter Flask
5 - F &• P Flowrator
6 - Sptague Meter
7 - Rotary Vacuum Pump
-------
c) Contained in the liquid in 2 Smith-
Greenberg impinger bottles.
The procedure for each of these three samples
is_j3hown schematically on Figure 3. Circled numbers
refer to determinations. Squared numbers '
refer to gravimetric weighings. Extensive details of
the laboratory procedures are included in Appendices
A through E.
List and Summary of the Determinations
Sample A - 47 mm filter paper
Total Solids - Determined gravimetrically by
difference in weight of filter paper before
and after sampling.
© - 0 -
2 ' Tar Fog (or Benzene Solubles) - Determined
gravimetrically by the difference in the
weight of the residue before and after a
hot benzene extraction.
r ——, . ,
• L?J - 111
•3, Inorganic Fume - (The amount of fluoride
materials including the
metallic ions in com-
bination) . Determined
gravimetrically by the difference in the
weight of the residue before and after a
hot 10% HClC-4 extraction
r3) = jTj -' \T\
'V.,^- V,, —J "> -1
'4) Carbon, Soot & Smoke - Residue from perchlo-
ric acid extraction ashed in a Leco Gasometer
with a flow of C-2 to convert all C to C02•
CC-2 measured volumetrically and calculated
back to C.
6 A-3 9
-------
4^
o
SAMPLE A
47mm Glass Paper
r\ J/ Benzene
Extraction
& Drying
i Extraction
& Drying
/Ash in
Leco
Gasometer
reatmen
& Potassium
Pyrosulfate
Puolon
SAMPLE B
Glass Head wit
•MMMMHVH
51
i U las s Wool
Drying
Filtrate
(Discard)
Benzene
Extraction
& Drying
iion V>
'i7
Filtrate
C02 Measured
Volumetri-
cally
ru 113
F with
Technicon
Autoanalyzer
F with
v
( Tschaicon /
\ Autoanalyzer /
Filtrate
(Discard)
SAMPLE C 2 Smith-
Greenberg Bottles
Aliquot
Impinger #1-
F with
Technicon
Autoanalyzer
or Orion F Electrode
:Impin.e:er #2
TO by BaSC,
Precipitation
SCHEMATIC DIAGRAM
OF
LABORATORY ANALYSIS
Determinations
Gravinetric Weighings
FIGURE 3
-------
Alumina, Particulate - Treat residue from
ashing with HF to remove silicon, fuse with
potassium pyrosulfate to acid solubilize,
precipitate Al with alkaline NH4, filter,
ash, weight
© -
V6 , Particulate Fluoride - An aliquot of the fil-
trate from the HC104 extraction in deter-
mination 3 is used to determine F (particulate
fluoride) utilizing a Technicon Autoanalyzer .
Sample B - Glass Filter Head
Condensible Tar Fog (or Benzene Solubles) -
Determined gravimetrically by the difference
in weight of the glass head before and after
a benzene extraction with glass wool in situ
© -
12
8
Gaseous Fluoride - Passage of gaseous fluoride
contaminant through the 4.0 grams of glass
fiber results in partial removal by reaction
with the glass. The mass of glass wool is
leached for ^ hour with 0.1N NaOH. F is then
determined in the liquor with the Technicon
Autoanalyzer.
Sample C - Two Smith-Greenberg Impingers
{ 9 ; Gaseous Fluoride - The aqueous solution from
the first impinger is run for F on the Tech-
nicon Autoanalyzer or the Orion Specific F
Electrode.
S02 - Determined gravimetrically from the
second impinger liquor by precipitation with
i.10'
Results of all determinations are reported
in milligrams. These are subsequently converted to
grains in the English Engineering System.
6A-41
-------
6A.5.7 Comments on Innovations to System
1. The use of the Gelman head in the hot
inlet stream offered the opportunity to separate the
solid and tarry impurities from the gaseous impuri-
ties at their existing temperature. The procedure
also eliminated the collection of solids in the tub-
ing before it reached a filter medium, one of the
early problems.
2. The high retentivity of the Gelman glass
fiber filter paper for small particle sizes trapped
all solid impurity as far as could be noted. It is
heat resisting. The 47 mm circles fit conveniently
into the Gelman head. The laboratory reported great-
er consistency with its use.
3. Much trouble was experienced in trying to
obtain an adequate size outlet sample. The filter
head would plug quickly. Passage of gas directly
into S-G bottles containing benzene followed by the
filter plugged erratically and gave inconsistent re-
sults. The use of a heated probe was tried to turn
any entrained waters into vapor. This was quite
effective.
4. Total sample volume was first measured by
striving to maintain a constant instantaneous flow
rate as measured by F & P Flowrator and multiplying
by the time of the run. Control was difficult, re-
quiring frequent adjustment. Conversion to standard
gas conditions was also a problem as the flowrator
calibration changed with pressure. The use of the
Sprague Dry Gas Test Meters was most helpful in
providing a cumulative ACF figure.
5. Very erratic results and negative collec-
tion efficiencies on Tar Fog (CgHg Solubles) were
originally obtained. Many solutions were tried, such
as passing gas into S-G bottles with CgHg, without
positive results. The use of a glass wool filter in
a container in a dry-ice bath was suggested. Some
changes were required in our case, namely a brine
bath rather than dry-ice, a glass container rather
than metal for ease in analysis, and a dense packing
of glass wool rather than loose. However, the use of
the brine trap filters on both the inlet and outlet
6 A-4 2
-------
samples brought about reasonable results on Tar Fog
collection efficiencies, probably since it helps
compensate for the cooling and condensing of hydro-
carbon vapors in the scrubbing operation.
6. Use of Bone Dry Air as the base in con-
centration and material balance calculations as com-
pared to just Air removes the effect of changes in
the moisture content due to the aqueous scrubbing
operation.
7. The analytical determination of Tar Fog
(CeHg Solubles) gravimetrically following a benzene
extraction, rather than colorimetrically was found by
the Lab to be more accurate. Different fractions of
the tar fog affect the coloration differently.
8. Determination of Inorganic Fume permitted
an evaluation of the metal ions associated with the
particle fluoride impurity. The Inorganic Fume value
is considered largely influenced by the preponderance
of "hot pots".
9. The determination of Carbon, Soot and
Smoke is considered a measure of the amount of con-
tamination being contributed by pitch and paste,
leaks and fires on the anode and on the crust. Efforts
were first made to determine Carbon by ashing and
weighing. Much better results were obtained by con-
verting to CC-2 in a Leco Gasometer combustion train
and measuring volumetrically.
6A.5.8 Calculations System
The mathematical logic underlying most work
on improving air control involves either the compar-
ison of concentration of output gas discharges or the
comparison of collection efficiencies. Both param-
eters are based on concentration values expressed in
these studies in "grains of pollutant per standard
cubic foot of dry air".
All of the sampling and analysis efforts are
used to arrive at concentration values.
6A-43
-------
Concentration is a fraction. Its numerator
is a weight of impurity. The denominator is the size
of the sample. The calculation methods used handled
the impurity weight and sample size separately, com-
bining them ultimately to obtain concentration values.
Weight of pollutants^
As stated in the Analysis Section, the com-
plex mixture of pollutants in a sample of scrubbed
or unscrubbed gas was measured by 10 analytical de-
terminations. Evaluation of the gas cleaning proc-
ess was made on the basis of 9 contaminant categories
calculated from these analytical determinations.
These contaminants, their description and method of
calculation are indicated on the following tables.
6A-44
-------
Contaminant Evaluated
Collection Components
Determinations
Included in Weight
<(*
en
1. Gaseous Fluoride
2. Particulate Fluoride
3. Total Fluoride
4. Total Solids &
Condensibles
5. Tar Fog (C5H6
Soluble)
6. Carbon, Soot & Smoke
7. Inorganic Fume
8. Alumina
9. S02
Gaseous F from Impinger plus
Gaseous F from Glass Head
Particulate F from Glass
Filter Paper
Gaseous F plus Particulate F
Total Solids & Condensibles on Glass
Filter Paper plus Condensible Tar
Fog on Glass Head
Benzene Soluble on Filter Paper plus
Benzene Soluble on Glass Head
Carbon from Filter Paper
Inorganic Fume from Filter Paper
Alumina from Filter Paper
Gaseous SC>2 from 2nd Impinger
6) + (o) + (9)
©+©
© - ©
lo
-------
Example of Calculation for Pollutant Weight in Sample
6) (4) (i)
Laboratory
Determination
©
I
©
>
1 (D
en
©
©
©
(£q)
Total Solids
Tar Fog
(C6H6Sol)
Inorganic Fume
Carbon, Soot &
Smoke
Alumina
Particulate F
Tar Fog (Glass
Head)
Gaseous F
(Glass Head)
Gaseous F
Impingers
SO?
Mg
128
25
76
27
18
14
18
20
29
-
.4
.8
.6
.8
.0
.7
.4
.8
.8
Grains
(2Jx .01543
1.981
.398
1.182
.429
.278
.227
.284
.321
.460
-
Weight
Additive (3)+ (4)
.284 2.265
.284 .682
1.182
.429
.278
.227
-
- -
.321 .781
.227 1.008
+ .321
+ .460
-
Contaminant
4.
5.
7.
6.
8.
2.
1.
3.
9.
Total Solids &
Condensibles
Tar Fog (C6H6Soluble)
Inorganic Fume
Carbon, Soot &
Alumina
Smoke
Particulate Fluoride
-
-
Gaseous Fluoride
Total Fluoride
SC-2
The contaminant weights in Column (5j above are carried forward
to the Cleaning Efficiency Calculations.
-------
Volume of Sample
Sprague Type 1A Dry Test Meters are widely
used for the measurement of sample volume in air
control testing. They provide a cumulative value
for actual gas thruput (ACF) under possible changing
conditions of pressure, temperature and moisture
content. Calculations are concerned with adjusting
the ACF measurement back to standard cubic feet of
dry air - a base unit or common denominator, which
is unchanged in its passage thru the scrubbing op-
eration and which is also equivalent to a mass of
dry air.
The pressure and temperature on the outlet
side of the Sprague Meter were read four or five
times during a run, and the values arithmetically
averaged since the variation was not excessive.
Humidity of the air following travel through two
Smith-Greenberg impingers was assumed to be 100%.
The Buffalo Forge Company's "Fan Engineering"
handbook provides a formula for the cubic feet oc-
cupied by a mixture of air and water vapor at various
temperatures and pressures and containing one Ib. of
dry air. (6th Ed., p. 27).
Q = 346.5 + .7535t
b - eh
Where Q = Cu.ft. of mixture per Ib. of dry air in it
b = Pressure of gas in inches of mercury
e - Vapor pressure of water in inches of mer-
cury at dry bulb temperature (available
from Table, p. 6A-50)
h = Relative humidity expressed as decimal
t = Dry-bulb temperature, deg. F
Dividing the actual cubic feet of mixture
(the Sprague ACF) by the number of actual cubic feet
of mixture per Ib. of dry air in it (Q above for the
corresponding conditions) yields the number of Ibs.
of dry air which have been sampled thru the Sprague
Meter.
6A-47
-------
It is then a simple matter to convert pounds
of dry air to standard cubic feet of dry air by
dividing by the density of standard dry air (0.07495
Ibs/cf).
Sample Calculation
Data
Elapsed
Time
(Min.
20 '00"
44 '00"
67 '00"
90 '00"
Average
Flow
Rate
(CFM)
.90
.80
.73
.65
Temp.
OF
85
92
92
94
91
Vacuum
(In. Hg)
14.0
14.9
15.8
15.8
15.1
Sprague
Meter
(ACF)
25.03
48.15
67.82
86.32
Barometer
(In. Hg)
30.09
30.09
30.09
30.09
Sprague Meter Thruput =
86.32 ACF @ 91°F&(30.09-15)" Hg
86.32 ACF @ 551°R & 14.99" Hg
Cu.Ft. Mixture/#BDA=Q = 346.5 + .7535t
b - eh
= 346.5 + .7535 x 91
Lbs. BDA in Sample
SCF BDA in Sample
14.99 - (1.467 x 1.00)
= 346.5 + 68.57
14.99 - 1.47
= 415.07 = 30.70
13.52
ACF
= 86.32
Cu.Ft. Mixture/#BDA 30.70
= 2.812 Ibs. BDA in sample
= #BDA = 2.812
.07495 .07495
= 37.52 SCF BDA
6A-48
-------
The standard cubic feet of bone dry air in
the sample as calculated is carried forward to the
Cleaning Efficiency Calculations.
Cleaning Efficiency
Figure 4, the Cleaning Efficiency Calculation
Form indicates the procedure for determination of
inlet concentration, outlet concentration, and scrub-
bing efficiency for a test. The contaminant weights
in the samples and the sample volumes for previous
calculations are divided to give inlet and outlet
calculations.
Efficiency calculations are made from the
basic concept:
inlet Cone. - Outlet Cone. x IQQ = % Efficiency
Inlet Cone.
6A-49
-------
FIGURE 4
CLEANING EFFICIENCY CALCULATION FORM
(D
1.
2.
-------
Appendix "A"
Analysis of Air Effluent Sample
The sample is collected on a tared Gelman Type E
fiberglass filter paper, 47 mm in diameter, that has
been brought to constant weight in the lab. Once
the sample is collected and received in the lab, it
is desiccated for at least forty-eight hours, then
weighed (constant weight is obtained).
Benzene Solubles
1. Place filter-sample in clean numbered sinter
glass crucible (coarse porosity), which is
placed in corresponding numbered beaker (200 ml)
mounted with stemless funnel.
2. With aid of burette extract sample with several
5 ml increments of warm benzene (not to boil)
until benzene dripping from crucible is clear.
(A blank is always carried along.)
3. After extractions are completed, place crucible
with sample in drying oven overnight maintain-
ing 155°C temperature.
4. Cool in desiccator for fifteen minutes and
weigh: repeat Step 4 until constant weight is
obtained.
Calculation; Wt. Benzene Soluble = Wt. Filter &
Sample - Loss in Wt. After Benzene Extraction
Inorganic Fume (Acid Solubles)
1. Again place crucible with residue remains from
sample in corresponding numbered beaker, mount-
ed with stemless funnel.
2. Extract with six to eight 5 ml portions hot 10%
HC1O4 (the acid dissolves bath and other inor-
ganic fluoride material - Na3AlFg, CaF2, Aids).
6 A-51
-------
3. Wash with six 5 ml portions hot distilled water.
(Save combined filtrates to determine particu-
late fluoride).
4. Place crucible-sample in drying oven, 155°C
overnight.
5. Cool in desiccator and weigh.
Calculation; Wt. Inorganic Fume = Wt. Filter &
Sample after C^H^ extraction - Wt. Filter &
Sample after HC1C-4 extraction.
Carbon
See procedure for Carbon Determination Using Gasometer,
Note: Carbon must be determined before proceeding
to alumina.
Alumina
1. Place filter sample in clean corresponding num-
bered platinum dish on hot plate with hood on.
2. Add ten ml Cone. HF and bake to dryness on
medium heat.
3. Remove from hot plate and cool. (HF is used to
remove Silicon by converting it to SiF4 - a gas),
4. Fuse sample in hood with 3 grams Potassium Pyro-
sulfate.
5. Cool and put sample into solution with 25 ml of
1:1 HCl.
6. Quantitatively transfer to numbered beaker, add-
ing 3-5 grams Ammonium Chloride and boiling the
salt into solution for three minutes.
7. Remove from hot plate and cool.
6 A-5 2
-------
8. Add 2 drops of phenol red indicator and adjust
to pink color with concentrated Ammonium
Hydroxide.
