EPA-600/4-77-014
March 1977
Environmental Monitoring Series
                      REGIONAL  AIR  POLLUTION STUDY
                                    Point  Source  Emission
                                                     Inventory
                                      Environmental Sciences Research Laboratory
                                           Office of Research and Development
                                           U.S. Environmental Protection Agency
                                     Research Triangle  Park, North Carolina 27711

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                 RESEARCH REPORTING SERIES

 Research reports of the Office of Research and Development, U.S. Environmental
 Protection Agency, have been grouped into nine series. These nine broad cate-
 gories were established to facilitate further development and application of en-
 vironmental technology.'Elimination  of traditional grouping was  consciously
 planned to foster technology transfer and a maximum interface in related fields.
 The nine series are:

      1.  Environmental Health Effects Research
      2.  Environmental Protection Technology
      3.  Ecological Research
      4.  Environmental Monitoring
      5.  Socioeconomic  Environmental Studies
      6.  Scientific and Technical Assessment Reports (STAR)
      7.  Interagency Energy-Environment Research and  Development
      8.  "Special" Reports
      9.  Miscellaneous Reports

This report has-been assigned to the ENVIRONMENTAL MONITORING series.
This series describes research conducted to develop new  or improved methods
and instrumentation for the identification and quantification of environmental
pollutants at the lowest  conceivably significant concentrations. It also includes
studies to determine the ambient concentrations of pollutants in the environment
and/or the variance of pollutants as a  function of time or meteorological factors.
This document is available to the public through the National Technical Informa-
tion Service, Springfield, Virginia  22161.

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                                         EPA-600/4-77-014
                                         March 1977
       REGIONAL AIR POLLUTION STUDY
      Point Source Emission Inventory
                    by
             Fred E.  Littman
            Robert W.  Griscorn
               Otto Klein
          Air Monitoring Center
         Rockwell International
          Creve Coeur, MO   63141
           Contract 68-02-1081
              Task Order 55
              Project Officer

          Francis A.  Schiermeier
       Regional  Air Pollution Study
Environmental Sciences Research Laboratory
        11640 Administration Drive
           Creve Coeur, MO 63141
ENVIRONMENTAL SCIENCES RESEARCH LABORATORY
    OFFICE OF RESEARCH AND DEVELOPMENT
   UpSo ENVIRONMENTAL PROTECTION AGENCY
    RESEARCH TRIANGLE PARK, N.C. 27711

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                                   DISCLAIMER
     This report has been reviewed by the Environmental Sciences Research
Laboratory, U.S. Environmental Protection Agency, and approved for publication.
Approval does not signify that the contents necessarily reflect the views aiid
policies of the U.S. Environmental Protection Agency, nor does mention of trade
names or commercial products constitute endorsement or recommendation for use.

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                                    ABSTRACT
     Emissions data from stationary point sources in the St. Louis
Interstate Air Quality Control Region  (AQCR) have been gathered during
the calendar year of 1975.  Data for "criteria" pollutants will be
available on an hourly basis.  Emissions from large sources are based on
hourly, measured values of pertinent operating parameters.  Those from
smaller sources, between 10 and 1000 tons per year are based on annual
data modified by a detailed operating pattern.

     An emission factor verification program has been initiated.  It is
carried out by source testing of typical sources using standard EPA
methods.  Results obtained so far indicate good agreement for SO
values.  The data obtained for NO  and particulates originating from
combusion sources tend to indicate that the existing factors are too
high by variable but substantial amounts.
                                   iii

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                               CONTENTS

ABSTRACT

FIGURES

TABLES                                                                viii

    1.0  SUMMARY                                                          1

    2.0  INTRODUCTION                                                     2
                        e
    3.0  EMISSION DATA ACQUISITION                                        3

    4.0  EMISSION FACTOR VERIFICATION STUDIES                             7
         4.1  INTRODUCTION                                                7
         4.2  DISCUSSION: METHODS AND RESULTS                            '8

    5.0  CONCLUSIONS                                                     15

    APPENDIX  I:   EMISSION FACTOR CALCULATIONS                           16

    APPENDIX  II:  SOURCE TEST REPORTS                                    24
         ILLINOIS POWER CO/WOOD RIVER PLANT/ALTON, ILLINOIS               25
          APPENDIX A:  PARTICULATE CALCULATIONS                          52
          APPENDIX B:  FIELD DATA                                        74
                                                      »
         HIGHLAND POWER AND LIGHT/HIGHLAND,  ILLINOIS                     104
          APPENDIX A:  PARTICULATE CALCULATIONS                         130
          APPENDIX B:  FIELD DATA                                       141
         CARLING BREWING CO/STAG BREWERY
         BELLEVILLE, ILLINOIS                                            155
          APPENDIX A:  PARTICULATE CALCULATIONS                         173
          APPENDIX B:  FIELD DATA                                       186

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                   TABLE OF CONTENTS (CON'T)

                                                               PAGE
GENERAL MOTORS ASSEMBLY DIVISION/ST. LOUIS, MO.
  APPENDIX A:  PARTICULATE CALCULATIONS                        239
  APPENDIX B:  FIELD DATA                                      252
AMOCO OIL REFINERY/WOOD RIVER, ILLINOIS                        271
  APPENDIX A:  PARTICULATE CALCULATIONS                        297
  APPENDIX B:  FIELD DATA                                      313

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                                FIGURES







Number                                                           Page




  1       RAPS MAJOR POINT SOURCE EMISSIONS                        4




  2       POINT SOURCE LISTING                                     6
                                     vii

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                                   TABLES


Number                                                           Page

   1      COMPARISON OF MEASURED AND CALCULATED FLOWS              9

   2      COMPARISON OF SO  EMISSIONS BASED ON CALCULATED
          AND MEASURED FLOWRATES                                  12

   3      COMPARISON OF "STANDARD" AND EXPERIMENTAL
          EMISSION FACTORS                                        13
                                    viii

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                             1.0  SUMMARY

     Emissions data from stationary point sources in the St.  Louis Inter-
state AQCR have been gathered during the calendar year of 1975.   Data for
"criteria" pollutants - S02> NCL, Particulates, CO and Hydrocarbons - will
be available on an hourly basis.  Emissions from large sources are based
on hourly, measured values of pertinent operating parameters.  Those from
smaller sources, between 10 and 1000 tons per year of S02, for example,
are based on annual data modified by a detailed operating pattern.
     An emission factor verification program has been initiated.  It is
carried out by source testing of typical sources using standard EPA meth-
ods.  Results obtained so far indicate good agreement for S02 values.  The
data obtained for N0» and particulates originating from combustion sources
tend to indicate that the existing factors are too high by variable but sub-
stantial amounts.
                                   -1-

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                           2.0  INTRODUCTION

     This is the third of a series of reports describing the operation of the
Regional Air Pollution Study (RAPS) Point Source Emission Inventory.   The two
prior reports dealt with the methodology (EPA 450/3-74-054) and the first six
months of operation of the inventory (SC553.T016FR).   This report describes
the data acquisition for May through December 1975, as well as the emission
factor verification program carried out by stack sampling during the same
period.
                                  -2-

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                         1. -'
                    3.0  EMISSION DATA ACQUISITION

     During the period of 1 May to 31 December 1975, the collection of
hourly, measured data from all major sources of S02 was continued.  The
methodology used is described in detail in "Point Source Emission Inven-
tory - Final Report, Task Order 16, Phase II" EPA Contract No. 68-02-1081,
dated May 1975.
     Hourly process or consumption data covering 145 points were recorded
and coded on punched cards as described in the same report.  The cards were
verified and processed through an editing routine (also described in the
named report).  The information was then transferred to the Univac 1110
computer at the National Environmental Research Center at Research Triangle
Park, NC.  Major point sources in the St. Louis AQCR are shown in Figure 1.
     The emissions from 60 smaller sources were obtained and recorded as
annual data, together with the operating patterns.  The pattern is capable
of indicating the actual operating hours, operating days (in Julian form)
and weekly patterns by days..  For example, the entry
     D:2-48, 50-184, 186-244, 246-365, W:l-5, H:8-17
denotes the operation of a plant which normally operates Monday through
Friday (W:l-5), from 8 AM to 5 PM (H:8-17), but is closed down for New
Year's (D:l), Washington's Birthday (D:49), Independence Day  (0:185), and
Labor Day (D:245).  If an hourly output for a specific hour and day is
requested, the computer will first make sure the plant was operating that
day, then divide the annual number by the actual number of hours of oper-
ation for a 5 day week, 9 hours a day operation, less the number of days
when the plant was shut down.
     A 3 month long strike at Union Electric Company delayed  the acquisition
of data from all U.E. plants; however, since the resumption of normal con-
ditions, the delayed data are forthcoming.
                                  -3-

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                                       ArVROX.
           MAP NO.          SOURCE      TON/VH SOz
             1     Union Etactric - So««       116.000
             2     Illinoh Font - Wood Riw     73.000
                   LlctadtSM                 375
                   Alton Ion lonl            13.000
                   0»m m.non Gtai            300
                   Amoco Oil Rriinry          12.000
                   SnrtlOillMinvv            30.000
                   AflUnCo.                  2.500
                   Ctok Oil MiMry            « 000
             10     Qwiiu City SM             2.000
             11     Union Etactric - Vimoi       25.000
             12     AMAX Zinc                1.500
             13     EoVnnCoopv                MO
             14     MoniMrto. - WG Krummrich     12.000
             IS     Union ElKtric - CHiokil       10.000
             1*     Sti|Bn<«ty                 000
             17     Illmoil fow« - B^dwtn      200.000
             16     Hifhlml Etactric             1.400
             19     Union Etactric - Ktarune      90.000
             20     N.L. IndiMtrin               9.000
             21     QnMUknCvbon            700
             22     MBteOmtm                500
             23     Anhwrlwft              2.SOO
             24     Momma -If Ouonr        2.000
             25     Union Etactric - KMn        4,«00
            M     rvoinl.                   I ,«00
            27     ammMonn               1.600
            21     Utaowirarttond              900
            29     Union EKctric - Ukltfta      200.000
            30     HWinnon Un, - ImSt 9n.     160
            31     «H»liHi»ii Urn.. - Cmmn       360
                        RAPS
             Major  Point  Source
                     Emissions
                  FIGURE  1
sr loots

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     Arrangements are being made with all companies furnishing data to
continue the data collection through 1976.  It appears that most, if not
all, companies will again cooperate in this effort.
     Once the necessary output programs become fully operational, it will
be possible to obtain emissions for criteria pollutants emanating from
stationary sources for any one-hour period in the St. Louis AQCR for the
calendar year of 1975.  The information for hydrocarbon emissions will be
refined and supplemented under a separate task order next year.
     A typical printout, showing hourly data for Particulates, SO^, N(L,
Hydrocarbons (HC) and CO, is shown in Figure 2.  The printout gives name
and address of the source, its classification, location in UTM coordinates,
stack parameters, fuel analysis and method of calculation, in addition to
the emission values.
                                   -5-

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       08/25/75
                                                                                                                                  PAGE:
                                         RAPS  ST.  LOUIS  EMISSION  INVENTORY

                                                          ******************************
                                                          *    POINT SOURCE LISTING    *
                                            03? UNION ELECTRIC CO
                                                HIGHWAY M LABADIE 63055
                                          5200: MISSING "STATE OR CITY CODE
                                          16801 FRANKLIN CO
                                            26J MISSOURI
                                                                           STACK ID: 0:1.
                                                                           POINT" IDS 0:1.
                                                                           SIC! 4911
                                                                           AQCR: o?o
                                                                           OWNERSHIP: UTILTY
                             SCCU--01-002-01 >:EXTCOMB BOILER   - ELECTRIC GENERATN- BITUMINOUS COAL
                      UTM GRID COORDINATES
                      ********************
                      UTM ZONE: is
                      HORIZONTAL:  688.37 KM
                      VERTICAL:  4270.23 KM
                                     STACK  PARAMETERS
                                     ****************
                                     STACK  HEIGHT:   700  FT
                                     STACK  DIAMETER:   20.5  FT
                                     GAS  TEMPERATURE:  285  F
                                     GAS  FLOW  RATE:  1600000 CFM
                                     BOILER CAPACITYJ5387 MBTU/HR
                 EMISSION  FACTORS
                 ft***************
                 PART!
                 sox:
                 NOX :
                 HC :
                 co:
                   AP-42
                   AP-42
                   AP-42
                   AP-42
                   AP-42
                                                                                           >:I.OOMMBTU PULVWET

                                                                                                  FUEL CONTENT
SULFUR:  3,05 %
ASH:    10,11 7,
HEAT:   21,99 MBTU/SCC
i
Ol
*PRIMARY CONTROLS*
PAR r; ELECTROSTATIC PRECIPITATOR-HIGH  EFFICIENCY
SOX,'  NO EQUIPMENT
NOX:  NO EQUIPMENT
HC:   NO EQUIPMENT
CO!   NO EQUIPMENT
                                                                 CONTROL EQUIPMENT
                                                                 *****************

                                                                 *SECONDARY CONTROLS*
                                                                 PART: NO EQUIPMENT
sox:
NOX:
HC :
co:
NO EQUIPMENT
NO EQUIPMENT-
NO EQUIPMENT
NO EQUIPMENT
            *EFFICIENCIES*
                98.0 7.
                  .0 %
                  .0 %
                  .0 %
                  ,0 X
                                                          * * * * EMISSIONS IN LBS * * * *
DATE
********
10/
10/
10/
10/
10/
10/
10/
10/
10/
10/
1 0/
10/
10/
10/
10/
10/
10/
10/
10/
1C/
10/
10/
to/
1/74
1/74
1/74
1/74
1/74
1/74
1/74
1/74
1/74
1/74
1/74
1/74
1/74
1/74
1/74
1/74
1/74
1/74
1/74
1/74
1/74
1 / 74
j./y»
HOUR
****
0
1
2
3
4
5
6
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
                                             PART
                                          **********

                                             497.92
                                             505.42
                                             540.76
                                             478.65
                                             475.44
                                             476.51
                                             522.55
                                             542.90
                                             482.93
                                             447.60
                                             452.95
                                             455.09
                                             458.30
                                             458.30
                                             454.02
                                             528.98
                                             531.12
                                             533.26
                                             534.33
                                             538.62
                                             537.54
                                             534.33
                                             493.64
                                                      SOX
                                                   **********

                                                    21954.44
                                                    22284.94
                                                    23843.00
                                                    21104.60
                                                    20962.95
                                                    21010.17
                                                    23040.36
                                                    23937.43
                                                    21293.45
                                                    19735.39
                                                    19971.46
                                                    20065.89
                                                    20207,53
                                                    20207.53
                                                    20018.68
                                                    23323.65
                                                    23418.07
                                                    23512.50
                                                    23559.72
                                                    23748.57
                                                    23701.36
                                                    23559.72
                                                    21765.59
                    NOX


                   5682.77
                   5768.32
                   6171.61
                   5462.79
                   5426.13
                   5438.35
                   5963.86
                   6196.06
                   5511.68
                   5108.38
                   5169.49
                   5193.93
                   5230.60
                   5230.60
                   5181.71
                   6037.18
                   6061.62
                   6086.07
                   6098.29
                   6147,17
                   6134.95
                   6098.29
                   5633.89
                                   HC


                                   56. (33
                                   57.68
                                   61.72
                                   54.63
                                   54.26
                                   54.38
                                   59.64
                                   61.96
                                   55.12
                                   51.08
                                   51.69
                                   51.94
                                   52.31
                                   52.31
                                   51.82
                                   60.37
                                   60.62
                                   60.86
                                   60.98
                                   61.47
                                   61.35
                                   60.98
                                   56.34
                CO
            **********

               189.43
               192.28
               205.72
               182.09
               180.87
               181.28
               198.80
               206.54
               183.72
               170.20
               172.32
               173.13
               174,35
               174.35
               172.72
               201,24
               202.05
               202.87
               203.28
               204.91
               204.50
               203.28
               187.80
                                                        FIGURE 2 -  POINT SOURCE LISTING

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               4.0  EMISSION FACTOR VERIFICATION STUDIES

4.1  INTRODUCTION
     Emission estimates are based on consumption or production figures from
which emissions are calculated using an emission factor.   Emission factors
are averaged numbers relating emissions to consumption or process data.   In
some cases, the relationship is direct and relatively uncomplicated.   For
example, for every ton of bituminous coal burned, a total of 38S^ pounds  of
sulfur dioxide is produced, where S^ indicates the sulfur content of the
fuel, on a weight percent basis.  Thus, if a plant burns 100 tons of 3%  sul-
fur coal per hour, it emits
                           100 x 38 x 3 = 11,400
11,400 Ibs of S02 per hour.  Since in this particular case the sulfur is
contained in the fuel and is converted virtually completely to S02, the
numbers resulting from the use of the emission factor are quite accurate and
reliable.
     If, on the other hand, we wish to determine the amount of oxides of
nitrogen produced by the same operation, a somewhat different situation
ensues.  The emission factor for a boiler burning bituminous coal, as given
in the EPA publication AP-42 "Compilation of Air Pollution Emission Factors",
varies with both boiler type and size, from 6 to 55 Ibs. of NOX per ton of
coal.  This is because the factors affecting NO^ production include flame
and furnace temperature, residence time of the combustion gases, rate of
cooling, amount of excess air, as well as the amount of nitrogenous com-
pounds in the fuel.  Thus, the emission factor of 18, which is applicable
to a pulverized coal boiler of this size, is an averaged value.  Actual  values
may depart significantly from the numbers obtained by such a factor.
     In order to improve the accuracy of the emission inventory gathered at
St. Louis, a number of representative sources were sampled and their stack
effluents analyzed.  An attempt was made to encompass a wide variety of the
larger point sources: large and medium sized power plants burning coal, fuel
oil and gas; industrial boilers of different types and sizes; and  industrial

                                   -7-

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operations, such as catalyst recovery units in a petroleum refinery, known
or  suspected of being major sources of pollution.
     The  program is an ongoing one; during 1975, the following sources were
sampled:
     Illinois  Power's Wood River Power Plant
           Boiler No. 1, operated on gas
           Boiler No. 1, operated on fuel oil
           Boiler No. 4, operated on coal
     Highland  Power Plant, Highland, Illinois

           Boiler No. 3, operated on coal
     Stag Brewery, Belleville, Illinois
;           Boiler No. 1, operated on coal
     General Motors Power Plant, St. Louis
           Boiler No. 2, operated on coal
     Amoco Refinery, Hartford,  Illinois
           Boiler No. 6, operated on oil and gas
           Catalyst Regeneration Unit
Complete  stack sampling reports are attached as  Appendix II.

4.2 DISCUSSION:  METHODS AND RESULTS
     In general, the test methods  specified in the Appendix of  Part 60,  CFR
Title  40,  "Standards of Performance for New Stationary  Sources" were used.
The methods include:
       Method  1 - Sample and Velocity Traverses
               2 - Determination of Stack Gas Velocity
               3 - Gas Analysis for C02, Excess Air and  Dry Molecular Weight
               4 - Determination of Moisture in Stack Gases
               5 - Determination of Particulate Emissions
               6 - Determination of S02 Emissions
               7 - Determination of Nitrogen Oxide Emissions
                                   -8-

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The only deviation from these methods was the use of a higher probe and
oven temperature in Method 5. .A temperature of 325° was used instead of
250°F to avoid any problems with condensation of sulfuric acid.
     Serious problems were encountered with stack gas velocity measurements
using Method 2.  Using mass balance methods as a check, it became apparent
that the values obtained with an S-type pi tot tube, used in accordance with
Method 2, were too high by varying, but substantial amounts.  Reproduci-
bility was adequate, and repeated calibration of the pitot tube indicated
that correct readings were obtained.  A careful check of the literature
indicated that high readings had been,observed by other investigators.
                                      : ,  • •      .;•.*,
Burton (1) indicated that values of 104 to 150% of the rated value can be
obtained.  Grove (2) presented data indicating that a) significant errors
are always.positive and b) they can be very large.  The most common source
of errors is due to cyclonic flow, unfortunately a fairly common occurrence
in power plant stacks, where "double entry" stacks (two boilers feeding one
stack) are frequently used.
                                TABLE 1
            COMPARISON OF MEASURED* and CALCULATED** FLOWS    '
Location
Wood River #1
Wood River #4
Highland Power
Stag Brewery
Monsanto
General Motors
Amoco
Flow, SCFH
Measured Calculated
10,086,750
17,981,280
1,386,070
1,394,990
1,687,655
1,598,005
2,543,040
8,237,263
13,089,200
910,920
782,900
1,563,000
1,434,847
-
% A
+22.5
+37.4
+52.2
+78.2
+ 8.0
+11.4
-
*   Using  S-type  Pi tot  tube,  EPA  Method  2
**  Based  on  stoichiometry and  excess  air.
(1)   Burton,  C.S., Quantisation of Stack Gas  Flow.  Jnl.,  APCA  22,  pp.  631-
      635  (1972).
(2)   Grove, D.O.  and  Smith, W.S.,  Pi tot  Tube  Errors due  to  Misalignment and
      Non-streamlined  Flow.  Stack  Sampling  News,  1974.

