&EPA
United States
Environmental Protection
Agency
Office of
Toxic Substances
Washington DC 20460
EPA-560/5-83-004
June, 1983
Toxic Substances
Comprehensive Assessment of
the Specific Compounds Present
in Combustion Processes
Volume I
Pilot Study of Combustion
Emissions Variability
II ft!!: I HO'
'77 -n
3*P
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PILOT STUDY OF INFORMATION OF SPECIFIC COMPOUNDS
FROM COMBUSTION SOURCES
by
Clarence L. Haile and John S. Stanley
Midwest Research Institute
Robert M. Lucas and Denise K. Melroy
Research Triangle Institute
Carter P. Nulton
Southwest Research Institute
and
William L. Yauger, Jr.
Gulf South Research Institute
TASK 3
FINAL REPORT
EPA Contract No. 68-01-5915
MRI Project No. 4901-A(3)
Prepared for
U.S. Environmental Protection Agency
Office of Pesticides and Toxic Substances
Field Studies Branch
401 M Street, S.W.
Washington, D.C. 20460
Attn: Dr. Frederick Kutz, Project Officer
Mr. David Redford, Task Manager
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DISCLAIMER
This document has been reviewed and approved for publication by the
Office of Toxic Substances, Office of Pesticides and Toxic Substances, U.S.
Environmental Protection Agency." Approval does not signify that the. contents
necessarily reflect the views and policies of the Environmental Protection
Agency, nor does the mention1 of trade names or commercial products constitute
endorsement or recommendation for use.
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PREFACE
This final report was prepared for the Environmental Protection Agency
under EPA Contract No. 68-01-5915, Task 3. The task was directed;by
Dr. Clarence L. Haile. Substantial portions of the effort were, subcontracted
to Southwest Research Institute under Or. Carter -P Nulton and;to Gulf South
Research Institute under Mr. William L. Yauger, .Jr^ This work was completed
in-coordination with statistical design studies ,-conducted by Research Triangle
Institute under Dr. Robert M. Lucas. This report was prepared by Dr. Clarence L.
Haile and Dr. John S. Stanley with substantial contributions from Dr. Robert M.
Lucas, Ms. Denise K. Melroy, Dr. Carter P. Nulton, and Mr. William L. Yauger, Jr.
RESEARCH,INSTITUTE
f
inn E. Going
Program Manager
Approved:
James L. Spigarelli, Director
Analytical Chemistry Department
June 1983
iii
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CONTENTS
Preface iii
Figures v
Tables vi
1. Introduction 1
2. Summary ?
3. Recommendations 5
4. Plant Descriptions fc
Ames Municipal Power Plant, Unit No. 7 6
Chicago Northwest Incinerator, Unit No. 2 ~
5. Sampling Methods 9
Flue Gas 9
Plant Background Air 12
Solid and Aqueous Media 12
Continuous Monitoring 12
Process Data Collection 15
6. Analysis Methods 16
Organics 16
Cadmium 31
7. Field Test Data 34
Ames Municipal Power Plant, Unit No. 7 34
Chicago Northwest Incinerator, Unit No. 2 42
8. Analytical Results 52
Ames Municipal Power Plant, Unit No. 7 52
Chicago Northwest Incinerator 83
9. Analytical Quality Assurance Results . 107
Surrogate Compound Recoveries 1C?
Interlaboratory Comparison Studies 107
10. Emissions Results 112
Ames Municipal Power Plant, Unit No. 7 112
Chicago Northwest Incinerator, Unit No. 2 112
11. Statistical Summary of Pilot Study Data 129
Overview 129
First Tier Summary 129
Second Tier Summary 137
References 147
Appendix A - TRW Field Test Report for the Ames Municipal Electric System,
Unit No. 7 148
Appendix B - TRW Field Test Report for the Chicago Northwest Incinerator,
Unit No. 2 242
IV
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FIGURES
Number
1
2
3
4
5
Modified Method 5 train for organics sampling
Locations of flue gas sampling ports on a typical combustion
unit
Sector schemes for sampling bottom ash --.-,.,,,.-•
General analytical scheme
TOC1 chroma to zr am for Aroclor 1254
Page
10
11
14
18
23
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TABLES
Number Page
1 PAH Compounds Selected 16
2 Recovery of Selected PAHs and 1,2,3,4-TCDD From Ames Fly Ash. 20
3 TOC1 Analysis Parameters 22
4 HRGC Screening Parameters 24
5 Extract Compositing Scheme for Tier 2 Analyses 25
6 HRGC/MS Parameters Used for Analyses of PCDDs and PCDFs in
Composite Chicago NW Flue Gas Outlet Extracts 26
7 HRGC/MS-SIM Parameters Used for Analysis of PCBs in Composite
Flue Gas Outlet Extracts 27
3 PCS Compounds Used for Determinations in Composite Flue Gas
Outlet Extracts 27
9 Ions Monitored During HRGC/HEMS Confirmatory Analysis of
PCDDs and PCDFs in Composite Chicago NW Flue Gas Outlet
Extracts 29
10 PCDD and PCDF Compounds Used for Determinations in Composite
Chicago NW Flue Gas Outlet Extracts . 29
11 HRGC/HRMS Parameters Used for Analysis of 2,3,7,8-Tetrachloro-
dibenzo-o-dioxin in Composite Chicago NW Flue Gas Outlet
"Extracts 30
12 Recovery of Cadmium From Fortified Samples of Fly Ash From
the Chicago NW Incinerator 33
13 Recovery of Cadmium From Fortified Samples From the Ames
Municipal Power Plant 33
14 Daily Data Summaries for Flue Gas Sampling, Ames Municipal
Power Plant, Unit No. 7 35
15 Average Process Data for the Ames Municipal Power Plant,
Unit No. 7 38
VI
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TABLES ( continued)
Number Page
16 Fuel Combustion During Flue Gas Sampling ........... 40
17 Daily Production and Consumption at Ames Municipal Power
Plant, Unit Mo. 7 ..................... 41
18 Heat Content of Fuels Used at the Ames Municipal Power Plant
During Sampling Period ................... 43
19 Daily Data Summaries for Flue Gas Measurements, Chicago
Northwest Incinerator, Boiler No. 2 ............ 44
20 Means of the Means for Process Data, All Test Days, Chicago
NW Incinerator, Boiler No. 2 ........ . ....... 46
21 Weekly Inventories of Refuse and Residue at the Chicago NW
Incinerator (All Boilers) ................. 48
22 Charges Fed to Boiler No. 2 on a Shift Basis Chicago North-
west Incineration Facility ................. 49
23 TOC1 and Surrogate Recovery Results for the Ames Flue Gas
Inlet Samples ....................... 53
24 TOC1 Results and Surrogate Recoveries for the Ames Flue Gas
Outlet Samples ....................... 55
25 TOC1 Results and Surrogate Recoveries for Ames Plant Back-
ground Air Particulate Samples ............... 56
26 TOC1 Results and Surrogate Recoveries for Ames ESP Ash
Samples .............. ............ 57
27 TOC1 Results and Surrogate Recoveries for Ames Bottom Ash
Samples .......................... 60
28 TOC1 Results and Surrogate Recoveries for Ames Coal Samples . 63
29 TOC1 Results and Surrogate Recoveries for Ames Refuse -
Derived Fuel Samples .................... 64
30 TOC1 Results and Surrogate Recoveries for Ames Bottom Ash
Hopper Quench Water Influent Samples ............ 67
31 TOC1 Results and Surrogate Recoveries for Ames Bottom Ash
Hopper Quench Overflow Water Samples ............ 68
32 TOC1 Results and Surrogate Recoveries for Ames Untreated Well
Water ........................... 71
vii
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TABLES (continued)
Number Page
33 Compounds Quantitated in Samples From the Ames Municipal
Power Plant, Unit No. 7 72
34 Concentrations of Polychlorinated Biphenyl Isomers in Flue
Gas Outlet Samples From the Ames Municipal Power Plant,
Unit No. 7 77
35 Cadmium Results for Ames - ESP Ash Samples 78
36 Cadmium Results for Ames - Bottom Ash Samples 79
37 Cadmium Results for Ames - Coal Samples 80
38 Cadmium Results for Ames - Refuse-Derived Fuel Samples. ... 81
39 Cadmium Results for Ames - Flue Gas Outlet Particulates ... 82
40 TOC1 Results and Surrogate Recoveries for Chicago NW Flue
Gas Samples 84
41 TOC1 Results and Surrogate Recoveries for Chicago NW Plant
Background Air Samples 85
42 TOC1 Results and Surrogate Recoveries for Chicago NW ESP Ash
Samples 86
43 TOC1 Results and Surrogate Recoveries for Chicago NW Combined
Bottom Ash Samples 89
44 TOC1 Results and Surrogate Recoveries for Chicago NW Refuse
Samples 92
45 TOC1 Results and Surrogate Recoveries for Chicago NW Tap
Water Samples 95
46 Compounds Quantitated in Samples From the Chicago NW
Incinerator, Unit No. 2 96
47 Comparison of TOC1 Results From Direct TOC1 Assays Versus
Calculated TOC1 From Specific Compounds Identified in
Composite Chicago NW Extracts 98
48 Concentrations of Polychlorinated Biphenyl Isomers in Flue
Gas Outlet Samples From the Chicago Northwest Incinerator
Unit No. 1 99
49 Concentrations of Polychlorodibenzo-p_-dioxins and Furans in
Flue Gas From the Chicago Northwest Incinerator and Cor-
responding Emission Rates 100
viii
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TABLES (continued)
Number Page
50 Concentrations of 2,3,7,8-Tetrachlorodibenzo-p_-diojcin in
Flue Gas From the Chicago NW Incinerator 102
51 Cadmium Concentrations in Fly Ash From Chicago Northwest
Incinerator, Unit No. 2 103
52 Cadmium Concentrations in Combined Bottom Ash From Chicago
Northwest Incinerator, Unit No. 2 104
53 Cadmium Concentrations in Refuse From Chicago Northwest
Incinerator 105
54 Cadmium Concentrations in the Flue Gas Outlet Particulates
From Chicago Northwest Incinerator, Unit No. 2 106
55 Summary of Surrogate Recovery Data 108
56 Results of Interlaboratory TOC1 Analyses 109
57 Interlaboratory Comparison of Analytical Results for the Ex-
traction and Analysis of Specific Compounds in Four Sets
of Quality Assurance Samples 110
58 Interlaboratory Comparison of the Levels of PCDDs and PCDFs
in Composite extracts From the Chicago NW Incinerator . . . Ill
59 Total Organic Chlorine Inputs and Emissions - Ames Municipal
Power Plant, Unit No. 7 113
60 Compounds Quantitated in the Primary Input and Emission Media
for the Ames Municipal Power Plant, Unit No. 7 114
61 Flue Gas Concentrations for PCBs and Emission Rates for the
Ames Municipal Power Plant, Unit No. 7 118
62 Cadmium Inputs and Emissions - Ames Municipal Power Plant,
Unit No. 7 119
63 Total Organic Chlorine Inputs and Emissions - Chicago North-
west Incinerator, Unit No. 2 120
64 Compounds Quantitated in Input and Emission Media Chicago NW
Incinerator, Unit No. 2 122
65 Flue Gas Concentrations of PCBs and Emission Rates for the
Chicago Northwest Incinerator Unit No. 1 124
IX
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TABLES (continued)
Number Page
66 Concentrations of Polychlorodibenzo-£-dioxins and Furans in
Flue Gas From the Chicago Northwest Incinerator and Cor-
responding Emission Rates 125
67 Concentrations of 2,3,7,8-Tetrachlorodibenzo-£-dioxin in
Flue Gas From the Chicago NW Incinerator and Corresponding
Emission Rates 127
68 Cadmium Input and Emissions From Chicago Northwest
Incinerator, Unit No. 2 128
69 Summary Statistics for Total Organic Chlorine Concentration
Data From Ames, Iowa 132
70 Summary Statistics for Total Organic Chlorine Concentration
Data From Chicago NW 133
71 Summary of Surrogate Compounds Percent Recovery for
Specimens From Ames , Iowa 134
72 Summary of Surrogate Compound Percent Recovery for Specimens
From Chicago, NW : 135
73 Validity of Confidence Statements for Selected Levels of
Bias 136
74 Summary of Coefficient of Variation for the Pilot Study. . . 138
75 Summary of Statistics for Compounds Quantitated in Primary
Input Media at Ames, Iowa 140
76 Summary Statistics for Compounds Quantitated in Gaseous
Emissions at Ames, Iowa 141
77 Summary Statistics for Compounds Quantitated in Solid Emis-
sions at Ames, Iowa 142
78 Summary of Total Input and Emissions From Ames, Iowa .... 143
79 Summary of Statistics for Compounds Quantitated in Gaseous
Emissions From Chicago 144
80 Summary of Flue Gas Emissions of Polychlorinated Biphenyl
Isomers from Ames, Iowa 145
81 Summary of Flue Gas Emissions of Polychlorinated Biphenyls,
Dibenzo-£-diojcins, and dibenzofurans from Chicago NW . . . 146
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SECTION 1
INTRODUCTION
This pilot study was conducted as a prelude to a nationwide survey of
organic emissions from major stationary combustion sources. The primary ob-
jectives of the pilot study were to obtain data on the variability of organic
emissions from two such sources and to evaluate the sampling and analysis
methods. These data are used to construct the survey design for the nation-
wide survey. The compounds of interest are polynuclear aromatic hydrocarbons
(PAHs) and chlorinated aromatic compounds, including polychlorinated biphenyls
(PCBs), polychlorinated dibenzo-£-dioxins (PCDDs), and polychlorinated di-
benzofurans (PCDFs). Of particular interest is 2,3,7,8-tetrachlorodibenzo-
p_-dioxin (TCDD). In addition, total cadmium was also determined in special
samples from both plants to meet special Environmental Protection Agency
(EPA) needs.
Midwest Research Institute (MRI) was responsible for overall task man-
agement, specifying the sampling and analysis methods, assisting in the col-
lection of samples, receiving samples at the plant sites, shipping the sam-
ples to the analysis laboratories, and conducting all sample analyses. MRI
was assisted in this effort by two subcontractors. Southwest Research In-
stitute (SwRI) assisted in sampling, exercised sample control, and conducted
most of the analyses for samples from the first plant. Gas chromatographic/
mass spectrometric confirmation of PCBs, PCDDs, and PCDFs was conducted by
MRI. Gulf South Research Institute (GSRI) provided similar assistance for
the second plant.
The statistical design of the pilot study was constructed by Research
Triangle Institute (RTI). RTI also conducted statistical analysis of the re-
sulting emissions data and constructed the design for the nationwide survey.
The results of the statistical analysis are summarized in Section 9 of this
report. The survey design is summarized in a report to the EPA Office of
Toxic Substances.l
TRW, Inc. was responsible for conducting the field sampling and data
collection. The results of TRW's efforts are described in two reports to
EPA's Industrial Environmental Research Laboratory in Research Triangle
Park.2'3 The body of these reports are contained in Appendices A and B.
A summary of the results of this study is contained in Section 2 of this
report. Section 3 presents recommendations for future work. Brief descrip-
tions of the two combustion sources are contained in Section 4. The sampling
and analysis methods are described in Sections 5 and 6. Sections 7 and 8
present the field test data and analytical results. The analytical quality
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assurance results are summarized in Section 9. Section 10 presents the emis-
sions results and Section 11 is a statistical summary of the emissions re-
sults .
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SECTION 2
SUMMARY
Two major stationary combustion sources, a municipal incinerator and a
co-fired (refuse-derived fuel plus coal) power plant, were studied to deter-
mine the variability of organic emissions between sources and over a desig-
nated time period for each plant. The pilot study results served as a basis
for structuring the survey design for a nationwide survey1 for organic emis-
sions from stationary combustion sources.
All inputs and outputs (including fuel, air, water, ash, and flue gas)
that were influenced by the combustion process at each facility were sampled
for a minimum of 11 days. Daily flue gas samples (20 m3) were collected con-
currently at the inlet and outlet of the control devices using a modified
Method 5 sampling train. The solid and aqueous inputs and outputs from each
plant were collected six times per day (at roughly 4-hr intervals).
The samples were extracted and analyzed for total organic chlorine
(TOC1), PAHs, PCBs, PCDDs, and PCDFs. A limited number of samples were
analyzed for cadmium. The TOC1 procedure (more correctly, total extractable
organic halide) was developed for this study to provide a sensitive measure
of the variability of chlorinated organic emissions.
The TOC1 emissions from the municipal incinerator and the co-fired power
plant differed and were variable within the test duration for each plant.
The flue gas accounted for more than 80% of each plant's TOC1 emissions. The
TOC1 emissions averaged 322 mg/hr from the municipal incinerator and 246 mg/hr
from the co-fired power plant. The variability of the TOC1 results was the
key element in the construction of the nationwide survey design.1
A number of specific compounds including chlorinated benzenes and chlori-
nated phenols were detected in the flue gas from the municipal incinerator.
The sum of the organic chlorine concentrations attributable to these specific
compounds is comparable to the TOC1 results. Fewer chlorinated compounds were
identified in the flue gas extracts of the co-fired plant and were generally
present at lower concentrations than in extracts from the municipal incinerator.
Polycyclic organic compounds including PAHs, PCDDs and PCDFs were iden-
tified in the flue gas extracts from the municipal incinerator. Some PAHs
and PCBs were also identified and quantitated in the flue gas from the co-
fired power plant, but PCDDs and PCDFs were not detected.
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The mean concentration observed for total PCBs from the municipal incin-
erator was 42 ng/dscm (dscm = dry standard cubic meter), compared to an aver-
age of 19 ng/dscm from the co-fired power plant. However, the order of the
average emission rate is reversed because of the lower flue gas flow rate of
the refuse incinerator. The average PCB emission rates for the RDF/coal-fired
power plant and the refuse incinerator were 6 mg/hr and 3.6 mg/hr, respectively.
Because of the variability observed in the data, no significant differences
between concentrations or emission rates between the two plants can be deter-
mined. The PCB isomer distribution ranged from dichlorinated to pentachlori-
nated compounds for the municipal incinerator and trichlorinated to deca-
chlorinated compounds for the co-fired power plant. PCDDs and PCDFs were not
identified in sample extracts from the co-fired power plant. However, several
PCDDs and PCDFs were identified in composited sample extracts from the munici-
pal incinerator. Trichloro- and tetrachlorodibenzofurans were the most abundant
of the PCDDs and PCDFs in these extracts, averaging 300 ng/dscm and 90 ng/dscm,
respectively. The specific PCDD isomer 2,3,7,8-tetrachlorodibenzo-£-dioxin
(2,3,7,8-TCDD) was also identified in these extracts from the municipal incin-
erator and averaged 0.4 ng/dscm (average mass emission 34 pg/hr). This isomer
was identified in these extracts using high resolution gas chromatography/high
resolution mass spectrometry. This identification was confirmed by an inde-
pendent laboratory using similar instrumentation.
The level of cadmium was also measured in the inputs and outputs for a
limited number of sample days for each plant. The mass balance observed for
the inputs and emissions of the co-fired power plant was fairly good. How-
ever, the agreement for cadmium inputs and emissions for the municipal incin-
erator was poor. This was likely due to the difficulties encountered in ob-
taining representative samples of the refuse burned at this facility.
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SECTION 3
RECOMMENDATIONS
The nationwide combustion study should be conducted. The results in
this report provide the basis for a sound statistical design for sampling and
analysis procedures in future programs (i.e., municipal incinerators, coal-
fired power plants, etc.).
Extraction studies should be undertaken with fly ash samples that have
been shown to contain PCDDs and PCDFs. Analysis of such a material could pro-
vide a better measure of recovery efficiency of these compounds than from
other similar solid materials.
The modified Method 5 sampling procedure used in this study is based on
sound developments for particulate sampling coupled with adsorption of organic
vapors on a resin of known properties. However, this sampling procedure should
be rigorously evaluated for the collection efficiencies of PCDDs and PCDFs as
an additional quality assurance measure.
The preliminary data presented in this report suggest that the TOC1 mea-
surement should be further evaluated for use as an indicator of chlorinated
organic emissions. The development of a good TOC1 measurement could signifi-
cantly reduce the costs of obtaining large amounts of combustion source data.
Additional work should be conducted to improve the selective separation
and detection of PCDDs and PCDFs. Current methods require labor-intensive
extractions and cleanup procedures.
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SECTION 4
PLANT DESCRIPTIONS
AMES MUNICIPAL POWER PLANT, UNIT NO. 7
The Ames Municipal Power Plant is owned and operated by the city of Ames,
Iowa, and is located within the city limits. The coal-fired utility boiler
tested at this plant was Unit No. 7, one of three units that have been modi-
fied to burn processed refuse as a supplemental fuel with coal. Unit No. 7,
a pulverized coal suspension fired boiler, is used under normal operating
condition. The other two units are operated under peak demand or when Unit
No. 7 is down. This unit was originally designed to burn either coal or
natural gas as the primary fuel. It was first brought into operation in 1968
and was modified to burn refuse-derived fuel (RDF) in 1975.
Unit No. 7 generally burns a mixture of Colorado coal, Iowa coal, and
RDF. Generally, the ratio of the two types of coal varies, although during
this particular testing period a 45 to 55% ratio of Colorado to Iowa coal was
maintained in the pulverized coal mixture. Approximately 20% (by weight) of
the total fuel prepared and fired at this facility was RDF and 80% was pul-
verized coal.
The RDF is produced at a separate Ames city facility located near the
power plant. Raw refuse is sorted to remove glass and metals for recycling.
The remaining material (largely papers and plastics) are milled and pneumati-
cally conveyed to a storage bin. The RDF is fed from this bin to the boiler
at the required rate. The maximum RDF feed rate is 8.5 tons/hr (7.7 metric
tons/hr).
Pulverized coal is supplied to the furnace by tangentially orientated
nozzles so that combustion is accomplished in a suspension. Approximately
20% of the total ash produced during coal-only firing is bottom ash. RDF is
supplied to the furnace at a point just above the primary coal combustion zone.
Moveable grates hold the residual RDF at the bottom of the coal combustion
zone to enhance RDF combustion. The grates are lowered during bottom ash wast*
ing and when RDF is not being fired.
The ash and slag deposited in the hopper are removed at least three times
per day. An average of 758,000 liters/day (200,000 gal./day) of well water
(sluice water) is used to remove the solid waste from the furnace bottom.
This waste is drained to a holding pond where the ash is dredged out and stock
piled. The water from the holding pond is allowed to percolate through the
soil and eventually into a nearby river.
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Electrostatic precipitators (ESPs) are used to remove particulates from
the stack gases. The ESFs require at least 61 kw of the maximum 35,000 kw
gross output of Unit No. 7. Fly ash collected in the ESP hoppers is pneu-
matically conveyed (3 times/day) to the bottom ash hopper drain system.
Additional information including schematics of the plant site, the flow
system, Unit No. 7 design, and the solid waste recovery system is presented
in the pilot test program engineering report provided by TRW (see Appendix A).
Other tables in the TRW report list the boiler design data, the pulverizer
specifications, the fan design performance parameters, performance character-
istics of the ESP, and the predicted performance characteristics of Unit No. 7.
CHICAGO NORTHWEST INCINERATOR, UNIT NO. 2
The Chicago Northwest Incinerator is one of four municipal incinerators
owned and operated by the city of Chicago (Illinois) and located within the
city limits. This plant has four incinerators, each having a nominal burning
capacity of 400 ton/24 hr day (363 metric tons/24 hr day). Each incinerator
has a charging hopper, feed chute, hydraulic powered feeders and stoker,
boiler, economizer and fly ash hoppers. Draft through the furnace is pro-
vided by forced draft fans, overfire air fans, and induced draft fans.
Mixed refuse from domestic sources is brought to the incinerator in
trucks having a capacity of 5 tons (4,500 kg) or 25 cubic yards (19 m3). The
refuse varies considerably in consistency and moisture content seasonally and
from load to load. All refuse is collected in a storage pit of 9,700 cubic
yard (7,400 cubic yard) capacity. The refuse is not sorted prior to storage
in the pit except for large items (e.g., furniture and large appliances) which
are milled prior to storage in the pit. The refuse typically contains con-
siderable quantities of automobile tires, small appliances, and similar dis-
carded durable goods. The refuse is removed from the pit by one of three
transfer cranes and is dumped directly into the four furnace feed hoppers.
Refuse in the charging hopper of each incinerator flows by gravity from the
hopper to three stoker feeders through a feed chute. The stoker feeders at
the bottom of the feed chute push the refuse into the stoker by a reciprocat-
ing action.
Alternate lateral rows of grate steps have controlled continuous recipro-
cating action with the moving grate steps pushing in reverse direction to the
flow of refuse. This action moves a portion of the burning refuse under the
unignited material and thereby effects an agitation and blending of the whole
burning mass. Combustion air entering from below the grates cools the grates,
helps to agitate the burning refuse and supplies the oxygen which produces a
maximum burn-out in the shortest length of grate travel.
The combustion air combines with the burning refuse to generate heat and
raise the temperature of the flue gas to as high as 2000°F (1100°C). At rated
burning capacity and based on 50% excess air (dry) the flue gas flow rate at
550°F (290°C) is estimated to be 142,300 actual cubic feet per minute (acfm)
or 4,030 m3/min. The flue gas passes upward through the furnace, through the
boiler passes and finally through the economizer to the electrostatic pre-
cipitator. As it passes through the boiler it transfers heat to the water.
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At the inlet to the electrostatic precipitator the temperature is reduced to
approximately 500°F (260°C) because of the above heat exchange. During the
passage of the flue gas through the boiler passes and economizer the heavier
fly ash particles drop out. Hoppers are provided below the boiler and econo-
mizer for the collection of the particulates.
In order to obtain maximum combustion efficiency, the depth of the refuse
bed is controlled by automatic discharge or clinker rollers located at the
end of the grate. As the residue reaches this point it is dumped into an ash
discharger and is quenched in water. The residue is pushed up an inclined
slope that permits draining and produces a residue of less than 15% moisture.
In addition to quenching, the ash discharger also serves as a water seal for
the furnace and prevents infiltration of air into the furnace. The furnace
operates under slight negative pressure.
The residue leaving each incinerator ash discharger passes through a
hydraulically operated chute to one of two residue conveyors. The residue is
screened to separate material larger than 2 in. (5 cm) in diameter. Hydraulic
powered chutes are used to direct the flow of the residue away from the rotary
screens and into a by-pass hopper.
The residue conveyors also receive and transport stoker grate sittings
and fly ash accumulations from the boiler hoppers, economizer hoppers, and
the electrostatic precipitators. Stoker grate siftings collect in six hoppers
under each of the three stoker grate sections. Residue from the hoppers is
removed from the plant by trucks. The weight of the residue leaving the plant
is measured and recorded at the weighing station.
The boiler fly ash is collected in four hoppers, two of which discharge
to the stoker grates. The other two hoppers are discharged directly through
a common pipe to the residue conveyor. The fly ash from the economizer hop-
pers passes through a common pipe connected to the discharge end of a conveyor
handling fly ash from the two electrostatic precipitator hoppers. The fly
ash is deposited directly into the residue discharge chute.
The flue gas exiting the ESPs is vented to a 250-ft (76 m) high stack
via an induced draft fan. Flue gases from two identical units are discharged
from a single stack via a breaching.
A more detailed description of the plant operation and schematics of the
plant site, the flow system, and the flue gas and grab sampling locations is
presented in the TRW pilot test program engineering report (see Appendix B).
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SECTION 5
SAMPLING METHODS
FLUE GAS
Flue gas sampling for organic compounds was accomplished concurrently at
points both inlet and outlet to the electrostatic precipitators using two mod-
ified Method 5 sampling trains (shown in Figure 1) at each location. Figure 2
shows the locations of sampling ports on a typical unit. The sampling crew
collected 10 m3 (10 ± 1 m3) samples with each sampling train by extracting
the flue gas at rates approximating the flue gas velocity for each plant.
Cadmium was sampled at the ESP outlet using a single Method 5 sampling train.
The standard train was operated the same as depicted in Figure 1, but without
condenser and the XAD-2 sorbent trap. EPA Method 5 Procedures4 for particu-
late sampling were followed for both organic and inorganic sampling procedures,
except that 10 m3 was sampled with each organic train.
Detailed descriptions of the Method 5 calibration and actual sampling
procedures for specific ducts and stacks at the Ames Municipal Power Plant
and Chicago Northwest Incinerator have been presented in the respective field
data reports (Appendices A and B). Additional details on the pretest prepara-
tion and sample recovery procedures are described in a methods manual for the
nationwide combustion source survey.5 The flue gas sampling at the Ames facil-
ity was conducted both on the duct just before the electrostatic precipitator
and on the stack. Sampling for organics was to be performed for 14 consecutive
days with an additional 3 days sampling for particulate cadmium. However,
due to extreme weather conditions only 11 days of concurrent inlet and outlet
samples were collected. Eight additional inlet samples were also collected.
The flue gas sampling at the Chicago plant was conducted at the duct in-
let to the electrostatic precipitator and at the duct leading from the pre-
cipitator to the stack. Despite boiler down time and equipment malfunction,
11 days of organic samples (including concurrent inlet and outlet flue gas)
were taken.
A complete sampling train, including resin trap filter and impinger so-
lutions was set up as a train background (blank) at each plant. The train
was taken to normal operating temperature and allowed to remain at this tem-
perature for 1 hr.
Upon completion of testing, the sampling equipment was brought to a clean
laboratory area for recovery. Each sampling train was kept in a separate area
to prevent sample mixup and cross contamination. The individual sample train
components were recovered as follows:
-------
Cyelent
(optional)
Prow
Tncrmocouoi* j
R«v«r»«-Tyo« *
Pitor Tub*
Conewmer
& K«in
Cartridge
VACUUM
\ UNE
Silica G.I
Coraoi*
a/ Impingen 1.3 and 4 or* of the Modified Greenburg-Smilh Type
Impinger 2 it of the Greenburg-Smilh Design
Impinger 1 and 2 Contain 100 ml Water
Impinger 3 Empty
Impinger 4 Contairn 200-300 Graim Silica Gel
Figure 1. Modified Method 5 train for organies sampling.
-------
Stack
Platform
and Ports
Figure 2. Locations of flue gas sampling ports on a typical combustion unit.
11
-------
• Dry particulate in cyclone - cyclone flasks were transferred to cy-
clone catch bottle.
• Probe was wiped to remove all external particulate matter near probe
ends.
• Filters were removed from their housings and placed in proper con-
tainers .
• After recovering dry particulate from the nozzle, probe, cyclone, and
flask, these parts were rinsed with distilled water to remove remain-
ing particulate. They were subsequently rinsed with glass distilled
acetone and cyclohexane and put into a separate container. All rinses
were retained in an amber glass container.
Sorbent traps were removed from the train, capped with glass plugs,
and given to an on-site MRI representative.
Condenser coil, if separate from the sorbent trap-, and the connecting
glassware to the first impinger was rinsed into the condensate catch
(first impinger).
First and second impingers were measured, volume recorded and retained
in an amber glass storage bottle. The impingers were then rinsed with
small amounts of distilled water, acetone and cyclohexane. These rins-
ings were combined with the condensate catch. Rinse volumes were also
recorded.
The volumes of the third and fourth impingers were measured and re-
corded. Solutions were discarded.
Silica gel was weighed, weight gain recorded and regenerated for fur-
ther use.
To maintain sample integrity, all containers were amber glass, with TFE-
lined lids.
PLANT BACKGROUND AIR
A high volume air sampler was used to collect organic compounds and cad-
mium associated with particulates in the air used for combustion. The sam-
ples were collected on 8 in. x 10 in. (20 cm x 25 cm) glass fiber filters. A
high volume sampler was placed on the roof of each facility to obtain a repre-
sentative background of outside ambient air, rather than sampling air inside
the building that could have been contaminated or influenced by the combustion
process.
SOLID AND AQUEOUS MEDIA
Solid and aqueous samples that directly contact the combustion process
were collected several times during each 24-hr period according to schedules
12
-------
provided by RTI. Four solid sample types were collected from the Ames plant,
coal, ESP hopper ash, bottom ash, and RDF. ESP ash, refuse, and combined ash
were sampled at the Chicago plant. Combined ash includes mixed ESP ash and
bottom ash since the design of the Chicago ash handling system did not allow
separate access to bottom ash. All solid samples were collected six times
per day at roughly 4-hr intervals.
Some solid samples were accessible from more than one nominally equiva-
lent point in the plant. In these cases, samples were taken from specific
points according to a randomized scheme provided by RTI. Hence, coal was
sampled from two feed streams, RDF was sampled from four feed streams, and
ESP ash was sampled from two collection hoppers at the Ames plant based on
this scheme. Similarly, bottom ash from the Ames plant and bottom ash and
refuse from the Chicago plant were sampled from specific sectors of the ex-
posed material according to the randomized scheme. Figure 3 shows the sector
systems used in sampling bottom ash from the Ames and Chicago plants. Raw
refuse was sampled at the Chicago incinerator from the two sides of the feed
hopper.
The aqueous streams sampled at Ames included cooling tower blowdown water,
well water, and bottom ash quench overflow. Only city tap water (plant intake
water) was sampled at the Chicago facility. Liquid streams that did not flow
continuously were allowed to purge for 3 min prior to obtaining samples. Sam-
ple containers were rinsed three times with sample liquid prior to being filled
with that liquid. The streams sampled and frequency of sampling were as fol-
lows:
Bottom ash quench overflow water was sampled twice per shift, for a
total of six samples per 24-hr period.
Cooling tower blowdown feed for the bottom ash quench system was sam-
pled once per day.
Three well water samples were collected over the testing period.
City tap water was sampled once per day.
CONTINUOUS MONITORING
The continuous monitoring data collected for the two different plants
included: (1) oxygen [02] concentrations, (2) carbon dioxide [C02] concen-
trations, (3) carbon monoxide [CO] concentrations, (4) hydrocarbon concentra-
tions [THC] [G! through C6] and (5) ambient temperatures. On-line monitoring
was performed at the inlet of the electrostatic precipitators (ESP) at both
plants and in the duct leading from the exit side of the ESP to the induced
draft fan at the Chicago Northwest Incinerator and at the 100 ft (30 ra) level
on the stack at the Ames Municipal Power Plant.
A stainless steel filter connected to a 3-ft (91-cm) probe was inserted
into the sample port for each sample location. Heat traced line was run from
the sample port to a gas conditioner. Vacuum pumps were used to draw the in-
let and outlet sample gas from the sample ports through the gas conditioner
13
-------
North Hopper Door
Ames Municipal Electric System, Unit No. 7
Bottom Ash Hopper
A
B
C
D
F
Chicago Northwest Incinerator, Unit No. 2
Residue Discharge Chute
Figure 3. Sector schemes for sampling bottom ash.
-------
and to the analytical instruments. An automatic timer switched the continuous
monitoring equipment from inlet to outlet every 15 min.
The average values for 02, C02, CO and THC recorded during each test
period are presented in Section 8 of this report with a summary of the flue
gas testing parameters. A more detailed description of the continuous moni-
toring data is presented in Appendices A and B.
PROCESS DATA COLLECTION
In order to fully characterize the operation of the two different com-
bustion facilities and to designate periods of dramatic changes in the per-
formance of a particular unit, numerous operating parameters were recorded
throughout the flue gas sampling periods, as well as on a 24-hr basis. This
information included mass flow data for fuels (coal, fuel oil, and RDF), per-
iods of soot blowing, unit downtime, steam flow rate, steam pressure, steam
temperature, feedwater flow rate, feedwater temperature, combustion air flow
rate, combustion air temperature, percent excess oxygen, induced and forced
fan pressures, furnace draft, furnace temperature, flue gas temperature, and
ambient temperature and ambient pressure.
The process data averages based on 24-hr periods and the flue gas test
durations are presented in Section 7 of this report. Data for these param-
eters taken on an hourly basis are presented in detail in the Appendices.
15
-------
SECTION 6
ANALYSIS METHODS
ORGANICS
The analysis methods for organics were designed to provide qualitative
and quantitative determinations of several specific analytes and to provide
semiquantitative information on any additional polychlorinated aromatic com-
pounds identified. The specific analytes included eight PAH compounds (listed
in Table 1), PCBs, PCDDs, and PCDFs. Special emphasis was placed on highly
selective and sensitive procedures for determining 2,3,7,8-TCDD.
TABLE 1. PAH COMPOUNDS SELECTED
Benzo [ ajpyrene
Pyrene
Fluoranthene
Phenanthrene
Chrysene
Indeno[l,2,3-cd]pyrene
Benzo[g,h,i]perylene
Anthracene
Samples were also assayed for total organic chlorine (TOC1) to provide a
general measure of the variability of chlorinated emissions. Since it was
anticipated that concentrations for many specific compounds would be near mini-
mum detectable levels, the variabilities observed for specific compounds may
be more representative of measurement error than emission variabilities. The
sensitivity of the TOC1 procedure should allow more reliable detection of the
variability of emissions for chlorinated organics.
16
-------
A tiered scheme was used to economize on the total number of analyses
required. The tier 1 operations, schematically shown in Figure 4, included
sample extraction, TOC1 assays, capillary gas chromatographic (HRGC) screen-
ing for halogenated compounds and hydrocarbons, and PAH analysis by capillary
gas chromatography/mass spectrometry (HRGC/MS). Extract analysis by capil-
lary gas chromatography with Hall electrolytic conductivity and flame ioniza-
tion detectors (HRGC/Hall-FID) provided a sensitive screen for halogenated
compounds that was used to aid the identification of specific halogenated
compounds in the HRGC/MS data. Some of the individual grab samples were com-
posited to form daily and shift composite samples prior to extraction for
tier 1 analysis. The sample compositing scheme was provided by RTI.
The tier 2 analyses, also shown in Figure 4, focused on very sensitive
and selective determinations of PCBs, PCDDs, and PCDFs. Extracts were ana-
lyzed by HRGC/MS operated in selected ion monitoring mode (HRGC/MS-SIM).
Suspected responses for PCDDs and PCDFs were confirmed by using high resolu-
tion mass spectrometry (HRGC/HRMS-SIM). In addition, three extracts were sub-
mitted to the EPA laboratory at Research Triangle Park for collaborative con-
firmation of PCDDs and PCDFs.
The analytical quality assurance program included analyses of method
spikes, method blanks, and field blanks in addition to the use of stable
isotope-labelled surrogate compounds spiked into all samples to provide some
analytical recovery data for all samples. Scanning HRGC/MS analyses were con-
ducted using a stable isotope-labelled internal standard, d10-anthracene.
HRGC/HRMS-SIM analyses for TCDD employed 37Cl4-2,3,7,8-tetrachlorodibenzo-p_-
dioxin. In addition, two sets of check samples, one set for TOC1 and one set
for specific chlorinated aromatic compounds, were sent to the two laboratories
conducting the tier 1 analyses.
The analytical methods used are described in detail in the subsections
that follow. Additional details of the analytical procedures are described
in methods manual for the nationwide combustion source survey.5
Tier 1 Methods
Sample Preparation and Compositing—
Flue gas samples—The contents of the two modified Method 5 sampling
trains used at each sampling point on each day were analyzed as a single sam-
ple. That is, the four trains used each sampling day (except for several days
at the Ames site on which outlet flue gas was not sampled) comprised daily
samples for outlet and inlet flue gas. Hence, the corresponding sample com-
ponents from both trains were extracted together, i.e., filters, cyclone catch,
train rinsings, and resin cartridges. All extracts resulting from the two
trains were then combined.
All filters and cyclone catches were weighed prior to extraction to al-
low estimation of particulate emissions. However, the filters were not des-
iccated to constant weight according to the Method 5 procedures in order to
maintain sample integrity for subsequent organic analyses. Hence, the par-
ticulate emissions estimates may not be valid.
17
-------
Sompl* Extract
Short Packed Column
GC/Holl (TOCI)
HRGC/Hall-FIDor
HRGC/FID Screen
TIER 1
Add Internal Standard
Anthracene - d]Q
HRGC/MS
(Scanning) Surrogates •»•
Pol/cyclic Organic Compounds
Add Internal Standard
2,3,7,8- Tetrachlorodibenzo-p-dioxin-
37,
HRGC/AAS-SIM
Chlorinated Polycyclic Organic
Comoounds (Bianenyls, Dioxira. Purans)
Hold
HRGC/HRMS-SIM
Confirmation
• Hold
Interlaboratory Verification
HRGC/HRMS-SIM
TIER 2
Figure 4. General analytical scheme.
18
-------
Grab samples—Portions of the ash, fuel, and aqueous samples were com-
posited according to a schedule provided by RTI to form daily and shift com-
posites for each sample type for selected sampling days. Fly ash, bottom ash,
and coal from the Ames site were prepared prior to compositing by pulverizing
in a ceramic ball mill with stainless steel balls.
Plant background air samples—The single combustion air sample collected
each day was extracted and analyzed individually. Prior to extraction, the
filters were weighed to allow estimation of the total particulate catch.
Sample Extraction—
Solid samples—In order to determine the most appropriate extraction
procedure, a number of solvent and extraction systems were evaluated using
samples of Ames fly ash spiked with selected PAH's and 1,2,3,4-TCDD. Chlor-
inated solvents were avoided in order to minimize the possibility of produc-
ing chlorinated species during the extraction. Preliminary evaluations of
simple sample-solvent contact techniques added by mechanical or ultrasonic
agitation produced low recoveries. Subsequent evaluations were focused on
Soxhlet and reflux procedures. Table 2 summarizes the results of evaluations
of seven sample pretreatment and solvent system combinations using Ames fly
ash spiked with selected PAHs and 1,2,3,4-TCDD. Pretreatment with water and
Soxhlet extraction with benzene provided the highest recovery for all spiked
compounds. The average recovery for the nine compounds was 81%. The range
of recoveries obtained with this procedure was 56 to 107%.
The influence of pretreatment with water on the extractability of the
target compounds is not clear. However, a general improvement in recoveries
was observed for extractions with acetone/cyclohexane azeotrope when water
was added to the ash prior to extraction. Similar effects have been reported
for soil and sediment extraction by many researchers. Possibly, the water
hydrates cations in the ash that tend to associate with the mobile 7t-cloud of
polynuclear species so that they are more easily extractable.
Some researchers have reported good recoveries with procedures involving
pretreatraent with aqueous acid and extraction with aromatic solvents, e.g.,
pretreatment with 1 N HC1 and extraction with toluene.6 However, this pro-
cedure was determined to be unsatisfactory for several reasons. Acid pretreat-
ment may encourage degradation of some compounds. Reflux or Soxhlet extraction
with toluene must be conducted at a higher temperature than for benzene (the
boiling points of toluene and benzene are 111 and 80°C, respectively) so that
thermally unstable and relatively volatile compounds may be lost. In addition,
toluene extracts cannot be conveniently concentrated using Kuderaa-Danish
evaporation over a steam or hot water bath.
All solid samples were Soxhlet extracted with benzene for 8 to 16 hr.
The entire sample was extracted for the flue gas train components. Twenty-
gram aliquots of coal, refuse, refuse-derived fuel (RDF), bottom ash, and fly
ash were extracted. The fly ash was mixed with 10 ml of prepurified water
just prior to analysis. All samples were spiked with the two surrogate spik-
ing compounds, d8-naphthalene and d12-chrysene, just prior to extraction.
However, since the extracts for various flue gas components were later com-
bined, only one component for each flue gas sample was selected for surrogate
19
-------
TABLE 2. RECOVERY OF SELECTED PAHs AND 1,2,3,4-TCDD FROM AMES FLY ASH
% Recovery
Compound
Phenanthrene
Anthracene
Fluoranthene
Pyrene
1,2,3,4-TCDD
Chrysene
Benzo[a]pyrene
Indeno [ 1 , 2 , 3-c , d ] pyrene
Benzo [ g ,h , i ] perylene
Average
A
62
49
60
64
72
38
26
15
17
45
B
76
67
61
60
54
40
28
20
24
48
C
60
48
65
65
74
NSa
35
27
25
50
D
63
63
68
68
75
NS
52
40
41
59
E
62
49
60
64
72
38
26
15
17
44
F
46
42
25
24
67
15
8
0
0
25
G
102
107
94
86
81
73
69
58
56
81
Note: A. Soxhlet 16 hr, cyclohexane, dry fly ash (20 g).
B. Same as A except 5 ml 1^0 •»• 5 ml acetone added to fly ash.
C. Soxhlet 16 hr, acetone/cyclohexane azeotrope (67% acetone).
0. Same as C except 5 ml H20 added to fly ash (80% cyclohexane).
E. Soxhlet 16 hr, cyclohexane/ethanol azeotrope + 10 ml water
on fly ash (20 g).
F. Reflux 4 hr with 250 ml H20 + 50 ml toluene.
G. Soxhlet 16 hr with benzene + 10 ml H20 added to 20 g fly ash.
a NS = No chrysene in spike.
20
-------
spiking. The component selected was varied so as to provide some recovery
data for all components.
The extracts from coal, refuse, and RDF were washed with three 100-ml
portions of prepurified water to remove polar interferences. The extracts
from all solid samples were dried by passage through short columns of pre-
extracted anhydrous sodium sulfate before concentration to 2 to 10 ml in
Kuderna-Danish evaporators. The extracts were further concentrated under a
gentle stream of dry nitrogen. The final extract volume was typically 1.0
ml. However, some extracts were analyzed at volumes ranging from 0.20 to
10.0 ml. All extracts were spiked with the internal standard for scanning
HRGC/MS, d10-anthracene, prior to analysis.
Aqueous samples—All aqueous samples, i.e., flue gas rinses, first ira-
pinger waters, overflow waters, raw waters, etc., were batch extracted in
separatory funnels with three 60-ml portions of cyclohexane. As in the case
of the solid samples, the aqueous samples were spiked with the surrogate spik-
ing compounds just prior to analysis. The resulting extracts were dried and
concentrated to 0.20 to 1.0 ml according to the procedures described for solid
samples.
TOC1 Assay--
The TOC1 contents of all extracts were determined using a simplified GC/
Hall procedure. A short packed column and a rapid temperature program were
used to elute all chromatographable compounds with volatilities equal to or
greater than dichlorobenzene as a single peak. The TOC1 contents of sample
extracts were determined by comparing the area response of the peak with that
obtained for chlorinated standards. TOC1 results were expressed as chloride.
The specific parameters used by SwRI and GSRI for TOC1 assays of the Ames and
Chicago samples, respectively, are shown in Table 3. A sample TOC1 chroraato-
gram for an Aroclor 1254 PCS standard (GSRI procedure) is shown in Figure 5.
HRGC/Hall-FID Screening-
Sample extracts were screened by HRGC/Hall-FID prior to HRGC/MS analysis
to provide a preliminary indication of their halogenated and hydrocarbon con-
tents. In addition, the Hall responses were used to help identify elution
times on which to focus examination of the subsequent mass spectral data for
halogenated compounds. The specific parameters used by SwRI and GSRI are
shown in Table 4. Fused silica capillary columns were used with Grob-type
capillary injection systems operated in the splitless mode. GSRI did not have
a fused silica column effluent splitter available; hence, extracts from the
Chicago plant were screened using FID detection only.
Scanning HRGC/MS—
Sample extracts were analyzed by HRGC/MS to determine the target PAH com-
pounds and to allow identification and quantitation of specific chlorinated
compounds. The primary determinations of surrogate spiking compound recover-
ies were made from the HRGC/MS data. The chromatographic parameters utilized
were essentially identical to those used for the HRGC/Hall-FID screening.
21
-------
TABLE 3. TOC1 ANALYSIS PARAMETERS
Parameter
SwRI
(Ames samples)
GSRI
(Chicago NW samples)
Column
Packing
Carrier gas
Column temperature
External standard
compound
0.9 m x 4 mm ID, glass
2.5 can of 10% SP-2100
UltraBond
He at 60 ml/min
60°C for 3 min, then
to 230°C at 40°C/min
ch.lorobiph.enyl
1.0 m x 2 mm ID, glass
3.8 cm of 2.5% SE-30 on
80/100 mesh Chromosorb G,
rest of column filled
with 80/100 mesh glass
beads
He at 30 ml/min
60°C for 3 min, then to
250°C at 40°C/min
Aroclor 1254
22
-------
25 ng Aroclor 1254
Attenuation - 500
in
0)
Vent Valve
Closed
8
Time (Minutes)
12
16
Figure 5. TOC1 chromatogram for Aroclor 1254.
23
-------
TABLE 4. HRGC SCREENING PARAMETERS
SwRI GSRI
Parameter (Ames samples) (Chicago NW samples)
Column 30 m fused silica, 30 m fused silica,
wall coated with SE-30 wall coated with SE-30
Column temperature 100°C for 5 min, then 60°C for 2 min, then
to 300°C at 10°C/min to 300°C at 10°C/min
Detectors Hall-FID, 1:1 split FID
During the runs, the spectrometer was repetitively scanned over the range m/e
35 to 550 at 1.0 sec/scan. The PAH compounds, including the surrogates, were
identified using three extracted ion current plots (EICPs). The criteria for
compound identification are coincident peaks in all EICPs at the appropriate
retention time with the characteristic response ratios. Compounds identified
were quantitated by comparing the EICP response for the most abundant ion with
that for the same compound in a mixed standard solution.
Tier 2 Methods
Following completion of the tier 1 chemical analyses, RTI conducted a
statistical analysis of the TOC1 results and constructed a preliminary design
for the nationwide survey based on the observed TOC1 variabilities. The pre-
liminary survey design specified sampling programs of 5 and 3 days duration
for coal-fired and refuse-fired plants, respectively. Hence, in order to al-
low inclusion of the pilot study data in the survey data set, the extracts
were composited prior to further analysis to simulate a 5-day test at the Ames
plant and a 3-day test at the Chicago plant. The compositing scheme, provided
by RTI, is shown in Table 5. The composite extracts for each composite day
were prepared by combining equal volumes of daily composites from the desig-
nated sample days. This necessitated the preparation of daily composites from
shift composite extracts or individual sample extracts for many samples and
sample days.
24
-------
TABLE 5. EXTRACT COMPOSITING SCHEME FOR TIER 2 ANALYSES
Sample days combined
Composite day Ames samples Chicago samples
I 3/2, 3/15 5/6, 5/9, 5/16
II 3/13, 3/22 5/7, 5/10, 5/12
III 3/14, 3/19 5/11, 5/13, 5/15
IV 3/17, 3/20
V 3/3, 3/23
The composite extracts were screened by HRGC/Hall-FID or HRGC/FID prior
to analysis for PAH compounds by scanning HRGC/MS, and for PCBs, PCDDs, and
PCDFs by HRGC/MS-SIM. Only extracts for which positive responses were ob-
tained for PCDDs and PCDFs were analyzed by HRGC/HRMS-SIM.
HRGC/Hall-FID and HRGC/FID Screening—
The composited extracts were screened by HRGC/Hall-FID (Ames samples) or
HRGC/FID (Chicago samples) by the procedures described for Tier 1 screening
except that fused silica capillary columns wall-coated with SE-54 were used.
Scanning HRGC/MS Analysis—
The HRGC/MS procedures employed for the composite extracts were essen-
tially the same as was used for tier 1 analyses. The target PAH compounds
were determined and any other compounds observed were identified by manual
and computer-assisted spectral interpretation. Quantitative estimates for
all compounds identified were based on responses versus responses for the
same or similar compounds in standard solutions.
HRGC/MS-SIM Analysis--
All composite extracts were screened for the presence of PCDDs and PCDFs
by HRGC/MS-SIM. The chromatographic parameters used by SwRI and GSRI for the
Ames and Chicago extracts, respectively, were the same as were used for scan-
ning HRGC/MS analyses. The ions selected for detection were the two most abun-
dant ions in the molecular cluster for each compound. No positive responses
were detected in any of the Ames extracts. Positive responses were detected
in composite flue gas extracts from the Chicago plants. However, interfering
materials in the extracts hindered reliable identifications.
Three composite flue gas extracts from the Chicago plant were cleaned by
a vigorous base treatment, an acid treatment, and an alumina chromatographic
procedure specifically developed for PCDD and PCDF assays. The composited
extracts were split into two fractions each. One fraction was spiked with
l,2,3,4-tetrachlorodibenzo-p_-dioxin and octachlorodibenzo-p_-dioxin, and the
other fraction was not spiked. The extracts were stirred with 45% aqueous
KOH solution at ambient temperature for 3 hr. The mixture was extracted with
hexane and the extract was washed with concentrated sulfuric acid until the
washes remained colorless. The extract was concentrated and chromatographed
on an alumina column using dichloromethane as the eluting solvent.
25
-------
The cleaned extracts were analyzed at MRI by KRGC/MS-SIM. The instru-
mental parameters are listed in Table 6. These analyses were conducted using
a high resolution mass spectrometer operated at 1,000 resolution (10% valley).
Positive PCDD and PCDF responses were detected in all extracts. Since low
resolution mass spectrometric analysis of PCDDs and PCDFs in environmental
extracts may be obscured by the presence of similar chlorinated aromatic com-
pounds (e.g., PCB's), these extracts were held for analysis by capillary gas
chromatograpy/high resolution mass spectrometry using selected ion monitoring
(HRGC/HRMS-SIM).