9. Again return beaker to hot plate and boil for
one to two minutes.
10. Using Whatman No. 41H paper, filter while still
warm.
11. Police thoroughly and wash about six times with
hot 2% Ammonium Chloride solution.
12. Place filter with residue in numbered tared
crucible and ignite in furnace for 30 minutes
at 1000°C.
13. Cool in desiccator and weigh.
Calculation; Wt. Alumina = Wt. obtained after Igni-
tion - determined blank.
Reagents;
10% HC104 - 900 ml H2O, 100 ml Cone. HClCvj.
1:1 HC1 - 500 ml H20, 500 ml Cone. Hcl.
Ammonium Chloride Solution, 2% - 10 grams dis-
solved in 500 ml H20.
Phenol Red Indicator - 0.1 gram dissolved in
100 ml H20.
6 A-5 3
-------
Appendix "B"
Carbon Determination Using Gasometer
1. Preheat tube furnace for about two hours.
2. Turn burette stopcock to exhaust or furnace posi-
tion and raise levelling bottle to upper cup until
red levelling solution seats burette float value.
3. Place crucible (boat) with sample in tube furnace,
(because of large sample size, it is represent-
atively divided using only one-half of sample),
making sure sample is in hottest region. Connect
tube with oxygen flow.
4. Slowly begin oxygen flow and place levelling
bottle in lower cup. (The sample will combust
exothermically and use up so much of the oxygen
while burning that there will be a hesitation
of red fluid about 1/3 of the way down the bu-
rette bulb.) When sample has completely burned,
the liquid will start down the bulb into the
calibrated stem. When red levelling liquid is
about 2/3 way down calibrated stem, turn off
oxygen value. In no case should red solution
be allowed to go below zero point on the cali-
brated stem.
5. Disconnect oxygen flow and remove sample, allow-
ing the bottom of meniscus to settle to the zero
point on burette stem.
6. Turn burette stockcock clockwise to caustic
position and raise levelling bottle to upper cup.
The red levelling solution will rise and force
all the gas into the absorption vessel contain-
ing caustic (KoH) solution.
7. Lower levelling bottle by hand to below table
level until the caustic rises and seats the float
value (blue in color) in the absorption vessel.
All gas should now be in burette. Repeat again.
6 A-54
-------
8. Turn burette stopcock clockwise to lock position,
keeping the levelling bottle below table level so
that the float in the absorption vessel remains
seated.
9. Now raise levelling bottle so the side arm reading
tube is adjacent to the calibrated stem. Adjust
levelling bottle height so the two menisci are on
the same horizontal level. Hold for a few sec-
onds while drainage becomes complete. Take
burette reading. Reading is in milligrams of
carbon.
Calculation; Total mg Carbon =
2 x burette reading - 2 x blank.
6 A-5 5
-------
Appendix "C"
Technicon Autoanalyzer
The autoanalyzer consists of a train of intercon-
nected modules; a sampler, a proportioning pump and
manifold, a heating bath, colorimeter, and a record-
er. Each unit automatically carries out a different
analytical function, including sampling of unknowns
and standards, metering of reagents, heating and
incubation, detection and recording.
Once the samples are collected, manually prepared and
transferred to the sampler in 8.5 ml sample cups,
manual manipulations cease. The sample is automat-
ically pumped through the system and distilled in
hydrogen fluoride at 170°C using sulfuric acid. There
is a subsequent reaction of the distillate with ali-
zarin fluorine blue-lanthomum reagent to form a lilac-
blue complex, which is measured colorimetrically at
624 manometers. All results, in absorbance and/or
optical density, appear as a series of peaks on the
instrument's recorder chart.
A. Glass Wool - The sample is quantitatively trans-
ferred from the head to clean stainless steel
beakers. Samples are then digested for 30 min-
utes with 200 ml of 0.1M NaOH and kept alkaline
to 2-4 drops of 1% phenolphthalein solution.
The sample is cooled, filtered and diluted to
a known volume (200 ml) with distilled H20.
B. Particulate F - Sample is extracted with 5-5 ml
increments of hot 10% HC104 and an equal amount
of hot distilled H20. Combine filtrates and
dilute to 50 ml with distilled
6 A-5 6
-------
Appendix "D"
Analysis of Air Effluent Sample - Glass Head
The sample is collected on a tared glass head packed
with approximately four grams of glass wool that has
been dried and brought to constant weight in the Lab.
Once the sample is collected and received in the Lab,
it is dried by passing dry air through it for at
least forty-eight hours, then weighed.
1. The glass head containing the sample, by its
small end, is connected with rubber tubing to
the stem of a short stem funnel, which has been
placed into a larger metal funnel and clamped
to an iron stand.
2. Through the funnel, extract the sample with ten
10-ml increments of warm benzene, or until the
dripping solvent is clear. To enhance rate of
filtration an air vacuum is used.
3. Place glass head with sample into a drying oven
overnight at 155°C. Dessicate and weigh.
(Discard filtrate)
Calculation; Wt. Benzene Solubles =
Wt. Glass Head / Wool and Sample -
Less Wt. Head / Wool / Residue
after CgHg extraction.
Inorganic Fume (Acid Solubles)
1. Quantitatively remove glass wool from head with
aid of forceps or other feasible means and place
in 250 ml distilling flask.
2. Proceed with Willard-Winter Perchloric Acid -
Steam Distillation.
6 A-5 7
-------
Appendix "E"
Analysis of Smith-Greenberg Impinger Bottles
Bottle #1 - Gaseous Fluoride
Gaseous Fluoride is determined utilizing the Tech-
nicon Autoanalyzer or the Orion Fluoride electrode
by the following procedure:
1. Aliquot 50 ml of sample and 50 ml 0.2M sodium
citrate buffer into a 100 ml plastic beaker,
adding stirring bar.
2. Place on magnetic stirrer and insert electrode
(fluoride and reference) into solution.
3. Turn stirrer and instrument on, recording milli-
volt reading when stability is obtained.
4. Read ppm F from curve obtained by plotting stand-
ard solutions versus millivolts.
6A-58
-------
Bottle #2 - SO?
Procedure
1. Adjust volume by dilution or concentration to
250 ml and adjust to pH 7.0 using 1-1 HCl .
2. Add 10 ml of 3% hydrogen peroxide, B.2°2' an<^ let
stand for 15 minutes.
3. Using 1+1 HCl adjust pH to 4.0-5.0 and place
on hot plate to boil.
4. While boiling add 10 ml of 10% Barium Chloride
solution slowly with stirring.
5. Digest precipitate for 2 hours at 80-90°C
(low heat) .
6. Filter using Whatman #40 paper and wash with
warm distilled water until filtrate is chloride-
free to silver nitrate-nitric acid test solution.
7. Ignite precipitate at 950 °C for 30 minutes.
8. Be sure to carry along blank.
Calculation:
Total mg SC>2 = nig BaSC-4 (residues) x 0.274.
6 A-5 9
-------
6A.6 Reference Material
In addition to the information cited in Section 6
and that contained in this appendix, the following pub-
lications are referenced as sources of directly related
technical information:
1. "Determining Dust Concentration In A Gas
Stream" - American Society of Mechanical
Engineers Performance Test Codes PTC-27-1957
2. "Stack And Duct Sampling For Gases And Par-
ticulates" - Gelman Instrument Co.
3. "Methods For Determination Of Velocity,
Volume, Dust And Mist Content Of Gases" -
Western Precipitation Division, Joy Manu-
facturing Co.
4. "Standards Of Performance For New Stationary
Sources" - Environmental Protection Agency
(Aug. 17, 1971)
5. "Sampling Atmospheric Fluorides With Glass
Fiber Filters", M. R. Pack, A. C. Hill and
H. M. Benedict - Journal of The Air Pollu-
tion Control Association, 13: No. 8, 374-377
(1963)
6. "A Source Sampling Technique For Particulate
And Gaseous Fluorides", J. A. Dorsey, D. A.
Kemnitz - Journal of Air Pollution Control
Association, 18: No. 1, 12-14 (1968)
7. "Determination Of Fluoride In Air And Stack
Gas Samples By Use Of An Ion Specific Elec-
trode", L. A. Elfers, C. E. Decker, Analyt-
ical Chemistry, 40: No. 11, 1658-1661 (1968)
8. "Tentative Method Of Analysis For Fluoride
Content Of The Atmosphere And Plant Tis-
sues" - American Public Health Association,
Inc., 6: No. 2, 64-101 (1969)
6A-60
-------
9. "Method 5 - Determination of Particulate
Emissions from Stationary Sources" -
Appendix to Federal Register, Volume 36,
Number 247, December 23, 1971.
10. "Determination of Fluorides in Stack
Gas: SPADNS-Zirconium Lake Method",
C. E. Decker and W. S. Smith, U.S. De-
partment of Health, Education, and
Welfare. Public Health Service, Bureau
of Disease Prevention and Environmental
Control, National Center for Air Pollu-
tion Control, Cincinnati, Ohio,
(July 1967).
11. "Analysis of Fluoride in Air and Stack
Gas Samples by Use of a Specific Ion
Electrode", L. A. Elfers and C. E. Decker,
154th Meeting of the American Chemical
Society (September 15, 1967).
6 A-61
-------
Appendix 6B
Method 13 - Determination of Total Fluoride Emissions
from Stationary Sources
1. Principle and Applicability
1.1 Principle. Gaseous and particulate fluorides
are withdrawn isokinetically from the source. The
fluorides are collected in the impinger water and on
the filter of the sampling train. The weight of total
fluorides in the train is determined by the SPADNS
Zirconium Lake colorimetric method.
1.2 Applicability. This method is applicable for
the determination of fluoride emissions from station-
ary sources only when specified by the test procedures
for determining compliance with New Source Performance
Standards.
2. Range and Sensitivity
2.1 The analytical procedure covers the range
from 0-1.4 ug/ml fluoride.
3. Interferences
3.1 Analysis. Aluminum in excess of 300 ing/liter
and silicon dioxide in excess of 300 ug/liter will
prevent complete recovery of fluoride. Chloride will
distill over and interfere with the subsequent color
reaction. Addition of 5 mg of silver sulfate (see
Section 7.3.5) for each mg of chloride will prevent
chloride interference.
6B-1
-------
4. Precision and Accuracy
4.1 Sampling. A relative standard deviation of
+ 18% was obtained from sixteen sampling runs made on
one industrial source. This measure is for combined
sampling and analytical procedure and includes source
variations.
4.2 Analysis. A relative standard deviation of
3 percent was obtained from twenty replicate intra-
laboratory determinations on a stack emission sample.
A phosphate rock standard containing a certified value
of 3.84 percent fluoride was analyzed by this proce-
dure. The average of five determinations was 3.88
percent fluoride.
The color obtained when the sample and colorimet-
ric reagent are mixed is stable for approximately two
hours. After formation of the color, the temperature
of the samples and standards should be nearly iden-
tical when absorbances are recorded. A 1°F tempera-
ture difference between samples and standards will
produce an error of approximately 0.005 mg F/liter.
5. Apparatus
5.1 Sampling train. See Figure 6B.1. Many of
the design specifications of this sampling train are
described in APTD -0581.
5.1.1 Nozzle - Stainless steel (316) with
sharp, tapered leading edge.
5.1.2 Probe - Borosilicate* glass, long
enough to traverse stack.
5.1.3 Pitot tube - Type S, or equivalent,
attached to probe to monitor stack gas velocity.
* Pyrex has been found suitable for this purpose. Men-
tion of trade names or specific products does not con-
stitute endorsement by the Environmental Protection
Agency.
6B-2
-------
PROBE
THERMOMETER,
FILTER HOLDER
CHECK VALVE
REVERSE-TYPE
PITOT TUBE
^>> IMDIM^PRQ •
MANOMETER
Figure 6B-1. Fluoride sampling train.
-------
5.1.4 Filter holder - Borosilicate glass.
5.1.5 Impingers - Four impingers connected
as shown in Figure 6B.1 with ground glass, vacuum
tight fittings. The first, third, and fourth im-
pingers are of the Greenburg-Smith design, modified
by replacing the tip with a 1/2 in. inside diameter
glass tube extending to 1/2 in. from the bottom of the
flask. The second impinger is of the Greenburg-Smith
design with the standard tip.
5.1.6 Metering system - Vacuum gauge, leak-
free pump, thermometers capable of measuring tempera-
ture to within 2.8°C (5°F), dry gas meter with 2%
accuracy, and related equipment, or equivalent, as
required to maintain an isokinetic sampling rate and
to determine sample volume.
5.1.7 Barometer - To measure atmospheric
pressure to + 2.5 mm Hg (0.1 in.)
5.2 Sample recovery.
5.2.1 Probe brush - At least as long as
probe.
5.2.2 Glass wash bottle - Two.
5.2.3 Sample storage containers - Wide mouth
polyethylene or polypropylene bottles, 900 ml or
greater capacity.
5.2.4 Sample storage containers - Glass,
900 ml or greater capacity.
5.2.5 Graduated cylinder - 250 ml.
5.3 Analysis.
5.3.1 Distillation apparatus - Glass distil-
lation apparatus assembled as shown in Figure 6B.2.
5.3.2 Spectrophotometer - Instrument capable
of measuring absorbance at 570 nm and providing at
least a 1 cm light path.
6B-4
-------
CONNECTING TUBE
12-mm ID
3" 24/40
THERMOMETER
WITH S~ 10/30
f 24/40
1-liter
FLASK
J24/40
CONDENSER
HEATING
MANTLE
500-ml
ERLENMEYER
FLASK
Figure 6B-2. Fluoride distillation apparatus.
6B-5
-------
5.3.3 Hot plate - Capable of heating to
500°C.
5.3.4 Electric muffle furnace - Capable of
heating to 600°C.
5.3.5 Crucibles - Nickel or platinum, 75 to
100 ml capacity.
5.3.6 Spectrophotometer cells - 1 cm.
5.3.7 Volumetric flask - 50 ml.
5.3.8 Erlenmeyer flasks or plastic bottle -
500 ml.
5.3.9 Constant temperature bath - Capable of
maintaining a constant temperature accurate to + 0.3°C
in the range of room temperature.
5.3.10 Trip balance - 300 g capacity to
measure to i 0.05 g.
6. Reagents
6.1 Sampling.
6.1.1 Filters - Whatman No. 1 filter or
equivalent to fit filter holder.
6.1.2 Silica gel - Indicating type, 6-16
mesh, dried at 175°C (350°F) for 2 hours.
6.1.3 Water - Distilled or deionized.
6.1.4 Crushed ice.
6.2 Sample recovery.
6.2.1 Water - Distilled or deionized.
6.2.2 Acetone - Reagent grade.
6B-6
-------
6.3 Analysis.
6.3.1 Calcium oxide (CaO) - Certified grade,
0.005% fluoride or less.
6.3.2 Hydrochloric acid (HCl) - Concentrated,
reagent grade.
6.3.3 Phenolphthalein Indicator - 0.1 percent
in 1:1 ethanol-water mixture.
6.3.4 Silver sulfate (Ag2SC>4) - Reagent grade.
6.3.5 Sodium hydroxide (NaOH) - Pellets, re-
agent grade.
6.3.6 Sulfuric acid (H2S04) - Concentrated,
reagent grade.
6.3.7 Sodium fluoride - Standard solution.
Dissolve 0.2210 g of sodium fluoride in 1 liter of dis-
tilled water. Dilute 100 ml of this solution to 1
liter with distilled water. 1 ml of the solution con-
tains 0.01 mg of fluoride.