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     One way of ascertaining the correctness of the data is by comparing
the mass flow of S02 calculated from fuel  consumption and sulfur analysis
of the fuel, on one hand, with the value obtained from stack gas flow and
analysis, on the other.  The former is calculated according to Eq.  1

     WS02=Wcx38xS  •                                      (1)

where
     WJQ  - weight of S02 produced, Ibs/hr

     W    - weight of coal consumed, Tons/hr
     S    - % sulfur in coal, dry basis
This value should be equal to one obtained from EQ. 2

      S02    S02    S  '                                        (2)

where
     Ccn  - Concentration of S09 in stack gas, Ibs./SCF
      Owo                      £
     Qs   - Stack gas flow rate, SCF/hr
                                  -10-

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For example, the flow rate for Boiler #4 at Wood River was calculated thusly:
                               Boiler #4                    n	 ..   .  , _
Composition of Coal
C
H2
S
°2
N2
H20
Ash
61.43%
4.38
3.21
9.67
1.11
(moisture)11.82
8.55
Lb-mols/100
5.12
(2-19)
0.10
0.30
0.04
(0.66)

Ibs Coal
(1)
(2)
(3)

(4)
(2)

uxyyen Kequirea rur
Combustion, mols
5.12
.0-09) ,
0.10
-.30
-
-

Chlorides 0.02

100.19


6.01 mols oxyq<
                                         Average Excess Air: 40%   2.40
                                         Total                     8;41 ••••"-•
                                         Corresponding Nitrogen   31.77
Assumed reactions:
(1)  C + 02  -»• C02
(2)  Excluded from calculation for dry flue gas
(3)  S + 02  •* S02
(4)  Oxidation reaction uncertain
Dry flue gases per 100 Ibs coal, Ib-mols:
     C02             5.12
     S02             0.10        Ib-mol x 386 = SCF
     02              2.40
     N2              0.04
     Air Nitrogen   31.77
Total               39.43       =   15,220 SCF/100#

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                                 TABLE 2
                   COMPARISON OF S02 EMISSIONS BASED ON
                    CALCULATED AND MEASURED FLOWRATES
Location
Wood River #1 (oil)
Wood River #4
Highland Power
Stag Brewery
General Motors
Amoco (boiler)
(catalytic cracker)
WSQ - Weight of S02 Produced, Based on
Emission Factor
153 Ibs/hr
5245
414
75
479
309
708
Calc. Gas Flow
178 Ibs/hr
5104
433
82
472
-
Measured Gas Flow
217 Ibs/hr
7035
658
125
546
320
354
     For this reason, calculated flow rates were used whenever there was an
indication of non-linear flow in the stack, as indicated by the fact that
turning the pitot tube 90° on axis did not give a zero reading on the manometer.
     Using the most reliable available results, experimental emission factors
were calculated for S02> NOX and particulates for the sources tested so far.
These emission factors are compared with "standard" emission factors, taken
from AP-42, in Table 3.  Calculations are shown in Appendix I.
                                  -12-

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                                                         TABLE 3
                               COMPARISON OF "STANDARD" AND EXPERIMENTAL EMISSION FACTORS

Location
Wood River #1 (gas fired)(1)
#1 (oil fired)(2)
#4 (coal fired)(3)
Highland Power (coal fired)^
Stag Brewery (coal fired)'3^
General Motor (coal fired)^
Amoor 'Boiler #6
Cat. Cracker Recovery^ '
Standard Emission Factors
S02*
-
144S
38S
38S
38S
38S
160S
493
NOX
600
105
18
15
15
15
69
71
Part**
10
8
17A
5A
5A
13A
20
242
CO
17
3
1
2
2
2
1
-
HC
1
2
0.3
1
1
1
.3
220
Experimental Emission Factors
S02*
-
168S
37S
40S
41 S
37S
-
246
NOX
105
16
1.4
4.1
7.21
10.8
-
153
Part**
-
1 .0'
10. OA
.4A
1.9A
23.6
-
360
CO
2.8
.4


.3-i
.7
-
-
HC
-
.17
.02

.14
.03'
-
.48
CO
I
          *s
         **A
         (1)
         (2)
         (3)
         (4)
-  percentage sulfur in fuel
-  percentage ash in fuel; emissions before control equipment
-  Ibs per 106 cu. ft.
              3
-  Ibs. per 10  gal. Both process gas and fuel oil were burned simultaneously.
-  Ibs. per ton of coal
-  Ibs. 103 bbl fresh feed.
   Unit equipped  with'electric precipitator and CO boiler -

-------
     Even though relatively few^source tests have been run so far,  certain
conclusions can be drawn from the results obtained:
     1.  Determinations of stack gas volumes according to EPA Method 2 is
         uncertain.  Incorrect results are obtained  in a high number of
         cases, since the basic assumption of laminar flow, parallel to
         the walls of the stack does not pertain in  many cases.
     2.  Engineering calculations of mass flow,  based on ultimate analysis
         of the fuel and determinations of the excess air in the stack gases,
         give reasonably accurate results.  This is  borne out by sulfur bal-
         ance calculations.  For example, the average experimental  emission
         factors for SOp for coal burning installations comes out to 38.755^
         compared with 38S^ suggested in AP-42.
     3.  The emission factors shown in Table 3 are applicable to the specific
         installations for which they were obtained.  However, definite pat-
         terns appear to exist, which seem to have more general  validity:
           a)  Emission factors for NO^ for combustion sources appear to be
               too high by a variable, but substantial margin.  The experimen-,
               tally obtained factors range from a low of 7.7% to 72% of the
               applicable AP-42 factors.
           b)  Experimental emission factors for particulates similarly vary
               from 8 to 58% of the applicable AP-42 factors for installations
               which do not have precipitators.   In the presence of the latter,
               their assumed efficiency becomes an overriding factor.
           c)  Hydrocarbon and CO emissions, which are rather insignificant
               for combustion sources, likewise run less than suggested by
               AP-42 factors.
                                 -14-

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                           5.0  CONCLUSIONS

     The RAPS Point Source Emission Inventory has produced an extensive and
accurate data base with an hourly resolution for the base year of 1975, with
a temporal resolution of 1 hour for the important point sources in the AQCR-
70.
     The emission factor verification program, though somewhat limited in
scope, indicates that good accuracy can be expected from the SO^ inventory.
Estimates for oxides of nitrogen and particulates appear to be on the high
side and may have to be adjusted by changes in the emission factors.
     The continuation of the program for another year will do much in im-
proving the definition of the data obtained so far.
                                  -15-

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         APPENDIX I
EMISSION FACTOR CALCULATIONS
              -16-

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                     EMISSION FACTOR CALCULATIONS


WOOD RIVER fl - GAS FIRED

Burn Rate: 580 x 103 SCF/hr   Sulfur:  -   Ash:   -    Flow Rate:  8,237,280  SCFH

     N0.x expected .580 x 600 = 348 Ibs/hr
         found: 7.4 x 106 Ibs/SCF (average)

                7.4 x 106 x 8,237,280 = 60.9 Ibs.
                                           j

         Experimental EMFAC: 600 x 60.9 =105
                                   348
     CO  expected:  .580 x 17 =9.9 Ibs/hr
         found: 2.5 ppm

                2.5 x 106 x 8,237,280 x 28.3 x 28   x  2.205  x 103  = 1.6 Ib/hr
                                               22,4
         Experimental  EMFAC:  17 x 1.6 = 2.76
                                  9.9

WOOD RIVER #1 - OIL FIRED

Burn Rate:  3.66 x 103  gal/hr   Sulfur: .29% Ash:    -    Flow Rate: 8,237,263 SCFH

     Sp_2  expected:  3.66 x 144 x .29 = 152.8 Ibs/hr
          found:   178.0 Ibs/hr


          Experimental  EMFAC:   144 x 178   =167.7
                                     152.8


     NOX  expected:  3.66 x 105 = 384.3 Ibs/hr
          found:   7.1 x 106 x  8,237,263 =  58.5 Ibs/hr
                                           i

          Experimental  EMFAC:   105 x 58.5   =16.0
                                     384.3
                                 -17-

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                     EMISSION FACTOR CALCULATIONS
     C0_  expected:  3.66 x 3 « 11.0 Ibs/hr
         found:  2.5 x 10"6 x 8,237,263 x 28.3 x 28  = .635 = 1.6 Ibs/hr
                                            J   454
         Experimental EMFAC:  3 x 1.5   = .44
                                  11.0
     PARTICULATE   expected: 3.66 x 8 = 29.3 Ibs/hr
                   found: 4.55 x 107 x 8,237,263 = 3.7  Ibs/hr
                   Experimental EMFAC:  8 x 3.7  _ ,  n
                                           29.3 " l>u
     HC_  expected:  3.66 x 2 = 7.3 Ibs/hr

         found:  1.7 ppm

                 1.7 x 10"6 x 8,237,263 x 28.3 x 16  » .635 Ibs/hr
                                          22.4   454

         Experimental EMFAC:  2 x.635 = .17
WOOD RIVER #4 - COAL FIRED

Burn Rate: 43 T/hr   Sulfur: 3.21%   Ash:   10.95%  Flow Rate:  13,089,200 SCFH

         expected:  5245 Ibs/hr

         found:  5104 Ibs/hr
         Experimental  EMFAC:   38 x 5104 = 36.97
                                   5245

    ,NOX expected:   18 x 43 = 774 Ibs/hr

         found:   4.46  x 106 Ib/SCF

                 4.46  x,106 x 13,089,200 = 58.37 Ibs/hr
         Experimental  EMFAC:   18 x 58.4 = 1.36
                                   774"

                                  -18-

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                     EMISSION  FACTOR CALCULATIONS


     Particulates:   expected:   43  x 17  x  10.95 = 8004 Ibs/hr

                    Less:   Precipitator at 99.5% off = 7964

                                                      40 Ibs/hr
                    found:  23.45 Ibs/hr
                    Experimental  EMFAC:   17 x 23.5  = 9.96
                                              40

     HC_  expected:   43 x .3  =  12.9  Ibs/hr
         found:   1.3 ppm

                 1.3 x 106 x 13,089,200  x 28.3 x 16_ = .76 Ibs/hr
                                         22.4   454

         Experimental  EMFAC: .3 x .76  = 0.018
                                  12.9

HIGHLAND POWER COMPANY
Burn Rate:  6702 Ibs/hr    3.25% Sulfur     10.98% Ash    Flow Rate:  910,920

     S02:   expected:   414 Ibs/hr
           found:  433 Ibs/hr


           Experimental  EMFAC:   38  x  433  = 39.7
                        „             4T4        ,     .

     NOY:   expected:   6702 x 15 =  50.26  Ibs/hr
       A              2000
           found:". 1.5 x 105  x  910,920  =  13.66 Ibs/hr


           Experimental  EMFAC:   15  x  13.7 =4.1
                                     50.3

     Parti culates:   expected  6702  x  5  x  1.95 =183.5 Ibs/hr
                             2000   '
                    found:  1.76 x  10D  x  910,920 =16 Ibs/hr
                    Experimental  EMFAC:   5  x    —  = 0.44
                                            183.5
                                 -19-

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                     EMISSION  FACTOR CALCULATIONS


STAG BREWERY

Burn Rate:   3604 Its/hour       Sulfur:  3.25%     Ash  10.98%  Flow Rate: 782900
                                                                            SCFM

     S02  expected:   74.9       81.4 Ibs/hr

          founded:    79.0       91.1 Ibs/hr


          Experimental  EMFAC:   38 x 79  = 40.1  38 x 91.1 • 42.5
                                   749              8TT


     NOY  expected:   3604  x 15 - 27.0 Ibs/hr
       A             2000  ,
          found:  1.65 x 10° Ibs/SCF

                  1.65 x 105 x 782,900 = 12.9 Ibs/hr


          Experimental  EMFAC:   15 x 12.9  =7.16
                                   ~TT

     Particulates  expected:  3604  x 5 x 10.98 = 98.9 Ibs/hr
                              2000

                   found:  37  Ibs/hr


                   Experimental  EMFAC:  5x37  =1.87
                                          9879

     Hydrocarbons:   expected:  3604 x 1 = 1.8 Ibs/hr
                              2000
                    found:   7  ppm

                            782,900 x 7 x 106 x 28.3  x  16 =  .24  Ibs/hr
                                               22.4   454

                    Experimental EMFAC:  1 x  .24  -  .14
                                            Ot


     CO  expected:   1.802 x 2  = 3.6 Ibs/hr

         found:   8.9 ppm =  .54 Ibs/hr


         Experimental  EMFAC:  2 x ^54  =  .30
                                . 3.6

                                  -20-

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                     EMISSION FACTOR CALCULATIONS


GENERAL MOTORS
     S02  expected:  479 Ibs/hr
          found:  472 Ibs/hr
          Experimental EMFAC:  38 x 472 = 37.4
                                    479

     NOY  expected:  7491  x 15 = 56.2 Ibs/hr
       A             2000  ,
          found:  2.81 x 105 x 1,434,847 = 40.3 Ibs/hr
          Experimental EMFAC: 15 x 40.3 =10.8
     Particulates  expected:  749T  x 13 x 10.9 = 531  Ibs/hr
                              2000
                                                  520
                                                      Ibs/hr
less:  Precipitation at 98%   2£±

found:  1.396 x 105 x 1,434,847 =  20.0 Ibs/hr
                   Experimental EMFAC:  13 x 20 = 23.6
                                             IT

     CO  expected: 7491  x 2 = 7.5 Ibs/hr
                   2000

   /      found:  1,434,847 x 25 x 106 x 28.3  x 28_   =2.8 Ibs/hr
                                        22.4    454

         Experimental EMFAC:  2 x 2^8 = .74
                                  7.5

     HC  expected:  7491 x 1 = 3.8 Ibs/hr
                    2000

         found:  1,434,847 x 1.8 x 106 x 28.3  x 1_6  = .11 Ibs/hr
                                         22.4    454

         Experimental EMFAC:  1 x .11  = .03
                                 3.8
                                 -21-

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                     EMISSION FACTOR CALCULATIONS


AMOCO - BOILER #6

Burn Rate:  64,063 SCF/W Refinery Gas  308 gal/hr Fuel  Oil   Sulfur 3.5%f
Flow Rate:  21,453,040                                             1.4%
                                        *
     S09  expected: 64.063 x 3.5 x 1.069  = 239.7   *Spec.  Emission Factor
       c            .308 x 1.4 x 160 =       68.9
                  I                          308.6

          found:  1.26 x 104 x 2,543,040 = 320.2 Ibs/hr


AMOCO - CATALYTIC CRACKER RECOVERY

Feed Rate: 34,485 bbl/day fresh feed        Flow Rate:  5,160,271

     S09  expected:  34.485 x 493 x 1   =         708 Ibs/hr
                                   24  ,
          found:  5,160,271 x 6.853 x!0s = 353.6 Ibs/hr


          Experimental EMFAC:  493 x 354 = 246.3
                                     708

     NOY  expected: 34.485 x 71 x 1   = 102.0 Ibs/hr
                           ,     W
          found:  4.26 x 10s x 5,160,271 = 219.8 Ibs/hr


          Experimental EMFAC:  71 x 220  =153
                                    102

     Particulates  expected:  34,485 x 242 xj_  = 347.7 Ibs/hr
                                            24
                   less precipitator at 94%       327.9
                                                   19.8
                   found:   29.5 Ibs/hr
                   Experimental,EMFAC:   242 x 29.5 = 360
                                              TO"
                                  -22-

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HC expected:  34.485 x 220 x 1  =316.1 Ibs/hr
                             24
   found:  5,160,271 x 3 x 28.3  x 16
                           22.4    454 = .69 Ibs/hr
   Experimental EMFAC:  220 x .69   = .48
                              316.1
                              -23-

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    APPENDIX II
SOURCE TEST REPORTS
           -24-

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  SOURCE TEST REPORT

ILLINOIS POWER COMPANY

   WOOD RIVER PLANT

    ALTON, ILLINOIS

  BOILERS NO. 1 AND 4

      JUNE, 1975
                 Tested by:  Rockwell International

                             R.W. Griscorn
                             O.C. Klein
                             F.E. Littman
                             W.G. Norris
                             R.G. Ducker
         -25-

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                           TABLE OF CONTENTS

                                                                       PAGE

1.0   SUMMARY                                                           29

2.0   INTRODUCTION                                                      30

3.0   PROCESS DESCRIPTION                                               31

4-0   SOURCE TEST DESCRIPTION                                           34

5.0   PROCESS OPERATION                                                 37

6.0   DISCUSSION                                                        38
                                   i

7.0   SAMPLING & ANALYTICAL PROCEDURES                                  39
      7.1  PARTICULATE MATTER                                           39
      7.2  NITROGEN OXIDE                                               39
      7.3  SULFURIC ACID MIST AND SULFUR DIOXIDE                        41
      7.4  PARTICLE SIZE                                                43

8.0   RESULTS                                                           45

      APPENDIX A:  PARTICULATE CALCULATIONS                             52

      APPENDIX B:  FIELD DATA                                           74
                                  -26-

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                                TABLES






                                                                   PAGE





TABLE 1   BOILER NO. 1/SUMMARY OF RESULTS                           46





TABLE 2   BOILER NO. 4/SUMMARY OF RESULTS                           47





TABLE 3   COMPARISON OF RESULTS                                     48





TABLE 4   MINOR CONSTITUENTS                                        49





TABLE 5   PARTICLE SIZE DETERMINATION/RUN 1                         50
                                 -27-

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                                FIGURES
FIGURE 1      BOILER NO. 1
FIGURE 2      BOILER NO. 4
FIGURE 3      PLOT PLAN/WOOD RIVER PLANT
FIGURE 4 & 5  SAMPLING LOCATION, AND ARRANGEMENTS FOR TEST
FIGURE 6 & 7  SAMPLING LOCATION AND SET UP
FIGURE 8      PARTICULATE SAMPLING TRAIN
FIGURE 9      SULFURIC ACID MIST SAMPLING TRAIN
FIGURE 10     ANDERSEN STACK SAMPLER
FIGURE 11     PARTICLE SIZE DISTRIBUTION/BOILER NO. 4
PAGE





32





33





34





35





36





40





42





44





51
                                 -28-

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                             1.0  SUMMARY

     In conjunction with the RAPS project, a limited stack testing program is
being conducted.  This report details the results obtained on boilers No.  1
and 4 at the Wood River Plant of the Illinois Power Company.
     The stack testing included the following pollutants: SCL, particulates,
NOw, HgSO^, and hydrocarbons.  Orsat analysis for C02, CO, and 02 were also
performed.  Detailed results are included in this report.  Although these  tests
were not conducted to ascertain compliance with Illinois standards, it is  of
interest that the emissions were well within limits, with the exception of SCL
emissions from the coal fired boiler No. 4.                            -
     We acknowledge and appreciate the excellent cooperation we obtained from
both local and home office representatives of Illinois Power Co.
                                   -29-

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                           2.0  INTRODUCTION

     The current stack testing program is being conducted in conjunction with
the emission inventory work for the St.  Louis RAPS project.   The emission in-
ventory is being compiled using published emission factors.  The stack testing
is being conducted to evaluate the emission factors and to gather information
for additional  emission factors.
     This stack test was conducted at the Illinois Power Co.-Wood River Plant
in Alton, Illinois.  Testing was  performed on boiler No.  1 during natural gas
and oil firings and on boiler No. 4 during coal firing. The test on boiler No.
1 was during the week of 16 June  1975 and the test on boiler No. 4 was during
the week of 23 June.
     Boiler No. 1 is a gas and/or oil fired, 450,000 pounds per hour steam gen-
erating unit.  There are no stack emission controls on boiler No. 1. Boiler No.
4 is a pulverized coal fired, 713,000 pounds per hour steam generating unit.
There are mechanical and electrostatic precipitators on boiler No. 4.
     Both units were sampled for  total particulates, nitrogen oxides, hydro-
carbons, sulfur dioxide, sulfuric acid mist, carbon dioxide and oxygen.  Boiler
No. 4 was also sampled for particle size distribution.
                                   -30-

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                        3.0 PROCESS DESCRIPTION

     Boiler No. 1 was built by Combustion Engineering and installed in
1949.  It was originally operated as a pulverized coal  fired unit but was
converted to gas and/or oil fired.  The unit is rated at 450,000 Ibs per
hour steam at 1325 psi and 1010°F.  Boiler No.  1  is a forced draft unit and
it has no stack emission controls.  This boiler is illustrated in Figure 1.
Boilers 1, 2 and 3 are similar units and are served by a common stack.  The
stack is of brick construction, 250 ft tall and 15.5 ft inside diameter at
the top.
     Boiler No. 4 was built by Combustion Engineering and installed in
1954.  It is a pulverized, coal-fired steam generating unit.  The unit is
rated at 713,510 Ibs per hour at 1500 psi and 1005°F.  The boiler is an
induced draft type and it  is equipped with centrifugal and electrostatic
precipitators, rated at 99.5% collection efficiency.  This boiler is illus-
trated in Figure 2.
     Boiler No. 4 is served by a" brick stack, 250 ft tall and, 17 ft inside
diameter at the top.
     There is a Monsanto CATOX, sulfur dioxide scrubber installed on unit
No. 4 adjacent to the electrostatic precipitator.  This unit is currently
not  in operation and should have no effect on this source test.
                                    -31-

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              FIGURE 1  - BOILER NO.  1
              C-E STEAM GENERATING UNIT
 MAX. CONT. CAP.-45O.OOO IB PiR HR AT 1325 PSI AND 1O10 F TOTAL TEMP.
             WOOD RIVER POWER STATION
        Illinois  Power Company, Wood River, III.
DESIGNED AND BUILT BY COMBUSTION  ENGINEERING-SUPERHEATER, INC.
                 SARCINT « IUNOT. Conlulting Ingm>*r>
                              -32-

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                 :','   .     : a :.), ;  ;', I i
                 I'J:.:' iXfTr J .ifl •.•'ff.vA.iJia.j.^ JL
            FIGURE  2  -  BOILER NO.  4

            C-E REHEAT  STEAM GENERATOR


        U.SIOLl Pl» H» AT15OOMIAND IOOS f TOTAL UMP. IIHiAT TO IOO1 f


            WOOD RIVER POWER  STATION


        Illinois Power Company, Wood River, III.