TABLE 6. HRGC/MS PARAMETERS USED FOR ANALYSES OF PCDDs AND PCDFs IN
COMPOSITE CHICAGO NV FLUE GAS OUTLET EXTRACTS
Column
Column temperature
Injector
Spectrometer resolution
Scan rate
Ions selected (m/e)
Trichlorodibenzo-£-dioxin
Tetrachlorodibenzo-£-dioxin
Pentachlorodibenzo-£-dioxin
Hexachlorodibenzo-£-dioxin
Heptachlorodibenzo-£-dioxin
Octachlorodibenzo-£-dioxin
Trichlorodibenzofuran
Tetrachlorodibenzofuran
Pentachlorodibenzofuran
Hexa chlo rodibenzo furan
Heptachlorodibenzofuran
Octachlorodibenzofuran
18 m fused silica wall-coated with SE-54
110°C for 2 min, then to 325°C at 10°C/
min
J&W on-column
1,000 (10% valley)
1-2 sec/scan (3-5 ions/scan)
285.9, 287.9
319.9, 321.9
353.9, 355.9
389.8, 391.8
423.8, 425.8
457.7, 459.7
269.9, 271.9
303.9, 305.9
337.9, 339.9
373.8, 375.8
407.8, 409.8
441.7, 443.7
The Ames and Chicago composite flue gas outlet extracts were also analyzed
at MRI for PCBs by HRGC/MS-SIM. The instrumental parameters and ions selected
are shown in Table 7. The focused ions were switched several times during a
single HRGC/MS run so that all PCB compounds could be analyzed in two runs,
one for odd chlorine substitutions and a second for even chlorine substitu-
tions. PCBs were quantitated by comparing the total area response for all
26
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TABLE 7. HRGC/MS-SIM PARAMETERS USED FOR ANALYSIS OF PCBs
IN COMPOSITE FLUE GAS OUTLET EXTRACTS
Column 15 m fused silica, wall-coated with DB-5
(a specially bonded SE-54 coating)
Column temperature 60°C for 2 min, then to 265°C at 8°C/min
Injector Grob-type, splitless
Spectrometer resolution 1,000 (10% valley)
Scan rate 1-2 sec/scan (2-4 ions/scan)
Ions selected (m/e)
Dichlorobiphenyl 221.9, 223.9
Trichlorobiphenyl 255.9, 257.9
Tetrachlorobiphenyl 291.9, 293.9
Pentachlorobiphenyl 323.9, 325.9
Hexachlorobiphenyl 357.8, 359.8
Heptachlorobiphenyl 393.8, 395.8
Octachlorobiphenyl 427.7: 429.7
Nonochlorobiphenyl 461.7, 463.7
compounds identified for a specific chlorine substitution with the area re-
sponse for a specific isomer of the same chlorine substitution number. For
example, total trichlorobiphenyls were quantitated against 2,5,2'-trichloro-
biphenyl. The PCB isomers used for quantitation are listed in Table 8.
TABLE 8. PCB COMPOUNDS USED FOR DETERMINATIONS IN COMPOSITE
FLUE GAS OUTLET EXTRACTS
2,2'-Dichlorobiphenyl
4,4'-Dichlorobiphenyl
2,5,2'-Trichlorobiphenyl
2,4,2',4'-Tetrachlorobiphenyl
2,4,2',5'-Tetrachlorobiphenyl
2,3,4,5,6-Pentachlorobiphenyl
2,4,6,2',4',6'-Hexachlorobiphenyl
2,3,4,2',3',4'-Hexachlorobiphenyl
2,3,4,5,6,2',5'-Heptachlorobiphenyl
2,3,4,5,2',3',4',5'-Octachlorobiphenyl
Decachlorobiphenyl
27
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HRGC/HRMS-SIM Confirmatory Analysis of PCDDs and PCDFs—
PCDDs and PCDFs were identified and quantitated in the composite Chicago
flue gas outlet extracts by HRGC/HRMS-SIM. The instrumental parameters em-
ployed were the same as for low resolution screening at MRI except that the
spectrometer was operated at 10,000 resolution (10% valley). The selected
ions monitored are listed in Table 9.
In order to achieve maximum sensitivity while minimizing the number of
HRGC/HRMS-SIM runs, ions for a specific chlorine substitution for both dioxins
and furans were monitored in a single run. For example, trichlorodibenzo-£-
dioxins and trichlorodibenzofurans were analyzed in the same run. However,
the tetra-substituted compounds were analyzed in separate runs to provide even
better sensitivity for the most toxic PCDDs and PCDFs.
The PCDD and PCDF compounds identified were quantitated by comparing the
total area response for all compounds of a specific chlorine substitution with
the area response for a specific isomer of the same chlorine substitution
number. The specific PCDD and PCDF isomers used for quantitation are listed
in Table 10. Compounds for which no corresponding authentic compound was
available were quantitated against the most similar compound. Hence, hexa-
chlorodibenzofurans were quantitated against hexachlorodibenzo-p_-dioxin. The
response factor used for pentachlorodibenzodioxins was the average of responses
for tetra- and hexa-isomers. Tetrachlorodibenzo-£-dioxins were quantitated
using 37Cl4-2,3,7,8-tetrachlorodibenzo-£-dioxin as an internal standard. Since
discrete isomers were not identified, only totals were determined for each
chlorine substitution.
A separate HRGC/HRMS-SIM analysis with a 60-m Carbowax column was used
to determine 2,3,7,8-tetrachlorodibenzo-£-dioxin. The instrumental parameters
are shown in Table 11. The Carbowax column, although providing good separa-
tion of specific tetra-isomers, required longer analysis times and caused
signficant peak broadening. Hence, it was not used for general PCDD and PCDF
analyses. The internal standard method employing 37Cl-labeled compound was
used for quantitation.
Quality Assurance Procedures
The analytical quality assurance program consisted of the use of surrogate
spiking compounds in all samples; the use of internal standards for most GC/MS
analyses; analyses of field blanks and method blanks; and interlaboratory com-
parison studies for selected determinations. Surrogate spiking compounds were
used as the primary analytical quality indicators. The two stable isotope
labeled surrogates, dg-naphthalene and d12-chrysene, were spiked immediately
prior to extraction into all samples at 5 to 10 times the limits of detection.
The surrogate concentrations were determined using scanning HRGC/MS data.
The surrogate compound recoveries provide indications of overall quality of
the extraction and extract concentration procedures.
All scanning HRGC/MS analyses were conducted using AIQ- anthracene as the
internal standard. Tetrachlorodibenzo-£-dioxin analyses by HRGC/HRMS-SIM were
conducted using 37Cl4-2,3,7,8-tetrachlorodibenzo-£-dioxin.
28
-------
TABLE 9. IONS MONITORED DURING HRGC/HRMS CONFIRMATORY ANALYSIS
OF PCDDs AND PCDFs IN COMPOSITE CHICAGO NW FLUE
GAS OUTLET EXTRACTS
Compound m/e
Trichlorodibenzo-£-dioxin 285.9355, 287.9325
Tetrachlorodibenzo-£-dioxin 319.8965, 321.936
37Cl4-2,3,7,8-Tetrachlorodibenzo-£-dioxin 327.8847
(internal standard)
Pentachlorodibenzo-£-dzoxin 353.8887, 355.8858
Hexachlorodibenzo-g-dioxin 389.8157, 391.8127
Heptachlorodibenzo-£-dioxin 423.7688, 425.7659
Octachlorodibenzo-£-dioxin 457.7377, 459.7347
Trichlorodibenzofuran 269.9406, 271.9376
Tetrachloridibenzofuran 303.9017, 305.8987
Pentachlorodibenzofuran 337.8938, 339,8909
Hexachlorodibenzofuran 373.8208, 375.8178
Heptachlorodibenzofuran 407.7739, 409.7710
Octachlorodibenzofuran 441.7428, 443.7398
TABLE 10. PCDD AND PCDF COMPOUNDS USED FOR DETERMINATIONS IN
COMPOSITE CHICAGO NW FLUE GAS OUTLET EXTRACTS
1,2,4-Trichlorodibenzo-£-dioxin
1,2,3,4-Tetrachlorodibenzo-£-dioxin
2,3,7,8-Tetrachlorodibenzo-£-dioxin
Hexacnlorodibenzo-£-dioxin
(isomer unknown)
Octachlorodibenzo-£-dioxin
2,3,7,8-Tetrachlorodibenzofuran
Octachlorodibenzofuran
29
-------
TABLE 11. HRGC/HRMS PARAMETERS USED FOR ANALYSIS OF 2,3,7,8-TETRACHLORO-
DIBENZO-E-DIOXIN IN COMPOSITE CHICAGO NW FLUE GAS OUTLET EXTRACTS
Column
Column temperature
Injector
Spectrometer resolution
Scan rate
Ions selected
Tetrachlorodibenzo-£-dioxin
37C142,3,7,8-Tetrachloro-p_-
dioxin (internal standard)
60 m fused silica, wall-coated with
Carbowax 20M
110°C for 2 min, then to 220°C at
10°C/min
J&W on-column (1 |Jl injection)
10,000 (10% valley)
1 sec/scan (3 ions)
319.8965, 321.8936
327.8847
Analyses of field blanks and method blanks (i.e., laboratory blanks) pro-
vided indications of possible sample contamination due to contact with the
sampling and analysis equipment as well as general sample and extract handling.
Field blanks comprised 10 to 15% of the total samples and included unused com-
ponents of the flue gas sampling train, a complete sampling train for each
plant (as described in Section 5), unused sample containers, and aliquots of
solvents used for sample recovery at the plant. Method blanks were extracts
prepared in the same manner as sample extracts although no samples were ex-
tracted.
Since the tier 1 analyses were conducted by two laboratories (SwRI and
GSRI), interlaboratory comparison studies were conducted to check the compar-
ability of the resulting data. Three such studies were conducted. Compara-
bility of TOC1 results was investigated by a set of TOC1 check extracts pre-
pared by MRI and by an exchange of selected sample extracts between SwRI and
GSRI. Check samples of fly ash spiked with selected chlorinated compounds
were also prepared by MRI and analyzed by SwRI and GSRI using HRGC/Hall and
scanning HRGC/MS. In addition, extracts in which positive responses were ob-
served for PCDDs and PCDFs by HRGC/HRMS-SIM were submitted to Robert Harless
at EPA's Environmental Monitoring and Support Laboratory in Research Triangle
Park for collaborative analysis. The results of these analyses are described
in Section 9.
30
-------
CADMIUM
Samples of fly ash weighing 0.1 g or samples of bottom ash weighing 0.1
to 1 g were placed in 150-ml beakers that had been precleaned with nitric
acid. Ten milliliters of aqua regia were initially added to each ash sample.
The samples were gently heated and allowed to reflux until the evolution of
yellow fumes subsided. An additional 5 ml of aqua regia was then added, and
the ash was allowed to continue digesting. Another 5 ml of aqua regia was
added to all samples, and the samples were allowed to digest for at least 20
more min.
The samples were permitted to cool, and all of the material was trans-
ferred to 50-ml plastic centrifuge tubes. Centrifugation was accomplished at
2,500 rpm for approximately 5 min. The supernatant liquid was transferred by
Pasteur pipets to the original beakers. Deionized water was added to the
residue in the centrifuge tubes, the mixtures were agitated, the tubes were
once again centrifuged, and the supernatant was added to that in the original
beakers. This washing procedure was repeated again. The residue remaining
in the centrifuge tube was then washed three times with a 5% (v/v) nitric acid
solution. For each washing, 5 ml of the acid solution was added to each sam-
ple, and the samples were centrifuged and processed as described above.
The final solutions in the beakers (approximately 85 ml) were returned
to the hot plate and heated gently until the volume of the solution was re-
duced to 20 ml. The solutions were allowed to cool, filtered through Whatman
No. 4 filter paper, and diluted to 50 ml with deionized water.
A modification of this procedure was used for the digestion of refuse
and filter samples. Fifteen milliliters of aqua regia and 10 ml of deionized
water were added to 1-g portions of refuse or to the entire air filter. Tap
water and probe-rinse water were digested by adding 3 ml of concentrated nitric
acid and 1 ml of concentrated hydrochloric acid to 200 ml of sample and heating
gently until the volume was reduced to less than 50 ml. The digested sample
was diluted to 50 ml with deionized water. Solutions prepared by digestion
of solid samples were analyzed by flame atomic absorption spectrophotometry
(AAS) using an air-acetylene flame. Water samples were analyzed by heated-
graphite atomization AAS.
A comprehensive QA/QC control program was conducted for cadmium analy-
ses. The program included analysis of the National Bureau of Standards coal
fly ash standard reference material, aqueous solutions of cadmium prepared
in-house, fortified and duplicate samples, and reagent blanks. Samples were
usually digested and analyzed in groups of eight: four distinct samples, a
duplicate of one of the original four which had been fortified with 10 pg of
cadmium, a duplicate of another of the original four which was unaltered, a
quality-control sample, and a reagent blank. The fresh dilutions of a stan-
dard solution of cadmium were prepared on each day of analysis and were used
to calibrate the AAS.
The precision and accuracy of the analytical method used by GSRI were
determined by analysis of a coal fly ash standard reference material from the
National Bureau of Standards (NBS) and fortified fly ash from the Chicago
31
-------
Northwest Incinerator. The average and standard deviation of the percentage
of cadmium recovered by analysis of four replicate samples of the NBS coal
fly ash was 98 ± 11. Analysis of seven replicate samples of incinerator fly
ash showed the cadmium concentration to be 260 Mg/g. The recovery of cadmium
from the incinerator fly ash was determined by analysis of samples fortified
with cadmium. The results of the recovery study are presented in Table 12.
An average of 95 ± 15% of the cadmium was recovered from the fortified sam-
ples. SwRI provided QA measures in terms of analysis of all sample types
spiked at the levels shown in Table 13.
32
-------
TABLE 12. RECOVERY OF CADMIUM FROM FORTIFIED SAMPLES OF
FLY ASH FROM THE CHICAGO NW INCINERATOR
Cadmium in Cadmium
original added to
sample sample
Sample (Mg/g)3 (Mg/g)
1
2
3
4
5
6
7
Mean recovery
260 100
260 99
260 100
260 97
260 100
260 100
260 100
Cadmium
determined
in fortified
sample (Mg/g)
330
370
360
350
360
370
340
Standard deviation
Percent
cadmium
recovered
70
111
100
93
100
110
80
95
15
a Average of seven replicate analyses.
TABLE 13. RECOVERY OF CADMIUM FROM FORTIFIED SAMPLES
FROM THE AMES MUNICIPAL POWER PLANT
Sample type
Fly ash
Bottom ash
Refuse
Coal
Aqueous
Spike level
0.5 Mg/g
0.5 Mg/g
0-1 Mg/g
0-5 Mg/g
4 (Jg/100 ml
Recovery
97
93
98
94
110
33
-------
SECTION 7
FIELD TEST DATA
AMES MUNICIPAL POWER PLANT, UNIT NO. 7
The field test activity at the Ames Municipal Power Plant took place
from February 25, 1980 to March 28, 1980. All required tests were completed
and all recovered samples were sent to SwRI for analysis.
A summary of the reduced data for flue gas sampling on a daily basis as
calculated from the field data sheets is presented in Table 14. The follow-
ing abbreviations are used throughout this report: DSCF = dry standard cubic
feet, DSCM = dry standard cubic meters, ACFM = actual cubic feet per minute,
DSCFM = dry standard cubic feet per minute, and DSCMM = dry standard cubic
meters per minute. The data listed are corrected to standard conditions, i.e.,
20°C (68°F) and a barometric pressure of 29.92 in. of mercury (1.0 atm). Per-
cent isokinetic is the sampling velocity expressed as percent of the gas ve-
locity in the stack or duct at the sampling points. Events that may have
created uncertainties as to the quality of the flue gas sampling procedures
are noted. Due to severe weather conditions, flue gas outlet samples were
not collected on test days 3 to 11.
Process data was monitored on an hourly basis during the entire testing
period. Table 15 presents a summary of the pertinent process data as averages
for daily 24-hr plant operation and operation during the flue gas sampling
durations. The process data gathered indicated that the operating conditions
fluctuated in patterns related to the amount of electricity generation demand
placed on the boiler, and on the type of fuel being burned to meet that de-
mand. Overall fluctuation consisted of two components. The first component
was the daily variation. The load peaked in the afternoon and fell to a min-
imum before dawn. The second type of variation was caused by sudden opera-
tional changes, which was due to reduced power generation for various reasons
such as the buying of cheaper power from a private utility, or the reduction
in flow of RDF to the boiler.
Unit No. 7 was generally operated between a range of 16 to 35 MW. Pro-
duction over 35 MV placed considerable wear on the unit, and was avoided when-
ever possible. Production under 16 MW introduced instability and the possi-
bility of large transient swings in operating conditions. Usually the boiler
was operating close to one of these limits. It operated at 35 MW during peak-
loads because the load of the serviced community was over 35 MW. Production
was reduced to 16 MW when off-peak power could be bought more cheaply from
neighboring utilities.
34
-------
TABI.E 14. DAILY DATA SUMHAKIES F«H KI.UE CAS SAMPLING, AtlKS MUNICIPAL I'OWEK 1'I.ANT. UNIT NO. 7
U)
Lfl
Half
(1980)
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
3-11
3-12
Teal Siu»ling
no. location
Inlet
1 Outlet
2 Inlet
Outlet
Inlet
1 Outlet
Inlet
* Outlet
5 Inlet
6 Inlet
7 Inlet
„ Inlet
o
9 Inlet
10 Inlet
" „,.,,
North
South
'"j
Northe
North'
South'
South
I&4
2S3
North
South
2*"8
North
South
IS4*
2S3h
North
South
North
South
North
South
North}
North)
South'
South1
North*
South
North
South
Nnrlli*
South
Saaplr voluae
DSCF
204.62
262.52
214.10
243.02
173.54
126.93
212.05
101.52
324.36
307.31
184.21
252.78
256.88
246.73
367.65
323.17
368.68
365.42
351.42
333.61
74.03
294.81
121.92
140.22
130.81
193.61
394.09
383.01
DSCH
5.80
7.43
6.06
6.88
4.92
3.60
6.01
2.88
9.19
8.70
5.22
7.16
7.28
6.99
10.41
9.15
10.44
10.35
9.95
9.45
2.10
8.35
3.45
3.97
3.70
5.48
11.16
10.85
_ Gai^colkuovltiqu' Slack
Oj CO, CO TIIC lrin|ieraturc Molecular Hoislure
t X »!>• PUB °F weight X
4.48
4.48
6.34
6.34
4.38
4.33
4.33
4.33
5.87
5.87
4.43
4.43
4.41
4.41
4.35
4.35
4.59
4.59
4.79
4.79
7.
7.
7.
7.
3.
3.
4.7
4.7
12.79
12.79
11.31
11.31
13.80
13.80
13.80
13.80
12.44
12.44
14.41
14.41
14.56
14.56
13.79
13.79
13.92
13.92
13.60
13.60
11.6
11.6
11.6
11.6
13.9
13.9
13.5
13.5
18.00
18.00
15.00
15.00
12.00
12.00
11.00
11.00
11.00
17.00
17.00
18.00
18.00
18.00
18.00
16.00
16.00
28.00
28.00
25.00
25.00
25.00
25.00
25.00
25.00
22.0
22.00
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
334.31
311.78
320.93
309.92
351.55
373.36
234.83
369.90
342.38
336.94-
370.46
352.55
361.09
349.23
363.83
347.46
351.00
335.86
377.55
359.83
316.83
364.73
344.38
315.88
352.09
130.65
374.75
356.59
29.01
29.35
29.30
29.31
29.34
29.32
29.41
29.39
29.31
29.31
29.56
29.30
29.49
29.38
29.28
29.18
28.14
29.27
29.19
29.16
29.19
29.16
29.20
29.17
29.31
28.25
29.49
29.30
9.95
7.15
6.32
6.24
8.39
B.59
7.81
7.97
7.45
7.48
7.43
9.48
8.14
9.03
8.93
9.72
18.32
9.18
9.56
9.75
7.79
8.05
7.78
8.02
8.59
17.13
6.98
8.48
Velocity Ca» ilowb
rt/cec ACFH DSCFH
29 09 247> 70° I4>.°°0
"'j9 296,000 182.000
37.78
46 61 650,300 376,000
37.15
ll.To 324'6°° 19°'60°
Jj'J" 346,200 193,100
J3-2J 333,300 189,800
"-9g 341.600 200,300
44'.OI 346.400 187.400
39;'2 312.000 171.460
30.27
36 '43 ««.300 286,000
27.38
*j'j3 351.900 196,200
l\'*l 355.400 201,000
liokinetlc
rate
DSCHH X
4 162 " "
*•'" 89.01
>••» IMS
.-°.«° ll:ll
107.14
5 397 96'33
5>J" 90.33
QC CQ
5'"7 H."
5 375 91 *3
b'3'5 104.10
5 671 97'28
*•*" 90.54
« ,nl 105.93
*• 99.65
4 ass l03-54
**8" 105.53
95.60
B 098 98'51
8'°98 106.23
50.55
5 555 88'8<1
5'"5 89.58
07 1 7
• AQ9 '
• 105.29
(continued)
-------
VAHI.I. I') (mill hiuril)
Date
(1980)
3-13
1-14
1-15
3-17
1-IB
3-19
3-20
1-22
1-21
~
Test Sfttf
II Hi Saaule uoliiuc
nu . IIM at Inn
Inlet
12 Outlet
Inlel
11 Outlet
Inlet
14 Outlet
Inlet
15 Outlet
Inlet
16 Outlet
Inlet
" Outlet
Inlel
'" Outlet
Inlet
19 Outlet
Inlet
20 Out let
North
South
IM
2M
North
South
IM
261
North
South
IM
2&1
North
South
IM
2&1
North
South
IM
North
South
IM
2&1
Northo
South
IM
263
North
South
IM
2&1
North
South
IM
263
nscr
150.46
369.82
158.98
305.29
374.34
352.11
367.77
351.36
276.77
26B.37
319.13
307.00
159.80
390.47
406.86
391.84
369.16
371.50
392.69
351.25
349.71
168.75
174.10
160.58
147.89
108.08
156.20
188.52
161.46
148.60
402.14
401.16
116.53
330.73
301.61
158.98
iisui
9.92
10.47
4.50
10.15
10.60
9.97
10.42
9.95
7.81
7.60
9.04
8.69
10.19
11.06
11.52
11.10
10.45
10.52
11.12
10.00
9.90
10.44
10.60
10.21
9.85
10.42
10.09
11.00
10.29
9.87
11.19
11.16
9.51
9.37
8.54
10.17
Gas l uufiuslt ion*
0, til, CO
X
1.14
1.14
5.17
5.17
1.70
1.70
5.11
5.11
6.11
6.11
8.17
8.17
1.71
1.71
5.41
5.41
1.82
1.82
5.42
5.42
3.60
3.60
5.30
5.10
1.80
1.80
6.00
6.00
1.60
1.00
5.10
5 10
6.00
6.00
9.70
9.70
X IT"
15.56 21.011
15.56 21.011
11.97 18.00
11.97 18.00
14.81 28.00
14.81 28.00
11.18 10.00
11.18 10.00
12.59 22.00
12.59 22.00
10.67 19.00
10.67 19.00
14.40 22.00
14.40 22.011
12.90 22.00
12.90 22.00
14.19 21.00
14.39 21.00
11.00 24 00
11.00 24.00
14.40 24.00
14.40 24.00
11.00 26.00
11.00 26.00
11.80 22.00
11. BO 22.00
12.50 17 00
1 2 . 50 1 7 . 00
14.20 18.00
14.20 18.00
12.711 18.110
12.70 18.110
12.60
12.60
10. Oil
10.00
SI irk
IIM* lrn|il'l At u ic
|I|IM
•. 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
« 2
< 2
< 2
• 2
< 2
< 2
< 2
< 2
»l
161.78
340.61
119 44
115.08
184.68
175.70
165.94
158.75
168 21
157.65
119.42
156 . 65
171.21
148.41
154.56
145.11
181.96
154.96
160.06
157.50
180.28
161.59
171.12
165.94
150.96
142.65
118.12
142.81
148.64
142.09
140 . 00
110.60
164.41
155.41
Iri4 . 1 »
llfl 11
Molri ill .11
U. 1*1.1
29.53
29 54
29 56
29.28
29 31
29.30
29.14
29.15
29.27
28.32
29.09
29.10
29 . lr.
29.44
29.21
29.25
29.29
29.17
29.24
29.18
29.29
29.17
29.01
29.24
29.11
29.19
29.29
29.21
29.16
29.41
29.19
29.24
2<3 . 26
28.69
28.82
29.28
Mil i si in e
I
8 61
8.54
7. 10
9.17
9.6;
9.70
9.60
9.50
8.14
7.68
7.88
7.81
B.B1
8.17
8.71
8.41
9.16
8.71
8.62
9.09
9.68
8.68
10.28
8.59
8.11
7.86
7.79
8.44
8.54
8.07
8.61
8.21
8.16
12.74
971
5.87
Vi-lurily
ll/tn
42.45
41.41
25.85
26.58
41 48
41.49
24.14
24.84
10.85
29 96
20.00
21.11
41.89
42.84
26.01
27.27
41.06
41.89
27.12
25.60
41.87
41.42
26.75
26.92
42.11
42.11
24.61
26.91
41 65
19.61
26.26
26.81
28.65
27.26
16.61
11 70
Cis
A(fll
112,100
126,700
116,000
106,506
240,400
257.500
115 ,(inu
112,100
115,900
128,600
317,100
114,500
111,100
121,200
121,400
110.700
221,100
226,400
Howh
Isnklnrl lr
rale
nstfii nsrmi i
187,100
191.600
185,400
170,100
115,400
152,100
189,000
191,500
186,100 .
187,800
184,100
185,100
191,000
188,400
185,000
195,500
121,500
112,800
5 298 l02 "
5'"8 102.21
».- :.:,;
».'« :::£
4 822 "-80
*•"* 96.74
102.11
'•"* 108.67
, ,«, 104.05
*'301 96.83
5 151 '°6 '"
5|KI 99.99
5423 '" •"
*• J 95.48
».»• S:i!
».™ K:K
5 218 l07'21
^•"' 97.16
101.01
S<2*6 92.62
5 408 " 2I
5<*OB 104.11
5 114 " °9
i.™* „ ,,
5 219 IOS '"
5>2:" 96.42
5517 l0*-10
5t5" 99.01
, ,.„ 101.54
1.440 ||S „
, ,/• no-*s
1'161 102.66
(rout inueil)
-------
TAIUK K (rum In.k-d)
.. - i»!> .. S1'1*1 ,, Isokinetlc
Date Test Sampling ^J?il!? ^°!'!aS °2 CO2 co TIIC trnpuraluir HnlciiiUr Huislnri- Velocity Cas _f lou t»te
(1980) no. location DSCF ns"lS t 1 PP* pp» "f uitiglu X ll/iicr ACl'ti DSCFH ~ OSCfifi %
1-24 21 Outlet 1,2. 130.42 3.69 5.4 13.2 <2 Io5.47 2".lr> 9.53 25.76 160.SOU 90,170 2553 103.72
3S4
3-2s 22 lnlel
3-26
Outlet
23 Inlet
Outlet
1.2.
3&4
Nurtli
South
1.2
3&4
122.79
326.82
344.98
138.67
3.48
9.26
9.77
3.93
5.4
6.00
6.00
4.80
13.2
12.60
12.60
13.70
< I
< 2
< 2
< 2
356.40
380.80
382.45
364.38
29. 10
29.13
29.14
29.24
9.92
9.17
9.09
9.26
24.58
37.23
37.40
26.42
153,200
295,100
164,700
87,030
162,500
93,240
2,464
4,602
2,640
101.06
106.24
118.43
106.64
a Average value* (or duration of te«t.
b Sun of Clou through total inlet anil total outlet.
c Lou volume collected due to high leak rate at end. Volume was corrected (or leak rate. Test quality [air.
d Lou voluaie collected due to freezing of iapingen. Teal quality was good.
e At 250 Bin. noted nozzle pointed in urong direction. Switched nozzle Iron 0.312 to 0.250 in. diameter tip to Maintain iaoklnelic flou.
Test quality uaa good lor gal and fair for particulale.
f Switched nozzle iron 0.312 to 0.237 in. dianeter lip to Maintain iiokiiii-l u flow.
g Due to aiiow and Icy conditions, no sample was obtained.
li Cancelled pur instructions of tl'A until 3/13/80.
I Switched nozzle from 0.250 to 0.310 In. diameter lip to Maintain isokinetic How.
j Switched nozzle I mm 0.310 to 0.240 with diameter lip lu Maintain iiokinetic lluw.
k Probe found broken al 140 Mill, nu saMplea retained. Trst restarted uilh a new prohe but only one hall the duct was traversed due to freezing
conditions. Test <|nallly uaa fair.
I No soI in Ions retained due to backup of Ilj02 into all iMplngers. The resin, cyclone and filters uere retained. Test quality was fair.
M QA tesl cancelled alter 240 M!II due to leak al one of the probe lips.
n Test slopped at 296 •((! due to c out i HIM I freezing ol the train . <>i.|.om-nls . Test quality was lair In |umr.
u 1'rohleMi uilh I In- Ualrlle liap fret-zing and Irak* in the Teilmt limr were rut nmiifrril. Thr lilli-r and traps were rculnccil to solve leak proMea)!i.
Test quality was l.iir lu good.
p QA lesl only No samples were aavrd |M-C*IIM- 1107.71 r was in Ihr wrung illmlion ami I hr l<-st would not hi' iluplic.ilr.
-------
TABLE 15. AVERAGE PROCESS DATA FOR THE AMES MUNICIPAL
POWER PLANT, UNIT NO. 7
24-hr
Process data
Steam flow rate
(1,000 Ib/hr)
Steam pressure (psig)
Steam temperature (°F)
Feedwater flow rate
(1,000 Ib/hr)
Feedwater temperature
Fuel feed rate 1
(1,000's Ibs/hr) 2
Fuel oil (gal./hr)
I.D. fans amps
I.D. fans pressure (psig)
F.D. fans amps
F.D. fans pressure (psig)
Furnace draft (psig)
Flue gas temperature (°F)
Boiler exit3
ESP inlet3
Ambient temperature (°F)
Ambient pressure in. Hg
Mean
255
852
892
263
366
30.4
30.6
10.7
45
5.5
29
4.0
0.6
667
323
31
29.01
Standard
deviation
35
3
3
37
16
3.2
3.4
11.2
1
0.7
1
0.6
-
24
15
13
0.13
Flue gas
test duration
process data
Mean
289
853
896
298
377
33.1
-
46
5.9
30
4.5
0.6
674
326
393
29.01
Standard
deviation
50
3
5
51
19
4.2
-
2
1.0
1.1
0.9
0.1
31
18
20
0.13
a Not total time means.
38
-------
The daily mean of gross electrical output (24-hr basis) was typically
between 29 and 32 MW due to boiler operation at full output for a large por-
tion of the day. In fact, the hourly readings indicated that output was
rarely below 35 MW between the hours of 8 AM and 10 FM or longer. During
non-peak hours the boiler operated between 16 and 25 MW, depending on load
and the amount of power being purchased from neighboring utilities.
Fuel consumption varied directly with the amount of electricity produced.
Of the three types of fuels used in Unit No. 7 (coal, RDF, and fuel oil), coal
was used in the largest quantity. The amount of RDF burned was limited to
approximately 17% in terms of the total heat produced. This was because RDF,
due to its lower heating value, cannot sustain sufficient temperatures to
maintain required boiler efficiency and steam quality. Also, RDF requires a
longer residence time in the boiler for complete combustion, and this places
another physical restriction on the amount of RDF in the fuel mixture. Fuel
oil is used sparingly, and only as an igniter to insure flame continuity dur-
ing soot blowing. The large variations in fuel oil consumption noted in Table
15 were more related to operating practices than to the boiler requirements.
The means and standard deviations for coal consumption follow those of
the gross electrical output. This indicates that coal consumption is closely
related to electrical output, as expected. However, these daily averages mask
out one important effect. The amount of coal burned depends on whether there
is RDF in the mixture or not. All other things being equal, the flow of coal
will always go up or down, depending on whether RDF is being removed or intro-
duced into the mixture, respectively.
Data for the steam cycle in the boiler are also listed in Table 15 on an
average basis. Examination of the data on a daily basis indicated that the
steam and feedwater flow rates fluctuate in a daily cycle, with means and
standard deviations following the gross electrical output. However, the
values for steam temperature and pressure remain fairly constant. The feed-
water temperature also varied. It was higher on days of high electricity pro-
duction, and lower on days of low production.
The induced and forced draft fan measurements listed in Table 15 are of
limited significance, since they did not respond to increases in production
with greater airflows and correspondingly greater current consumption. The
furnace draft data indicated little or no correspondence to any of the other
measured data. Most of the flue gas and ESP inlet temperature readings were
incomplete as they did not cover the entire 24-hr day. Most of this informa-
tion was recorded during peak operation, and may therefore be considered rep-
resentative for peak operation conditions. Both the flue gas and ESP inlet
temperatures decreased during off-peak periods.
The continuous supply of RDF to the boiler during the test was found to
be unreliable. The RDF conveyors which feed Unit No. 7 were prone to jamming
and required frequent maintenance. Often the RDF supply ran out because the
solid waste recovery plant was experiencing mechanical problems, or had run
out of refuse to process. The durations of RDF-firing during the flue gas
sampling periods are shown in Table 16 along with the mean coal feed rates.
39
-------
TABLE 16. FUEL COMBUSTION DURING FLUE GAS SAMPLING
Date
3/2/80
3/3/80
3/4/80
3/5/80
3/6/80
3/7/80
3/8/80
3/9/80
3/10/80
3/11/80
3/12/80
3/13/80
3/14/80
3/15/80
3/17/80
3/18/80
3/19/80
3/20/80
3/22/80
3/23/80
3/24/80
3/25/80
3/26/80
Test period
1120-2000
0920-1855
0900-1800
0900-1820
0840-2140
0850-2220
0840-2215
0830-2211
0810-1733
0825-2235
0910-1315
0835-2147
0840-2255
0905-2206
0849-2225
0900-2325
0843-2407
0905-1625
0947-1412
0927-1410
1110-1547
1120-1546
0922-1406
Mean coal
feed rate
(1,000 Ib/hr)
34.9
36.2
34.3
35.5
35.4
35.7
32.1
25.2
36.3
33.8
35.1
38.6
34.4
23.0
35.1
33.5
32.6
33.3
33.2
21.4
33.1
33.8
35.1
RDF feed period
None
1100-1530
Entire run
1020-finish
0900- finish
1230-finish
0900-finish
None
1512-finish
Entire run
Entire run
1608-finish
Entire
None
1010-1105
1340-finish
Entire run
Start-1310
1610-finish
1100-1135
Start-1212
None
Entire run
Entire run
Start-1330
Mean RDF
density
(lb/fts)
—
5
4.7
5
4.3
4
3.7
-
4
4
4.3
4.3
4.5
a
NAa
3.7
4
3.5
-
4
3.8
3.3
a NA = not available.
Out of 23 days of sampling, RDF was burned during the entire test run for
only 7 days. On 12 days RDF was burned part of the time, and on 4 days it
was not burned during the flue gas sampling.
Routine activities such as ash removal and soot blowing were performed
at times designated in the test plan. RDF was observed to have a substan-
tially higher ash content than coal, and this characteristic was reflected by
longer ash removal periods, and more periodic soot blowing. Both activities
decreased substantially when RDF was not being burned.
Table 17 contains information on daily production and consumption at the
Ames Municipal Power Plant, Unit No. 7 recorded by the power plant operators
40
-------
TABLE 17. DAILY PRODUCTION AND CONSUMPTION AT AMES MUNICIPAL POWER PLANT, UNIT NO. 7
Power production
(kwh)
Date
3/2/80
3/3/80
3/4/80
3/5/80
3/6/80
3/7/80
3/8/80
3/9/80
3/10/80
3/11/80
3/12/80
3/13/80
3/14/80
3/15/80
3/17/80
3/18/80
3/19/80
3/20/80
3/22/80
3/23/80
3/24/80
3/25/80
3/26/80
gross
681,000
709,000
761,000
759,000
740,000
735,000
648,000
494,000
693,000
739,000
750,000
742,000
729,000
508,000
699,000
759,000
748,000
753,500
706,000
426,000
710,000
700,000
726,000
net
623,902
648,682
700,072
698,461
679,858
674,470
590,057
443,496
635,037
678,629
688,456
681,889
668,119
457.939
639,942
696,494
682,596
689,205
647,644
382,263
650,039
642,011
664,973
Thermal
energy"
(Btu/kwh)
gross
11,186
11,296
11,396
11,697
11,693
11,652
11,602
11,524
10,955
11,440
11,348
11,544
11,537
11,434
11,170
10,855
10,794
11,368
11,077
11,311
10,841
11,080
10,949
net
12,210
12,346
12,388
12,711
12,728
12,697
12,742
12,836
11,985
12,458
12,362
12.562
12,588
12,684
12,201
11,829
11,829
12,388
12,075
12,605
11,841
12,081
11,954
Steam
production
(Ib/kwh)
9.57
9.59
9.53
9.73
9.50
9.64
9.54
9.47
9.54
9.57
9.62
9.68
9.51
9.50
9.59
9.52
9.51
9.56
9.55
9.49
9.61
9.52
9.60
Fuel consumption u
Iowa coal Colorado coal
(Ibs)
339,988
418,330
412,290
434.538
432,096
427,127
358,286
301,888
486,980
334,328
408,980
432,270
412,440
322,448
412,335
417,010
414,315
445.392
410,520
269,610
629,920
610,880
612,960
(Ibs)
432,712
342,270
351,210
370.162
339,504
378,773
317,720
267,712
262,220
392,472
334,620
368,230
324,060
253,352
337,365
341,190
338,985
379,408
335,880
220,590
157,480
152,720
153,240
RDF"
ObO
0
113,000
226,800
192.375
213.200
130,800
168,460
26,000
81,200
229,600
229,075
144,075
230,400
22,050
97,650
154,874
134,816
63,700
92,000
0
51,600
93,000
134,970
Oil
(gal.)
60
160
70
60
90
100
130
150
100
270
290
50
90
910
70
60
100
490
640
800
490
680
40
Sluice water
for bottoa
and fly ash
Renewal
(gal.)
250,000
340,000
320,000
380,000
450,000
320,000
360,000
314.908
386,716
403,172
413,644
422,620
418,132
335,104
396,000
473,000
477,000
320,000
250,000
180,000
300,000
430.000
540,000
Water input
to evaporator
(gal.)
8,300
9,000
2.200
6.800
9,200
2,500
1,120
8,500
6,300
5.800
3,500
9,100
0
5,700
11,100
15,200
6,000
7,300
5,400
16,600
4,500
4,000
18.500
a This value is derived from the average Btu content of each fuel.
b This is only a rough neasure of RDF weight.
-------
on a daily basis. The total gross and net power production was recorded di-
rectly from meters inside the plant. The total steam produced divided by the
gross power production gave a good indication of boiler efficiency. Separate
meters were used for measuring the water used for ash removal and the total
input to the evaporators. The days of highest sluice water use corresponded
with days of prolonged use of RDF in the fuel mixture. The evaporators even-
tually feed into the working fluid cycle of the boiler, and gave a fair indi-
cation of make-up water required, except that there was a water reclamation
system attached to the boiler. Hence, these values indicated new input to
the system, but did not account for total make-up water requirements.
Most of the fuel types were very accurately measured. Coal was measured
through a weight integrating system, and fuel oil was similarly measured
through a volume integrating system. However, no accurate measurement of the
RDF was possible. The values listed were derived from volumetric readings
and a very rough measurement of the RDF density, taken once every shift. Al-
though rough estimates of the RDF content were made, there was no effective
means for obtaining a representative sample of the refuse mixture. The vari-
ability of the RDF in the total pulverized mixture is reflected in the results
for TOC1 and inputs and emissions of cadmium from this plant.
The BTU contribution of each fuel was then calculated by doing calori-
metric analyses. This was done periodically, and the values used for the
duration of this test program are given in Table 18. By summing the Btu con-
tribution of each fuel, a value for total heat production was found. This
value was then divided by either the gross or net electricity production to
express thermal energy as it related to the power production of the day.
CHICAGO NORTHWEST INCINERATOR, UNIT NO. 2
The field test activity took place from April 30, 1980 to May 23, 1980.
All required tests were completed and all recovered samples were sent to GSRI
for analysis. A summary of the reduced flue gas data (inlet and outlet) on a
daily basis as calculated from the field data sheets is presented in Table 19.
Events that may influence the .quality of the tests are also noted on this table.
The process parameters considered to be important to the operation of
Boiler No. 2 included the steam flow rate, steam pressure, feedwater flow rate,
feedwater temperature, combustion air flow rate, combustion air temperature,
% oxygen, I.D. fan pressure, F.D. fan pressure, furnace draft and furnace
temperature. Most of this data was available from instrumentation in the con-
trol room. Table 20 summarizes this plant process data in terms of the average
values of the typical sampling date operations. This data is presented in
terms of 24-hr plant operation and the flue gas test period durations. Al-
though there are some slight variations, the values are readily comparable
for the two time intervals. A comparison of the daily process data with the
average of the data collected indicates that the Chicago Northwest Incinera-
tion facility operated in essentially the same mode 24 hr a day, 7 days a week.
Although major changes in steam production were noted to occur over short time
intervals (less than 1 hr) no significant variation in steam production oc-
curred day to day indicating a rather consistent fuel feed rates during the
duration of the tests.
42
-------
TABLE 18. HEAT CONTENT OF FUELS USED AT THE AMES MUNICIPAL
POWER PLANT DURING SAMPLING PERIOD
Heat content for each fuel
Duration of test
3/2/80 thru 3/16/80
3/17/80 thru 3/26/80
Iowa coal
(Btu/lb)
8,946
9,035
Colorado
coal
(Btu/lb)
10,556
10,298
RDF
(Btu/lb)
5,587
6,128
type
Fuel oil
(Btu/gal.)
138,603
138,603
43
-------
1ABI.F. 19. DAILY DATA SIIIUIAKIK.S |OH H.IIK (iAS lit ASIIHCIIl HIS, I (IITAHO IK IK III WIST INCINFHATOR. 11(111 til Nil I
Dale Test
(1980) No.
5-4
5-6
5-7
5-8
5-9
5-10
5-11
5-12
5-11
5-15
10
Ini nl ion
'"'" Erf
Dill let N"'lh
South
llilllrl *^{jj«
. . , Hoi III
lulrt
Soul h
Inlet Jj^Hl
Out Irt - .
Inlrl NoMb|
Soullr1
(lull el
Inlel
(lullel
Inlel
Outlet
Illlel
Out let
Inlet
(lul lei
Inlel
n»llrl
North
Soul h
North
South.
North
South
North
South
North"
South"
North
South
North
South
North
South
Hnilh
South
North
South
North
South
Samiilc volume
DSCr DSTH
256.84 7.27
135.20 1.83
117.86 9.00
324.14 9.20
408.46 11.57
179.18 10 74
418.41 11.85
457.89 12.97
124 (6 9.19
400 . 66 II. 14
401.12 11.42
407.07 11.51
111.52 9.19
170.81 10.50
427.50 12.11
457.50 12.96
142.70 9.77
167.81 10.42
171.55
181.75
120.56
147.61
367.97
412.06
144.80
378.50
299.62
459.6]
316.55
171.0}
376.48
391.17
308.71
164.16
166.28
388.71
338.45
376.86
377 44
396.28
10.52
10.87
9.08
9.84
10.42
11.67
9.76
10.72
8.49
11.02
8.96
10.56
10.66
11.08
8.74
10.11
10 17
11.01
9.59
10.67
10.69
11.22
Gal
"*
11.2
11.2
11.3
11.3
9.6
9.6
10 4
10 4
9.4
94
9.4
9.4
9.9
9.9
10.4
10.4
7.9
7.9
8.1
8.1
8.8
8.8
9.4
9.4
9.8
9.8
9 B
9.8
8.7
8.7
10.4
10.4
9.7
9.7
9.1
9.1
10.2
10 2
96
9.6
composition Stark
COJ, " CO""fHC temperature
X l'|'« |'l'« °'
7.4 I721' < 2 459.47
7.4 172 < 2 444.88
7.7 156 < 2 412.76
7.7 156 < 2 451.27
10. 1 159 < 2 459.04
10. 1 159 < 2 445.78
9.5 171 < 2 442.00
9.5 171 < 2 451.04
9.8 185 < 2 445 55
9.8 185 < 2 431.46
9.7 189 < 2 459.04
9.7 189 < 2 457 78
9.5 142 < 2 445 11.
9.5 142 < 2 460.60
89 169 < 2 454 20
8.9 169 < 2 464.32
10.5 61 ' 2 42.1 77
10.5 61 ' 2 460.80
10.7 59 < 2
10.7 59 < 2
10.3
10.1
9.7
9.7
9 0
9.0
9.5
9.5
9 7
9.7
9.0
9.0
9.6
9.6
9.8
9.8
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
< 2
2
2
2
9.4 III0 2
9.4 III 2
9 7 98 2
9.7 98 2
449.64
437 76
452 59
457 6}
448.92
452 28
463.29
462 48
462 53
447.47
456.24
468.33
442.84
452.88
465.61
468.65
457.16
453.52
465.4.3
458.88
459.56
463.68
MnltM nlar
we i Rill
28.26
28.52
28 33
28.41
28.53
28.56
28.45
2'). 58
28 14
28 16
28.39
28.41
28.57
28 50
28.82
28.47
28 10
28 . 10
28 17
28.24
28.37
28.34
28.50
28.33
28 19
28 15
28 17
78. 10
28.40
28.18
28.41
28.42
28. 19
28.19
28 25
28.20
28.29
28 27
28 88
28 24
Noislure
I
11.56
9.57
II 56
10.87
12.24
12.01
12 47
2.95
11 41
13 26
12.86
12.75
II 27
II 85
8.61)
II 60
14 14
14.94
15 46
14.89
13.62
13.83
11.94
13.40
13.86
14.24
12.91
13.52
12 57
12 79
12 21
12.08
14 57
14 52
14 10
14.54
13 60
13 75
8.89
14 22
Vrlorily
ll/srr
20 17
21 27
36.40
39. II
20.62
18.42
18.21
40 . 60
19 -III
21 21
36 70
18 87
19 14
19.96
IR 19
41.69
I/ 71
17.11
32 99
32 48
18 12
17.86
35 43
in sn
19 12
18.51
18.99
38 11
17.58
19.11
36.73
39.17
16 42
17.82
l(> 85
19.39
18 05
17 67
15 47
18 49
ACrtl OSCFfi
111,400 56.500
102,200 51,810
104,1(10 51.300
106,400 55,110
110, '100 54,910
102,000 49,780
105,600 52.770
IIIR.IOII 54,410
93. "00 45.870
8R.4IIO 42.770
06.510 46,250
101.200 49.320
101 ttOtt 4R.28I1
101,900 50.470
9K.RIO 47,970
102,500 50,800
92,240 43.110
102,900 49,060
95.870 46,760
99.H50 49.810
bscim
1,600
1,468
1,453
1.566
1.555
1,410
1.494
1.541
1.299
1,211
1,310
1.197
\.167
1,429
1,158
1.438
1.227
1,389
1,324
1.410
(rmil inue
llokineUr
ralr
1
90.82
79.24
94.61
97.96
96.25
98.32
98.85
91.21
98.17
97.71
100.75
96.29
100.22
97.28
96.59
100.04
99.85
101.90
105.57
107.99
108.82
105.61
98.61
96.51
100.85
100.82
99.20
102.22
98.95
94.91
102.67
100.42
IDS. 21
102.11
104.01
102.82
102.87
102.67
102.40
106.10
1)
-------
TABI.K IV (inni i m,ed)
Dale
(1980)
5-16
5-17
5-18
5-19
Test Sampling
N<) . local idil
Inlei
" Oiulel
,2 Inlet11
Onl|rlp
13 lnlel
Outlet
U "'let
Onllel
North
Soiilli
North
South
North
South
North
South
North
Suulh
Sawn If volume
nscr
153.83
35;. jo
404.61
416.58
324.92
331.75
218.81
q
219.36
q
240.61
OSCH
10.02
10.12
11.46
11.80
9.20
9.40
6.20
6.20
6.81
lias
0,
111
II. 1
118
11.8
10.3
10.3
10.7
10.7
12.7
inmjmsi t ion
co,
X
85
85
7.9
7.9
10.0
10.0
9.0
92
7.2
Slai It
CO 1IIC t enipei.it me IMeiular
l'l'« Pl"»
88° < 2
BB < 2
98 * 2
98 < 2
80 < 2
80 < 2
84 < 2
102 r
304 r
°r
465.32
467.67
455.72
460.24
474.80
475.00
451.00
463.00
465.60
wrighl
28.49
2B.42
28.35
28.38
28.27
26.37
2B.I6
2B.25
28 36
Huislnre Velocity Gas flow
I
11.15
11.69
11.79
11.59
13.47
13.70
14 38
13.91
11.65
ll/sor ACril OSCFH
IB 22 99.300 49.200
H'll 117,500 58.310
\ll\ 91.430 43.540
lo . o j
39.27 106,000 51.350
44.37 119,800 57,360
44.53 120,200 59,140
DSCHH
1.395
1,651
1,233
1,454
1,624
1,675
Isokinclic
rate
t
101.23
93.06
104.09
101.62
97.56
102.20
103.01
92.45
98.36
a Average during test period.
b Sun ol the North and South train Measurements.
c Test was run (or 350 min. Test was discontinued because of unsuccessful leak checks after filler replacement.
d High due to excessive Instrument ilrifl.
e Test ran for only 193 min due lo plant shut down because o| a boiler leak.
f Only 21 of the required 24 points were traversed.
g Test quality was poor due to crack In the probe.
h Low moisture obtained because of cracked probe.
i Sampling time increased from 20 to 25 min per point after 180 win Test quality was good.
j Sampling time increased from 20 to 25 min per point after 267 min. Test quality was gnud.
k Test was halted one point from completion due to stormy water Test quality was good.
I Analyzer taken off line (scr d).
m Due lo excessive leak rate in the noitli tracer, 601 of the sample was collected with tlir sonlh tracer, 401 with the north.
n Prnhe was (mmd with a narked tip. Based on 8.91 miiixtiiiv versus 121 moisture lor llir ollu-r tests, it was determined HIM only the lasl 10 points
were traversed with I lie broken probe. Teat quality was fair.
o Results t 101 due to drift.
p Inlet QA test, outlet 1st day cadmium leal
<| Intel sample not lequired for cailmium test.
r Till: data not leipiired lor tadiiiiim lest.
-------
TABLE 20. MEANS OF THE MEANS FOR PROCESS DATA, ALL TEST DAYS,
CHICAGO NW INCINERATOR, BOILER NO. 2
Parameter
Steam flow rate (Ibs/hr)
Disc recorder
Chart recorder
Digital integrator
Steam pressure (psig)
Feedwater flow rate (Ibs/hr)
Chart recorder
Digital integrator
Feedwater temperature (°F)
Combustion air flow rate (ft3/hr)
Chart recorder
Digital integrator
Combustion air temperature (°F)
I.D. fans pressure (inches H20)
F.D. fans pressure (inches H20)
Furnace draft (inches ^0)
Furnace temperature (°F)
24-hr
Mean
99,000
103,000
99,000
282
99,000
97,000
221
79,000
72,000
663
2
14
0
1,160
process data
Standard
deviation
4,500
4,500
3,600
4
4,800
5,400
1
2,000
2,600
21
.6 0.2
.1 0.4
.23 0.06
42
Flue gas test
process
Mean
100,000
104,000
100,000
287
101,000
100,000
221
78,000
70,000
673
2.5
14.1
0.22
1,198
duration
data
Standard
deviation
8,100
8,300
10,300
2
8,400
11,000
1
2,700
2,200
23
0.3
0.6
0.8
67
a From Appendix B.
46
-------
Additional information collected for daily process tables included the
times of soot blowing, fuel input to Boiler No. 2, down time on Boiler No. 2,
daily barometric pressure and miscellaneous comments concerning the boiler
operation. Soot blowing was to follow a set schedule of three times per day,
although deviations from this schedule were observed. Barometric pressure
was obtained once per day from nearby Midway airport and deviations from
typical plant operation were noted from the operator's log book.
The measurement of fuel input posed a somewhat more difficult problem.
All refuse and residue hauling trucks entering and leaving the incinerator
plant were carefully weighed. This facilitated the accurate characterization
of overall inputs and outputs. However, there was no accurate way of propor-
tioning these materials between specific boilers for a given period of time.
Attempts to determine the fuel burned or ash discharged from Boiler No. 2 were
approximations.
Chicago Northwest Incinerator maintains inventory sheets listing inputs
and outputs from the facility on a weekly basis. Relevant data from these
sheets are reproduced in Table 21. The weight of refuse received was measured
on scales before and after the refuse trucks released their loads. The volume
of refuse received was determined by multiplying the number of truck loads by
the volume of each truck (19.5 cubic yards). Density of the refuse was esti-
mated using these two measurements, and is therefore the density of refuse
inside the trucks. In order to quantify the amount of refuse burned, the
number of loads, or charges, handled by the grab bucket cranes were noted for
each boiler. The total number of charges to Boiler No. 2 for daily operations
are given in Table 22.
To approximate the amount of refuse burned in Boiler No. 2, it was neces-
sary to determine an average weight per charge. When refuse trucks enter the
plant, they discharge their contents into a large storage pit. Although the
weight of refuse added to the pit is well characterized for each weekly period,
the carry-over of material from week to week cannot be accurately measured.
Furthermore, this carry-over is quite variable over the length of time being
considered. It is necessary to quantify the carry-over in terms of weight,
so that the total weight of refuse burned, and hence, the average weight per
charge, can be approximated.
The calculation of the average weight per charge involves using visual
measurements of the pit volume taken at the end of each week. This "pit esti-
mate" can then be used in association with the density of the incoming garbage
to approximate the weight of refuse in the pit. The average weight per charge
can be determined by the following equation:
Average wt _ (pit estimate for previous week - pit estimate + refuse delivered)
per charge ~ total number of charges
All terms in parenthesis must be expressed as weights. This method, however,
has a drawback in that the density in the pit is probably not the same as the
density inside the refuse trucks, since the refuse inside the trucks is com-
pacted and is liable to expand somewhat as the trucks are unloaded.