6.3.8 SPADNS solution - {.4,5 dihydroxy - 3 -
(p - sulfophenylazo) -2,1- naphthalene - disulfonic
acid trisodium salt}. Dissolve 0.959 g of SPADNS re-
agent in 500 ml distilled water. This solution is
stable indefinitely, if stored in a well-sealed bottle
protected from sunlight.
6.3.9 Reference solution - Add 10 ml of
SPADNS solution to 100 ml distilled water and acidify
with a solution prepared by diluting 7 ml of concen-
trated HCl to 10 ml with distilled water. This solu-
tion is used to set the spectrophotometer zero point
and is stable indefinitely.
6.3.10 SPADNS Mixed Reagent - Dissolve 0.133
g of zirconyl chloride octahydrate (ZrOCl2 • 8H20),
in 25 ml distilled water. Add 350 ml of concentrated
HCl and dilute to 500 ml with distilled water. Mix
equal volumes of this solution and SPADNS solution to
form a single reagent. This reagent is stable for
approximately two years.
6B-7
-------
6.3.11 Filters - Whatman No. 541, or equiv-
alent.
7. Procedure
7.1 Sampling.
7.1.1 Select the sampling site and the min-
imum number of sampling points; determine the stack
pressure, temperature, moisture and range of velocity
head as described in Method 1, 2, 3, and 4 (Federal
Register, Volume 36, Number 247, Thursday, December 23,
1971).
7.1.2 Preparation of collection train - Place
Whatman No. 1 filter into filter holder. Weigh approx-
imately 200 g of silica gel to the nearest gram. Place
100 ml of distilled water in each of the first two im-
pingers, leave the third impinger empty, and place the
preweighed silica gel in the fourth impinger. Assemble
the train without the probe as shown in Figure 6B.1
with the filter between the third and fourth impingers.
Leak check the sampling train at the sampling site by
plugging the inlet to the first impinger and pulling a
380 mm (15 in.) Hg vacuum. A leakage rate not in ex-
cess of 0.02 cfm at a vacuum of 380 mm (15 in.) Hg is
acceptable. Attach the probe. Place crushed ice
around the impingers. Add more ice during the run to
keep the temperature of the gases leaving the last
impinger at 21.1°C (70°F) or less.
7.1.3 Train operation. For each run, record
the data required on the example sheet shown in Figure
6B.3. (Note: On the standard data sheet shown in
Figure 6B.3, the entries for heater box setting, probe
heater setting, and sample box temperature are not
applicable to this method and should be disregarded).
Take readings at each sampling point, at least every
5 minutes, and when significant changes in stack con-
ditions necessitate additional adjustments in flow
rate. To begin sampling, position the nozzle at the
first traverse point with the tip pointing directly
into the gas stream. Immediately start the pump and
adjust the flow to isokinetic conditions. Sample for
6B-8
-------
PLANT.
DATE_
PROBE LENGTH AND TYPE.
NOZZLE I.D.
SAMPLING LOCATION.
SAMPLE TYPE
RUN NUMBER
OPERATOR
AMBIENT TEMPERATURE
BAROMETRIC PRESSURE .
STATIC PRESSURE, (Ps)_
FILTER NUMBER (s)
FIGURE 6B-3. FIELD DATA
SCHEMATIC OF TRAVERSE POINT LAYOUT
ASSUMED MOISTURE, % .
SAMPLE BOX NUMBER.
METER BOX NUMBER _
METER AHg
C FACTOR
PROBE HEATER SETTING.
HEATER BOX SETTING
REFERENCE Ap
READ AND RECORD ALL DATA EVERY.
MINUTES
TRAVERSE
POINT
NUMBER
\. CLOCK TIME
SAMPLING^v J2*rh'
— ,..- . \LLUl/F\|
TIME, mm X^
" ' -___
GAS METER READING
og.it3
VELOCITY
HEAD
(APS), in. H20
ORIFICE PRESSURE
DIFFERENTIAL
(AH), in. H20)
DESIRED
ACTUAL
STACK
TEMPERATURE
(T$),°F
DRY GAS METER
TEMPERATURE
INLET
dm in).°F
OUTLET
(Tmou,),°F
PUMP
VACUUM,
in. Hg
SAMPLE BOX
TEMPERATURE,
°F
IMPINGER
TEMPERATURE,
°F
COMMENTS:
EPA (Dur) 235
4/72
-------
the same amount of time at each traverse point. Main-
tain isokinetic sampling throughout the sampling
period. Nomographs are available which aid in the
rapid adjustment of the sampling rate without other
computations. APTD - 0576 details the procedure for
using these nomographs. Turn off the pump at the con-
clusion of each run and record the final readings.
Remove the probe and nozzle from the stack.
7.2 Sample recovery. Move the impinger train to
the clean-up area. Measure the volume of water in the
first three impingers. Place the samples in containers
as follows:
7.2.1 Container No. 1. Add the water from
the first three impingers to this container. Add the
filter to this container. Also add a water wash of
sample exposed surfaces of the probe tip, probe, first
three impingers, impinger connectors, and front of fil-
ter holder. This water wash must be performed thor-
oughly. Distilled or deionized water should be used.
Rinse each component three separate times with water
and clean the probe with the probe brush. This sample
container must be made of polypropylene or polyethylene,
with one exception: a glass container may be used if
samples are to be stored for less than 30 days.
7.2.2 Container No. 2. Wash all sample ex-
posed surfaces between probe tip and front of filter
holder with acetone. If visible material remains,
rinse or clean with a brush until the surface is clean.
Add these washings to this container. This container
must be made of glass.
7.2.3 Container No. 3. Transfer the silica
gel from the fourth impinger to this container and
seal.
7.3 Analysis. Treat the contents of each sample
container as described below.
7.3.1 Container No. 1
7.3.1.1 Filter this container's con-
tents, including the Whatman #1 filter, through filter
6B-10
-------
paper, Whatman #541 or equivalent. Add an aliquot of
filtrate (not exceeding 0.6 mg F) to the distillation
flask as described in Section 7.3.5. For an estimate
of what size aliquot does not exceed 0.6 mg F, select
an aliquot of the filtrate and treat as described in
Section 7.3.6. This will give an approximation of
the fluoride content, but only an approximation since
interfering ions have not been removed by the distil-
lation step.
7.3.1.2 Place the Whatman #541 filter
containing the insoluble matter in a nickel or plat-
inum crucible, add a few ml of water and macerate the
filter with a glass rod.
Add 100 mg CaO to the crucible and mix the con-
tents thoroughly to form a slurry. Add a couple of
drops of phenolphthlein indicator. The indicator will
turn red in a basic medium. The slurry should remain
basic during the evaporation of the water. If the
indicator turns colorless during the evaporation, an
acidic condition is indicated. If this happens add
CaO until the color turns red again.
Place the crucible in a hood under infrared lamps
or on a hot plate at low heat. Evaporate the water
completely.
After evaporation of the water, place the crucible
on a hot plate and slowly increase the temperature
until the paper chars. It may take several hours for
complete charring of the filter to occur. This should
be done under a hood.
Place the crucible in a cold muffle furnace and
gradually (to prevent smoking) increase the tempera-
ture to 600°C, and maintain until the contents are
reduced to an ash.
7.3.1.3 Remove the crucible from the
furnace and allow it to cool. Add approximately 4 g
of NaOH pellets to the sample, return the crucible to
the muffle furnace, and fuse the sample for 10 min.
at 600°C.
6B-11
-------
Remove the sample from the furnace and cool to
ambient temperature. Transfer the contents of the
crucible to a 250 ml volumetric flask with several
rinsings of warm water. To assure complete sample
removal, rinse finally with two 20 ml portions of 25
percent (v/v) sulfuric acid and carefully add to the
flask. Dilute to volume with distilled water. Trans-
fer an aliquot of sample, not exceeding 0.6 mg flu-
oride to a distillation flask and distill as described
in Section 7.3.5. This will be a separate distilla-
tion from that described in Section 7.3.1.1 for fil-
trate.
If the sample contains insoluble matter preventing
the withdrawal of a representative aliquot, add the
entire sample to the distillation flask and carry out
multiple distillations (by adding 300 ml of water to
the distillation flask after each distillation and re-
distilling) until the distillate coming from the con-
denser is free of fluoride. Determine that the
distillate is free of fluoride by catching an aliquot
(about 10 ml) of distillate as it comes from the con-
denser. Check the aliquot for fluoride content as
described in Section 7.3.6. If this small aliquot
contains fluoride, calculate the amount and add this
to the total fluoride obtained for the run. If the
aliquot contains fluoride, let the distillation pro-
ceed for awhile then take another aliquot to check
for fluoride. Repeat this procedure until the dis-
tillate is fluoride free.
7.3.2 Container No. 2.
7.3.2.1 Filter the acetone washings
through a Whatman No. 541 filter or equivalent to
remove particulate matter. Thoroughly rise the res-
idue on the filter with acetone.
The residue on the filter is treated as previously
described for water insoluble particulates in Sections
7.3.1.2 and 7.3.1.3.
7.3.2.2 Add 100 mg of CaO to the
filtrate and evaporate the acetone with ambient air
in a forced draft hood. Add the residue to a nickel
6B-12
-------
or platinum crucible, fuse the residue with NaOH, and
treat as described previously in Section 7.3.1.3
7.3.3 Container No. 3. Weigh the spent
silica gel and report to the nearest gram.
7.3.4 Adjustment of acid/water ratio in dis
tillation flask - Place 400 ml of distilled water in
the distilling flask and add 200 ml of concentrated
H2SO4. Caution: Observe standard precautions when
mixing the H2SO4 by slowly adding the acid to the
flask with constant swirling. Add boiling stones and
assemble the apparatus as shown in Figure 6B.2. Heat
the flask until it reaches a temperature of 180°C to
adjust the acid/water for subsequent distillations.
Discard the distillate.
7.3.5 Distillation - Cool the contents of
the distillation flask to below 100°C and add the
sample from Section 7.3.1.1, 7.3.1.3, 7.3.2.1, or
7.3.2.2 contained in 300 ml of distilled water. Per-
form a separate distillation step for each of these
fluoride fractions. If the sample contains chloride,
add 5 mg Ag2SC-4 to the flask for every mg of chloride
Gradually increase the heat and collect all the
distillate up to 180°C. The carryover of sulfate, an
interference in the analysis, becomes excessive above
180°C.
The acid in the distilling flask can be used until
there is carryover of interferences or poor fluoride
recovery. An occasional check of fluoride recovery
with standard solutions is advised.
7.3.6 Determination of concentration -
Record the volume of the distillate from each distil-
lation.
Pipet a suitable aliquot from the distillate (con-
taining 10 jig to 40 ug fluoride) and dilute to 50 ml
with distilled water. Add 10 ml of SPADNS Mixed Re-
agent (see Section 6.3.10) and mix thoroughly.
6B-13
-------
After mixing, place the sample in a constant tem-
perature bath for thirty minutes before reading the
absorbance with the spectrophotometer. The constant
temperature bath should be at the same temperature at
which the reference standards were measured (see
Section 8.2).
Set the spectrophotometer to zero absorance at
570 nm with reference solution (see Section 6.3.9).
Read the absorbance of the sample and determine the
concentration from the calibration curve. If the con-
centration does not fall within the range of the cali-
bration curve, repeat the procedure using a different
size aliquot.
8. Calibration
8.1 Sampling train. Use methods and equipment
which have been approved by the Administrator to cal-
ibrate the orifice meter, pitot tube, and dry gas
meter.
8.2 Spectrophotometer. Prepare a standard by
adding 10 ml of SPADNS Mixed Reagent to 50 ml of dis-
tilled water. Prepare a series of standards from the
standard fluoride solution (see Section 6.3.7) by
diluting 1, 2, 3, 4, 5, 6, and 7 ml volumes to 50 ml
with distilled water and adding 10 ml of SPADNS Mixed
Reagent to each. These standards will contain 0, 10,
20, 30, 40, 50, 60, and 70 jig of fluoride (0 - 1.4
ug/ml) respectively.
After mixing, place the reference standards and
reference solution in a constant temperature bath for
thirty minutes before reading the absorbance with the
spectrophotometer. All samples should be adjusted to
this same temperature before analyzing. Since a 1°F
temperature difference between samples and standards
will produce an error of approximately 0.005 mg
F/liter, care must be taken to see that samples and
standards are at nearly identical temperatures when
absorbances are recorded.
With the spectrophotometer at 570 nm, use the
reference solution (see Section 6.3.9) to set the
6B-14
-------
absorbance at zero.
Determine the absorbances of the standards. Pre-
pare a calibration curve by plotting jag F/50 ml versus
absorbance on linear graph paper. A new standard
curve should be prepared whenever a new batch of
SPADNS Mixed Reagent is prepared.
9. Calculations
9.1 Average dry gas meter temperature and average
orifice pressure drop. See data sheet (Figure 6B.3).
9.2 Dry gas volume. Correct the sample volume
measured by the dry gas meter to standard conditions
[21.1°C, 760 mm Hg (70°F, 29.92 inches Hg)] by using
equation 6B.1
?-,__„ •+ AH
t>ar T - ,
xj.b
Equation
where :
V
m
std
v
m
std =
Volume of gas sample through the dry
gas meter (standard conditions),
liter (cu ft) .
Volume of gas sample through the dry
gas meter (meter conditions) , liter
(cu ft).
Absolute temperature at standard
conditions, 294°K (530°R) .
Tm = Average dry gas meter temperature,
°K (°R).
Pbar = Barometric pressure at the orifice
meter, mm Hg (in. Hg) .
AH = Average pressure drop across the
orifice meter, mm H20 (in. H20) .
6B-15
-------
13.6 = Specific gravity of mercury.
= Absolute pressure at standard
conditions, 760 mm Hg (29.92 in.
Hg).
9.3 Volume of water vapor.
\
Equation
6B.2
sra c\ "2" / \ °1-'-1 7
where:
Vw = Volume of water vapor in the gas
sample (standard conditions), liter
(cu ft).
= Total volume of liquid collected in
^ impingers and silica gel, ml. Vol-
ume of water in silica gel equals
silica gel weight increase in grams
times 1 ml/gram. Volume of liquid
collected in impinger equals final
volume minus initial volume.
PH 0 = Density of water, 1 g/ml.
MTT Q = Molecular weight of water, 18 g/g-mole
2 (18 Ib/lb -mole).
R = Ideal gas constant, 62.36 mm Hg -
liter/g mole-°K (21.83 in. Hg -
cu ft/lb mole - °R).
Tstd = Absolute temperature at standard con-
ditions, 294°K (530°R).
pstd = Absolute pressure at standard condi-
tions, 760 mm Hg (29.92 in. Hg).
6B-16
-------
9.4 Moisture content.
Vw
R _ f Equation
vm + vw 6B.3
mstd wstd
where:
BWQ = Proportion by volume of water vapor
in the gas stream, dimensionless.
Vw = Volume of water in the gas sample
(standard conditions), liter
(cu ft).
Vm = Volume of gas sample through the dry
s^ gas meter (standard conditions),
liter (cu ft) .
If liquid droplets are present in the gas stream
assume the stream to be saturated and use a psychromet-
ric chart to obtain an approximation of the moisture
percentage.
9.5 Concentration.
9.5.1 In the analysis, a separate distilla-
tion was performed on each of four fractions of the
sample: filtrate and residue of water wash, and fil-
trate and residue of acetone wash. Calculate the
amount of fluoride in each fraction as follows:
F
f
tyig
1000 ug
Equation
6B.4
where:
Ff = Amount of fluoride in total
fraction, mg.
Vf = Total volume of fraction, ml.