O«ign»d and Built by COMBUSTION INGINIIRING -SUPf RHEATIK. INC.


             5ARCINT « lUNor. Coniulling lngin««r>





                             -33-

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                        4.0 SOURCE TEST DESCRIPTION
     Boiler No.  1 was tested in the duct work,  just ahead of where the
duct combines  with flow from Boiler No.  2 (see  Figure 3 below).
        M
d
                                    Boi
                                     No.
                                     Boi Jer
                                     Klo-3
                                     Boi ler
                                      NJo.I
                                     Mo.
                                                                       No.
                                                                 Tested
                    FIGURE 3 - WOOD RIVER PLANT, PLOT PLAN
                                   -34-

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     At this sampling point the duct is 7'1"  x 11'6  5/8"  inside  dimensions.
To obtain forty-two sampling points, eight,  3 inch sampling  ports were weld-
ed in place, approximately 17 1/2 inches apart vertically and  six points
were sampled at each port.  This sampling point is only 1-2  duct diameters
from the nearest induced draft fan outlet and is therefore not an ideal spot
for sampling,  but it is the best available  location for  testing this boil-
er without going to the large expense of constructing a sampling platform
on the stack.
     As it turned out, the bottom sampling port was  at the same  level as
the build-up of particulates in the duct.  The inside duct dimensions are
then revised for this point to 7'1" x 10'8 5/8".
     Figures 4 and 5 illustrate the sampling location and arrangement for
this test.
           FIGURE 4
FIGURE 5
                                     -35-

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     The test on boiler No. 4 was performed on a platform on the stack at
roof top level, approximately 140 feet above ground level.   This platform
was installed for the testing of this unit in conjunction with the eval-
uation of the CATOX scrubbing system.  There is a ramp connecting this plat-
form to the roof of the power plant building.
     At this level there are four 6 inch ports installed at 90 degrees
around the stack.  At each of these points on the platform, there are ex-
tensions to the platform to allow for a good working area and for set-up
and supporting sampling equipment.  An adapter was made to give us a 3 inch
coupling to attach to for our supporting monorail.
     At this location the stack diameter is 24.75 feet and it is approx-
imately four diameters from the inlet to the stack.  A full traverse of the
stack was performed with eighteen sampling points on the traverse.
     Figures 6 and 7 illustrate the sampling location and set-up for this
test.
            FIGURE 6
                                                               FIGURE  7
                                    -36-

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                        5.0 PROCESS OPERATION

     Boiler No. 1 was tested 17 June to 20 June.  On 17 and 18 June, the
boiler was fired with natural gas only and on 19 June and 20 June the boil-
                                 - !    I '  '<
er was fired with distillate oil only.  During testing periods on all four
days the boiler was under constant load of 420,000 Ibs per hour steam.   There
was only one short fluctuation for approximately.30 minutes on 19 June when
some oil burners malfunctioned.  Only one time was there any excessive emis-
sions from stack No. T and this was due to an unbalanced fuel/air ratio in
getting boiler No. 1 up to full load prior to our testing.
     Boiler No. 4 was tested from 24 June to 27 June.  During this entire
sampling period the load on this boiler was maintained almost constant, with
a generator output of 100 MW.  There were no noticeable excessive emissions
during this period.  Ashes are blown from the boiler at approximately 10:30 AM
and 3:00 PM.  There was no visible change in emissions during these periods,
although the actual amount of particulates apparently increased as shown by
our particle size testing before and during this time period.
                                     -37-

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                           6.0 DISCUSSION

     The EPA standard method 2, Volumetric Flow Rate Determination, has
come under question as a result of this testing.  On boiler No.  1  the flow
rate as determined by method 2 is 168,113 SCFM compared to a flow rate de-
termined stoichiometrically from the fuel rate and fuel composition of
137,288 SCFM.  At the sampling point for boiler No. 1, method 2 was not ap-
plied precisely since only 42 points were used instead of perhaps 48 or 50
due to the bottom port being blocked, but by observing the values that were
obtained it is unlikely that more sampling points would bring these two flow
rates into agreement.
     On boiler No. 4 the average flow rate determined by method 2 is 299,688
SCFM compared to an average flow rate of 218,497 SCFM determined stoichio-
              i
metrically.  At the sampling point for boiler No. 4 only one complete traverse
was made per test instead of two on perpendicular diameters as described in
method 2.  Despite this, the values obtained corresponded with values obtained
by other testers of this unit, so it is felt that this test is a valid meas-
urement using method 2.
     The flow rate determined stoichiometrically compares very well with the
expected flow as seen by a comparison of sulfur dioxide emissions using both
                                                                          '
flow rates.  Using the published emission factor of 38 S, which allows for a
95% conversion of sulfur in the coal to sulfur dioxide emission, the emissions
should be 5245 Ib/hr.  With the flow rate using method 2 the emissions would
be 6689 to 7318 Ib/hr,  which is definitely too great.  With the stoichiome-
tric flow rate the emissions would be 4877 to 5335 Ib/hr, which is a reas-    -
enable result.  For this reason the emissions determined using the stoichio-
metric flow rate are reasoned to be the correct results.  For comparison the
emissions are expressed using both flow rates.
     On boiler No. 4 the coal scales were not functioning during the test
period.   The fuel  firing rate of 43 tons per hour was determined by comparing
the operating conditions with similar conditions on record  as part of  the
ongoing emission inventory.
                                     -38-

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                    7.0 SAMPLING AND ANALYTICAL PROCEDURES

     All testing was performed with sampling equipment from Joy Manufactur-
ing, designed for isokinetic sampling to enable testing by EPA standard methods.
     Gas flow rates were calculated using the observed gas temperature, mol-
ecular weight, pressure and velocity, and the flow area.   The gas velocity
was calculated from gas velocity head measurements made with an S-type,pitot
tube and a magnehelic pressure gauge, using standard method 2.
     Moisture contents were determined by passing a measured amount of gas
through chilled impingers containing a known volume of deionized water, meas-
uring, the increase in volume of the impingers liquid and the increase in
weight of silica gel used to finally dry the gas, and calculating the amount
of water vapor in the sample from this increase and the measured amount of gas.
     The-stack gas concentrations of carbon dioxide, oxygen, carbon monoxide,
and nitrogen by difference were measured with a standard Orsat apparatus.   These
concentrations and the moisture content were used to determine molecular weight
Of the stack gas.

7.1  PARTICULATE MATTER
     Standard method 5 was used for determining particulate emissions with
the exception that the probe and oven were operated at 300-350 F.  Measured
stack gas samples were taken under isokinetic conditions.  The samples were
passed through a cyclone, fiberglass filter, impingers, pump, a meter and  an
orifice as shown in Figure 8.
     The total particulate matter collected in each test was the sum of the
filter catch plus material collected ahead of the filter in the sampling
train.  The amount of filter catch is determined by the difference in the
weight of the filter before and after the test, after dessicating.  The par-
ticulate matter from other portions of the train were determined by rinsing
the probe, cyclone and all glassware ahead of the filter with acetone, evap-
orating  to dryness and weighing.

7.2  NITROGEN OXIDE
     Using method 7, gas samples were withdrawn from the stack  into evacu-
                                     -39-

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    STACK
    WALL
*V
     5
REVERSE-
TYPE
PITOT TUBE
                  ORIFICE
                  GAUGE
                                                                               CHECK
                                                                               VALVE
                 VELOCITY
                 PRESSURE
                 GAUGE
                                                 FINE CONTROL
                                                  VALVE
                                                                         VACUUM
                                                                         LINE
                                    FIGURE 8

                           PARTICULATE SAMPLING  TRAIN
                                     -40-

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ated 2-liter flasks containing a dilute solution of hydrogen peroxide and
sulfuric acid.  The hydrogen peroxide oxidizes the lower oxides of nitrogen
(except nitrous oxide) to nitric acid.  The resultant solution is evaporated
to dryness and treated with phenol disulfonic acid reagent and ammonium hy-
droxide.  The yellow trialkali salt of 6-nitro-1-phenol-2, 4-disulfonic acid
is formed, which is measured colorimetrically.

7.3  SULF.URIC ACID MIST AND SULFUR DIOXIDE
     The "Shell Method"* was chosen for this determination due to uncertain-
ties which exist about the validity of the results using method 8.  A gas
sample  is drawn from the stack using a heated probe and passed through a water
cooled, coil condenser maintained below the dew point of sulfuric acid at
140 -194 F, followed by a fritted glass plate and then passed through a chilled
impinger train with two impingers containing an isopropanol and hydrogen per-
oxide mixture and followed by an  impinger containing silica gel for drying.
This set-up is shown in Figure 9.
     The condensed sulfuric acid mist in the coil condenser is water washed
from the condenser.  The final determination is made by titrating the solution
with barium chloride, using a thorin indicator.  Isopropanol must be added
to the  solution to be titrated to improve the rapidity with which the barium
sulfate precipitates during titration.
     Sulfur dioxide in the gas sample is oxidized to sulfur trioxide the im-
pingers containing the hydrogen peroxide.  Sulfur dioxide  is then determined
by titrating the hydrogen peroxide solution with barium chloride, using a
thorin  indicator.
* Lisle,  E.S. and J.D.  Sensenbaugh,  "The  Determination of Sulfur Trioxide
  and Acid  Dew  Point  in Flue Gases",  Combustion, Jan. 1965.

  Gokstfyr,  H. and K.  Ross,  "The  Determination of Sulfur Trioxide  in Flue
  Gases",   J. Inst. Fuel, No. 35,  177,  (1962).
                                    -41-

-------
STACK
 WALL
REVERSE-
TYPE
PITOT TUBE
     ORIFICE
      GAUGE
                                                                     CHECK
                                                                     VALVE
      VELOCITY
      PRESSURE
      GAUGE
                                     FINE CONTROL
                                        VALVE
                                                                         VACUUH
                                                                         LINE
                         FIGURE 9

             SULFURIC ACID MIST  SAMPLING TRAIN
                            -42-

-------
7.4  PARTICLE SIZE
     An Andersen, fractionating, inertia! impactor is used for the determina-
tion of particle size in the range of approximately 0.5 to 10.0 microns.   The
sampling head is placed either in the stack at the end of the sampling probe
or in the oven after the heated sample probe.  A sample of stack gas is drawn
isokinetically through the sampler (see Figure 10).  The particulate matter is
fractionated and collected on the plates inside the sample head and a deter-
mination is made by the difference in weight of the plates before and after
testing.  Results are expressed for particles of unit density.
                                   -43-

-------
AIR FLOW
                        FIGURE  10
                  ANDERSEN STACK SAMPLER
                           -44-

-------
                          8..0  RESULTS

     The results obtained from these tests are summarized in Table 1 and 2.
As discussed previously, the main flow of pollutant is based on calculated,
rather than measured, flow rates.  The actual calculations and field data
are attached as Appendixes A and B.  Although these tests were performed for
research purposes and not as part of compliance procedures, standard EPA
methods were used (except as indicated).  It is thus of interest to compare the
results obtained with State of Illinois standards.  A comparison is shown  in
Table 3.
                                    -45-

-------
                                       TABLE 1
                                     Boiler No. 1
                                 SUMMARY  OF  RESULTS
Date
Stack Flow Rate - SCFM * dry
% Water Vapor - % Vol .
% COa - Vol % dry
% 0 2 - Vol % dry
% Excess air @ sampling point
S02 Emissions - lbs/106 Btu
NOX Emissions - lbs/105 Btu
H2S04 Mist - lbs/106 Btu
Particulates
Probe, Cyclone, & Filter Catch
Ibs./hr.
lbs/106 Btu
Total Catch

Ibs./hr.
lbs/106 Btu
% Isokinetic Sampling
6/18






0.08







6/19
137,288
10.1
10.3
8.9
70.7

0.12

3.7
0.007



79.8
6/20





0.35
0.10
0.01




























'.:•




R


*70° F, 29.92" Hg
Calculated flow, dry

-------
                              TABLE 2
                            Boiler No. 4
                       SUMMARY  OF  RESULTS
Date
Stack Flow Rate - SCFM * dry
% Water Vapor - % Vol .
% C02 - Vol % dry
% 0 - Vol % dry
% Excess air @ sampling point
S02 Emissions - lbs/106 Btu
NOX Emissions -, lbs/106 Btu
H2S04 Mist - lbs/106 Btu
Particulates
Probe, Cyclone, & Filter Catch
Ibs./hr.
lbs/106 Btu
Total Catch

Ibs./hr.
lbs/106 Btu
% Isokinetic Sampling
g/oc
218497
8.25
16.4
6.4
45.3

0.65

29.8
0.03



96.8
fi/?fi
• U/ C.U
218,497
8.16
v
14.7
5.6
35.9
5.77
0.62
0.05
17.1
0.02



93.4
fi/97
.. ... —..\yj.£-f---
218,497

15.3
5.5
35.3
5.27

0.05




































*70° F, 29.92" Hg
Calculated Flow,  dry
                                     -47-

-------
      TABLE 3



COMPARISON OF RESULTS
Pollutant



NOX


Particulates


Fuel

Oil (Dist)
Coal
Gas
Oil(Dist)
, Coal
Gas
Oil
Coal
Standard
lbs/106 Btu

0.3
1.8
0.3
0.3
0.9
0.1
0.1
0.1
Found
lbs/106Btu

0.35
5.52
0.08
o.n
0.64

0.007
0.02
Comment
ROT "1 ^y* 1
Boiler 1
Boiler 4
Boiler 1
Boiler 1
Boiler 4
Boiler 1
Boiler 1
Boiler 4
         -48-

-------
Minor Constituents are summarized in Table 4.

                                TABLE 4
                          MINOR CONSTITUENTS

                             Boiler No. 1                    Boiler No. 4

H2S04 (mist)"   ~       "       0.01 lbs/106 Btu            '    0.05 lbs/106 Btu
                 a                                         v' '
CO                           2.5 ppm  (Avg)
Hydrocarbon                  1.7 ppm  (Avg)                   1.3 (Avg)
   . - • •••-,.'                                                                    •.
     In addition to measuring particulate loadings, a particle size analysis was
made using an Andersen impactor.  The  results are shown in Table 5 and Figure 11.
The high percentage of particles less  than 0.4 microns in diameter is probably
spurious.  Microscopic examination indicates the presence of large ammonium sul-
fate particles, which apparently were  formed by subsequent reactions of ammonia
with sulfuric acid.  The  latter, present in vapor form at stac/k temperature, was
apparently retained by the glass fiber filter.
                                    -49-

-------
                TABLE 5
       PARTICLE  SIZE DETERMINATION
    Test:

 Plate   Tare(g)


   1

   2

   3

   4

   5

   6

   7

   8 :

 Back Up
 Filter
Final(g)   Net(mg)
            3-V
Filter
  Net
                                  Date:

                                     Total
Z |. 6>035

22.5153
II. 73fl?

II.VM3
II. 74o?

21.^0*7
 % of
Total
 4.2.
I aa

II.2
 Cum %   BCD
       (Microns)

IO0.O    11.1  * (*.kov
-------
•45
 30
 25
 20
 16
 10
               FIGURE 11
       PARTICLE SIZE DISTRIBUTION
              WOOD RIVER
               BOILER #4
10
                     *    7   6   5
                            ECD, microns
                                -51-

-------
       APPENDIX A
PARTICIPATE CALCULATIONS
            -52-

-------
                         PARTICULATE  CALCULATIONS

Volume of dry gas sampled at standard conditions - 70° F, 29.92 "Hg
       /   \ /   \ /
      -[Vm_W  Pm UTstd
       \CFm M Pstdll  Tm

V%td = Volume of dry gas sampled  at  standard conditions, ft3
                             3
Vm = Meter volume sampled, ft
1.021 = Meter correction factor
Pm = Meter pressure,  barometric pressure,  PB> plus  orifice
     pressure, AH, in. Hg.
Pstd = Standard pressure, 29.92 in. Hg.
Tstd = Standard temperature, 530°  R or 70° F
Tm = Meter temperature, 530  R for compensated meter
CFm = Meter correction factor

Volume of water vapor at standard  conditions
Vw = Vl    fiH20RTstd        Ib.          =  0.0474 x V]c
Vw   V1c I  MH20 )(   Pstd  )     454 gm.
                                                    3
Vw = Volume of water vapor at standard  conditions, ft
Ml  = Volume of liquid collected in impingers and silica gel, ml
     = Density of water, Ig/ml.
M H20 = Molecular weight of water,  18 Ib/lb  mol
R = Ideal gas constant, 21.83 in.  Hg. -  cu.  ft./lb-mol  - °R
% Moisture in Stack Gas
                       Vw std
        % M = 100 x
                    Vmstd
                                    -53-

-------
 Average molecular weight of dry stack gas

               \t   TfTf I . I rt/ *\     O£  1  . I Ml K I  ._   fc%J
 MWp = ,  A,uv,2  A __,+ , 7o u2 X -JQJ I i-l 7o IN2 X  ^
 Molecular  weight of  stack gas
 MW  =   100  -  *H          MW  M-ftr  X   18
   W  \   100            "Wrvl  4  T nK  A   10
 Stack  velocity  at  stack conditions
 v    -   85 48 x  C   /TS x AP avg. \  I/,
 Vs   -   »b.4B x  Lp i   ps  x  M     i   i.
                    \          "  /
 V   =  stack  velocity,  fps.
)
 85.48  =  pi tot  constant, ||r  [  ..  Jb"	  \ V2
                        sec.  I  ib. Mols - oR  J   c
 C   = pi tot  coefficient, dimension!ess
 T   = average stack temperature, °R
 P.   = stack  pressure, barometric pressure plus  static pressure, in. Hg,
 AP  Avg = average differential pressure, in. H«0

 Stack gas volume at standard conditions
                   V.
                    s
Q  = stack gas volume flow rate, SCF/hr
                                  2
A = stack cross sectional area, ft
3600 = seconds per hour
Qs1 = Qs 7 60 = SCFM
                                    -54-

-------
Per cent isokinetic sampling
I = 1.667
(0.00267)    Vic    +   r^~
                               o vs
 I = per cent isokinetic sampling
 1.667 = minutes per second, X IOC
0.00267 =  5^§-  X  R  X      1bl
           MH20      "       454 gnu
Q = sampling time, min.
                                                2
A  = cross sectional area of sampling nozzle,  ft

Particulate emission
Cs = 2.205  X  10"
C  = particulate emission, Ib/scf
2.205 X 10   = pounds per mg.
Mn = total mass of particulate collected, mg.