47
-------
TABLE 21. WEEKLY INVENTORIES OF REFUSE AND RESIDUE AT THE CHICAGO
NW INCINERATOR (ALL BOILERS)
Refuse received
By weight (tons)
By volume (cu yd)
Density (lbs/yd3)
Storage pit condition
At beginning of week
(% full)
At end of week (% full)
Refuse consumed
No. charges burned
Average weight per
charge (Ibs)
Total weight (tons)
Total volume (cu yd)
Residue
Fine ash fraction (tons)
Fine ash fraction (cu yd)
Metal fraction (tons)
Metal fraction (cu yd)
Total ash (tons)
Total ash (cu yd)
Volume reduction thru
incineration
Weight reduction thru
4/28/80
to
5/4/80
6,747
24,490
551
84
65
5,205
2,771
7,212
28,562
2,511
3,100
949
5,423
3,460
8,523
70%
52%
5/5/80
to
5/11/80
9,152
29,618
618
65
61
5,710
3,240
9,250
36,634
2,500
3,086
750
4,286
3,250
7,372
80%
65%
5/12/80
to
5/18/80
7,902
26,561
595
61
42
5,952
2,812
8,367
33,138
1,815
2,240
1,514
18,651
3,329
10,891
67%
60%
5/19/80
to
5/25/80
8,720
28,778
606
42
42
4,714
3,700
8,720
34,535
2,904
3,585
629
3,594
3,533
7,179
79%
60%
incineration
48
-------
TABLE 22. CHARGES FED TO BOILER NO. 2 ON A SHIFT BASIS
CHICAGO NORTHWEST INCINERATION FACILITY
Date,
4-28,
4-29,
4-30,
5-1,
5-2,
5-3,
5-4,
5-5,
shift
2nd
3rd
1st
2nd
3rd
1st
2nd
3rd
1st
2nd
3rd
1st
2nd
3rd
1st
2nd
3rd
1st
2nd
3rd
1st
Total
for week
No. of
charges
98
99
100
94
101
90
94
101
94
49
98
100
98
101
100
102
99
97
96
12
-
1,823
Date, shift
5-5, 2nd
3rd
5-6, 1st
2nd
3rd
5-7, 1st
2nd
3rd
5-8, 1st
2nd
3rd
5-9, 1st
2nd
3rd
5-10, 1st
2nd
3rd
5-11, 1st
2nd
3rd
5-12, 1st
No. of
charges
—
68
112
99
84
100
81
101
100
100
98
100
99
101
100
102
101
105
103
'1,754
Date, shift
5-12, 2nd
3rd
5-13, 1st
2nd
3rd
5-14, 1st
2nd
3rd
5-15, 1st
2nd
3rd
5-16, 1st
2nd
3rd
5-17, 1st
2nd
3rd
5-18, 1st
2nd
3rd
5-19, 1st
No. of
charges
99
99
100
100
60
96
104
106
108
106
97
110
112
97
114
108
104
118
105
1,943
Date, shift
5-19, 2nd
3rd
5-20, 1st
2nd
3rd
5-21, 1st
2nd
3rd
5-22, 1st
2nd
3rd
5-23, 1st
2nd
3rd
5-24, 1st
2nd
3rd
5-25, 1st
2nd
3rd
5-26, 1st
No. of
charges .
110
105
104
118
110
100
106
90
80
105
100
107
107
102
98
105
94
101
105
107
105
2,159
49
-------
It seems likely that the level of compression would have a more pronounced
effect upon the refuse density than the actual characteristics of the refuse.
Since the compaction inside the pit is always similar, one would also expect
the density in the pit to be reasonably constant. The plant personnel indi-
cated that the typical refuse density was 505 Ib/cu yd. Therefore, this
value can be used as an assumed density, and the pit estimates used in the
equation:
Volume of refuse in pit = pit estimate & of total ™l™*e) x total pit volume
total pit volume = 9,700 cu yd
Weight of refuse in pit = volume of refuse in pit x refuse density in pit
assumed refuse density = 505 Ib/cu. yd
Weight of refuse incinerated per week = (weight of refuse in pit at beginning
of week - weight of refuse in pit at
end of week + weight of refuse
delivered)
Average weight per charge = total weight of refuse incinerated
e total number of charges
Volume of refuse incinerated = wei*ht °f/efuse incinerated
assumed refuse density
The amounts of fine ash and metal fractions produced by the incinerator
during the test period are listed in Table 21. It should be noted that these
are the amounts leaving the plant during this time period, and are not neces-
sarily the same as the ash being produced during this period. Since no ac-
count has been taken of any carry-over from week to week, it can only be as-
sumed the carry-over is similar each week. In order to obtain total ash, the
metal and fine ash fractions were summed together. The ash volumes were cal-
culated using the following densities:
Density of fine ash fraction = 1,620 Ib/cu yd (960 kg/m3)
Density of metal fraction = 350 Ib/cu yd (210 kg/m3)
These values were based on previous analyses done by the plant, and have been
assumed to be typical. Since all of the combined ash was subjected to a water
quench, these weights incorporate a rather large moisture content. However,
no better characterization was available. The volume and weight reductions
achieved through incineration have been calculated as an indication of how
efficiently the boilers were operating.
Due to the heterogeneous nature of the refuse used to fuel this plant,
it was very difficult to obtain representative samples for laboratory analy-
ses for organic compounds and cadmium. The previous discussion of the ap-
proximation of refuse burned in Unit No. 2 reflects an additional problem in
providing accurate information for the levels of the analytes introduced as
inputs to this combustion source. Both the variabilities of TOC1 and cadmium
50
-------
and the agreement of cadmium between the inputs and emissions from the plant
were highly affected by the difficulty of obtaining representative refuse sam-
ples.
51
-------
SECTION 8
ANALYTICAL RESULTS
AMES MUNICIPAL POWER PLANT, UNIT NO. 7
Organics
The results of TOC1 determinations in flue gas inlet and outlet samples
from the Ames plant are shown in Tables 23 and 24, respectively, along with
the recoveries observed for the surrogate spiking compounds. The results for
plant background air particulates, ESP ash, bottom ash, coal, RDF, bottom ash
quench influent water (cooling tower blowdown), bottom ash quench overflow
water, and untreated well water (plant intake water) are shown in Tables 25
to 32. These results, as well as all other results in this report, are shown
uncorrected for surrogate recoveries. The coal extracts apparently contained
very high levels of hydrocarbons. Hence, the Hall detector used for TOC1 as-
says required cleaning after only one to two analyses. Hence, TOC1 assays
were completed on only six coal extracts. Organic chlorine was not detected
by the TOC1 procedure in any of the field blanks, method blanks, or flue gas
first impinger extracts.
In general, the surrogate recoveries were good in all samples. The re-
coveries for da-naphthalene (typically 50-80%) were generally lower than for
d12-chrysene (typically 70-100%). This is likely due to the much higher vol-
atility of naphthalene compared to chxysene. Hence, naphthalene losses may
be partially attributed to volatility losses during extract concentration.
The results of determinations of PAH compounds and additional compounds
identified in the composite extracts are shown in Table 33. In addition to
PAH compounds, chlorinated benzenes and phenols were identified in some sam-
ples. Notably, phenol was detected at parts-per-million concentrations in
the coal extracts. Phthalate esters were also identified in RDF and ash sam-
ples. As anticipated, phthalate levels were high in the RDF extracts. Low
levels of phthalate esters were also identified in the composite flue gas ex-
tracts, although the levels were similar to those observed in the flue gas
train blanks. The levels of phthalate esters in the train blank ranged from
0.3 to 4 pg/dson.
The results of HRGC/MS-SIM analysis of the composite Ames flue gas out-
let extracts for PCBs are shown in Table 34. These results are similar to
those obtained by Richard and Junk7 for the Ames Unit No. 7. The primary
chlorobiphenyl compounds identified were tetra- through hexachloro-substituted.
52
-------
TABLE 23. TOC1 AND SURROGATE RECOVERY RESULTS FOR THE AMES FLUE GAS INLET SAMPLES
Ul
co
TOC1
Test day
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Date
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
3-11
3-12
3-13
3-14
3-15
Sample volume
(dscm)
13.23
17.41
12.38
14.27
19.56
20.79
19.40
17.87
9.18
22.01
Mass
(ng)
3,210
20,000
9,480
6,480
18,600
8,560
7,110
7,350
7,650
12,400
Cone.
(ng/dscm)
243
1,150
766
454
951
412
367
411
833
562
Surrogate recovery .
d8-Naphthalene
0
63, 85
61, 82
31
57
51
43
44, 48
55
42
d12-Chryseue
85
100, 100
98, 79
33
58
82
60
76, 74
81
63
Test scrubbed
20.39
20.57
15.43
11,600
11,500
6,320
568
559
410
59
54
49
76
81
87
(continued)
-------
TABLE 23 (concluded)
TOC1
Test day
15
16
17
18
19
20
Date
3-17
3-18
3-19
3-20
3-22
3-23
Sample volume
(dscm)
21.25
20.97
20.34
20.27
20.16
18.90
Mass
(ng)
8,170
22,600
6,390
13,100
6,330
4,780
Cone.
(ng/dscm)
394
1,080
314
647
314
253
Surrogate
d8-Naphthalene
(%)
120
45
63
54
103
50
recovery
di2"Chrysene
«)
86
39
60
52
87
55
Ul
-------
TABLE 24. TOC1 RESULTS AND SURROGATE RECOVERIES FOR THE AMES FLUE GAS OUTLET SAMPLES
Ui
TOC1
Test day
1
2
3-lla
12
13
14
15
16
17
18
19
20
Date
3-2
3-3
3-13
3-14
3-15
3-17
3-18
3-19
3-20
3-22
3-23
Sample volume
(dscm)
12.94
17.89
14.85
20.37
17.73
22.62
21.12
20.81
21.09
22.75
18.71
Mass
(ng)
2,020
21,600
4,920
34,200
4,230
21,500
18,100
21,800
4,330
2,830
2,930
Cone.
(ng/dscm)
156
1,210
332
1,680
238
948
855
1,050
205
124
157
Surrogate
dg-Naphthalene
m
53
60
59
64
24
43
43
49
46
35
41
recovery •
d12~Chrysene
(%)
92
78
98
76
64
85
84
105
89
77
98
a No flue gas outlet samples collected due to severe weather.
-------
TABLE 25. TOC1 RESULTS AND SURROGATE RECOVERIES FOR AMES
PLANT BACKGROUND AIR PARTICULATE SAMPLES.
Test Day
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Date
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
3-11
3-12
3-13
3-14
3-15
3-17
3-18
3-19
3-20
3-22
3-23
Filter
Filter
Volume* TOC1
(m3) (ng)
500
540
510
550
800
700
600
870
750
830
600
960
930
910
910
950
960
1,110
840
1,040
Blank
Blank
2,930
3,920
3,150
3,190
4,940
3,240
3,160
3,460
3,750
5,110
4,180
3,260
2,980
4,530
3,820
5,090
6,580
4,620
2,690
1,880
4,260
2,110
Surrogate Recovery
TOC1
(ng/m3)
5.9
7.3
6.2
5.8
6.2
4.6
5.3
4.0
5.0
6.2
7.0
3.4
3.2
5.0
4.2
5.4
6.9
4.2
3.2
1.8
da-Naphthalene
(%)
23
3
24
26
41
56
24
45
39
36
48
59
59
32
80
68
65
73
51
73
95
45
dj2"Chrysene
(%)
85
110
100
96
100
110
73
88
93
93
140
130
140
92
79
110
77
89
120
83
120
57
a Calculated from the sampling time and the flowmeter reading
on the Hi-Vol sampler.
56
-------
TABLE 26. TOC1 RESULTS AND SURROGATE RECOVERIES
FOR AMES ESP ASH SAMPLES
Test day Date Time
0
1
2
3
4
5
3-1 0300
0430
0830
1230
1630
2030
3-2 0030
0430
0830
1230
1630
2030
3-3 0030
0430
0830
1230
1630
2030
3-4 0030
0430
0830
1230
1630
2030
3-5 0030
0430
0830
1230
1630
2030
3-6 0030
0430
0830
1230
Hopper
code3
B x
A
B
A
A
B
B
B
A
B
B
B
B }
t }
I }
B
B
A
B
B
B
B }
B }
BB }
B }
B }
Surrogate
recovery
TOC1 rig-Naphthalene - d12-Chrysene
(ag/g) (%) (%)
1.8
5.9
6.3
5.8
0.3
4.5
5.3
4.1
2.2
1.1
5.1
8.7
1.1
10.6
5.4
8.0
2.7
8.5
4.4
3.4
2.5
57
36
78
38
60
91
61
73
57
59
46
40
46
71
61
70
71
52
54
54
1
5
(continued)
100
140
140
87
69
73
95
84
58
88
110
65
110
78
69
90
98
90
71
100
83
-------
TABLE 26 (continued)
Surrogate recovery
Test day
5
6
7
8
9
10
Date Time
3-6 1630
2030
3-7 0030
0430
0830
1230
1630
2030
2330
3-8 0330
0730
1130
1530
1930
2330
3-9 0330
0730
1130
1530
1930
2330
3-10 0330
0730
1130
1530
1930
2330
3-11 0330
0730
1130
1530
1930
Hopper
code
B
A
A
A
A
A
B
B
B
B
A
A
B
A
A
A
B
B
A
B
B
B
A
B
A
A
A
A
B
A
A
B
TOC1
(ng/g!
\ 2.2
\ 2.4
i 3.0
I 4.0
| 210
\ 3.7
} 5"2
8.1
2.5
1.9
3.2
3.6
6.4
| 9.8
| 5.7
I 2>1
3.0
3.8
1.9
0.9
2.9
3.7
da-Naphthalene
) (%)
28
0
60
65
9
41
59
47
53
33
20
34
56
52
57
35
54
1
45
1
59
8
(continued)
dig-Chrysene
100
90
98
89
90
100
99
53
83
69
69
66
90
110
110
110
120
140
110
110
110
73
58
-------
TABLE 26 (concluded)
Test day Date Time
Hopper
code*
Surrogate recovery
TOC1 dg-Kaphthalene
(ng/g)
11
3-12
12
3-13
13
3-14
22
3-25
2330
0330
0730
1130
1530
1915
2330
0330
0730
1130
1530
1930
2330
0330
0730
1130
1530
1930
0001
0400
0800
1200
1600
2000
A
B
A
B
B
B
B
B
A
A
B
B
A
A
B
B
B
A
A
B
A
A
B
A
3.2
2.6
2.1
2.1
2.1
4.4
2.6
1.7
90
9
38
69
71
130
60
103
100
130
120
120
130
59
-------
TABLE 27. TOC1 RESULTS AND SURROGATE RECOVERIES
FOR AMES BOTTOM ASH SAMPLES
Surrogate recovery
Test day
0
1
2
3
4
5
Date Time
3-1 0105
0530
0930
1330
1730
2130
3-2 0130
0530
0930
1300
1730
2130
3-3 0130
0530
0930
1330
1730
2130
3-4 0130
0535
0930
1300
1730
2130
3-5 0130
0530
0930
1330
1730
2130
3-6 0130
0530
0930
1330
Sector
code*
D N
B
D
D
D
B '
D
E
C
C
D
C
I }
* 1
D \
B I
0
E
F
E
A
E
I }
B }
; }
E \
A )
C \
B ]
TOC1
(ng/g)
30.3
9.0
13.0
0.6
3.3
1.6
99.5
0.2
362
11.1
79.0
251
114
26.3
60,0
52.5
72.0
22.7
13.8
66.5
55.0
dfl-Naphthaleiie d^-Chrysene
(%) (%)
65
31
42
57
85
39
43
75
92
30
81
52
53
41
57
47
67
72
50
58
68
130
31
77
67
85
52
110
68
110
130
69
21
79
47
84
95
50
92
96
89
110
(continued)
60
-------
TABLE 27 (continued)
Test day
5
6
7
8
9
•
10
Date Time
3-6 1730
2130
3-7 0130
0530
0930
1300
1730
2130
3-8 0030
0430
0830
1230
1630
2030
3-9 0030
0430
0830
1230
1630
2030
3-10 0030
0430
1445
1630
2030
3-11 0030
0430
0830
1230
1630
2030
Surrogate
Sector TOC1 dg-Naphthalene
code8 (ng/g) (%)
C
E
C
A
E
F
C
F
E
C
B
C
A
A
B
B
D
D
F
A
E
E
C
F
B
D
A
A
D
D
A
> 11.6
| 51.0
? 34.0
} 81.0
} 35.9
} 4.9
} 57.5
127
5.8
1.3
8.0
0.8
6.2
I >••
| 92.5
16.4
5.7
38.6
136
85.5
97.0
316
55
39
19
38
65
63
54
77
56
12
29
51
6
77
87
11
86
53
77
44
79
66
recovery
dj2-Chrysene
90
81
83
103
79
20
46
70
76
46
48
31
49
63
120
120
97
87
160
130
130
120
(continued)
61
-------
TABLE 27 (concluded)
Test day
11
12
13
22
Date Time
3-12 0030
0430
0830
1230
1630
2030
3-13 0030
0430
0830
1630
2030
3-14 0030
0430
0830
1230
1630
2030
3-25 0100
0500
0900
1300
1700
2100
Sector
code8
C
D
A
E
E
A
A
A
D
A
F
F
C
B
B
A
B
A
D
B
F
B
E
TOC1
(ng/g)
57.0
} 43.3
76.0
| 349
| 32.3
| 15.8
} 64.5
V
14.8
Surrogate recovery
d,j-Napht.halene d^-Chryscne
61 120
62 100
54 110
59 100
59 80
51 96
62 110
68 70
a The accessible portion of the hopper was divided into six sectors which
were sampled according to a randomized selection scheme,
62
-------
TABLE 28. TOC1 RESULTS AND SURROGATE RECOVERIES FOR AMES COAL SAMPLES
Test day
Date
Time
Feed stream
code
TOC1
(ng/g)
Surrogate recovery
dg-Naphthalene
di2-Chrysene
0
3-1
3-2
0300
0700
1100
1500
1900
2300
0300
0700
1100
1500
2300
A
A
A
B
B
B
B
B
A
B
A
4
7
4
5
4
92
97
110
87
92
61
97
110
96
83
97
59
a Two coal feed lines were sampled according to a randomized selection scheme.
-------
TABLE 29. TOC1 RESULTS AND SURROGATE RECOVERIES FOR
AMES REFUSE - DERIVED FUEL SAMPLES
Test day Date
0 3-1
2 3-3
3 3-4
4 3-5
5 3-6
6 3-7
Food
stream
Tine code8
0225 B
0630 D
1030 D
1430 A
1430 C
1830 B 1
2230 B J
0230 A
0630 A
1030 C
1430 C
1830 A
2230 C
0230 B
1030 D }
1440 D j
1830 D \
2250 C J
0230 B \
0630 B 1
1030 A \
1430 C )
1830 C \
2230 B J
0230 A
1430 B
1830 B >
2230 A f
TOC1
(n*/R)
5,550
10,800
29,500
5,500
370
19,000
23,600
4,400
2,800
480
5,100
5,000
9,500
13,300
1,900
4,250
18,500
7,050
Surrogate
dg-Naphthalene
tt)
42
58
54
45
75
50
41
66
64
61
76
71
80
62
55
77
50
63
recovery
dxj-Chrysene
(%)
61
80
160
82
120
98
56
120
110
140
150
120
140
110
110
100
110
170
(continued)
-------
TABLE 29 (continued)
Food
stream TOC1
Test day Date Tine code (ng/g)
7 3-8 0130 B
0930 D \
1330 D j
1730 D 1
2130 C J
8 3-9 0130 B
9 3-10 1730 C
2130 A
10 3-11 0130 A
0530 C
0930 A
1330 A
1730 D
2130 A
11 3-12 0130 D
0530 B
0900 D
1330 D
1730 C
2130 C '
12 3-13 0130 D )
0530 D j
1730 D )
2130 C J
13 3-14 0130 B \
0530 C J
0930 B }
1330 C j
1730 A )
2130 C j
22,000
4,300
9,900
5,000
7,350
3,150
4,950
21,100
23,200
8,600
9,550
10,300
19,900
> 10,900
> 8,200
> 16,500
4,300
46,300
Surrogate
dg-Naphthalene
(«
88
. 68
55
71
64
42
73
86
68
35
64
55
88
66
91
77
57
84
recovery
di2-Chrysene
(%)
98
110
120
110
120
68
150
130
93
120
130
69
130
84
98
150
84
98
(continued)
-------
TABLE 29 (concluded)
Test day Date Time
22 3-25 1000
1400
1800
2200
Food
Surrogate recovery
stream TOC1 dg-Naphthalene d^-Chrysene
code8 (njj/e) tt) (%)
A
B
C
13,100 83 130
D
a Four RDF feed lines were sampled according to a randomized selection scheme.
66
-------
TABLE 30. TOC1 RESULTS AND SURROGATE RECOVERIES FOR AMES
BOTTOM ASH HOPPER QUENCH WATER INFLUENT SAMPLES
Test day
1
3
5
8
10
13
Date
3-2
3-4
3-6
3-9
3-11
3-14
Time
2400
0400
1400
2100
0800
0300
TOC1
(ng/A)
239
271
441
339
369
576
Surrogate
dg-Naphthalene
(%)
47
51
80
82
89
64
recovery
dj2-Chrysene
(%)
87
120
100
100
130
130
67
-------
TABLE 31. TOC1 RESULTS AND SURROGATE RECOVERIES FOR AMES BOTTOM ASH HOPPER
QUENCH OVERFLOW WATER SAMPLES
Test day Date
0 3-1
1 3-2
2 3-3
3 3-4
4 .3-5
5 3-6
Time
0100
0500
0900
1300
1700
2100 '
0100
0500
0900
1300
1700
2100
0100 \
0500 j
0900 \
1300 j
1700 '
2100 j
0100
0500
0900
1255
1700
2100
0100 \
0500 j
0900 \
1300 /
1700 :
2100 J
0100 1
0500 /
0900 \
1300 J
TOC1
(ng/D
90
698
656
680
494
626
528
> 518
524
706
1,180
488
558
274
294
678
• 825
889
691
301
• 427
Surrogate
dg-Naphthalene
NDa'b
47
25
44^
NDb
35
28
19b
50
64
30
57
51
37h
NDb
28
37
49
38
ND
ND
recovery
d12-Chrysene
72
80
82
120
56
97
92
79
89
76
54
66
50
22
78
96
98
110
94
24
55
(continued)
68
-------
TABLE 31 (continued)
Test day
5
6
7
8
Date Time
3-6 1700 |
2100 J
3-7 0100 i
0500 j
0900
1300 ,
1700
2100
3-8 2400
0400
0800
1200
1600
2000
2400
3-9 0400
0800
1200
1600
2000
2400
3-10 0400
0800
1200
1600
2000
2400
3-11 0400
0800
1200
1600
2000
2400
TOC1
(ng/1)
I 947
\ 819
} 866
| 852
} 863
\ 1,100
J
? 1,040
'
776
1,050
984
516
496
376
776C
\ 605
\ 795
776C
870
806
778
864
880
728
Surrogate
dg-Naphtnalene
87
2
80
81
94
74
71
42
63
53
24h
«?
NDb
0
80
46
0
c
130
110
90
17
57
recovery
di2"(%rsene
100
80
55
98
120
94
94
120
110
87
140
130
120
85
120
100
85
120
120 -
86
88
83
(continued)
-------
TABLE 31 (concluded)
Test day Date Time
8 3-12 0400
0800
1200
1600
2000
2400 '
3-13 0400 )
0800 f
1200 \
1600 J
2000 )
2400 /
3-14 0400 )
0800 /
1200 )
1600 (
2000
TOC1
(na/1)
603
892
916
613
458
770
1,060
Surrogate
dg-Naphthalene
no
2»
e
44
ND
34
42
42
recovery
d12-Chrysene
81
84
57
78
97
80
3-25 0030
0430
0830
1230
1630
2030 '
638 36 110
a ND = not detected.
b Extract was inadvertently evaporated to dryness.
c Samples collected at 0400 and 2400 on 3-10 were inadvertently composited.
d This sample was not spiked with the surrogate compounds.
e This extract was lost prior to analysis for surrogate recoveries.
70
-------
TABLE .32. TOC1 RESULTS AND SURROGATE RECOVERIES
FOR AMES UNTREATED WELL WATER
Surrogate recovery
Test day Date
0 3-1
5 3-6
23 3-26
Time
0200
2200
1615
TOC1
(ng/JH)
33
65
62
dg-Naphthalene
(%)
NDa
65
66
di2-Chrysene
(%)
68
99
97
a Extract was inadvertently evaporated to dryness.
71
-------
TABLE 33. COMPOUNDS QUANTITATED IN SAMPLES FROH TIIE AHF.S HUNICIPAL TOWF.H PLANT, UNIT NO. 7
K>
Compound
Target PAH coapounda
Phenanthrene
Anthracene
Fluoranthene
Pyrene
Chryaene
•enxo|a|pyrene
IndeaolI,2,3-c,d|pyrene
Concentration
Plant
Refuae-derived background
Composite Coal fuel air
dly <"«'•)
7,550
9,090
15,400
1,500
18,600
1,570
1.840
1,260
2,120
4,110
1,190
1.640
3.320
900
3,210
1,340
1,960
3.810
1.070
4.040
370
425
1,060
238
5 1,300
1
2
3
4
5
1
2
3
4
5
(!<(/<>
32
250
140
43
500
24
130
10
52
30
450
9.0
64
29
6.0
420
170
•
(rontlnurd)
-------
TABLE 33 (continue,!)
Compound
Concentration
Boll OB Bo t ten
Plant ash hopper ash hopper
Refuse-derived background Flue gas Flue gas Bottoa quench water quench water Well
Composite Coal fuel air inlet outlet ESP ash ash overflow overflow water
day (ng/g) (ng/g) (ng/dsca) (ng/dsr«) (ng/dsr*) (ng/g) (ng/g) (M8/*) (Mg/*) («/*)
Benzo|g,h,l|perylenc 1 3.3
2
3 22
4 0.09 4.6
5
Additional compounds identified
Oichlorobenzene
1 ,2,4-Trichlorobenzfne
Hexachlorobutadiene
Tetrarhlorolicnzene
Penlach 1 oropheno 1
1 3.3 0.07
2 1,300 25 24
3 1,200 79 0.07
4 S20 S
5 430 25
1
2 0.02 99
3 0.01 180 110
4
5 69 85
2
3 0.02 103
4
5
2
3
4
5
1 0.07
2 1,300
3 24
4
5 690
(continued)
-------
TABLE HI (i oil! I mini)
Compound
Phenol
2,4-Dluthylphenol
Naphthalene
Fluorcne
Benxfa. (anthracene
lensofluoranlhrene
Beuzo|e|pyrene
Composite
day
,
2
3
4
5
1
2
3
4
S
1
2
3
4
5
1
2
3
4
S
1
2
3
4
S
1
2
3
4
S
1
2
3
4
S
Cod
(n|/|)
10,000
12,000
2.800
23,000
29,000
1,400
1,100
1,100
1,100
2,700
3,500
3,100
5.600
3,300
7,000
261
410
960
260
1,200
Refuse-derived
fuel
(ng/l)
36,000
2.200
1,500
1,500
600
450
380
320
Plant
background
• Ir
|/|) (pi/1) (MI/O
980 0.06
1,600
1,100 0.06
360
730
27
1
15 0.02
360
110
29 ,
/
14
0.03
- -•
Well
water
(Ml/0
0.5
0.02
(rontlnurd)
-------
TABLE 31 (continued)
Ul
Compound
Acenaphthene
Aceniphthylene
Tr i ch 1 o robeozene
2,4-Dicblorophenol
£-Chloro-B-creiol
DiBethylpulhaUte
Dietliylphthalale
PUnl
Refuse-derived background
Composite Coil fuel lir
day (ng/g) (ng/g) (ng/di»)
1 650
2 970 1,200
3 1,600
4 1,400
5 1,500
1 220
2 240
3 S<0
4 400
S 450
2
3
4
5
1
2
3
4
5
1
2
3
4
5
2
3
4
5 730
1
2 9,100
3 250
4 1,400
5 1 1 ,000
Concentration
BottcM BottoD
ash hopper aib hopper
Flue gai Flue gai Bottoa quench water quench water Well
inlet outlet ESP ash aih overflow overflow water
(ng/d«c«) (ng/dsc.) (ng/g) (ng/g) (|i(/t) <«/«)
-------
TABU 11 (concluded)
-4
O\
Plant
Refuie-derlved background
Composite Coal fuel air
Compound day (ng/g) (ng/g) (ng/darai)
Dl-g-butylphlhalale
Butylbeniylphthalate
•ia(2-ethylheiiyl)phthalate
11.000
I*. 000
6,400
I*. 000
49.000
22,000
350.000
44,000
35,000
22,000
Concentration
Flue gas Flue gai
inlet outlet ESP aih
(ng/dtra) (ng/daca) (og/g)
IS
3.0
4.0
6.0
6.0
3.0
2.0
1.0
BottoB Botioa
acb hopper ash hopper
Boltoa quench valer quench water Well (
ash overflow overflow water
(ng/g) (|ig/t) (|ig/<) (|'«/O
4.0
42
12
35
170
32
SI
980
1,200
410
110
• All extract! lro« theie tuplei were combined for a (ingle co*po«lte extract.
fa Specific lioawr not determined.
-------
TABLE 34. CONCENTRATIONS OF POLYCHLORINATED BIPHENYL ISOMERS
IN FLUE GAS OUTLET SAMPLES FROM THE AMES MUNICIPAL
POWER PLANT, UNIT NO. 7
Composite day
(Concentration, ng/dson)
Compound identified
Tri chlo rob ipheny 1
Tetrachlorobiphenyl
Pentachlorobiphenyl
Hexachlo rob ipheny 1
Hep tachlo rob ipheny 1
Decachlorobiphenyl
Total chlorobiphenyl
1234
6.4 1.1
2.2 4.5 4.1
3.0 6.4 22.0 9.8
4.3 11.0
2.9
2.9
5.2 27.0 23.0 25.0
5
3.8
3.6
10.1
i^_>^_^_
17.0
PCDDs and PCDFs were not detected in the Ames samples. The detection
limit for PCDD and PCDF compounds in the composite flue gas extracts was 0.1
to 0.25 ng/dscm.
Cadmium
The results for cadmium analysis of samples of fly ash, bottom ash, coal
and refuse-derived fuel for test days 11 to 14 and 21 to 23 are presented in
Tables 35 to 39. The fly ash samples contained the highest concentrations of
cadmium ranging from approximately 1.5 to 11 pg/g, while the cadmium concen-
tration in bottom ash samples varied from approximately 0.5 to 4 Mg/g- The
concentration of cadmium in the coal samples was generally less than 1 Mg/g
while values of 1 to 5 (Jg/g were recorded for refuse-derived fuel. In general,
the cadmium concentration for all water samples was below the detection limit
(0.6 |jg/liter) of the analysis method. Table 35 presents the cadmium concen-
trations for the flue gas outlet particulate samples for test days 21 to 23.
The concentrations of cadmium in flue gas particulates for the three test
days did not vary markedly. The mean concentration was 25.3 |Jg/dscm with a
standard deviation of 2.7 (Jg/dscm.
77
-------
TABLE 35. CADMIUM RESULTS FOR AMES - ESP ASH SAMPLES
Test day
11
12
13
14
21
22
23
Date
3/12
3/13
3/13
3/13
3/13
3/13
3/13
3/U
3/14
3/14
3/14
3/14
3/14
3/15
3/15
3/15
3/15
3/15
3/16
3/16
3/16
3/16
3/16
3/16
3/24
3/24
3/24
3/24
3/24
3/24
3/25
3/25
3/25
3/25
3/25
3/25
3/26
3/26
3/26
3/26
3/26
3/26
Time
2330
0330
0730
1130
1530
1930
2330
0330
0730
1130
1530
1930
2330
0330
0730
1130
1530
1930
2330
0330
0730
1130
1530
1930
0001
0400
0800
1200
1600
2000
0001
0400
0800
1200
1600
2000
0001
0400
0800
1200
1600
2000
Hopper
j a
code
B
B
A
A
B
A
A
A
B
B
B
A
B
A
B
B
A
B
A
B
A
B
B
B
B
A
A
B
B
A
A
B
A
A
B
A
A
A
B
A
A
B
Cadmium
(Wg/g)
9.01
10.3
10.8
8.14
9.89
3.67
7.36
8.42
8.16
9.11
9.96
6.78
6.84
8.47
4.39
3.43
8.00
2.88
5.55
2.35
1.94
1.65
2.97
2.93
3.29
2.16
2.16
3.53
7.89
5.69
4.53
5.11
3.36
8.93
9.70
6.41
5.76
5.73
6.86
8.03
9.19
9.70
a Two hoppers were sampled according to a randomized selection scheme.
78
-------
TABLE 36. CADMIUM RESULTS FOR AMES - BOTTOM ASH SAMPLES
/
Test day
12
13
14
21
22
23
Date
3/13
3/13
3/13
3/13
3/13
3/14
3/14
3/14
3/14
3/14
3/14
3/15
3/15
3/15
3/15
3/15
3/15
3/16
3/16
3/16
3/16
3/16
3/16
3/24
3/24
3/24
3/24
3/24
3/24
3/25
3/25
3/25
3/25
3/25
3/25
3/26
3/26
3/26
3/26
3/26
3/26
Time
0030
0430
0830
1630
2030
0030
0430
0830
1230
1630
2030
0130
0430
0830
1230
1630
2030
0030
0430
0830
1230
1630
2030
0100
0500
0900
1300
1700
2100
0100
0500
0900
1300
1700
2100
0100
0500
0900
1300
1700
1200
Sector
code3
A
A
D
A
F
F
C
B
B
A
B
D
A
A
D
D
A
C
D
A
G
E
A
E
C
C
C
A
A
D
D
B
F
B
E
B
A
C
C
B
C
Cadmium
(M8/2)
3.92
1.86
2.24
0.25
1.28
1.66
3.28
2.96
1.90
1.90
1.46
4.36
7.15
0.74
0.78
0.96
0.46
0.62
0.78
0.48
1.08
0.90
1.00
1.02
2.82
0.60
1.64
0.76
1.34
0.78
3.68
3.24
3.76
1.94
2.78
2.00
2.20
2.28
2.84
2.02
2.48
a The accessible portion of the hopper was divided into six sectors which
were sampled according to a randomized selection scheme.
79
-------
TABLE 37. CADMIUM RESULTS FOR AMES - COAL SAMPLES
Test day
12
13
14
21
22
•
23
Date
3/13
3/13
3/13
3/13
3/13
3/14
3/14
3/14
3/14
3/14
3/14
3/15
3/15
3/15
3/15
3/15
3/15
3/16
3/16
3/16
3/16
3/16
3/16
3/24
3/24
3/24
3/24
3/24
3/24
3/25
3/25
3/25
3/25
3/25
3/25
3/26
3/26
3/26
3/26
3/26
3/26
Time
0600
1000
1400
1800
1800
0200
0600
1000
1400
1800
2200
0200
0600
1000
1400
1800
2200
0200
0600
1000
1400
1800
2200
0230
0630
1030
1430
1830
2230
0230
0630
1030
1430
1830
2230
0230
0630
1030
1430
1830
2230
Feed stream
code*
A
B
A
B
B
B
B
B
B
A
B
A
A
A
A
A
B
B
B
A
B
A
B
A
B
A
B
B
B
B
A
B
A
A
A
B
A
B
B
A
B
Cadmium
(Pg/g)
0.124
0.024
0.068
0.116
4.04
0.043
0.087
0.219
0.159
0.128
0.176
0.210
0.293
0.040
0.153
0.055
0.075
0.138
0.027
0.094
0.099
0.367
0.141
0.157
0.104
0.129
0.241
0.090
0.173
0.122
0.045
0.079
0.055
0.084
0.286
0.193
0.109
0.055
0.222
0.166
0.641
a Two coal feed lines were sampled according to a randomized selection scheme.
80
-------
TABLE 38. CADMIUM RESULTS FOR AMES - REFUSE-DERIVED FUEL SAMPLES
Test day
12
13
14
21
22
Date
3/13
3/13
3/13
3/13
3/14
3/14
3/14
3/14
3/14
3/14
3/15
3/24
3/25
3/25
3/25
3/25
3/26
3/26
3/26
3/26
3/26
Time
0130
0530
1730
2130
0130
0530
0930
1330
1730
2130
0130
1400
1000
1400
1800
2200
0200
0600
1000
1800
2200
Feed stream
code3
D
D
D
C
B
C
B
C
A
C
A
C
A
B
C
D
B
B
B
A
A
Cadmium
(UK/g)
2.84
1.99
2.41
1.14
2.31
2.96
4.85
2.79
2.37
3.68
5.30
2.63
3.71
3.72
2.37
1.73
1.59
1.69
6.26
3.60
0.94
a Four RDF feed lines sampled according to a randomized selection scheme.
81
-------
TABLE 39. CADMIUM RESULTS FOR AMES - FLUE GAS
OUTLET PARTICULARS
Cadmium
Volume Mass Concentration
Test day Date (dson) (Mg) (Mg/dscm)
21 3/24 3.69 83.2 22.6
22 . 3/25 3.48 97.3 28.0
23 3/26 3.93 100.0 25.5
82
-------
CHICAGO NORTHWEST INCINERATOR
Organics
The results of TOC1 analyses of flue gas inlet and outlet samples from
the Chicago incinerator are shown in Table 40 along with the corresponding
surrogate recovery data. TOC1 and surrogate results for plant background,
air particulates, ESP ash, combined bottom ash (i.e., bottom ash plus ESP ash),
refuse, and tap water (plant intake water) are shown in Tables 41 to 45.
Organic chlorine was not detected by the TOC1 procedure in any of the field
blanks, method blanks, or flue gas first impinger extracts. These results,
as well as all other results in this report, are shown uncorrected for sur-
rogate recoveries.
In general, the surrogate recoveries were poor. As with the Ames results,
d8-naphthalene recoveries (typically 10-50%) were lower than d12-chrysene re-
coveries (typically 30-60%). Although a portion of the apparent losses may
be attributed to difficult sample matrices, the cause of consistently lower
recoveries is not known.
The results of determinations of PAH compounds and additional compounds
identified in the composite Chicago extracts are shown in Table 46. Composite
refuse extracts were not analyzed due to extremely high levels of interfering
materials and the likely nonrepresentatative nature of the refuse sample col-
lection. A large number of chlorinated benzene and phenolic compounds were
identified. Dibenzofuran was identified in the flue extracts. As noted for
the Ames samples, only very low levels of phthalate esters were identified in
the flue gas blank extracts.
Interestingly, the compound specific determinations compare very favor-
ably with the TOC1 results for the same extracts. Table 47 shows a comparison
of the TOC1 results for selected composite extracts (i.e., those in which sig-
nificant levels of chlorinated compounds were identified) calculated from the
TOC1 concentrations in the component extracts with those calculated from the
sums of chlorinted compounds identified. The percent deviation from the mean
for these pairs is 14%.
The results of analysis of the composite Chicago flue gas outlet extracts
for PCBs are shown in Table 48. In contrast to the results from the Ames ex-
tracts, the PCB contents of the Chicago flue gases were largely di- through
pentachloro-substituted.
The results of HRGC/HRMS analyses of the composite Chicago incinerator
extracts for PCDDs and PCDFs are shown in Table 49. The mean recoveries for
1,2,3,4-tetrachlorodibenzo-p_-dioxin and octachlorodibenzo-p_-dioxin through
the extract cleanup were 60 and 25%, respectively. Although a number of PCDD
and PCDF compounds were identified, trichlorodibenzofurans were found at the
highest concentrations. Table 50 shows the results of specific analyses for
2,3,7,8-tetrachlorodibenzo-£-dioxin. This compound was detected in all three
extracts, although the concentrations measured were substantially less than
1 ng/dscm. No PCDD or PCDF isoraers were detected in any blank extracts.
83
-------
TABLE 40. TOCI RESULTS AND SURROGATE RF.COVF.R ILS FOR CHICAGO NV FI.IIE GAS SAIIPLES
Teil day
I
2
3
4
5
6
I
I
9
10
II
I
2
5
4
5
6
1
8
9
10
II
Date
VollMU
5-4
5-6
5-7
5-8
5-9
5-10
5-11
5-12
5-13
5-15
5-16
5-
5-
5-
5-
5-
5-10
5-11
5-12
5-13
5-15
5-16
11.10
22.31
20.53
19.69
20.19
18.92
20.48
19.52
19.05
20.26
20.22
18.20
24.82
22.95
25.07
21.39
22.09
21.51
21.74
21.38
21.91
23.26
fieiin
TOCI
_ __ _ Surrogate recovery
" '""
Total
c
Reiin
17.500
33.900
12,300
13.900
22.600
10.700
11,900
11,700
11,000
12,100
33,200
16,800
69,100
32,700
309,000
32,200
63,200
47.900
39,400
19,100
44.500
30,600
14,400
52,200
26.700
21.330
19.700
23,900
10.900
36,300
30,400
17.400
22,500
3.460
8.780
7.720
28,600
12.000
9.940
6,750
24,000
7.070
5,940
4.060
Flue Cat Inlet
2.800
3.860
1,900
1,770
2,090
1,830
1,110
2,470
2,170
1.460
2,753
Flue
1,100
3,140
1.760
13,500
2,070
3,310
2,540
2,920
1,230
2.300
1.490
37
80
49
54
38
9
17
30
22
25
92
Cat Outlet
7
19
0
16
5
38
44
6
64
64
18
HI ___ , __
Parliculalr*
38
20
41
62
54
27
16
13
46
27
13
40
19
52
16
48
27
17
36
24
28
13
-------
TABLE 41. TOC1 RESULTS AND SURROGATE RECOVERIES FOR
CHICAGO NW PLANT BACKGROUND AIR SAMPLES
Test day
2
3
4
5
6
7
8
9
10
11
Date
5-6
5-7
5-8
5-9
5-10
5-11
5-12
5-13
5-15
5-16
5-17
5-19
Volume
(m3)
660
490
570
590
510
590
390
580
490
710
520
320
TOC1
Cag)
1,510
1,400
1,840
1,730
< 30
430
< 30
540
890
1,240
760
590
Surrogate
TOC1 da-Naphthalene
(ng/m3) (%)
2.3
2.9
3.2
3.0
< 0.1
0.7
< 0.1
0.9
1.8
1.7
1.5
1.8
58
67
46
23
7
55
0
34
26
37
11
2
recovery
d12-Chrysene
(%)
45
74
71
55
1
170
0
33
28
44
24
66
a Calculated from the sampling time and the flowmeter reading on the Hi-
Vol sampler.
85
-------
TABLE 42. TOC1 RESULTS AND SURROGATE RECOVERIES FOR
CHICAGO NW ESP ASH SAMPLES
Surrogate Recovery
Test Day Date
0 5-3
1 5-4
2 5-6
3 5-7
4 5-8
5 5-9
6 5-10
Time
0200
0600
1000
1400
1800
2200
0200
0600
1000
1400
1400
1800
2200
0200
0600
1000
1400
1800
2200
0200
0600
1000
1400
1800
2200
0200
0600
1000
1400
1800
2200
0400
0800
1200
TOC1
(ns/g)
226
203
68
89
143
54
} 59
| 62
62
} 76
| 192
} 49
} 95
370
150
15
14
23
49
130
340
41
210
160
38
111
84
57
dg-Naphthalene d12-uxrysene
fa tt)
41
36
0
44
•45
18
8
28
8
7
58
20
0
60
28
0
18
5
44
40
56
44
37
28
26
37
19
9
68
63
46
80
72
35
35
52
24
39
97
15
0
83
24
12
7
18
31
28
14
32
21
20
30
32
35
32
(continued)
86
-------
TABLE 42 (continued)
Test Day Date Time
6 5-10 1600
2000
5-11 0000
7 0400
0800
1200
1600
2000
5-12 0000
8 0400
0800
1200
1600
2000
5-13 0000
9 0400
0800
1200
1600
5-14 1600
2000
0000
10 5-15 0400
0800
1200
1600
2000
TOC1
(ng/g)
59
65
76
\ 108
} 54
31
} 132
} 43
1 38
I «
| 150
76
| 20
220
203
70
159
< 1
Surrogate
d g -Naphtha 1 ene
39
8
23
66
30
13
40
36
30
40
30
26
12
0
52
28
23
0
Recovery
di2-Chrysene
40
76
57
21
38
0
36
21
32
35
30
26
16
48
. 49
25
0
(continued)
37
-------
TABLE 42 (concluded)
Test Day Date Time
TOC1
(ng/g)
Surrogate Recovery
dg-Naphthalene di2~Chrysene
5-16
11
12
5-17
0000
0400
0800
1200
1600
2000
0100
0900
1300
1700
2100
137
211
78
173
15
154
12
22
24
39
50
9
0
14
49
59
57
17
39
26
88
-------
TABLE 43. TOC1 RESULTS AND SURROGATE RECOVERIES FOR
CHICAGO NW COMBINED BOTTOM ASH SAMPLES
Surrogate Recovery
Test day Date
5-2
0 5-3
1 5-4
2 5-6
3 5-7
4 5-8
5 5-9
Time
2300
0300
0700
1100
1500
1900
2300
0300
0700
1100
1500
1500
1900
2300
0300
0700
1100
1500
1900
2300
0700
1100
1500
1900
1900
2300
0300
0700
1100
1500
1900
2300
Sector
code
A
E
E
E
A
B
A \
A J
D \
A
C )
A J
A 1
E J
B )
E J
D )
B J
B
B
D
E
C
B
B
C
D
C
B
A
TOC1
(ng/g)
< 1
< 1
< 1
< 1
< 1
< 1
< 1
< 1
< 1
< 1
6
< 1
6
3
< 1
< 1
< 1
124
< 1
< 1
7
76
5
3
< 1
38
dg-Naphthalene
(W
18
39
33
18
31
56
52
12
34
29
34
0
38
46
8
22
19
37
13
0
11
75
48
72
47
85
d12-Chrysene
23
35
26
23
20
21
25
0
7
52
32
26
58
52
24
26
20
64
8
0
5
9
11
78
13
10
(continued)
89
-------
TABLE 43 (continued)
Test day Date Time
6
7
8
9
10
5-10 0100
0500
0900
1300
1700
2100
5-11 0100
0500
0900
1300
1700
2100
5-12 0100
0500
0900
1300
1700
2100
5-13 0100
0500
0900
1300
1700
5-14 1700
2100
5-15 0100
0500
0900
1300
Sector
code3
A
£
B
C
£
£
£
£
£
D
B 1
C J
E '
B j
A 1
B j
B
E ;
D
D
C )
A ]
£
A ]
A j
A \
E J
C \
C j
Surrogate
TOC1 da-Naphthalene
(ne/2) (%)
7
16
< 1
< 1
< 1
49
J 6
J < 1
1 < *
1 < l
\ 28
1 1S
| 3.8
\ 21
< 1
\ 2
18
2
13
42
34
41
34
33
43
31
36
8
17
37
57
60
28
19
34
35
Recovery
d12-Chrysene
11
7
8
8
11
12
34
25
36
13
25
26
100
12
7
0
8
7
(continued)
90
-------
TABLE 43 (concluded)
Surrogate Recovery
Test day Dae Time
5-15 1700
2100
11 5-16 0100
0500
0900
1300
1700
2100
Sector
code
E \
c (
E
C
C
E
B
D
TOC1
(ng/g)
< 1
< 1
7
< 1
< 1
< 1
< 1
d g -Naphtha 1 ene
(%)
21
26
26
50
44
6
24
di2-Chrysene
(%)
5
6
8
7
6
6
6
The accessible portion of the bottom ash discharge hopper was divided
into five sectors which were sampled according to a randomized
selection scheme.
91
-------
TABLE 44. TOC1 RESULTS AND SURROGATE RECOVERIES FOR CHICAGO NW REFUSE SAMPLES
VO
Test day Date Time
0 5-3 0100
0515
0900
1300
1700
2100
1 5-4 0100
0500
0900
3 5-7 0900
1300
1700
2100
2110
4 5-8 0100
0500
0900
1300
1700
2100
5 5-9 0100
0500
0900
1300
1700
2100
Sector
code
A
B
B
B
A
B
A \
B 1
A
AB >
S }
A
A
B
A
B
A
B
B
A
A
B
B
A
TOC1
(ng/g)
1,780
9,940
961
62
778
12,300
221
< 1
14
1,350
< 1
84
165
38
583
27
567
1,550
246
41
607
1,670
273
Surrogate
dg-Naphthalene
15
12
12
5
28
15
0
0
0
0
25
8
12
19
9
0
9
36
5
0
14
2
0
recovery
d12-Chrysene
15
12
0
5
18
15
0
0
0
0
0
4
15
32
26
0
9
120
5
0
10
0
0
(continued)
-------
TABLE 44 (continued)
Surrogate recovery
Test day
6
7
8
9
Date Time
5-10 0300
0700
1100
1500
1900
2300
5-11 0300
0700
1100
1500
1900
2300
5-12 0300
0700
1100
1500
1900
2300
5-13 0300
0700
1100
1500
Sector
o
code
B
A
B
A
B
A
B \
A 1
B \
A 1
B \
B )
B \
A 1
B I
A 1
B \
B 1
A \
A 1
B \
A f
TOC1
(ng/g)
108
467
< 1
167
11
54
< i
^ »
599
95
< i
^ &
389
< 1
< i
< i
dg-Naphthalene
0
9
0
6
46
0
o
2
0
o
8
0
0
o
ryme
0
1
0
6
38
0
o
0
0
o
3
0
0
0
(continued)
-------
TABLE 44 (concluded)
--— • - ••—
Surrogate recovery
Test day Date Time
10 5-14 1500
1900
5-15 0300
0700
1100
1500
1900
2300
11 5-16 0300
0700
1100
1500
1900
5-17 0000
Sector
code
B
A
A
A
B
B
A
B
A
B
A
A
B
B
TOC1
(ng/g)
< 1
2,700
22
8,070
< 1
< 1
< 1
< 1
26
< 1
45
< 1
< 1
< 1
da-Naphthalene
0
5
68
30
0
0
0
4
16
0
0
17
6
6
^rysene
50
10
68
32
0
0
0
5
15
0
0
1
6
0
The accessible portion of refuse was divided into two sectors which were sampled
according to a randomized selection scheme.
-------
TABLE 45. TOC1 RESULTS AND SURROGATE RECOVERIES
* FOR CHICAGO NW TAP WATER SAMPLES
Test day
5-
6
7
Date
5-9
5-10
5-11
5-14
TOC1
(ng/JE)
< 30
< 30
< 30
< 30
Surrogate recovery
tig-Naphthalene
14
0
68
12
16
0
24
10
95
-------
vO
Compound
I»ri?L PAH Compound;
Tlienanthrene
Fluoranthene
Pyrene
Additional Conpounda Idendlfled
1,3-DichlorofceMene
1 ,4-Dlchlorobenzene
1 ,2-Dichlorobenzene
1,2,3-Trlchlorobenzene
1,2,4-Trlchlorobenzene
1 ,3,5-Trichlorobenzene
Trtrachlorobenzeae
Plant backbround
air parllculalrs
Conpoiltr concentration
1
2
3
1 1.0
2
3 0.28
1 • 0.82
2
3 0.18
1
2
3
1
2
3
1
2
3
1
2
3
1
2
1
,
2
3
1
2
3
Flnr gas inlrl
concent rat Ion
120
32
28
110
27
IB
300
140
S7
130
130
18
96
98
14
140
120
20
140
81
27
SSO
380
160
490
280
120
1,400
1.000
1.400
Flue gai outlet Combined alb ESP Alb
concentration concent rat ion concentration
200
no
340
39 17
27
SI 9.4
92 12
91
77 7.8
48
57
ISO
200
220
S60
190
180
460
790
610
(continued)
-------
TABLE 46 (ronrluded)
Compound
Hexachlorolienzrnr
Dichlorophenol*
Trichlorophenol*
Tetracbloropbenol*
Pentacblorophenol
Dibenzofuran
DiBctbylpblbalate
Dlethylphthalale
Di-n-butylphtbalate
Butylbenzylpbthalate
BU(2-elbylbexyl )phthalate
.
Plant background
air particulale*
Composite concentration
day (on/dica)
,
2
3
1
2
3
,
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
2
3
1
2
3
1
2
3
— - -- -
Flue gas inlet
concentration
(nf/dicn)
100
39
12
560
240
190
2,100
970
600
2,200
1,100
600
130
64
86
28
23
Flue gai outlet Combined a«h ESP Ash
concentration concentration concentration
(ng/dsc.) (ni/t) (ni/g)
110
4S
260
240
280
630
,400
,200
,900
,500
.100
,700
190
160
430 83
100
67
140
4.8
SO
IS
6.1
32
130 170
47 230
370 89
— ._ -. .
a Specific isoaer not determined.
-------
TABLE 47. COMPARISON OF TOC1 RESULTS FROM DIRECT TOC1 ASSAYS
VERSUS CALCULATED TOC1 FROM SPECIFIC COMPOUNDS
IDENTIFIED IN COMPOSITE CHICAGO NW EXTRACTS
Sample type
Composite
day
TOC1 assay
Sun of compounds
identified
Flue gas inlet
Flue gas outlet
ESP Ash
1
2
3
1
2
3
130 mg/hr
88 mg/hr
67 mg/hr
97 mg/hr
110 mg/hr
86 mg/hr
98 ng/g
200 mg/hr
110 mg/hr
56 mg/hr
120 mg/hr
96 mg/hr
190 mg/hr
93 ng/g
98
-------
TABLE 48. CONCENTRATIONS OF POLYCHLORINATED BIFHENYL ISOMERS
IN FLUE GAS OUTLET SAMPLES FROM THE CHICAGO
NORTHWEST INCINERATOR UNIT NO. 2
Composite day
(Concentration, ng/dson)
Compound identified
Dichlorobiphenyl
Trichlorobiphenyl
Tetrachlorobiphenyl
Pentachlorobiphenyl
Total chlorobiphenyl
1
5.8
7.6
4.2
2.3
19.9
2
6.0
4.3
1.5
1.0
12.8
3
40
36
13
4.5
93.5
99
-------
TABLE 49. CONCENTRATIONS OF POLYCHLORODIBENZO-P-DIOXINS AND FURANS
IN FLUE GAS FROM THE CHICAGO NORTHWEST INCINERATOR
Concentrations
(ng/dscm)
Total trichlorodibenzo-p-diozins
Day 1
2
3
Mean
S.D.