6B-17
-------
Af = Aliquot of total fraction added
to still, ml.
Vd = Volume of distillate collected, ml.
A^ = Aliquot of distillate taken for
color development, ml.
ug F = Concentration from the calibration
curve, ug.
9.5.2 Total fluoride weight. Determine the
total fluoride weight caught in a run by summing the
fluoride weights of the separate fractions of the run.
9.5.3 Concentration in mg/m^.
Ft
0.0283 Equation
Vmstd 6B.5
where:
Cs = Concentration of fluoride in stack
gas, mg/m^, corrected to standard
conditions of 21.1°C, 760 mm Hg
(70°F, 29.92 in.Hg) on a dry
basis.
F-(- = Total weight of fluoride in sample,
mg from Section 9.5.2.
Vm = Volume of gas sample through the
stc3 dry meter (standard conditions),
cu ft from equation 6B.1.
6B-18
-------
9.6 Isokinetic variation.
I =
T
s
\
-------
= Density of water, 1 g/ml
R = Ideal gas constant,
62.36 mm Hg-liter/g mole -
°K (21.83 in. Hg - cu ft/lb mole -
oO = Molecular weight of water, 18 g/g
mole (18 Ib/lb - mole) .
Vm = Volume of gas sample through the dry
gas meter (meter conditions), m^
(cu ft).
Tm = Absolute average dry gas meter tem-
perature (see Figure 6B.3), °K
= Barometric pressure at sampling site,
mm Hg (in. Hg) .
= Average pressure drop across the
orifice (see Figure 6B.3), mm ^0
(in. H20).
Ts = Absolute average stack gas tempera-
ture (see Figure 6B.3), °K (°R) .
6 = Total sampling time, min.
Vs = Stack gas velocity calculated by
Method 2, Equation 2-2, (Federal
Register, Volume 36, Number 247,
December 23, 1971), m/sec (ft/sec).
Ps = Absolute stack gas pressure, mm Hg
(in. Hg).
An = Cross-sectional area of nozzle, m2
(sq ft).
9.7 Acceptable results. The following range sets
the limit on acceptable isokinetic sampling results:
If 90% ^ I 6 110%, the results are acceptable,
otherwise, reject the results and repeat the test.
6B-20
-------
10. References
Bellack, Ervin, "Simplified Fluoride Distillation
Method," Journal of the American Water Works Associa-
tion #50: 530-6, 1958.
Bellack, Ervin, and P. J. Schoube, "Rapid Photo-
metric Determination of Fluoride in Water," Anal. Chem.
30:2032, 1958.
Decker, C. E. and W. S. Smith, "Determination of
Fluorides in Stack Gas: SPADNS - Zirconium Lake
Method," PHS, NCAPC, July, 1967.
Martin, Robert M., "Construction Details of
Isokinetic Source Sampling Equipment," Environmental
Protection Agency, Air Pollution Control Office Publi-
cation No. APTD - 0581.
1972 Annual Book of ASTM Standards, Part 23.
Rom, Jerome J., "Maintenance, Calibration, and
Operation of Isokinetic Source Sampling Equipment,"
Environmental Protection Agency, Air Pollution Control
Office Publication No. APTD - 0576.
Standard Methods for the Examination of Water and
Waste Water, published jointly by American Public
Health Association, American Water Works Association
and Water Pollution Control Federation, 13th Edition,
1971.
6B-21
-------
Appendix 7A
EPA Source Sampling Data
The following tables 7A-la through 7A-8, present
data obtained .during the sampling of several operating
plants by -EPA teams. They are summarized in Section 7.5
of the report.
7A-1
-------
Table 7A-la
FACILITY - A (Primary Inlet - Fluorides)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - % opacity
Fluorides
Soluble
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Fluorides
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
11/11/71
76
0.512
6878
806,000
210
1.70
3.5
18.7
0.3
NA
0.3234
0.2452
19.06
37.6
0.3718
0.2819
21.92
42.2
2
11/11/71
76
0.512
6919
811,000
216
1.65
3.5
18.7
0.0
NA
0.4556
0.3402
27.02
52.0
0.4902
0.3660
29.97
56.1
3
11/11/71
76
0.512
7033
824,000
210
1.90
3.5
18.7
0.0
NA
0.5121
0.3860
30.87
59.6
0.5365
0.4650
32.34
62.3
Average
76
0.512
6940
814,000
212
1.75
3.5
18.7
0.1
NA
0.4304
0.3238
25.65
49.7
0.4662
0.3709
27.78
53.5
7A-2
-------
Table 7A-lb
FACILITY - FACILITY A (Primary Outlet - Fluorides)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - % opacity
Fluorides
Soluble
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Fluorides
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
11/11/71
86
0.512
7097
832,000
80
3.11
3.5
18.6
0.6
10%
0.0075
0.0071
0.4562
0.89
0.0108
0.0102
0.6569
1.28
2
11/11/71
88
0.512
6958
815,000
80
3.28
3.5
18.7
0.0
10%
0.0112
0.0105
0.6679
1.30
0.0145
0.0135
0. 8646
1.69
3
11/11/71
80
0.512
6970
817,000
70
3.10
3.5
18.7
0.0
10%
0.0110
0.0105
0.6571
1.27
0.0169
0.0162
1.0095
1.97
Average
85
0.512
7008
821,000
77
3.16
3.5
18.7
0.2
10%
0.0099
0.0094
0.5937
7.52
0.0141
0.0133
0.8437
1.65
7A-3
-------
Table 7A-lc
FACILITY - A (Secondary Inlet - Fluorides)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. 7»
C02 - Vol. 7, dry
02 - Vol. 7» dry
CO - Vol. 7o dry
Visible Emissions - 7» opacity
Fluorides
Soluble
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Fluorides
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
11/8/71
180
0.256
143,100
33,540,000
42
0.212
0.0
20.6
0.0
NA
0.00019
0.00020
0.235
0.92
0.00029
0.00030
0.353
1.38
2
11/9/71
180
0.256
143,100
33,540,000
47
0.626
0.0
20.9
0.0
NA
0.00094
0.00097
1.34
5.23
0.00105
0.00107
1.47
5.74
3
11/9/71
180
0.256
143,100
Average
180
0.256
143,100
33,540,000 33,540,000
52
0.0
0.0
20.9
0.0
NA
0.00078
0.00080
0.937
3.66
0.00081
0.00083
0.98
3.83
47
.279
0.0
20.8
0.0
NA
0.00064
0.00066
0.837
3.27
0.00072
0.00073
0.93
3.65
7A-4
-------
Table 7A-ld
FACILITY - A (Secondary Outlet - Fluorides)
Summary of Results
11/8/71
180
0.256
139,200
32,630,000
50
1.337
0.0
20.5
0.02
5-10%
11/9/71
180
0.256
3
11/9/71
180
0.256
139,200 139,200
32,630,000 32,630,000
50
1.006
0.0
20.6
0.03
5-10%
53
1.922
0.0
20.6
0.03
5-10%
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - % opacity
Fluorides
Soluble
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Fluorides
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
* Sample not consistent with normal range, probable picked up
particulate F during sample handling. Probable average
shown in parenthesis.
7A-5
Average
180
0.256
139,200
32,630,000
51
1.088
0.0
20.6
0.027
5-10%
0.00014
0.00014
0.168
0.66
0.00023
0.00023
0.273
1.07
0.00043
0.00044
0.512
2.00
0.00800
0.00810
9.52
37.20*
0.00041
0.00041
0.485
1.89
0.00049
0.00049
0.572
2.24
0.00033
0.00033
0.388
1.52
0.00291
0.00294
3.455
26.26*
(1.65)
-------
Table 7A-le
FACILITY - AX (Primary Inlet - Particulates)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - 7<, opacity
Particulate Emissions
Probe and filter catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
5/10/72
96
0.512
5507
645,000
267
1.10
3.3
18.9
0.0
NA
0.967
0.687
45.61
89.14
0.979
0.696
46.21
90.25
2
5/10/72
96
0.512
6496
760,000
239
0.65
3.3
18.9
0.0
NA
0.390
0.289
21.71
42.41
0.413
0.306
22.99
44.90
3
5/10/72
96
0.512
5485
643,000
252
1.34
3.3
18.9
0.0
NA
1.490
1.080
70.04
136.80
1.510
1.090
70.98
138.63
Average
96
0.512
5826
683,000
253
1.03
3.3
18.9
0.0
NA
0.949
0.6853
45.78
89.45
0.967
0.697
46.77
91.26
7 A-6
-------
Table 7A-lf
FACILITY - AI (Primary Outlet Particulates)
Summary of Results
Run number
Date
Test Time-minutes .
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
C02 - Vol. °L dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - % opacity
Particulate Emissions
Probe and filter catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
5/10/72
288
0.512
5092
598,000
51
2.60
6.0
15.5
0.0
0-5
0.00087
0.00088
0.038
0.074
0.00133
0.00135
0.058
0.113
2
5/10/72
288
0.512
5778
677,000
53
2.55
6.0
15.5
0.0
0-5
0.00041
0.00041
0.020
0.040
0.00104
0.00105
0.051
0.100
3
5/10/72
288
0.512
5608
657,000
53
2.61
6.0
15.5
0.0
0-5
0.00072
0.00073
0.034
0.067
0.00143
0.00145
0.068
0.133
Average
288
0.512
5493
644,000
52
2.58
6.0
15.5
0.0
0-5%
0.00067
0.00067
0.031
0.060
0.00127
0.00128
0.059
0.115
7A-7
-------
Table 7A-lg
FACILITY - AI (Secondary Inlet - Particulates)
Summary of Results
Run number
Date
Test Tirae-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. °L
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - % opacity
Particulate Emissions
Probe and filter catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
5/10/72
270
0.256
251,970
984,258
50
0.0
3.3
18.9
0.0
NA
0.00195
0.00204
4.21
16.46
0.00265
0.00277
5.73
22.38
2
5/10/72
300
0.256
251,970
984,258
60
0.0
3.3
18.9
0.0
NA
0.00322
0.00330
6.96
27.19
0.00367
0.00376
7.93
30.98
3
5/11/72
270
0.256
251,970
984,258
70
0.59
3.3
18.9
0.0
NA
0.00217
0.00216
4.68
18.20
0.00332
0.00331
7.17
27.99
Average
280
0.256
251,970
984,258
60
0.20
3.3
18.9
0.0
NA
0.00245
0.0025
5.28
20.62
0.00321
0.00328
6.94
27.13
NA = Not Applicable
7A-8
-------
Table 7A-lh
FACILITY - AI (Secondary Outlet - Particulates)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature. - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO . - Vol. % dry
Visible Emissions - % opacity
Particulate Emissions
Probe and filter catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
5/10/72
358
0.256
251,970
984,258
50
1.25
6.0
15.5
0.0
0-10
0.00031
0.00032
0.667
2.61
0. 00057
0.00058
1.221
4.77
2
5/10/72
325
0.256
251,970
984,258
60
1.22
6.0
15.5
0.0
0-10
0.00047
0.00047
1.006
3.95
0.00082
0.00083
1.766
6.90
3
5/11/72
330
0.256
251,970
984,258
70
0.82
6.0
15.5
0.0
0-10
0.0015*
0.0015
3.190
12.46
0.0020
0.0020
4.329
16.91
Average
338
0.256
251,970
984,258
60
6.0
15.5
0.0
0-10
0.00076
0.00076
1.621
6.34
0.00113
0.00113
2.440
9.53
*Stud blow
7A-9
-------
Table 7A-11
FACILITY - AI (Primary Inlet - Fluorides)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. 7» dry
Visible Emissions - 7» opacity
Particulate Emissions
Probe and filter catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
5/8/72
96
0.512
6551
12,795
262
1.13
3.3
18.9
0.0
NA
0.335
0.239
18.84
36.73
0.344
0.246
19.33
37.69
2
5.9.72
96
0.512
5327
10,404
280
1.22
3.3
18.9
0.0
NA
0.348
0.243
15.89
30.97
0.366
0.256
16.71
32.57
3
5/9/72
96
0.512
5664
11,062
269
0.71
3.3
18.9
0.0
NA
0.438
0.311
21.26
41.44
0.452
0.322
21.95
42.80
Average
96
0.512
5847
11,420
270
1.02
3.3
18.9
0.0
NA
0.374
0.264
18, 66
36.38
0.387
0.275
19.33
37.67
7A-10
-------
Table 7A-1J
FACILITY - AI (Primary Outlet - Fluorides)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSGF/ton
Temperature - °F
Water vapor - Vol. %
C02 - Vol. 7o dry
02 -.Vol. •% dty
CO - Vol. % dry
Visible Emissions - % opacity
Fluorides
Soluble
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of 'product
Total Fluorides
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
5/8/72
288
0.512
5758.0
663,000
52,0
2.38
6.0
45.5
0.0
5%
0.000145
0.000147
0.00715
0. 0140
0.000167
0.000170
0.00825
0.0161
2
5/9/72
288
0.512
5999.8
586,000
52.2
2.65
6.0
15.5
0.0
5%
0.000118
0.000120
0.00516
0.0101
0.000118
0.000120
0.00516
0.0101
3
5/9/72
288
0.512
5114.7
588,000
51.7
2.60
6.0
15.5
0.0
57o
0.000124
0.000125
0.00535
0.0104
0.000124
0.000125
0.00535
0.0104
Average
288
0.512
5324.2
612,333
52.0
2.51
6.0
15.5
0.0
5%
0.000129
0.000131
0.00587
0.0115
0.000136
0.000138
0.000625
0.0122
7A-11
-------
Table 7A-lk
FACILITY - AI (Secondary Inlet - Fluorides)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. 7o dry
Visible Emissions - 70 opacity
Particulate Emissions
Probe and filter catch
gr/DSCF
gr/ACF .
Ib/hr
Ib/ton of product
Total Catch
. gr/DSCF
gr/ACF . ,
Ib/hr
Ib/ton of product
1
5/8/72
300
0.256
251,970
984,258
50
0.17
3.3
18.9
0.0
NA
0.0003
0.0003
0.64
2.50
0.00031
0.00032
0.683
2.67
2
5/9/72
300
0.256
251,970
984,258
75
0.05
3.3
18.9
0.0
NA
0.0004
0.0004
0.84
3.28
0.0004
0.0004
0.873
3.41
3
5/9/72
290
0.256
251,970
984,258
75
0.00
3.3
18.9
0.0
NA
0.0003
0.0003
0.70
2.76
0.00035
0.00035
0.766
2.99
Average
297
0.256
251,970
984,258
67
0.07
3.3
18.9
0.0
NA
0.00033
0.00033
0.73
2.84
0.00035
0.00036
0.774
3.02
7 A-12
-------
Table 7A-1L
FACILITY - AI (Secondary Outlet - Fluorides)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
C02 - Vol-. 7» dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - 7o opacity
Fluorides
Soluble
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Fluor ide,s
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
5/8/72
300
0.256
251,970
59,000,000
50
1.34
6.0
15.5
0.0
5-107o
0.00084
0.000087
0.182
0.711
0.000084
0.000087
0.182
0.711
2
5/9/72
300
0.256
251,970
59,000,000
60
1.40
6.0
15.5
0.0
5-107o
0.000122
0.000123
0.263
1.026
0.000126
0.000128
0.273
1.066
3
5/9/72
280
0.256
251,970
Average
293.3
0.256
251,970
59,000,000 59,000,000
60
0.995
6.0
15.5
0.0
5-107»
0.000065
0.000066
0.141
0.551
0.000076
0.000077
0.165
0.643
63.3
1.24
6.0
15.5
0.0
5-107o
0.000090
0.000092
0.195
0.762
0.000095 '
0.000097
0.207
0.806
7A-13
-------
Table 7A-lm
FACILITY - A£ (Primary Outlet - Fluorides)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
C02 - Vol. 7o dry
02 - Vol. 7o dry
CO - Vol. 7, dry
Visible Emissions - 7<, opacity
Fluorides
Soluble
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Fluorides
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
10/2-3/72
1442
0.516
3929
7614
81
3.3
6.0
15.5
0.0
0-5
0.000084
0.000080
0.0028
0.0060
0.000087
0. 000082
0.0030
0.0006
2
10/3-4/72
1440
0.516
4705
9188
81
3.2
6.0
15.5
0.0
0-5
0.00016
0.00015
0.0068
0.013
0.00016
0.00016
0.0069
0.013
3
10/4-5/72
1080
0.516
5187
10052
80
3.5
6.0
15.5
0.0
0-5
0.00027
0.00026
0.0128
0.025
0.00029
0.00028
0.014
0.027
Average
1321
0.516
4607
8928
81
3.3
6.0
15.5
0.0
0-57»
0.00017
0.00016
0.0075
0.015
0.00018
0.00017
0.0079
0.016
7A-14
-------
Table 7A-ln
FACILITY - A2 (Secondary Outlet - Fluorides)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
C02 -< Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - % opacity
Fluorides
Soluble
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Fluorides
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
10/2-3/72
1440
0.258
253,000
59,000,000
74
2.0
6.0
15.5
0.0
0-5%
0.00032
0.00031
0.703
2.73
6.00035
0.00034
0.757
2.93
2
10/3-4/72
1440
0.258
255,100
59,300,000
71
1.9
6.0
15.5
0.0
0-5%
0.00017
0.00016
0.363
1.4.