C£ = C$ X Qs = Ib/hr
Cr = particulate emission per  hour
CH = CE -f H
Cu = particulate emission, Ib. per million  BTU
 n
H = heat input, million BTU per hour
                                    -55-

-------
Excess air at sample point
  EA
             100 x % o2
        (0.266 X
% EA = excess air at sample point, %
0.266 = ratio of oxygen to nitrogen in air by volume
                                  -56-

-------
                 PARTICULATE SAMPLING CALCULATIONS


          Test;  IP- UcxyQ   /?tts£.'J . ** / B If  Date:    d, //?
          , IP*....^	          tatf" *™ ^^       ^^ *    /  ^f | f   T-  {  { m    ^£f •  r

Material collected  (mg)  =

          Filter Catch   =    /V- £
          Dry Catch      =
          Acetone Wash   =     / < 6"
          TOTAL         *   /.£"• 7

Gas Volume   Vm   =  0.0334  / Vm  \/PB +    AH  \
               std          V1-021A       13.6 /

          o.0334(77.7/sV^ ^ +  o.7^y  7^.05?   SCF
                  1.021\  '        13.6/

Volvime of water vapor    Vw   =  0.0474 x Vic

          0.0474  (181.1ml  ) =   ?/5 S'V   SCF
       /
% Moisture    %M  = 100 x Vwstd
                         Vmstd + Vwstd

          100 Ji  ''     ^
Molecular Weight of  dry stack  gas

                   CO2  x 0.44   +

                  x  0.44)  +  ( 8/1   x 0.32  )  +  ( to- 8  x  0.28)= 3O,O
MW        MW =   % CO2 x 0.44  +   %02 x 0.32 +   %N2 x 0.28
Molecular Weight  of  stack gas

          MWw = 100  -  %M x MWD   +   %M   x  18
                     100             100

         [100 - to,I    x  50 ol  +[  lo>t  x 18
       ,  j"   100          ' J   I  100
                                   -57-

-------
                  PARTICIPATE SAMPLING CALCULATIONS


     Test:  iP-Uoo/  ^^  ~ * '   Blr'

Stack Velocity   Vs = 85.48 x Cn  |"Ts  x P avgl  1/2

                              P  LPs  * Mww  J


85.48 x (C,*)     743   x  Q-7/7 1   1/2
                              Q-7/7  1
                              £?<7?  J
                                                  „
                                                  57,
Stack Gas  Volume  Qs = 3600/1-  %M  \ (Vs)(A)/Tstd\ / Ps \
                          \   TOO/       \Ts  y \Pstd/


3600    l-   ()OJ  )1(5-7.gV)    (5-.5?)    530
       f
       L
              100   J                    (7V3)  2S-92
Stack Emission Rate   C<- = 2.205 x IP"6/ Mn   \
   i i -1   1111 	— --ii     O               I —-• ii • *•-• ii i I


2.205 x 1Q-6   (  /S,7  )    -    V^sfx/a"7       Ib/scf
CE = Cs x Qs = WSS-x/o')     (10,0^^3) =     V,£? _ Ib/hr


CH = cE T H  = ;    5   ) =     ^.x/tf        wip  Btu
Isokinetic Variations  1 = 1.667


                                       9VS  Ps

            00267)    ( /
-------
                 PARTICULATE SAMPLING CALCULATIONS


          Test: | P Uj^jo Rw f H   * 1          Date:

Material collected (mg) =
          Filter Catch  =
          Dry Catch     =
          Acetone Wash  =    H I • o
          TOTAL         =   / #6 ' 7
Gas Volume   Vm   = 0.0334  / Vm  VPB t   A H
               std           1-02          13-6
                   1.021

Volume of water vapor    Vw   =   0.0474 x Vic

          0.0474  (»%.?ml  )=   9.3^3 SCF

% Moisture     %M = 100 x Vwstd
                         Vms.td +  Vwstd

          100  x (  ?,333 )
Molecular Weight of dry  stack  gas

MW        MW =   % C02 x 0.44   +    %02 x  0.32 +   %N2 x  0.28

           ( \L,,<{  x 0.44) +  (  C,,1   x  0.32 ) +  (  17. A.  x  0.28)

Molecular Weight of stack gas

          MWw = 100 - %M x MWD  +  %M    x 18
                     100             100
                             f-f  P ^        I
           LOO - 8.35  x ,  g/? + ?/lS x  18h
              100       -3W««7J  |^ 100      J
                                   -59-

-------
                  PARTICULATE  SAMPLING CALCULATIONS
     Test:  IP -\Jood Rwtfr  -  V Br              Date:
Stack Velocity   Vs = 85.48 x Cn  fTs x P avg~]  1/2
                                fTs x P avg~]
                                LPsxMww  J
                 [ ISU,^ x Q.OSJ8    ]
                 L^.66,  x  29'S**   J
85.48 x ( 0,£6)     ISU,^  x Q.OSJ8       1/2  =
                                                          fps
Stack Gas  Volume  Qs = 3600 fl- %M \ (Vs)(A)/Tstd\ / PS \
-           \  TOO/       7\jr7 \iPitdj

3600   [l-   (Z, 2^)1(^.37)   (
       L      100   J
                                    ^ )    530
                                         (TS(0j}  29.92
Stack Emission Rate   Cs = 2.205 x IP"6/  Mn   \
                                     V VMstd )

2.205 x 10~6   ( /QG.9 )    -    2.Z7 ^/O"      Ib/scf
CE = Cs x QS =  (2,47>V6 \|
      L _           530   \ _ 13.6  /J
Excess  Air at Sample Point
                                                100 x % 0?   	
                                                (0.266 x % N2)  - % 02

                                                100 ( 6.

-------
                 PARTICIPATE  SAMPLING CALCULATIONS


          Test:  |P  \JooCs  RwCfc   ** ^        Date:   Co

Material collected  (mg)  =

          Filter Catch  =    37.^
          Dry Catch      =
          Acetone Wash  =    XI, S
          TOTAL          s*   5"o •

Gas Volume   Vra    =0.0334
/ Vm VPB +   ^ H \
VL.o2iA       13.6 y
                std
                            "•      '           9

                   . -. •. j***.\ V         > 11 ^  v    ^-^i A — . / i
                                                    SCF
Volume of water  vapor    Vw   =  0.0474 x Vic

          0.0474 (l§t,|ml )=  ?. £*/   SCF
% Moisture     %M ==  100 x Vwstd
                          Vmstd + Vwstd

          100  x  ( 8,gAI  )
                                           =  * •
Molecular Weight of dry stack gas

MW        MW  =    %  C02 x 0.44  +   %02 x 0.32 +   %N2 x 0.28

           ( ;V. 7  x 0,44)  + ( d", 6>; x 0.32 )  + (11, 7  x 0.28)

Molecular Weight of stack gas

          MWw =  100 - %M x MWD   +  %M   x 18
                      100             100
          ioo -
               100
              t
                                  -61-

-------
                   PARTICULATE SAMPLING CALCULATIONS
     Test:   lP-Wcod(  Rwer  - *
                                                         Date:
 Stack Velocity   Vs = 85.48 x C_   |Ts x P avgl  1/2
                                  'Ps x Mw.
85.48 x
               )    76.3.1  x  O.QS7      1/2 =
                                 fTs x P avgl
                                 |_PsxMww  J

                                       ]
                                                            fps
Stack Gas Volume  Qs = 3600



3600   fl-   (£-/k)n
                           /I- %M  \ (Vs)(A)/Tstd\ /Ps \
                           \   100/       \Ts  / \Pstdj
       fl
       L
                                             530
                                                   29'92
 Stack Emission Rate   Cs = 2.205 x IP"6/  Mn   \
                                       V VMstd /
2.205 x 10~6



CE = Cs x Qs =


CH « CE T H  =
                   > 7
                                                   Ib/scf
                                                                .Ib/hr
                                0,Q2S
                                                       Btu
Isokinetic Variations  1  =  1.667
                                  (0.00267)  Vlr  +  Vra  /  + AH   \]
                                               c     Tm  \PB   T3TF/[T
                                  *   --—^^-^~^~———		     •>•
                                                                           SGFH
         (0.
      L
1.667    (0.00267)
                                        evs  PS  An

                                          (tf.(.Z. +
                                     530   \          13.6
Excess Air at Sample  Point
                                           % EA = 100 x  %  Op   _
                                                  (0.266 x %  N2)  -  % 02
                                                  100
                                   .62-
                                                                -  is,

-------
                                 STOICHIOMETRIC
                              FLOWRATE CALCULATIONS

                                   Boiler #1
Oil  Composition                  mols/100#                    mols 0  required

 S      0.29%                    #32              x 1        =     0.009
 C      86.4                     #12              x 1        =     7.200
 Ho     12.7                     * 2 = 6.35        x 0.5      =     3.175
 N2     0.2                      * 28 = 0.007
 02     0.2                      #32              x -1       =    -0.006
 Ash    trace
 Btu    140,000 Btu/gal
                                            Theoretical 02    =    10.378

 Excess air = 70.7%                         excess 0,         =     7.337
                                            02 Total^         =    17.715
 N2 = 3.76 x 02                                               =    66.608

 Mols Flue Gas = C02 + SO? + N? + 02 + N?
               = 7.200 + 0.009 + 0.007 +7.337 + 66.608 = 81.161

 Flue Gas = 58.54 x 386.7 1*  = 31385 scf/100#
                          mol
 @61gpm = 61 x 7.171 t   x I    x 22637.4 = 137,288 SCFM
                     gal   100#
                                          = 8,237,263 SCFH
                                         -63-^

-------
                             STOICHIOMETRIC
                          FLOWRATE CALCULATIONS

                                Boiler #4
Composition of
C
H2
S
°2
N2
H20 (moisture)
Ash
Chlorides

Coal
61.43%
4.38
3.21
9.67
1.11
11.82
8.55
0.02
100.19
Lb-mols/100
5.12
(2.19)
0.10
0.30
0.04
(6.66)
I
_
. •
Ibs Coal
(1)
(2)
(3)

(4)
(2)



Oxygen Required for
Combustion, mols
5.12
(1.09)
0.10
-.30
-
-


6.01 Moles o
Assumed reactions:
(1)  C . + 0
              C0
          2     2
(2)  Excluded from calculation for dry flue gas
(3)  S + 02 ->- S02
(4)  Oxidation reaction uncertain
Dry flue gases per 100 Ibs coal, Ib-mols:
Average Excess Air: 40%  2.40
Total                    8.41
Corresponding Nitrogen  31.77
co2
so2
°2
N2
Air (Nitrogen)
Total
5.12
0.10
2.40
0.04
31.77
39.43
@ 43 tons coal/hour
                                        Ib-mol x 386 = SCF
                             =  15,220 SCF/100#
                               =  13,089,200 SCF#
                                   -64-

-------
                              N0  EMISSION  DATA
                                                    Date.
Run No.
Time
ug N02
T.- Initial Flask Temp,.°F
Tf- Final Flask Temp, °F
Vf - Flask Volume, ml.
P - Initial Flask Pres "Ha

P - Final Flack Pvoc "Hn
r/r rillal rlabK. rrcb, ny
lb/scf N02 X/0"U
lb/106Btu N0?
1 jj-^****" - " " - /
/
-
U^l<
fo
fo
20^/7

3.o

21/7
_
'• -
^
—
25^
^
fo
203S




«,*?
i5./2
3
-
ll(*
90
,\"
O. o .?
Vsc= M7.71  °R
(Vfc)
                                                  =  scf
            in.  Hg/              V T*        T,
Vfc = Vf - 25
C = 6.2 x 10"5  lb/scf
                yg/ml
fyg  NO,
  Vsc
            = lb/scf
                                    -65-

-------
                              NO   EMISSION DATA
                                                    Date.
                                                                           fired
Run No.
Time
yg N02
T.- Initial Flask Tetoo °F

T - Final Fla<;lf Tpmn °F
* £ riiicii r I d j N i chip y r
^fc~ fr^as'< volume» ml-
P.- Initial Flask Pres, "Hg
1 > 3
P - Final Flack PVPQ "Hn
~ f riiiui riuaiN ricd) ny
Ib/scf N02 x/0*4
1b/l06Btu N02
/
I2oo
eao
Q/\
CC
210
»— — u



2^J"i




7, 7
•-<5JZ
Vsc- (17.71  ^R    \    (Vfc)
     \      in.  Hg/
= scf
Vfc. - Vf - 25
            "5
C = 6.2 x 10 "  Ib/scf   /yg N02  \  = Ib/scf N02
                                    -66-

-------
                              NO  EMISSION DATA
                                                     Date.
Run No.
Time
yg N02
Ti- Initial Flask Temp, °F
Tf- Final Flask Temp, °F
V- - Flask Volume, ml.
P.- Initial Flask Pres, "Hg
Pf- Final Flask Pres, "Hg
Ib/scf N02 x/0-6>
lb/106Btu N02
/
/33S-
113
c
-------
                        H2S04 MIST and S02  EMISSION DATA
Date
Run No.
Vmc-Meter Volume, Ft3
Vmstd-Keter Volume, Std. Cond.
Pg-Barometric Pressure, "Hg
AH-Avg. Orifice Pres. Drop, "F^O
VfVol . of Titrant, ml.
Vtb-Vol. of Titrant for Blank, ml.
Vsoln"v°V- of Solution, ml.
Vg-Vol . of Aliquot, Titrated, ml.
Ib/scf H2S04 X/0"7
lb'106 Btu H2S04
Ib-scf S02 X/O~S
lb/106 Btu S02
(o/ZO
I
7.5/J
7/33G
my
O.(
®,q
«.v
loo
to
SW
O.QI
















<*/zo
I
?,07?
G».?/^
zt.gy
0,1
o.1
/./•/
/oo
/o
6.25T
0.0 /


<*/?o
/'£
H.31Z
i
-------
                          Hydrocarbon Results



Test:!P~lcWtf(/?!*«• a*HA-   / / I *9             Tiin^'
     : vJOOA  K \tf £ f   '     L»eitc.   \O I • (             i J.UKS .



     Carbon Monoxide:                       O/373



     Methane:



     Total Hydrocarbons, as 014:            D. , 11 *i   ppm
                                        -69-

-------
                             NO  EMISSION DATA
                               A
                                                   Date.
Run No.
Time
ug N02
T.- Initial Flask Temp, °F
i
TJT- Final Flask Temp, °F

Vf - Flask Volume, ml.
P.- Initial Flask Pres, "Ha

PJ-- Final Flask Pres "Ha

Ib/scf N02 X/0~S
lb/106Btu N02
/
1 210
IZ10
fa
i u
&r\
fo
2oHj
3s+
,o

21,<+
1,s-
O/4V
2
13/0
1500




lotf




£,J>
0,15
2>
1120
//£o




ZOtf




H.I
0,S%
y
HIS
1310




2o?8




V,7
O.(ol
6
He 10
'f SO




202*





-------
                              NO  EMISSION DATA
                                A
                                                     Date.
                                                6/g
Run No.
Time
yg N02
T.- Initial Flask Temp, °F
Tr-- Final Flask Temo. F

Vf - Flask Volume, ml.
P.- Initial Flask Pres, "Hg

P Final Flacl/ Dvoc "Hn '
i-f rinal rlaSK rres, ny . .-., ,
Ib/scf N02 '. x/0^
,lb/106Btu N02 	
/
llco
U$6
io

*to
ZWI
'3,0


24, b
^V
O,(fl
^
IW
;j io



2oj^




V»«
0,(&
3
U3o
"116
~± 	 ...


20J?




3.3-
Ml
••••••••••••••
Y
/JJS
72/0
:^:_. ••....


?o#




'V,3
a
-------
                        H2S04 MIST and S02 EMISSION' DATA
*
Date
Run No.
Vmc-Meter Volume, Ft3
Vmstd-Meter Volume, Std. Cond.
Pg-Barometric Pressure, "Hg
AH-Avg. Orifice Pres. Drop, "^0
VfVol . of Titrant, ml.
Vtb-Vol. of Titrant for Blank, ml.
Vsoln-Vo1- of Solution, ml.
V -Vol. of Aliquot, Titrated, ml.
a
lb/scf H2S04 X/&"**
lb/10° Btu H2S04
Ib-scf S02 X/O~^
lb/106 Btu S02
Ut(t>
/
1.<*K
7*537
If-bl
0.(
S.<1
*;/
lOO
13
3.1
O.oS


(+k(*
1
l.W
7,S37


n.&£



«11
ICO
Z£
3,f
O&$


(*/H
in
*
mu


30. /
»;/
230
/,£


3,72
5,27
Vmstd = 0.0334 (Vm)   /PB + AH
                pr-    \      1V C
                Lrm   \      lO.O
CH2S04
        CFm ~ Meter correction factor
        /1.08 x 10'4 lb-1  \  (Vt - Vtb)  (JD
        \            g-ml  /
                                  Vmstd
                                               \
                             Ib/scf    N.* 0-01 Normal
                                           Barium
                                           Perch!orate
CS02 =(
      \
     =7.05 x 10"5
                   g-ml
(Vt-Vtb)   (N,   (^),WKf



      Vmstd
                                       -72-

-------
                     HYDROCARBON ANALYSIS

TEST: IP Wood River #4        DATE: 6/26               TIME: 1400

       COMPOUND                           CONCENTRATION (ppm)
     Ethane
     Propane
     1 - Butene
     n - Butane
     iso - Pentane
          2 - Pentene
         Hexene
         Hexane
         dimethyl
CIS,
1 -
n -
3,3
      2,4 dimethyl
 1 - Pentene
Pentane + Benzene
      1  -  Heptene
      n  -  Heptane
      Toluene
      Ethyl  Benzene
      meta-, para-,  xylene
      orthoxylene
0.074
0.043
0.015
0.018
0.018
0.016
0.046
0.117
0.029
0.068
0.040
0.016
0.065
0.113
0.394
0.087
      C 's
      C7'S
      cs's
                                         0.043
                                         0.052
                                         0.143
                                         0.308
                                         0.185
                                         0.622
                                 -73-

-------
APPENDIX B
FIELD DATA
    -74-

-------
             SUPPLEMENTARY PROCESS & EMISSION DATA FOR POWER PLANTS
Test number
Net Unit Load - MW
Boiler
Boiler
Heat Rate - BTU/KW hr.
Heat Input - 106 BTU/hr.
Emission Level - lb./106 BTU

Particulates
so2
K°x
Fuel Heating Value - BTU/lb.
Fuel Burning Rate During Test - Ib./hr.
Fuel Ash Content - %
Additive Rate - Ib/hr.
6/77


532.1




/03O
Mu/CF
S7S,
iP*CF/kr


&//#
43-
13, $n
sn*t




/030
S+u/CF
sreoj
tO*Cf/kr


(e/tf


5/3, y




1 ^SZb
(a\ GPM


6/?0*


S/J> ^








*Aj
                                     -75-

-------
        ORSAT FIELD DATA
T.nr.iMnr, J- {£.. /Q !//£/?- Bel LEft /
Date
Tim*
Operator

Test
£-/7
6-/S









(CO )
Reading 1
/• S J0
73 °/c









(0)
Reading 2
9.3 <£
#./<









Comments :
(CO)
Reading 3
0.0 °/>
c.c /









(5 /C.6
O
                           1.7
                         l.CS
                               --  39. 5
                                             /9. 7 3


-------
                                   ORSAT FIELD DATA
             Date




             Time
                                                     Cornnents :
. I Go/LZR
             Operator
DAT&
£-/?. 75
£.20. 75
a*'-
£-/
«
r\a
Test
// 10 firs.
/(.Cohr*.
lldohrs.
/3CG f)rs.