Total trichlorodibenzofurans
Day 1
2
3
Mean
S.D.
Total tetrachlorodibeazo-p-dioxins
Day 1
2
3
Mean
S.D.
Total tetrachlorodibenzofurans
Day 1
2
3
Mean
S.D.
Total hexachlorodibenzo-p-dioxins
Day 1
2
3
Mean
S.D.
15
12
11
13
2.1
350
280
270
300
44
7.2
5.4
6.2
6.3
0.90
89
84
96
90
6.0
14
21
14
16
4.0
(continued)
100
-------
TABLE 49 (concluded)
Concentrations
(ng/dscm)
Total hexachlorodibenzofurans
Day 1 43
2 84
3 59
Mean 62
S.D. 21
Total heptachlorodibeazo-p-dioxins
Day 1 7.2
2 7.8
3 7.7
Mean 7.6
S.D. 0.32
Total heptachlorodibenzofurans
Day 1 7.2
2 7.2
3 8.0
Mean 7.5
S.D. 0.46
Octachlorodibenzo-p-dioxin
Day 1 2.6
2 . 2.2
3 2.8
Mean 2.5
S.D. 0.39
Octachlorodibenzofuran
Day 1 0.72
2 0.63
3 0.46
Mean 0.60
S.D. 0.13
101
-------
TABLE 50. CONCENTRATIONS OF 2,3,7,8-TETRACHLORODIBENZO-P-DIOXIN
IN FLUE GAS FROM THE CHICAGO NW INCINERATOR
Concentration
(ng/dscm)
Day 1 0.35
2 0.36
3 0.52
Mean 0.41
S.D. 0.10
Cadmium
The results for cadmium analysis of samples of fly ash, bottom ash, and
refuse for test days 8 to 14 are presented in Tables 51 to 53. The fly ash
samples contained the highest concentrations of cadmium, ranging from 86 to
560 |Jg/g. The concentration of cadmium in bottom ash was approximately one
order of magnitude lower than that of the fly ash samples. The cadmium con-
tent of refuse samples ranged from less than 0.12 to 1.4 (Jg/g. Cadmium was
not detected in the tap water from this plant. The concentrations of cadmium
in the flue gas outlet samples are listed in Table 54. Also included in these
tables are results for the recoveries of spiked samples, which was part of
the QA program discussed in the analysis methods. The recovery of cadmium
averaged 91% from both the combined ash and the refuse and 114% from the fly
ash.
102
-------
TABLE 51. CADMIUM CONCENTRATIONS IN FIT ASH FROM CHICAGO
NORTHWEST INCINERATOR, UNIT NO. 2
Test day Date
9 5/13
5/14
10 5/15
11 5/16
12 5/17
13 5/18
Spiked distilled water
Time
0000
0400
0800
1200
1600
1700
2000
0400
0800
1200
1600
200
0000
0400
0800
1200
1600
0100
0500
0900
1300
1700
2100
0100
0500
Spike
Cadmium recovery
(U2/K) (%)*.
283 139
201, 212
209, 217,
222
376
458
391
86.1, 82.3
250
225
209, 218 109
380, 392 124, 118,
419, 425, 114
440
361
560
306 135
325, 325
237
250
216
230 94
279, 348
289
290
313 100
328, 323
309
326
97 ± 9C
a Spiked with 10 jjg total cadmium.
b Spiked with 10 |Jg total cadmium and analyzed with the sample digests.
c Mean and standard deviation for eight determinations.
103
-------
TABLE 52. CADMIUM CONCENTRATIONS IN COMBINED BOTTOM ASH FROM
CHICAGO NORTHWEST INCINERATOR, UNIT NO. 2
Test day Date
9 5/13
5/14
10 5/15
11 5/16
12 5/17
13 5/18
14 5/19
Spiked distilled water
Time
0100
0500
0900
1300
1700
1700
2100
0100
0500
0900
1300
1700
2100
0100
0500
0900
1300
2000
2100
0200
0600
1000
1400
1800
2200
0200
0600
1000
1400
1800
2200
0200
0600
1000
1400
.
Cadmium
(UR/g)
8.20
23.4
8.30, 7.34
36.1, 31.2
15.1
5.40
30.8, 27.8
15.9, 9.20
31.7
48.8
7.3
17.1
18.5, 49.4
31.7, 60.5
7.88, 28.7.
6.80
27.8
13.3
10.7, 8.64
12.1
7.5
14.5
10.4
6.00
14.3
13.1, 14.8
17.6
6.35
8.00
21.7
4.60
71
3.60
13.1
46.9
7.85
14.3
Spike
recovery
(%)a
95
61
88
81, 106
98
67
120
105
93 ± 6C
a Spiked with 10 (Jg total
b Spiked with 10 M8 total
cadmium.
cadmium and
c Mean and standard deviation for six
analyzed with the sample
determinations .
digests .
104
-------
TABLE 53. CADMIUM CONCENTRATIONS IN REFUSE FROM CHICAGO
NORTHWEST INCINERATOR
Test day
8
10
11
12
13
14
Spiked distilled
Date
5/12
5/13
5/13
5/13
5/13
5/14
5/14
5/14
5/15
5/15
5/15
5/15
5/15
5/15
5/16
5/16
5/16
5/16
5/16
5/17
5/17
5/17
5/17
5/17
5/17
5/18
5/18
5/18
5/18
5/19
5/19
5/19
5/19
water
Time
2300
0300
0700
1100
1500
1500
1900
2300
0300
0700
1100
1500
1700
2300
0300
0700
1100
1500
1900
0000
0400
0800
1200
1600
2000
0000
1200
1600
2000
0000
0400
0800
1200
Spike
Cadmium recovery
(M8/S) (%)
1.45
0.50, 1.25
0.85
0.28 91
0.45
0.63 72
1.07
0.95, 1.02
0.67
0.14 95
0.85 106
< 0.12
0.20
1.10, 1.04
1.07
0.83, 0.80
< 0.12
< 0.12, < 0.12
0.63
1.10
0.68
< 0.12
0.18
0.16 105
0.60
0.57
0.25 94
1.04, 0.94
0.55
1.25
9.85, 8.44
0.79
8.13
78 ± 22C
a Spiked with 10 pg total cadmium.
b Spiked with 10 |Jg total cadmium and analyzed with the sample digests.
c Mean and standard deviation for seven determinations.
105
-------
TABLE 54. CADMIUM CONCENTRATIONS IN THE FLUE GAS OUTLET
PARTICULATES FROM CHICAGO NORTHWEST INCINERATOR,
UNIT NO. 2
Test day
12
13
14
Date
5/17
5/18
5/19
Volume
(dscm)
6.20
6.20
6.81
Mass
(Mg)
520
1,490
1,850
Cadmium
Concentration
(Mg/dscm)
84
240
272
106
-------
SECTION 9
ANALYTICAL QUALITY ASSURANCE RESULTS
The principal quality assurance indicators used for this study were the
recoveries for surrogate compounds spiked into all samples prior to extrac-
tion and the results of three interlaboratory comparison studies.
SURROGATE COMPOUND RECOVERIES
The surrogate recoveries determined for all samples from both plants are
summarized in Table 55. As indicated in the previous section, the recoveries
observed for naphthalene are generally lower than those for chrysene. Since
the compounds of primary interest in this study are less volatile than naphtha-
lene, the naphthalene recoveries likely indicate the maximum losses attributa-
ble to volatilization. The chrysene recoveries likely provide a more accurate
indication of the recoveries of the principal analytes related to extraction
efficiency and general extraction handling.
The apparent analytical accuracy and precision as indicated by the re-
coveries and standard deviations of surrogates observed for each media was
likely influenced by the dilution of extracts prior to analysis. Many of the
more complex extracts required dilution such that the concentrations of the
surrogate compounds in the diluted extracts were near the analytical detec-
tion limits.
In general, the surrogate recoveries observed for the Ames samples were
higher than those observed for the Chicago samples. This is likely attribut-
able, at least in part, to the complexity of the Chicago samples.
INTERLABORATORY COMPARISON STUDIES
TOC1
Two interlaboratory comparison studies were conducted to check the com-
parability of TOC1 assay as conducted by SwRI and GSRI. In the first study,
selected extracts from the two plants were submitted for TOC1 assay by the
other laboratory. A second set of TOC1 extracts was prepared at MRI by mix-
ing several extracts of organic chemicals manufacturing wastewaters. The re-
sults of these two studies are shown in Table 56. Although some significant
discrepancies are apparent, the data from the two laboratories are generally
comparable.
107
-------
TABLE 55. SUMMARY OF SURROGATE RECOVERY DATA
Plant Sample type
Ames Flue gas outlet
Flue gas inlet
Plant background air
participates
ESP ash
Bottom ash
Coal
RDF
Bottom ash hopper
Determinations
11
22
21
51
51
6
36
6
Surrogate
d8 Naphthalene
(%)
47 ± 12
57 ± 24
48 ± 23
44 ± 25
55 ± 20
90 ± 16
65 ± 15
69 ± 17
recovery
di2-Chrysene
(%)
86 ± 12
73 ± 19
98 ± 22
96 ± 22
85 ± 31
90 ± 18
110 ± 28
110 ± 18
quench water influent
Bottom ash hopper
quench water overflow
Well water
Chicago Flue gas outlet3
Flue gas inlet
Plant background air
particulates
ESP ash
Bottom ash
Refuse
Tap water
50
11 (resin)
11 (filter)
11 (resin)
11 (filter)
12
53
51
51
4
42 ± 32
44 ± 38
26 ± 23
29 ± 13
41 ± 26
32 ± 17
31 ± 23
26 ± 18
33 ± 18
9 ± 13
24 ± 30
88 ± 25
88 ± 17
61 ± 37
62 ± 34
93 ± 28
55 ± 22
51 ± 45
35 ± 22
21 ± 20
10 ± 21
13 ± 10
a The resin and filter catch portions of the Chicago flue gas samples were
spiked, extracted, and analyzed separately for the surrogate compounds.
108
-------
TABLE 56. RESULTS OF INTERLABORATORY TOC1 ANALYSES
Sample
TOC1 (ng/extract)
GSRI results
SwRI results
Chicago flue gas outlet (5/15) resin3
Chicago flue gas inlet (5/7) particulate
Chicago flue gas outlet (5/12) resin
Chicago flue gas outlet (5/9) particulate
Chicago flue gas outlet (5/6) particulate
Chicago flue gas outlet (5/11) resin
Ames bottom ash (3/7, 0130 + 0530)b
Ames bottom ash (3/9, 2030)
Ames flue gas outlet (3/15)C
Ames flue gas outlet (3/18) C
Ames RDF (3/4, 0230)
Ames RDF (3/3, 1430)
Synthetic Extract I
II
III
IV
44,500
26,700
39,400
12,000
8,780
47,900
227
91.8
702
443
78,800
181,000
7,300
10,700
7,600
10,400
23,000
19,200
39,300
42,800
10,020
31,400
1,020
124
4,230
18,100
109,000
215,000
11,300
10,900
13,800
12,400, 16,200
a Prepared by GSRI.
b Prepared by SwRI.
c Resin and particulate combined.
d Prepared by MRI.
Specific Compound Analysis
An interlaboratory study was also conducted using spiked fly ash ali-
quots spiked with specific compounds. Mixed fly ash from the Ames and Chicago
plants was divided into 20-g aliquots. The aliquots were spiked by MRI with
six chlorinated compounds and submitted to GSRI and SwRI for analysis by the
same extraction, HRGC and scanning HRGC/MS procedures used for the plant sam-
ples. Four pairs of duplicate fly ash aliquots were submitted to each labor-
atory. The results of these analyses are shown in Table 57 along with the
surrogate recoveries. Most compounds were identified in the spiked samples
by both laboratories. Exceptions were pentachlorophenol in most samples and
decachlorobiphenyl in one sample by SwRI.
109
-------
TABIf 57. INTERLABORATORV COMPARISON OF ANALYTICAL RESULTS FOR TIIF. EXTRAaiON AND ANALYSIS
OF SPECIFIC COMPOUNDS IN FOIIR SETS OF QUALITY ASSIIHANCE SAHPttS
s
1
Compound (
1 ,2-Dlchlorobenzene
1,2,4 -Tr 1 cb 1 orobenzene
Heiachlorohenzene
2 ,4 ,6-Trlchlorophenol
Penlarblorophenol
Decachloroblpbenyl
pike
evel
«i/jL
0
0
0
0
0
0
_ J
Concentration*
CSSI^S-WRI
ND"
ND
ND
ND
ND
ND
ND
ND
HI)
ND
ND
ND
Spike
level
11
Concent
("B/8i GSR'
585
560
550
2,850
2,680
490
90,
too,
«5.
ND,
ND.
425,
125
170
65
45
ND
970
ratlnn
till
SwRI
952, 1.110
1,170. 1,220
295, 150
1,040, 748
tr, tr
tr, tr
Spike
level
2,910
4,200
2,750
570
535
1,230
Concentration
GSRT~" ' Swll
940.
1,660,
790,
75.
HD.
6,050,
410
865
365
ND
ND
2,890
7,420, 6,300
11,700, 10,200
1,630, 1,680
73. 112
tr, tr
403, 566
Spike
level
4,390
2,800
275
4.280
4,020
2,450
Concentration
in.S/8l
GSRI ~ SwRI
700,
720,
«5,
355,
ND.
8,650.
1,010
855
75
840
HD
6,800
20,200,
7,660,
170,
3,690,
lr,
2,460,
4,410
8,420
103
2,040
tr
1,280
Surrogate Compound Recovery (X)
Haphlhalene-d,
Cbryaene-d||
38,
*»,
2
21
88, 88
73, 84
25, 40
41, 40
89, 88
88, 76
59
SO
,30
, 18
98,
'5.
84
71
34, 42
45, 45
101. 89
III, 103
• Concentration value! reported for two Identical aanplea prepare! by HHI.
b HD a not delected.
c tr = trace.
-------
PCDD and PCDF Analysis
The results of the interlaboratory comparison of PCDD and PCDF analyses
conducted on Chicago flue gas outlet extracts by MRI and R. Earless at EPA's
Research Triangle Park laboratory are shown in Table 58. Both the qualita-
tive and quantitative results from the two laboratories were quite comparable.
There were no qualitative discrepancies. The agreement in quantitation is
reasonable, particularity in view of the facts that: (1) the two laboratories
utilized different gas chromatographic systems and different selected ion
monitoring procedures (computer controlled ion selection by MRI and hardware
controlled ion selection by EPA) and (2) that the levels were near the limits
of detection.
TABLE 58. INTERLABORATORY COMPARISON OF THE LEVELS OF PCDDs AND PCDFs
IN COMPOSITE EXTRACTS FROM THE CHICAGO NW INCINERATOR
Total mass in sample (ng)
Composite Parameter
1 2,3,7, 8-Tetrachlorodibenzo-p-dioxin
2 2,3,7, 8-Tetrachlorodibenzo-p-dioxin
3 2,3,7, 8-Tetrachlorodibenzo-p-dioxin
4 Total tetrachlorodibenzo-p-dioxin
5 Total tetrachlorodibenzo-p-dioxin
6 Total tetrachlorodibenzo-p-dioxin
7 Total tetrachlorodibenzofuran
8 Total hexachlorodibenzo-p-dioxin
MRI results
24
24
34
500
360
400
5,600
1,400
EPAa results
14
7.0
9.4
1,200
740
660
1,640
280
a Calculated from data in Reference 8.
111
-------
SECTION 10
EMISSIONS RESULTS
AMES MUNICIPAL POWER PLANT, UNIT NO. 7
The TOC1 input and emission rates determined for the Ames plant during
the test period are shown in Table 59. These results were calculated from
the daily mean levels of TOC1 in coal, RDF, and ash from Section 8 and the
mass and volume flow rates from the engineering and process data in Section
7.
Since TOC1 is not a conservative parameter, it is not surprising that
the mean TOC1 destruction rate is greater than 99%. Interestingly, these
data indicate that flue gas was responsible for the largest fraction of TOC1
emissions, 83%. Bottom ash and fly ash contributed only 11 and 5%, respec-
tively, of the total emissions.
Table 60 shows the input and emission rates for the target PAHs and other
compounds identified in the composited Ames extracts. The mass and volume
flow data used for the input and emission calculations are averages for the
sampling days comprising the composite days.
The emission rates for PCBs in the Ames flue gas samples are shown in
Table 61. Only the composited flue gas outlet extracts were analyzed for
PCBs by HRGC/MS-SIM. PCBs may have been present in other inputs and emis-
sions media at concentrations below the limit of detection of scanning HRGC/MS.
A summary of the cadmium inputs and emissions for the test days investi-
gated at the Ames Municipal Power Plant is presented in Table 62. The total
inputs and emissions represent a good mass balance.
CHICAGO NORTHWEST INCINERATOR, UNIT NO. 2
The calculated TOC1 inputs and emissions are shown in Table 63. The ap-
parent mean TOC1 destruction rate (97%) is slightly lower than was observed
for the Ames plant. However, the difficulty experienced in taking representa-
tive samples of raw refuse hinders accurate destruction efficiency determina-
tions. The contribution of flue gases to total TOC1 emissions is remarkably
similar, 87% for the Chicago incinerator relative to 83% for Ames power plant.
112
-------
TAILE 19. TllTAl UDUAHIC CUUNHNF. INI1ITS AND EMISSIONS - AHES MUNICIPAL MUT-i fUHT, UNIT Nn I
Load
fisls. 181.
1/2 16
1/1 16
1/4 90
1/S 91
1/6 If
I/I II
I/I M
3/9 60
1/10 11
l/ll II
1/12 19
l/ll 19
1/14 II
I/IS 62
I/I! 14
l/ll 91
1/19 19
1/20 17
1/22 14
1/21 S2
Deleraln- 20
atlona
Mean 11
Standard II
deviation
RDF
feed
0
11
21
If
22
14
20
4
10
24
21
16
24
4
12
II
IS
I
II
0
20
14
I.I
Coal
toci tocr
Feed cone. Input
Ik.l&l.jFI/lI ..iSI/hrl
14.600 7)
14,400 72
14.400 72
IS, 200 76
14.600 71
IS, 200 76
12,100 64
10,100 54
14,200 II
11,100 6I.S
16.000 M.O
14,100 10.1
11,900 69. S
10,900 S4.S
14,200 II
14,100 71.5
14,200 II
IS. 600 71
14,100 10. S
_9J2SO 46.1
20 20 20
11,100 S 69
1,100 M) 1.4
Inputs
Refuse-derived
"TOCI'
Feed eonc.
-i*l&).j5l/l).
0
2,1)0 20,100
4,290 .100
1,640 .500
4.0)0 .200
2.470 ,900
1,110 1 ,100
411 .000
1.530 ,100
4,140 11,000
4,120 19,900
2.120 9.600
4.150 22.000
411
I.ISO
2.910
2.SSO
1.200
1.7*0
0
20 12
2,112 11,500
1,570 6,200
.
fuel Total
mr TOCI
Input Input
(•i/krj. IfttttTl _
42,900 4),000
19,900 40,000
12,100 12,100
33.050 11,100
24,500 24,600
11.500 11.600
2.SOO 2,600
1,100 1,200
56.400 56,500
16,000 16.100
26.100 26,200
95.700 95,100
12 12
11,900 19,000
21,100 21.100
-Ha..-
Clow
!>
100
150
550
450
550
400
500
200
300
550
500
400
550
200
150
500
400
250
150
100
20
110
ISO
— —
notion iik
'"Wei"
cone . «a
-Jsrti! <
5.5
124
97
36
44
55
11
4.4
11
111
SI
156
31
1)
62
47
- ••• — •-•
Toci ' ft. TBci*
laalona flow cone, rn
Sl/St I Jtl/h.£j . (HiYli-I
o.ss ,200
4) ,200
51 ,200
16 ,200
24 ,200
22 ,200
17 .200 5
0.11 ,200
11.4 ,200
61 ,200
29 ,200
62 ,200 2.
21 ,200 1.
,200
,200
.200
.200
,200
.200
1.200
11 20 11
21 1.200 1.7
21 HO 14.6
billions
TOCT HaTi
laalont eBinslons
•(&>_ .HiaftiL
309.200
121.100
121,000'
122,500°
140,100°
3II.400C
6 29I.100C
242,900*
333.3001
14I,SOOC
121,900
219,100
251,400
125,400
119,100
114.100
120,000
112.200
225,100
11 19
9.2 10S.700
II. 4 32,900
-E!feP~
eonc. ei
_(M/tasi—
IS6
1,210
166
4S4
9SI
412
161
411
111
562
112
1,610
211
950
US
I.OSI
205
124
HI
19
616
42S
Tntnl
fBEI TOCI
•laalnni ratlsaloni
tsttel — !u/lil_
41.2 54.4
192 411
2SI 112
146 161
124 151
111 IS4
101 191
100 105
271 296
192 251
109 114
416 Sll
61.5
309
til
111
6S.6
41.2
M.t
19 12
194 246
114 111
Percent of
TOCI esltilona
flue
— •*_. !»_ .Hi.
1 10 19
10 1 19
IT 1 10
10 1 II
I 1 92
14 2 U
9 35 54
1 4 95
4 2 94
24 1 IS
16 2 62
4 1 9S
12 12 12
II S 11
10 10 11
*
• I*llMl<4 I tarn mm cBlliioni df outlet luple* were lot collected on Ikii day. The •»< enliilon* and TOCI coiirenlrallun data «ie lor Hue |i> Intel lupin collected
oo tkli dly. Flue |« TOCI eaUilont ire corrected lor tkr TOCI !• Ike ESf i«k
-------
TABLE 60. COMPOUNDS QUANTITATED |H THE PRIMARY INPUT AND EMISSION tIEDIA FOR TIIF. AJIES MUNICIPAL POUF.R PLANT. UNIT NO. 7
Inputa
Reruae-d
Coal lui
Cnapoalte
Compound day
Target PAH coapounda
Fhenanlhrene
Anthracene
Fluorantbene
Pyrene
Chryaene
•enzo|a|pyrene
lndeno(l,2,)-c,d)pyrene
lenzo||,h.i|perylene
1
2
3
4
S
1
2
3
4
S
1
2
3
4
S
1
2
3
4
5
1
2
3
4
S
1
2
3
4
5
1
2
3 '
4
5
1
2
3
4
5
Cone.
7,550
9,090
15,400
8,500
18.600
1,570
1,840
1,260
2,120
4,110
1,190
1,640
3,320
900
3,210
1,340
1.960
3,810
1,070
4,040
370
425
1,060
238
1,300
Input
rale Cone.
J«g/hr) (nt/i)
110,000
130,000
210.000
110,000
270,000
23,000
26,000
18,000
28,000
59,000
17,000
23,000
46,000
12.000
46.000
20.000
28,000
53.000
14,000
58,000
5,400
6,000
15,000
3,200
19,000
1,400
940
948
828
296
984
271
306
198
552
436
282
372
434
le rived
!l
Input
rale
3,100
4,100
1,800
1.800
810
1,300
1,200
580
420
1,500
1.900
530
790
1,200
Plant
background
Cone.
n|/dicn)
0.29
0.6
0.8
0.8
0.32
0.17
0.16
0.19
0.36
0.7
0.7
1.0
0.5
0.36
0.7
0.7
I.I
0.5
0.29
0.40
0.37
0.60
0.38
0.07
0.17
0.11
0.09
0.07
0.02
0.09
atr
Input
rate
In/h'L- L
0.04
0.09
on
0.13
0.044
0.028
0.024
0.030
0.05
0.11
0.11
0.16
0.07
0.05
0.12
0.11
0.17
0.07
0.04
0.07
0.06
0.09
0.05
0.01
0.28
0.016
0.015
0.008
0.003
0.01%
Flue gaa
Inlet
Eailialona
Flue gaa
outlet ESP aih Bottoa) aah
Fjaitiion filiation EaUaaion Eailaalon
Cone. rate Cone. rate Cone. rate Cone. rate
ng/dic«i Jaii/hr) (nc/dsn) fa/hr) (n«/t) (»i/br) (og/gLJfE^ll
270
420
660
640
200
59
57
77
89
100
70
240
140
87
94
220
850
480
230
330
3-5
28
9.6
2.8
21
64
120
19
63
76
140
200
200
54
16
18
22
28
28
20
78
42
28
26
64
280
140
74
90
1.0
8.0
3.2
0.16
6.0
22
38
6.2
17
390
320
320
37
480
49
77
78
46
77
46
40
97
28
130
110
96
250
66
330
2.7
13
28
3.3
22
4.6
110 0.3
100
96 0.2
12 0.2
13 0.2
14
26
24
14
22
13
13
30
8.8
36
32
32
74
22
90
0.3
0.76
3.8
6.0
0.96
6.6
1.5
0.4 32
250
0.2 140
0.2 43
0.2 500
24
130
10
52
30
450
9.0
64
29
6.0
420
0.4
170
3.2
99
78
14
180
13
46*
1.0
21
17
160
0.90
26
16
1.9
150
58
(emit I nurd)
-------
TABI.E 60 (Continuc.l)
Ol
Compound
Additional compounds
Dicblorobenzene
1 ,2,4-Trlchlorobenzene
HeKachlorobutadlene
Tetracblorobenzene*
Pentacblorophenol
Phenol
2,4'Diawlbylphenol
Inputs
Refuse-derived
Coal fuel
Input Input
Composite Cone. rate Cone. rale
day (ng/g) (.g/hr) (ng/g) (.g/hr)
1
2 1,300 3,500
3 1.200 5,200
4 520 980
S 430 920
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2 1,300 3,500
3
4
5 690 1,500
1 10,000 150,000
2 12.000 170.000
3 2.800 39,000
4 23.000 310.000
5 29,000 420,000
1
2
3
4
5
Emissions
Plant . Flue gas Flue ga« ,
background air inlet
Input E
Cone. rate Cone.
(ng/dsc.L («g/hr) (ng/dsc.)
25
79
25
0.02 0.0028 99
0.01 0.0016 ISO
69
0.02 0.0024 103
0.07 0.010
24
3.3 0.46 4,700
1.3 0.21 4,000
0.8 0.11 13,000
1.5 0.23 5,100
1.8 0.25 9,500
•1st Jon
rate
out
Cone.
(.g/hr) (ng/dsc.)
8.2
24
6.8
32
52
19
30
7.2
1,300
1,300
4,000
1,600
2,600
3.3
5
110
85
6,400
7.700
3.000
6.000
6.200
1,000
1,200
1,300
2,100
let
Emission
rate
(•g/hr)
1.0
1.5
34
24
1,800
2.600
920
1,900
1,700
300
400
400
580
ESP ash Bolto. ash
Emission Emission
Cone. rate Cone. rate
(ng/g) (.g/hr) (ng/g) (.g/hr)
24 . 9.6
0.07 0.08
220 260 980 98
1 ,600 640
1.800 990
190 230 360 110
380 460 730 260
27 II
8 2.5
(continued)
-------
TABU 60 (Continued)
Compound
Naphthalene
Fluorene
leiu|a|anthracene
Beniofluoranthrene
Benio|e|pyrene
Acenaphlhene
Acenaphthylene
Trichlornlicnzen*
— _ __
Composite
day
4
5
1
2
3
4
5
1
2
3
4
5
,
2
3
4
5
Coal
Cone.
_iai/ii_J
1,400
1,100
1,800
1,800
2,700
3,500
3,100
5,600
3,300
Inputs
Refuse-derived
luel
Input input
rate Cone. rate
•i/hr) (ng/«.) (•t/hr|
20,000
16,000 36,000 98,000
25,000 2,200 9,600
24,000 1,500 2,800
39,000 1,500 3,200
50,000
43,000 600 1,600
78,000 450 1,900
45,000 380 712
7,000 100,000 320 677
261
470
960
260
1,200
650
970
1,600
1,400
1,500
220
240
560
400
450
3,800
6.600
13,000
3,400
18,000
9,500
14,000 1,200 3,200
22,000
18,000
22,000
3,200
3,400
7,700
5,300
6., 500
HIHt
background
Cone.
(ng/dicai)
0.28
0.22
0.32
0.28
0.13
0.22
0.32
0.28
0.13
0.14
0.44
0.53
0.55
0.38
0.42
0.67
0.63
0.65
0.51
Emission*
— — —
Fiiie gas Flue gas
.•«.!._
input
rate
(58/h.r)
0.040
0.037
0.048
0.045
0.017
0.037
0.048
0.045
0.017
0.020
0.073
0.079
0.089
0.052
0.060
0.11
0.095
O.I
0.070
_lnlel on
£•1 ii ion
Cone. rate Cone.
tlet __ __£SP ash _
Eat ii Ion "filiTlon
rate Cone. rate
(ni/dsc.) (.i/hr) (m/dsc.) (.i/hr) (ai/i) (M/hr)
710 200 650
1,000 340 550
620 190 81
1,800 560 300
740 200 850
120 34
7.2 2.2
6.
9.9 3.2 2.
12
6.
17 2.3
29
20 6.6
24 7.2
36
77
24
190 0.17 0.2
180
24
98
240 0.18 0.22
5 1.9
7 0.88
3.6
9 2.2
8.8
10.2
26
7.2
_Bollos_ash
Earfsiloli
Cone. rate
(nt/t) (.g/hr)
15 1.5
360 140
110 61
29 9.2
14 7.7
•
1.0 O.SS
120 12
75 30
10 5.5
100 32
130 47
(ronlinucil)
-------
TABLE 60 (cnnrluilnil)
Inputs
Refuse-
Coal fi
Compound
OiMthylphthaUle
Diethylpbthalate
Di-n-butylphtbalate
Butylbenzylphlbailte
Bia(2-ethylhexyl)-
pbtbalate
Input
Coaponite Cone. rate Cone.
day Jng/g) (.g/hr) (ng/g)
2
3
4
5
1
2
3
I
S
1
2
3
A
5
1
2
3
I
5
1
2
3
4
S
9
1
II
ia
u
6
14
59
22
350
44
35
22
730
,100
290
,400
,000
,000
,000
,400
,000
,000
,000
,000
,000
,000
,000
-der
KL
r
(•
25
1
2
23
49
61
12
28
no
46
970
190
66
46
Emissions
ived Plant Flue gas Flue gat
background air inlet outlet ESP
ash
nput Input Emission Emission Emission
ate Cone. rale Cone. rate Cone. rate Cone. rate
g/hr) (ng/dsc.) (.g/hr) (ng/dsc.) (aig/hr) (ng/dsc,.) («g/br) (ng/g) (ag/hr)
,600
,000
,300
,700
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
0
11
0
2
IS
3
4
6
6.0 14
3
2
a
.20
.5
.0
.0
.0
.0
.0
.0
.0
0.48
26
1.20
48
36
7.2
9.6
14
7.2
4.8
19
Boltnai ash
Eviction
Cone. rate
(ng/g) (ait/br)
3.0
37
16
4.0
42
12
35
170
32
51
980
1,200
480
810
0.30
15
5.1
0.40
16.8
6.6
11
58
3.2
28
9. B
470
260
260
a Specific lioner not determined.
-------
TABLE 61. FLUE GAS CONCENTRATIONS OF PCBs AND EMISSION RATES
FOR THE AMES MUNICIPAL POWER PLANT, UNIT NO. 7
Total PCBs
Concentrations Emission rate
(ng/dson) (mg/hr)
Ames composite day 1 5.2 1-4
2 27 9.0
3 23 6.8
4 25 8.2
5 17 4.8
Mean 19 6.0
S.D. 8.8 3.0
118
-------
IAIIX 62. CADHIUH IHI'HIS AND MISSIONS - AJES IIUMICirAL KM.K PUNT. UNIT HO I
Teal
*•»... ."•««
II 3/12
12 3/13
13 1/14
14 I/ IS
1/16
21 3/24
22 3/25
23 3/26
OelciBlo-
allona
Mean
Standaid
deviation
Load
(X)
II
19
17
62
15
14
|7
1
•i
9.5
RUf
..tti...
23.5
IS. 3
23. t
3.69
6. IS
10.9
J5.0
7
14
1.1
~Ka»
flow
13,900
15.010
13,100
10,100
14, tOO
14,300
14.400
'
13.900
1,420
Coal
id
cone.
JuliL.
0.136
0.135
0.131
0.144
0.149
0.112
OJ3I
'
0.235
0.224
ij«r
Cd Han
input flou
iM/fc!l_!U/kil-
4,300
11,050 2,700
1,160 4.JOO
1,490 410
2,200 920
1,600 1.740
..*i2?9 L»9
6 }
1,590 2,420
3.720 1,510
"«DT
tr
CMC.
JHt/.l
2.10
3.16
5.30
2.61
2 II
2.12
6
3.15
l.ll
" Total'
tT~ cd
Input Input
l5l/nrl_ (an/hr)
5.670 16,700
11.600 15,500
2,170 J.660
2,550 4,750
S.OIO 6,610
-i.»9 !9.«9
6 6
6,020 9,620
4.I6P 5,540
.
Eal.aloal
" lotlna aih (IA)
Man Cd
flow conr.
(a«/br) (PI/I)
550
400
510
150
200
300
400
7
360
160
1.91
1 l»
2.41
0.176
1.36
2.70
1-JS
7
1.96
0.64
Cd
760
1.200
360
210
110
_920
6
720
350
Naaa
flOH
(kl/or)
1.200
1.200
1,200
1,200
1.200
1.200
1.200
i.m
1
1,200
Cd
cone.
(Ml/l)
9.01
1.36
1.21
5.43
2.90
4.12
6.34
7.54
1
6.41
2.2
!*!__
Cd
calaalona
(«a/ar)
10,100
10.030
9.150
6.S20
3.410
4,940
7.600
9.050
1
7,710
2.610
flan
fdacWkr)
164.000
145.000
129.000
1 51.0OO
141 ,OOO
141.000
6
141,000
11,400
Flue fia Pamat of
Cd Cd Total tota| amlaalona
cone. ealaaiona calaalana Flue
(lll/dacai) (.l/kr) («/kc) M FA aaa
22.55 1,450 1,660 1 57 40
27.95 4.140 12,600 6.S 60.5 11
25.46 3,770 13.700 1 66 H
3 1 1111
25.3 3.790 11,600 S.S 61 11
-------
TABLE 61. TOTAL ORGANIC CHLORINE INPUTS AND EMISSIONS - CHICAGO NORTHWEST INCINERATOR. UNIT NO. 2
10
o
.
Re
Feed —
rate
Date (kg/hr)
5/3 15,800
5/4 15.200
5/6 20.300
5/7 17,300
5/8 17.300
5/9 18,200
S/IO 18,400
S/ll 18,900
5/12 16,000
5/13 15,800
5/15 16,900
5/16 16,600
5/17 17,200
Deternln- 13
atlona
Mean 17,200
Standard 1,440
deviation
—
—
fuie Input
fOCt
cone.
(ng/tj
4,300
no
0
470
260
730
130
230
130
< |
1,350
12
< 1
13
590
1,180
TOCl
Input
(•t/hr)
67,900
1,670
0
8,100
4,500
13,300
2,390
4,350
2,100
< 16
22,800
200
< 17
12
9.800
18,700
—
Combined ash
Haii "TOCl tOCT "HiiT
flow
cone.
Ul/hO ("/*>
5,500
5,290
5,490
4,680
4,680
4,920
4,970
5,110
3,470
3,430
3,670
3,600
3,730
13
4,500
800
< 1
3
2.9
21
21
12
2.2
15
10
6.6
< 1
-
12
8.1
7.6
ealsalona
ii*8/hr)
< 5.5
< 53
16
14
87
103
60
II
S3
34
24
< 3.6
-
12
35
34
evictions
(dtcn/lu)
88.080
93.960
84.600
92,460
72.600
83,820
85,740
86,280
83,340
84,600
99,060
.
II
86.780
6,830
Ealsilon*
Flue tat*
— foci
cone . e
(ni/dira)
1,100
3,140
1,760
13,500
2,070
3,310
2.540
2,920
1,230
2,300
1,490
.
11
3,200
3,500
TOCl
•1 scions
(•S/hr)
97
295
U9
1,250
ISO
277
218
252
103
195
148
-
II
285
327
Total
TOCl
ealtiioni
J'llhr)
102
311
163
1,33?
253
337
229
305
137
219
152
-
II
327
345
Percent of TOCl ealitloni
CoMhinrd
<*>
5
5
9
6
41
18
5
17
25
I.I
3
-
II
13
12
a*b Flue g»«
(X)
.
95
95
91
94
59
82
95
83
75
89
97
-
II
87
12
a Flue gai collected at the outlet of the ESP.
-------
The input and emission rates for target PAHs and other compounds identi-
fied in the composited Chicago extracts are shown in Table 64. Since the
refuse extracts contained very high levels of extracted organics and were very
difficult to analyze, composite refuse extracts were not prepared. Hence,
the data were not available for the target PAHs and other compounds in the
primary input medium for these composite days.
The emission rates for PCBs in the Chicago flue gas samples are shown in
Table 65. As in the case of the Ames data, only flue gas data was available
although PCBs may have been present in other media at low concentrations.
The emission rates for PCDDs and PCDFs in the Chicago flue gas sam-
ples are shown in Table 66. The mean emission rates for total PCDDs and PCDFs
are 3,900 and 38,600 Mg/hr, respectively. Table 67 shows the flue gas emis-
sion rates for 2,3,7,8-tetrachlorodibenzo-p_-dioxin. The mean emission rate
is 34 Mg/hr.
A summary of the cadmium inputs and emissions for the test days investi-
gated is presented in Table 68. The agreement between the total cadmium in-
puts and emissions is poor and reflects the problems encountered in obtaining
representative samples of the refuse materials and resulting ashes.
121
-------
TARI.E 64. rOHI-nilNIIS QUANTITATED IN IMCIIT AND F.HISSIOH IIF.OIA CHICAGO NV INCINERATOR, UNIT NO. 2
riant
background air Flue gas Inlet
Coapoaite
Conpound day
Target PAH coapounJt
Fhenanthrene
Fluoranthene,
Pyrene
Additional coapoundt identified
1,3-Dlcblorobenzene
1 ,4-Dlrhlorobenzene
1 ,2-Oicblorobenzene
1 ,2,3-Trtrhlorobenzene
1,2,4-Trlrhlorobenzene
1 ,3,5-Trlrhlorobenzene
Tetrachlorobenzene*
Heiach 1 orobenzene
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
Conr. Input ralr Conr. Ealision ralr
(ng/daia) (ag/hr) (ng/daca) (ag/far)
120
32
28
1.0 0.044 110
27
0.2B 0.012 IB
0.82 0.035 300
140
O.IB 0.008 57
130
130
IB
96
98
14
140
120
20
140
81
27
SSO
380
160
490
280
120
1,400
1.000
410
100
39
12
II
2.8
2.4
9.8
2.4
1.6
26
12
4.B
12
II
1.6
a. 2
1.2
1.2
12
10
17
12
7.0
2.2
46
32
13
44
24
10
120
86
40
9.0
3.4
1.0
fjne gai_oullet
Conr. Ealsiioii ralr
(ng/dica) (ag/hr)
200
110
340
39
27
SI
92
91
77
48
S7
ISO
200
220
S60
190
180
460
790
630
1,400
110
48
260
17
9.2
28
3.4
2.2
4.4
S.O
7.B
6.6
4.0
4.8
12
17
19
48
16
IS
40
68
54
120
9.0
4.0
22
Coablnrd aili
Cone. Eaiailon rate
(ng/|t) tag/far)
17 78
9.4 38
12 56
7. 6 32
(rnntlnnrd)
-------
TABLE 64 (Concluded)
Is)
to
Compound
Dichlorophenol*
Trichlorophenol*
Tetrachlorophenol*
Pentachloropheool
Dibenzofuran
Diaetbylpbtbalate
Dietbytpbthalate
Dl-n-butylphtbalate
Butylbenzylphlhalate
Bii(2-etbylhexyl)-
a Specific I toner not determined.
Plant
background air
Coapoiite Cone. Input rate
day (ng/dscm) (ng/hr)
1
2
3
1
2
3
i
2
3
1
2
3
1
2
3
1
2
3
1
2
3
e 1
2
3
le 1
2
3
1
2
3
Flue
Cone.
(ng/dscn)
560
240
190
2,100
970
600
2,200
1,100
600
130
64
86
28
23
gaa inlet
Emission rale
(•g/hr)
40
20
16
180
82
52
190
90
52
II
5.4
7.4
2.4
2.0
Flue
Cone.
(ng/dara)
240
280
630
,400
,200
,900
.500
,100
,700
190
160
430
100
67
140
4.8
50
IS
6.1
32
130
47
370
gai outlet Combined aab
Emission rate Cone. Eaiaslon rate *
(•g/hr) (ng/g) (a>8/hr)
22
24
54 86
120
98
160
130
96
140
16
14 83
36
8.8
5.8
11
42
400
144
54
260
1,200
420
3,000
-------
TABLE 65. FLUE GAS CONCENTRATIONS OF PCBs AND EMISSION
RATES FOR THE CHICAGO NORTHWEST INCINERATOR
UNIT NO. 1
Concentrations Emission rate
(ng/dson) (mg/hr)
Composite day 1 20 1.7
2 13 1.1
3 93 7.8
Mean 42 3.5
S.D. 45 3.7
124
-------
TABLE 66. CONCENTRATIONS OF POLYCHLORODIBENZO-P-DIOXINS AND FURANS
IN FLUE GAS FROM THE CHICAGO NORTHWEST INCINERATOR
AND CORRESPONDING EMISSION RATES
Concentrations
(ng/dson)
Emission rate
(u«/hr)
Total trichlorodibenzo-p-dioxins
Day 1
2
3
Mean
S.D.
Total trichlorodibenzofurans
Day 1
2
3
Mean
S.D.
Total tetrachlorodibenzo-p-dioxins
Day 1
2
3
Mean
S.D.
Total tetrachlorodibenzofurans
Day 1
2
3
Mean
S.D.
Total hexachlorodibenzo-p-dioxins
Day 1
2
3
Mean
S.D.
15
12
11
13
2.1
350
280
270
300
44
7.2
5.4
6.2
6.3
0.90
89
84
96
90
6.0
14
21
14
16
4.0
(continued)
1,300
1,000
920
1,100
200
30,000
24,000
22,000
25,000
4,000
620
460
520
530
81
7,600
7,200
8,000
7,600
400
1,200
1,800
1,200
1,400
350
125
-------
TABLE 66 (concluded)
Concentrations
(ng/dson)
Emission rate
(Mg/hr)
Total hexachlorodibenzofurans
Day 1
2
3
Mean
S.D.
Total heptachlorodibenzo-p-dioxins
Day 1
2
3
Mean
S.D.
Total heptachlorodibenzofurans
Day 1
2
3
Mean
S.D.
Octachlorodibenzo-p-dioxin
Day 1
2
3
Mean
S.D.
Octachlorodibenzofuran
Day 1
2
3
Mean
S.D.
43
84
59
62
21
7.2
7.8
7.7
7.6
0.32
7.2
7.2
8.0
7.5
0.46
2.6
2.2
2.8
2.5
0.39
0.72
0.63
0.46
0.60
0.13
3,800
7,200
5,000
5,300
1,700
620
660
660
650
23
620
620
680
640
34
220
190
240
220
25
62
54
40
52
11
126
-------
TABLE 67. CONCENTRATIONS OF 2,3,7,8-TETRACHLORODIBENZO-P-DIOXIN
IN FLUE GAS FROM THE CHICAGO NW INCINERATOR
AND CORRESPONDING EMISSION RATES
Concentration Emission rate
(ng/dscm) (ug/hr)
Day 1 0.35 30
2 0.36 30
3 0.52 44
Mean 0.41 34
S.D. 0.10 8.0
127
-------
TABU 68. CADtllUH INI'IIT AND EMISSIONS FROH CHICAGO HORTIIVF.ST INCINERATOR. UNIT NO. 2
oo
Ealaiiona
Teat
day Dale
8 5/12
9 5/1)
10 5/15
II 5/16
12 5/17
13 5/18
14 5/19
Deteninationa
Mean
Standard
deviation
jtefuie Input Combined aah
Haaa Cd Cd" ~HiiT £3
feed cone. Input ealuloni cone.
<««/hr) (|i«/«) (.«/hr> (k./hr) (n./.l
16,000
17.500
16,900
16,600
17,200
17,500
22,400
7
17,700
2,100
l.45b
0.54
0.47
0.52
0.46
0.59
..02b
S
O.S2
0.05
23,200b
9,450
7.940
6.630
8.260
10,300
I35,000b
S
8,920
960
3,470
3,800
3,670
3,600
3,730
3,800
7,460
7
4,220
1,430
17.6
26.6
14.5
12.8
6.55
20.5
6
16.8
6.3
eaiiaalona
(•J/hrJ
66,900
97,600
52,200
47,700
32,500
153,000
6
75,000
44,100
F'»e.B»»
-------
SECTION 11
STATISTICAL SUMMARY OF PILOT STUDY DATA
OVERVIEW
This section summarizes the data obtained from the chemical analysis of
specimens collected in the pilot study. The chemical analysis was performed
in two phases or tiers. In the first tier, the total organic chlorine (TOC1)
concentration was measured in nearly all of the specimens collected. Some
compositing of specimens was performed before chemical analysis to reduce cost.
In the second tier, many more specimens were composited because of the greater
expense at this level of analysis. Also, only specimens from selected media
were analyzed.
For the first tier chemical analysis data, the mean, coefficient of vari-
ation (CV) and nominal 95% confidence intervals for the TOC1 concentration
are calculated for each sampling location at both combustion sites. The mean
and CV are calculated for the concentrations of compounds quantified in the
second tier analysis. In addition, the total mass flow rate and its CV are
calculated. The mass flow rate is calculated by weighting the measured concen-
tration of the compounds by the total mass flow rate associated with each mea-
surement .
The summary statistics are presented below with brief descriptions of
the calculation methods.
FIRST TIER SUMMARY
Total Organic Chlorine
For the sampling locations where each specimen was chemically analyzed
independently (no compositing) the arithmetic mean (X) was calculated using
the equation
X = Z X./n
where X. is the TOC1 concentration of the i specimen and n is the number of
specimens. The CV is calculated by first calculating the sample variance (S2)
129
-------
S2 = Z (X. - X)2/(n - 1) .
The CV = S/X. The nominal 95% confidence intervals are calculated by
(X - tfQ5(df) S/Vn" , X + t 05(df) S/Vn") .
where t Q_(df) is obtained from tables of Student's t distribution9 and df
denotes 'tne appropriate number of degrees of freedom, which is equal to the
number of independent chemical analyses minus one.
For several media many specimens were collected. To minimize the cost
of chemical analysis for these media while retaining sufficient statistical
information, a complex compositing protocol was developed for the sample loca-
tions where more than one specimen per day was collected. The compositing
varied for the samples collected each day. On some days all were composited,
on others the two within a shift were composited, and on others none were com-
posited. These locations were fly ash, bottom ash, .coal, RDF and OW at Ames
and fly ash, combined ash and refuse at Chicago, NW. No compositing was done
for the specimens collected at the other sample locations.
To modify the calculations for X and S2 to compensate for the compositing,
each chemical determination was assigned a weight equal to the number of speci-
mens composited. Then the weighted mean Y was calculated by
m m
YsIWY/IW
' '
where Y. is the i chemical determination, W. is the number of specimens
composited for the i chemical determination1and m is the number of chemical
m
determinations. Because Z W. = n and, on average,
m n
Z W. Y. = Z X., then Y equals X, on average.
i=l * x i=l 1 w
130
-------
To estimate S2 from the composited data, calculate
S = I W2 (Y - Y )2 /I W
w x x w
m
where W., Y., Y , and m are the same as above. Because I W? (Y. - Y )2
1 1 W •{—1
a
approximately equals I (X. - X)2 on average, S2 approximately equals S2 on
i=l _1 *
average. Hence the CV (S/X) is estimated by S /Y .
The technique above gives a method to estimate X and S2 as if no composit-
ing were done. A theoretical justification of these techniques is given in
Appendix C of Lucas et al.1
Tables 69 and 70 display the statistical summary of the TOC1 concentra-
tions measured in the pilot study.
Chemical Analysis Measurement Errors
To assess the measurement errors in the chemical analysis, a method of
standard additions was employed. Known amounts of two surrogate compounds,
dg-naphthalene and d^-chrysene, were added to the composited specimens
before the chemical analysis. The mean percent recoveries of the surrogate
compounds and their CVs are given in Tables 71 and 72.
If the percent recoveries in these tables are indicative of the recovery
rate for TOC1, then the concentrations of TOC1 are underestimated. This under-
estimation would be greater for the specimens from Chicago than those from
Ames. However, the summary statistics reported in Table 66 and 67 above are
not adjusted for the percent recovery. Biases of this type can affect the
true confidence of a nominal 95% confidence interval. For example, in Table
68 the mean percent recovery of the surrogate compounds of the flue gas inlet
is 59%. If this indicates a negative bias in estimating the true mean con-
centration of TOC1 of 41%, the true confidence of the nominal 95% confidence
interval can be estimated using Table 73. To calculate the ratio of the bias
(BIAS) and standard error (SE), use
BIAS/SE = 4l/(49/Vl9) = 3.7 ,
where 41 is the absolute percent bias, 49 is the CV in Table 69, and 19 is the
number of specimens analyzed. Table 73 indicates the true confidence of the
nominal 95% confidence interval in Table 66 is less than 6%. Table 73 also
includes the impact of other levels of bias (relative to the SE) on the true
confidence of a nominal 95% confidence interval.
131
-------
TABLE 69. SUMMARY STATISTICS FOR TOTAL ORGANIC CHLORINE
CONCENTRATION DATA FROM AMES, IOWA
Media (units)
Number of
specimens
Mean
Coefficient
of
variation (%)
Degrees
of
freedom
a
Nominal 95%
confidence
interval
Gaseous (ng/dscm)
Flue gas inlet 19
Flue gas outlet 11
Ambient air 20
Solid (ng/g)
Fly ash 90
(c) (89)
Bottom ash 88
Coal 11
Refuse-derived 62
fuel
562
632
*
8.3
3.6
58.6
4.4
11,900
49
85
536
81
183
23
116
18 (426, 698)
10 (254, 1,010)
50 (-1.0, 17.6)
(49) (2.9, 4.2)
50 (35.1, 82.1)
5 (3.5, 5.3)
36 (8,342, 15,470)
Liquid (ng/liter)
owd
Quench water
influent
Well water
91
6
3
664
373
54
70
33
32
51
5
2
(570,
(231,
(1.4,
760)
514)
107)
a Number of independent chemical analyses minus one.
b Nominal value based on normal probability distribution theory.
c Numbers in ( ) are estimates excluding the maximum value of 210 ng/g. This
value is 21 times larger than the next largest value. Both sets of sum-
mary statistics are included to illustrate the impact of the one extreme
value on the estimates.
d Bottom ash hopper quench water overflow.
* Measured values in field specimens not significantly different from blanks.
132
-------
Table 70. SUMMARY STATISTICS FOR TOTAL ORGANIC CHLORINE
CONCENTRATION DATA FROM CHICAGO NW
Media (units)
Number of
specimens Mean
Coefficient
of
variation (%)
Degrees3
of
freedom
Nominal 95%b
confidence
interval
Gaseous (ng/dson)
Flue gas inlet
Flue gas outlet
(c)
Ambient air
Solid (ng/g)
Fly ash
Combined ash
Refuse
Liquids (ng/liter)
City tap water
11
11
(10)
12
72
67
61
2,200
3,220
(2,190)
1.67
93.6
9.9
902
30
34
109
( 36)
64
85
162
251
10 (1,698, 2,702)
10 (862, 5,578)
( 9) (1,330, 3,040)
11 (-.68, 4.02)
52 (71.7, 115.6)
50 (5.8, 13.9)
50 (283.8, 1,520)
* Not calculated because there was no variability in the data.
a Number of independent chemical analyses minus one.
b Nominal value based on normal probability distribution theory.
c Numbers in ( ) are estimates excluding the maximum value of 13,500 ng/dscm.
This value is 4 times larger than the next largest value. Both sets of
summary statistics are included to illustrate the impact of the one
extreme value on the summary statistics.
133
-------
TABLE 71. SUMMARY OF SURROGATE COMPOUNDS PERCENT RECOVERY FOR SPECIMENS FROM AMES. IOWA
dg-Naphthalene
Media
Gaseous
Flue gas inlet
Flue gas outlet
Solid
Fly ash
Bottom ash
Coal
Refuse-derived fuel
Liquid
ow"
Quench water influent
Well water
No. of
analyses
IB
11
51
42
6
37
40
6
2
Mean %
recovery
56
47
44
55
90
65
51
69
66
Coefficient
of
variation (%)
45
25
56
36
18
22
54
25
1
No. of
analyses
19
11
51
49
6
37
48
6
3
di2~Chrysene
Mean %
recovery
71
86
96
85
90
111
88
111
88
Coefficient
of
variation (X)
26
14
24
37
19
25
29
16
20
a Bottom ash quench water overflow.
b Specimens that were inadvertently evaporated to dryness were excluded.