0.00017
0.00016
0.367
1.42
3
10/4-5/72
1440
0.258
261,000
61,100,000
64
1.5
6.0
15.5
0.0
0-5%
0.00020
0.00020
0.450
1.74
0.00021
0.00021
0.468
1.81
Average
1440
0.258
256,700
59,800,000
70
1.8
6.0
15.5
0.0
0-5%
0.00023
0.00022
0.505
1.96
0.00027
0.00025
0.531
2.05
7A-15
-------
Table 7A-2a
FACILITY - B (Primary Inlet - Particulates, Glass Filter)
Summary of Results
Run number
Date
Test Tine-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. °U
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - 70 opacity
Particulate Emissions
Probe and filter catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
10/22/71
144
0.373
30600
82037
188
0.67
1.10
19.90
0.40
NA
0.1498
0.1179
39.28
105.3
2
10/23/71
144
0.373
30300
81233
174
1.66
0.50
19.70
0.80
NA
0.1657
0.1314
43.03
115.3
3
10/23/71
144
0.373
31000
83110
178
0.97
0.60
20.40
0.60
NA
0,1579
0.1257
41.95
112.5
Average
144
0.373
30633
82126
180
1.10
0.73
20.00
0.60
NA
0.1578
0.1250
41.30
111.0
NS
NS
NS
NS
7A-16
-------
Table 7A-2b
FACILITY - B (Primary Inlet - Particulates, Paper Filter)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - % opacity
Particulate Emissions
Probe and filter catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
10/20/71
240
0.373
31,000
83,110
175
0.58
0.3
19.5
1.3
NA
0.1216
0.0982
32.31
86.6
2
10/21/71
144
0.373
32,100
86,059
176
0.66
1.1
19.8
0.8
NA
0.1786
0. 1449
49.13
131.7
3
10/22/71
144
0.373
31,600
84,718
178
1.15
1.1
19.9
0.4
NA
0.1514
0.1209
41.00
109.9
Average
176
0.373
31,567
84,630
176
0.8
0.8
19.7
0.8
NA
0.1505
0.1213
40.81
109.4
NS
NS
NS
7A-17
-------
Table 7A-2c
FACILITY - B (Primary Outlet - Particulates, Glass Filter)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - 7» opacity
Particulate Emissions
Probe and filter catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
10/22/71
220
0.116
11,600
100,000
204
0.74
0.30
20.30
0.60
0-10
0.02037
0.0159
2.03
17.30
2
10/23/71
220
0.116
11,900
102,586
193
0.76
0.50
19.70
0.80
0-10
0.01199
0.00946
1.23
10.60
3 Average
10/25/71
220
0.116
11,800
101,724
196
0.49
0.60
20.10
0.70
0-10
0.02123
0.0168
2.147
18.55
220
0.116
11,767
101,440
198
0.67
0.47
20.03
0.70
0-1 07o
0.01786
0.01404
1.82
15.81
NS
NS
NS
NS
7A-18
-------
Table 7A-2d
FACILITY - B (Primary Outlet - Particulates, Paper Filter)
Summary of Results
Run numoer
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
C02 - Vol.. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - 70 opacity
Particulate Emissions
Probe and filter catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
10/20/71
220
0.116
11,700
100,862
187
0.57
0.4
19.7
1.0
0
0.0126
0.0101
1.26
10.86
2
10/21/71
220
0.116
12,500
107,759
187
0.77
1.1
19.8
0.8
0
0.0179
0.0145
1.91
16.46
3
10/22/71
220
0.116
12,600
108,620
194
0.74
0.3
20.3
0.6
0
0.0228
0.0181
2.46
21.20
Average
220
0.116
12,267
105,750
189
0.69
0.6
19.9
0.8
0
0.0178
0.0142
1.88
16.20
NS
NS
NS
NS
7A-19
-------
Table 7A-2e
FACILITY - B (Primary Outlet - Particulates, Membrane Filter)
Summary of Results
Run number
Dace
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - % opacity
Particulate Emissions
Probe and filter catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
10/25/71
220
0.116
11,800
101,724
196
0.54
0.6
20.1
0.7
0
0.0121
0.0096
1.23
10.60
2
10/26/71
220
0.116
12,100
104,310
187
0.32
0.5
20.5
0.6
0
0.0140
0.0112
1.45
12.50
3
10/26/71
220
0.116
12,200
105,172
189
0.29
0.5
20.5
0.6
0
0.0075
0.0060
0.78
6.72
Average
220
0.116
12,033
103,733
191
0.38
0.5
20.4
0.6
0
0.0112
0.0089
1.15
9.91
NS
NS
NS
NS
7 A-20
-------
Table 7A-2f
FACILITY - BI (Primary Inlet - Particulates)
Summary of Results
Run number
Date
Test Time -minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - 70 opacity
Particulate. Emissions
Probe and filter catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Catch..
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
5/3/72
96
0.373
31,945
85,643
151
0.83
0.4
20.6
0.0
NA
0.1363
0.1175
37.32
100.0
0.1377
0.1187
37.69
101.0
2
5/3/72
96
0.373
30,323
81,295
161
0.89
0.4
20.6
0.0
NA
0.1408
0.1186
36.59
98.2
0.1429
0.1204
37.14
99.5
3
5/5/72
96
0.371
30,232
81,488
173
0.38
0.4
20.6
0.0
NA
0.1374
0.1145
35.59
95.8
0.1396
0.1164
36.16
97.4
Average
96
0.372
30,833
82,884
162
0.70
0.4
20.6
0.0
NA
0.1382
0.1169
36.50
98.0
0.1401
0.1185
37.00
99.3
7A-21
-------
Table 7A-2g
FACILITY - BI (Primary Outlet - Particulates)
Summary of Results
Run number
Date
Test Tine-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature -' °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. %' dry
CO - Vol. % dry
Visible Emissions - 7» opacity
Particulate Emissions
Probe and filter catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
5/4/72
384
0.124
11,639
93,863
187
0.46
0.0
19.8
0.0
0-5
0.00148
0.00119
0.1475
1.19
0.00165
0.00132
0.1644
1.32
2
5/4/72
383
0.124
11,729
94,589
188
0.46
0.0
19.8
0.0
0-5
0.00137
0.00261
0.1381
1.10
0.00313
0.00284
0.3144
2.54
3
5/5/72
384
0.125
11,629
93,032
181
0.50
0.0
19.8
0.0
0-5
0.00174
0.00141
0.1730
1.39
0.00190
0.00154
0.1896
1.53
Average
384
0.124
11,666
93,556
185
0.47
0.0
19.8
0.0
0-5
0.00153
0.00174
0.1528
1.23
0.00223
0.00157
0.2228
1.80
7A-22
-------
Table 7A-2h
FACILITY - B! (Primary Inlet - Fluorides)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - 7o opacity
Fluorides
Soluble
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Fluorides
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
5/1/72
96
0.366
31,900
87,158
167
1.15
0.4
20.6
0.0
NA
0.0412
0.0341
11.28
30.7
0.0594
0.0491
16.25
44.4
2
5/2/72
96
0.369
31,838
86,282
160
0.93
0.4
20.6
0.0
NA
0.0234
0.0197
6.37
17.3
0.0235
0.0198
6.40
17.4
3
5/2/72
96
0.371
30,905
83,302
170
0.84
0.4
20.6
0.0
NA
0.0516
0. 0430
13.67
36.8
0.0724
0.0603
19.18
51.7
Average
96
0.369
31,548
85,495
166
0.97
0.4
20.6
0.0
NA
0.0387
0.0323
10.44
28.2
0.0518
0.0430
13.94
37.8
7A-23
-------
Table 7A-2i
FACILITY - Bl (Primary Outlet - Fluorides)
Summary of Results
Run Number
Date
Test Time -minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - 7» opacity
Fluorides
Soluble
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Fluorides
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
5/1/72
336
0.122
10,334
5,170,000
192.2
0.00
0.0
19.8
0.6
0
0.000082
0.000065
0.00724
0.0592
0.000092
0.000073
0.00814
0.0667
2
5/2/72
384
0.123
10,512
5,260,000
179.1
0.00
0.0
19.8
0.6
0
0.000365
0.0000290
0.0321
0.260
0.000374
0.000300
0.0329
0.267
3
5/3/72
384
0.124
10,532
5,280,000
176.1
0.33
0.0
19.8
0.6
0
0.00023
0.00019
0.0210
0.168
0.000230
0.000190
0.0210
0.168
4
5/4/72
384
0.124
9,389
4,690,000
181.0
0.49
0.0
19.8
0.6
0
0.000084
0.000068
0.0068
0.055
0.000084
0.000069
0.00068
0.055
Average
123.3
123.3
10,192
5,100,000
182.1
0.21
0.0
19.8
0.6
0
0.000190
0.000153
0.0168
0.135
0.000195
0.000158
0.0172
0.139
7A-24
-------
Table 7A-2J
FACILITY - B! (Roof Emissions) Fluorides
Summary of Results
Run Number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - °L opacity
Fluorides
Soluble
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Fluorides
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
5/1/72
565
3.72
1,403,000
2,265,000
84.7
0.00
0,4
20.6
0.0
0
0.000173
0.000166
2.075
1.12
0.000173
0.000166
2.075
1.12
2
5/2/72
1229
3.72
1,551,000
2,500,000
91.7
0.00
0.4
20.6
0.0
0
0.000188
0.000178
2.492
1.34
0.000191
0.000181
2.542
1.37
3
5/3/72
1377
3.72
1,407,000
2,275,000
106.3
0.291
0.4
20.6
0.0
0
0.00186
0.000171
2.244
1.21
0.000188
0.000174
2.284
1.23
4
5/4-5/72
1350
3.72
1,492,000
2,410,000
106.5
0.110
0.4
20.6
0.0
0
0.000158
0.000146
2.022
1.09
0.000160 .
0.000148
2.050
1.10
Average
1130
3.70
2,362,500
1,463,250
97.3 -
0.10
0.4
20.6
0.0
0
0.000176
0.000165
2.208
1.19
0.000178
0.000167
2.238
1.20
7A-25
-------
Table 7A-3a
FACILITY - C (Primary Inlet - Fluorides)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - 7» opacity
Fluorides
Soluble
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Fluorides
gr/DSCF
• gr/ACF
Ib/hr
Ib/ton of product
1
11/2/71
94
0.292
27,500
5,651,000
185
0.10
0.0
21.0
0.0
NA
0.0324
0.0269
7.64
26.1
0.0354
0.0298
8.13
27.9
2
11/3/71
94
0.292
27,500
5,671,000
188
0.51
0.0
20.6
0.1
NA
0.0335
0.0275
7.92
27.1
0.0364
0.0299
8.61
29.5
3
11/3/71
94
0.292
26,200
5,384,000
204
0.63
0.0
20.6
0.1
NA
0.0264
0.0209
7.30
25.0
0.0288
0.0228
7.85
26.9
Average
94
0.292
27,100
5,570,000
192
0.41
0.0
20.7
0.07
NA
•
0.0308
0.0251
7.62
26.1
0.0335
0.0275
8.20
28.1
7A-26
-------
Table 7A-3b
FACILITY - C (Primary Outlet - Fluorides)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - % opacity
Fluorides
Soluble
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Fluorides
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
11/2/71
144
0.625
61,600
5,925,000
98
3.42
0.0
20.9
0.3
10%
0.01830
0.0207
9.67
15.45
0.0694
0.0785
26.98
43.20
2
11/3/71
144
0.625
61,200
5,890,000
98
3.47
0.0
20.8
0.0
10%
0.00913
0.0102
4.77
7.64
0.0100
0.0112
5.26
8.42
3
11/3/71
144
0.625
59,500
5,720,000
108
4.43
0.0
20.8
0.0
10%
0.00118
0.0129
6.01
9.63
0.1822
0.2103
98.35
157.30
Average
144
0.625
60,800
5,840,000
101
3.44
0.0
20.8
0.0
10%
0.00954
0.0146
6.82
10.91
0.0872
0.1000
43.53
69.64
7A-27
-------
Table 7A-3c
FACILITY - C (Secondary Inlet - Fluorides)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. 7»
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - 7» opacity
Fluorides
Soluble
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Fluorides
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
11/4/71
180
0.125
33,400
16,032,000
66
1.06
0.0
20.8
0.1
NA
0.00283
0.00285
0.803
6.43
0.00398
0.00400
1.136
9.10
2
11/5/71
180
0.125
38,400
18,432,000
52
0.529
0.0
20.7
0.0
NA
0.00340
0.00360
1.150
9.20
0.00361
0.00380
1.190
9.53
3
11/5/71
180
0.125
33,400
16,032,000
68
0.745
0.0
20.7
0.0
NA
0.00335
0.00338
0.969
7.75
0.00373
0.00380
1.069
8.55
Average
180
0.125
35,100
16,830,000
62
0.788
0.0
20.7
0.03
NA
0.00316
0.00324
0.974
7.79
0.00371
0.00387
1.132
9.06
7A-28
-------
Table 7A-3d
FACILITY - C (Secondary Outlet - Fluorides)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - % opacity
Fluorides
Soluble
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Fluorides
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
11/4/71
192
0.125
42,600
20,500,000
95
1.32
0.0
20.7
0.0
10
0.00232
0.00221
0.847
6.76
0.00255
0.00243
0.931
7.45
2
11/5/71
192
0.125
43,300
20,800,000
79
0.985
0.0
20.7
0.1
10
0.00222
0.00220
0.824
6.59
0.00236
0.00234
0.876
7.02
3
11/5/71
192
0.125
43,000
20,600,000
90
0.984
0.0
20.7
0.1
10
0.00233
0.00225
0.859
6.86
0.00252
0.00243
0.929
7.43
Average
192
0.125
42,600
20,700,000
88
1.096
0.0
20.7
0.07
10
0.00226
0.00222
0.843
6.73
0.00248
0.00240
0.912
7.30
7A-29
-------
Table 7A-4a
FACILITY - D (Primary Inlet - Fluorides)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
C02 - Vol. 7, dry
02 - Vol. 7» dry
CO - Vol. 7o dry
Visible Emissions - 7» opacity
Fluorides
Soluble
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Fluorides
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
2/29/72
121
0.449
18,277
40,706
269
0.25
0.97
17.20
0.13
NA
0.1390
0.0980
21.70
48.20
0.1590
0.1130
25.00
56.20
2
3/1/72
108
0.449
17,762
39,559
241
1.21
0.97
17.20
0.13
NA
0.1726
0.1263
26.28
58.50
0.1947
0.1424
28.40
63.30
3
3/3/72
108
0.449
18,458
41,109
241
1.31
0.97
17.20
0.13
NA
0.1538
0.1109
24.34
54.40
0.1839
0.1325
29.10
64.80
Average
112
0.449
18,160
40,222
250
0.92
0.97
17.20
0.13
NA
0.1551
0.1117
24.10
53.7
0.1792
0.1293
27.50
61.4
7A-30
-------
Table 7A-4b
FACILITY - D (Primary Outlet - 'Fluorides)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - % opacity
Fluorides
Soluble
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Fluorides
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
* Operator experienced feed control problems this date.