£L\/
-------
oo
 I
Plant IP WOOD RIVER
Run No.
1

Location 1 BOILED
Date <^.
./$

Operator
Sample Box No.
Meter Box No.
Meter A
C Factor
Point
/-<£
/-£
/- 4
/-J
/- 2




-?-/
3. 3

•?-<•/
3-5
3-C.
-

H@ /. 0 ?3


Clock
/?-'o^
/S-'/y
/3:/ ' /tff
P
P
A
Pitot
in H20
AP


o. ys
A. 75
0.9
0.?
0^7*
Qf/±
?
r



.35
Of 9



/. 3
^ /
• O.9 :
" '

Orifice AH
in H20
Desired
O.C
/, O
/. %
/. 3
/. 0




G.6
/.3
'.3
AC5
/.£
rt \y


Actual
0.6
/. 0
/'•?
/.^
/.o
' •(



0f£
/.J
/.£
/' 5
/•<$
/, 3


Impinger
°F Temp.
Inlet
/S£
330
330
330
3^*5
350



2/0
380
38o
38Q
385
380


Outlet
80
70
CS
65
C5
7Q



9o
70
70
75
ffo
85


Pump
Vacuum
In. Hg.
Gauge
S.5
8.5
//, o
//, 0
9.5




V.5
/3.S

/5
/5
/1 5


Temp °F
tar. Press. "Hg
Assumed Mo is tun
[eater Box Sett:
'robe Tip Dia.,
robe Length /
£S- 9o

3 % /«5
Lng °F (
-------
                                                                                               Ho. i
Point
v?- /
3- 2
dm? " t 7
c3- V
i^r ~ t^
<3-£
Q-ff





















Clock
Time
^?-'«5^
«3:c /
<3:oV
.3:07
^:/o
<3: A3
v? : /<£
.




















Dry Gas
Meter; CF
/5^.93
/£ 
-------

Plant TP Hfef»/) ff/l/£ff
Run No.
2

Location j£ / $/f~

Date £
-/?

Operator
Sample Box No.
Meter Box No.
i
00
o



Meter A
C Factor
Point
/-/
A •?
y. 3
/- .£
/7.5
/7.5

/7.S




J
/7f£
/7.5
/7.5
/7


Temp °F
tar. Press. "Hg
issumed Moistur
(eater Box Sett
'robe Tip Dia.,
'robe Length /
7c°S

3 % /&?0
ing °F <32£€. $
In. /*///)
O rt •
'robe Heater Setting */ 38c ^3d
ivg. AP Avg. AH

Box
Temp
op
«J?o
33o
31/0

»35o
355



*3Vo
&M~
*3£5
*3i5£
*3CO



Probe
Temp
op
3
3%£
385

3X5




37 o
37o
370
3. 70

•C \A %*f


. c
          cc

-------
                                                                                                               R
un
      ct
Point
<3- /
3- 3

3- y
3-5
3-6
erf*

I
*/-/
^S ^
'*5y
3 '-£7
«-?• GO
^/' fj^

/7





Box
Temp
op
355
360
3£6
3(.0
3C5
<3(*5



335
330
335
oV0
345
35O



<3yb
3V5
<3£Q
35o
<355
3C5




Probe '
Temp
op
-?Vo
395
3/5
335
33C




330
370
380
39o
<3G<5
i3c£



•33o
375

330
<33o
330




Stack
Press
In.Hg




























Stack
Temp
op
370
37o
3SO
3%o
2CO
35C>



380

<39o
390
3fO
390



390
395

395
395
39 £



\
 cr //O %
i
00
     °f
         Comments

-------
                                                                                                 R
       Point
        Clock
        Time
Dry Gas
Meter, CF
Pitot
In.H20
A P
                   Desired Actual
Orifice 4 H
In.H20
Impinger °F
Temp
                                                        Inlet
                                                     Outlet
Pump
Vacuum
In.Hg
Gauge
                                                                                  Box
                                                                                  Temp
                                                                                  op
Probe
 Temp
 oF
Stack
Press.
In. Hg
Stack
Temp
oF
       JLL
                                                /9£
                                                                                  393
                           0.8
                                                                        3.3
                                                                                380
                                                        376
                                                                        365
                           .
                                                        380
        7-3
                          €>.•/
                    0.5S
                                                       385
        7-3
00
ro
7.5
                       *<*''.78
                           0.7
                                                        285
                                                              /o
       off
                        7 /~7o<
                                 f
       c-ff
      Comments
                        ± •'  O'^v 7)C.

-------
                         PARTICULATE  CLEANUP SHEET
Date:
                hs
Run Number:

Operator: _
Sample Box No.
Plant:  IP  - WpoD   R \ vcff

Location Of Sample Port:  * I Bailer

Barometric Pressure:    29. ^

Ambient Temperature _ ^0  p
                                                                  U »  f/4.
Impinger H20

Volume After Sampling JO I  ml

Impinger Prefilled With 2 DO ml

Volume Collected      (       ml
                                  Silica Gel

                                  Weight After     373,2
Weight Before
                                                       ; /
                                  Moisture Weight  20* I g Moisture Total / £*/..•/ g
Dry Probe and Cyclone Catch:
                                  Container No.

                                  Extra No.
                                                       Weight Results
Probe, Cyclone, Flask
And Front Of Filter
Acetone Wash:
                                  Container No.

                                  Extra No.
                                                          Weight Results Q,
Filter Papers and Dry Filter Particulate

Filter No.   Container No.   Filter No.    Container No.
                                                           Filter Particulate
                                                           Weight  O* 0/V^    g
                                                           Total Particulate

                                                           Weight  &,OAf 7 g
% Moisture By Volume   V    -  O.O33Y

                                                            ~~ 76.057
    V
                                     -83-

-------
                      OXIDES OF NITROGEN FIELD DATA
Date
Plant
Sample Collected By




Run No.
Power Stat Setting
                              -  B
Field Data

Clock Time
Flask number
Volume of flask less correction (ml)
Pressure before sampling in. Hg.
Pressure after sampling, in. Hg.
Flask temperature, F
6 //?
l*U*k
1
W7
30
Z?.7
90
_
2
2038
3.0
29,7
10
m
3
2031
3.0
#<7
10
-
4
£0*8
3.0
&7
?o
v* f /«
//30
/
wn
3.0
tf.l
10
I2DC
^
2039
3.0
11.7
10
HOQ
•;-.£
2C3f
3.0
».'7
10
H3&
y
f

*i^ •>
•<7' /
*?<9
                                     -84-

-------
                      OXIDES OF NITROGEN FIELD DATA
Date 	5s£




Plant XP "
                                          /
Sample Collected *y




Run No.
                       0»
Power Stat Setting
Field Data
Clock Time
Flask number
Volume of flask less correction (ml)
Pressure before sampling in. Hg.
Pressure after sampling, in. Hg.
Flask temperature, F
teoo
i
QDW
3,0
ft. 7
to
/330
2
203?
3»O
*1>?
3D
I3oo
3
.203?
3,0
Xj,7
1°
UJto
y
ao*8
3,0
A1.7
10 \
1160
S
^OJS
4,0
af/7
^
ISOG
&
30S±
2-.0
31,7
iO
\'/-S3d
•7
ADSJ
3,0
W,7
io
Ikes
^
?03&
-"i
O»- *- • ;
2c~f. 7
rc i
                                      -85-

-------
                      OXIDES OF NITROGEN FIELD  DATA
Date
Plant
IP '
Sample Collected By.




Run No.	
Power Stat Setting
Field Data
                                         *
Clock Time
Flask number
Volume of flask less correction (f"l)
Pressure before sampling in. Hg.
Pressure after sampling, in. Hg.
Flask temperature, F
MS
1
i&n
3.0
3*?.?
ft
/3&
1
lto#
3.0
2.^7
^
1230
3
&*$
3,0
2% 7
go
ites
f
2CM
3.0
J1.7
90










•













                                     -86-

-------
                     GAS SAMPLING FIELD DATA


Material Sampled  For  Su/furic  MlS"f J SO,

Date  <£. 3 o - 7*5"

                                 Location  & /
Plant

Bar. Pressure

Ambient Temp

Run No   /
                          "Hg    Comments :
Power Stat Setting

Filter Used:   Yes

Operator
                              & <3/<5
                           No
                                                 cL
Clock
Time
          Meter
          (Ft.3)
                       Pitot
                       in.  H20
                        P
Orifice
in H20
 H
   Temperatures
Stack
Probe
Coil
Impinger
                                                             In   Out
               - 747
                        C,7
                                G.I
                                                       73
                        G.7
                                0.1
               3/0°f
                                                        3
         267S5
                        0.7
                                G.I
                           3c°?
                          F
                        o,7
                                 oJ
                                                       73 °c
                                81
         3CC./Q
                                                                  £51
Comments:
                               -87-

-------
                      GAS SAMPLING FIELD DATA
Material Sampled For



Date  &. 30
                                   MlSJ*
Plant  WeiAfL /?/VdV



Bar. Pressure  39, 8 */    "Hg
                                  Location
                                                / j(3/r.
                                  Comments :
Ambient Temp




Run No
Power Stat Setting



Filter Used:  Yes



Operator     .	
                            No
                                             -So •?
                                                                 not:

                                                                          •> & cd.
Clock
Time
/'.c7
/:/!
/'/I
A'W
/'?7
/-•^
/-J7



Meter
(Ft.3)
«/. ^<5
^
-------
SUPPLEMENTARY PROCESS & EMISSION DATA FOR POWER PLANTS
Test nuaiber
Net Unit Load - MW
Boiler
Boiler
Heat Rate - BTU/KW hr.
Heat Input - 10 BTU/hr.
Emission Level - Ib . /10 BTU

Particulates
so2
»°x
Fuel Heating Valve - BTU/lb.
Fuel Burning Rate During Test - Ib./hr.
Fuel Ash Content - %
Additive Rate - Ib/hr.
£/2S
100

KS.O




101 5(*
86000


6/A6
too

1Z5.0




I01S&
§600 o


(*kl
/CO

925>G




IG7$(*
8(eQOG












, \
\
                       -89-

-------
                                  ORSAT FIELD DATA
                      2 ~ LL  P<) W £ ft  C Q .
DAT/E.
 - It. 75
 . 37. 76
              Date




              Time




              Operator
                                                    COEffietltS :




                                                         /Vo.
Test
/_3rs.
/345/>fS.
/S3S/H-3.
/0<3G /irS.







(CO )
Reading 1
/^5/
/J.^
/t.l
/S.3







(0 )
Reading 2
31.8/£.tf
/9.0/S.t
l/.L/Sd
30.8 /S. 5
/






(CO)
Reading 3
33-3
/9.o
3/.C
3o.8







               ./* 
-------
          Plant
          Run No.   /
          Location
          Date  £ - 33. 7S
          Operator
                                         PARTICULATE FIELD DATA

                                   VERY IMPORTANT - FILL IN ALL BLANKS
                                   Read and record at the start of each
                                   test point.
                                                                         Ambient  Temp  °F
                                                                         Bar.  Press.  "Hg  3?. C3


                                                                         Assumed Moisture %  &
Sample Box No.


Meter Box No.
                                                                         Heater Box Setting °F


                                                                         Probe Tip Dia.,  In.


                                                                         Probe Length  /Q
Meter A H@ /.p 33


C Factor
                                                                    .  C,
                                                                                  Probe Heater Setting _


                                                                                  Avg . A P . O<5 Avg . A H
Point
/
.3
3
.








2?3:
-------
                                                                                           R
un
ro
Point
/8
/7
'{
/£
/7fi
s,S>
'.<5
/,75
Af



















Impinger °F
Temp
Inlet
3*5
38V
J9S
3?e
38S
376
385
373
373



















Outlet
C5
C3
7o
7o
7D
7*
Sc
73
7o



















Pump
Vacuum
In.Hg
Gauge
4<0
7.0
ff.o
g.<0

7.o
7.G
8.G
7.0



















Box
Temp
op
\3CO
*370
38o
055
c?*5
c?
-------
                         PARTICULATE CLEANUP SHEET
Date:
Run Number:

Operator: _
Sample Box No.
Plant:  ! F*  WOOD
Location Of Sample Port: **•*/.  &o'det SlU8,S   ml
Silica Gel
Weight After
Weight Before
                    « |  g
Moisture Weight  28(e5l   g


                         Total Particulate

                         Weight  Q. 10&"? g
% Moisture By Volume
                                    -93-

-------
 Plant  ,/4/tf 7
a.o7
0.0S
f>'.a£
o.oS








Orifice AH
in H20
Desired
o.7£
/.25
/- 7-5
/. 75
/. 7.5
/>7S
/.3£
/.3£
/.3£








Actual
0.75
/.3S
/.73
/. 75
/Z5
/,7£
/•IS
/,*£
/.3f








Impinger
°F Temp.
Inlet
330
•?/«£
365
380
3?Q
3Z5
395
W
390








Outlet
CS
£3
ts
*?
ti
$
fr
7o
7/








Pump
Vacuum
In. Hg.
Gauge
¥
£
1
?
?
?
C
£
4








Box
Temp
0F
330
Jlc
,330
<34o(5)
3
-------
                                                                                                                  R
Point
7

7
\&
tj
y
3
3
/



















Clock
Time




























Dry Gas
Meter, CF
* a
o.oC
o.o C
0.0*1*



















Orifice A H
In. H20
Desired
/.S
/,s
/.S
/.S

AS
/.S
/.£
/.o



















Actual
/,£

/.S

/,£
/.S
/.S

/•o



















Impinger °F
Temp
Inlet
/85

38o
38/
?£S-
3So
3££
3Co
3S£


















•
Outlet
75
7/
7o
7/
7S
7o

AS
xs



















Pump
Vacuum
In HP
J.11, -lig
Gauge
ff.S
AS
8.5
as
9.0
9.0

9.0
7.0



















Box
Temp
op
,3/5(3]
<3¥o
380  '
•jys
JUS



















Probe"
Temp
op
/7o
3fS (7)
364 (S)

*SS(7)
^«3«5 LCt j

JaS
3/Q



















Stack
Press
In. Hg















'•












Stack
Temp
0F
t33Q
J2S

<33O
<33 o
330
33.C
33o
^??«5"

•

















i
<£>
en
       Comments
                                 e.fi

                                                                             o°o

-------
                         PARTICUIATE  CLEANUP SHEET
Date:
Run Number:

Operator:
Sample Box No.
Plant:  \ P
                     *
Location Of Sample Port:

Barometric Pressure:

Ambient Temperature
Impinger H20

Volume After Sampling

Impinger Prefilled With ^QQ ml

Volume Collected    fS 8-    ml
Silica Gel
Weight After
                                   g
Weight Before  SOO-0  g

Moisture Weight 3g, /g Moisture Total
Dry Probe and Cyclone Catch:
Container No.

Extra No.
                                                       Weight Results
Probe, Cyclone, Flask
And Front Of Filter
Acetone Wash:
Container No.

Extra No.
                                                          Weight Results 0,03/5 g
Filter Papers and Dry Filter Particulate

Filter No.   Container No.   Filter No.    Container No.
                                                           Filter Particulate
                                                           Weight  Q,Q3 73   g
                                                           Total  Particulate

                                                           Weight 0,0581 g
% Moisture By Volume
                                    -96-

-------
                     OXIDES OF NITROGEN FIELD DATA
Date
Plant
IP  WOOD
Sample Collected By




Run No.
Power Stat  Setting
Field Data
                             BO
                                ILE&
                         Q. ft /gin
Clock Time
Flask number
Volume of flask less correction (ml)
Pressure before sampling in. Hg.
Pressure after sampling, in. Hg.
Flask temperature, F
MO
1
Wll
.3,0
39.6.
1C
13)0
Z
ao3§
—
--••
— -..
wo
3
*G3y
—
....

MIS
f
AMg



/6/o
S
yeas



Me.
6
2O5i



We
.-*>
JflsS'V


•- . .
/7/L"
;^
20ST?
,
.
'
                                    -97-

-------
                      OXIDES OF NITROGEN FIELD DATA
Date
Plant  r?-Ue?Ofc
                             r  Boiu£R  Mp- V,
Sample Collected *y    Q. KleJv\




Run No. . _ ___
Power Stat Setting
Field Data
Clock Time
Flask number
Volume of flask less correction (ml)
Pressure before sampling in. Hg.
Pressure after sampling, in. Hg.
Flask temperature, F
I'lOO
1
2&il
3.0
2
-------
                     GAS SAMPLING FIELD DATA
Material Sampled For
Date   £
                                 Location
Plant  Wood. ff/VCf'
Bar. Pressure  «?ff C 2    "Hg    Comments :
Ambient Temp  ?Q _ °F
                                 verse, fo i
Run No    /
Power Stat Setting
Filter Used:  Yes
Operator 	
NO
                                   £/>&
Clock
Time
O
S
/G
/s
30
36
<3o



Meter
(Ft.3)
¥78. c ¥6

-------
                           GAS SAMPLING FIELD DATA
/.
      Material Sampled For

      Date   &-  37
   / 6o
      Plant  lA/asxT, /7/VC.f        Location _
      Bar. Pressure 3% £<>/7   "Hg    Comments:
      Ambient Temp

      Run No    /
      Power Stat Setting
      Filter Used:  Yes _
      Operator 	
No
Clock
Time
O
^
/O
/S
3o
35
Jo



Meter
(Ft.3)

&>C
                     tn/zt

                                    -100-

-------
                      GAS SAMPLING FIELD DATA
Material Sampled For  <$' ' Q ^   
Power Stat Setting



Filter Used:  Yes



Operator 	
                            No
Clock
Time
O
s
/o
/£
3o
3S
30



Meter
(Ft.3)
v^j. ice
*s?^. y
vrs. 7

V?8./
./
O./
0. /

O./
0. /




Temperatures
Stack
315
<3D5
32S

333
<33Q




'robe
3/4tff
310
310

338
Z&(7]




Coil
°C
7/t
°c
jj.f
#y°c

f/^
Sc°c




Impinger
In
ffc'F
tlfi
/<&

/JJ°f
/3o°f
':



Out
85'°f
fo °F
78 °f

78 *f
!
$G°F




Comments:
                                -101-

-------
         Plant Wend
         Run No.   /
         Location
         Date ..£.37
         Operator
      PARTICULATE FIELD DATA

VERY IMPORTANT - FILL IN ALL BLANKS
Read and record at the start of each

test point.
Ambient Temp °F   7*O



Bar. Press. "Hg 	
Assumed Moisture %   O
         Sample Box No.  	



         Meter Box No. 	



         Meter A H@  /, Q 3D



         C Factor
                                      Heater Box Setting °F



                                      Probe Tip Dia.,  In.  _



                                      Probe Length   .	
                                      Probe Heater Setting



                                      Avg.AP 	
Point
^
















Clock
/:o£
/ : /S
/•'3S
/ 3£
/•'"
7o
7o
70
70
73











Pump
Vacuum
In. Hg.
Gauge
C
&
(c
£
6
C,











Box
Temp
0F
/<£J"
38£
3oc
370
372
376











Stack
Temp
oF
















.
Stack
Press.
In. Hg
















-
Stack
Temp.
op
a.SSO/--'{
&ys
















o
no

-------
o
CO
I
         Plant
         Run No.
         Locat ion ~



         Date
         Operator
                                                       •>sr> _
                                                  PARTICULATE FIELD DATA

                                            VERY IMPORTANT - FILL IN ALL BLANKS
Read and record at the start of each

test point.
                                      Ambient Temp °F



                                      Bar. Press. "Hg
                                                                          Assumed Moisture %  9
Sample Box No.



Meter Box No.