-------
TABLE 72. SUMMARY OF SURROGATE COMPOUND PERCENT RECOVERY
FOR SPECIMENS FROM CHICAGO, NW
da-Naphthalene dn>-Chrysene
Number Mean Coefficient Number Mean Coefficient
of percent of of percent of
Media analyses recovery variation (%) analyses recovery variation (%)
Gaseous
Flue Gas Inlet 11 37 84 11 74 48
Flue Gas Outlet 11 27 98 11 62 82
Ambient Air 12 31 75 12 51 88
Solid
Fly Ash 53 26 68 52 36 61
Combined Ash 33 35 57 33 22 105
Refuse 44 9 51 44 12 193
Liquid
City Tap Water 3 27 131 3 13 92
135
-------
TABLE 73. VALIDITY OF CONFIDENCE STATEMENTS
FOR SELECTED LEVELS OF BIAS
True confidence level*
BIAS/SEa for the x ± 1.96 SE interval
0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
0.95
0.92
0.83
0.68
0.48
0.29
0.15
0.06
0.02
* Calculated according to the integral of the
1.96 + BIAS/SE
/
-1.96 + BIAS/SE
BIAS/SE is used because the true confidence depends on the relative mag-
nitude of the bias with respect to the SE, not the absolute magnitude.
Here, BIAS denotes the absolute average deviation of the estimate from
the true value and SE denotes the standard error of the estimate and is
equal to the standard deviation (s) divided by the square root of the
sample size
136
-------
Table 74 summarizes the estimates of the' CVs (S/X) for both the sampling
and measurement (as indicated by the surrogate recovery data) component. One
should note that the measurement CVs for Ames are uniformly less than those
for Chicago. In fact, for some sampling locations at Chicago NW, the measure-
ment component dominates the total variability giving negative estimates of
the sampling component. This is not unexpected for the ambient air and city
tap water because at these two locations one would expect the media to be
rather homogeneous. However, this is unexpected at the flue gas inlet.
SECOND TIER SUMMARY
In the second tier of chemical analysis the concentrations of many com-
pounds were measured. Because of the expense at this level of chemical analy-
sis, much compositing of specimens was done before the analyses were performed.
At Ames, five pairs of days were randomly selected. For each sampling location,
all specimens collected during the pair of days were composited for one chemical
determination. This gave a total of five independent chemical determinations
in this tier for each sample location from Ames except RDF, where only four
chemical determinations were performed. At Chicago, three sets of three days
were randomly selected. For the selected sampling locations, all specimens
collected during the three days were composited for one chemical determination.
This gave a total of three independent chemical determinations in this tier
for the selected sample locations at Chicago.
To statistically summarize the second tier data, the arithmetic mean (X)
and CV (S/X) were calculated for the concentration measurements. Also, to
estimate the mass flow rates, the variable Y. was defined as
where X. is the concentration for the i .chemical determination and r. is
the mass flow rate associated with the i chemical determination. The
arithmetic mean Y and CV (S/Y) were calculated to summarize the flow rates.
In calculating the mean concentrations and flow rates, all trace values
were assumed to be zero. This will result in an underestimate of the true
values. The number of quantifiable values are also included in the summaries.
The magnitude of underestimation resulting from substituting zero for trace
values depends upon the number of traces and the levels of quantifiable values
compared to the minimum quantifiable level.
Because of the relatively few composites measured for each compound, the
presence of trace values, and the relative large variability in the data (large
CVs), no confidence intervals are included in the data summaries.
137
-------
Table 74. SUMMARY OF COEFFICIENT OF VARIATION
FOR TEE PILOT STUDY
Media
Gaseous
Flue gas inlet
Flue gas outlet
Ambient air
Solid
Fly ash
Bottom ash
Combined ash
Coal
Refuse-derived
fuel
Refuse
Sampling
42
84
a
535 (78)b
179
12
114
Ames
Measurement
25
13
a
24
38
" .
18
Sampling
c
85
c
56
143
194
Chicago, NW
Measurement
68
68
87
64
76
159
Liquid
ow
Quench water
influent
City tap water
58
17
38
28
c 132
a Not calculated because specimen amounts were not significantly different
from blanks.
b Number in ( ) are estimates excluding the maximum value of 210 ng/g.
This value is 21 times larger than the next largest value. Both summary
statistics are included to illustrate the impact of the one extreme
value on the estimate.
c The estimates of these values were negative and were excluded because the
CV must be non-negative.
* The measurement CVs presented above are a weighted average of the CVs in
Tables 68 and 69. They were calculated by CV = (S§ + Sf2)V(X8 + X12),
where the subscripts 8 and 12 denote dg-naphthalene and
respectively.
138
-------
The second tier chemical analysis data is summarized in Tables 75 through
81. These tables include summaries of the primary input and emissions media
at Ames. These are coal, refuse-derived fuel, combustion air, flue gas inlet,
flue gas outlet, fly ash and bottom ash. The secondary input and emission
media, bottom ash hopper quench water influent, well water, and bottom ash
water quench water overflow, were excluded because of the sparsity of the data.
These tables also include the summaries for the flue gas inlet and outlet from
Chicago. The combustion air, combined ash, and fly ash are excluded because
of the sparsity of the data. No second tier chemical analysis was done on
the refuse from Chicago.
139
-------
TABLE IS. SIRBIARY STATISTICS FOR COHTOIfllUS QUAHTITATEO IN 1'BIHARV INPUT HF.DIA AT AHKS, IOWA
_
Coal
Concentration
NiiaOier of (ng/g)
Compound detect lona Bean CVTX)
Phenanlhrene
Anthracene
Fluoranlhene
Pyrene
Chryaene
Benzo|a|pyrene
1 ndeno? 1,2,3-
Cjdl-pyrcne
Bensof|,h.l|-
perylene
Dlchlorobenzene
1,2,4-Tricbloro-
benzene
Hexachloro-
butadlene
Pentacbloro-
phenol
Peotachlorobl-
pbenyl
Phenol
Naphthalene
Flourene
Benzo|a|an-
thracene
Benzofluorao-
threne
Acenaphtbene
Acenaphtbylene
5
5
5
5
5
0
0
0
0
0
0
0
0
5
S
5
0
S
5
5
11.830
2,180
2,050
2,440
679
15,360
1,760
4,500
630
1,220
374
41
52
56
57
69
68
34
38
68
33
38
. — - —
Reluae-derived
Input rate
HelS 5I £
166,000
30,800
. 28,800
34,600
9,720
217,800
24,800
63,200
8,960
17,100
5.220
Concentration
) Niwber of (n|/|)
V fl5 delect lona (lean CV {11
43
53
56
57
71
68
35
39
71
32
37
4
1
4
4
1
0
0
0
4
0
0
2
2
0
4
4
0
0
4
0
1,030
74
440
411
109
863
498
a
10,300
438
300
25
200
83
28
200
52
126
166
28
200
furl
Coabuitlon air
Input rale
KS**
2,700
202
875
1.180
300
2,650
1,250
28,400
1,220
800
*!»
41
200
50
53
200
79
133
164
51
200
Niwber of
detect loni
S
3
5
5
S
I"
4e
0.
3d
2k
2b
0
5
S
4
5
5
0
0
Concentration
Input
rale
J|ng/gj rjag/hr)
"Hean " CV (XJ Rean CV (I)
0.56
0.10
0.65
0.67
0.41
0.10
0.004
0.02
0.006
0.004
0.01
1.7
0.25
0.19
0.41
0.58
44
92
37
42
28
41
224
224
149
224
224
54
30
67
40
19
0.083
0.016
0.10
0.10
0.06
0.066
0.001
0.003
0.0009
0.0005
0.002
0.25
0.037
0.029
0.063
0.087
48
95
42
45
31
182
224
224
145
224
224
51
33
69
44
24
* CV denote! the coefficient of variation and It calculated by dividing the alandard deviation by the awan.
a Only trace valuta were detected, hence no quantification waa attempted.
b One cpeclawn contained a quantifiable level and one a trace. The trace i« aluaya aa«uau-d to be zero to calculate the aiean and CV.
c One apeciawn contained a quantifiable level and three were Iracea.
d Two aperlawni contained a quantifiable level and one a trace.
-------
TABLE 76. SUMMARY STATISTICS FOR COMPOUNDS QUANTITATEI) IN GASEOUS EMISSIONS AT AMES, IOWA
Flue
gas inlet
Concentration
Number of (ng/g)
Compound detections Mean CV (%)
I'henanthrene
Anthracene
Fluoranlhene
Pyrene
Chrysene
Benzo | a ] py rene
Benzols, h.il-
perylene
Dichlorobenzene
1 ,2,4-Trichloro-
benzene
llexachloro-
butadiene
Tetrachloro-
benzene
Pentachloro-
phenol
Phenol
2,4-Dimethy-
phenol
Naphthalene
Fluorene
Benz|a]anthra-
cene
Benzofluoran-
threne
Benzoje |py rene
Acenaphthylene
Trichloro-
benzene
5
5
5
5
5a
5
0
3
3
1
lb
1
5
0
5
1
1
2
0
2
0
438
76.4
126
422
8.8
57.4
25.8
69.6
20.6
4.8
7,260
974
24
1.4
5.4
8.8
48
24
55
62
129
72
125
108
224
224
53
50
224
224
145
138
,
Flue gas outlet
Emission rate
(mg/hr)
Mean
134
22
39
130
2.6
18
7.8
20
6.0
1.4
2,160
298
6.8
0.44
1.1
2.8
CV (I)
51
25
60
68
125
74
126
108
224
224
54
53
224
224
140
135
___^_— __
Concentration
Number of (ng/g)
detections Mean CV (%)
5
5
5
5r
5'
3d
3
2
3
0
0
0
5
4
5
0
0
5a
1
0
3
309
65.4
68.2
170
0.54
8.2
6.0
1.7
39
5,860
1,120
486
5.6
5.8
27
54
25
64
67
224
151
154
142
139
30
67
62
81
224
116
Emission rate
(mg/hr)
Mean
66
20
20
50
0.15
2.0
1.8
0.50
12
1,780
336
146
1.7
1.8
8.7
CV «l)
74
28
60
60
224
143
153
141
140
33
63
58
80
224
123
* CV denotes the coefficient of variation and calculated by dividing the standard deviation by the mean.
a Four specimens contained quantifiable levels and one a trace. All trace values are assumed to be zero when
calculating the mean and CV.
b One specimen contained a trace.
c One specimen contained a quantifiable level and four contained traces.
d Two specimens contained quantifiable levels and one a trace.
-------
TAIII.K 11. SUMMARY STATISTICS FOR COMPOUNDS QUANTITA'IF.I) IN .SOLID EMISSIONS AT AMF.S, IOWA
K>
_ — II-.
. _ _ .
..._.. _-,._... . .. .
Fly ash
Conrenlral ion
Nunlicr ol (ng/g)
Compound del eel inns
Plieiianlhrene
Anthracene
Fliioraiillirrne
Pyrene
Chrysene
Dichloro-
benzeue
Phenol
2,4-Dimethyl-
phenol
Naphthalene
Fluorene
Acenaphthene
Acenaphlhylene
5"
0
0
0
' 1
1
3
0
2
0
0
0
Mean CV (I)
0.2 61
O.I 224
0.01 224
158 102
0.07 137
i . . i .
Emission rale
(rag/hr)
Mean CV (X5
0.2 71
O.I 224
0.02 224
190 102
0.08 137
*• — • • •"
Niimlicr of
drlerl ions
5
2
4
5
1.
3
5
4C
5*
1
1
5
Do I lorn ash
Conrpiil r.il ion
d'g/g)
Mean CV (X)
I9J 100
31 183
108 177
106 168
34 224
4.8 224
1 ,094 55
7.0 167
103 146
3 224
0.2 224
87 55
Emission rale
(mg/hr)
Moan CV (X)
75 96
12 169
40 170
39 162
12 224
1.9 224
420 92
2.7 176
42 142
1.5 224
0.11 224
25 66
* CV denotes the coefficient of variation and is calculated by dividing the standard deviation by the Mean.
a Four specimens contained quantifiable levels and one a trace. Trace values are always assumed to be zero vhrn
calculating the Mean and CV.
b One specimen contained a quantifiable level and two a trace.
c Two specimens contained quantifiable levels and two a trace.
-------
TABLE 78. SUMMARY OF TOTAL INPUT AND EMISSIONS
FROM AMES, IOWA
Total input rate
(mg/hr)
Total emission rate
(mg/hr)
Compound
Phenanthrene
Anthracene
Fluor anthene
Pyrene
Chrysene
Benzo [ a ] pyrene
Indenojl ,2,3-c,d]pyrene
Benzo [£,h,ijperyiene
Dichlorobenzene
1,2, 4-Tri chlorobenzene
Hexachlorobutadiene
Tetrachlorobenzene
Pentachlorophenol
Pent a chlo r ob ipheny 1
Phenol
2 , 4-Dimethylphenol
Naphthalene
Fluorene
Benz [a] anthracene
Benzofluoranthrene
Benzo [ejpyrene
Acehaphthene
Acenaphthylene
Tri chlorobenzene
Mean
169,000
31,000
29,700
35,800
10,020
0.066
0.001
0.003
2,650
0.0009
0.0005
nd
1,250
tr
217,800
nd
53,200
64,400
.063
8,960
nd
17,900
5,220
nd
CV (%)
42
53
54
55
69
182
224
224
79
145
224
133
68
89
38
44
71
32
37
Mean
141
32
60
89
12.2
2.0
nd
1.8
2.4
12
nd
nd
ad
nd
2,390
339
188
1.5
nd
1.7
1.8
0.11
25
8.7
CV (%)
62
66
115
79
219
143
153
178
140
31
63
55
224
80
224
224
66
123
nd denotes not detected.
tr denotes trace.
* CV denotes coefficient of variation and is calculated by dividing
the standard deviation by the mean.
143
-------
TAIil.K 79. SUMMARY STATISTICS FUR COMPOUNDS QUANTITATF.I) IN liASF.OIIS EMISSIONS FROM CIIICACO
Flue gas in lei
Nimber
Concent
of (ni
Compound detections Mean
I'henanthrene
Fluoranlhene
I'yrene
1,1-Dichloro-
bcnzcne
1,4-Uichloro-
benzene
1 ,2-Dichloro-
benzene
1,2,3-Trlchlo-
robenzene
1,2,4-Trlchlo-
robenzene
1,3,5-Trichlo-
robenzene
Tetrachloro-
benzene
llexachloro-
benzene
Dichlorophenol
Trichloro-
phenol
Tetrachloro-
phenol
Pentachloro-
phenoi
Dibenzofuran
3
3
3
3
3
3
3
3
3
3
3
3
3
3
2
3
60
52
166
93
69
93
83
363
297
957
50
330
1,220
1,300
65
46
.ration
5/8) ...
CV (X)
87
98
75
70
69
69
68
54
63
49
90
61
64
63
101
77
Emission rale
Mean
5.4
4.6
14
8.4
5.9
8.0
7.1
30
26
82
4.5
25
105
III
5.5
3.9
CV (X)
90
98
76
71
69
69
69
55
66
*
49
92
51
64
64
101
76
Number of
detect ion
3
3
3
0
0
0
3
3
3
3
3
3
3
3
3
3
Flue gas out lei
Concentration Emission rate
(ng/g) (Mg/hr)
s Mean CV ft) Mean CV TX)
217
39
87
85
327
277
940
139
383
1,500
1,430
260
102
53
31
10
66
62
57
43
78
56
24
21
57
36
18
3.3
7.5
6.9
28
24
81
12
33
126
122
22
8.5
52
33
10
64
62
60
43
80
54
25
19
55
31
-...,_.
* CV denotes the coefficient of variation anil is ralinlaled by dividing tbr standard deviation by the mean.
-------
TABLE 80. SUMMARY OF FLUE GAS EMISSIONS OF POLYCHLORINATED
BIPHENYL ISOMERS FROM AMES, IOWA
Concentration
(ng/dson)
Compound
Dichlorobiphenyl
Trichlorobiphenyl
Tetrachlorobiphenyl
Penta chlo rob ipheny 1
Hexacb.lorobiph.enyl
Heptachlorobiphenyl
Decachlorobiphenyl
Total Chlorobiphenyl
Mean
nd
1.5
2.9
9.0
5.1
0.6
0.6
19.4
CV (%)
185
63
87
104
224
224
46
Emission rate
(mp/hr)
Mean
0.48
0.94
2.8
1.7
0.2
0.2
6.1
CV (%)
189
64
80
104
224
224
47
* CV denotes the coefficient of variation and is calculated by dividing
the standard deviation by the mean.
f: US. EPA
OPPT LIBRARY (7407)
145 '" 401 M STREET S.W.
•WASHINGTON, D.C. 20460
202-260-3944
-------
TABLE 81. SUMMARY OF FLUE GAS EMISSIONS OF POLYCHLORINATED
BIPHENYLS, DIBENZO-£-DlOXINS, AND DIBENZOFURANS
FROM CHICAGO NW
Concentration
(ng/dson)
Compound
Dichlorobiphenyl
Trichlorobiphenyl
Tetrachlorobiphenyl
Fenta ehlo robiphenyl
Total chlo robiphenyl
Total trichlorodibenzo-£-dioxins
Total trichlorodibenzofurans
Total tetrachlorodibenzo-£-dioxins
Total tetrachlorodibenzofurans
Total hexachlorodibenzo-£-dioxins
Total hexachlorodibenzofurans
Total heptachlorodibenzo-£-dioxins
Total heptachlorodibenzofurans
Octachlorodibenzo-£-dioxin
Octachlorodibenzofuran
Mean
17.3
16.0
6.2
2.6
42.1
13
300
6.3
90
16
62
7.6
7.5
2.5
0.60
CV «)
114
109
96
68
105
16
15
14
7
25
33
4
6
12
22
Emission rate
(mg/hr)
Mean
4.4
4.1
1.6
1.6
10.7
1.1
27
0.53
7.6
1.4
5.3
0.65
0.64
0.22
0.05
CV (%)
113
108
95
67
104
19
11
15
5
25
32
4
5
12
21
* CV denotes the coefficient of variation and is calculated by dividing
the standard deviation by the mean.
146
-------
REFERENCES
1. Lucas, R. M., D. K. Melroy, "A Survey Design for Refuse and Coal Combus-
tion Process," from Research Triangle Park to EPA/EED/OTS/Washington,
DC, EPA Contract No. 68-01-5848, June 1981.
2. TRW Environmental Engineering Division, RTW, Inc., "Pilot Test Program,
Ames Municipal Power Plant, Unit No. 7," from TRW, Inc., to EPA/IERL/
ORD, Research Triangle Park, NC, under EPA Contract No. 68-02-2197,
April 1980.
3. Bakshi, P. S., T. L. Sarro, D. R. Moore, W. F. Wright, W. P. Kendrick,
and B. L. Riley, "Pilot Test Program, Chicago Northwest Incinerator,
Boiler No. 2," from TRW Environmental Engineering Division to EPA/
IERL/ORD, Research Triangle Park, NC, under EPA Contract No. 68-02-
2197, June 1980.
4. Federal Register. 41(111), 23060-23090, 1976.
5. Stanley, J. S., C. L. Haile, A. M. Small, and E. P. Olson, "Sampling and
Analysis Procedures for Assessing Organic Emissions from Stationary
Combustion Sources in Exposure Evaluation Division Studies," from
Midwest Research Institute to EPA/OPTS/Washington, DC, under Contract
No. 68-01-5915, Report No. EAP-560/5-82-014, August 1981.
6. Lustenhouwer, J. W. A., K. Olie, and 0. Hutzinger, "Chlorinated Dibenzo-
£-dioxins and Related Compounds in Incinerator Effluents: A Review of
Measurements and Mechanisms of Formation," Chemosphere, 9, 501, 1980.
7. Richard, J. J., and G. A. Junk, "Polychlorinated Biphenyls and Effluents
from Combustion of Coal/Refuse," Environmental Science and Technology,
15, 1095, 1981.
8. Memorandum from R. Harless, Analytical Chemistry Branch, ETD, IERI/RTP
to Dr. A. Dupuy, EPA/Toxicant Analysis Center, "Collaborative Analysis
for Chlorinated Dibenzo-p_-dioxins and Dibenzofurans in Combustion Source
Extracts," August 10, 1981.
9. Snedecor, G. W., and W. G. Cochran, Statistical Methods, The Iowa State
University Press, Ames, Iowa, 1980, 507 pp.
147
-------
APPENDIX A
TRW FIELD TEST REPORT FOR THE AMES MUNICIPAL
ELECTRIC SYSTEM. UNIT NO. ?
148
-------
PILOT TEST PROGRAM
AMES MUNICIPAL POWER PLANT
UNIT NO. 7
TRW ENVIRONMENTAL ENGINEERING DIVISION
TRW, INC.
28 April 1980
EPA Contract .68-02-2197
EPA Project Officer: Michael C. Osbome
Industrial Environmental Research Laboratory
Office of Research and Development
U.S. Environmental Protection Agency
Research Triangle Park, N.C. 27711
149
-------
CONTENTS
Figures
Tables -jv
1. Introduction 1-1
2. Summary 2-1
2.1 Sampling and Analysis 2-1
2.2 Process Data 2-1
2.3 Continuous Monitoring Data 2-23
3. System Description 3-1
3.1 Boiler Description . . . . 3-1
3.2 Electrostatic Precipitator 3-12
4. Sampling Locations 4-1
5. Sampling 5-1
5.1 Gas Sampling 5-1
5.2 Solid Sampling 5-5
5.3 Liquid Sampling • 5-5
5.4 Hi Volume Sampler 5-6
5.5 Quality Assurance 5-6
5.6 Sampling Train Background 5-6
5.7 Sample Recovery 5-8
5.8 Problems Encountered During Recovery 5-8
6. Calibration 6-1
6.1 Method Five Calibration Data 6-1
6.2 Instrument Calibration 6-3
7. Technical Problems and Recommendations 7-1
7.1 Problems 7-1
7.2 Recommendations 7-1
%
Appendices
A. Continuous Monitoring Data •. A-l
B. Field Data Sheets B-l
C. Solid and Liquid Sampling Schedule.- , C-l
D. Process Data Sheets , D-l
-------
FIGURES
Number Page
2-1 Oxygen in the gas before and after the air preheater. . . . 2-31
3-1 Layout of plant site 3-2
3-2 Flow diagram for unit #7 at Ames Municipal powervplant. . . 3-4
3-3 Schematic of Ames Municipal power plant boiler #7 3-7
3-4 Solid waste recovery system 3-11
4-1 Unit #7 flow diagram and measurement locations 4-2
4-2 Cross section of stack showing traverse point locations . . 4-3
4-3 Inlet duct - showing port locations 4-4
4-4 Inlet traverse point locations 4-5
5-1 ESP inlet sampling train 5-2
5-2 Stack sampling train 5-3
5-3 EPA Method 5 particulate sampling train 5-4
5-4 Ambient air sampler 5-7
6-1 Calibration equipment set-up procedures 6-4
iii
151
-------
TABLES
Number Page
2-1 Dally Organic Sampling Summary 2-2
2-2 Daily Data Summaries 2-12
2-3 24 Hour Process Data for the Ames Municipal Power Plant,
Unit No. 7 2-14
2-4 Test Duration Process Data for the Ames Municipal Power
Plant, Unit No. 7 2-17
2-5 Daily Production and Consumption at Ames Municipal Power
Plant, Unit No. 7 2-24
2-6 Heat Content of Fuels Used at the Ames Municipal Power
Plant During Sampling Period 2-25
2-7 Continuous Monitoring Data 2-27
2-8 Excess Air Readings 2-29
2-9 Air Preneater Continuous Monitoring Data 2-30
3-1 Boiler Design Data 3-3
3-2 Design Specification for Raymond Bowl Pulverizers 3-5
3-3 Fan Design Performance 3-8
3-4 Predicted Performance Characteristics of Unit $1 at Ames
Municipal Power Plant 3-9
3-5 Performance Characteristics of the American Standard ESP. . 3-13
4-1 Sampling Locations 4-1
1v
152
-------
1. INTRODUCTION
This document describes the sampling and monitoring activities at the
Ames Municipal Power Plant, boiler unit No. 7. The sampling and field mea-
surement work performed was part of an overall pilot scale test program
sponsored by the Office of Pesticides and Toxic Substances in cooperation
with the Office of Research and Development, of the U.S. Environmental Pro-
tection Agency.
The ultimate objective of the pilot scale test program is to develop
an optimum sampling and analysis protocol to characterize polychlorinated
organic compounds which may be emitted in trace quantities through conven-
tional combustion of fossil fuels and refuse. The genesis of the program
is an industrial study by Dow Chemical Company and two groups of European
investigators reporting emissions of polychlorinated dibenzo-p-dioxins
(PCDD), dibenzofurans (PCDF) and biphenyls (PCS) from stationary convention-
al combustion sources.
The immediate objective of the sampling and field measurements program
(for a fossil-fuel 17% RDF-fired utility boiler) is the specification of
procedures and equipment to obtain sufficient multimedia samples for the
subsequent analytical protocol, and to satisfy the program statistical
design requirements. In this respect, the TRW Environmental Engineering
Division of TRW, Inc., was one of three contractors participating in the
overall EPA program. These contractors, their key individuals and respec-
tive roles are:
1. Research Triangle Institute
Research Triangle Park, North Carolina
Statistical design of the overall test program
Mr. R. M. Lucas, Task Manager
2. TRW Environmental Engineering Division, TRW, Inc.
Redondo Beach, California
Acquisition of samples and field measurements
Mr. B. J. Matthews, Project Manager
3. Midwest Research Institute
Kansas City, Missouri
"Laboratory analysis of all field samples
Dr. C. L. Haile, Task Manager
1-1
153
-------
The sampling was oriented toward acquiring multimedia samples for
organic compound analysis by Midwest Research Institute (MRI). Compounds
of particular interest included:
Benzo [a] pyrene Chrysene
Pyrene Indeno [1,2,3-cd] pyrene
Fluoranthene Benzo ts.,h_,ij perylene
Phenanthene Anthracene*"
In addition, MRI is to make a determination of total organic chlorine
emissions from the acquired samples. Potentially, selected samples are to
be analyzed for dibenzo-p-dioxins, dibenzofurans and biphenyls.
Instrumentation for on-line combustion gas stream monitoring was part
of the test program. In addition, utility boiler process information (in-
cluding RDF data) was also gathered. This information together with the
monitoring data were acquired to assist in evaluating and interpreting chem-
ical analysis results.
This report contains all the field data for the Ames Municipal Power
Plant pilot test program conducted in March 1980. Data provided include
the following:
• Chlorinated hydrocarbon collection using a modified EPA Method
5 train and Method 5 sampling methodology,
• Gas velocities using EPA Method 2,
t Continuous monitoring for CCk, $2» an(* ^0 and THC,
• Particulate collection for inorganic analysis utilizing EPA Method
5.
• Process data.
The test program followed was described in the Pilot Test Program, Ames
Municipal Power Plant, Unit No. 7 site test plan. Deviations from this
program are documented and explained in their respective sections of this
report.
1-2
154
-------
2. SUMMARY
2.1 Sampling and Analysis
The field test activity took place from February 25, 1980 to March 28,
1980. All required tests were completed and all recovered samples were
sent to Southwest Research Institute (SRI)'for analysis. MRI had subcon-
tracted this part of their assignment to SRI.
A summary of tests conducted including any significant commentary is
presented in Table 2-1. A summary of the reduced data on a daily basis as
calculated from the field data sheets is presented in Table 2-2. Data listed
are corrected to standard conditions, i.e., 20°C and a barometric pressure
of 29.92 inches mercury.
Sampling and calibration procedures are described in Sections 4, 5 and
6. Hourly data is provided in the appendices. Appendix A contains contin-
uous monitoring data; Appendix B contains field data; and Appendix C contains
the solid and liquid sampling schedule.
2.2 Process Data
Process data was monitored on an hourly basis. A summary of the aver-
aged daily process data is provided in Table 2-3. The process data was also
averaged for the time duration of actual testing performed. This data is
presented in Table 2-4.
The process data gathered indicated that the operating conditions fluct-
uated in patterns related to the amount of electricity generation demand
placed on the boiler, and on'the type of fuel being burned to meet that
demandT~ Overall fluctuation consisted of two components. The first com-
ponent was the Daily variation - the load peaked in the afternoon and fell
a minimum before dawn. The second type of variation was caused by sudden
operational changes, which was due to reduced power generation for various
reasons such as the buying of cheaper power from a private utility, or the
reduction in flow of RDF to the boiler.
2-1
155
-------
TABLE 2-1. DAILY ORGANIC SAMPLING SUMMARY
Date
1900
Test
No.
Sampling locations
Test coninents
3/2
1
3/3
Inlet North
Inlet South
Outlet Ports 2
and 3
Outlet - Ports 1
and 4
HI Volume Sampler
Continuous
monltors
Inlet North
Inlet Soul..
Test started at 1120 and ran for 520 minutes. Low volume collected
due to high leak rate at end. Volumes corrected for leak rate. If leak
occurred over the entire test period then, at worst case, the results are
502 low. Test quality fair. (Port 13 to be dropped due to absence of flow).
Test started at 1125 and ran for 520 minutes. Low volume collected
trying to stay within 12 hour time limit. Test quality good. (Port 1 to
be dropped due to absence of flow.)
Loss of 3 hours start due to freezing of pumps. Stopped test 360 minutes
Into test due to freezing of Implngers. All of Port 3 traversed and only
1/2 of Port 2 - low volume collected but test quality Is good due t(t the
evenness of flow In stack.
Started at 1200, ran for 390 minutes - stopped due to freezing of
Implngers and equipment - low volume due to{Stoppage - Implngers backed
up due to freezing of impinging solutions. Resin In Implngers 1 and 2
also due to freezing. Test quality fair.
Test started at 1115 and off 1939. Test quality good.
Started at 1300 hrs and off at 1930 - lost start time due to gas condi-
tioner being frozen. Unable to maintain heat line temperature due to cold
weather and moisture condensing In heat line possibly scrubbing hydro-
carbons, hydrocarbon results low. Test quality good. Hydrocarbon fair.
Dropped port 13 from test. Test started at 0925 and ran for 550 minutes.
At 250 minutes nozzle was found to be facing In the wrong direction, re-
versed nozzle direction continued test. Partlculate catch and sjze distribu-
tion will be approximately 25% low. Ho effect on Battelle trap. Switched to
smaller diameter nozzle to maintain '.'sokinetic flow rate. Test quality for
particulate fair, for gas good.
Test started at 0945 and ran for 550 minutes. Switched to smaller diameter
nozzle to maintain isokinetlc flow rate. Test quality good. Dropped port 1
from test.
-------
TABLE 2,1. (Continued)
Date
1980
Test
No.
Sampling Locations
Test comments
3/3
3/4
Oi
ro
i
3/5
Outlet Ports 2
and 3
Outlet Ports 1
and 4
HI Volume Sampler
Continuous Monitors
Inlet North
Inlet South
Outlet
Ports 2 and 3
Ports 1 and 4
Hi Volume Sampler
Continuous Monitors
Inlet North
Inlet South
Test started at 0945 and ran for 480 minutes. Test quality good,
Test started at 0945 and ran for 480 minutes. Test quality good.
Started at 1032 ended at 1915. Test quality good.
Started at 0930 ended at 1900. Test quality good except hydro-
Carbon values being low and hydrocarbon quality fair.
Test started at 0905 and ran 417 minutes. At 75 minutes Battelle trap
plugged and replaced with new one. At 250 minutes Battelle trap replaced
due to leak and points (total of 2) retested. Switched to 10 minutes a
point traverse rather than 25 minutes to complete test. All 3 Battelle
traps should be composited due to lower volume sampled during 10 minute/
point traverse. Test quality fair - total volume 50% of required.
Test started 0900 ran for 550 minutes. Test quality good.
Test started 0938 ran for 15 minutes. v
Cancelled due to snow and icy conditions.
No samples retained.
Started at 0930 ended at 1800. Filter covered with snow. Test quality
fair due to snow blanket.
Gas conditioner frozen until 1230. Started at 1230 ended at 1800. Test
quality good. Hydrocarbon results fair.
Test started 0900 and ran for 560 minutes. Test quality good.
Test started at 0900 and ran for 550 minutes. Test quality good.
-------
TABLE 2-1. (Continued)
CD
IV)
Date
1900
3/5
3/6
3/7
Test
No.
4
5
6
Sampling Loci
Outlet - All
Hi Volume San
Continuous ft
Inlet North
Inlet South
Hi Volume Sar
Continuous M<
Inlet North
Inlet South
Hi Volume Sai
Continuous H
Test Coninents
Cancelled per Instructions of EPA until 3/13/80.
Started at 1025 ended at 1940. Test quality good.
Started at 0945 ended at 1150 am. Stopped due to freeze up of lines;.
Test quality good for data collected.
Test started at 0850 and ran for 770 minutes. At 11 minutes Into test
Battelle trap plugged and was replaced. Test restarted from beginning.
Test quality good.
Test started at 0840 and ran for 770 minutes. Test quality good.
Test started at 0852 and ended at 2220 llrs. Test quality good,.
Only inlet tested due to outlet freeze up. Test started at 1230 and
ended 2045. Two hours late start and shut down 2 hours early to overlap
sampling time. Test quality good. Hydrocarbons still fair.
Test started at 0930 and ran for 770 minutes. Due to Increased amount
of water collected, Implngers needed changing and during changeout resin
flowed into first implnger. Trap replaced and test resumed. Test
quality good.
Test started at 0850 and ran for 770 minutes. Test quality good.
Test started at 1038 and ended at 2225. Construction welding going on
nearby. Test quality expected to be good.
Test started at 1315 hrs and shut down at 2100 hours. Overlap of Inlet
test. Test quality good. Hydrocarbons fair.
-------
TABLE 2-1. (Continued)
Date
1980
Test
No.
Sampling Locations
Test Comments
3/8
3/9
UI
i
en
3/10
Inlet North
Inlet South
HI Volume Sampler
Continuous Monitors
8 Inlet North
Inlet South
111 Volume Sampler
Inlet North
Inlet South
Test started at 0855 and ran for 770 minutes. 10 minute power failure -
no problems caused by this. Test quality good.
Test started 0840 and ran for 770 minutes. 30 minute power failure on
this side - no problems. Probe broken at end of test during removal from
port. Approximately 2% of probe catch lost. Test quality good.
Test started at 1335 and ended at 2330. Test quality good.
Test started at 1215 and ended 2030 hrs. Data not taken at Inlet during
1300 hrs. to 1400 hours due to change out of probe filters. Test quality
good. Hydrocarbon data fair.
Test started at 0900 and ran for 770 minutes. Point 8D was run for
70 minutes to correct sampling time lost on point 11A not being sampled
after nozzle change. Test quality good.
Test started at 0830 and ran for 770 minutes. Changed to larger nozzle to
maintain Isokinetlc flow rate. Due to severe leak, that occurred during
last portion of test, this test Is questionable.
Test started at 0908 and ended at 2320 hrs. Test quality good.
Test started at 1245 and ended at 2320 hrs.
Hydrocarbon data fair.
Test quality good.
Test started at 0825 and ran for 140 minutes. Probe found to be broken and
test restarted, no samples retained. Restarted at 1155 ran until 1745. Test
stopped, with only 1/2 the duct traversed, due to cold, freeze ups and power
failures. Resin, cyclone, filter, 1st Implnger saved. Test quality fair.
Test started at 0810 ran for 515 minutes. Power failures and freeze ups
happening cancelled test with the North side. No solutions retained from
South due to H202 backup Into all Implngers - resin, cyclone and filters re-
tained. Test quality fair.
-------
TABLE 2.1, (Continued)
Data
1980
Test
No.
Sampling Locations
Test Consents
O I
0»
3/10 9 111 Volume Sampler
Continuous Monitors
3/11 10 Inlet North
Inlet South
111 Volume Sampler
Continuous Monitors
3/12 11 QA Test
HI Volume Sampler
Continuous Monitors
3/13 12 Inlet North
Inlet South
Outlet Ports 2 & 3
Test started at 1050 and ended at 2235 hrs. Test quality good.
Test started at 1130 am and ended at 1730 hours. Stopped with inlet.
Test quality good. Hydrocarbon fair.
Test started at 0825 and ran 770 minutes. Dattelle trap replaced at
220 minutes. 2nd Dattelle trap resin broke through and was replaced.
3 Battelle traps used. Test quality good.
Test started at 0830 and ran for 770 minutes. Filter clogged and replaced.
Test quality good.
Test started at 0920 and ended at 2375 hrs. Test quality good.
Test started at 1200 and ended at 2030 hrs. Test quality good.
Hydrocarbon fair.
Test cancelled after 240 minutes - a leak was found at one of the probe
tips-unable to repair and no sample had been drawn through the train.
Test started at 0955 stopped at 1955. Test quality good.
Test started at 0830 stopped at 1430 hrs. Test quality good. Hydrocarbon
fair.
Test started at 0915 and ran for 770 minutes. Power failures occurred-
no effect on test. Filter changed due to clogging. Test quality good.
Test started at 0835 and ran for 770 minutes. Power failure occurred no
effect on test. Test quality good.
Test started at 1210 and ran for 560 minutes. Lost startup due to freezing
of equipment and traps - thawing took 1-2 hours. Test quality good.
-------
TABLE 2-1. (Continued)
Date
1980
Test
No.
Sampling Locations
Test Comments
0» I
3/13 12 Outlet Ports 1 £ 4
HI Volume Sampler
Continuous Monitors
3/14 13 Inlet North
Inlet South
Outlet Ports 2 & 3
Outlet Ports 1 & 4
HI Volume Sampler
Continuous Monitors
3/15 14 Inlet-North
Inlet South
Outlet Ports 2 & 3
Outlet Ports 1 & 4
HI Volume Sampler
Continuous Monitors
Test started at 1125 and ran for 296 minutes. Stopped due to continual
freezing of train components. One port completely traversed. Only 16
minutes of the second. Test quality - fair to poor.
Test started at 0950 and ended 0130. Test quality good.
Test started at 1145 and ended at 1845 hours. Test quality good.
Hydrocarbons fair.
Test started 0845 and ran for 770 minutes. Filter clogged and was replaced.
Test quality good.
Test started at 0840 and ran for 770 minutes. Test quality good.
Test started at 0945 and ran for 560 minutes. Test quality good.
Test started at 1010 and ran for 560 minutes. Probe broken during port
change - replaced and test continued. Test quality good.
Test started at 0905 and ended at 2355 hrs. Test quality good.
Test started at 0900 and ended at 2045 hrs. No data from 1330 to 1515 hrs
due to feeeze up. Test quality good. Hydrocarbon fair.
Test started at 0909 and ran for 770 minutes. Test quality good.
Test started at 0905 and ran for 770 minutes. Test quality good.
Test started at 0958 and ran for 560 minutes. Test quality good.
Test started at 1025 and ran for 560 minutes. Test quality good.
Test started at 0850 and ended at 2341 hrs. Test quality good.
Test started at 0845 and ended at 2000 hrs. Test quality good.
Hydrocarbon data fair.
-------
TABLE 2-1. (Continued)
Date
1980
Test
No.
Sampling Locations
Test Comments
3/17
3/18
15
3/19
16
17
Inlet North
Inlet South
Outlet Ports 2 & 3
Outlet Ports 1 & 4
Mi Volume Sampler
Continuous Monitors
Inlet North
Inlet South
Outlet Ports 2 & 3
Outlet Ports 1 & 4
Hi Volume Sampler
Continuous Monitors
Inlet North
Inlet South
Outlet Ports 2 & 3
Test started at 0849 and ran for 770 minutes. Test quality good.
Test started at 0900 and ran for 770 minutes. Test quality good.
Test started at 1000 and ran for 560 minutes. Test quality good.
Test started at 1010 and ran for 560 minutes. Test quality good.
Test started at 0926 and ended at 0020 hrs. Test quality good.
Test started at 1030 and ended 2015 hrs. Test quality good. Hydrocarbon
data fair.
Test started at 0939 and ran for 770 minutes. Test quality good.
Test started at 0900 and ran for 770 minutes. Test quality good.
Test started at 0930 and ran for 560 minutes. Test quality good.
Test started at 0940 and ran for 560 minutes. Probe broke during port
change - switched to 5 ft glass probe to traverse first 6 points of
second part. After 10 ft probe of ports 2 and 3 had been recovered and
cleaned, It was sent to the stack to finish remaining 2 points of
ports 1 and 4. Test quality good.
Test started at 1033 and ended 0200 hours. Test quality good.
Test started at 0845 and ended at 1945 hrs. Test quality good. Hydro-
carbon data fair.
Test started at 0859 and ran for 770 minutes. Test quality good.
Test started at 0843 and ran for 770 minutes. Test quality good.
Test started at 0945 and ran for 560 minutes. Test quality good.
-------
TABLE 2-1. (Continued)
Date
1980
Test
No.
3/19
17
3/20
18
3/22
19
Sampling Locations
Outlet Ports 1 & 4
HI Volume Sampler
Continuous Monitors
Inlet-North
Inlet South
Test Comments
Outlet Ports 2 & 3
Outlet Ports 1 & 4
HI Volume Sampler
Continuous Monitors
Inlet North
Inlet South
Outlet Ports 2 & 3
Test started at 0940 and ran for 560 minutes. Test started with 5 foot
probe until new 10 ft arrived. Finished Test with 10 ft probe. Test
quality good.
Test started at 1006 and ended at 0120 hrs. Test quality good.
Test started at 0845 and ended at 1915. Test quality good. Hydrocarbon
data fair.
Test started at 0905 and ran for 770 minutes. Filter clogged and was
replaced. Test quality good.
Test started at 0914 and ran for 770 minutes. At 1850 hrs. Battelle trap
froze and was thawed with warm water. Leak developed In Teflon heat line •
retarded leak rate with Teflon tape but leak was still 0.11 cfra. At
2250 Battelle trap froze up and was replaced. It was later found that
the filter had separated from the housing and partlculate had gotten
down to the Battelle first. Both filter and trap were replaced and points
were retraversed. Test quality good.to fair.
Test started at 1000 and ran for 560 minutes. Test quality good.
Test started at 0930 and ran for 560 minutes. Test quality good.
Test started at 1117 and ended at 0540 hrs. Test quality good.
Test started at 1130 and ended at 2030 hrs. Test quality good.
Hydrocarbon data fair.
Test started at 0947 and ran for 770 minutes. Test quality Is good.
Test started at 1001 and ran for 770 minutes. Filter clogged and was
replaced. Test quality Is good.
Test started at 1000 and ran for 560 minutes. Test quality Is good.
-------
a* «
Date
1980
3/22
3/23
3/24
Test
No.
19
20
21
Samp
Outl
Hi V
Cont
Inle
Inle
Outl
Outl
Hi \
Conl
Blai
Outl
Hi V
Cont
TABLE 2-1. (Continued)
Sampling Locations
Outlet Ports 1 & 4
Hi Volume Sampler
Continuous Monitors
Outlet Ports 2 & 3
Outlet Ports 1 & 4
Hi Volume Sampler
Continuous Monitor
Hi Volume Sampler
Continuous Monitors
Test Comments
Test started at 1030 and ran for 560 minutes. Test quality is good.
Test started at 1422 and ended at 0415 hrs. Test quality Is good.
Test started at 1145 and ended 2115 hrs. CO drift problems. CO taken
off line until 1445 hrs. Test quality good. Hydrocarbon data fair.
Test started at 0927 and ran for 990 minutes.
lower plant out put.
Test started at 0935 and ran for 990 minutes,
lower plant output. Test quality good.
Test started at 1005 and ran for 640 minutes,
lower plant output. Test quality good.
Increased time due to
Increased time due to
Increased time due to
Test started at 1027 and ran for 640 minutes. Increased time due to
lower plant output. Implnger 3 backed up into Impinger 2 - not saved.
Test quality good.
Test started at 1034 and ended at 0350. Test quality good.
Test started at 1100 and ended at 0800 hrs. Electronic source balancing
problem on CO analyzer. Analyzer (CO) taken off line. No outlet data -
gas conditioner not In cycle mode. Test quality good for Inlet, hydrocarbon
data fair.
Blank test started at 1200 and ran for 60 minutes at temperature. Test
quality good. :
Test started at 1110 and ran for 192 minutes. Test quality good.
Off line
Test started at 1030 and ended at 1530 hrs. Outlet only for Inorganic
sampling. Mo CO on line. Test quality good hydrocarbon data fair.
- QA Test
to outlet stream. Test quality good.
-------
TABLE 2-1. (Continued)
Date
1980
Test
No.
Sampling Locations
Test Comments
Oi
ro
3/25 22 Inlet North and
South - QA Test
Outlet Ports 1,2,
3 and 4
Continuous Monitors
111 Volume Sampler
3/26 23 Inlet North
Inlet South
Outlet Ports 1.2.
3 and 4
Continuous Monitors
Test started. No solids or liquids taken for QA. QA test only.
Test scrubbed, no samples saved because nozzle was In wrong direction
and test would not be duplicate.
Test started at 1120 and ran for 192 minutes. Test quality good.
Test started at 1115 and ended at 2106 hrs. Test quality good.
Hydrocarbon data fair.
Test started at 1030 and ended at 2320 hrs. Filter covered with coal
dust. Test quality fair.
QA test started at 1510 and ran for 770 minutes. Test quality good.
QA test started at 1515 and ran for 770 minutes. Test quality good.
Test started at 0922 and ran for 192 minutes. Test quality good.
i
Test started at 1100 and ended at 0830 hrs. No outlet data due to failure
of gas conditioner to switch to outlet stream. Test quality good.
Hydrocarbon data fair.
-------
TABLE 2-2. DAILY DATA SUMMARIES
DM*
1 19301
32
1 3
34
36
36
3-1
3 8
3-9
3-10
3 -II
3 12
1 13
Ten
No
I
2
3
4
6
6
7
8
e
10
n
12
Singling
1 uttiion
ntal Nu"i'
Sonlh
ou,.,, }«
ri.ii ih A
nbl Noilll5
ntol SouiliC
SoulhD
«"- &
*- £2
°— ££
•"" ££
Oull*l ""*
UUIIM 2&3
tel" &*
o.,,u, «*«
Inkl K"""
Soulli
Ouitei JJ*
*» J
""•• £S
Outkl 5J«
Na>lliF
InU. NoMl-G
Suulli"
South'
OU.K, £«
— &£
OU.M J*S
— £::
O.M 5*5
(Midi N°"|'C
Smilli
OI.IIM '"
4TO* J
""" IS
Ou*, |*f
S>ni|>l
3365
2609
2? (39
2479
3778
4794
4661
37.16
2000
26.10
4E.IO
43.72
4320
41.09
42.92
43.48
4361
44.01
3U62
3d 28
3027
30.38
3643
27.38
4523
4377
4bC3
44.20
424fi
41.41
25 B6
2ilfid
Gil
Flow
•elm
I32U73.22
1 16010 IS
14 1428 02
164523 14
149181 62
169792 93
IB42B023
14008/30
102012 17
I67637.0B
1733 12 «i
I72BG682
Ten Siiul
leu Saut
17080285
IG24&6.26
leu Stint
leilSciul
IG9692 4.1
171937.31
IMlcti
Not l«l
fi.i
flow
ilsclin
76549 BB
70423.17
8628562
95704.38
85761.77
B5/B2 34
100410.17
8600468
0106998
OU037 93
OGGB4 71
9638009
liwl
IKI!
97049 64
92751 DC
ilieil
Iwtl
102970 OG
0720507
«l
ail
17242559 1 8743205
17399436 | 9090591
Nul Teita'l
Nullc>l>.-d
15057308
166327 60
Km Teil
Nul Its
1
1I9C 08 00
I20l0d.29
144173.75
108274.04
Nul Tfti
Nul lull
17805320
I7304SI2
Nul Ten
Hoi Inl
1 80S 19 64
I74/B347
Nul In
Not It-il
BS2C627
CGI 79.64
L-ll
ej
7132578
61223.13
B2077.4B
84436.73
ml
ai
10320595
8298029
eil
«l
IOIB67f>6
09143.40
•til
ill
TKM Stintilicil
Tu>l Stiulilifil
llni 1«sli»l
N.MlciU'J
icnu/o no
IC4U36 1 7
I6II023'J
160622.22
9347348
9362805
95I4GBI
98470.04
SIM*
Teinp
Of
334.31
311.78
32093
30992
35165
37336
23483
36990
31738
31694
37048
3b2.6S
381.09
34923
383 63
347.46
35 100
33680
377.65
36983
31683
364.73
344.38
318.88
352 CU
33065
37475
368.59
341 78
34UOI
33944
31608
On Conipotillon
*
448
448
6.34
634
438
433
433
433
5.87
587
4.43
4.43
4.41
441
4.36
4.35
4.59
4.59
4.79
4.7B
7.1
M
7.1
7.1
3.7
3.7
4.7
4.7
3.34
334
617
6.17
C02
%
12.79
12.79
11.31
11.31
13.80
1380
1380
1380
12.44
1244
14.41
14.41
14.68
14 WJ
1379
13.79
1302
13.92
13 GO
1360
11.6
11.6
11.6
11.6
139
13.9
136
13.6
IS 56
15 W
13.97
1367
CO
IH>m
1800
1000
1600
1600
1200
12.00
1100
11.00
11.00
1700
1700
1800
1800
1800
1800
1000
18.00
2800
28.00
2500
2500
2500
36.00
25.00
2500
2200
22.00
2100
31.00
1800
1800
TMC
W«n
'2
<2
<2
<2
v2
<2
<2
<2
<2
<2
<2
<2
<2
<:
<2
-------
TABLE 2-2. (Continued)
Out
doaot
3-14
3 15
3-17
3 18
3-19
320
322
3-23
3-24
3-25
3-26
Tin
No.
13
14
IB
16
17
18
19
20
21
22
23
Sampling
location
Intel North
lnW South
Out.., J*5
""« S3
O..M J*S
Ink! No''!;
Soil III
Outlet j'J
, . . Noilh
lnl" South
Ouil.1 J*«
li,l.i Nollh
'""" to.ul.
Outlo, £]
. . , Nuilh
lnlsl South
Quito, J|<
Intel Norlh
'""" So.Hl.
Outlet £«
Intel Nl""'
lnh!l Sw.ll.
Ou"" 2M
— £S
Oullil 1.2.3*4
- Sltf
Outlet 1.2.38.4
. . . Noilli
""«' South
Outlet I.2.3&4
Sample Volume
SCF M3
374336
352110
367.772
35 1.384
276707
266.37
31913
307.00
359800
390.474
406 BBS
391.836
309.159
371.497
392686
353752
349.709
366761
374.299
360678
347.692
366076
366.204
388522
363462
348697
402.144
401.160
336.525
330733
301.612
366.878
130.420
122.708
326820
344.976
138073
10.60
997
1042
9.96
7.83
7.60
9.04
869
10.19
1106
11.62
11.10
1045
1052
11.12
1000
9.90
1044
1060
10.21
986
1042
1009
11.00
10.20
• 87
11.39
11.30
953
937
864
10.17
3.09
3.48
0.20
077
303
Moisture
%
967
9.70
9.60
9.60
814
7.08
768
783
883
817
871
843
930
873
662
9.09
91)8
868
1028
869
8.31
7Bd
7.79
644
864
807
861
823
816
12.74
973
6.67
9.53
9.92
9.17
9.09
926
Molecular
Walghl
2931
29.30
2914
2915
2027
2832
2909
20.10
29.35
2944
2921
2025
2929
2937
2024
2916!
2929
2937
29.03
2924
29.33
2039
29 29
2921
2936
2941
29.19
29.24
2926
2869
2882
2928
29.16
2910
20.13
2914
20.24
•Velocity
Ipl
N 42.48
41.49
2434
24.84
3086
2996
2000
2131
4I.B9
4284
2601
2727
43 M
4I.B9
27.12
2560
41.87
4342
26.76
26 1)2
42.13
42.11
2463
20.81
4I.C5
3363
2020
2681
2BG6
27.26
1663
19.70
2576
24.58
37.23
37.40
76.42
QM
Fkiw
acln.
171004.76
164046.73
151 720 16
I646IB.20
121971/44
116444.96
12466269
132801.77
IOU322CQ
16938166
162117.20
169966.05
I702&9.70
165631.94
169022.81
159531.72
106660.57
17169537
166099 02
16776285
1665/0.31
166487.56
153481.74
16772565
1646110.40
15607709
I636&604
167077.26
113282.76
107773.46
10307907
12276669
Blank II
Blank ft
100547.70
Ton Sen.