Malfunction corrected before next test.
This data questionable.
7A-31
1
2/29/72
192
0.449
19,579
43,650
239
0.514
3.40
16.3
0.3
0
0.0015
0.0011
0.252
0.561
0.0016
0.0012
0.276
0.612
2*
3/1/72
192
0.449
18,162
44,850
228
1.358
3.40
16.3
0.3
0
0.0042
0.0031
0.720
1.560
0.0043
0.0032
0.744
1.656
3*
3/1/72
192
0.449
19,711
43,950
237
1.36
3.4
16.3
0.3
0
0. 0042
0.0031
0.234
1.560
0.0043
0.0031
0.240
1.602
Average
192
0.449
19,150
44,150
234
1.08
3.4
16.3
0.3
0
0.0033
0.0024
0.402
1.23
0.0034
0.0025
0.42
1.29
-------
Table 7A-4c
FACILITY - D (Primary Outlet - Fluorides)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - °l» opacity
Fluorides
Soluble
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Fluorides
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
3/2/72
192
0.449
19,313
43,050
233
1.54
3.4
16.3
0.3
0
0.0013
0.0010
0.072
0.483
0.0014
0.0010
0.078
0.519
2
3/2/72
192
0.449
20,976
46,650
235
0.97
3.4
16.3
0.3
0
0.0012
0.0009
0.072
0.477
0.0013
0.0009
0.075
0.504
3
3/3/72
192
0.449
19,598
43,800
225
1.31
3.4
16.3
0.3
0
0.0008
0.0006
0.135
0.297
0.007
0.0007
0.147
0.321
Average
192
0.449
19,962
44,500
231
1.28
3.4
16.3
0.3
0
0.0011
0. 0008
0.093
0.419
0.0011
0. 0008
0.100
0.448
7 A-3 2
-------
Table 7A-4d
FACILITY - D (Primary Inlet - Particulates)
Summary of Results
Run number
Date
Test Time -minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - % opacity
Particulate Emissions
Probe and filter catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
2/28/72
74
0.449
17,870
39,799
254
0.57
3.4
16.3
0.3
NA
0.1422
0.1026
21.77
48.49
0.1873
0.1351
28.66
63.83
2
2/29/72
72
0.449
22,623
50,385
256
0.99
3.4
16.3
0.3
NA
0.1396
1.005
27.06
60.27
0.1928
0.1388
37.37
83.23
3
3/3/72
56
0.449
17,790
39,621
251
0.91
3.4
16.3
0.3
NA
0. 1445
0.1032
22.02
49.04
0 2054
0.1466
31.31
69.73
Average
67
0.449
19,427
43,268
254
0.82
3.4
16.3
0.3
NA
0.1421
0.1021
23.61
52.60
0.1952
0.1402
32.44
72.26
7A-33
-------
Table 7A-4e
FACILITY - D (Primary Outlet - Particulates)
Summary of Results
Run number
Bate
Test Tine-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CC - Vol. % dry
Visible Emissions - % opacity
Particulate Emissions
Probe and filter catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
3/6/72
192
0.150
6627
44,180
215
0.33
3.4
16.3
0.3
0
0.0019
0.0015
0.106
0.71
0. 0061
0.0048
0.344
2.30
2
3/7/72
192
0.150
6233
41,553
213
0.31
3.4
16.3
0.3
0
0.0023
0.0018
0.118
0.79
0.0064
0.0049
0.344
2.16
3
3/7/72
192
0.150
6668
44,453
224
0.55
3.4
16.3
0.3
0
0.0020
0.0015
0.113
0.75
0.0059
0.0045
0.333
2.22
Average
192
0.150
6509
43,395
217
0.40
3.4
16.3
0.3
0
0.0021
0.0016
0.112
0.75
0.0061
0.0047
0.333
2.22
7A-34
-------
Table 7A-4f
FACILITY - D (Primary Outlet - Particulates, Thimble)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - % opacity
Particulate Emissions
Probe and filter catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
2/28/72
75
0.150
6725
44,833
232
0.18
3.4
16.3
0.3
0
0.0026
0.0020
0.148
0.98
0.0144
0.0109
0.827
5.50
2
2/28/72
144
0.150
6248
41,653
233
0.80
3.4
16.3
0.3
0
0.0065
0.0048
0.344
2.29
0.0191
0.0143
1.019
6.80
3
3/3/72
144
0.150
7139
47,593
223
1.03
3.4
16.3
0.3
0
0.0035
0.0026
0.207
1.38
0.0124
0.0093
0.757
5.04
Average
121
0.150
6704
44,693
229
0.67
3.4
16.3
0.3
0
0.0042
0.0031
0.233
1.55
0.0153
0.0153
0.867
5.78
7A-35
-------
Table 7A-4g
FACILITY - D (Roof Emissions)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. °L
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - % opacity
Fluorides
Soluble
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Fluorides
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
3/1-2/72
1441
1.740
(665,310)
382,000
105.9
0.0
1.8
20.8
0.8
0
0.00022
0.00020
1.28
0.73
0.00026
0.00024
1.50
0.86
2 3
3/2-3/72
1200
1.740
(754,152)
433,000
103.5
0.0
1.8
20.8
0.8
0
0.00036
0.00033
2.32
1.33
0.00040
0.00036
2.57
1.48
Average
1320.5
1.740
709,731
407,500
104.7
0.0
1.8
20.8
0.8
0
0.00029
0.00027
1.80
1.03
0.00033
0.00030
2.04
1.17
7A-36
-------
Table 7A-4h
FACILITY - DI (Primary Outlet - Fluorides)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
CO 2 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - 7o opacity
Fluorides
Soluble
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Fluorides
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
4
3/6/72
192
0.449
19,671.3
43,800
209.8
0.374
3.4
16.3
0.3
0
0.0012
0. 0009
0.1998
0.484
0.0013
0.0010
0.2223
0.495
5
3/7/72
192
0.449
18,868.2
42,000
216.3
0.353
3.4
16.3
0.3
0
0.0009
0.0007
0.1506
0.336
0.0011
0.0008
0.1710
0.381
6
3/7/72
192
0.449
18,903.00
42,150
221.3
0.700
3.4
16.3
0.3
0
0.0011
0.0008
0.1761
0.393
0.0012
0.0009
0.1968
0.438
Average
192
0.449
19,147.00
42,650
215.8
0.476
3.4
16.3
0.3
0
0.0011
0.0008
0.1755
0.404
0.0012
0. 0009
0.1967
0.438
7A-37
-------
Table 7A-4i
FACILITY - D-L (Primary Outlet - Single Point)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 •'- Vol. % dry
CO - Vol. % dry
Visible Emissions - % opacity
Particulate Emissions
Probe and filter catch
gr/DSCF
gr/ACF
lb/hr
Ib/ton of product
Total Catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
3/6/72
192
0.150
7646
50,973
210
1.98
3.4
16.3
0.3
0
0.0007
0.0005
0.045
0.30
0.0008
0.0006
0.054
0.36
2
3/7/72
192
0.150
7757
51,713
211
0.66
3.4
16.3
0.3
0
0. 0003
0.0003
0.022
0.15
0. 0005
0.0004
0.030
0.20
3
3/7/72
192
0.150
7219
48,126
225
0.87
3.4
16.3
0.3
0
0.0005
0.0004
0.029
0.19
0.0006
0. 0004
0.037
0.25
Average
192
0.150
7541
50,273
215
1.17
3.4
16.3
0.3
0
0.0005
0.0004
0.032
0.21
0.0006
0.0005
0.040
0.27
7A-38
-------
Table 7A-5a
FACILITY - E (Primary Inlet - Fluorides)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. 7» dry
Visible Emissions - 7» opacity
Fluorides
Soluble
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Fluorides
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
5/15/72
96
0.441
49,267
111,716
213
0.90
0.7
19.9
0.0
NA
0.0255
0.0200
10.77
24.40
0.0365
0.0286
15.43
35.00
2
5/15/72
96
0.441
48,235
109,376
216
1.45
0.7
19.9
0.0
NA
0.0363
0.0282
15.00
34.00
0.0538
0.0417
22.22
50.40
3
5/16/72
96
0.441
47,052
106,693
217
1.10
0.7
19.9
0.0
NA
0.0401
0.0311
16.16
36.60
0.0593
0.0460
23.90
54.20
Average
96
0.441
48,184
109,260
215
1.15
0.7
19.9
0.0
NA
0.0340
0.0264
13.97
31.67
0.0499
0.0387
20.51
46.53
7A-39
-------
Table 7A-5b
FACILITY - E (Primary Outlet - Fluorides)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. 7o
C02 - Vol. 7o dry
02 - Vol. 7o dry
CO - Vol. 7» dry
Visible Emissions - 7» opacity
Fluorides
Soluble
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Fluorides
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
5/15/72
240
0.441
50,596
115,000
57.4
5.42
0.6
20.2
0.0
107o
0.00040
0.00039
0.174
0.394
0.00042
0.00040
0.181
0.410
2
5/12/72
240
0.441
48,795
111,000
57.6
5.76
0.6
20.2
0.0
107o
0.00039
0.00031
0.162
0.365
0.00044
0.00033
0.169
0.382
3
5/16/72
240
*
0.441
47,121
107,000
83.7
5.64
0.6
20.2
0.0
10%
0.00046
0. 00042
0.186
0.422
0.00046
0.00042
0.186
0.422
Average
240
0.441
48,837
111,000
66.3
5.61
0.6
20.2
0.0
107»
0.00043
0.00038
0.174
0.394
0.00044
0.00038
0.179
0.405
7A-40
-------
Table 7A-5c
FACILITY - E (Roof Emissions)
Summary of Results
Fluorides
Run Number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - % opacity
Fluorides
Soluble
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Fluorides
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
5/12/72
1062
2.64
2,811,000
1,065,000
75
0
0.7
19,9
0.0
0
0.00012
0.00012
2.87
1.09
0.00012
0.00012
2.92
1.10
2
5/15/72
735
2.64
2,811,000
1,065,000
70
0.87
0.7
19.9
0.0
0
0.00021
0.00021
5.12
1.93
0.00022
0.00022
5.32
2.01
3
5/16/72
645
2.64
2,811,000
1,065,000
70
0.95
0.7
19.9
0.0
0
0.00024
0.00024
5.87
2.22
0.00025
0.00025
6.04
2.28
4
5/17/72
450
2.64
2,811,000
1,065,000
65
0.64
0.7
19.9
0.0
0
0.00030
0.00030
7.30
2.76
0.00031
0.00031
7.54
2.85
Average
723
2.64
2,811,000
1,065,000
89
0.62
0.7
19.9
0.0
0
0.00022
0.00022
5.29
2.00
0.00022
0.00022
5.45
2.06
7A-41
-------
Table 7A-5d
FACILITY - E (Primary Inlet - Particulates)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. 70
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - % opacity
Particulate Emissions
Probe and filter catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Catch
£r/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
5/16/72
96
0.441
47,895
108,605
214
1.31
0.7
19.9
0.0
NA
0.0653
0.0508
26.81
60.8
0.0801
0.0623
32.87
74.5
2
5/16/72
96
0.441
48,389
109,725
219
1.10
0.7
19.9
0.0
NA
0.0782
0.0604
32.42
73.5
0.0965
0.0746
40.00
90.8
3
5/17/72
96
0.441
47,960
108,752
208
0.50
0.7
19.9
0.0
NA
0.0703
0.0556
28.88
65.5
0.0860
0.0681
35.35
80.1
Average
96
0.441
48,081
109,027
214
0.97
0.7
19.9
0.0
NA
0.0713
0.0556
29.37
66.60
0.0875
0.0683
36.07
81.8
7A-42
-------
Table 7A-5e
FACILITY - E (Primary Outlet - Particulates)
Summary of Results
Run number
Date
Test Tine-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. 7o dry
CO - Vol. Z dry
Visible Emissions - 7° opacity
Particulate Emissions
Probe and filter catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
5/16/72
240
0.441
45,021
102,088
85
5.18
0.6
20.2
0.0
107»
0.0016
0.0015
0.615
1.39
0.0037
0.0034
1.415
3.21
2
5/17/72
240
0.441
49,007
111,127
79
4.97
0.6
20.2
0.0
107o
0.0052
0.0049
2.200
4.98
0.0094
0.0088
3.937
8.91
3
5/17/72
240
0.441
47,313
107,285
78
5.10
0.6
20.2
0.0
107,
0.0027
0.0026
1.111
2.52
0.0062
0.0058
2.528
5.74
Average
240
0.441
47,113
106,832
81
5.08
0.6
20.2
0.0
10%
0.0032
0.0030
1.308
2.96
0.0064
0.0060
2.63
5.95
7A-43
-------
Table 7A-6a
FACILITY - F (Primary Inlet - Particulates)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. 70
C02 - Vol. 7, dry
02 - Vol. 7o dry
CO - Vol. 7o dry
Visible Emissions - % opacity
Particulate Emissions
Probe and filter catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Catch
gr/DSCF
gr /ACF
Ib/hr
Ib/ton of product
1
9/27/71
64
0.544
7040
15,679
271
2.8
5.03
16.03
NS
NA
0.250
0.178
15.10
27.80
0.323
0.299
19.70
36.25
2
9/28/71
64
0.544
6920
15,412
281
3.1
4.63
17.83
NS
NA
0.299
0.210
17.70
32.55
0.360
0.253
21.40
39.35
3
9/28/71
64
0.544
6780
15,100
308
2.7
4.63
17.83
NS
NA
0.234
0.159
13.60
25.05
0.302
0.205
17.60
32.35
Average
64
0.544
6913
15,396
287
2.8
4.76
17.23
NS
NA
0.261
0.182
15.46
28.46
0.328
0.252
19.56
35.98
7A-44
-------
Table 7A-6b
FACILITY - F (Primary Outlet - Particulates
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
• Water vapor - Vol. %
C02 - Vol. "L dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - 70 opacity
Particulate Emissions
Probe and filter catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
Total Catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of product
1
2/27/71
112
0.544
6440
11,838
88
9.7
3.67
18.50
NS
0-10
0.00285
0.00251
0.155
0.285
0.01335
0.01174
0.734
1.35
2
9/28/71
112
0.544
6750
12,408
87
5.4
4.20
18.10
NS
0-10
0.00225
0.00208
0.128
0.235
0.01019
0.00943
0.588
1.08
3
9/28/71
112
0.544
6240
11,470
98
6.1
4.20
18.10
NS
0-10
0.00186
0.00167
0.100
0.184
0.01281
0.01152
0.686
1.26
Average
112
0.544
6744
11,906
91
7.1
4.02
18.23
NS
0-10
0.00232
0.00208
0.128
0.268
0.01211
0.0109
0.669
1.23
7A-45
-------
Table 7A-7a
FACILITY - G (ESP* Outlet - Particulates)
Summary of Results
Run. numoer
Date
Test Tirae-minutes
Production rate - TPH (Anode)
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. 7»
C02 - Vol. % dry
0? - Vol. 7, dry
CO - Vol. 7o dry
Visible Emissions - 70 opacity
Particulatc Emissions
Probe and filter catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of anode
Total Catch
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of anode
1
6/20/72
224
9.1
45,490
3,619
119
4.80
0.66
14.30
1.60
10-20
0.0176
0.0149
6.85
0.75
0.0405
0.0344
15.80
1.74
2
6/21/72
140
9.1
45,670
3,633
132
6.80
0.66
14.30
1.60
10-20
0.0169
0.0138
6.63
0.73
0.0324
0.0264
12.70
1.40
3
6/21/72
140
9.1
50,330
4,004
131
6.10
0.66
14.30
1.60
10-20
0.0172
0.0141
7.42
0.82
0.0324
0.0266
13.98
1.54
Average
168
9.1
47,163
37,520
127
5.90
0.66
14.30
1.60
10-20
0.0172
0.0143
6.97
0.77
0.0351
0.0291
14.16
1.56
* Electrostatic Precipitator
7A-46
-------
Table 7A-7b
FACILITY - G (ESP* Outlet - Fluorides)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH (Anode)
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. %
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - % opacity
Fluorides
Soluble
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of anode
Total Fluorides
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of anode
1
6/20/72
224
9.1
38,830
2,930
117.3
7.52
0.66
14.3
1.6
20
0.0182
0.0150
5.75
0.63
0.0201
0.0166
6.35
0.70
2
6/21/72
140
9.1
44,620
3,550
125.2
7.36
0.66
14.3
1.6
20
0.0211
0.0173
8.06
0.89
0.0221
0.0183
8.69
0.96
3
6/21/72
140
9.1
37,060
2,950
125.1
6.46
0.66
14.3
1.6
20
0.0206
0.0170
6.54
0.72
0.0216
0.0179
8.87
0.98
Average
168
9.1
39,503
3,143
122.5
7.11
0.66
14.3
1.6
20
0.0200
0.0164
6.78
0.74
0.0213
0.0176
7.97
0.88
* Electrostatic Precipitator
7A-47
-------
Table 7A-8
FACILITY - H (Anode Furnace - ESP*)
Summary of Results
Run number
Date
Test Time-minutes
Production rate - TPH (Anode)
Stack Effluent
Flow rate - DSCFM
Flow rate - DSCF/ton
Temperature - °F
Water vapor - Vol. "L
C02 - Vol. % dry
02 - Vol. % dry
CO - Vol. % dry
Visible Emissions - % opacity
Fluorides
Soluble
gr/DSCF
gr/ACF
Ib/hr
Ib/ton
Total Fluorides
gr/DSCF
gr/ACF
Ib/hr
Ib/ton of anode
* Electrostatic Precipitator
JL/ ORSAT analyzer was not operating properly.