Meter A H(f	/,_



C Factor
                                      Heater Box Setting °F



                                      Probe Tip Dia., In. _



                                      Probe Length 	
                                                                                  Probe Heater Setting _



                                                                                  Avg.AP 	Avg.AH
Point
JT


\













Clock
3:/8
3:38
3:3$
J?;ytf
21 5%
<3:oB
<3-/8










Dry Gas
Meter, CF
^V«5". 850
J-SJ. £
333










...
Stack
Temp
oF

















Stack
Press.
In. Hg

















Stack
Temp.
oF
ee~Ss>Jrr<
&s*

















-------
  SOURCE TEST REPORT
HIGHLAND POWER & LIGHT
  HIGHLAND, ILLINOIS

     BOILER NO. 3
      JULY, 1975
                     Tested by: Rockwell International
                                R.W. Griscom
                                O.C. Klein
                                F.E. Littman
           -104-

-------
                           TABLE OF CONTENTS

                                                                      PAGE

1.0  SUMMARY                                                           ,108

2.0  INTRODUCTION                                        •     :        ' log

3.0  PROCESS DESCRIPTION           ;                                    110

4.0  SOURCE TEST DESCRIPTION                                 ''        m

5.0  PROCESS OPERATION                                                 113

6.0  DISCUSSION                                                        114

7.0  SAMPLING AND ANALYTICAL PROCEDURES                                115
     7.1  PARTICULATE MATTER                                           115
     7.2  NITROGEN OXIDE                                               117
     7.3  SULFURIC ACID MIST AND SULFUR DIOXIDE                         117
     7.4  PARTICLE SIZE                                                119

8.0  RESULTS                                                           121

     APPENDIX A: PARTICULATE CALCULATIONS                              130

     APPENDIX B: FIELD DATA                                            141
                                    -105-

-------
                                TABLES





                                                                      PAGE





TABLE 1   BOILER 3/SUMMARY OF RESULTS                                  122





TABLE 2   COMPARISON OF RESULTS                                        123





TABLE 3   PARTICLE SIZE DETERMINATION/TEST NO;  1                        124





TABLE 4   PARTICLE SIZE DETERMINATION/TEST NO.  3                        125
                                  -106-

-------
                                FIGURES


                                                                      PAGE


FIGURE 1    POSITIONING OF UNI-STRUTS TO CARRY EPA EQUIPMENT              111


FIGURE 2   GAS ANALYSIS AND PROBE ADJUSTMENT BY OPERATOR IN
           CHERRY PICKER BUCKET                                         111


FIGURE 3   DETAIL SHOWING UNI-STRUTS AT 90° PLACEMENT ON STACK
           OPERATOR ADJUSTS PITOT POSITION                              112


FIGURE 4   PARTICULATE SAMPLING TRAIN                                   116


FIGURE 5   SULFURIC ACID MIST SAMPLING TRAIN                            118


FIGURE 6   ANDERSEN STACK SAMPLER                                       120


FIGURE 7   PARTICLE SIZE DISTRIBUTION/BOILER NO. 3                      126


FIGURE 8   TOTAL PARTICULATE FILTER                                     127
FIGURE 9   SMALL CARBONACEOUS PARTICLES AND SULFATES FROM STAGE
           5 OF ANDERSEN IMPACTOR                                       128
FIGURE 10  CARBONACEOUS PARTICLES AND SULFATES FROM STAGE 6 OF
           ANDERSEN IMPACTORS                                           128


FIGURE 11  ANDERSEN IMPACTOR BACK-UP FILTER                             129


FIGURE 12  CYCLONE COLLECT                                              129
                                   -107-

-------
                             1.0  SUMMARY

     In conjunction with the RAPS project,  a limited stack testing program is
being conducted.   This report details the results obtained on boiler No.  3 at
the Highland Power and Light Co. in Highland, Illinois.
     The stack testing included the following pollutants:  SOg, particulates,
NOw, and HgSO,.  Orsat analysis for COg.  CO, and 0^ were also performed.   De-
tailed results are included in this report.   Although these tests were not con-
ducted to ascertain compliance with Illinois standards,  it is of interest that
the particulate emissions are within limits while the S02 emissions are not.
     We acknowledge and appreciate the excellent cooperation we obtained from
the officials of the power company and the City of Highland.
                                   -108-

-------
                           2.0  INTRODUCTION

     The current stack testing program is being conducted in conjunction with
the emission inventory work for the St. Louis RAPS project.  The emission in-
ventory is being compiled using published emission factors. The stack testing
is being conducted to evaluate the emission factors and to gather information
for additional emission factors.
     This stack test was conducted at the Highland Power and Light Co. in
.Highland, Illinois.  Testing was performed on boiler No. 3 during the week of
14 July 1975.
     Boiler No. 3 is a coal fired, 75,000 pounds per hour steam generating unit.
There are no emission controls on this unit.  This boiler was sampled for total
particulates,  particle size, nitrogen oxides, sulfur dioxide, sulfuric acid mist,
carbon dioxide, and oxygen.
                                    -109-

-------
                       3.0  PROCESS DESCRIPTION

     Boiler No. 3 was built by Union Iron Works and installed in 1959.  It
is equipped with a traveling grate stoker which is gravity fed.  The econo-
mizer has not been used for 10 years.  The boiler was originally rated at
75,000 pounds per hour steam, however, present operating capacity is approx-
imately 60,000 pounds per hour.  Steam pressure is maintained at approximately
610 psi.  Boiler No. 3 is an induced draft unit and has no stack emission con-
trols.  The stack is of steel construction, 90 feet tall and 5 feet inside
diameter.
                                    -110-

-------
                     4.0  SOURCE TEST DESCRIPTION
     Boiler No. 3 was tested in the stack, approximately 35 feet above the
ground.  The City of Highland provided the use of a "cherry picker" for the
period of testing.  The testing arrangement is illustrated in Figure 1, 2
and 3.
                                                             FIGURE 1

                                                             POSITIONING OF
                                                             UNI-STRUTS TO
                                                             CARRY  THE  EPA
                                                             EQUIPMENT

            ANALYSIS
           AND PROBE
          ADJUSTMENT
         BY OPERATOR
           IN CHERRY
       PICKER BUCKET
                                   -111-

-------
                                   FIGURE  3
        DETAIL SHOWING UNI-STRUTS AT 90 DEGREE PLACEMENT ON STACK.
                       OPERATOR ADJUSTS PITOT  POSITION.

     The No. 3 stack is 5.0 feet inside diameter and approximately 90 feet tall,
This sampling point is approximately 5 diameters from the flue gas inlet.   In
accordance with the EPA Standard Method 1, fourteen samolinq points were chosen
on each of two perpendicular diameters.  Two,  3 inch couplings were installed
on the stack for use as sampling ports.
                                    -112-

-------
                     5.0  PROCESS OPERATION

     Boiler No.  3 was tested 14 July to 16 July.  During this testing period,
the load on the boiler remained fairly constant since this boiler drives a
turbine which provides the baseline electrical generation for the plant.  Gen-
erator output was generally between 4000 and 4300 KW.  There was no visible
change in emissions during testing. Ashes were pulled almost every hour.  Dur-
ing these periods visible emissions didn't change, but the flow rate in the
stack increased.
                                   -113-

-------
                             6.0  DISCUSSION

     A problem exists about the use of EPA Standard Method 2, Volumetric Flow
Rate Determination.  On boiler No. 3 the flow rate determined by method 2 is
23101.2 SCFM compared to a flow rate determined stoichiometrically from the
fuel rate and fuel composition of 15182 SCFM.  At this sampling point this should
have been a good check of method 2, since it was a reasonable distance downstream,
5 diameters, and two complete, perpendicular traverses were made.
     The flow rate determined stoichiometrically compares very well with the
expected flow as seen by a comparison of sulfur dioxide emissions using both
flow rates.  Using the published emission factor of 38S, which allows for a
95% conversion of sulfur in the coal to sulfur dioxide emission, the emissions
would be 413.87 Ib/hr.  With the flow rate using method 2 the emissions would
be 658.4 Ib/hr, which is definitely too great.  With the stoichiometric flow
rate the emissions would be 432.6 Ib/hr, which is a reasonable result.  For
this reason the emission determined using the stoichiometric flow rate are
reasoned to be the correct results.
     To determine the amount of coal consumed, the generator output and a ratio
of kw to pounds of coal were used to calculate coal consumption.  The ratio used
was based on operating records for the previous month.  Using the current ratio
of 1.6, the average fuel consumption for 15 July was 6702.4 Ib/hr.
     During testing for particle size, the first run was with the Andersen im-
pactor in the stack while the other two were run with the impactor in the oven.
For this test, a problem existed which forced the use of an unheated probe.  With
the impactor in the stack this is no problem, however with the impactor in the
oven there was probably some condensation in the probe which increases the weight
of particulates.
                                   -114-

-------
                7.0  SAMPLING AND ANALYTICAL PROCEDURES

     All testing was performed with sampling equipment from Joy Manufacturing,
designed for isokinetic sampling to enable testing by EPA standard methods.
     Gas flow rates were calculated using the observed gas temperature, molec-
ular weight, pressure and velocity, and the flow area.  The gas velocity was
calculated from gas velocity head measurements made with an S-type pitot tube
and a magnehelie pressure gauge, using standard method 2.
      f
      i
     Moisture Contents were determined by passing a measured amount of gas
through chilled impingers containing a known volume of deionized water, meas-
uring the increase in volume of the impingers liquid and the increase in weight
of silica gel used to finally dry the gas, and calculating the amount of water
vapor in the sample from this increase and the measured amount of gas.
     The stack gas concentrations of carbon dioxide, oxygen, carbon monox-
ide, and nitrogen by difference were measured with a standard Orsat apparatus.
These concentrations and the moisture content were used to determine molecular
weight of the stack gas.

7.1  PARTICULATE MATTER
     Standard method 5 was used for determining particulate emissions with the
exception that the probe and oven were operated at 300-350°F.  Measured stack
gas samples were taken under isokinetic conditions.  The samples were passed
through a cyclone, fiberglass filter, impingers, pump, a meter and an orifice
as shown in Figure 4.
     The total particulate matter collected in each test was the sum of the fil-
ter catch plus material collected ahead of the filter in the sampling train.  The
amount of filter catch is determined by the difference in the weight of the fil-
ter before and after the test, after dessicating.  The particulate matter from
other portions of the train was determined by rinsing the probe, cyclone and
all glassware ahead of the filter with acetone, evaporating to dryness and weigh-
ing.
                                   -115-

-------
              STACK
              WALL
 ft
                HEATED
          J    PROBE
REVERSE-
TYPE
PITOT TUBE
        >"
VELOCITY
PRESSURE
GAUGE
                  ORIFICE
                  GAUGE
                      FILTER
                      HOLDER
                                                                               CHECK
                                                                               VALVE
                                                 FINE CONTROL
                                                   VALVE
                                /  AIR-  \
                                I  TIGHT  J
                                V  PUMPJ
                                 /•*«- ~-X
                                    FIGURE 4

                           PARTICULATE SAMPLING TRAIN
                                     -116-

-------
7.2  NITROGEN OXIDE
     Using method 7, gas samples were withdrawn from the stack into evacuated
2-liter flasks containing a dilute solution of hydrogen peroxide and sulfuric
acid.  The hydrogen ..peroxide oxidizes the lower oxides of nitrogen (except
nitrous oxide) to nitric acid.  The resultant solution is evaporated to dry-
ness and treated with phenol disulfonic acid reagent and ammonium hydroxide,
The yellow trialkali salt of 6-nitro-l-phenol-2, 4-disulfonic acid is formed,
which is measured colorimetrically.

7.3  SULFURIC ACID MIST AND SULFUR DIOXIDE
     i
     The "Shell Method"* was chosen for this determination due to uncertainties
which exist about the validity of the results using method 8.  A gas sample is
drawn from the stack using a heated probe and passed through a water-cooled,
coil condenser maintained below the dew point of sulfuric acid at 140°-194°F,
followed by a fritted glass plate and then passed through a chilled impinger
train with two impingers containing an isopropanol and hydrogen peroxide mix-
ture and followed by an impinger containing silica gel for drying.  This set-
up is shown in Figure 5.
     The condensed sulfuric acid mist in the coil condenser is water washed
from the condenser.  The final determination is made by titrating the solution
with barium chloride, using a thorin indicator.  IsopropanoT must be added to
the solution to be titrated to improve the rapidity with which the barium sul-
fate precipitates during titration.
     Sulfur dioxide in the gas sample is oxidized to sulfur trioxide the im-
pingers containing the hydrogen peroxide.  Sulfur dioxide is then determined
by titrating the hydrogen peroxide solution with barium chloride, using a
thorin indicator.


*Lisle, E.S. and J.D. Sensenbaugh, "The Determination of Sulfur Trioxide
and Acid Dew Point In Flue Gases", Combustion, Jan. 1965.

Gokstfyr, H. and K. Ross "The Determination of Sulfur Trioxide  in  Flue  Gases",
J. Inst. Fuel. No. 35, 177, (1962)
                                     -117-

-------
STACK
 WALL
                                                                     CHECK
                                                                     VALVE
REVERSE-
TYPE
PITOT TUBE
                                           "j/   f "
      VELOCITY
      PRESSURE
      GAUGE
                                     FINE  CONTROL
                                        VALVE
     ORIFICE
      GAUGE
                                                                         VACUUf
                                                                         LINE
                         FIGURE  5

             SULFURIC ACID MIST SAMPLING TRAIN
                            -118-

-------
7.4  PARTICLE SIZE
     An Andersen, fractionating, inertia! impactor is used for the deter-
mination of particle size in the range of approximately 0.5 to 10.0 microns.
The sampling head is placed either in the stack at the end of the sampling
probe or in the oven after the heated sample probe (see Figure 6).  A sample
of stack gas is drawn isokinetically through the sampler.  The particulate
matter is fractionated and collected on the plates inside the sample head
and a determination is made by the difference in weight of the plates be-
fore and after testing.  Results are expressed for particles of unit density.
                                  -119-

-------
AIR FLOW
                        FIGURE 6
                  ANDERSEN STACK SAMPLER
                        -120-

-------
                         8.0  RESULTS

     The results obtained from this test are summarized in Table 1.  As dis-
cussed previously, the main flow of pollutant is based on calculated, rather
than measured flow rates.  The actual calculations and field data are attached
as Appendixes A and B.  Although these tests were performed for research
purposes and not as part of compliance procedures, standard EPA methods were
used (except as indicated).  It is thus of interest to compare the results ob-
tained with State of  Illinois standards.  A comparison is shown in Table 2.
                                  -121-

-------
                                TABLE  1

                        Boiler 3 - Highland Power
                        SUMMARY  OF  RESULTS
Date
Stack Flow Rate - SCFM * dry
% Water Vapor - % Vol .
% C02 - Vol % dry
% 0 - Vol % dry
% Excess air @ sampling point
S0£ Emissions - lbs/106 Btu
NOX Emissions - lbs/106 Btu
H2S04 Mist - lbs/106 Btu
Particulates
Probe, Cyclone, & Filter Catch
Ibs./nr.
lbs/106 Btu
Total Catch

Ibs./nr.
lbs/106 Btu
% Isokinetic Sampling
7/15/75
15182
8.798
14.0
4.3
24.7
5.9
0.17
0.04
16.08
0.22



92.67
7/16/75
16962
8.55
11.8
5.2
30.8

0.24




V


























v





'
•







•



,,
•
*70° F, 29.92" Hg
Calculated, dry
                                   -122-

-------
                                TABLE 2
                         COMPARISON OF RESULTS
Pollutant
S02
NOX
Parti culates
Standard
U>s/106BTU
1.8
no standard for
sources < 250xl06BTU/hr
0.23
Found
Ibs/lO^BTU
5.9
O.T9
0<22
     The only minor constituent measured during this test was  sulfuric  acid
mist which was determined to be 0.04 lbs/10  BTU.
     In addition to measuring particulate loadings, a particle size analysis
was made using an Andersen impactor.  The results are shown in Tables  3 and 4
and Figure 7.  The high percentage of particles less than 0.5 microns  in
diameter is probably spurious.  Microscopic examination indicates  the  presence
of large ammonium sulfate particles, which apparently were performed by sub-
sequent reactions of ammonia with sulfuric acid.  The latter,  present  in va-
por form at stack temperature, was apparently retained by the glass fiber fil-
ter.  The results for the first few plates on runs 2 and 3 are misleading since
the cyclone was ahead of the Andersen impactor and it fairly effectively re-
moves the larger,particles.
     Some of the photomicrographs are included for illustration.   Figure 8 is
of the total particulate filter from the run on 15 July.   It shows bits of un-
burned to partially burned coal and sulfate needles.  Figure 9 is  from stage
5 of the impactor and shows small carbonaceous particles and sulfates, which
are the white, shiny areas.  Figure 10 is from stage 6 of the impactor and
shows less carbonaceous particles and much more sulfate particles. The sul-
fate particles are definitely recrystallized on the filter since they  fol-
low filter fibers and are much larger than the impactor plate holes would
allow.
                                   -123-

-------
                             TABLE  3
                    PARTICLE SIZE DETERMINATION
Test:  Mo. /    ,
Date:
                      H7S
Plate Tare (g)
1 20,4711
3 2i,(,02/
4 22,5/36
5 11,7377
6 |l,*/8&
7 U.7W
8 2I,*/0*4
Back Up
Filter
Test: ^Q,£
Plate Tare (g)
1 20, 1^/4
2 21, 3706
•j 0 ! / O'lJ'A
J 6. 1 " (pOQ U
4 22.371*
s j 1 . 6965
6 ||. ^0?
7 M.^
8 2^,^210
Back Up
Filter
Final (g)
2I.47S2T
£1.6.10*
2 1. 5 17?
11,74/2
MloV
l|,74l£
21,^1^0
Total

Final (g)
to.wt-
21,3707
21 1 6** /
22,372/
11,6^72
ii.au
lUfc^
^,^2S-/

Net (mg)
3,-y
5.Z
?,7
12
3,5
i.a
1 ^}
l*i
6-6

35,3 '

Net(mg)
OA
P.I
p.V;
0-3
ay
0/6
l,i
^•l

Filter Total % of Cum % BCD
Net Total (Microns)
s% 6 100-c i3/ra 4
ft *7 <3^y ^J ^ <9/
1 | ^ ^Ir ' ^^
1,0 l\,i 4,(*l
S.2 M.I 2,1*
SO 5^.^ ),3 1 3*J« T w*/ o O
11,0 52.3 £OA
9^,5 **'^7
/ ,3 C?6»C 3,^6'-
3,1 K? 2-3i
2.6 
-------
   Test:
                   i £• M I.
                                 TABLE  4
                        PARTICLE SIZE DETERMINATION

                            Po uu r. i«
                                       Date:   Jul^ /<,,/? tf
Plate   Tare(g)    Final(g)   Net(mg)
                            O.I
                            0,5
                                      Net
2   C

3   0

4   0

5   O.HffO

6   £

7   n
                                             Total   % of  Cum %   ECD
                                                 .' Total        (Microns)
1,7

1.3
                                                                   ^,07
                            \>O     Qtf

                            2,3     /,o
mterP^UO   0,2232    12,2    1,1
                                            3J
                                            7,6"
       s;o    ?2/3    2,3Y
       «",3    77,3    /'/?
                  l    0,13.