I63IG6.3I
14720078
14787205
164670 85
Gti
Flow
dsclin
94404 C8
91011.47
8380092
86429.91
66066.12
6730785
75394.62
76706.46
9177443
9721069
0333449
0818362
P2S73.1I
63091.17
0671962
91103.76
88914.41
95341.29
9108067
94194.67
94786.10
Ofl 189.05
90622.79
97760.61
94207.94
UOB2I.39
05997.17
0964906
U3470.17
5600538
68763 10
74046.66
HO
Illl
801 72.86
ilwil
8/02M5
81 BOO 81
B0733 46
03244.39
Slack
Temp
Of
36468
376.70
36594
356.76
366.23
367.65
319.42
366.65
371.23
348.41
354.66
34531
30196
35406
36006
367.60
38028
J6I.E9
373.12
36504
35096
34265
33812
312.81
34884
34209
34000
3:10.60
304.41
365.41
354.13
33B.I3
36547
3b6.40
380.60
38245
36438
Get Competition
0*
%
3.70
370
6.31
6.31
6.31
6.31
• 37
8.37
3.73
373
643
643
362
382
642
6.42
360
3.60
630
6.30
380
360
6.00
6.00
360
300
6.30
630
600
6.00
9.70
9.70
6.4
64
600
000
480
C02
X
1481
14.81
13.18
13.18
1269
1250
10 07
10,67
14.40
14.40
1290
1290
1439
1439
1300
U.uO
14.40
1440
1300
1300
13.80
13.60
12.50
12.60
14.20
1420
12.70
12.70
1260
12.60
10.00
1000
132
13.2
1260
1260
1370
CO
ppm
2800
28.00
30.00
3000
2200
2200
1900
10.00
2200
2200
2200
2200
23.00
23.00
2400
24.00
24.00
2400
26.00
2000
2200
22.00
17.00
17.00
3800
3800
3800
38.00
I
THC
ppm
<2
<2
<2
<2
<2
<2
0
<2
<2
<2
<2
<2
<2
<2
<2
O
<2
<2
<2
M ivcjllnr. Sample lived
I Miin.lnr i.ni Aiiikinu
-------
TABLE 2-3. 24 HOUR PROCESS DATA FOR THE AMES MUNICIPAL POWER PLANT, UNIT NO, 7
0 (°f )
Boiler exit
ESP Inlet
Ambient teapertlure
tabient pressure
Inches Ug
3-2.80
Hetn o
30.19*
26.25*
252.2
867.7
899.61
261.17
166*
11.7
32.2
4.6
22
46.42
5.15
10.29
4.26
0.60
647*
118.5*
16.06
29.14
2.8*
1.51*
16.49
4.16
B. 61
17.94
7.18*
7.07
2.1
I.I
0.89
1.12
0.77
0.20
9.78*
6.69*
7.58
0.18
1-1-80
Hetn ii
10.1 7.11
32.04* 0.98*
268.8 71.48
852.71 4.66
890.1 24.01
278.18 71.65
J80.8I 2.14
11.91 7.12
11.69
4.6
22.011 B. 28
45.76 2.15
5.67 1.40
29.91 1.79
1.94 l.ll
0.59 0.18
688* 17.51*
27.19* 10.19*
28.89* 0.11*
1-4-80
Hetn a
11.58
29.25
284.87
B&0.61
891.46
290.79
189.7
11.01
11.81
2.9
20.1)
46.04
6.17
29.54
4.12
0.69
687*
341*
24.08
28.88*
6.19
4.91
66.59
5.95
14.61
52.98
7.61
5.17
2.15
1.76
1.14
1.41
0.78
0.15
9.19*
1.16*
6.81
0.06*
1-5-80
Hetn o
11.9
29.72
289.58
848.64
895.6
100.42
182.8
12.45
11.51
2.5
20.17
46.75
6.09
10.46
4.12
0.62
695*
345.5*
7.63
29.17
4.76
4.44
48.47
5.61
10.97
46.6
17.36
6.09
3.92
l.ll
1.04
1.15
1.06
O.IS
6.67*
1.58*
6.22
0.08
1.6.
Hetn
11.7
28.88
279.79
847.11
895.11
291.7
177.5
15.38
32.15
3.75
22.21
46.2
6.06
10.3
4.5
0.6
688*
340*
19.79
29.04
80
a
5.55
5.30
56.71
7.22
9.89
54.21
21.01
1.51
6.1
1.6
0.89
1.5
1.1
0.11
6.1*
0*
9.19
O.I
1-7.
Hetn
10.6
28.24
274.8
850.21
891.8
286.11
178.75
11.66
11.6
4.2
25.25
46.46
6.06
30.67
4.54
0.61
699*
142*
24.58
28.97
80
a
7.51
7.21
74.9
5.21
15.19
76.82
26.6
8.21
11.2
2.41
1.4
1.79
1.41
0.12
1.94*
4.22*
4.29
0.048
1-8
Hetn
27.85
25.66
219.11
851.04
891
251.4
160.2
12.01*
28.17
6.4
25.48
45
5.21
29.44
1.54
0.51
662*
127*
2B.I7
29.01
-80
o
6.01
5.79
61.67
6.08
12.91
62.96
25.81
,.»•
10.9
1.72
1.07
0.97
1.01
0.10
10.13*
8.23*
4.99
1-9-80
Hetn a-
20.9
18.9
178
854
888
181
118
24.8
21.7
6.25
14
44
4.2
28
1.1
0.59
629*
105*
17
0.06 28.89
(Continued)
5.31
5.12
46.7
12.1
15.5
59.1
24.0
5.75
12.6
1.6
0.76
1.5
1.05
0.092
20.2*
21.2*
7.5
0.097
* Hat b*s«d on 24 Hour retdlngs
I 8«sed on UchMieier type g*uge
2 feted on weight type g*uge
-------
TABLE 2-3. (Continued)
Date
HU Gross
Net
Steao flow rate
(1000's Ibs/br)
Steu pressure (pslg)
Steaa teaperature (°F)
Feedwater flow rate
(1000's Ibs/hr)
Feedwater temperature
Fuel feed rate 1
(1000's Ibs/hr) 2
Fuel oil (gallons/hr)
Excess air X
ID fans »«ps
ID fans pressure
(pslg)
FO fans asps
FO fans pressure
(pslg)
Furnace draft (pslg)
Flue gas teap (°F)
Boiler exit
ESP Inlet
/Ublent teaperature
Aablent pressure
Inches Hg
3-10-80
Hean a
29.1
26.7
254
853
892
266
362
28.8
31.2
4.17
24
45
5.4
30
4.0
0.60
685*
340*
27
28.91
8.77
8.43
80.2
9.1
11.5
83.1
34.9
9.03
12.9
2.5
1.32
1.3
1.18
0.036
5.3*
0*
7.S
0.195
3-11-80
Hean . a
30.8
28.0
277
855
894
277
372
29.1
30.3
11.25
20
46
6.0
30
4.6
0.58
664*
323*
25
29.14
6.10
6.20
62.8
6.24
11.2
78.5
23.6
7.08
S.I
3.1
1.18
I.I
1.12
0.024
37.3*
27.1*
7.9
0.061
3-12-80
Hean o
31.2
27.1
255
855
893
279
370
30.5
31.0
12.08
20
46
6.2
28
4.4
0.61
675*
327*
30
28.88
6.26
7.99
94.0
5.8
II. 0
80.2
25.2
7.13
5.9
1.8
1.20
6.2
1.46
0.042
31.1*
14.6*
1.6
0.08
3-13-80
Hean o
31.2
28.3
26U
853
893
286
371
31.9
33.4
2.08
23
46
6.0
30
4.2
0.63
686*
324*
28
28.89
6.11
6.16
82.2
8.6
12.2
71.0
23.4
9.81
9.8
1.5
0.91
1.5
1.20
0.024
37.5*
20.1*
2.6
0.13
3-14-80
Hean o
30.6
28.0
270
852
894
281
371
30.4
30.7
3.75
24
45
6.9
29
3.7
0?62
669*
326*
37
29.11
6.25
6.01
62.8
7.0
12.5
61.3
21.8
6.64
11.3
I.S
1.01
1.6
1.12
0.044
30.2*
16.0*
12.6
0.02
3-15-80
Hean o
21.7
19.6
186
850
aaa
194
330
24.2
24.0
37.9
39
42
4.3
28
3.0
0.74
625*
295*
51
28.98
S.95
5.68
55.06
8.6
11. 1
54.0
69.4
6.6
12.5
4.0
0.81
1.4
1.00
0.092
27.3*
20.2*
11.2
0.10
3-17-80
Hean o
29.S
27.2
259
850
892
268
367
30.9
31.2
2.92
26
46
6.0
30
4.1
0.69
669*
319*
34
29.09
7.74
7.58
76.1
5.3
9.4
74.5
26.3
7.23
13.3
1.6
1.00
1.6
1.09
0.074
48.9*
21.3*
4.9
3-18-80
Hean a
31.8 3.84
29.3 3.6S
283 40.0
850 6.3 .
890 16.2
295 38.1
375 11.7
32.0 3.84
31.6
2.50
21 3.6
46 0.98
5.8 0.77
30 1.0
4.1 0.97
0.59 0.1
676* 24.0*
326* 9.5*
49 12.8
0.04 29.06 0.07
(Continued)
-------
TABLE 2-3. (Continued)
Dale
HU Cross
Nut
Steui HUM rite
(1000's Ibs/hr)
Steaa pressure (pslg)
Sleaa temperature (°F|
feedwiter floM rate
(1000's Ibs/hr)
feeilwater temperature
fuel feed rate 1
(1000's Ibs/hr) 2
fuel oil (gallons/tor)
faces* air t
ID fans amps
ID fans pressure
(psl>)
fD fans aaps
fO fans pressure
(pslg)
furnace draft (pslg)
flue gas teup (°f)
Boiler exit
fSP Inlet
Anlilent temperature
(°f )
Ambient pressure
Inches !«
3-19.80
Hean u
11.0
27.2
277
853
BBS
287
376
31.1
31.4
4.17
20
46
5.7
29
1.9
0.6
666*
128«
66
28.81
6.01
6.96
62.1
7.0
12.1
50.6
16.5
6.74
6.9
1.1
0.86
1.6
1.18
0.10
10.2*
15.9*
9.3
0.09
3-20.80
Hean u
30.6
26.8
273
851
891
222
372
11.6
14.4
20.4
27
46
6.9
29
4.8
0.6
681*
324'
44
28.92
5.88
7.68
59.8
6.0
12.3
116.4
16.8
7.06
7.7
1.8
0.9
6.4
1.32
0.09
32.8*
12.7*
9.2
O.OB&
1-22-80
Hean o
29.4
27.1
260
851
891
270
165
31.1
11. 1
26.67
22
45
S.I
29
4.1
0.69
659*
120>
04
29.04
5.16
4.95
61.1
7.4
II. 8
60.5
18.9
8.12
l.B
1.7
0.9
1.6
0.99
O.I
10.4*
12.2*
5.9
0.114
3-23-BO
Hean a
18.1
16.2
153
BS2
BB4
162
326
20.8
20.4
11.11
42
42
1.8
27
2.1
0.69
599*
280*
37
28. 9/
1.98
1.80
16.2
5.7
10.0
17.8
7.1
1.71
II. 0
0.7
0.22
0.6
0.1
0.057
3.9*
0*
1.6
0.04
1-24-80
Hean u
29.7
27.4
264
BSB
891
271
167
12.1
12.8
20.4
25
46
6.1*
29
4.1
0.51
660*
122*
16
29.04
7.77
7.66
71.5
4.9
11.2
72.5
25.4
8.26
10.8
2.2
0.27*
1.7
0.92
0.07
36.1*
21.1*
1.0
0.08
1.25-80
Hean a
29.5
27.2
262
852
892
272
364
31 .8
31.8
28.33
27
46
5.7
30
4.2
0.57*
670*
121*
IB
29.17
7.54
7.21
71.9
4.8
10.7
71.4
27.6
7.66
14.1
1.6
1.14
1.1
0.84
0.11*
11.6*
2.03*
6.3
0.024
1-26-80
Hean o
10.5*
27.7*
258
854
890
281
169
29.6
11.9
1.67
22
45
5.6
29
1.9
0.61
664
1(6
40
29.17
6.17*
(.29*
79.1
4.4
16.6
61.6
20.9
7.16
4.8
1.1
1.24
1.5
1.17
0.09
17.1
16.6
4.1
0.05
-------
TABLE 2-4. TEST DURATION PROCESS DATA FOR THE AMES MUNICPAL POWER PLANT. UNIT NO. 7
Date
'Duration of lest
HU Gross
Net
Steam flow rate
1000' s Ibs/hr
Steam pressure pslg
Steam temperature F
Feedwater flow rate
1000* s Ibs/lir
Feedwtter temperature °F
1 Fuel feed rate (coal)
"^ Fuel oil gallons/hr
Excess air S
ID fans amps
10 fans pressure pslg
FO fans amps
FD fans pressure pslg
Furnace draft pslg
Flue gas temp (°f )
Boiler exit
CSP Inlet
Ambient temperature °F
Ambient pressure
inches Hg
3-2-80
Hean a
1100 to
31
NS
278.2
859.5
903.6
287.5
NS
34.9
22.1
47.3
5.6
30.8
4.6
0.7
NS
NS
23
29.22
2100
2.31
NS
21.5
3.5
6.4
24.6
HS
2.6
1.6
0.5
0.8
1.2
0.8
O.I
NS
NS
3.1
0.09
3-3-80
Hean a
0900 to
34.8
32.3
315.9
852.1
902.5
321.8
381.3
36.2
18.3
46.9
6.6
30.8
4.5
0.6
NS
NS
NS
NS
2000
0.3
0.3
5.2
4.0
6.2
5.8
2.3
2.1
4.7
0.8
0.4
0.8
0.7
O.I
NS
NS
NS
NS
3-4-80
Hean a
0900 to
35.2
32.7
324
850.5
900.5
325.5
390.5
34.3
20.1
47.2
7.0
30.4
4.7
0.6
NS
NS
24.2
28.85
1900
0.3
0.2
3.0
3.5
3.5
9.1
6.1
0.8
1.8
0.4
0.2
0.5
0.3
0.07
NS
NS
3.6
0.03
3-5-80
Hean a
0900 to
35.0
32.6
319.1
850.5
902.3
328.1
394.1
35.5
18.7
47.2
6.7
30.9
4.4
0.62
NS
NS
10.9
29.23
1900
0.2
0.2
3.8
3.5
6.8
6.0
3.0
3.0
1.3
0.4
0.2
0.7
0.6
0.11
NS
NS
4.1
0.01
3-6-80
Hean a
0800 to
34.6
32.2
315.4
848.8
897.8
325.4
388.8
35.4
18.9
47.1
6.5
31.2
5.2
0.57
NS
NS
25.3
28.98
2300
0.8
0.8
10.3
6.2
10.2
11.7
3.4
I.S
1.4
0.6
0.6
0.8
0.8
O.I
NS
NS
5.4
0.05
3-7-80
Hean a
0800 to
35.3
32.8
322.8
852.2
895.1
336.5
390.1
35.7
19.3
47.9
6.9
31.8
5.3
.0.65
NS
NS
26.9
28.94
2300
1.0
1.0
11.9
4.5
12.1
13.6
6.9
5.S
I.I
0.9
0.3
0.6
0.7
0.07
HS
NS
3.2
0.04
3-8-80
Mean a
0800 to
31.3
29
275.6
851. 9
895:3
288.5
375
32.1
19.5
46
5.84
30.0
4.1
0.5
NS
NS
30.1
29.05
(Continued)
2300
2.2
2.1
23.7
7.3 •
12.2
24.1
7.3
I.I
1.0
0.8
0.5
0.3
0.7
0.07
NS
NS
4.9
0.02
NS - Hot Sufficient Data
-------
TABLE 2-4. (Continued)
10
OO
Stapling Day
HM Gross
Net
SteaB (Ion rate
Steaa pressure
Slea* temperature
feedwater flow
feedwtter leaperature
fuel feed rate (coal)
1000' s Ibs/hr
fuel oil gallons/hr
Eicess air
ID fans *•)'»
10 fans pressure
fO fan *»ps
fO fan pressure
furnace draft
Boiler flue gas top
ESP Inlet imperative
tablent temperature
'Ambient pressure
Sampling duration
3-9-
Hean
21.0
19.1
177
849
B92
188
340
2S.2
6. 25'
34
44
4.2
28
2.9
O.S9
632*
309*
42
28.82
80
u
S.I4
4.94
46.6
2.3
12.2
47.8
21.9
6.04
HA
12.1
1.9
0.81
i.a
1.01
0.078
18.6*
16.9*
4.4
0.023
B:30A-IO:IIP
3.10-
Hean
3S.O
32.3
310
858
896
323
390
36.3
4.17'
16
47
6.2
30
4.8
0.61
686
340
22
28.96
8-.IOA-5
BO
a
0
0.04
S.O
S.6
11.9
3.5
0
2.27
HA
0.8
0.9
0.25
0
0.36
0.033
5.3
0
1.6
0.091
:33P
3.11-80
He*n a
3S.O
32.4
320
857
898
330
388
33.8
11.25*
18
47
6.8
30
5.3
0.50
688*
340*
31
24.11
B:25A-
0
0.09
S.S
4.7
8.6
3.2
2.6
1.18
HA
1.0
0.7
0.29
O.S
0.45
0.024
13.7'
0'
4.0
0.053
10: JSP
3.12.80
Hean u
3S.S
32.8
325
ass
905
332
390
3S.I
12. OB1
IB
48
7.4
30
6.0
0.60
690
335
30
28. 8S
9:lOA-l
0.58
0.61
0
0
5.8
6.0
0
0.26
HA
2.9
0.6
0.4B
0
0.71
0.071
11.6
0
O.S
0.022
I-.I5P
3.13.
Hean
3S.O
32.4
320
B6S
899
330
386
38.6
2.00*
IB
47
6.4
31
4.9
0.63
709
33S
30
28.92
B:J5A-9
'BO
o
0
0.10
0
3.2
S.I
0
1.4
2.82
HA
I.I
O.S
0.30
O.SI
0.71
O.OIS
II. 1
1.4
I.S
0.123
:47P
3-14-80
Hean o
34.4
31.8
309
B5S
896
319
304
34.4
3.7S»
17
46
6.4
30
4.2
0.62
685
334
46
29.11
1.12
l.ll
I4.S
S.7
12.3
13.8
3.1
2.03
HA
I.S
o.a
o.so
0.7
O.B6
0.047
IS.O
i.a
S.8
O.OIB
B:40A-|0:SSP
3.15-80
Head a
19.6 6.S9
IB. 2 6.56
182 66.8
B5I 3.7
889 I2.S
184 64.2
336 24.9
23.0 7.34
37.92* NA
41 14.1
41 4.B
4.0 0.80
28 I.S
2.7 1.00
0.70 0.03S
6IB 30.4
2B9 21.3
10 4.2
28.92 0.048
9:OSA-IO:06P
(Can
3.17-80 .
Hean e
34. B
32.4
312
853
B9S
321
3B3
35.1
2.92*
ia
46
S.S
30
4.7
o.sa
695*
131*
37
29.12
8:49A
0.24
0.62
3.8
3.8
B.4
4.B
2.S
1.71
HA
1.6
0.6
0.82
O.SI
0.60
0.071
3S.6*
2.2«
4.7
0.030
-10:25P
-------
TABLE 2-4. (Continued)
*°
Sup ling Day
MM Gross
Net
Steam flow rate
Steam pressure
Steam tenperature
Feedwater flow
Feedmter temperature
Fuel feed rate
Coal (lUOO's Ibs/hr)
Fuel oil gallons/lur
Excess air
ID fans amps
ID fans pressure
FO fan amps
FD fan pressure
furnace draft
Boiler flue gas temp
ESP Inlet temperature
Ambient temperature
Ambient pressure
Sampling duration
3-18-80
Hean
34.0
31.4
307
851
B94
318
383
33.5
20
46
6.2
30
4.4
0.60
687*
330*
58
29.02
9:OOA-II
0
1.90
1.91
I9.S
6.0
11. 1
20.5
4.2 '
2.26
I.B
0.5
0.46
0.4
0.61
0.107
7.B*
3.6*
6.8
0.056
:25P
3-19-80
Hean
33.0
30.4
297
852
B8B
307
382
32.6
19
45
4.5
30
4.4
0.60
686*
338*
62
28.75
a
4.30
4.15
44.1
6.8
13.9
44.1
12.7
6.16
6.0
0.9
0.99
1.5
1.01
0.109
8.6*
2.5*
6.3
0.042
B:43A-I2:07A
3-20-80
Hean
31.8
28.8
281
853
B92
292
372
33.3
24
46
5.8
30
6.5
0.81
695*
330*
42
29.03
9:05A-4
a
5.45
5.42
57.6
3.8
12.5
55. B
19.8
a. 20
3.4
2.4
1.09
1.9
6. CO
1.019
15.9*
4.8*
6.2
0.106
:25A
3-22-80
Hean
29.4
26.9
260
851
889
270
365
33.2
26
45
5.4
30
4.1
0.61
679*
328*
42
28.95
9:47A-2
0
6.93
6.66
66.3
7.5
13.6
66.2
25.7
7.92
13.0
1.3
1.02
1.6
1.14
0.056
9.8'
2.6*
4.2
0.078
:I2A
3-23-80
Hean
18.5
16.6
155
B56
886
156
328
21.4
38
42
3.8*
27
2.3
0.58
598*
280*
37
28,98
9:27A-2
a
1.51
1.36
11.9
4.8
7.7
38.2
7.9
1.28
10.6
0.6
0.24*
0.4
0.36
0.057
4.6*
0*
1.5
0.024
:IOA
3-24-80
Hean
34. B
32.7
311
855
899
321
384
33.1
16
48
6.2
30
4.5
0.52
674
335
37
29.05
o
0.29
0.76
2.5
5.B
II. 8
4.8
2.5
1.03
1.7
1.0
0.17
0
0.10
0.093
II. 1
0
1.5
0.012
II:IOA-3:47P
3-25-80
Hean
34.6
32.2
311
B51
B92
324
384
33.8
IB
48
4.8
30
4.8
0.59
676
335
44
29.16
o
0.48
0.57
3.0
4.8
9.6
2.4
2.5
0.50
1.0
0
I.B2
0
0.51
0.075
II. 1
0
0.8
o.oia
II:20A-3:46P
3-26-80
Hean o
35.0 0.6
32.5 0.6
310 0.9
852 2.7
902 14. B
327 3.9
380 0
35.1 2.84
IB 0.6
46 0
6.6 0.34
30 0
4.7 0.80
0.53 0.065
689 16.0
325 3.5
43 2.6
29.17 0.041
9;22A-2:06P
• Mot a total time mean.
-------
Unit No. 7 generally operated between a range of 16 to 35 MW gross,
(refer to daily process data tables provided in Appendix D). Production
over 35 MW placed considerable wear on the unit, and was avoided whenever
possible. Production under 16 MW introduced instability and the possibility
of large transient swings in operating conditions. Usually the boiler was
operating close to one of these limits. It operated at 35 MW during peak-
loads because the load of the serviced community was over 35 MW. Produc-
tion was reduced to 16 MW when off-peak power could be bought more cheaply
from neighboring utilities.
Examination of Table 2-3 indicates that the daily mean of gross elec-
trical output (24 hour basis) is typically between 29 and 32 MW due to boil-
er operation at full output for a large portion of the day. In fact, the
hourly readings provided in Appendix D indicate that output is rarely below
35 MW between the hours of 8 AM and 10 PM or longer. During non-peak hours,
the boiler operated between 16 and 25 MW, depending on load and the amount
of power being purchased from neighboring utilities. Comparison of the
daily cycles of power production with the standard deviations (24 hour basis)
given in Table 2-3, indicates that the standard deviations range between 5
and 7 for days representative of typical operation. Values not lying in
this range are indicative of abnormalities such as the buying of cheaper
power through the peak hours, or unusually high off-peak loads. The stand-
ard deviations in Table 2-3 show that these abnormalities happen most often
on weekends, especially Sundays. Weekday operation is fairly consistent,
due to uniformly high loads and the resultant high cost of power. Net power
output follows identical trends, since the power demand of the auxiliary
equipment associated with Unit No. 7 is fairly constant.
Fuel consumption varied directly with the amount of electricity produced.
Of the three types of fuels used in Unit No. 7 (coal, RDF, and fuel oil), coal
was used in the largest quantities. The amount of RDF burned was limited to
approximately 17% in terms of the total heat produced. This was because RDF,
due to its lower heating value, cannot sustain sufficient temperatures to
maintain required boiler efficiency and steam quality. Also, RDF requires
a longer residence time in the boiler for complete combustion, and this places
another physical restriction on the amount of RDF in the fuel mixture. Fuel
oil is used sparingly, and only as an igniter to insure flame continuity dur-
2-20
174
-------
1ng soot blowing. Different firemen have different procedures for its
use, and the large variations in fuel oil consumption shown in Table 2-3
are more related to operating practices than to what was happening in the
boiler.
The continuous supply of RDF to the boiler during the test was found
to be unreliable. Practical experience during the test indicated that RDF
supply, was very.unreliable. The RDF conveyors which feed Unit No. 7 were
prone to jamming and required frequent maintenance. Often the RDF supply
ran out because the solid waste recovery plant was experiencing mechanical
problems, or had run out of refuse to process. Out of 23 days of sampling,
only on 6 was RDF burned continuously. On 15 days RDF was burned part of
the time, and on 2 days it was not burned at all (refer to Appendix D).
The means and standard deviations for coal consumption given in Table
2-3 follow those of the gross electrical output. This indicates that coal
consumption is closely related to electrical output, as expected. However,
these daily averages mask out one important effect. Referring to the tables
in Appendix D, one can see that the amount of coal burned depends on whether
there is RDF in the mixture or not. All other things being equal, the flow
of coal will always go up or down, depending on whether RDF is being removed
or introduced into the mixture, respectively.
2.2.1 Operating Parameters
Data for the steam cycle in the boiler are also listed in Table 2-3.
Examination of the data indicates that the steam and feedwater flow rates
fluctuate in a daily cycle, with means and standard deviations following
the gross electrical output. However, the values for steam temperature and
pressure remain fairly constant. The feedwater temperature also varied.
It was higher on days of high electricity production, and lower on days of
low production.
Excess air is one of the most important parameters for describing con-
ditions inside the combustion chamber. Unit No. 7 is designed to operate
at about 20% excess air. Data in Table 2-3 indicates that on the average
this is true. However, the hourly data (refer to Appendix D) indicates wide
fluctuations. Excess air tended to increase as the boiler load decreased.
2-21
175
-------
This was possibly due to the operater not decreasing the intake air with the
reduction in fuel supply. On nearly each night the excess air reading was
greater than 50* (the maximum readable value on the meter). The standard
deviations of the mean excess air values indicate no direct relationshop to
the deviations of gross power output. Consequently, excess air is not a
function of power output alone. Unlike most other parameters, the excess
air setting was subject to the whim of the operator, and changes from work
shift to work shift could have introduced important variations.
The induced and forced draft fan measurements listed in Table 2-3 are
of limited significance , since they did not respond to increases in pro-
duction with greater airflows and correspondingly greater current consump-
tion. The furnace draft data indicated little or no correspondence to any
of the other measured data. Most of the flue gas and ESP inlet temperature
readings were incomplete as they did not cover the entire 24 hour day. Most
of this information was recorded during peak operation, and may therefore be
considered representative for peak operation conditions. Both the flue gas
and ESP inlet temperatures decreased during off-peak periods.
Routine activities such as ash removal and soot blowing was performed
at times designated in the test plan. ROF was observed to have a substan-
tially higher ash content than coal, and this characteristic was reflected
by longer ash removal periods, and more periodic soot blowing. Both activi-
ties decreased substantially when ROF was not being burned.
2.2.2 Test Duration Data
Table 2-4 contains means and standard deviations for all of the para-
meters given in Table 2-3 on a test duration basis. They are derived from
the same hourly data given in Appendix D, but the averages are taken over
shorter periods of time than the 24 hour means discussed previously. These
values are included only to indicate what operating conditions existed dur-
ing the hours of each test. They are not, however, indicative of overall
boiler performance. For instance, some tests were performed only over peak
hours. These means would be indicative only of peak conditions, and the
corresponding standard deviations would be very small, since the parameters
remained fairly constant during this period.
2-22
176
-------
2.2.3 Dally Production and Consumption Data
Table 2-5 contains information recorded by the power plant on a daily
basis. The total gross and net power production was recorded directly from
meters inside the plant. The total steam produced divided by the gross power
production gave a good indication of boiler efficiency. Separate meters are
used for measuring the water used for ash removal and the total input to the
evaporators. The days of highest sluice water use corresponded with days
of prolonged use of RDF in the fuel mixture. The evaporators eventually feed
into the working fluid cycle of the boiler, and gave a fair indication of
make-up water required, except that there was a water reclamation system
attached to the boiler. Hence, these values indicated new input to the sys-
tem, but did not account for total make-up water requirements.
Most of the fuel types were very accurately measured. Coal was measured
through a weight integrating system, and fuel oil was similarly measured
through a volume integrating system. However, no accurate measurement of
the RDF was -possible. The values listed were derived from volumetric read-
ings and a very rough measurement of the RDF density, taken once every shift.
The Btu contribution of each fuel was then calculated by doing calori-
metric analyses. This was done periodically, and the values used for
the duration this test program are given in Table 2-6. By summing the
Btu contribution of each fuel, a value for total heat production can
be found. This value was then divided by either the gross or net elec-
tricity production to express thermal energy as it related to the power
production of the day.
2.3 Continuous Monitoring Data
Table 2-7 presents the daily averages of Oj, COg, CO, and total hydro-
carbon monitoring on approximate test duration basis. Occasionally the con-
tinuous monitors were allowed to run longer than the actual test, but the
data can still be considered to be representative of the test duration.
Hydrocarbon values were always found to be lower than 2 ppm, the sensitivity
limit of the instrumentation used.
2-23
177
-------
TABLE 2-5. DAILY PRODUCTION AND CONSUMPTION AT AMES MUNCIPAL POWER PLANT, UNIT NO. 7
Date
1-2-80
' 1-1-80
1-4-80
1-6-80
1-6-80
1-7-80
1-8-80
1-9-80
1- 10-80
IN> 3-11-80
1
£ 1-12-80
1-1180
1-14-80
1-15-80
1-17-80
1-18 80
1-19-80
1-20-80
1-22-80
1-21-80
1-24-80
1-25-80
1-26-80
Power Production
(Mi)
Cross Net
681 000
709 000
761 000
759 000
740 000
715 000
648 000
494 000
691 000
719 000
750 000
742 000
729 000
606 000
699 000
759 000
748 000
751 500
706 000
426 000
710000
700 000
726 000
621 902
648 682
700 072
696 461
679 658
674 470
690 057
441 496
615 037
678 629
686 456
681 869
668 119
457 939
639 942
696 494
682 596
689 205
647 644
182 263
650 039
642 Oil
664 973
Iheriitl Cuergy*
(Blu/kwh)
Cross Net
II 166
II 296
II 396
II 697
II 693
II 652
II 602
II 524
10 945
II 440
II 348
II 544
II 537
II 434
II 170
10855
10 794
II 366
II 077
II 111
10 841
II 080
10 949
12 210
12 146
12 368
12 711
12 728
12 697
12 742
12 636
II 985
12 446
12 362
12 562
12 486
12 684
12 201
II 629
II 829
12 368
12 076
12 604
II 841
12 001
II 954
Steaa
Production
(Ib/kMh)
9.57
9.59
9.63
9.73
9.50
9.64
9.64
9.47
9.54
9.67
9.62
9.68
9.51
9.50
9.59
9.52
9.51
9.56
9.55
9.49
9.61
9.52
9.60
fuel Consumption
Iowa Coal Colorado Coal HOT*
(Ibs) (Ibs) (Ibs)
319 908
418 110
412 290
414 616
412 096
427 127
348 286
301 868
48b 980
334 326
406 980
412 270
412 440
122 448
412 115
417 010
414 115
445 192
410 520
269 610
629 920
610 U80
612 960
432 712
342 270
351 210
370 162
339 504
378 773
317 720
267 712
262 220
392 472
334 620
368 230
324 060
253 342
337 365
341 190
336 965
379 406
336 BBO
220 490
157 460
152 720
IS3 240
0
111 000
226 800
192 175
213 200
130 600
168 460
26 000
01 200
229 600
229 075
144 075
210 400
22 O&O
97 650
154 874
134 816
63 700
92 000
0
61 600
93 000
134 970
Sluice Utter
for BotloB
and fly Ash
Oil ReMval
(gallons) (gallons)
60
160
70
60
90
100
130
ISO
100
270
290
SO
90
910
70
60
100
490
640
800
490
680
40
250 000
340 000
120 000
180000
450 000
120 000
160 000
114 900
186 716
401 172
411 644
422 620
411 112
315 104
196 000
471 000
477 000
320 000
250 000
180 000
100 000
430 000
540 000
Utter Input
to (vaporator
(gallons)
8 300
9 000
2 200
6 800
9 200
2 600
1 120
8 500
6 300
S BOO
1 500
9 100
0
S 700
II 100
IS 200
6 000
7 300
S 400
16 600
4 500
4 000
18 500
•Ihti Is only * rough Measure of HOT uclgltt.
Ibis value Is derived from Hie average Blu toiilenl of each fuel.
-------
TABLE 2.6, HEAT CONTENT OF FUELS USED AT THE AMES MUNICIPAL POWER PLANT
DURING SAMPLING PERIOD _
Heat Content for each Fuel Type
IOW3
Cflal CQal RDF
Test (Btu/lb) (Btu/lb) (Btu/lb) (Btu/ gallon)
3-2-80 8946 10,556 5587 138,603
thru
3-16-80
3-17-30 9035 10,298 6128 138,603
thru
3-26-80
2-25
179
-------
Fluctuations in the 02, C02, and CO levels are usually indicative of
process conditions in the boiler. The means for these components at Ames
were fairly uniform, as can be seen from Table 2-7. The only unusual days
were March 9, 15, and 23, as evidenced by high 02 levels and low levels of CQ2
and CO. From Table 2-4, it can be seen that these were days of low electrical
output and correspondingly high levels of excess air. Furthermore, these were
the only days that were typical in this regard.
Although excess atr was monitored in the plant's control room, it has
also Been calculated on a theoretical basis for comparison using the follow-
ing expression
0, - CO/,
% excess air = 1QO x I?
where the gaseous components are expressed as percentages.
The results of these calculations are given in Table 2-8, along with
the values of excess air measured in the control room. The calculated val-
ues are consistently smaller, and the same anomalies appear (i.e., large
values on the 9th, 15th, and 23rd). In this case, the measured values are
larger because these were taken after the air preheater to the boiler. Evi-
dently, there is some air leakage in the preheater.
2.3.1 Air Preheater Leakage
Oxygen in the flue gas at the inlet and outlet to the preheater was
monitored on March 8, 1980 to determine air preheater leakage. Continuous
monitoring results are presented in Table 2-9. The oxygen readings were
also plotted and are shown in Figure 2-1.
Examination of the plots in Figure 2-1 indicates that the increases and
decreases in oxygen at the boiler exit are closely followed by similar in-
creases and decreases in oxygen at the ESP inlet which is located downstream
of the boiler. Since the variable oxygen readings at the inlet and outlet
were taken on an intermittent basis, at 15 minute intervals, it was difficult
to relate the data points at the boiler exit and the ESP inlet on a same time
basis. However, from the graph the similar trends of the two curves can be
easily observed.
2-26
180
-------
TABLE 2-7. CONTINUOUS HONUORING DATA
Sanpl Ing
Location
ESP Inlet
ESP Outlet
Inlet
Cutlet
Inlet
Outlet
Inlet
Inlet
Outlet
*> Inlet
A> Outlet
VJ
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Date
(1980)
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
3-11
3-12
3-13
3-14
°2
Hean
4.6
6.3
4.4
5.8
4.4
6.1
4.4
5.6
4.3
DATA
4.6
5.9
0
4.3
4.8
7.1
8.8
4.0
5.6
4.7
5.8
4.4
5.6
3.3
5.2
3.7
5.3
(*)
a
0.34
0.53
0.55
0.65
0.35
0.17
6.66
0.83
0.29
TArEN FOR
0.32
0.27
0.30
0.40
1.23
1.38
0.30
0.19
0.28
0.23
0.29
0.33
0.30
0.57
0.40
1.03
Hean 2
12.7
11.4
13.7
12.5
14.4
13.0
14.6
13.4
13.9
INLET ONLY
13.9
12.8
14.0
13.6
11.6
11.0
13.9
12.4
13.6
13.2
14.0
13.8
15.6
14.0
14.8
13.1
' «>
o
0.44
0.53
0.63
0.67
0.36
.19
0.58
.36
0.37
0.35
0.28
0.30
0.39
1.22
1.24
0.30
0.14
0.4B
0.51
0.43
0.56
0.33
0.96
0.47
0.74
CO (ppm)
Hean o
17.9
16.5
12.4
10.7
16.7
14.7
18.3
27.8
16.7
16.4
14.7
27.6
28.4
24.7
22.6
24.5
24.9
22.4
21.2
22.1
22.3
20.7
18.4
27.7
29.9
1.61
1.57
1.54
1.16
0.75
.89
1.22
10.14
2.30
1.50
1.63
0.85
2.29
1.82
2.31
1.51
1.04
1.88
1.29
1.75
3.77
0.90
1.03
4.21
16.56
THC (pp»)
Hean o
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
-------
TABLE 2-7. (Continued)
oo i
Saapllng
Location
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Inlet
Outlet
Inlet
Outlet
Date
(1980)
3-15
3-17
3-18
3-19
3-20
3-22
3-23
3-24
3-25
3-26
Mean
6.3
8.4
3.7
5.4
3.8
5.4
3.8
5.3
4.1
5.9
3.6
5.4
6.9
8.8
DATA
5.4
4.4
5.4
4.9
DATA
a
1.56
1.87
0.47
0.32
0.33
0.30
0.58
0.47
0.29
0.25
.34
.29
1.09
.75
TAKEN FOR
.24
.83
.23
.87
TAKEN FOR
co2 (x)
Mean a
12.6
10.7
14.4
12.9
14.4
13.0
14.7
13.2
14.3
12.8
14.2
12.6
12.7
10.1
OUTLET ONLY
13.2
13.8
13.1
13.7
INLET ONLY
1.45
1.67
0.62
0.33
0.46
0.40
0.72
0.47
0.41
1.11
.35
.46
1.08
.74
.24
.71
.26
.73
CO (PPM)
Mean a
22.0
18.7
21.5
20.0
23.3
23.7
23.6
26.2
20. l"
17.4
38.3
37.7
2.03
2.01
1.73
1.41
1.18
9.62
1.84
17.55
2.21
1.70
25.81
22.61
HOT OPERATING
M •
M
'•
f
M
M
M
M
TIIC (ppM)
Mean o
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
_
-
_
-
_
-
-
_
-
-
-------
TABLE 2-8. EXCESS AIR READINGS
Date
3-2-80
3-3-80
3-4-80
3-5-80
3-6-80
3-7-80
3-8-80
3-9-80
3-10-80
3- 11 -80
3-12-80
3-13-80
3-14-80
3-1 5-80
3-17-80
3-18-80
3-1 9-80
3-20-80
3-22-80
3-23-80
3-24-80
3-25-80
3-26-80
Excess Air X Excess Air %
26.7
25.5
25.8
25.9
24.9
27.2
24.9
49.4
22.6
27.9
25.7
18.2
20.8
41.7
20.6
21.4
21.4
23.5
19.9
37.8
NA
25.6
29.5
22.1
18.3
20.1
18.7
18.9
19.3
19.5
34
16
18
18
18
17
41
18
20
19
24
26
38
16
18
18
Based on
2
Control
continuous monitoring data from the ESP inlet
room readings
2-29
183
-------
TABLE 2-9. AIR PREHEATER CONTINUOUS MONITORING DATA
Time
1430
1445
1500
1515
1530
1545
1600
1615
1630
1645
1700
1715
1730 *
:745
1800
1815
1830
1845
1900
1915
1930
1945
2000
2015
Mean
Boiler
S02
4.237
4.094
3.741
4.637
4.083
4.089
4.198
4.192
4.295
3.937
4.742
4.632
4.24
0.30
Exit/Preheater
S C02
13.926
14.222
14.414
13.678
14.304
13.972
14.154
13.740
13.976
14.154
13.492
13.566
13.97
0.30
CO
ppm
28
27
28
28
28
26
27
26
28
29
28
28
27.58
0.9
Inlet
THC
ppm
0.42
0.49
0.45
0.37
0.41
0.22
0.18
0.23
0.19
0.22
0.26
0.21
0.304
0.114
ESP
%o2
4.593
4.975
4.544
4.901
5.207
4.879
4.153
5.141
4.359
4.959
4.397
4.401
4.71
0.34
Inlet/Preneater
% co2
13.784
13.542
13.668
13.520
12.43
13,538
14.246
13.574
13.902
13.564
13.946
13.558
13.51
0.43
CO
ppm
29
28
29
27
26
26
23
26
28
27
28
36
28.1
2.7
Outlet
THC
ppm
0.1
0.22
0.20
0.19
0.21
0.15
0.18
0.18
0.04
0.25
0.11
0.18
0.168
0.059
2-30
184
-------
Figure 2-1. Oxygen 1n the gas before and after the air
preheater
2-31
185
-------
Air preheater leakage is defined as the ratio of the difference between
the amount of flue gas out of the preheater and the amount of flue gas into
the preheater to the amount of flue gas into the preheater. In order to esti-
mate this leakage average values for oxygen for the inlet and outlet from the
monitored data were used. Based on an average oxygen reading of 4.24 percent
at the preheater inlet and 4.71 percent at the outlet an air preheater leak-
age of 2.9 percent was calculated. It must however be noted that during this
period the boiler load averaged approximately 88% and the RDF heat input to
the boiler was approximately 20 percent. Air preheater leakage will vary
with the steam load and type of fuel fired.
2-32
186
-------
3.0 SYSTEM DESCRIPTION
The coal-fired utility boiler tested was the No. 7 unit at the Ames
Municipal power plant. The power plant is owned and operated by the city of
Ames. Three boiler units, 5, 6, and 7, at the power plant have been modi-
fied to burn solid waste as a supplemental fuel with coal. Boilers 5 and 6
are Stoker-fired boilers and boiler No. 7 is a pulverized coal suspension
fired boiler. Under normal operating conditions only unit No. 7 is used.
Units Nos. 5 and 6 are operated only under peak demand conditions or when
unit No. 7 is down.
The power plant is located within the city limits of Ames, Iowa. Ames
is approximately 54 Km (34 miles) north of Des Moines. The Ames Municipal
power plant layout is shown in Figure 3-1.
3.1 Boiler Description
Boiler No. 7 was designed to burn coal or natural gas as the primary
fuel. It is a tangentially fired, pulverized co^al, balanced draft, Combus-
tion Engineering unit, rated at 175000 kg/hr (385,000 Ib/hr) of steam. The
generator is rated at 35,000 KW, gross. Unit No. 7 has been operating since
June 1968. However, modification to burn refuse derived fuel (RDF) was made
in T975. Boiler No. 7 specification data is provided in Table 3-1 and a flow
diagram of unit No. 7 is given in Figure 3-2.
As shown in Figure 3-2, coal from the plant stockpile is fed to two
Raymond Bowl Mill pulverizers. Air preheated to about 340°C (650°F) by the
combustion gases is supplied to the pulverizers to dry the coal, and to con-
vey the pulverized coal to the burners. Pulverizer air preheat is necessary
to prevent pulverizer to burner blockage which can be caused by wet fuel.
Design specifications of the Raymond Bowl Mill pulverizer are provided in
Table 3-2.
Pulverized coal entrained in 15 to 20 percent of the total combustion
air is conveyed to the individual burner nozzles which direct the coal and
primary air into the combustion chamber. Combustion air is supplied to the
boiler unit by a Westinghouse forced draft fan. The combustion air drawn
3-1
187
-------
00
00
I
i
I
STRtET
2mOO
clUSUt*
TRAJBFWU-.-..., ^loust
UOUSE ---...___ ' —-
Mfivserv
uopru^-1
^
\ J
fEECM*
uo»rfc»
*' U1CII CUAIU LINK
COAL STOkAOB A t I A
iMIIIIIIIIMiinnillllllllllllllllllllllllllllllllllllllllilllllltlllXIIIIIIIIIIIIIIIIIIIIIIIIIMIIIIIIIIIIIIIIIIIIIIMIIIIIIIIIIIIII
Figure 3-1. Layout of plant site
-------
TABLE 3-1. BOILER DESIGN DATA
Description
Size
Design pressure, psl
Total effective heating surface sq ft
Boiler
Furnace EPRs
Superheater • Conviction zone
Radiant ZBM
Economizer
Regenerative A1r Heater
Mr Preheating Coll
Furnace VoluM. cubic feet
Furnace width and depth
C to C of tubes, ft
Furnace design pressure. In HjO positive
Total weight complete, Ib
water required to fill boiler ind water
wells to operating level, gal
Inside diameter and thickness of steel dn«
Overall length of steam dnai
Dn» head thickness, 1n lifting weight
of dru» safety valves
Manufacturers, type, nuwer and size-
of drun safety valves
Hanufacurer, type, nunber and stze
of blowdown valves
Tubes 1n furnace
Size and thickness
water well tube spring, 1n
C to C
Furnace exit first row
tube spring. In C to C
Are tubes staggered?
Material
Number
Tube spring In C to C
Tubes In Boiler
Size and chlcXness
Material
Tube spring C to C (1n)
Number
Circulation ratio, nrinlmua
1085 p$1g
16550
6200
52QQ
1800
67200
5070
27300
19'-1T by la'-ll"
8- US
2.340,000
Appro*. 17,900 U.S Gallons
66" OIA - 4 || • x 2 || •
Appro*. 27' - 0*
2 1/4' 66* B Orua - 35000 IBS
Consolidated
Two (2) 3" I1757A
Two (21 sets 2* Yarway
6968-81
2 1/2* 0.0, x .180
3* all wells
9* (finishing superheater1
NO • IN LINE
SA - 192
26 Assemblies
9* (Finishing superheater)
2 1/2- 0.0. x .12
SA -192
3 3/4- Transverse
1472
Water walls - 10 to 1
3-3
189
-------
CJ
FIRST
STAGE
PRESSURE
COAL
STEAM JET
AIR EJECTOR
DLEED
STEAM'
PULVERIZER .
ATLAS BIN
T
REFUSE
DERIVED
FUEL
VOLUMETRIC
FLOW
DENSITY
COOLING TOWER
BI-OHIHV.JN
AMBIENT AIR
OVERGRATE
(RDF ONLY)
SPRAY HATER
DESUPERIIEATER
BOILER
FEED
PUMP
FEEDWATER |
INTEGRATOR
TEMPERATURE
FEED WATER IN
FEED
WATER
HEATER
FEED
WATER
HEATER
COMBUSTION
ENGINEERING
STEAM
GENERATOR
UNIT NO 7
UNDERGRATE
AIR
(RDF ONLY)
SEAL _
WATER
l
UNTREATED
-WELL WATER
TEMPERATURE
FLUE GAS IN
TEMPERATURE
AIR OUT
AIR HEATER
.EAKAGIJ
a RAFT
AN
1 f
PRIMARY AIR
TO PULVERIZER
TEMPERATURE
AIR IN
FORCED
DRAFT
FAM
ELECTROSTATIC
PRECIPITATOR
FLY ASH
BOTTOM ASH
COMBUSTION
AIR
Figure 3-2. Flow diagram for unit 17 at Ames Municipal power plant
-------
TABLE 3-2. DESIGN SPECIFICATION FOR RAYMOND BOWL PULVERIZERS
DESCRIPTION
SIZE
Pulverizers
Manufacturer's Model No.
No. of pulverizers
Type and size
Weight including driver
Weight and dimensions of largest piece
requiring removal for maintenance
Minimum stable firing rate, Ib per hr
each of specified coal
Maximum firing rate, Ib per hr of
specified coal each
Maximum turndown ratio
Maximum horsepower input required
Primary air temperature, F.
For the specified coal
Max. allowable
Maximum boiler .load with one pul-
verizer in operation with specified
coal, no gas fi ri ng, 1b per hr
C. E. Raymond No. 613
Two (2)
Bowl Mill
Approx. 98500 LBS each journal
assembly
3 x 4 x 4 ft 3900 LBS.
8000 LBS/HR
32000 LBS/HR @ 60 GR 17.12% M
Pul. - Burner Combination 4 to 1
265 each Shaft Incl. Exhauster
651
750
250,000
3-5
191
-------
by the forced draft fan is obtained from the 9th floor of the power plant
building (refer to Figure 3-3). Design specifications for the forced draft
fan are provided in Table 3-3. The "burners are designed to admit controlled
quantities of additional air through separate air ports surrounding or built
into the fuel nozzle.
In the combustion chamber, the combustible matter reacts with oxygen
of the air to release thermal energy at temperatures exceeding 1100°C
(2000°F). The walls of the combustion chamber are lined with water-filled
tubes which absorb thermal energy and generate steam. The water tubes are
filled with liquid or vapor, depending on pressure and temperature-condi-
tions.
Heat transfer in the combustion chamber cools the combustion gases.
The cooler combustion gases flow from the combustion chamber to the super-
heater where further heat transfer and gas cooling occurs. The superheater
is a combination Radiant-Convection type with 13 tube rows and 26 steam
passes on the primary side and 26 tube rows and 52 steam passes on the
secondary side. The maximum design temperatures in the superheater are:
steam side - 350°C (primary), 485°C (secondary); gas side - 1150°C (primary),
1050°C (secondary); and outside metal surface - 470°C (primary), 545°C
(secondary). Steam superheat is necessary for thermodynamic efficiency and
also to prevent steam condensation which would damage the blades of the
steam turbine.
Combustion gases from the superheater normally flow to the economizer
section where heat is transferred to the boiler feed water. However, the
No. 7 unit has no economizer and flue gases from the superheater flow to
the air preheaterrthen to a cold-side electrostatic precipitator via an in-
duced draft fan (refer to Table 3-3) out through the stack. The regenerative
air heater has an effective heat exchange surface area of 67200 sq ft. Com-
bustion gases enter the air heater at texperatures of 370° to 400°C (700 to
750°F) and exit at temperatures of 135° to 150°C (280 to 300°F). Air temper-
ature entering the air heater ranges from 35° to 50°C (100 to 120°F) and
exit temperatures range from 315" to 335°C (600 to 640°F). Performance
characteristics for unit No. 7 provided by the manufacturer are given in
Table 3-4.
3-6
192
-------
VO
U>
GAS
OUTLET
Figure 3-3. Schematic of Ames Municipal power plant boiler No. 7.
-------
TABLE 3-3. FAN DESIGN PERFORMANCE
Forced Draft Fan
Manufacturers name
Model No.
Blade type
Operating speed, rpm
Air inlet temperature, °F
Air flow (100% load), Ib/hr
Air flow (1005 load), ft3/min
Fan static pressure, psi
Static efficiency (100% load),
Power required, Kw
Induced Draft Fan
Manufacturers name
Model No.
Blade type
Operating speed, rpm
Air inlet temperature, °F
Air flow (100% load), Ib/hr
Air flow (100% load), ft3/min
Fan static pressure, psi
Static efficiency (100% load), %
Power to fan shaft, Kw
Westinghouse
#4054
Air foil
1180
80°
422,696
99,934
0.28
54.6
167.1
Westinghouse
#4073
Air fotfl
885
279
482,653
153,900
0.26
52.3
249.9
3-8
194
-------
VO
U1
TABLE 3-4. PREDICTED PERFORMANCE CHARACTERISTICS OF UNIT 17
AT AMES MUNICIPAL POWER PLANT.
FUEL COAL COAL COAL
Evaporation
Feedwater Temperature
Superheater Outlet Temperature
Superheater Outlet Pressure
Superheater Pressure Drop
Gas Drop, Furnace to Econ. Outlet
Gas Drop, Econ. Outlet to A.M. Outlet
Gas Temp. Entering Air Heater
Gas Temp. Leaving Air Heater, Uncorr.
Gas Temp. Leaving Air Heater, Corr.
Air Temp. Entering Air Heater
Air Temp. Leaving Air Heater
Air Press, at F.D. Fan
Ambient Air Temperature
Excess Air Leaving Economizer
Fuel Fired - Coal @ 9506 BTU/I
Efficiency
Ib/hr
F
F
pslg
psi
"wg
"wg
F
F
F
F
F
"wg
F
%
Ib/hr
%
216,000
375
905
900
30
0.85
2.00
705
281
265
119
598
5.10
80
22
28,600
87.99
360.000
428
905
900
75
1.85
4.35
732
296
279
101
633
7.75
80
22
45.600
87.28
385,000
433
905
900
85
2.15
4.90
743
297
280
99
635
8.70
80
22
48.500
87.21
Superheat steam temperature control range Is from 216,000 to 385,000 Ib/hr.
The fuel specifications on which the above are based are as follows:
F.C. 37.10 IIHV (as fired) 9506 BTU/I
V.M. 32.27
Ash 13.51
Moist. 17.12
100.00%
-------
Unit No. 7 generally burns a mixture o*f Iowa coal, Colorado coal, and
refuse derived fuel (RDF). The ratio of the two types of coal in the mixture
varies. However, during the test program a 55 to 45 percent ratio of Iowa
and Colorado coal was maintained in the pulverized coal mixture. Approxi-
mately 20 percent of the total fuel fired is RDF and 80 percent pulverized
coal.
Coal is stored in the coal yard in two separate piles. Front-end load-
ers are used to move the coal to the transport conveyor feeding the storage
bunker. Coal is alternately moved to the conveyor and is overlayed in the
bunker prior to the coal dropping into the pulverizer. This mixing of coal
is done on a weight basis and has proven satisfactory to the plant in main-
taining the proper blend.
RDF is produced at a separate Ames city facility located approximately
two blocks away. All of the RDF produced is pneumatically conveyed to a
storage bin (Atlas bin) 25 m (85 ft) in diameter with a holding capacity of
454- Mg (500 tons). The RDF is fed from the Atlas bin at the required rate
(8.5 tons/hr maximum) and pneumatically conveyed to the RDF burners. There
are two RDF burners located approximately 61 cm (24 inches) below the coal
burners at opposite corners of the firebox. The location of the RDF burners
is shown in Figure 3-4.
The by-products of combustion are stack gases and ash. With pulverized-
coal firing, all of the burning is accomplished in suspension with the re-
sult that about 80 percent of the ash remains in the flue gases. Due to the
utilization of REF to supplement coal as fuel, modifications were made to
the boiler. Grates were installed in-April 1978 to assist in the combustion
of RDF. Prior to the installation of the grates, RDF burning in suspension
was not very effective, and substantial portions of the RDF dropped unburnt
into the bottom ash hopper.