1
10/19/72
240
13.15
75,774
5,762
196
3.5
1.1
19.1
0.0
10-20%
0.02555
0.02002
16.58
1.26
2
10/19/72
240
13.15
72,460
5,510
215
3.7
1.1
19.1
0.0
10-20%
0.02708
0.02056
16.81
1.28
3 Average
10/20/72
240 240
13.15 13.15
70,340 72,858
5,349 5,540
206
3.2 3.5
1.1 -1 1.1
19.1 - 19.1
o.o - o.o
10-20% 10-20%
0.02605 0.02627
0.02027 0.02019
15.69 16.36
1.20 1.25
This data questionable.
7A-48
-------
Appendix 8A
Emission Flow Diagrams
The following figures present the quantities of
solid F, gaseous F, total F, and alumina appearing in
each of the several process streams of the emission con-
trol systems represented by various models considered
in the cost effectiveness analysis. Quantities are ex-
pressed in terms of pounds per 1000 pounds of aluminum
produced, and are derived from the effluent model param-
eters given in Table 8.1. The removal efficiencies for
control are derived from data given in Section 5.
These model flow diagrams represent performances
which are characteristic of the best aluminum potline
emission control with the equipment noted, and which may
be better than conditions obtained in any specific plant.
Variation in the designs of hooding and collection sys-
tems, in the design and construction of removal equip-
ment, and in the operations of potlines and control sys-
tems will result in departure from the predicted emission
control of the model.
8A-1
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODEL :1A-1 PREBAKE fl
OVERALL CONTROL EFFICIENCY:.^
REMOVAL
EFFICIENCY
Is
19
If
1.c= TOTAL F COLLECTION EFFICIENCY
CELL
EFFLUENT
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODEL: 1A-2 PREBAKE o
OVERALL CONTROL EFFICIENCY:_iU_4
EMISSION
Ib/MlbAI
CEIL
EFFLUENT
(POUND
1
10.5
2.9
1
LOSS
3.5
0-]
REMOVAL
EFFICIENCY
1,
19
It
1 TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODEL:1A-3PREBAKE «.
OVERALL CONTROL EFFICIENCY:JLLL
LEGEND
Ib/MlbAI
REMOVAL
EFFICIENCY
£
WATER TREATMENT |
(
ItPOUNO
!
10.3
2.6
1
LOSS
3.6
0.1
"Lc- TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODEL:lA-4 PREBAKE «,
OVERALL CONTROL EFFICIENCY:_iL4.^
EMISSION
SOLID F
GAS F
TOTAL F
ALUMINA
CELL
EFFLUENT
1
1POUND
9.0
i
LOSS
3.0
T,c= TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODEL:1A-S PREBAKE .
OVERALL CONTROL EFFICIENCY:_89V%
LEGEND
Ib/MlbAI
I WATER TREATMENT |
CELL
EFFLUENT
(POUND
1
9.8
1.2
<
LOSS
32
0.1
REMOVAL
EFFICIENCY
1*
If
1,c= TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODEL:lA-6 PREBAKE -
OVERALL CONTROL EFFICIENCY:_Sli2_%
EMISSION
Ib/MlbAI
WATER TREATMENT ]
CELL
EFFLUENT
(POUND
1
9.0
{
LOSS
3.0
REMOVAL
EFFICIENCY
1.
V
If
1c= TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODEl:lB-1,9PREBAKEej,
OVERALL CONTROL EFFICIENCY:.2jLi_%
EMISSION
Ib/MlbAI
REMOVAL
EFFICIENCY
(POUND
\
0.4
0.4
<
LOSS
i 0.1
<0.1
Is
1«
If
1c= TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODEL :1B-2,9PREBAKE «,
OVERALL CONTROL EFFICIENCY:_iLJ_%
EMISSION
LEGEND
:,
Ib/MlbAI
REMOVAL
EFFICIENCY
L
I WATER TREATMENT [
CELL
EFFLUENT
(POUND
1
11.0
3.2
i
LOSS
3.6
0.2
V
If
1,<= TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODEL:IB-^9PREBAKE-
OVERALL CONTROL EFFICIENCY:_2±£/%
EMISSION
Ib/MlbAI
CELL
EFFLUENT
1
1POUND
I
10.7
2.9
<
LOSS
3-6
0.2
REMOVAL
EFFICIENCY
Is
1.
If
1c= TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODEL :IB-4,9PREBAK€«
OVERALL CONTROL EFFICIENCY:_iijJ%
EMISSION
Ib/MlbAI
CELL
EFFLUENT
(POUND
9 4
0 4
1
LOSS
3.1
<0.1
1
REMOVAL
EFFICIENCY
1.
V
It
1c= TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODEL'IB-S^PREBAKE Q,
OVERALL CONTROL EFFICIENCY:_£J_J_4
EMISSION
Ib/MlbAI
REMOVAL
EFFICIENCY
Is
CELL
EFFLUENT
(POUND
1
10.1
1 6
1
LOSS
34
01
1c = TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODEL:IB-6,9 PREBAKE,
OVERALL CONTROL EFFICIENCY:_iZi
EMISSION
Ib/MlbAI
(POUND
i
t
9-4
0.4
(
LOSS
3.1
<0.1
REMOVAL
EFFICIENCY
Is
V
If
1c= TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODEL:HA-1VSS SODERBERG
OVERALL CONTROL EFFICIENCY:_ZlA/0
EMISSION
fMISSION
<1
3.2
<4 8
1.5
LEGEND
Ib/MlbAI
WATER TREATMENT
CELL
EFFLUENT
tPOUND
\
I
136
14
LOSS
46
01
REMOVAL
EFFICIENCY
1*
19
If
1.C- TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODEL01A-2VSS SODERBERG
OVERALL CONTROL EFFICIENCY:_Z2_5_
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODEL :HA-3VSS SODERBERG
OVERALL CONTROL EFFICIENCY:_Zil_,°/o
EMISSION
Ib/MlbAI
REMOVAL
EFFICIENCY
CELL
EFFLUENT
(POUND
1
126
0
1
LOSS
42
0
1,
V
1<: TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODEL :HA-4 VSS SODERBERG
OVERALL CONTROL EFFICIENCY:__Zi± °/o
EMISSION
Ib/MlbAI
1
(POUND
i
13.1
0.6
i
LOSS
4-3
< 0.1
REMOVAL
EFFICIENCY
1.
19
If
"\.e = TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODELOIA-5 VSS SODERBERG
OVERALL CONTROL EFFICIENCY:_iL4 °/o
Ib/MlbAI
CELL
EFFLUENT
\
(POUND
1
13.0
0.6
1
LOSS
4 3
<0-1
REMOVAL
EFFICIENCY
1.
i«
If
rtc= TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODEL3IA-6 VSS SODERBERG
OVERALL CONTROL EFFICIENCY:_I8jL°/o
PRIMARY REMOVAL
CFPB-5
1«= 71 1a= 98
SCRUBBER
UQUOR
I
I WATER TREATMENT
EMISSION
EMISSION
1.7
5.0
1.7
LEGEND
Ib/MlbAI
REMOVAL
EFFICIENCY
(POUND
1
.'2-9
0.5
1
LOSS
4-3
<0-1
1
1.
1.
If
1e = TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODEL:HB-1,7 VSS .
OVERALL CONTROL EFFICIENCY:.!!!.^
EMISSION
EMISSION
0.9
0.6
15
09
LEGEND
Ib/MlbAI
WATER TREATMENT J
CEll
EFFIUENT
1
tPOUND
16.0
19
\
LOSS
5.4
0 '?
REMOVAL
EFFICIENCY
Is
It
1c- TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODEL: HB- 2,7 VSS
OVERALL CONTROL
EMISSION
Ib/MlbAI
(POUND
1
' 1
2.4
0.5
1
LOSS
08
01
REMOVAL
EFFICIENCY
1,
19
•\.e= TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODEl:HB-3,7 VSS «
OVERALL CONTROL EFFICIENCY:
Ib/MlbAI
WATER TREATMENT j
CELL
EFFLUENT
1
IPOUND
i
«
[
12.6
1
LOSS
4.2
REMOVAL
EFFICIENCY
Is
19
If
1c = TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODElOLTB-4,7 VSS -
OVERALL CONTROL EFFICIENCY:.".*.^
EMISSION
SOI 10 F
GAS F
TOTAl F
ALUMINA
(POUND
i
r
15 4
1.1
1
LOSS
5. 2
0.1
1c: TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODEl:I[ B-5, 7 VSS *
OVERALL CONTROL EFFICIENCY:_!L*J%
EMISSION
Ib/MlbAI
ItPOUND
i
I
' 1
154
11
1
LOSS
5-1
0.1
REMOVAL
EFFICIENCY
1,
1.9
If
1c= TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODEL:HB-6,7 VSS
OVERALL CONTROL EFFICIENCY:.*!^
EMISSION
EMISSION
LEGEND
Ib/MlbAI
REMOVAL
EFFICIENCY
| WATER TREATMENT )
CELL
EFFLUENT
IPOUND
1
15.3
10
LOSS
5 .1
0.1
1*
If
1c = TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODEL:BEA-1 HSS 0
OVERALL CONTROL EFFICIENCY:_iiI_4
EMISSION
Ib/MlbAI
CELL
EFFLUENT
1
IPOUND
14.5
14-8
1
LOSS
4-8
0.8
1
REMOVAL
EFFICIENCY
Is
19
1c: TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODEUXA-? HSS 0
OVERALL CONTROL EFFICIENCY:_»L2-4
EMISSION
LEGEND
Ib/MlbAI
WATER TREATMENT 1
CELL
EFFLUENT
(
tPOUND
14.0
14.8
1
LOSS
4.7
0.8
REMOVAL
EFFICIENCY
Is
1.
It
c? TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODEL:IH A-3 HSS rt
OVERALL CONTROL EFFICIENCY:.-™.
Ib/MlbAI
CEU
EFFLUENT
'
rtPOUND
13.5
1 2^4
LOSS
4-5
0-6
REMOVAL
EFFICIENCY
Is
19
If
•\.c= TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODEL:HlA-4 HSS .
OVERALL CONTROL EFFICIENCY:_Z2^J%
EMISSION
Ib/MlbAI
CEIL
EFFLUENT
<
tPOUND
12.0
9.2
1
LOSS
4.0
1.2
REMOVAl
EFFICIENCY
1*
1,
It
<= TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODEL :JLlA-5 HSS
OVERALL CONTROL EFFICIENCY:
0
4
LEGEND
Ib/MlbAI
j WATER TREATMENT
CELL
EFFLUENT
1
APOUND
133
11.2
4
LOSS
4.4
1.3
1
REMOVAL
EFFICIENCY
1*
If
•\,e= TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MOOEl:HIB-l. 6 HSS „
OVERALL CONTROL EFFICIENCY:_ILJL_4
EMISSION
LEGEND
Ib/MlbAI
I WATER TREATMENT I
CELL
EFFLUENT
(POUND
1
I
16.1
16.5
1
LOSS
5.3
0.9
REMOVAL.
EFFICIENCY
Is
1.
It- TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODEL:HIB-2 6 HSS 0
OVERALL CONTROL EFFICIENCY:_il_i<)
EMISSION
LEGEND
Ib/MlbAI
WATIII TREATMENT )
CEIL
EFFLUENT
1
(POUND
15.4
156
t
LOSS
_5_.J
1.7
REMOVAL
EFFICIENCY
Is
18
If
1c: TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POUUTION CONTROL
SYSTEM MODEL: MB-3,6 HSS -
OVERALL CONTROL EFFICIENCY:_84iL^O
Ib/MlbAI
(POUND
U
J3
1
: 1
* i
:? ..i
LOSS
S.O
_J_.S_
REMOVAL
EFFICIENCY
Is
1.
If
1c = TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODEL: HB-4,6
OVERALL CONTROL EFFICIENCY:.ZLlJ%
EMISSION
EMISSION
4.1
1 I
5.2
6.1
t
LEGEND
Ib/MlbAI
V^ATER TREATMENT |
CELL
EFFLUENT
IPOUND
(
13.*
10.7
(
LOSS
4.4
1.2
1
REMOVAL
EFFICIENCY
If
19
If
1c: TOTAL F COLLECTION EFFICIENCY
-------
FIGURE 8.1
SCHEMATIC FLOW DIAGRAM
ALUMINUM SMELTER AIR POLLUTION CONTROL
SYSTEM MODEL:H1B-5,6 HSS.