                     Total
                                             35,7
     Test:
                                        Date:
Plate   Tare(g)   Final(g)   Net(mg)    Filter   Total   \ of   Cum %   ECD
                                     Net           Total         (Microns)
  1

  2

  3

  4

  5

  6

  7'

  8 •*}.. ;,

Back Up
Filter
                                                                         -i *&
                                                                    £,07
                                       ,5"
                                    1,0
                                    1.0
                                                                    2.3V
                                                      o /    oij .•
                                                      7' I    <5T.~

                                                      27,0  75,
                    Total
                                                    I&O.Q
                                     -125-

-------
35
30
25
20
15
                           FIGURE 7
                   PARTICLE SIZE DISTRIBUTION
                       HIGHLAND ELECTRIC
                           BOILER 3
13   12    II    10
                             g     7    6

                           E CD, microns
                               -126-

-------
         FIGURE 8



TOTAL PARTICULATE FILTER
         -127-

-------
                              C T r I "ir
     SMALL CARBONACEOUS PARTICLES ANC SULFATES FROM STAGE 5 OF
     ANDERSEN  IMPACTOR. WHITE SHINY  PARTICLES ARE SULFATES.
                              FIGURE  10
CARBONACEOUS PARTICLES AND SULFATES FROM STAGE 6 OF ANDERSEN
IMPACTOR.  NOTE INCREASE IN AMOUNT OF SULFATE FROM STAGE 5 TO STAGE 6.
                                  -128-

-------
     Figure 11  is the backup filter for the impactor and it  shows  mostly  sul
fates with some very fine carbonaceous particles.   Figure 12 is  of material
collected in the cyclone.  There are a large variety of particle sizes, al-
though somewhat misleading due to agglomeration of particles,  and  there is
the presence of fused and partially fused glassy material  and  minerals.
                                  FIGURE 11
        ANDERSEN IMPACTOR RACK-UP FILTER SHOWING VERY FINE CARBONACEOUS
        MATERIAL AND A GREAT NUMRER OF SULFATE CRYSTALS.
                                   FIGURE 12
           CYCLONE COLLECT.   NOTE AGGLOMERATION  AND PARTICULARLY  THE
           SPHERES OF FUSED  GLASSY PARTICLES.
                                   -129-

-------
       APPENDIX A
PARTICULATE CALCULATIONS
           -130-

-------
                         PARTICULATE CALCULATIONS

Volume of dry gas sampled at standard conditions  -  70°  F. 29.92 "Hq
                                                     AH
Vmstd = Volume of dry gas sampled at standard conditions,  ft3
Vm = Meter volume sampled, ft
1.021 = Meter correction factor
Pm = Meter pressure, barometric pressure, PB, plus   orifice
     pressure, AH, in. Hg.'
Pstd = Standard pressure, 29.92 in. Hg.
Tstd = Standard temperature, 530° R or 70° F
Tm = Meter temperature, 530° R for compensated meter
CFm = Meter correction factor
Volume of water vapor at standard conditions
VW-VT  /PH20\/R Tstd\       lb.         =  0.0474xVic
vw - vlc I  MH20 II  Pstd  1     454 gm.
         \     /  \       /                           2
Vw = Volume of water vapor at standard conditions, ft
VT  = Volume of liquid collected in impingers and silica gel,  ml
  \*
     = Density of water, Ig/ml.
M H20 = Molecular weight of water, 18 Ib/lb mol
R = Ideal gas constant, 21.83 in. Hg. - cu. ft./lb-mol   - °R
% Moisture in Stack Gas
                       Vw std
        % M = 100 x
                                  -131-

-------
 Average molecular weight of dry stack gas
HW0  =2               22    TO
                                                    )
Molecular weight of stack gas
 Stack  velocity at stack conditions
 ..       oc aa y r   / Ts x AP avg. \  I/
 Vs   =   85.48 xCp  (  ps  x  MW»   1   '2
 Vg  =  stack velocity, fps.
 85.48 - pitot constant,
                                lb.
 C  = pitot coefficient, dimensionless
 T  = average stack temperature, °R
 PS = stack pressure, barometric pressure plus static pressure, in. Hg.
 AP Avg = average differential pressure, in. H^O
Stack gas volume at standard conditions
                                  Ps   \
nc - ^nni  m \ \i
Qs - 3600^1 -T55-)VS
Q  = stack gas volume flow rate, SCF/hr
                                  2
A = stack cross sectional area, ft
3600 = seconds per hour
Qs1 = Qs 7 60 = SCFM
                                  -132-

-------
Per cent isokinetic sampling
          f                      Vmr   / D
I = 1.667  (0.00267)   VIG   +   r^     B
          L	Tm    \
 AH
13.6
                               9 Vs Ps An
I = per cent isokinetic sampling
1.667 = minutes per second, X 100
°-00267 •         x  R  x
0 = sampling time, min.
                                                p
A  = cross sectional  area of sampling nozzle,  ft
Particulate emission
Cs - 2.205  X  ID'6
C  = particulate emission, Ib/scf
2.205 X 10"6 = pounds per mg.
Mn = total mass of particulate collected,  mg.
CE = C$ X Qs = Ib/hr
Cr = particulate emission per hour
CH = CE ; H
C.. = particulate emission, Ib.  per million  BTU
H = heat input, million BTU per hour
                                  -133-

-------
Excess air at sample point


% EA =       100 X % Q2
        (0.266 X % N2) - X 02


% EA = excess air at sample point, %

0.266 = ratio of oxygen to nitrogen in air by volume
                                 -134-

-------
                 ^ARTICULATE SAMPLING CALCULATIONS

               4,
          Test;  [                                Date;

Material collected (mg) =

          Filter Catch  = C.I 33 '6
          Dry Catch     = C'-ko^l
          Acetone Wash  = t> < O 3 $ 3-
                          O.^Gl
          TOTAL         s.  a * ,  -,
                           "3Cs. / w4
Gas Volume   Vm   = 0.0334 / Vm VPB +     H \
               std         \1.02]A       13. 6 j

                                          iri.0%^ SCF
                  1.021\          13.

Volume of water vapor    Vw   =  0.0474 x Vic

          •0.0474  C&B3. ml )=  U-£g>j    SCF

% Moisture    %M = 100 x Vwstd
                         Vmstd + Vwstd

          100 x ( (l-£Ql )
Molecular Weight of dry stack gas

MW        MW =   % CO2 x 0.44  +   %02 x 0.32  +    %N2 x 0.28

          ( |4i0  x 0.44)  + ( Cft3  x 0.32 )  +  ( gi,7  x 0.28) =

Molecular Weight of stack gas

          MWw = 100 - %M X MWD   4-  %M   x 18
                     100             100

                                        18/ =
         fioo -8'm x-to4n1+fS'W> x is]
         [    100            J L 10°     J
                                -135-

-------
                   PARTICIPATE SAMPLING CALCULATIONS
     Test:
Stack Velocity    Vs = 85.48 x C_  fls  x  P  avg")  1/2
                                                        Date
85.48 x (0,$?)
                                 fls x P avg")
                                 Lps * Mww  J

                  f^gST    x  O.ei 7  1   1/2  =
                  [30. to x  2.^320  J
Stack Gas Volume  Qs =  3600/1- %M \ (Vs)(A)/Tstd\ / Ps \
                           \  TOO/        ^Ts/ \Pstd/
f
L
3600    l-    (2.
               100
                                            530
                                          (9^5")   Z9'92
                                                                          SCFH
Stack Emission Rate   Cs = 2.205 x IP"6/  Mn
2.205 x 1Q-6



CE = Cs x Qs  =


C ' = C  T H  =
                                           -£•
                                                   Ib/scf
                                                               Ib/hr
                                                      Btu
Isokinetic Variations   I = 1.667
                                  (0.00267)   V1   +  Vrn  /   + AH  \1
                                                    Tm  \PB   T3T6"/jT
      r
 .667    (0.
      L
            00267)
                                    530
                                                     13.6
Excess Air at  Sample Point
                                            EA »
                                                 100 x % 0?
                                                 (0.266 x % N2)  -
                                                                    02
                                                 100
                                 -136-

-------
                                STOICHIOMETRIC
                             FLOWRATE CALCULATION

                                  Boiler #3
       Coal Composition

       S          3.25%
       H00       12.89
7/15/75 A£h       10.98
       Btu        10856 Btu/lb
c
5/27/67 [J2
4
61.63%
4.37
0.77
8.86
Excess air = 24.7%
N2 = 3.76 x 0,2
                                       mols/100#

                                       T 32      x 1
                                       * 18 = 0.716
                                       * 12           xl
                                       * 2 = 2.185    x 0.5
                                       * 28 = 0.028
                                       * 32           x -1
                                            Theoretical 02

                                            excess 00
Mols Flue Gas = C0? + S0? + N9 + 0~ + N9
              = 5.T36 + 6.102N- 0.028 +^1.
                                                              moIs  02 required

                                                              = 0.102
                                                                     =  5.136
                                                                     =  1.093

                                                                     =-0.277
                                                                        6.054

                                                                     =  1.495
                                                                        7.549

                                                                     =28.384
                                          495 + 28.384 = 35.145 mols
Flue Gas = 35.145 x 386.7
                              = 13590.6 SCF/100*

@ 6702.4 Ib coal/hr = 6702.4 x-ij- x 13590.6 = 910,896 SCFH
                                            = 15,182 SCFM
     Sulfur Check - SQ  emissions
by emission factor   6702.4 * 2000 x 38 x 3.25 = 413.9 #/hr S02

using calculated flow
        910,896 x 4.75 x 10
                           "4
                                   = 432.6 #/hr S02
                             -137-

-------
                              N0v EMISSION DATA
                                A
                                                     Date.
                                                           7
                                      r^>
Run No.
Time
vg N02
T-- Initial Flask Temp, °F
Tf- Final Flask Temp, °F
^fc" ^as'c Vo^me, ml.
P- Initial Flask Pres, "Hg
Pf- Final Flask Pres, "Hg
Ib/scf N02 XIO"5
lb/106Btu N02
/
00
zom
Z.SS
3o,l
i,nl
0,1%
*
/oof
V*£




2qj?
m ••


\*sw
0,fi
J
/C3-i3
408




lo^




I.WS
o.\%
y
/t/Q
32<*




102$




i. i&r
o*\s
s
/3oo
y^^




^o^J




1.538
0,2-0
6
/3Vtf
//i




2
^*/5
?
yybo
-^G




2^5?


—
//-J^b
0,tb
Vsc=
                                                  = scf
Yfc - Vf - 25
C = 6.2 x 10"5  Ib/scf

                yg/ml
N02 \ = Ib/scf
                            Vsc
                                  -138-

-------
                             NOV EMISSION DATA
                               J\
                                                   Date.
                                                               /
                                         7S
Run No.
Time
ug N02
T.- Initial Flask Temp, F
Tf- Final Flask Temp, °F
Vf - Flask Volume, ml .
P^ Initial Flask Pres, "Hg
Pf- Final Flask Pres, "Hg
Ib/scf N02 x/o-5
lb/106Btu N02
/
0W
^£T2
10
IZO
ZQ<*I1
l.ss
3u.l
I*W
Oato
2
/J20
*m


^•MM
2~m
••1 • .tf
—
/.;<5?
^22
J
/J^.
£32


— , 	
aoif
	
	
Af/6

V7?
_, 	 :
	
2D22
_...
—
A ; /j
d^.23

















- •
•

















. ...

. ,.,;

Vsc=  17.71
            in. Hg,
(Vfc)     [_!±_  -  _!i_l =  scf

           Tf       Ti
Vfc - Vf - 25
C = 6.2 x 10"°  Ib/scf

                yg/ml
  /yg N02 \  =  Ib/scf  N02
                            Vsc
                                  -139-

-------
                            ,! MIST and S02  EMISSION  DATA
Date
Run No.
Vmc-Meter Volume, Ft3
Vmstd-Meter Volume, Std. Cond.
Pg-Barometric Pressure, "Hg
AH-Avg. Orifice Pres. Drop, "H20
Vt-Vol . of Titrant, ml.
Vtb-Vol. of Titrant for Blank, ml.
Vsoln-Vo1- of Solution, ml.
Va-Vol. of Aliquot, Titrated, ml.
Ib/scf H2S04 x/o"^
lb/106 Btu H2S04
Ib-scf S02 X/d"^
lb/106 Btu S02
7//S-
/
6>237
6«/£3
30,1
0,\
/,8
*;i
z.so
a4-
-±.16
0,0^


")//£
z
£>?J/
S.<*#2
3o,e
O.I
I.*
«l\
2.&D
ze
s.W
o.cy


7//S
I+Z
II, ft 8
If. $4(e


3i.n
^;i
Z£&
l.o


1.7$
*
-------
APPENDIX B



FIELD DATA
     -141-

-------
              SUPPLEMENTARY PROCESS & EMISSION DATA FOR POWER PLANTS
Test nuraber
Net Unit Load - J*T KW
Boiler Heat Rate - BTU/KW hr.
Boiler Heat Input - 106 BTU/hr.
Emission Level - lb./106 BTU

Particulates
so2
vo
X
Fuel Heating Valve - BTU/lb.
Fuel Burning Rate During Test - Ib./hr.
Fuel Ash Content - %
Additive Rate - Ib/hr.
n/<^
4/W.?

12.K




IO8S6
  jt
                /
                               //S"
                                   -142-

-------
ORSAT FIELD DATA
Location It / 0 r) Az/7 & ^ ^/, //.
Date 7- /£ - 73
T-fraA
Operator // /C//7

Test
tf^Vtf/A*
/3J15//*

/OoS nrs
/33G trs.






(CO )
Reading 1
/^/ O/ /*/, 0
/4o//
-------
Run No.  	1_

Location  j

Date
                                        .PARTICIPATE FIELD DATA        i  Ambient Temp °F
                                   VERY IMPORTANT - FILL IN ALL BLANKS '
                                                                     i  Bar. Press. "Hg
                                   Read and record at the start of each '
                                   test  point.
                                                                    i  Assumed Moisture %
                                                                                            8
 Oerator
Sample Box No.

Meter Box No.

Meter z, H-,3   )

C Factor
                                                                      : Heater  Box Setting °F   3lO

                                                                       Probe Tip Dia., In.

                                                                       Probe Length
                                                                       Probe Heater Setting   3)0

                                                                       AvgvA P «I6   Avg. AH 	
              O-SS"
i Point
    ._&.
     7
    10
	LI
    !.*•_
    i3
          Clock •  Dry Gas  !  Pitot   j   Orifice AH  ,  Impinger   Pump   Box    Probe   Stack  ;  Stack
                  Meter, CFl  in H20  }   in H20      !  °F Temp.   Vacuum  Temp    Temp   Press.   Temp.
                                                                In.  Hg.. °F      °F     In. -8g..<  °F
                                                               .Gauge
                            i AP
         10'. Q6
         	LI
         ._ J£
         _._.3JL
            56
          	li_
     L-L-UU6—-
                                     ,_o...i.^_.j.
                   .753,.]
                               ...12..
                               ...12,
                             ._J«,	
                            ..  •.!£_
                  73P.-3
                ....7M-.&.
                                      Desired jActual ijnletjOutlet   ° _ 1 _  _ i	
                                                                        _3j.a
                                                                                    .-fi^-LiiSL^
                                              L...74- L
                                        .,34r-.l..,a4_|.
                                       JLf2.a.:Ll.
                                                         :_7Q
                                                         !  70
                                                          •!—
                                            ..Ti-ia.
                                                          u ...7.fe.
1' i."s~'4 JLSJ3.iCL^l
.2-.£._L:
                                                                    —t.
                                                                           >J-.3Ao.
                                  :_...._Z1_
                                    _.J...5L&..
                                                        S.feQ
                                                        Sv/b
                                                                                              S6o
                                                                                              56^

-------
p.
      3
PART ICU LATE FIELD DATA         ! Ambient  Temp °F
Run Vo. .i
*"7 "^ **'~
Location Jj uon.&fc C>TA^'>
Date "7/1 S /TS"
• i • i 	 — 	
Operator
Sample Box No.
Meter Box No.
Meter .;.. H^
C Factor

! Point i Clock j Dry Gas
1 ]' Meter, CF
I . :
tn ; ;
2r_L J£'VU£QO,&S8L.

^ : 5-^.; g^jgvg)
V i 53 ; 8| 3.0
5 i _ o4 1617-1 .

7 l4-:0*6-2>
8 : 15 : 831-1
£L • 24- ; &B6.1
}Q < *3 i $4o.#
I \ ! Vh i 84S. ST
12, • 35» ! 0SC3.3
l^ V*- ! S^^'^
^iV . :r^lillf^
; VERY IMPORTANT - FILL IN ALL BLANKS
i
, Reac
(< : test
1 	
Pitot
in H20
0-ZO
-Z^
. z.4-
«2Jt
. 26
. ^
•^. 	

•_/0 *
."^TSsT 	
"X A-
^> **t~
- >•''*•• 	
*
. .• , .
I and record at the start of
. point.

Orifice AH '. Impinger
in H20 i °F Temp.
Desired j Actual , Inlet: Outlel
Bar. Press. "H?
each '
; Assumed Moisture ?6
Heater Box Setting °F
, pTQke ^.-Lp Dj_a-j in.
Probe Length
Probe Heater Setting
.Avg.AP Avg.A H
:
i ' • '
Pump , Box ' Probe '' Stack . Stack :
Vacuum Temp i Temp ' Press. Temp. •
In., Hg.. °F :, °F . In. Hg. °F i
uGauge ; j ' .
1.2- ! l-Z. 1 2nrt i SO ft. & i 315 j 2^>o ! 2Ad> i
"l7£~" riA"~i TlJ^LJJl"
!A ! \ A_ ! *? £t f\ **j t^1
i ^"" ! I * ^" i £ ^*J \J 1 ^J
1 C~ ^ s / CI *> i *? d'jyN • If ^T"
" ( 1 ;> t^- . J * •* AN^ ' C~- ^SCJ> ' I W
j.B M.fe ! !

2,Q T~2.o i ZSo 73
2-Q ! 2.Q . i j

^. 1 ; 2.1 i 2>2j? 1 7s~
, i i >*
.. .Vr,- . n, J , ^ ^_
!• 6> '• lt_fe • "J 15" i SO
i
' '
- i 1 '
, - !
i '
: 2>'5" 325" ' 32.$" -: $SO :
8-5" 34 S" ! 33O : S"SO
BSO 1 *>?>fr
i 1
12.5" S^o 32^ ^SSO •
34o i i So s so
i 	 i_
j 2>55 F 3.SS" *Tj^Q :
13.5" i 3-25 ! 340 .S g O '
i "i6o ; "^o 5?4:SL ;'
li'S" i 2>6>S'_; ^>^>S" i?4-<^
IZ.Q i 32_S" S^£>
1 i
i i
	 	 _. j i • j.
_ 	 	 -.1 . .. L 	 i. „. - i-
      ••;

-------
                         PARTICULATE CLEANUP SHEET
Date:
Run Number: 	\_

Operator: 	
Sample Box No.
                                   plant.
                                   Location Of  Sample Port: 3p'A3/*£ *"*' "°

                                   Barometric Pressure:     3

                                   Ambient  Temperature
Impinger H20

Volume After Sampling ^b(  ml

Impinger Prefilled With  'Loo ml

Volume Collected  	2.c>l	ml
                                   Silica Gel
                                   Weight After
                                  _g
Weight Before
                                                          g
                                   Moisture Weight l>n.Z.g Moisture Total 1W-Z
Dry Probe and Cyclone Catch:
                                   Container No;

                                   Extra No.
                                                        Weight Results
Probe, Cyclone, Flask
And Front Of Filter
Acetone Wash:
                                   Container No.

                                   Extra No.
                                                           Weight Results Q
Filter Papers and Dry Filter Particulate

Filter No.   Container No.   Filter No.   Container No.

   II
                                                            Filter Particulate
                                                            Weight
                                                            Total Particulate

                                                            Weight 0.8*61  g
% Moisture By Volume
                                    -146-

-------
                      OXIDES OF NITROGEN FIELD DATA
Date  Z- /V-  />~	

       //.  /  •     '  /-/   /  -
Plant n f? h  /a f:'(jL L.  /CC'lt •' C
Sample Collected By.


Run No. 	
Power Stat Setting
Field Data
Clock Time
Flask number
Volume cf flask less correction (ml) ;
dfl
Pressure before sampling ui. Hg. * ;
Pressure after sampling, in. Bg/^,^,, 1
Flask temperature, F
7'/5
/
**7
£J
3c,^o
?o
\/Q:O&>
3,
3o38
(*.5
3c2v
9o
/o;5l
J
1*3?
6.0
&o3o
?o
//•/S
¥
3cl8
&$
Jo 3.0
?o
/'CO
6
3ol6
C.3
30.40
?0 .
/'•- £~,'7
^C
-------
                      OXIDES OF NITROGEN FIELD DATA
Date _




Plant
Sample Collected By.




Run No. 	
Power Stat Setting
Field Data
Clock Time
Flask number
Volume of flask less correction (ml)
£AA
Pressure before sampling •$». Hg.
Pressure after sampling, in. Bg.
Flask temperature, F
£>W
I
104-7
£
>.
2**6
6.r
V-*'
$0
f>s-^
*>
^^3
6.r
?o -
3o
n,o>
4-
«LOi^
6.^"
i». *-
*>t>
















.