Deposited ash and slag in the boiler furnace bottom are removed at least
3 times per day. An average of 758,000 liters/day (200,000 gallons/day) of
sluice water (raw well water) is used to remove the solid waste from the fur-
nace bottom. This waste is then drained to a holding pond where the ash is
dredged out. The water from the holding pond percolates through the soil
eventually Into the nearby Skunk river. Any overflow from the holding pond
o
3-10
196
-------
BOILER NO. 6
BOILER NO. 5
. Section CC
Fpom Atlas Bin
South •
Figure 3-4. Solid waste recovery system
-------
is also absorbed by the river. Also deposited 1n the holding pond 1s the
electrostatic precipitator (ESP) fly ash. The fly ash from the ESP hoppers
is pneumatically conveyed (3 times per day) to the bottom ash hopper drain
system which transports it to the holding pond. The dredged ash is stored
on site in piles.
Make up water for the boiler is obtained from the city water supply.
Boiler feedwater is processed by water softeners and deaerators and treated
with caustic soda, phosphates and hydrazine to prevent scaling and corrosion.
Tannin is also added to maintain particles in suspension.
Normal operation of the boiler is 24 hours per day, 7 days per week.
The boiler is scheduled to be offline once per year for 10 to 14 days for
various types of maintenance.
3.2 Electrostatic Precipitator
Flue gases from the air heater are treated in an electrostatic preci-
pitator (ESP) for the removal of particulate matter. The ESP in unit No. 7
is an American Standard Model 371. It is a wire/plate type with rappers
and is designed to handle 4900 m /min (175000 cfm) of gas at an average in-
let dust loading of approximately 9.27 gm/m (4 gr/scf). The ESP has 4
cell units with 2 fields and 8 insulator compartments. Performance charac-
teristics for the ESP are given in Table 3-5.
The collection system of the ESP has an effective surface area of 2030
m (21840 sq ft) with 28 gas passages having a space of 23 cm (9 inches)
each. The collecting surface area rappers are of the electric vibrator type
2
and the maximum collecting surface area rapped at one instant is 113 m
(1215 sq ft). Total hopper capacity is 48 m (1700 cubic feet) with over-
all dimensions of 5.2 m x 6.8 m x 18.1 m (17* x 22.5' x 59.5').
The electrical system of the ESP requires a maximum operating voltage
of 45 KV. Power requirement at maximum demand is 33 KVA and the total con-
nected load is 61 KW. There are 8 electric vibrator type high voltage rap-
pers and two rectifiers. The two rectifiers are rated at 45 KV each.
The primary voltage is approximately 260 volts at the inlet field and
200 at the outlet field. The primary current is approximately 52.0 amps at
the inlet field and 34 amps at the outlet field. The secondary voltage and
3-12
198
-------
currents average 34.0 KV, 35 ma and 29.0 KV, 80 ma at the inlet and outlet
fields respectively. The spark rate averages around 120 per minute at the
inlet field and 145 per minute at the outlet field.
TABLE 3-5. PERFORMANCE CHARACTERISTICS OF THE
AMERICAN STANDARD ESP
Performance at 385,000 Ib/hr load, coal fuel
Gas to ESP cfm 167,000
Gas to ESP, Ib/hr 510,000
Gas Temp °F 300
Inlet dust loading, gr/cf 3.7
Outlet dust loading, 0.074
gr/cf
Efficiency, % 98
Gas velocity, fpm 266
Pressure drop, in. HgO 0.5
Time of gas contact, sec. 2.94
3-13
199
-------
4. SAMPLING LOCATIONS
All sampling locations are identified in Table 4-1 and Figure 4-1.
Figure 4-2 is a cross sectional schematic depicting the traverse point loca-
tions at the stack. Figure 4-3 is a horizontal view of the ESP inlet show-
ing port locations, and Figure 4-4 is a cross sectional view of the ESP in-
let depicting the traverse point locations.
The continuous monitoring probe was located on the North side of the
ESP inlet duct prior to the gas sampling ports and at a depth of approxi-
mately 4 feet. At the stack,the monitoring probe was alternated between
ports 2 and 3 and at a depth of 4 feet. These two ports were also used for
the gas sampling trains.
TABLE 4-1. SAMPLING LOCATIONS
Solid Sample Locations
1 - Blended Coal
2 - Refuse Derived Fuel
3 - Bottom Ash
4 - Fly Ash
Gaseous Sampling Locations
5 - ESP Inlet
6 - Stack
10 - Hi Volume Ambient Air Sampler
Liquid Sample Locations
7 - Untreated Well Water
3 - Seal Water
9 - Cooling Tower Water
4-1
200
-------
ro .$»
o i
FIRST
STAGE
PRESSURE
STEAM JET
AIR EJECTOR
COAL
GRAVIMETRIC
QPAIR
aliALK
PULVERIZER
AT I. AS BIN
3
REFUSE
DERIVED
FUEL
AMBIENT AIR
OVERGRATE
(RDF ONLY)
VOLUMETRIC
FLOW
DENSITY fO
COOLING TOWER
BLOUDOVIN
nunPiirRATP
UNDERCRATE
1
(RDF ONLY)^
SEAL
WATER
SPRAY WATER
DESUPERIIEATER
BOILER
FEED
PUMP
FBI
]
[TEMPERATURE
FEED WATER IN
BUWATEK _ _ j ^
INTEGRATOR ^
FEED
WATER
HEATER
FEED
WATER
HEATER
COMBUSTION
ENGINEERING
STEAM
GENERATOR
Unit NO. 7
i
UNTREATED
-WELL WATER
TEMPERATURE
FLUE GAS IN
TEMPERATURE
AIR OUT
AIR HEATER
LEAKAGE
TEMPERATURE
AIR IN
DRAFT
FAM
PRIMARY AIR
TO PULVERIZER
BOTTOM ASH
COMBUSTION
AIR
STACK S
SAMPLI
STACK
O INDUCED
!
4
(Ql
i
ELECTROSTATIC
PRECIPITATOR
HI VOLUME
SAMPLER
Source: Compliance test report data prepared by Iowa State University Engineering Research Institute
personnel under the direction of Or, J. L. Hall, et al. from tests conducted during Sept. 1978.
Figure 4-1. Unit 7 flow diagran and measurement locations.
-------
SAMPLING
PLATFORM
4 in. PORT
-CAPPED WHEN
NOT SAMPLING
CONCSZTZ WALL
NOT TO SCALE
SAMPLING POINTS
TRAVERSE
POINT
NUMBER
1
2
3
4
DISTANCE FROM
OUTSIDE EDGE OF STACK
IN
38.2
42.8
47.8
53.2
CM
97.03
108.71
121.41
135.13
POINT
5
• 6
7
8
DISTANCE FROM
OUTSIDE EDGE OF STACK
IN
59.4
66.4
75.
87.8
CM
150.88
168.66
190.75
223.01
Figure'4-2. Crocs S«ction of stack shoving trsrorse point locations,
202
4-3
-------
SOTTTH
Figure 4-3.
- Showing
4-4
203
-------
CONTINUOUS MONITORING
PROBES
Traverse Point Number
Traverse Point Location From
Outside of Nipple
1
2
3
4
Inches_
22
34
46
56
Centimeters
53.9
83.3
112.7
142.1
Figure 4-4. Inlet Traversa Point Locations
4-5
204
-------
5,0 SAMPLING
This section includes information on the sampling program conducted
at the Ames facility. Any changes or pertinent comments are included in
this section.
5.1 Gas Sampling
The flue gas sampling at the Ames facility was performed at the elec-
trostatic precipitator inlet and at the stack.
Sampling for organics was to be performed for fourteen consecutive
days with an additional three days sampling for particulate cadmium. How-
ever, due to extreme weather conditions the program was modified to collect
nine inlet and outlet gas samples. Sampling for organics was accomplished
concurrently at the inlet and outlet utilizing two modified method 5 trains
(Figures 5-1 and 5-2) at both sampling locations. Inorganic cadmium was only
sampled at the stack and utilized one standard Method 5 train, Figure 5-3.
The sampling crew collected a ten m (10 £ 1 ra ) sample by extracting
the flue gas at a rate approximating the flue gas velocity. The particulate
matter was collected in a cyclone and on the filter media. The gas stream
was passed through an XAD-2 resin trap to absorb the organic constituents.
and through an impinger system to condense any moisture present in the gas.
Parameters such as temperatures, pressures, and gas volumes were monitored
throughout the sampling period. The sample fractions were recovered from
the sampling trains and turned over to an MRI representative. The outlet
(stack) sampling position was sampled with no change to the sampling plan
while the ESP inlet sampling was modified.
• ESP Inlet
During the initial tests, it was found that the outermost ports
exhibited little or no flow. At one point of the traverse, the velo-
city head (A?) was negative while the next point indicated positive
&P, thereby cancelling each other. It was therefore recommended that
these two outer ports be dropped from the test. The recommendation
was accepted and implemented as part of the test program.
5-1
205
-------
FILTER HOUSING
N> in
o i
ILjV
HEATED LIKE
THERM3-ETER
CYCLONE
FLASK
OVEN BOX
STAND
ORIFICE
BY-PASS
VALVE VACUU1
GAUGE
VACUUM
LINE
DRY Tt£T AIR Tiarf
N-TER KHP
Figure 5-1. ESP Inlet sampling train
-------
HOUSING
CYCLONE
FLASK
OVEN BOX
STAND
TKERMOfETER
ORIFICE
BY-PASS
VALVE VACUUM
THSRPDMETEBS / GAUG£
DRY TEST
• .'ETER
AIR TIGHT
Pitt?
VAOJLT1
UN'S
Figure 5-2. Stack sampling train
5-3
207
-------
12
Figure 5-3. EPA Method 5 parti cul ate sampling train
Calibrated nozzle 13)
Glass lined probe 14)
Flexible teflon sample line 15)
Cyclone 16)
Filter holder ' 17)
Heated box 18)
Ice bath 19)
Impinger (water) 20)
Impinger (water) 21)
10) Impinger (empty) 22)
11) Impinger (silica gel) 23)
12) Thermometer 24)
1)
2)
3)
4)
5)
6)
7)
8)
9)
Check value
Vacuum line
Vacuum gauge
Main value
A1r tight pump
Bypass value .
Dry test meter
Orifice
Pitot manometer
Potentiometer
Orifice manometer
S type pitot tube
5-4
208
-------
5.2 Solid Sampling
During each test day, four solid streams: coal, precipitator ash,
bottom ash, and refuse derived fuel (RDF) were sampled six times per day
following a schedule set up by Research Triangle Institute (RTI). The
sampling was coordinated between RTI, the sampling crew and power plant
personnel. The schedule provided the basis for collection of unbiased
samples by obtaining a random selection from the multiple sources avail-
able for sampling. This approach was taken to avoid any cyclic biases
which might have been present in the daily operation of the power plant.
The samples and their sampling frequencies were:
• The coal samples were taken from the feed line leading from the
storage bunkers into the gravimetric feeders supplying the coal
pulverizers. A metal scoop was used to remove the sample from
the feed line and transfer it to the sample containers.
• The precipitator ash was removed and collected from the bottom
of the precipitator hoppers. A metal scoop was used to remove
the sample from the access pipe and transfer it to the sample
container. The hoppers were pneumatically evacuated after each
sample was taken. A visual inspection was made to insure complete
evacuation of ash from the hoppers.
0 The bottom ash samples were collected from the base of the fur-
nace. These samples were collected wet with a high solids con-
tent from the furnace floor prior to sluicing out the ash by
plant personnel. The ash doors were open during the washing
procedure and the ash sample was scooped up in a teflon line pan
and transferred to the sample container with teflon lined forceps
before the furnace floor was washed with water to remove the ash.
To provide representative samples of ash, as distributed over the
entire rectangular base of the furnace, the area of the furnace
floor was divided into an equal-area grid system. The samples
were scooped from a specific grid area as provided by Research
Triangle Institute each time a sample was taken.
t The RDF samples were taken from the feeders in the Atlas bin prior
to being pneumatically conveyed to the boiler furnace for firing.
The material was placed into sample containers from a specific
feeder and returned to the recovery area for labeling. Protective
clothing was worn within the feeder area and plant personnel were
notified when entering and leaving the area.
5.3 Liquid Sampling
Three liquid streams were sampled during the course of the test pro-
gram: cooling tower blowdown, well water, and bottom ash seal water (over-
flow water). Liquid streams which did not have continuous flows, were
*
5-5
209
-------
allowed to purge for three minutes prior to obtaining samples. Sample con-
tainers were rinsed three times with sample liquid prior to being filled
with that liquid. The streams sampled and frequency of sampling were as
follows:
t Seal water was sampled twice per shift, for a total of six samples
per 24 hour period.
• Cooling tower blowdown was sampled once per day.
• Three well water samples were collected over the testing period.
Appendix C contains the time frequency schedule utilized by members
of the solid and liquid sampling team.
5.4 Hi Volume Sampler
To monitor the ambient air background, a high volume ambient air sampl-
er (Figure 5-4) was used. It was placed on the roof of the Ames facility
to obtain a representative background utilizing outside ambient air rather
than sampling air inside the building that could have been contaminated or
influenced by the combustion process.
5.5 Quality Assurance
A quality assurance sample was also taken of the final test day. To
collect the quality assurance sample, two sampling trains were placed at
the same point in the same port at the inlet of the ESP. No traversing was
performed. Both trains were run at the same isokinetic rate for the same
duration as a normal test day. Also during the Q/A day, solids and liquids
were collected as in a normal test day.
5.6 Sampling Train Background
To obtain the train background (blank) an entire sampling train, in-
cluding resin trap filter and impinger solutions was set up at the ESP in-
let. The train was taken to normal operating temperatures and allowed to
remain at these temperatures for one (1) hour. All train components were
recovered as a normal run and all sample blanks were given to an MRI repre-
sentative.
5-6
210
-------
HIGH VOLUME AIR SAMPLER
\MODEL 230 HIGH
VOLUME CASCADE
IMPACTOR - OPTIONAL
MODEL 310/310A/310B
CONSTANT FLOW CONTROLLEF
\
-7
JUST
MENT
LINE CORD
Figure 5-4. Ambient air sampler
5-7
211
-------
5.7 Sample Recovery
Upon completion of the ESP and stack sampling, the sampling equipment
was brought to the laboratory area for recovery. Each sample train was kept
'in a separate area to prevent sample mixup and cross contamination.
The dry powder in the cyclone, probe, and heated flexline was collected
in the cyclone catch bottle. After this collection procedure, the indivi-
dual sample train components were recovered per the following:
• Probe was wiped to remove all external particulate matter
near probe ends.
• Filters were removed from their housings and placed in proper
container.
0 After recovering dry particulate from the nozzle, probe, heated
teflon line, cyclone, and flask, these parts were rinsed
with distilled water to remove remaining particulate. They
were subsequently rinsed with B & J acetone and cyclohexane
and put into a separate container. All rinses were retained
in an amber glass container.
• Sorbent traps v/ere removed from the train, capped with glass plugs, .
and given to an on-site Midwest Research Institute (MRI) represen-
tative.
• Condensing coil, if separate from the sorbent trap, and the con-
necting glassware to the first impinger was rinsed into the con-
densate catch (first impinger).
t First and second impingers were measured, volume recorded and
retained in an amber glass storage bottle. The impingers were
then rinsed with small amounts of distilled water, acetone and
cyclohexane. These rinsings were combined with the condensate
catch. Rinse volumes were also recorded .
• Third and fourth impingers were measured, volume recorded and
solutions discarded.
• Silica gel was weighed, weight gain recorded and regenerated for
further use.
To preserve sample integrity, all glass containers were amber glass, with
Teflon-lined lids.
5.8 Problems Encountered During Recovery
• If the temperature of the probe, flexline, or oven box was not
sufficient (<. 250°F) to prevent moisture from condensing, the
particulate would cake on the inner walls and become very dif-
ficult to remove.
5-8
212
-------
Due to the cyclohexane not readily evaporating and adhering to
the inner walls, the flex lines and probe liners gave the appear-
ance of being clean when in reality they were still wet and masked
any particulate that remained on the walls. Therefore, all com-
ponents must be thoroughly dry before a visual inspection can be
made. If the initial rinses do not remove all the particulate,
then brushing with additional water rinses is required to clean
tne walls. This is then followed with acetone and cyclohexane
rinses.
5-9
213
-------
6,0 CALIBRATION
This section describes the calibration procedures used prior to conduc-
ting the field test at Ames Municipal Power. Figure 6-1 shows the calibra-
tion equipment and how it was set up.
6.1 Method Five Calibration Data
6.1.1 Orifice meter calibration. The orifice meter calibration is per-
formed using a pump and metering system as illustrated in Figure
6-1(a). The dry gas meter with attached critical orifice is run at various
orifice flows for a known time. After each run the volume of the dry gas
meter, meter inlet/outlet temperatures, time, and orifice setting is record-
ed. The orifice meter calibration factor is derived by solving the equation.
AH@ » 0..317 A H r(Tw + 460) e-,2
a u Pb (Td + 460) L 7wJ
where
AH s Average pressure drop across the orifice meter, inches
H20
Pb » Barometric pressure, inches Mercury
Td = Temperature of the dry gas meter, °F
Tw » Temperature of the wet test meter, °F
e a Times, minutes
Vw » Volume of wet test meter, cubic feet
The AH@ yielded is utilized to adjust the sampling train flow rate by regu-
lating the orifice flow.
6.1.2 Dry gas meter calibration. Meter box calibration consists of check-
ing the dry gas meter for accuracy. The dry gas meter with attached criti-
cal orifice is connected to a wet test meter (see Figure 6-1(b) below) and
run at various orifice flows for a known time. After each run wet and dry
gas rneter volumes, temperatures, time, and orifice readings are recorded.
Utilizing the equation
v , Vw Pb (Td+460)
Vd lPb+AH) (T * 460)
TT.6 w
6-1
214
-------
where
V = Volume correction factor
Vw = Volume of wet test meter, cubic feet
Pb = Barometric pressure, inches Mercury
Td = Temperature dry gas meter, °F
Vd = Volume of dry gas meter, cubic feet
AH = Average pressure drop across the orifice meter,
inches H^O
TW = Temperature of wet test meter, °F
a volume factor which compares the dry gas meter with the wet test meter
is obtained. *
6.1.3 Pi tot tube calibration. Pi tot tubes are calibrated on a routine
basis utilizing two methods.
The type S pi tot tube specifications are illustrated and outlined in
the Federal Register, Standards of Performance for New Stationary Sources,
[40 CFR Part 60], Reference Method 2 (refer to Figure 6-1(c)). When mea-
surment of pi tot openings and alignment verify proper configuration, a co-
efficient value of 0.84 is assigned to the pitot tube.
If the measurements do not meet the requirements as outlined in the
Federal Register, a calibration is then performed by comparing the S type
pitot tube with a standard pitot tube (known coefficient of 1.0). Under
identical conditions, values of &P, for both S type and standard pitot tube
are recorded using various velocity flows (14 fps to 60 fps). The pitot
tube calibration coefficient is determined utilizing the following equation,
1/2
Pitot Tube Calibration = (Standard Pitot Tube Xr&P reading of std. pitot •* '
Factor (CP) Coefficient) LdP reading of S type pitot-1
The coefficient assigned to the pitot tube is the average of calculated
values over the various velocity ranges.
6-2
215
-------
6.1.4 Nozzle diameters. The nozzle diameters were calibrated with the
use of a vernier caliper if the nozzle showed excessive wear or was con-
sidered not fit for use, it was discarded.
6.2 Instrument Calibration
Manufacturers recommended calibration procedures were used with the
following gases which had an analytical accuracy of ± IS:
SCOTT CO 812 ppm
C02 11.94%
02 4.98%
Propane 34.4 ppm
in Nitrogen Balance
Zero and Calibration adjustment were made prior to the start of the test
day. Zero drift checks were made at the end of each test period. Data was
recorded every fifteen minutes thus providing two data points per hour for
each sampling position.
6-3
216
-------
Come Cental W»t
ttmotrtlvrt T,
/ / I
ff«lA*H» / /
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A
/ Ut!H*ntt*
Gtuft
Figure 6-1(b)
Dry gas meter calibration.
*B*» IWwr* f.fl « P*o»
Two* V7ouw E* wnen
Figure 6-1(c)
Equipment used to calibrate pi tot
tubes
Figure 6-1. Calibration equipment set-up procedures
6-4
217
-------
7.0 TECHNICAL PROBLEMS AND RECOMMENDATIONS
This section describes some of the problems encountered during the Ames
test program and recommends a solution to these problems,
7.1 Problems
• Construction of weather shelters was not completed on schedule
causing a one day delay.
• Because of extreme cold weather additional heaters had to be
supplied to both the stack and monitoring truck. This resulted
tn additional power requirements and caused approximately a half
day down time for installation of power switches.
• Cold weather also effected the following:
1 L heat lines did not maintain temperature causing moisture to
condense and possibly act as a scrubber for hydrocarbons.
Therefore, hydrocarbon data are considered only fair.
21 The gas conditioner would freeze restricting sample gas flow
to the monitoring equipment. This created data gaps during
the test period.
3J_ Solutions tn the sampling trains would freeze causing the
test to be shortened or scrubbed.
4]_ Cyclohexane would freeze at the temperatures encountered at
the sampling locations because it has a freezing point higher
than water.
• Three instruments malfunctioned due to electronics failure or change.
These instruments were:
1L Infrared Industries CO/CO- analyzer. The CO section would not
maintain calibration and was removed from the system. It was
replaced with the Sectarian CO analyzer.
2\ Beckman 02 analyzer. Detector malfunctioned and was replaced
with backup Oj analyzer.
31 Beckman CO.Analyzer. Energy source went out of adjustment and
could not maintain calibration. No other replacement was_avail-
able, as a result, 2 days of CO data were not recorded.
7.2 Recommendations
The only significant problems that occurred at the Ames faciltty were
caused by severe weather conditions. In the future, the testing should pre-
ferably take place in a wanner environment, during the wanner time of the
year or heated constant temperature shelters should be provided.
7-1
218
-------
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APPENDIX B
TRW FIELD TEST REPORT FOR THE CHICAGO
NORTHWEST INCINERATOR. UNIT NO. 2
242
-------
PILOT TEST PROGRAM
CHICAGO NORTHWEST INCINERATOR
BOILER NO. 2
P, S. Bakshi, T. L. Sarro, D, R. Moore,
W. F. Wright, W. P. Kendrick, B. L. Riley
TRW ENVIRONMENTAL ENGINEERING DIVISION
TRW, INC.
EPA Contract 68-02-2197
EPA Project Officer: Michael Osborne
Industrial Environmental Research Laboratory
Office of Research and Development
U.S. Environmental Protection Agency
Research Triangle Park, N.C. 27711
243
-------
CONTENTS
Figures 111
Tables 1v
Acknowledgment v
1. Introduction .' . . . 1-1
2, Summary . , , . , 2-1
2.1 Sampling and Analysis 2-1
2.2 Process Data . , , 2-1
2,3 Contiguous Monitoring Data 2-25
3, Plant Description , 3-1
3,1 General Description 3-1
3.2 Detailed Descriptions ,,,,., 3-3
4. Sampling Locations. ,,..,.,...,.., 4-1
5. Sampling, , ,.,,.,., 5-1
5.1 Gas Sampling ,,,,,,,,, , . 5-1
5.2 Solid Sampling ....,..,,,,,..,.,... 5-1
5.3 Liquid Sampling. ,..,.,,..,,.., 5-4
5.4 Hi Volume Sampler , . . , 5-4
5.5 Quality Assurance 5-4
5.6 Sampling Train Background, . . , . , , . . 5-4
5.7 Sample Recovery 5-6
5,8 Observations During Recovery , 5-7
6. Calibration 6-1
6.1 Method Five Calibration Data 6-1
6.2 Instrument Calibration 6-4
7. Technical Problems and Recommendations 7-1
7.1 Problems 7-1
7.2 Recommendations , 7-1
Appendices
A. Continuous Monitoring Data. . , . , A-l
B. Field Data Sheets B-l
C, Sample Inventory Sheets , , . . . C-l
D. Process Data ,...., D-l
11
244
-------
FIGURES
Page
Layout of plant site 3-2
Flow diagram of Chicago Northwest Incinerator 3-4
Combustion air and flue gas system 3-11
Flow diagram and measurement locations 4-2
Outlet sampling position 4-3
Top view of ESP inlet showing port locations 4-4
Cross sectional of ESP inlet showing traverse point
locations 4-5
5-1 Sampling train 5-2
5-2 EPA Method 5 particulate sampling train 5-3
5-3 Ambient air sampler , 5-5
6-1 Calibration equipment set-up procedures 6-3
iii
245
-------
TABLES
Number page
2-1 Daily Sampling Summary 2-2
2-2 Daily Data Summary 2-9
2-3 24 Hour Process Data for the Chicago Northwest Municipal
Incinerator, Unit No. 2 2-13
2-4 Means of the Means for 24-Hour Process Data, All Test Days,
Chicago Northwest Municipal Incinerator 2-15
2-5 Test Duration Process Data for the Chicago Northwest
Municipal Incinerator, Unit No. 2 2-16
2-6 Weekly Inventories of Refuse and Residue at the Chicago
Northwest Municipal Incinerator (All Boilers) 2-18
2-7 Charges Fed to Each Boiler on a Shift Basis Chicago
Northwest Incineration Facility 2-19
2-8 Down Time Expressed as Lost Furnace Hours for the Entire
Chicago Northwest Incineration Facility 2-26
2-9 Continuous Monitoring Data 2-27
2-10 Means of Percent Oxygen Taken by Control Room Gauge and
Og Analyzer for Test Duration 2-28
3-1 Characteristics of Chicago Northwest Incinerator 3-3
4-1 Sampling Locations 4-1
iv
246
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ACKNOWLEDGEMENTS
This sampling and field measurement work was performed for the U.S.
Environmental Protection Agency (EPA) under Contract No. 68-02-2197. The
program was sponsored jointly by the Office of Pesticides and Toxic Sub-
stances in cooperation with the Office of Research and Development (ORD) of
the EPA.
The ORD-sponsored portion of the program was directed by Mr. Michael
C. Osborne, Industrial Environmental Research Laboratory, Research Triangle
Park, North Carolina. The Office of Pesticides and Toxic Substances -
sponsored portion of this study was directed by Mr. Martin Hal per,
Washington, D.C.
Three contractors participated in the overall test program, namely, TRW
Inc., Midwest Research Institute (MRI) and Research Triangle Institute
(RTI). TRW Inc. was responsible for the field testing; MRI had responsi-
bility for the sampling analysis;and RTI had overall responsibility for the
statistical design of the test program.
Many individuals contributed to the sampling, testing, data reduction
and report preparation for this study. Mr. Birch Matthews had overall re-
sponsibility for this program at TRW Inc. He was assisted in his management
activities by Dr. Chris Shih and Mr. Don Price. The Field Team Leader was
Mr. Dave Moore and the field sampling team members were Mr. J. Berger,
Mr. M. Drehsen , Mr. J. Gordon, Mr. W. Kendrick, Mr. J. McReynolds,
Ms B. Riley, Mr. T. Rooney, Mr. D. Savia, Mr. B. Wessel and Mr. W. Wright.
The Process Engineers were Mr. P. Bakshi and Mr. T. Sarro.
The Chicago Northwest Incinerator personnel who provided significant
assistance in completing the study were: Mr. Emil Nigro, the Supervising
Engineer of the city of Chicago, Bureau of Sanitation; Mr. Stanley Oenning,
the Chief Operations Engineer at the plant; and Mr. Gerry Golubski, Plant
Chemist. In addition, there were numerous other plant personnel who pro-
vided assistance during the field testing. Their efforts are greatly appre-
ciated and their contribution is hereby acknowledged.
v
247
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1.0 INTRODUCTION
This document describes the sampling and monitoring activities per-
formed at the Chicago Northwest Incinerator, Boiler No. 2. The sampling
and field measurement work was part of an overall pilot scale test program
sponsored by the Office of Pesticides and Toxic Substances in cooperation
with the Office of Research and Development, of the U.S. Environmental Pro-
tection Agency.
The ultimate objective of the pilot scale test program is to develop
an optimum sampling and analysis protocol to characterize polychlorinated
organic compounds which may be emitted in trace quantities through conven-
tional combustion of fossil fuels and refuse. The genesis of the program
is an industrial study by Dow Chemical Company and two groups of European
investigators reporting emissions of polychlorincted dibenzo-p-dioxins
(PCDD), dibenzofurans (PCDF) and biphenyls (PCB) from stationary convention-
al combustion sources.
The immediate objective of the sampling and field measurements program
is the specification of procedures and equipment to obtain sufficient multi-
media samples for the subsequent analytical protocol, and to satisfy the
program statistical design requirements. In this respect, the TRW Environ-
mental Engineering Division of TRW, Inc., was one of three contractors par-
ticipating in the overall EPA program and was responsible for the acquisi-
tion of samples and measurements in the field.
The sampling was oriented toward acquiring multimedia samples for
organic compound analysis by Midwest Research Institute (MRI). Compounds
of particular interest included:
Benzo [a] pyrene Chrysene
Pyrene Indeno [1,2,3-cd] pyrene
Fluoranthene Benzo [g,h,i] perylene
Phenanthene Anthracene
In addition, MRI is to make a determination of total organic chlorine
emissions from the acquired samples. Potentially, selected samples are to
be analyzed for polychlorinated dibenzo-p-dioxins, dibenzofurans and
biphenyls.
1-1
248
-------
Instrumentation for on-line combustion gas stream monitoring was part
of the test program. In addition, incinerator process informatipn was also
gathered. This information together with the monitoring data were acquired
to assist in evaluating and interpreting chemical analysis results.
This report contains all the field data for the Chicago Northwest
Incinerator pilot test program conducted in May 1980. Data provided in-
clude the following:
• Chlorinated hydrocarbon collection using a modified EPA Method
5 train and Method 5 sampling methodology.
• Gas velocities using EPA Method 2,
• Continuous monitoring for CO, O, and CO and THC,
t Particulate collection for inorganic analysis utilizing EPA
Method 5.
t Process data.
The test program followed was described in the Pilot Test Program,
Chicago Northwest Incinerator, Boiler No. 2, site test plan. Deviations
from this program are documented and explained in their respective sections
of this report.
249
-------
2.0 SUMMARY
2.1 SAMPLING AND ANALYSIS
The field test activity took place from April 30, 1980 to May 23, 1980.
All required tests were completed and all recovered samples were sent to
Gulf South Research Institute (GSRI) for analysis.. MRI had subcontracted
this part of their assignment to GSRI.
A summary of tests conducted including any significant commentary is
presented in Table 2-1. A summary of the reduced data on a daily basis as
calculated from the field data sheets is presented in Table 2-2. Data listed
are corrected to standard conditions, i.e., 20eC and a barometric pressure
of 29.92 inches mercury.
Sampling and calibration procedures are described in Sections 4, 5 and
6. Hourly data is provided in the appendices. Appendix A contains contin-
uous monitoring data; Appendix B contains field data; and Appendix C con-
tains sample inventory sheets supplied by GSRI.
2.2 PROCESS DATA
For every day of inlet or outlet testing, a 24 hour record of process
data was obtained. This information is provided in the daily process data
sheets in Appendix D. Most of this data was obtained from instrumentation
in the control room. The parameters considered important to the operation
of Boiler No. 2, and for which instrumentation was available include steam
flow rate, steam pressure, feedwater flow rate, feedwater temperature, com-
bustion air flow rate, combustion air temperature, % oxygen, I.D. fan pres-
sure, F.D. fan pressure, furnace draft, and furnace temperature. No data
were available for steam temperature, excess air, or the power consumption
of the fans.
A chart recording instrument located in the control room provided
continuous instantaneous readings for steam flow rate, feedwater flow rate,
and combustion air flow rate. These were read directly from the instrument
in 1000's of pounds per hour, 1000's of pounds per hour, and 1000's of cubic
feet per hour, respectively. These are given in Appendix D under the head-
ing "chart recorder" for each of the three parameters.
2-1
250
-------
TABLE 2-1. DAILY SAMPLING SUMMARY
Date
(1980)
Test
No.
Sampling locations
Test comments
5/4
1 Inlet-North
Inlet-South
Test started at 0835 hours and ran for 350 minutes. Low volume
was obtained. Test was discontinued because of unsuccessful leak
checks after filter replacement.
Test started at 0835 hours and ran for 193 minutes. Low volume
was obtained. Battelle trap also appeared to plug up and was
therefore changed. However, this did not occur during remaining
tests. Filter blockage also occurred probably due to filter oven
temperature not being hot enough (250°F). At 1600 hours the plant
had to shut down due to boiler leaks. Test quality was fair.
ro
INJ
N>
in
5/6
Outlet-North
Outlet-South
HI Volume Sampler
Continuous
monitors
Inlet-North
Inlet-South
Outlet-North
Test started at 0825 hours and ran for 404 minutes. No signi-
ficant problems occurred. Test quality was good.
Test started at 0820 hours and ran for 375 minutes. No new
leak rate was obtained at filter change. New filter housing
was found to be warped which caused the leak problem. Test
quality was good.
Sample was lost due to the wind blowing the filter out of the
filter holder.
No problems were encountered. Test quality was good.
Test started at 1230 hours and ran for 525 minutes. There
were no significant problems. Test quality was good.
Test started at 1230 hours and ran for 525 minutes. There
were no significant problems. Test was Inadvertently stopped
with only 21 of the required 24 points traversed. However,
both gas volume and partlculate collections were sufficient.
Test quality was good.
Test started at 1235 hours and ran for 500 minutes. There
were no significant problems. Test quality was good.
-------
TABLE 2-1. (Continued)
Date
(1980)
5/6
Test
No.
2
Sampling locations
Outlet-South
Test comments
Test started at 1230 hours and ran for 500 minutes.
Probe was
5/7
M ro
In I
ro u»
5/8
111 Volume Sampler
Continuous
monitors
Inlet-North
Inlet-South
Outlet-North
Outlet-South
HI Volume Sampler
Continuous
monitors
Inlet-North
Inlet-South
Outlet-North
Outlet-South
found to be cracked at the end of test. However, based on a
moisture calculation of only 3% (vs. 12% In other test), 1t
appears that the probe cracked during the first 280 minutes.
The probe was switched and the test continued an additional
200 minutes. Test quality was poor as only air was sampled
for 50% of the test.
Test started at 1311 hours and was stopped at 2325 hours.
quality was good.
Test quality was good.
Test
Test started at 0835 hours and ran for 420 minutes.
were encountered. Test quality was good.
Test started at 0837 hours and ran for 480 minutes.
were encountered. Test quality was good.
Test started at 0930 hours and ran for 500 minutes.
were encountered. Test quality was good.
Test started at 0955 hours and ran for 500 minutes.
were encountered. Test quality was good.
Test started at 1215 hours and was stopped at 2000 hours.
quality was good.
No problems were encountered. Test quality was good.
No problems
No problems
No problems
No problems
Test
Test started at 0845 hours and ran for 420 minutes. No problems
were encountered. Test quality was good.
Test started at 0832 hours and ran for 480 minutes. No problems
were encountered. Test quality was good.
Test started at 0930 hours and ran for 500 minutes. Low moisture
obtained because of cracked probe.
Test started at 0925 hours and ran for 500 minutes.
were encountered. Test quality was good.
No problems
-------
TABLE 2-1. (Continued)
Date
(1980)
Test
No.
Sampling locations
Test comments
5/8
5/9
IM
N>
Ul
LJ
5/10
HI Volume Sampler
Continuous
monitors
Inlet-North
Inlet-South
Outlet-North
Outlet-South
HI Volume Sampler
Continuous
monitors
Inlet-North
Inlet-South
Test started at 1015 hours and was stopped at 1910. Test
quality was good.
No problems were encountered. Test quality was good. CO
readings were suspect, refer to 5/9/80 continuous monitoring
data.
Test started at 0820 hours and ran for 480 minutes. After
180 minutes the sampling time was Increased from 20 to 25
minutes per point to collect sufficient sample volume.
Boiler was operating at lower load conditions during this
period. Test quality was good.
Test started at 0805 hours and ran for 542 minutes. After
267 minutes the sampling time was Increased from 20 to 25
minutes per point. (See Inlet-North above). Test quality
was good.
Test started at 0905 hours and ran for 500 minutes. Test
quality was good.
Test started at 0920 hours and ran for 500 minutes. Test
quality was good.
Test started at 0915 hours and was stopped at 1850 hours.
Test quality was good.
CO was exhibiting drift problems due to exhausted desslcant.
Oesslcant was therefore replaced. Previous days (5/8/80)
data were suspect as CO dropped to lower level after
desslcant changeout. Test quality was good.
Test started at 0815 hours and ran for 420 minutes. No
problems were encountered. Test quality was good.
Test started at 0810 hours and ran for 480 minutes. No
problems were encountered. Test quality was good.
-------
TABLE 2-1. (Continued)
Date Test
(1980) No. Sampling location
Test comments
5/10
5/11
01 I
*• 01
Outlet-North
Outlet-South
HI Volume Sampler
Continuous
monitors
Inlet-North
Inlet-South
Outlet-North
Outlet-South
Test started at 0915 hours and ran for 480 minutes. No
problems were encountered. However, test was halted one
point from completion due to stormy weather. There was
little effect on test data. Test quality was good.
Test started at 0840 hours and ran for 550 minutes. No
problems were encountered. Test quality was good.
Test started at 1100 hours and was stopped at 1900 hours.
(Problems due to wind were encountered but the sample was
not destroyed). Results were fair to good*
CO was taken off line due to span and balance problems.
Remaining data were good.
Test started at 0828 hours and ran for 462 minutes. No
problems were encountered. Test quality was good (changed
sampling time to 22 minutes per point for Inlet trains prior
to starting test).
Test started at 0934 hours and ran for 528 minutes. No
problems were encountered. Test quality was good. Excessive
number of filters were used during this test day for both
Inlet trains.
Test started at 0900 hours and ran for 360 minutes. Due to
excessive amount of time needed to correct malfunctioning
equipment, the north train was utilized for only 20 points
Instead of the normal 25 points. Total volume sampled for
north and south trains was 20 nr. Test quality was good.
(Changed sampling time to 18 minutes per point prior to start
of test).
Test started at 0915 hours and ran for 540 minutes. South
train traversed 30 points (see comments for Outlet-North
train for 5/11/80). No problems were encountered and test
quality was good.
-------
TABLE 2-1. (Continued)
Date
(1980)
Test
No.
Sampling locations
Test comments
5/11
5/12
r\>
Is)
I/I
Ol
5/13
7 Hi Volume Sampler
Continuous
monitors
8 Inlet-North
Inlet-South
Outlet-North
Outlet-South
Hi Volume Sampler
Continuous
monitors
9 Inlet-North
Inlet-South
Outlet-North
Outlet-South
Hi Volume Sampler
Test started at 1014 hours and was stopped at 1930 hours.
Test quality was good.
CO was still off line. Backup unit was ordered but had
not arrived. Remaining data quality was good.
Test started at 0840 hours and ran for 462 minutes. No
problems were encountered. Test quality was good.
Test started at 0837 hours and ran for 528 minutes. No
problems were encountered. Test quality was good.
Test started at 1040 hours and ran for 450 minutes. No
problems were encountered. Test quality was good.
Test started at 0854 hours and ran for 450 minutes. No
problems were encountered. Test quality was good.
Test started at 1243 hours and was stopped at 1840 hours.
Test quality was good.
No CO data was being monitored. Remaining data was good.
Test started at 0833 hours and ran
was down at conclusion of test for
quality was good.
Test started at 0815 hours and ran
quality was good.
Test started at 0832 hours and ran
quality was good.
Test started at 0818 hours and ran
quality was good.
Test started at 0912 hours and was
Test quality was good.
for 472 minutes. Boiler
grate cleaning. Test
for 528 minutes. Test
for 450 minutes. Test
for 450 minutes. Test
stopped at 1820 hours,
-------
TABLE 2-1. (Continued)
Date
(1980)
Test
No.
Sampling locations
Test comments
5/13
5/15
9
10
Ul
5/16
11
Continuous
monitors
Inlet-North
Inlet-South
Outlet-North
Outlet-South
HI Volume Sampler
Continuous
monitors
Inlet-North
Inlet-South
Outlet-North
Outlet-South
CO was still off line, however remaining data was good.
Test
Test
Probe
Test started at 0805 hours and ran for 464 minutes.
quality was good.
Test started at 0803 hours and ran for 528 minutes.
quality was good.
Test started at 0840 hours and ran for 450 minutes.
was found with a cracked tip. Based on 8.9% moisture vs.
12% moisture for the other tests, it seems only the last
10 pts. were traversed with broken probe. Test quality was
fair.
Test started at 0820 hours and ran for 450 minutes. Test
quality was good.
Test started at 1110 hours and was stopped at 1840 hours.
Test quality was good.
New CO analyzer came on line. Test quality was good.
Test started at 0830 hours and ran for 462 minutes. No
problems were encountered. Test quality was good.
Test started at 0924 hours and ran for 528 minutes. Final
leak rate was not obtained, however the data was corrected
by subtracting out the last two unknown points (35 cu. ft.),
This caused little effect on the final outcome of the test.
Test quality was good.
Test started at 0808 hours and ran for 450 minutes. No
problems were encountered. Test quality was good.
Test started at 0828 hours and ran for 450 minutes. No
problems were encountered. Test quality was good.
-------
TABLE 2-1. (Continued)
Date
(1980)
Test
No.
Sampling locations
Test comments
5/16
5/17
ro
Ul
-j
Oo
5/18
5/19
11 Hi Volume Sampler
Continuous
monitors
12 Inlet-North
and South
Outlet-North
and South
Blank
Hi Volume Sampler
Continuous
monitors
13 Outlet-North
Hi Volume Sampler
Continuous
monitors
14 Outlet-North
and South
Hi Volume Sampler
Continuous
monitors
Test started at 0806 hours and was stopped at 1910 hours.
Test quality was good.
THC data reading was high (300 ppm) between 1000 hours and
1030 hours due to temporary shortage of garbage in chute.
Test started at 0928 hours and ran for 500 minutes. QA test
was performed simultaneously at Inlets on the north and the
south. Test quality was good.
Test started at 0815 hours and ran for 250 minutes. This was
the first day for the cadmium test. Test quality was good.
Test started at 0820 hours and ran for one hour at 250°F.
Test quality was good.
Test started at 1028 hours and was stopped at 1835 hours.
Test quality was good.
No problems were encountered. Test quality was good.
Test started at 0820 hours and ran for 250 minutes. For
the cadmium test the outlet was only tested. No problems
were encountered. Test quality was good.
Test started at 0800 hours and was stopped at 1305 hours.
Test quality was good.
The outlet was only tested and no THC data was recorded
since it was not required for the cadmium test. Test
quality was good.
Test started at 0810 hours and ran for 250 minutes. No
problems were encountered. Test quality was good.
Test started at 0800 hours and was stopped at 1300. Test
quality was good.
No problems were encountered. Test quality was good.
-------
TABLE 2-2. DAILY DATA SUMtARY
D»lt
(1980)
6-4
68
6-7
M
6-9
5-10
6-11
6-12
Tert
No.
1
2
a
4
6
6
7
8
Sampling
Location
""•' £2
<""'•' £2
Inlet Nollh
lnlil South
Outlet North
OOH" South
- sNS
<*""• £2
'•*« »K2
<""'•' £2
Inl.l Noflh
lnlil South
<*"'•' sN±
'•"•« £2
— £2
- SSL
°"'"« SSS
- £2
<*"'« £2
Sample V
SOCF
256.837
I3S.203
317.860
324.144
408.462
379.181
418.430
467.890
324.361
400.656
403.319
407.071
331.522
370.826
427.497
457.496
342.697
367.809
371.551
383.750
320.664
347.607
367.971
412.061
344.803
378.495
299.617
459.634
316.651
373.034
376.483
391.172
ohunt
Nm3
7.27
3.83
9.00
9.20
11.57
10.74
11.85
12.97
8.19
11.34
11.42
11.63
9.39
10.60
12.11
12.98
9.77
10.42
10.62
10.87
9.08
9.84
10.42
11.87
9.76
10.72
849
13.02
8.98
10.68
10.66
11.08
GM Competition*-*
*
11.2
11.2
11.3
11.3
9.6
9.8
10.4
10.4
9.4
9.4
9.4
9.4
9.9
9.9
10.4
10.4
7.9
7.9
8.1
8.1
8.8
88
9.4
9.4
98
9.8
9.6
9.8
8.7
8.7
10.4
10.4
CO?
*
7.4
7.4
7.7
7.7
10.1
tat
9.6
9.6
9.8
9.8
9.7
9.7
9.6
9.6
8.9
8.9
10.5
10.6
10.7
10.7
10.3
10.3
9.7
9.7
9.0
9.0
9.6
9.6
9.7
9.1
9.0
9.0
CO
ppm
172®
172
156
156
169
169
171
171
165
186
189
189
142
142
169
169
61
61
69
69
•
.
*
TtIC
ppm
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
Slack
Temperature
•F
469.47
444.86
432.78
451.27
459.04
445.78
442.00
451.04
446.66
431.46
459.04
457.78
446.36
460.60
454.20
464.32
423.77
460.80
44964
437.78
462.69
457.63
448.92
452.28
463.29
462.48
462.53
447.47
458.24
46833
442.84
452.88
Molecular
Weight
28.26
28.62
2833
2841
28.63
28.66
28.46
29.68
28.34
28.36
2839
28.41
28.67
28.60
2882
28.47
28.30
28.20
26.17
28.24
28.37
2834
28.60
28.33
28.19
28.16
28.37
28.30
28.40
28.38
28.41
28.42
Molttun
X
11.66
9.67
11.66
10.87
12.24
12.03
12.47
2.95
13.43
13.26
12.86
12.75
11.27
11.86
8.60
11.60
14.14
14.94
15.48
14.89
13.62
13.63
11.84
13.40
13.86
14.24
12.91
13.62
12.57
12.79
12.21
12.08
Velocity
tl/MC
20.17
21.27
36.40,
39.33
2062
18.42
3821
4060
19.90
21.23
36.70
3a87
19.34
19.98
38.39
41.69
17.71 V
17.31
32.99
3X48
18.12
17.86
36.43
39.50
19.12
1861
38.99
38.13
17.68
19.11
36.73
39.17
Oat Flow
ACFM DSCFM
50332.218
61074.783
49138.860
63101716
61452.653
62895.304
61588.416
64822.866
49666.946
61308.230
49556.634
62477.089
48268.622
67305.160
51835.952
66292.692
44193.634
49705.623
44544.600
43856.604
4S2S7.690
61287.447
47837.327
63339.650
47760487
63212.840
42103.978
61760.300
43898.089
64933.801
49588.850
62884.900
24952.931
31643.243
25074.591
26764.698
25077.734
26217.876
25526.669
29782.359
.24406.919
30518.360
24144.057
26634.970
24418.182
28349.017
26693.603
27732.316
22187.466
23679.662
21337.899
21431.687
21770.430
24476.323
23572.100
25751.431
22677.439
26400.444
20346.095
30126.657
21492.745
1647«. 660
24703.730
26093.924
Itoklfwtlc
Rata
• %
90.82
79.24
94.61
97.96
96.25
98.32
98.85
93.23
98.17
97.71
100.76
96.29
100.22
97.28
96.69
100.04
99.85
101.90
105.57
107.99
108.82
105.61
9861
96.51
100.85
100.82
99.20
102.22
9885
84.83
102.67
10042
Is*
Ul
00
-------
TABLE 2-2. (Continued)
IM
«o
Ul
*O
Date
(1980)
C •**
6-19
6-16
\
6-16
==
6-17
=====
6-18
: =
6-19
0 Tetl
Test
No.
to
11
,
12
-
13
^^^K~«—
14
oerlod
Sampling
Location
• nl**
inlet
Outlet
Inlel
Outlet
Inlet
Outlet
=====
Inlet®
Outlet®
=====
Inlet
Outlet
Inlet
Outlet
— ^•••^•^^•l"
average
North
South
North
South
North
South
North
South
North
South
North
South
.
North
South
North
South
-
North
South
Sample Volume
SOCF Nm3
308.728
364.161
366.284
388.729
338.460
376.BS8
377.441
396.276
363.833
357.302
404.610
416.676
324.920
331.760
218.810
^— ^ ' •—
219.36
======
240.61
'6.74
10.31
10.37
11.01
9.69
10.67
10.69
11.22
10.02
10.12
11.48
11.60
8.20
9.40
6.20
J^^^^^J^
6.20
=====
.
6.81
Gas Composition^
°2
X
0.7
0.7
0.1
0.1
10.2
10.2
0.6
9.8
11.1
11.1
11.6
11.6
10.3
10.3
10.7
•-. '_"
10.7
1X7
C02
X
0.6
0.0
0.8
0.8
8.4
9.4
9.7
9.7
8.6
6.6
7.9
7.0
10.0
10.0
9.0
9.2
==
7.2
CO
ppm
0
1110
111
98
98
erfD
66
98
06
MMMMM
80
80
84
102
304
THC
ppm
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
<2
-------
These three parameters were also monitored by means of integrating
counters. Each numerical reading multipled by 150 yielded the amount of
steam in pounds, the amount of feedwater in pounds, or the amount of combus-
tion air in cubic feet. These numbers have been included in the tables in
Appendix D in terms of 1000's of pounds or 1000's of cubic feet. The dif-
ferences of these numbers were also calculated on an hourly basis to deter-
mine flow rates from these quantities and are listed under "digital integrator"
in Appendix 0.
Each integrator reading is assumed to have been taken at the end of
the hour in question. For instance, the 5 PM reading represents the hour
ending at 5 PM, as opposed to the hour beginning at 5 PM. This was necessary
in order to maintain consistency, especially in the case of the integrator
differences. The difference between the 5 PM integrator reading and the
4 PM integrator reading represents the flow occuring between 4 PM and 5 PM,
and therefore is a 5 PM flow measurement, according to this end-of-the-hour
convention. Further, the digital counters recycle occasionally. Since the
counters have six digits, the largest possible number is 999,999 x 150 *
1000 or 150,000. It must also be noted that even a 5 minute delay in taking
a reading introduces a substantial error in the hourly value. Finally, these
integrator values were the only readings not routinely taken by plant person-
nel on a 24 hour basis. As a result, large gaps exist in this data. Aver-
ages were taken over these periods whenever possible.
The steam flow rate was also recorded on a continuous basis. This
was done by an ink pen recorder located outside the control room. The re-
corder plotted instantaneous steam flow values on graph paper. Hourly values
were recorded from these sheets, and are presented in Appendix D under the
heading "disc recorder". Although this instrument may have been very accur-
ate, the operators were not always careful at aligning the paper discs.
The erratic nature of steam production at the plant was easily observable
from these plots. Oscillations of an amplitude of 30,000 Ibs/hr and a fre-
quency of 6-10 cycles per hour seemed typical. A sample plot is provided in
Appendix D.
2-11
260
-------
Steam pressure, combustion air temperature, % oxygen, I.D. fan pressure,
F.D. fan pressure, furnace draft, and furnace temperature were all noted from
pointer gauges in the control room. The combustion air temperature was actual-
ly a measurement of the flue gas leaving the boiler and entering the econo-
mizer. The sensor for % oxygen was located on the ESP side of the economizer.
It must also be noted that the furnace draft and I.D. fan meters were actually
measuring a vacuum.
Other information contained in the daily process data tables includes
times of soot blowing, fuel input to Boiler No. 2, down time on Boiler No.
2, a daily barometric pressure and miscellaneous comments concerning the
boiler operation. According to plant procedure, soot blowing should have
always occurred at 3 AM, 11 AM, and 7 PM every day, but deviations from this
schedule were often observed. Fuel input is usually expressed as crane loads,
or charges of refuse. In only one instance was natural gas burned to start up
the boiler. The amount of gas burned is reported in cubic feet, but the
actual measurement involved reading a numeric counter and multiplying by
3.5. Down time is expressed as lost burning time, and was available by con-
sulting plant records. The barometric pressure was obtained once a day from
nearby Midway airport. Comments listed on the process sheets (refer to
Appendix D) were derived from the operator's log book or by discussing plant
conditions first-hand with the operators and firemen on duty.
2.2.1 24-Hour Data
The means and standard deviations of the parameters included in the
daily process sheets were calculated on a 24-hour basis for every day of
testing. This information has been presented in Table 2-3. On some days
Boiler No. 2 did not operate for the entire 24 hour period. For these days,
data was not available on a 24 hour basis, consequently values have been cal-
culated based on available information. Also, since the integrator differ-
ences were often averaged over long periods of time, it did not seem appro-
priate to provide standard deviations in these instances.
A qualitative observation from Table 2-3 indicates that the plant oper-
ation is very uniform over a time average of one day. According to the
daily process sheets, no strong diurnal variations occurred. This is not
to say that large variations did not exist. Shorter averaging times (less
2-12
261
-------
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••It
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ll|ll>l IHItrllM IM|IW| 1
Ikvl'lnvlrfllM/hl
Illllri IHWOO ItMhl
•— •"--— '••••
O«l •«•»••• |I|VW|
•llll.l Ian.** |H*/W|
1^.«_U.I^.«.. II,
....« I.,-
u. •«•..,... |U. V>
"'— "-*«
t-« M
"••a •
HMI* IIMI 1
Man* IM •
MOM* M
•oar MM •
IMM* M
III* II
m* MM«
ItMl* II
m* 11. i
M.I* i.n
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IMM* «
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in- ii
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than an hour) would indicate large swings, and this is reflected in the
large standard deviations for steam production in Table 2-3. This was due
to the intermittent nature of fuel feed to the boiler. However, these pro-
duction swings did not depend on time of day or day of week. Consequently,
it was possible to calculate means and standard deviations over a large
number of test days. This has been done for all of the test days (refer to
Table 2-4). An examination of data in Table 2-4 indicates that the standard
deviations are smaller than most of the standard deviations in Table 2-3.