OVERALL CONTROL EFFICIENCY:_*LLj%
EMISSION
EMISSION
30
0.5
3.5
5.7
t
LEGEND
Ib/MlbAl
) WATER TREATMENT |
CELL
EFFLUENT
IPOUND
(
I
JL4.6
128
1
LOSS
4.9
1.4
1
REMOVAL
EFFICIENCY
•U
1.
•Ve= TOTAL F COLLECTION EFFICIENCY
-------
Appendix 8B
Removal Equipment Purchase Costs
Capital costs for pollutant removal equipment
which were developed in Section 8.2 of this report were
derived from purchase costs reported by equipment man-
ufacturers. In general, the cost of equipment per unit
of flow rate goes down as its size increases; one
100,000 cfm unit is usually less costly than two 50,000
cfm units. In order to show this relationship between
equipment capacity and unit cost, manufacturers were
asked to provide purchase price data at several flow
rates. These data are plotted in the following curves
as total purchase price versus outlet flow rate from
the equipment. They represent estimated FOB prices
for typical equipment and are believed to reflect aver-
age 1970 prices.
The costs of removal equipment for the capac-
ities required by the control models were taken from
these curves.
8B-1
-------
FIGURE 8-B-1
REMOVAL EQUIPMENT
PURCHASE COST
(1970)
MUTIPLE CYCLONE
O
o
O
O
o
o
in
O
O
u
o:
3
100
1
1
3
/
t
1
/
3
>
x
4
^
^
•
>
^
6
x
3
^
a
^
F
9
/
1 2
]PB
3
4
6
7
8
9 1
I
_^J
i
10
100
1,000
GAS VOLUME FLOW 1,000's aefm
8B-2
-------
FIGURE 8B-2
REMOVAL EQUIPMENT
PURCHASE COST
(1970)
BAGHOUSE FILTER
1,000
3 4567891
3 4567891
O
K
O
O
O
o
o
i
O
o
X
U
100
10
10
100
3 4567
GAS VOLUME FLOW 1,000's acfm
SOURCE- MANUFACTURER
INDICATE RANGE OF DATA
1,000
8B-3
-------
FIGURE 8-B-3
REMOVAL EQUIPMENT
PURCHASE COST
(1970)
DRY ELECTROSTATIC PRECIPITATORS
PURCHASE COST-ljOOO's DOLLARS J1970)
i i
<
^.•^
vss
^
+ *
+
,*
X
^
X
*
^
«
*
5
_^r_.^
r^ ^^r
+*^
"^PB
4*
'^-
X
^
1
9
i
| 10 100 1,000
GAS VOLUME FLOW 1,000's acfm
8B-4
-------
FIGURE 8B-4
REMOVAL EQUIPMENT
PURCHASE COST
(1970)
WET ELECTROSTATIC PRECIPITATOR
CSTAINLESS STEEL)
PURCHASE COST-ljOOO's DOLLARS (1970)
S 1
V
>s,
t
x
jT
_S
r
X
>
/
/
^
/
H
S
^
S
X
X
to
100
GAS VOLUME FLOW 1,000's acfm
1,000
'SOURCE -MANUFACTURE
8B-5
-------
o
K
0-
wt
at
o
o
o
I
O
u
X
u
ee
r>
0.
FIGURE 8-B-5
REMOVAL EQUIPMENT
PURCHASE COST
(1970)
SPRAY TOWERS
1 2 34567891 2 34567891 2 34567891
10
1
4
/s
V
>
J
^
jr
s
s
HS
^
i<
^
^
^
.S
s^
PB
"
• 8
j
10
100
1,000
GAS VOLUME FLOW 1,000's acfm
8B-6
-------
O
Q
O
o
o
U)
O
u
FIGURE 8B-6
REMOVAL EQUIPMENT
PURCHASE COST
(1970)
SPRAY SCREEN
,no'
i
i
3
4
5
«
' 1
9
I 1
3
t
\ i
t
/
7
f
a
>
9
f
1 1
f
/
X
X
1
1 1
• 9
• 8
• ^
1
10
100
GAS VOLUME FLOW 1,000's acfm
1,000
SOURCE-INDUSTRY QUESTIONNAIRE
8B-7
-------
FIGURE 8-B-7
PURCHASE COST REMOVAL EQUIPMENT (1970)
HIGH PRESSURE SCREEN
10,000 i
2 3 4567891
2 3 4567891
2 34567891 2 34 5 67 89 1
2 3 4567891,
l*«
VSS.HSS
PB
00 ,-.
W p 1,000
i f*«
O
o
o
o
o
t- 100 I
vt
o
u
in
<
X
u
4S T AGE
SINGLE
STAGE
10.
|VS|<
10
100
1,000
GAS VOLUME FLOW 1,000'« acfm
10,000
SOURCE-MANUFACTURER
100,000
-------
o
K
DC
<
_j
mj
O
Q
o
o
o
I
h-
wi
O
u
X
u
of
3
FIGURE 8B-8
REMOVAL EQUIPMENT
PURCHASE COST
(1970)
WET CENTRIFUGAL SCRUBBER
(TYPE 304 STAINLESS)
10
100
GAS VOLUME FLOW 1,000's acfm
1 2 34567891 234567891 2 34567891
10
1
J
Jr
^
^f
*
/
/
F
/
/
/
/
/
.
1
1,000
SOURCE- MANUFACTURER
8B-9
-------
o
K
O
to
B£
<
_j
_(
O
Q
O
O
o
,_•»
I
I-
«/>
O
u
iu
t/»
<
z
u
of
3
O.
100
10
FIGURE 8B-9
REMOVAL EQUIPMENT
PURCHASE COST
(1970)
VENTURI SCRUBBER
4 567891
4 567891
10
100
GAS VOLUME FLOW 1,000's aefm
1,000
SOURCE -MANUFACTURFR
8B-10
-------
FIGURE 8-B-10
REMOVAL EQUIPMENT
PURCHASE COST
(1970)
CHAMBER SCRUBBER
PURCHASE COST-ljOOO's DOLLARS (1970)
— o
•
•
_^
*^
X*
X*
^
X
w
t
s
s
-------
,00
o
fN
o>
O
0
o
o
I/I
O
u
z
otf.
10
FIGURE 8BH1
.REMOVAL EQUIPMENT
PURCHASE COST
11970)
WET IMPINGEMENT SCRUBBER
(STAINLESS STEEL)
1 1
3
4
5
6
1
' t
9
S
\ 2
X
a
x
4
x
x^
j
X
I 6
'4
^
7
/
a
F1
9
x
1 J
a
10
100
GAS VOLUME FLOW 1,000's acfm
1,000
SOURCE- MANUFACTURER
8B-12
-------
FIGURE 8B-12
PURCHASE COST REMOVAL EQUIPMENT (1970)
CROSS FLOW PACKED BED
10,000
ei-as
PURCHASE COST - 1,000's DOLLARS (1970)
s § i
3
a
t
\ i
> <
vs
3
"
' t
•'
9
*
1 1
i-fOOT B
/
'
xl
3
D~v
X1
X
X
x
y
X
HS
^'
X
s,
1
p
}
/•
I
\
,
1 2
>
s/'
3-fOOT
BED
3
v
y
1 4
y
x^
T
5
/
«
/
7
/
1
^
M
/
t
*
1
/
/
f
:
A
/
f
\ 4
/
f
5
/
6
/
3
/
' 1
V
»>
19
ii>
^ '
1 1
(WS
IPB
I
3
t
1 10 100 1,000 10.000
\ 5
4
J
a
1
i
9
e
7
6
s
4
3
2
1
9
8
7
4
S
4
1
I
1
9
•
/
S
4
3
2
1
100,000
GAS VOLUME FLOW 1,000'* acfm
SOURCE-MANUFACTUMR
-------
o
tx
O-
O
O
o
o
o
O
u
u
et
=>
FIGURE 8B-13
REMOVAL EQUIPMENT
PURCHASE COST
(1970)
FLOATING BED WET SCRUBBER
1
1,000
100
10
2 34567891 2 34567891 2 34567891
j
>
S
s
s
r
/
s
r
.
r
4
/
*
S
S
s
s
9
1
10
100
1,000
GAS VOLUME FLOW 1,000's acfm
10,000
SOURCE-MANUFACTURER
8B-14
-------
o
o>
0
o
o
o
o
I/I
o
u
X
u
ee.
100.
10
FIGURE 6B-14
REMOVAL EQUIPMENT
PURCHASE COST
(1970)
ORIFICE TYPE SCRUBBER
3 4 567891
3 4567891
3 4 567891
10
100
GAS VOLUME FLOW 1,000's acfm
SOURCE- MANUFACTURER
SS - STAINLESS STEEL
FRP- FIBERGLASS REINFORCED PLASTIC
Cs - CARBON STEEL
8B-15
-------
O
Q
O
O
o
I
o
o
X
u
ae
FIGURE 8B-I5
REMOVAL EQUIPMENT
PURCHASE COST
(1970)
AXIAL FLOW FANS
100
10
i
2 34567891 2 34567891 2 34567891
<
>
/
s
_x
/
>
x
>
r
s
x
/
^
X*
X
*
10
100
GAS VOLUME FLOW 1,000's acfm
1,000
FAN PRESSURE 4.7-5.6 IN. WATER
SOURCE - MANUFACTURER
8B-16
-------
O
tx
O
O
O
O
O
O
ft
O
u
«J
of
10
FIGURE 8B-16
REMOVAL EQUIPMENT
PURCHASE COST
(1970)
LOW PRESSURE
SCRUBBER PUMP
3 4567891
3 4567891
3 45*7891
10
too
1,000
CAPACITY-GPM
1
10,000
SOORCE -MANUFACTURER
8B-17
-------
O
Q
O
O
o
O
u
z
u
at
100
10
FIGURE 8B-17
REMOVAL EQUIPMENT
PURCHASE COST
(1970)
PUMP AND FAN MOTORS
1
«
9
3
>
x^
X"
S
s
3
X
4
/
3
«
/
7
i>
8
/
9
f
\ 1
/
s
/
s
s
\
\
' 7
i
10
100
GAS VOLUME FLOW 1,000's acfm
FAN PRESSURE 6.0 in. water
SPRAY PRESSURE 'Spsig
SOURCE- MANUFACTURER
1,000
8B-18
-------
Appendix 9A
Sample Calculation of Industry Control Improvement Costs
The pollution control practices representative
of the various segments of the industry have been de-
scribed by the models developed in Section 8 in such
a way that modification from one model to another can
be carried out and evaluated. The cost elements given
in Tables 8.4a through 8.4c can be applied to such
modification to determine the incremental costs, and
Section 9.4 develops costs of upgrading the present
level of control to several higher standards by summing
the incremental costs so estimated.
The method of obtaining the incremental cost of
upgrading is illustrated by the following example. It
considers the portion of the industry represented by
Model IA-6 (old), in which the emission control uses a
multiple cyclone followed by a spray tower to treat the
cell effluent of older type prebake cells collected in
a primary system, and in which there is no secondary
treatment. Improvement in control is achieved by con-
version of the model to others with higher overall effi-
ciencies by substitution of removal elements.
9A-1
-------
Example
Original Model - IA-6 (old)
Control System
Primary: Multiple tube cyclone followed by spray tower
Secondary: None
Industry Capacity, this model, - 542,000 tons per year
Effluent Fluorides - 12,305 tons per year
Overall Control Efficiency - 76.0%
Fluoride Emission 2,935 tons per year
Case I - Upgrade to Minimum 80% OCE
New Model - IA-5 (old)
Overall Control Efficiency 80.0%
Fluoride Emission 2,765 tons per year
Control System
Primary: Multiple cyclone followed by a cross flow packed
bed scrubber.
Secondary: None
Modifications Required
a) Modify collection system to accomodate CFPB-5
b) Demolish spray tower
c) Install CFPB-5 with 1.12 times the model flow rate
Added Costs, per ton capacity (Ref. Table 8.4a)
Capital Annualized
a) (1.60*)x($5.62) = $ 9.00 $0.72
b) (0.75*)x($2.47) = 1.85 (2.37)
c) (1.12 flow factor)
x ($14.35) = _L6_._QT_ 4.60
Added Model Costs $26.92 $2.95
Adjustment for old
plant, 15% 4.04 12% - 0.35
Net Added Costs $30.96 $3.30
* Ref. page 9-12 for cost factor.
9 A-2
-------
Case II - Upgrade to Best Primary Technology
New Model - IA-1
Overall Control Efficiency - 84.4%
Fluoride Emission - 2,156 tons per year
Control System
Primary: Fluid Bed Dry Scrubber
Secondary: None
Modifications Required
a) Modify collection system
b) Demolish multiple cyclone
c) Demolish spray tower
d) Abandon Water treatment
e) Add FBDS
Added Costs per ton capacity (Ref. Table 8.4a)
Capital Annualized
a) (1.60*)x($5.62) = $ 9.00 $0.72
b) (0.75*)x($0.87) = 0.65 3.12
c) (0.75*)x($2.47) = 1.85 (2.37)
d) (1.63)
e) (1.12) x(40.07) = 44.88 3.23
Added Model Costs $56.38 $3.07
Adjustment for old
plant, 15% 8.46 12% - 0.37
Net Added Costs $64.84 $3.44
* Ref. page 9-12
9A-3
-------
Case ill - Upgrade to Industry Minimum 90% OCE
New Model - lB-4,9
Overall Control Efficiency - 90.9%
Fluoride Emission - 1,258 tons per year
Control System
Primary: Dry electrostatic precipitator followed by
existing spray tower.
Secondary: Spray screen.
Modification Required
a) Modify collection system
b) Demolish multiple cyclones
c) Add DESP with 1.12 times the model flow rate
d) Add secondary spray screen
e) Add secondary water treatment.
Added Costs, per ton capacity (Ref. Table 8.4a)
Capital Annualized
a) (1.60*) x($5.62) = $ 9.00 $ 0.72
b) (0.75*)x($0.87) = 0.65 3.12
c) (1.12) x($17.24) = 19.30 (0.25)
d) 37.10 12.99
e) 5.76 2.34
Added Model Costs $71.82 $18.92
Adjustment for old
plant, 15% 10.77 12% - 2.27
Net Added Costs $82.59 $21.19
* Ref. Page 9-12
9A-4
-------
Case IV - Upgrade to Best Available Technology
New Model - IB-1, 9
Overall Control Efficiency
Fluoride Emission
Control System
93.0%
968 tons per year
Primary: Fluidized Bed Dry Scrubber
Secondary: Spray Screen
Modification Required
a) Modify collection system to accomodate FBDS
b) Demolish MC
c) Demolish ST
d) Add FBDS
e) Abandon Primary Water Treatment
f) Add SS secondary
g) Add Secondary Water Treatment
Added Costs, per ton capacity (Ref. Table 8.4a)
Capital
a)
b)
c)
d)
e)
f)
g)
(1.60*)x($5.62) =
(0.75*)x($0.87) =
(0.75*)x($2.47) =
(1.12) x($40.07)=
$ 9.00
0.65
1.85
44.88
-
37.10
5.76
Added Model Costs $99.24
Adjustment for old
plant, 15% 14.89
Net Added Costs
$114.13
Annualized
$ 0.72
3.12
(2.37)
3.23
(1.63)
12.99
2.34
$18.40
12% - 2.21
$20.61
* Ref. Page 9-12
9 A-5
------- |