Although variations may be expected to decrease over longer averaging times,
this would not be true if certain days had significantly different modes of
operation. The aforementioned therefore indicates that the Chicago North-
west Incineration facility operates in essentially the same mode 24 hours a
day, 7 days a week, although instantaneous swings in steam production do
occur continuously over short time intervals (less than one hour).
2.2.2 Test Duration Data
Means and standard deviations have been calculated on a test duration
basis for all of the test days. This information has been provided in Table
2-5. The discussion on diurnal variations pertaining to the 24-hour data
also pertains here, although the standard deviations should, in general,
be smaller due to the shorter period of time being considered. An examina-
tion of the data in Table 2-5 bears this out.
None of the data in Table 2-5 appears particularly anomalous. No sig-
nificant variation in steam production occurred from day to day indicating
a rather consistant fuel feed rate during the duration of the tests. Some
days exhibited wider variations as reflected by higher standard deviations,
particularly on the 19th of May. The variation of feed water flow does not
core!ate well with the variation in steam productfon. The operating para-
meters seemed to fluctuate rather independently, without any pronounced im-
pact on other aspects of plant operation.
2-14
263
-------
TABLE 2-4. MEANS OF THE MEANS FOR 24-HOUR PROCESS DATA, ALL TEST DAYS,
CHICAGO NORTHWEST MUNICIPAL INCINERATOR.
Steam
Steam
Parameter
Flow Rate (Ibs/hr)
Disc Recorder
Chart Recorder
Digital Integrator
Pressure (psig)
Mean
99,000
103,000
99,000
282
a
4,516.8
3,577.0
4.02
Feedwater Flow Rate (Ibs/hr)
-
Chart Recorder
Digital Integrator
i
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2.2.3 Weekly Refuse and Residue Inventory
All refuse and residue hauling trucks entering and leaving the inciner-
ator plant were carefully weighed. This facilitates the accurate characteri-
zation of overall inputs and outputs. However, there is no accurate way of
proportioning these materials between specific boilers for a given period of
time. Any attempt to determine the fuel burned or ash discharged from Boiler
No. 2 can only be an approximation.
Chicago Northwest Incinerator maintains inventory sheets listing inputs
and outputs from the facility on a weekly basis. Relevant data from these
sheets have been reproduced in Table 2-6. The weight of refuse received was
measured on scales before and after the refuse trucks released their loads.
The volume of refuse received was determined by multiplying the number of
truck loads by the volume of each truck (19.5 cubic yards). Density of the
refuse was estimated using these two measurements, and is therefore the den-
sity of refuse inside the trucks. In order to quantify the amount of refuse
burned, the number of loads, or charges, handled by the grab bucket cranes
were noted for each boiler. A total number of charges are listed in Table
2-7. The charges delivered to Boiler No. 2 are given in the daily process
data sheets on a shift basis. These are provided in Appendix D.
To approximate the amount of refuse burned in Boiler No. 2, it is neces-
sary to determine an average weight per charge, since the number of charges
fed into this boiler are known (Appendix D). The method for doing this,
however, is not entirely obvious. When refuse trucks enter the plant, they
discharge their contents into a large storage pit. Although the weight of
refuse added to the pit is well characterized for each weekly period, the
carry-over of material from week to week cannot be accurately measured.
Furthermore, this carry-over is quite variable over the length of time being
considered. It is also significant, as the pit is sometimes over half full,
corresponding to roughly 5000 cubic yards of refuse. It is necessary to
quantify the carry-over in terms of weight, so that the total weight of
refuse burned, and hence, the average weight per charge, can be approximated.
This can be done by 3 different methods.
2-17
266
-------
TABLE 2-6. WEEKLY INVENTORIES OF REFUSE AND RESIDUE AT THE CHICAGO
NORTHWEST MUNICIPAL INCINERATOR (ALL BOILERS).
Refuse Received
By weight (tons)
By volume (cubic yards)
Density (Ibs/yd3)
Storage Pit Condition
At beginning of week
(% full)
At end of week (% full)
Refuse Consumed
# charges burned
Average weight per
charge (Ibs)
Total weight (tons)
Total volume (cubic
yards)
Residue
Fine ash fraction (tons)
Fine ash fraction (cubic
yards )
Metal fraction (tons)
Metal fraction (cubic
yards)
Total ash (tons)
Total ash (cubic yards)
Volume Reduction
thru incineration
Weight Reduction
thru incineration
4/28/80
to
5/4/80
6,746.65
24,490
551
84
65
5,205
2,771
7,212
28,562
2,511
3,100
949
5,423
3,460
8,523
70%
52%
•5/5/80
to
5/11/80
9,152.34
29,618
618
65
61
5,710
3,240
9,250
36,634
2,500
3,086
750
4,286
3,250
7,372
80%
65%
5/12/80
to
5/18/80
7,902.34
26,561
595
61
42
5,952
2,812
8,367
33,138
1,815
2,240
1,514
18,651
3,329
10,891
67%
60%
5/19/80
to
5/25/80
8,720.21
28,778
606
42
42
4,714
3,700
8,720
34,535
2,904
3,585
629
3,594
3,533
7,179
79%
60%
2-18
267
-------
TABLE 2-7. CHARGES FED TO EACH BOILER ON A SHIFT BASIS CHICAGO
NORTHWEST INCINERATION FACILITY
Date,
4-28,
4-29,
4-30,
5-1,
5-2,
5-3,
5-4,
5-5,
Total
Shift
2nd
3rd
1st
2nd
3rd
1st
2nd
3rd
1st
2nd
3rd
1st
2nd
3rd
1st
2nd
3rd
1st
2nd
3rd
1st
for week
Unit
No. 1
88
101
101
27
89
35
—
78
75
38
94
101
101
97
33
27
62
20
94
36
101
1398
Unit
No. 2
98
99
100
94
101
90
94
101
94
49
98
100
98
101
100
102
99
97
96
12
—
1823
Unit
No. 3
101
100
101
89
97
94
99
94
95
45
93
98
95
96
102
96
97
98
93
101
100
1984
Unit
No. 4 Total
287
300
302
210
287
219
193
273
264
132
285
299
294
294
235
225
258
215
283
149
201
0 ' 5205
2-19
268
-------
TABLE 2-7. (Continued)
Date,
5-5,
5-6,
5-7,
5-3,
5-9,
5-10,
5-11,
5-12,
Shift
2nd
3rd
1st
2nd
3rd
1st
2nd
3rd
1st
2nd
3rd
1st
2nd
3rd
1st
2nd
3rd
1st
2nd
3rd
1st
Unit
No. 1
106
83
102
104
70
37
14 -
101
77
102
102
101
101
101
98
52
101
103
102
99
104
Unit
No. 2
--
• «
68
112
99
84
100
81
101
100
100
98
100
99
101
100
102
101
105
103
Unit Unit
No. 3 No. 4
101
86
103
107
m
98
83
97
101
101
98
100
100
101
101
100
102
103
101
102
100
Total
207
169
205
279
293
234
181
298
259
304
300
301
299
302
298
253
303
308
304
306
307
Total for week 1860
1754
2096
5710
2-20
269
-------
TABLE 2-7. (Continued)
Date,
5-12,
5-13,
5-14,
5-15,
5-16,
5-17,
5-18,
5-19,
Total
Shift
2nd
3rd
1st
2nd
3rd
1st
2nd
3rd
1st
2nd
3rd
1st
2nd
3rd
1st
2nd
3rd
1st
2nd
3rd
1st
for week
Unit
No. 1
39
97
102
104
98
100
98
94
106
105
107
108
38
112
no
98
118
106
75
—
—
1815
Unit
No. 2
99
99
100
100
60
__
—
96
104
106
108
106
97
no
112
97
114
108
104
118
105
1943
Unit Unit
No. 3 No. 4
98
99
100
104
103
100
96
102
no
107
106
no
85
108
112
98
108
109
105
124
no
2194 0
Total
236
295
302
308
261
200
194
292
320
318
321
324
220
330
334
293
340
323
284
242
215
5952
2-21
270
-------
TABLE 2-7. (Continued
Date,
5-19,
5-20,
5-21,
5-22,
5-23,
5-24,
5-25,
5-26,
Total
Shift
2nd
3rd
1st
2nd
3rd
1st
2nd
3rd
1st
2nd
3rd
1st
2nd
3rd
1st
2nd
3rd
1st
2nd
3rd
1st
for week
Unit
No. 1
„
103
104
120
—
--
--
68
21
--
—
__
--
—
-_
--
—
._
__
--
—
416
Unit
No. 2
no
105
104
118
no
100
106
90
80
105
100 '
107
107
102
98
105
94
101
105
107
105
2159
. Unit Unit
No. 3 No. 4
114
105
106
100
108
103
104
88
82
107
100
104
104
100
92
107
101
104
108
102
100
2139 0
Total
224
313
314
338
218
203
210
246
183
212
200
211
211
202
190
212
195
205
213
209
205
4714
2-22
271
-------
The first method involves using visual measurements of the pit volume
taken at the end of each week. This "pit estimate11 can then be used in asso-
ciation with the density of the incoming garbage to approximate the weight
of refuse in the pit. Then the average weight per charge can be determined
by the following equation:
Average wt (pit estimate for previous week - pit estimate
per charge * + refuse delivered) * total number of charges
All terms in parenthesis must be expressed as weights. This method however
has a drawback in that the density in the pit is probably not the same as
the density inside the refuse trucks, since the refuse inside the trucks is
compacted and is liable to expand somewhat as the trucks are unloaded.
The second method is essentially the same as the first, but a different
assumption is made for pit density. It seems likely that the level of com-
pression would have a more pronounced effect upon the refuse density than
the actual characteristics of the refuse. Since the compaction inside the
pit is always similar, one would also expect the density in the pit to be
reasonably constant. In principle, this is the method applied by the plant
personnel, but in practice it is not consistently used by them. It has been
found from plant operational experience that a density.of 505 Ibs/yd is
typical of the pit contents. Therefore, this value can be used as an assumed
density, and the pit estimates used in the equation as before.
The third method circumvents the problem of pit estimation entirely.
Assuming that every charge constitutes a full load of the crane grab bucket,
the weight of the charge can then be estimated by multiplying the maximum
volume of the bucket by an assumed density. The maximum volume of the bucket
is five cubic yards. The primary disadvantage of this method is that any in-
accuracy in the density is directly reflected in the average weight per charge.
In this report the second method was chosen as the most appropriate,
and the values for total refuse consumed and average weight per charge were
tabulated (refer to Table 2-6 ). A constant, assumed pit density (assumed
in method 2) was preferred to a variable "measured" density of method 1.
2-23
272
-------
Furthermore, a "bad" density assumption. will cause smaller errors in the
first and second cases than in the third case. The second method can be
summarized as follows:
Volume of refuse in pit = pit estimate (% of total volume) X total pit volume
100
total pit volume = 9700 yd3
Weight of refuse in pit = volume of refuse in pit X refuse density in pit
assumed refuse density = 505 Ib/yd
Weight of refuse
incinerated per week * (weight of refuse in pit at beginning of week
- weight of refuse in pit at end of week +
weight of refuse delivered)
Average weight per
charge = total weight of refuse incinerated
total number of charges
rird = weight of refuse incinerated
incinerated = assumed refuse density -
The amount of fine ash and metal fractions produced by the incinerator
during the test period are listed in Table 2-6 . It should be noted that
these are the amounts leaving the plant during this time period, and are
not necessarily the same as the ash being produced during this period.
Since no account has been taken of any carry-over from week to week, it can
only be assumed the carry-over is similar each week. In order to obtain
total ash, the metal and fine ash fractions were summed together. The ash
volumes were calculated using the following densities:
Density of fine ash fraction = 1620 lbs/yd3
Density of metal fraction = 350 Ib/yd
These values are based on previous analyses done by the plant, and have been
assumed to be typical. Since all of the combined ash was subjected to a
water quench, these weights incorporate a rather large moisture content.
However, no better characterization was available. The volume and weight
reductions achieved through incineration have been calculated as an indica-
tion of how efficiently the boilers were operating.
2-24
273
-------
The ash pj-oduced by each boiler can be estimated by either of two ways.
First, by estimating the number of hours each boiler was down, the total num-
ber of operating hours can be found, and an approximate ash production rate
per boiler operating hour can be calculated. All necessary information con-
cerning boiler down hours is presented in Table 2-8. Alternatively, by know-
ing the number of charges fed to the boilers in a weeks time, an approximate
ash production rate per charge of refuse can be calculated. A distribution
of charges fed to each boiler on a shift basis is presented in Table 2-7.
2.3 CONTINUOUS MONITORING DATA
Table 2-9 presents daily averages of 02, C02, CO, total hydrocarbons,
and ambient temperature as monitored by continuous data logging instrumenta-
tion over test duration periods. Hydrocarbon values were consistently lower
than the instrument sensitivity of 2 ppm. Most of the data indicates very
little variation except for the CO values. The rapid change between May 8,
1980 and May 9, 1980 was due to instrument drift, which places doubt on the
validity of the previous data also. The CO analyzer was taken off line, and
a new one replaced on May 15, 1980. The high CO value on May 19, was due
to unusally high moisture in the fuel on this day. Moreover, the operators
did not compensate for the wet feed by changing boiler condition. They were
reluctant to change conditions because a new supply of dry feed was anticir
pated. The high moisture content in the fuel probably inhibited combustion
and made burning less efficient. This is reflected in higher Og, lower COg,
and higher CO concentration as compared to those on normal operating days.
In Table 2-10, values of percent oxygen measured in the control room
and by TRW continuous monitoring instrumentation are compared. The control
room readings were observed to be higher than the 0« analyzer readings on
all days except one. This is unusual since the readings should be identical.
In any event, the 0? analyzer should either yield identical or higher read-
ings, because the sample was obtained further downstream and any leakage in
the duct would tend to increase the 02 level of the gas stream. This dis-
crepancy could be due to offset instrument calibrations. It must be noted
that the 02 analyzer indicating lower readings was calibrated (for zero and
span), prior to the start of testing and also after the testing concluded for
each test day. The control room oxygen analyzer was calibrated once a week.
2-25
274
-------
TABLE 2-8. DOWN TIME EXPRESSED AS LOST FURNACE HOURS FOR THE ENTIRE
CHICAGO NORTHWEST INCINERATION FACILITY
Date
4-28-80
4-29-80
4-30-80
5-1-80
5-2-80
5-3-80
5-4-80
Total for week
5-5-80
5-6-80
5-7-80
5-8-80
5-9-80
5-10-80
5-11-80
Total for week
5-12-80
5-13-80
5-14-80
5-15-80
5-16-80
5-17-80
5-18-80
Total for week
5-19-80
5-20-80
5-21-80
5-22-80
5-23-80
5-24-80
5-25-80
Total for week
Total
Unit
No. 1
1
8
16
8
0
15
9
"57-
0
5
13
2
0
5
0
25
5
0
0
0
6
0
11
TZ~
10
8
18
23
24
24
24
131
235
Unit
No. 2
0
0
1
5
0
0
7
nrr
24
12
0
2
0
0
0
38
0
5
16
0
1
0
0
"zr
0
0
0
0
0
0
0
0
73
Unit
No. 3
0
0
0
6
0
0
0
-T
0
0
0
0
0
0
0
0
0
0
0
0
1
0
0
-T
0
0
0
0
0
1
0
1
8
Unit
No. 4
24
24
24
24
24
24
24
T5S~
24
24
24
24
24
24
24
168
24
24
24
24
24
24
24
T5a~
24
24
24
24
24
24
24
168
672
Total
25
32
41
43
24
39
40
2$T
48
41
37
28
24
29
24
231
29
29
40
24
32
24
35
ITT"
34
32
42
47
48
49
48
300
988
Total possible
Hours
hours - 2688
lost = 36.8%
2-26
275
-------
TABLE 2-9 . CONTINUOUS MONITORING DATA
•-J
o>
Sampling
location
ESP Inlet
CSP Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Inlet
Outlet
Date
(1980)
5-4
5-6
5-7
5-8
5-9
5-10
5-11
5-12
5-13
S-IS
5-16
5-11
5-18
5-19
Mean
11.2
II. J
9.6
10.4
9.4
9.4
9.9
10.4
7.9
8.1
8.8
9.4
9.8
9.8
9.6
10.4
9.7
9.6
10.2
9.6
II. 1
11.8
10.)
10.7
10.7
12.7
02 (SI
a
1.18
0.90
1.41
1.17
I.OB
1.78
1.98
1.61
1.09
1.62
1.36
1.74
1.18
1.58
l.ll
1.69
1.67
1.42
1.51
1.47
1.19
1.12
0.90
1.16
ft** k
0.91
Data
1.86
co2 in
Hean o
7.4
7.7
10. 1
9.5
9.8
9.7
9.5
8.7
II. 0
10.7
10.1
9.7
9.5
9.5
9.7
9.0
9.6
9.8
9.4
9.7
8.5
7.9
10.0
9.0
taken for
9.2
taken for
7.2
1.07
0.82
1.14
1.20
0.96
1.51
1.81
1.41
0.96
1.17
1.18
1.54
1.06
1.05
0.89
1.42
1.18
1.14
1.18
1.18
1.18
1.16
0.75
1.17
outlet
0.05
outlet
1.69
CO lp|») IMC (ppm)
Mean a Mean o
172
156
161
171
IBS
198
142
169
78
71
12.76
25.18
20.92
25.04
17.28
44.88
51.12
90.54
18.76
18.66
Instrument Halfunc-
. tlon .
H
•
N
M
M
H
112
98
88
98
80
84
102
only
104
«
•
•
«
•
16.01
25.70
61.92
75.58
29.61
27.26
M_«
18.71
Hot
184.86
.2
<2
<2
<2
«2
<2
<2
<2
<2
<2
<2
«2
«2
<2
<2
<2
«2
<2
«2
<*
«2
<2
«2
<2
Required
M
Required
M
fablent
Temperature <*C)
Mean a
24.7
15.5
11.6
10.0
14.1
18.4
16.7
12.4
11.6
15.6
16.3
12.8
12.0
11.0
2.36
5.45
1.10
1.21
1.98
3.56
1.77
0.66
5.60
2.71
1.19
1.21
1.14
0.96
-------
TABLE 2-10. MEANS OF PERCENT OXYGEN TAKEN BY CONTROL ROOM
GAUGE AND 0, ANALYZER FOR TEST DURATION
Testing
Date
5-4
5-6
5-7
5-8
5-9
5-10
5-11
5-12
5-13
5-15
5-16
5-17
5-18
5-19
Control
Room (%)
16.4
10.1
10.3
11.5
9.2-
12.0
9.8
10.3
11.1
11.2
14.0
9.8
10.9
13.1
2 Analyzer Difference
(ESP inlet) (%) (Control Room -
Analyzer)
11.2
9.6
9.4
9.9
7.9
8.8
9.8
9.6
9.7
10.2
11.1
10.3
10.7
12.7
5.2
0.5
0.9
1.6
1.3
3.2
0.0
0.7
1.4
1.0
2.9
-0.5
0.2
0.9
2-28
277
-------
•3.0 PLANT DESCRIPTION
Chicago Northwest Incinerator is located south of W. Chicago Avenue
between the tracks of the Chicago and North-western Railway on the west and
Kilbourn Avenue on the east. The principal building of the complex is the
Incinerator, a multi-storied structure of reinforced concrete with dimen-
sions of 330 feet by 180 feet and with a maximum height of 79 feet from
grade to the main floor. The lowest part of the structure is the floor of
the refuse storage pit, approximately 37 feet below grade. To the south of
the Incinerator Building and connected to it by the residue conveyors en-
closure is the Ash Discharge Building. To the north is the Incinerator
Office Building which also houses the maintenance shops. Two stacks each
250 feet in height are located east of the Incinerator Building. The elec-
trostatic precipitators and the induced draft fans are situated between the
Incinerator Building and the stacks. The Chicago Northwest Incinerator lay-
out is shown in Figure 3-1. The general characteristics of the Chicago
Northwest Incinerator are listed in Table 3-1.
3.1 General Description
Refuse is delivered to the dumping pit of the plant by trucks which
back into position above the refuse pit. From the refuse storage pit, crane
grapple buckets pick up the refuse and dump it directly into the four furnace
feed hoppers. The furnace feed hoppers open into feed chutes which feed auto-
matically onto the stoker grates of the four furnaces.
The grates operate with a reverse-reciprocating action producing an
initial downward movement of the refuse and then an upward movement. This
combined movement results in a tumbling action. The motion of the grates,
an underfire grate jet action, and overfire air jets above the grates all
combine to promote highly effective burn-out and complete oxidation of the
furnace gases.
The hot furnace gases travel through five boiler passes enroute to the
electrostatic precipltator (ESP). Approximately 110,000 pounds of steam is
generated by each of the four boilers. In passing through the boiler, the
3-1
278 '
-------
I
ro
10
WEIGK
STATION ^STACKS ELECTROSTATIC
PRECIPITATOR
CHICAGO NORTHWEST INCINERATOR
ASH REMOVAI
EQUIPMENT
REFUSE STORAGE PIT
330' TIPPING FLOOR AREA
PARKING AREA
Figure 3-1. Layout of plant site
-------
TABLE 3-1. CHARACTERISTICS OF CHICAGO NORTHWEST
INCINERATOR
Number of incinerator units
Number of refuse cranes
Number of chimneys
Refuse pit capacity
Capacity of each crane bucket
Average heating value range of refuse
Capacity: Refuse
Steam Generation
Furnace temperature
Stack gas temperature
Gas cleaning equipment
Precipitator efficiency
Precipitator outlet grain loading
4
3
2, each 250 feet high
9,700 cubic yards
5 cubic yards
5,000 BTU/lb
1,600 tons/days
440,000 IDS/hour
1,500° - 2,000°F
450° F
4 electrostatic precipitators
97?
0.05 grains/std. cu. ft.
gases are reduced in temperature to approximately 450°F.
The residue from the grates and the fly ash collected by the ESPs are
dumped into the ash discharger. The discharger which is partly filled with
water quenches the ashes and via residue conveyors transferred to the ash
building. The ashes are then screened. Salvageable metals are sold for
reuse. The remaining ashes are taken from the ash building by trucks and
used in construction projects or places as sanitary landfill.
A line diagram of the Incinerator is presented in Figure 3-2.
3.2 DETAILED DESCRIPTIONS
3.2.1 Refuse Handling
Mixed refuse from domestic sources 1s brought to the incinerator
plant in collection trucks, each truck has a capacity of 5 tons or 25 cubic
yards. *The refuse averages 400 pounds per cubic yard. The refuse varies
considerably in consistency and moisture content over a period of time and
3-3
280
-------
TRUCKED
REFUSE
|-*-SCALE
REFUSE
DELIVERY
PIT
to
N>
00
FEED WATER
REFUSE
FEED
HOPPER
1
^" BOII
/Qv OVER
INTAKE
FAN fifths
| STOKER 1 jBBSlft
1 GRATES 1 ^^*»
UNDEffJ
&
FOR(
DRA
FA
1 AIR COOLED)
^ | CONDENSERS |
r/v*FRriAi \
** STEAM 1
STEAM | ft^^fm^ i
1^ LKLMS ** ( EC°NQMIZCR |
^J BOILER | (ECONOMIZER)
FIRE ^ | HOPPER ) f HOPPER I
t 1
I \ f
ASH
*H% HOPPER
RE*"1
MH^H*
&
:ED
FT
N
_,
HEAVY
METALS
i ,
•^^
feLECTROSTATld .
""^PRECIPITATORi
l~
FLY ASHl
HOPPER 1
COMBINED
ASH
SIFTING
GRATES
1
JL
FINE
ASH
DRAFT
FAN
Figure 3-2. Flow diagram of Chicago Northwest Incinerator
-------
this condition is reflected in the changeable calorific (heat) content of
the refuse.
Trucks are weighed over scale platforms. After weighing these trucks
are directed to eleven stalls in front of the refuse storage pit. After
depositing their load the trucks leave the building through doors in the
south end. Refuse items that are too large to be handled through the charg-
ing hopper and feed chute (such as mattresses, upholstered furniture, etc.)
are removed. Bulky metal objects from the storage area are removed by trucks.
The refuse storage pit has a storage capacity of 9,700 cubic yards or
1,940 tons or sufficient "fuel" to last 29 hours when the four incinerators
are operating normally. This necessitates refuse collection on six days of
the week. However this is not always possible due to various reasons such
as unfavorable weather etc. At such times auxiliary gas firing is utilized
to meet steam demand and to keep the furnaces from cooling down.
The refuse is removed from the pit by one of three transfer cranes.
These cranes are overhead, high speed, two-girder, single trolley, travel-
ling, grab bucket cranes each of 8.5 tons capacity handling mixed refuse
from the storage pit to the furnace charging hoppers. An auxiliary hoist
of 2.5 tons capacity is provided on each of the end cranes and mounted on
crane trolleys. Each crane bucket has a 5 cubic yard capacity and is a four-
line, line-type grapple. All crane components are electric motor driven
under control of an operator in a cab suspended from the bridge and located
so as to permit the operator to see the bottom of the refuse storage pit as
well as the charging hoppers. The cranes are capable of performing a maxi-
mum of 29 cycles per hour per crane including an allowance of approximately
20 percent for rehandling refuse and other interruptions. The cranes span
44' - 8" center to center of rails and the crane runaway is 286' - 0" in
length.
Crane operations are manually controlled from within each respective
crane cab. Each refuse transfer crane was initially equipped with solid-
state computerized weighing systems to record the amount of material charged
into the hoppers by each crane and also record into which hopper the material
is charged. Due to various problems the use of the solid state systems was
abandoned and now the number of times the refuse is charged into the hopper
3-5
282
-------
1s monitored manually by the crane operator. Each charge is assumed to be
of 5 cubic yards capacity.
3.2.2 Refuse Burning
The plant has four incinerators each having a nominal burning capacity
of 400 tons per 24 hour day. Each incinerator has a charging hopper, feed
chute, hydraulic powered feeders and stoker (manufactured by Josef Martin,
Germany), boiler, economizer and fly ash hoppers. Draft throught the furn-
ace (boiler) is provided by forced draft fans, overfire air fans and induced
draft fans.
Refuse in the charging hopper of each incinerator flows by gravity
from the hopper to three stoker feeders through a feed chute, the lower
portion of which is water cooled. Near the bottom of each charging hopper
is a hydraulic powered pivoted type gate normally open but closed when the
feed chute is empty of refuse. The charging hopper gates are manually con-
trolled through operation of a four-way valve on the charging floor. The
stoker feeders at the bottom of the feed chute push the refuse into the
stoker by the reciprocating action of their hydraulic powered rams. The
stokers of each incinerator are assembled with three runs or sections and
have a sloping activated surface consisting of 17 rows of grate steps.
The grate sections incline from the hortizontal at an angle of 26°, the
lower end being at the rear. The stoker is of the reverse acting, reci-
procating grate type. Alternate lateral rows of grate steps have control-
led continuous reciprocating action with the moving grate steps pushing
in reverse direction to the flow of refuse. This action moves a portion of
the burning refuse under the unignited material and thereby effects an agi-
tation and blending of the whole burning mass. Combustion air entering
from below the grates cools the grates, helps to agitate the burning refuse
and supplies the oxygen which produces a maximum burn-out in the shortest
length of grate travel.
Although the spacing between the grate bars comprises less than two
percent of the total grate area, it is still possible for small siftings
or ashes to find their way through the grate. These ashes are handled by
the automatic sifting discharge which extends underneath the air plenum
chambers serving the stoker. At regular intervals high pressure air is
3-6
283
-------
directed through the slftlngs channel, driving the siftings into the ash
discharges.
In order to obtain maximum burn-out, the depth of the refuse bed is
controlled by automatic discharge or clinker rollers located at the end of
the grate. As the residue reaches this point it is dumped into the Martin
ash discharger where it is immediately quenched in water. The residue,
following quenching by means of a hydraulic powered ram is pushed up an
inclined slope which permits draining. This produces a residue of less
than 15 percent moisture, and permits dry type conveying. In addition to
quenching, the ash discharger also serves as a water seal for the furnace.
This seal prevents infiltration of air into the furnace which is under nega-
tive pressure.
Each refuse burning boiler is provided with two gas burners suitable
for use with natural gas. They are automatically controlled and have an
electric ignition.
3.2.3 Residue Handling
The residue leaving each incinerator ash discharger passes through
a hydraulically operated bifurcated chute to one or the other of two resi-
due conveyors. These apron type conveyors travel at a rate of 17 feet per
minute and have a capacity of 35 tons per hour. Only one conveyor operates
at a time and extends horizontally past the four incinerators. It discharges
its load onto rotary screens and storage hoppers in the Ash Discharge build-
ing. The electric motor driven rotary screens separate material larger than
2 inches in diameter from smaller sized material. Hydraulic power operated
diverting chutes are provided to direct the flow of residue away from the
rotary screens and into a bypass hopper.
Material from the hoppers is removed from the plant by motor trucks.
The weight of the residue leaving the plant is measured and recorded at the
weighing station.
The residue conveyors also receive and transport stoker grate siftings
and fly ash accumulations from the boiler hoppers, economizer hoppers, and
the electrostatic precipitators. Stoker grate siftings collect in six hop-
pers under each of three stoker grate sections. The siftings are conveyed
3-7
284
-------
to the residue conveyors through automatically controlled, pneumatic cylin-
der actuated ash dampers to ducts connected to the residue discharge (drop)
chute. Boiler fly ash is collected in four hoppers and the front two hoppers
discharge to the stoker grates through ducts equipped with pneumatic cylinder
actuated pendulum dampers. The rear two hoppers discharge to the residue
discharge chute through a common connecting pipe equipped with slide gate
and an electric motor driven rotary valve. Fly ash from the economizer
hoppers passes through a common pipe connected to the discharge end of the
conveyor handling fly ash from the electrostatic precipitator. The two fly
ash hoppers located under each precipitator discharge ash onto a drag con-
veyor which transmits the fly ash into the incinerator building onto a con-
ditioning conveyor. This conveyor discharges into the residue discharge
chute. Water is mixed with the fly ash in the conditioning conveyor.
The fly ash handling system is designed for continuous operation and
the various devices are actuated from controls on the stoker panel. The
control of residue handling equipment is manual.
3.2.4 Steam Supply
Refuse with a calorific value of approximately 5,000 BTU per pound at
the rate of 400 tons per day is used to generate 110,000 pounds per hour of
steam at 250 psig. Each boiler has the capacity to produce up to 135,000
pounds/hour of steam. The stokers and boiler heating surfaces are designed
to receive refuse of up to 6,500 BTU/lb. The allowable design of the stoker
grate loading is 65 Ibs/sq.ft. per hour and thus the average stoker heat
release is 325,000 BTU per hour/sq.ft. of projected grate area.
The boilers are convection, water well, natural circulation types with
economizers. Each boiler has 19,776 sq.ft. of heating surface and is design-
ed for a 300 psig working pressure.
Steam produced in the boiler accumulates above the water surface in
the steam drum and leaves the drum through double row of tubes connected to
the saturated steam header outside of and supported on the boiler steam drum.
From the saturated steam header the steam flows to the main header and then
through branch lines to turbines driving fans and pumps, export lines and
3-8
285
-------
high pressure condensers. Steam at reduced pressure 1s also used for heat-
ing various systems such as water chiller absorption units, office buildings,
low pressure condensers, etc.
When the steam produced in the plant is more than that required for
operating the steam turbine equipment, heating purposes or export, the ex-
cess quantity "spills over" to the high pressure condensers located on the
roof of the incinerator building. From the condensers the condensate flows
to the deaerating feed water heater, the rate of flow being automatically
controlled and modulated to equal the rate of condensation. The require-
ments for make-up to replace steam condensate lost or wasted are met by
using softened water. The water softening unit includes duplex softening
units containing synthetic type zeolite resin, a salt storage tank, a brine
measuring tank, electric motor driven brine pumps and interconnecting piping.
It has a nominal flow rate of 260 gpm and a maximum rate of 480 gpm.
From the feedwater heater, water flows by gravity to the inlets of the
boiler feed pumps. There are four pumps, each having a nominal capacity of
400 gpm. The pumps are multi-stage, horizontal, centrifugal type. These
pumps transmit the water to the boilers.
Each boiler has a continuous blowdown system with water drawn from the
steam drums. The blowdown pipe lines from the four boilers extend to a
single flash tank. Flash steam is returned to the deaerating feedwater
heater at 5 psig. From the heat exchanger the blowdown water flows to an
underground concrete blowdown tank where the water cools before overflowing
to a sewer.
3.2.5 Combustion Air and Flue Gas
The incinerator stokers are designed to utilize 67,200 scfm of primary
air (introduced under the stoker grates) at 18 inches w.c. and an overfire
air (secondary) flow of 16,800 scfm at 15 inches w.c. Overfire air is in-
troduced into the furnace to reduce stratification of gas and thus provide
more complete combustion of the gases. The air enters through the front
and rear water walls. The underfire air is discharged into several compart-
ments under the stoker grate. The compartments are provided with dampers
which are individually adjustable by manual operation of regulating stands
3-9
286
-------
located on the stoker operating floor. During the burning of refuse a con-
stant air pressure is maintained under the stoker grates by means of automa-
tic pneumatic controls.
Combustion air combines with the burning refuse to generate heat and
raise the temperature of the flue gas to as high as 2000°F. At rated burn-
1ng capacity and based on 50 percent excess air (dry) the flue gas flow rate
at 550°F is estimated to be 142,300 acfm. The flue gas passes upward
through the furnace, through the boiler passes and finally through the eco-
nomizer to the electrostatic precipitator. As it passes through the boiler
it transfers heat to the water. At the inlet to the electrostatic precipi-
tator the temperature is reduced to approximately 500°F because of the above
heat exchange. During the passage of the flue gas through the boiler passes
and economizer the heavier fly ash particles drop out. Hoppers are provided
below the boiler and economizer for the collection of the drop out material.
The plate type electrostatic precipitators (ESP) tone for each inciner-
ator) have a series of vertical collector plates between which are suspended
the charging electrodes. The ESP's are designed for an inlet grain loading
of 1.6 gr/scf (70°F and 29.92 in Hg) and an outlet grain loading of 0.05
gr/scf with a collection efficiency of 97 percent. The gas velocity through
the ESP is around 3 ft/sec.
From the precipitator the flue gas passes through a breaching continu-
ation to the inlets of the induced draft fans and then through the 250 ft.
stacks to the atmosphere.
A line diagram of the combustion air and flue gas system is provided
in Figure 3-3.
3-10
287
-------
I
I
I
FRESH AIR
INTAKE
OO __•
STORAGE
"m"
FURNACE
ROOM
FORCED
DRAFT
FANS
OVERFIRE
AIR FAN
BOILER
A
1
FURNACE
A
1
1
STOKER
J
CONOMIZEf
ELECTROSTATIC
PRECIP1TATOR
1
I.D.
FAN
Figure 3-3. Combustion air and flue gas system
-------
x 4.0 SAMPLING LOCATIONS
All sampling locations are identified in Table 4-1 and Figure 4-1.
Figure 4-2 is a schematic depicting the traverse point locations at the
stack. Figure 4-3 is a top view of the ESP inlet showing port locations,
and Figure 4-4 is a cross sectional view of the ESP inlet depicting the
traverse point locations.
The continuous monitoring probe was located on the South side of the
ESP inlet duct utilizing one of the gas sampling ports and at a depth of
approximately 4 feet. At the outlet, the monitoring probe was alternated
between ports 2 and 3 and at a depth of 4 feet. These two ports were also
used for the gas sampling trains.
TABLE 4-1. SAMPLING LOCATIONS
Solid Sample Locations
1 - Refuse derived fuel
2 - Fly ash
3 - Combined ash
Gaseous Sampling Locations
4 - Hi volume ambient air sampler
5 - ESP inlet
6 - ESP outlet
Liquid Sample Locations
7 - City tap water
4-1
289
-------
TRUCKED
REFUSE
BOILER
j-*SCALE
©L
REFUSE
DELIVERY
PIT
STOKER
GRATES
1 HATER
SE
D
EH
•*•
•^
-------
OUTLET - FRONT VIEW
(CONTINUOUS MONITORING PORTS)
• • • • •
(PARTICULATE SAMPLING PORTS)
OUTLET - TOP VIEW
60'
u
2
N-
U
3
•108"-
U
4
Traverse Point
No.
1
2
3
4
5
6
7
7
9
10
SAMPLING POINTS - OUTLET
Distance from Outside Edge of Nipple
In.
11.5
17.5
23.5
29.5
35.5
41.5
47.5
53.5
59.5
65.5
Cm.
29.21
44.45
59.69
74.93
90.17
105.41
120.65
135.89
151.13
166.37
Figure 4-2. Outlet sampling position
4-3
291
-------
ro
*o
N>
•ffc
X
Figure 4-3. Top view of ESP Inlet showing port locations
-------
K3
1C II
Oj
71M
60"
SL
DUSTCAKE
Traverse Point No
No.
1
2
3
4
5^,,.
6
7
8
9
10
11
12
SAMPLING POINTS - INLET
Distance from Outside Edge Nipple
In.
Cm.
11.5
15.375
19.625
23.875
28.125
32.375
36.625
40.875
45.125
49.375
53.625
57.375
29.21
39.05
49.35
60.64
7T.44
82.23
93.03
103.32
114.62
125.41
136,21
145.73
Figure 4-4. Cross sectional of ESP inlet showing
traverse point locations.
293
4-5
-------
5.0 SAMPLING
This section provides information on the sampling program conducted
at the Chicago Northwest Incinerator (CNI).
5.1 GAS SAMPLING
The original test plan called for sampling to be performed on Boiler
No. 1. However, upon arriving at the test site, this unit had been taken
off line for repairs. As all four (4) units at the Chicago Northwest faci-
lity are identical, the sampling effort was switched from unit 1 to unit 2.
The flue gas sampling was performed at the electrostatic precipitator (ESP)
inlet and at the duct leading from the precipitator to the stack. The
stack was common to two boiler units and for this reason, no testing was
performed at the stack level.
Sampling for organics was to be performed for fourteen consecutive
days with three additional days for sampling of inorganic cadmium. Due to
boiler down time and equipment malfunction, only eleven organic samples
were taken. Sampling for organics was accomplished concurrently at the in-
let and outlet utilizing two modified Method 5 trains (refer to Figure 5-1)
at both sampling locations. Inorganic cadmium was only sampled at the stack
and utilized one standard Method 5 train, Figure 5-2.
The sampling crew collected a ten m (10^1 m ) sample by extracting
the flue gas at a rate approximating the flue gas velocity. The particulate
matter was collected in a cyclone and on the filter media. The gas stream
was passed through an XAD-2 resin trap to absorb the organic constituents
and through an impinger system to condense any moisture present in the gas.
Parameters such as temperatures, pressures, and gas volumes were monitored
throughout the sampling period. The sample fractions were recovered from
the sampling trains and turned over to an MRI representative.
5.2 SOLID SAMPLING
During each test day, 3 solid streams: precipitator ash, combined ash,
and refuse derived fuel (RDF) were sampled six times per day following a
schedule set up by Research Triangle Institute (RTI). The sampling was co-
ordinated between RTI, the sampling crew and plant personnel. The
5-1
294
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HOUSING
THERMOf^ETER
DRY TEST
• ,'ETER
Figure 5-1. Sampling train
5-2
295
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12
Figure 5-2. EPA Method 5 particulate sampling train
1)
2)
3)
4)
5)
6)
7)
Calibrated nozzle
Glass lined probe
Flexible teflon sample line
Cyclone
Filter holder
Heated box
Ice bath
8) Impinger (water)
9) Impinger (water)
10) Impinger (empty)
11) Impinger (silica gel)
12) Thermometer
13) Check value
14) Vacuum line
15) Vacuum gauge
16) Main value
17) A1r tight pump
18) Bypass value .
19) Dry test meter
20) Orifice
21) Pitot manometer
22) Potentiometer
23) Orifice manometer
24) S type pitot tube
5-3
296
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schedule provided the basis for collection of unbiased samples by obtain-
ing a random selection from the multiple sources available for sampling.
This approach was taken to avoid any cyclic biases which might have been
present in the daily operation of the power plant.
The CNI sampling plan did not call out specific sampling protocol for
the RDF, At a meeting prior to the start of testing, it was decided that
the RDF would be sampled 6 times during the course of the day. The sample
was taken directly from the charge hopper, utilizing a post-hole digger
and alternating grab spots across the hopper. At the conclusion of RDF
sampling, one days collection (6 samples) was shredded, mixed and stored
in an amber glass jar. MRI had purchased a large leaf mulcher to do the
shredding. TRW performed the shredding of the sample provided by GSRI
5.3 LIQUID SAMPLING
Only one liquid stream (city water) was sampled at the incinerator
facility. The sampling was performed by GSRI. The sampling protocol and
frequency of sampling will be supplied by GSRI in their report.
5.4 HI VOLUME SAMPLER
To monitor the ambient air background, a high volume ambient air sampl-
er (Figure 5-3) was used. It was placed on the roof of the Chicago North-
west Incinerator facility to obtain a representative background utilizing
outside ambient air rather than sampling air inside the building that could
have been contaminated or influenced by the combustion process.
5.5 QUALITY ASSURANCE
A quality assurance sample was also taken of the final test day. To
collect the quality assurance sample, two sampling trains were placed at
the same point in the same port at the inlet of the ESP. No traversing
was performed. Both trains were run at the same isokinetic rate for the
same duration as a normal test day. Also during the Q/A day, solids and
liquids were collected as in a normal test day.
5.6 SAMPLING TRAIN BACKGROUND
To obtain the train background (blank) an entire sampling train, in-
cluding resin trap filter and impinger solutions was set up at the ESP in-
let. The train was taken to normal operating temperatures and allowed to
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297
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HIGH VOLUME AIR SAMPLER
FLOW
PROBE
MANOMETER OR
ROTAMETER
\MODEL 230 HIGH
VOLUME CASCADE
IMPACTOR - OPTIONAL
MODEL 310/310A/310B
CONSTANT FLOW CONTROLLEF
[-7
JUST-
MENT
LINE CORD
Figure 5-3. Ant lent air sampler.
5.5
298
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remain at these temperatures for one (1) hour. All train components were
recovered as a normal run and all sample blanks were given to an MRI repre-
sentative.
5,.7 SAMPLE RECOVERY
Upon completion of testing, the sampling equipment was brought to the
cleaned laboratory area for recovery. Each sampling train was kept in a
separate area to prevent sample mixup and cross contamination. The indivi-
dual sample train components were recovered per the following:
• Dry particulate in cyclone * cyclone flasks were transferred to
cyclone catch bottle.
• Probe was wiped to remove all external particulate matter near
probe ends,
• Filters were removed from their housings and placed in proper
container,
• After recovering dry particulate from the nozzle, probe, cyclone,
and flask, these parts were rinsed with distilled water to remove
remaining parttculate, They were subsequently rinsed with B & J
acetone and cyclohexane and put into a separate container. All
rinses were retained tn an amber glass container,
t Sorbent traps were removed from the train; capped with glass plugs,
and given to an on-sfte Midwest Research Institute (MRI) represen-
tative,
• Condensing coil, if separate from the sorbent trap, and the connect-
ing glassware to the first impinger was rinsed into the condensate
catch (first impinger).
• First and second impingers were measured, volume recorded and
retained in an amber glass storage bottle. The impingers were
then rinsed with small amounts of distilled water, acetone and
cyclohexane. These rinsings were combined with the condensate
catch. Rinse volumes were also recorded.
• Third and fourth impingers were measured, volume recorded and
solutions discarded.
• Silica gel was weighed, weight gain recorded and regenerated for
further use.
To maintain sample integrity, all glass containers were amber glass,
with Teflon-lined lids.
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299
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5.8 OBSERVATIONS DURING RECOVERY
t The first day setup of impingers did not include F^Og, as the
shipment had not been delivered from the manufacturer.
• Many filters that were supplied for the particulate catch, had
the identification number stamped in blue ink on the top; or,
particle gathering side.
• Some BatteHe Traps were packed with too much glass wool. (As
a result, flow rate was somewhat restricted.) The probe and
oven box did not remain hot enough to keep the cyclone and flask
dry. For the first few days of testing, the cyclone had moisture
on the inside walls, so no dry particulate could be collected.
• On 5/10/80, the wind blew the Hi Volume Air sampler cabinet over.
The cabinet had to be moved to a less exposed area nearer the
building.
• On 5/5/80, 5/8/80, and 5/9/80 yellow residue was noted in the
teflon line connecting the back of the filter housing to the
front of the Battelle cooling coil. When the teflon line was
rinsed with acetone, the rinse turned to reddish-brown.
• When the filters were not kept completely dry throughout the
particulate test period, the filter paper would stick to the
rubber gasket and was very difficult to completely remove.
• A reddish color remained on the inlet filter backing plates on
5/8/80 and 5/15/80. The color washed off with water, and the
rinse was discarded.
• The inlet glass transition tubes connecting the probe to the
cyclone, had to be wrapped in an attempt to keep moisture and
particulate from dropping out and depositing on the walls.
• All parts, were inspected for cleanliness after the water and
acetone rinses, but before the cyclohexane rinse. Cyclohexane
does not rapidly evaporate and gives any part rinsed with it
the appearance of being clean. In reality the parts were still
wet and masked any particulate that remained on the walls.
5-7
300
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6.0 CALIBRATION
This section describes the calibration procedures used prior to conduc-
ting the field test at Chicago Northwest Incinerator facility. Figure 6-1
shows the calibration equipment and how it was set up.
6.1 METHOD FIVE CALIBRATION DATA
6.1.1 Orifice Meter Calibration
The orifice meter calibration is performed using a pump and metering
system as illustrated in Figure 6-1(a). The dry gas meter with attached
critical orifice is run at various orifice flows for a known time. After
each run the volume of the dry gas meter, meter inlet/outlet temperatures,
time, and orifice setting is recorded. The orifice meter calibration factor
is derived by solving the equation.
- 0.317 & H r(Tw + 460) e-,2
' fb (Td + 460) C TC ]
where
AH = Average pressure drop across the orifice meter, inches
H20
Pb = Barometric pressure, inches Mercury
TJ = Temperature of the dry gas meter, °F
Tw = Temperature of the wet-test meter, °F
6 = Times, minutes
Vw = Volume of wet test meter, cubic feet
The AH@ yielded is utilized to adjust the sampling train flow rate by regu-
lating the orifice flow.
6.1.2 Dry Gas Meter Calibration
Meter box calibration consists of checking the dry gas meter for accuracy,
The dry gas meter with attached critical orifice is connected to a wet test
meter (see Figure 6-1(b) below) and run at various orifice flows for a known
time. After each run wet and dry gas meter volumes, temperatures, time, and
orifice readings are recorded. Utilizing the equation:
6-1
301
-------
V = Vw Pb (Td + 460)
Vd (Pb + AH) (T + 460)
TT.6 w
where
V = Volume correction factor
Vw = Volume of wet test meter, cubic feet
Pb » Barometric pressure, inches mercury
Td = Temperature dry gas meter, °F
Vd = Volume of dry gas meter, cubic feet
AH = Average pressure drop across the orifice meter,
inches
T = Temperature of wet test meter, °F
a volume factor which compares the dry gas meter with the wet test meter
is obtained.
6.1.3 Pi tot Tube Calibration
Pi tot tubes are calibrated on a routine basis utilizing two methods.
The type S pitot tube specifications are illustrated and outlined in
the Federal Register, Standards of Performance for New Stationary Sources,
[40 CFR Part 60], Reference Method 2 (refer to Figure 6-1 (c)). When mea-
surement of pitot openings and alignment verify proper configuration, a co-
efficient value of 0.84 is assigned to the pitot tube.
If the measurements do not meet the requirements as outlined in the
Federal Register, a calibration is then performed by comparing the S type
pitot tube with a standard pitot tube (known coefficient of 1.0). Under
identical conditions, values of AP, for both S type and standard pitot tube
are recorded using various velocity flows (14 fps to 60 fps). The pitot
tube calibration coefficient 1s determined utilizing the following equation,
Pitot Tube Calibration = (Standard Pitot Tube X rAP reading of std. pitot -il/2
Factor (CP) Coefficient) LAP reading of S type pitotj
The coefficient assigned to the pitot tube is the average of calculated
values over the various velocity ranges.
6-2
302
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Figure 6-1(a)
Orifice meter calibration
Co««se Co""** vjtvrv tatocrMft T,
i « A. * ft ra—^ O >
Figure 6-1(b)
Dry gas meter calibration.
Aouif wiior 7>n of Poor " *>ioi fuO* fleoig CiMntttf
Tuor Wou/tf £» wncn
taiwig t ftvtamg
Figure 6-1(c)
Equipment used to calibrate pi tot
tubes
Figure 6-1. Calibration equipment set-up procedures
6-3
303
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6.1.4 Nozzle Diameters
The nozzle diameters were calibrated with the use of a vernier caliper.
If the nozzle showed excessive wear or was considered not fit for use, it
was discarded.
6.2 INSTRUMENT CALIBRATION
The manufacturer's recommended calibration procedures were used with
the following gases:
Zero gas: Nitrogen, high purity dry grade (99.99755)
Union Carbide Co., Linde Division
Calibration gas: Carbon monoxide 798.5 + 0.8 ppm ?/,' „„":*• ZZv rrttvn
~~ V C)PPT LIBRARY (7407)
Carbon dioxide 11.93 + 0.01 % i 401 M STREET S.W.
Propane 39.6 + 0.04 ppm ; WASHINGTON, D.C. 20460
Oxygen 5.03 + 0.0052 fee,..,, 202~260"3
Nitrogen Balance
(all gases contained in one cylinder)
Scott Environmental Technology Inc.
Specialty Gas Division
Zero and Calibration adjustment were made prior to the start of the
test day. Zero drift checks were made at the end of each test period.
Data was recorded every fifteen minutes thus providing two data points
per hour for each sampling position, or four data points per hour for
a single sampling position
304
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7.0 TECHNICAL PROBLEMS AND RECOMMENDATIONS
This section describes some of the problems encountered during the
Chicago Northwest Incinerator test program and recommends a solution to
these problems.
7.1 PROBLEMS
• Electrical outlets were not installed on schedule (lost time -
1 day).
» One of the tubes in Boiler No. 2 developed a leak. The boiler
had to be shutdown for repairs. This caused a delay of one day.
• The boiler grates malfunctioned and required cleaning. This
resulted in down time of one day.
• Sampling equipment malfunctions caused further delays. This was
due to:
1) Difficulty in containing leaks during equipment operation.
2) Failure of oven box heaters.
3) Drift problems of the Beckman 865 CO analyzer. The analyzer
had to be taken off line and subsequent inspection by manu-
facturer indicated that the stationary shutters were knocked
out of alignment. This resulted in the loss of 4 days of CO
data before a replacement was obtained.
7.2 RECOMMENDATIONS
Most of the above problems frequently occur in the field and should be
considered normal during the course of a major field effort. The instrument
problem may have been caused during shipment. Perhaps, stronger shipping
containers should be used in the future.
7-1
305
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7. Autner(i) v*j.a^cui»c oaj»J.c auu .jwuu >>baiLxcy \iict_LJ j _ p
Carter Nulton (SWBI) wiiijam Yauger. Jr. (GSRI) _ _ |_ _^'
REPORT DOCUMENTATION >•- BE^-IT NO. • j.
. . . PAGE _______ 1.^0/5=83=004 ________ __________ J __
4. Tme ami subtitle Comprehensive Assessment of Specific Compounds
Present in Combustion Processes. Vol. 1. -Pilot study of
Combustion Emissions Variability.
is. 8w:iB,.0,-, Ac5t««m «»
*•
Clarence-Halle and John Stanley (m)
o»u
June 1983
9. Performing Or^anitiition Namn and Acdrns
Midwest Research Institute
425 Volker Blvd.
Kansas City, MO 64110
; Task-3
; "* Canlf»et(C) °' Cf»n" No-
!« 68-01-5915
12. SoaiKorine Orjan.iation Nam* and Address
Field Studies Branch, EED,TS-798
US EPA
401 M St. SW
_ Washington, _ pc_2 04 60
IS. Suooi«n-«nt*ry Mete*
13. Typ. o( R>Dorl
Final
Cov«rtd
F.W. Kutz, Project Officer
D.P. Redford, Task Manager
is. Ab«raei (L-m,:: 200 -or,™
Th±s piloc sCudy was conducted as a prelude to a nation wide survey of
organic emissions from major stationary combustion sources. The primary objectives of
the pilot study were to obtain data on the variability of organic emissions from two such
sources and to evaluate the sampling and analysis methods. These data are used to
construct the survey design for the nationwide survey. The compounds of interest are
polynuclear aromatic hydrocarbons (PAHs) and chlorinated aromatic compounds, including
polychlorinated biphenyls (PCBs) , polychlorinated dibenzo-p-dioxins (PCDDs) , and
polychlorinated di-benzofurans (PCDFs). Of particular interest is 2,3,7,8-
tetrachlorodibenzo-p-dioxin (TCDD). In addition total cadmium was also determined
in special samples from both plants to meet special Environmental Protection Agency
(EPA) needs.
A summary of the results of this study is contained in Section 2 of this report.
Section 3 presents recommendations for future work. Brief descriptions of the two
combustion sources are contained in Section 4. The sampling and analysis methods are
described in Sections 5 and 6. Sections 7 and 8 present the field test data
and analytical results. The analytical quality assurance results are summarized in
Section 9. Section 10 presents the emissions results and Section. 11 is a statistical
summary of the emissions results.
17. Oaeurtant Analysis a. Descriptors
Combustion, Emissions, Sampling and Analysis
S. lacnti(i«rj/Ooen-£nO«a Term,
PAH,PCDD,PCDF,POM
c. COSATI r.eld/G«nuo
13. Availaoility Statement
Release to public
19. Security Class (This Reoort)
Unclassified
I 21. No. of Paces
305
• UnciassMed"!"*
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