                                    -148-

-------
                      GAS SAMPLING FIELD DATA
Material Sampled For  /73

Date  7- /6'-75

Plant
                                              >?
      nig h /a.nd, L/fr trie. Co.
         j
Bar. Pressure  3o, J?	"Hg
Ambient Temp  ?£	°F
               	       /o //? T
Location

Comments :
                                                      & <3
Run No
          /
Power Stat Setting

Filter Used:  Yes
                            No
Operator  firi$Cz ,'.••;•  . ////£/'r
Clock
Time
&3S
<3.;4o
<3:*'£
<3:3c
3: Co
4:c6




Meter
(Ft.3)
gLtf/ol
ff&S.S
3CC.3
SL 7. 3
ftf£
87o.J3?
f



Pitot
in. H20
dP
o.3o
0.33
c.<39
c.<34
0,OO





Orifice
in H20
2IH
o./
o./
o./..
c,/
c,/





Temperatures
Stack
370
SCO
S6o
S6c
JSO





Probe
3
-------
                       GAS SAMPLING FIELD DATA
Material Sampled For  /~TQ
Date   7- /£- 75	
Plant  /9/«
                                       
                             No _
                             £ / /?
                                  Location
                                  Comments :

                                ••/> r  -?- 7
Clock
Time
^/8
*/:33
#38
*
3*6*




Coil

**n,

®\

£e°c

tfc



Impinger
In
**
&
ffil
t$5cf
tfr,*
"fat




Out
%5^
ft*'
?J°F
?3°f
^n°F
/tf0/*




Comments:
                                 -150-

-------
 Plant
Run No. 	l_

Location i/ff<

Date  7-/&< 7S
Operator
                                                          e. •S'/z.e.
                                         PARTICIPATE FIELD DATA
                                   VERY  IMPORTANT - FILL IN ALL BLANKS
                                   Read and record at the start of each
                                   test point.                        •
Ambient Temp °F   &Q
                                                                         Bar. Press. "Hg   v3o> 3 Q
Assumed Moisture %
Heater Box Setting °F

Probe Tip Dia., In.
Sample Box No.

Meter Box No.
                                                                         Probe Length
              £ 'ft.

Meter A H@ / Q
Probe Heater Setting 	

Avg.AP flol? Avg.AH  /
C Factor   C.6'2
Point
-?- 7



o-tf












Clock
^<*O rJ-ffr;.
/c;i6
:jc
;35
:yo
/o:333
3JS
<3^G











•'

Stack
Temp
op











-





Stack
Press.
In. Hg





_

••\ -••'.• - -







-

Stack
Temp.
oF
dSZ'Jf.'C
j.ys






...










-------
        Plant
                 o
        Run No.
        Location
        Date   7- /£. 76
Operator Gft'stntr, ////c/'/>


Sample  Box No.  	


Meter Box No. 	


Meter A H@ /0 32	


C Factor
                                          PARTICIPATE FIELD DATA

                                    VERY IMPORTANT - FILL IN ALL BLANKS
                                    Read and record at the start of each
                                    test point.
Ambient Temp °F


Bar. Press. "Hg
Assumed Moisture %    p
Heater Box Setting °F


Probe Tip Dia., In. <
                    ~~

Probe Length
                                                                                  Probe Heater Setting
                                                                                                Avg.AH
                                                                                                       (g
Point
->
3 -S3
















Clock
/3£2
/3£3
/3SS
/3£7
/3£















••
CJI
r\>
                                                            •^.- '- ef',-.-A-eat

-------
        Plant
        Run No.


        Location



        Date   Z/£- 7*5
Operator
                          ////£/ fi
                                                 PARTICULATE FIELD DATA.

                                           VERY IMPORTANT - FILL IN ALL BLANKS
                                   Read and record at the start of each

                                   test point.
                                                                         Ambient Temp °F
                                                                         Bar.  Press.  "Hg c?Q.
Assumed Moisture %
        Sample Box No.


        Meter Box No.


        Meter A H@_


        C Factor
Heater'Box Setting °F


Probe Tip Dia., In.



Probe Length  £ /t>
                                                                         Probe Heater Setting


                                                                         Avg. A P 	Avg. A H
Point
3-/3
















Clock
O
3
V
£
A
/C m-f)











Dry Gas
Meter, CF
9oo. 3 f'o
9c3.g
9e>3.3
9c£. 9
9o£.r^
?e7.«^o











Pitot
in H20 :
AP
«.£SUf;:f
0.3
















Orifice AH
in H20
Desired
AS















••
Actual

/.O
/.3
A3
A3











r _ L_ --'--- 	
Impinger
°F Temp.
Inlet



*












-
Outlet

7c


7o












Pump
Vacuum
In. Hg.
Gauge













•



Box
Temp
oF
%8G
330
333
32*5
33o









•!

-
Stack
Temp
oF

















Stack
Press.
In. Hg

















Stack
Temp.
oF
assv^e
v
-------
                         PARTICULATE CLEANUP SHEET
Date:
Run Number:

Operator:
Sample Box No.
Plant
               :   H
                                              lG>J4LAN/D
 I j 2, 3   Location Of Sample Port:  -^3

	r     Barometric  Pressure: 	

	  Ambient  Temperature 	
                                                                          li«.( |'
Impinger H20

Volume After Sampling 2.5* L ml

Impinger Prefilled With 2(20 ml

Volume Collected    .fT,?.nil
          Silica Gel

          Weight After

                                                                     _g
          Weight  Before
                                                       . C  g
          Moisture Weight
                                                          Moisture Total
> I :
Dry Probe and Cyclone Catch:
Container No.
Extra No.


Weight Results g

Probe, Cyclone, Flask
And Front Of Filter
Acetone Wash:
                                   Container No.
                                    if
                                   Extra No.
                                                           Weight Results
Filter Papers and Dry Filter Particulate

Filter No.   Container No.   Filter No.    Container No.
                                                            Filter Partieulate
                                                            Weight
                                                            Total Particulate
                                                            weight  37 7,; mg
% Hoiotuge By Volume

       .,=   (\*\.Wt *

                                       .™ cf
                              7.75") ^0.033V 4-1.021 X  (30.14  7175 )"
                     7V  X
       OO

-------
            PRELIMINARY
        SOURCE TEST REPORT
CARLING BREWING CO. - STAG BREWERY
        BELLEVILLE, ILLINOIS
            BOILER NO. 1
          4 NOVEMBER 1975
                                   TESTED  BY:  Rockwell  International
                                              R.W. Griscom
                                              O.C. Klein
                                              F.E. Littman
                 -155-

-------
                           TABLE OF CONTENTS





                                                                   PAGE





1.0  SUMMARY                                                       159





2.0  INTRODUCTION                                                  160





3.0  PROCESS DESCRIPTION                                           161





4.0  SOURCE TEST DESCRIPTION                                       162





5.0  PROCESS OPERATION                                             164





6,0  DISCUSSION                                                    165





7.0  SAMPLING AND ANALYTICAL PROCEDURES                            167





8.0  RESULTS                                                       168





     APPENDIX A:  PARTICULATE CALCULATIONS                         173





     APPENDIX B:  FIELD, DATA                                       186
                                 -156-

-------
                                TABLES


                                                             PAGE


TABLE 1    COMPARISON OF FLOW RATE DETERMINATIONS             166


TABLE 2   SUMMARY OF RESULTS                                 169


TABLE 3   COMPARISON OF RESULTS                              169
TABLE 4   PARTICLE SIZE DETERMINATION
          (TEST: STAG - ANDERSON #1 & 12)                    170
TABLE 5   PARTICLE SIZE DETERMINATION
          (TEST: STAG - ANDERSON #3)                         171
TABLE 6   HYDROCARBON ANALYSIS                               172
                                 -157-

-------
                                  FIGURES

                                                             PAGE
FIGURE 1        SAMPLING  LOCATION  FOR BOILER
               NO.  1                                           163
                                 -158-

-------
                                       t
                              1.0  SUMMARY
     In conjunction with the RAPS project, a limited stack testing program
is being conducted.  This report summarizes the results obtained on boiler
No.  1  at the Stag Brewery in Belleville, Illinois.  Some work remains,>onv
the combustion efficiency of.,the unit to better clarify some of the .obtained
results.  A final report will be issued at that point.
     The stack testing included the following pollutants:  SCL, particulates,
NCL, fLSCL,-and hydrocarbons.  Orsat analysis for CCL, CO, and 02 were also
performed.  Results of these tests are included in this report.  .Although
these tests were not conducted to ascertain compliance with Illinois stand-
ards, it is of interest that the particulate emissions and the SO,, emis-
sions are just slightly above the limits.                          (
     We acknowledge and appreciate the excellent cooperation we obtained
from the officials of the Stag Brewery.
                               -159-

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                     2.0  INTRODUCTION

     The current stack testing program is being conducted in conjunction
with the emission inventory work for the St. Louis RAPS project.  The
emission inventory is being compiled using published emission factors.  The
stack testing is being conducted to evaluate the emission factors and to
gather information for additional emission factors.
     This stack test was conducted at the Stag Brewery in Belleville, Illinois.
Testing was performed on boiler No. 1 on 11, 12 and 13 August and 15, 16
and 20 October 1975.
     Boiler No. 1 is a coal fired, 50,000 pounds per hour steam generating
unit.  There are no emission controls on this unit.  This boiler was sampled
for total particulates, particle size, nitrogen oxides, sulfur dioxide,
sulfuric acid mist, carbon dioxide, oxygen and hydrocarbons.
                                   -160-

-------
                       3.0, PROCESS DESCRIPTION
                                , '         *   t.  * •  '.   i

     Boiler No. 1 was built by He.nry Vogt Boiler Co.. and was installed, in
1939,  It is equipped with a gravity fed,, traveling grate stoker.  Steam
pressure is maintained at approximately 125 psiv  The. firing rate of (the
boiler is directly controlled by the steam requirements of the brewery.
As a result, there is a considerable fluctuation in the steam load through-
out the day.  Boiler No. 1 is 'a natural draft unit and has no stack emis-
sion controls.  The stack  is of brick construction and is 225 feet tall
and 8 feet inside diameter.
                                  -161-

-------
                     4.0  SOURCE TEST DESCRIPTION

     Boiler No.  1  was tested in the ductwork  between  the  boilers and  the
stack.  This is  a  common duct for both boilers  1 and  2, however, boiler
No. 2 was not in operation at the time of testing.  The sampling location
is illustrated in  Figure 1.
     The duct at this point is 52.5 inches wide by  102 inches deep.   The
cross-section of the duct at this point is not  rectangular  since fly  ash
is deposited at  the bottom and sloped to one  side.  Sample  points were cho-
sen accordingly  to avoid sticking the probe into this fly ash.  In accord-
ance with the EPA  Standard Method 1, thirty-five sampling points were cho-
sen, seven at each of five sampling ports. Five, 4-inch  pipe nipples were
installed on the duct for use as sampling ports.
                                  -162-

-------
                          PLAN VIEW
Sample
Ports
          f
                                      Boiler  2

Boiler  1
                             Elevation
               FIGURE 1
     SAMPLING LOCATION FOR BOILER NO. 1
                  -163-

-------
                         5.0  PROCESS OPERATION

     As mentioned previously, the firing rate on this  boiler is  determined
by the steam requirements of the plant operation.   As  a consequence,  load
fluctuations of up to 100% occurred.   During testing on 16  October,  the
boiler load was reduced considerably  since no brewing  operations were
taking place that day.  The load that day remained very constant.  Ashes
are pulled approximately once an hour.  At those times the  flow  rate  in
the ductwork increased.
i
     During testing in August, high sulfur coal was being burned; In  October
low sulfur coal, (1% S), was used.
                                  -164-

-------
                            6.0  DISCUSSION

     Flow determinations were made in accordance with EPA Standard Method
2, using an S-Type Pitot Tube.  This method gives correct results as long
as the pi tot tube is positioned normally to the flow of gases.   This is
no problem as long as the flow of gases is 1 ami nor and parallel  to the
walls of the ducts.  However, if the flow is turbulent or vortex-type, the
readings obtained are incorrect, with a positive bias (too high).  The ex-
istence of a turbulent condition can be ascertained by turning  the pitot
tube 90° on its axis.  A zero reading should then result.  If no zero read-
ing is obtained, the results are open to question.
     In the duct being tested, the existence of turbulence was  evident by
the fact that a zero reading could not be obtained except on 16  October
when the boiler was operated under reduced load.  Actually, the flow rate
on that day was not much lower than under full load conditions,  but the
gases consisted of a large excess of air and little combustion  products.
As a result, the flue gas temperature was lower.
     Under conditions when satisfactory flow measurements cannot be obtained,
a stoichiometric calculation of flow rates can be made, based on fuel consump-
tion, fuel composition, combustion rate and excess air.  As a check on the
correctness of the assumption, the mass flow of S02 can be calculated based
on gas flow and S02 concentration on one hand, and fuel consumption and sul-
fur analysis on the other.  The conversion of sulfur in coal to S02 is straight-
forward and occurs with 95% efficiency.
     To determine the amount of coal consumed, the steam output and a boiler
efficiency were used to calculate coal consumption.  The boiler efficiency
was determined by comparing steam output to coal usage on thirteen high pro-
duction day shifts.  By this method an efficiency of 82.5% was determined.
                                   -165-

-------
     Table 1 shows the comparison of the results obtained by the two method-


                                TABLE 1
                  COMPARISON OF FLOW RATE DETERMINATIONS
DATE
8/12
10/20
10/20
FLOW RATE, SCFH
Measured Calculated
1,394,989


782,909
736,170
776,420
SO 2
AP-42*

74.9
79.0
(Ibs/hr) BASE!
Ca'l art ated
Flow

81.4
91.1
> ON M
Measured
Flow



   * Compilation of air pollutant.
     Emission Factors, EPA Publ.  No. AP-42

     A small problem still remains in that these S02 emissions are still high-
er than predicted by emission factors.  There is evidence to believe that the
combustion efficiency of this boiler is very poor.  If this is the case, then
some amount of coal goes unburned.  The stoichiometric flow rate determination
is based upon complete combustion of the coal and, therefore, the actual flow
rate would be less if combustion is not complete and the SOg emissions would
be closer to the predicted results.  This assumption will be evaluated short-
ly with a coal  and ash analysis.   Following this test, a final report on this
installation will be completed.
                                  -166-

-------
         7.0  SAMPLING AND ANALYTICAL PROCEDURES

     All  testing was performed with sampling equipment from Joy Manufacturing,
designed for isokinetic sampling to enable testing by EPA standard methods.
The following EPA methods were utilized during testing;  ,
        Method 1:  Sample and Velocity Traverse
        Method 2:  Volumetric Flow Rate Determination
        Method 3:  Gas Analysis by Orsat Method
        Method 4:  Stack Gas Moisture Determination
      ,, Method 5:  Determination of Particulate Emissions
        Method 7:.  Determination of Nitrogen Oxide Emissions
     In addition, a modified method 8 using the "Shell Method for Sulfuric
Mist" was used for sulfuric mist and sulfur dioxide.  Particle size deter-
minations were made using an Andersen fractionating, inertial impactor.
Hydrocarbon grab samples were taken.
                               -167-

-------
                          8.0  RESULTS

     The results obtained from this test are summarized in Table 2.   As
previously discussed, the pollutant emissions are based on calculated,
rather than measured, flow rates.   Although these tests were performed
for research purposes and not as part of compliance procedures, stan-
dard EPA methods were used.  It is thus of interest to compare the results
obtained with State of Illinois standards.  A comparison is shown in Table 3.
     Since the measured flow rate is higher than the calculated flow rate,
the testing for particulates was apparently conducted at greater than iso-
kinetic conditions and the results are then higher than they should be.
For this reason, it would appear that for the testing on 12 August, this
boiler is very nearly within compliance.
     The results of a sample taken on 6 August for hydrocarbon was:
        Carbon Monoxide:                               8.93 ppm
        Methane:                                       0.33 ppm
        Total Hydrocarbons, as CH^:                    6.97 ppm
     The results of another sample for hydrocarbons taken on 11 August are
given in Table 6.  The total amounts to 7.14 ppm.
                                -168-

-------
                             IABLL ^
                       SUMMARY  OF  RESULTS
Date
Stack Flow Rate - SCFM * dry
% Water Vapor - % Vol .
% C02 - Vol % dry
% 0 - Vol % dry
% Excess air @ sampling point
S02 Emissions - lbs/106 Btu
NOX Emissions - lbs/106 Btu
H2S04 Mist - lbs/106 Btu
Particulates
Probe, Cyclone, & Filter Catch
Ibs./hr.
lb's/106 Btu
Total Catch
Ibs./hr.
lbs/106 Btu .
% Isokinetic Sampling
8/11
13048

-.



0.36






8/12
13048
9.02
10.5
10.4
97.7

0.31

37.03
0.95



10/15
13604

9.3
10.8
103.3
2.4







10/16
12359
4-7
5.6
4.8
232.2



7.46
0.37


"
10/20
12605

11.55 -
8.7
69.5
2.35

0.031
•




*70° F, 29.92" Hg -<
                                TABLE 3

                         COMPARISON OF RESULTS
POLLUTANT
S02
NOX
Particulates 8/12
10/16
ILLINOIS STATE
STANDARDS
lbs/106 BTU
1.8
No standard for
sources <250 X 106
BTU/hr
0.28
FOUND
lbs/106 BTU
2.4, 2.3, 2.4
0.36, 0.31
0.95
0.37
       In addition to measuring particulate loadings,  a particle  size  analysis
  .was made using an Andersen impactor.   The results are shown in  Tables  4 and  5,
                                    -169-

-------
                            TABLE 4
                    PARTICLE SIZE DETERMINATION
TEST:
PLATE
1
2
3
4
5
6
7
8
BACK UP
FILTER
TOTAL
TEST:
PLATE
1
2
3
4
5
6
7
8
BACK UP
STAG - ANDERSEN #1
NET(mg) FILTER TOTAL
NET
13.7
10.6
6.4
4.9
2.6
3.1
1.5
10.9
20.2
73.9
STAG - ANDERSEN #2
NET(mg) FILTER TOTAL
NET
9.4
6.4
5.2
4.3
3.0
2.6
3.0
6.8
23.9

% OF
TOTAL
18.6
14,3
8.7
6.6
3.5
4.2
2.0
14.8
27.3
100.0
% OF
TOTAL
14.6
9.9
8.1
6.7
4.6
4.0
4.6
10.5
37.0

CUM %
18.6
32.9
41.6
48.2
51.7
55.9
57.9
72.7
100.0
CUM %
14.6
24.5
32.6
39.3
43.9
47.9
52.5
63.0
100.0
DATE: 8/13
ECD
(MICRONS)
12.28 & Above
7.72
5.15
3.63
2.23
1.15
0.70
0.47
<0.47
DATE: 8/13
ECD
(MICRONS)
12.28 & Above
7.72
5.15
3.63
2.23
1.15
0.70
0.47
<0.47
FILTER
TOTAL   64.6
100.0
                                  -170-

-------
        TABLE 5
PARTICLE SIZE DETERMINATION
TEST: STAG - ANDERSEN #3
PLATE
1
2
3
4
5
6
7
8
BACK UP
FILTER
TOTAL
TEST:
PLATE
1
2
3
4
5
6
7
8
BACK UP
FILTER
TOTAL
NET(mg) NET(mg)
PLATE FILTER
3.3 16.1
2.5 5.0
2.1 4.3
1.8 2.3
1.2 2.0
1.5, 1.4
1.7 6.1
2.0 7.2
17.6
16.1 62TO~~
STAG - ANDERSEN #3
TOTAL
19.4
7.5
6.4
4.1
3.2
1.9
7.8
9.2
17.6
777T

TARE(g) FINAL(g) NET(mg)
•


FILTERS
ONLY














% OF
TOTAL
25.2
9.7
8.3
5.3
4.2
2.5
10.1
11.9
22.8
100.0

FILTER
NET
16.1
5.0
4.3
2.3
2.0
1.4
6.1
7.2
17.6
6O"
CUM %
25.2
34.9
43.2
48.5
52.7
55.2
65.3
77.2
100.0


TOTAL
, ' .•;•-, ;•'








DATE: 8/13
ECD
(MICRONS)
12.28 & Above
7.72
5.15
3.63
2.22
1.12
0.69
0.46
<0.46

DATE: 8/13
% OF CUM%
TOTAL
' 26.0 26.0
8.1 34.1
6.9 41.0
3.7 44.7
3.2 47.9
2.3 50.2
9.8 60.0
11.6 71.6
28.4 100.0
TOO"












ECD
(MICRONS)
12.28 & Above
7.72
5.15
3.63
2.22
1.12
0.69
0.46
<0.46

                -171-

-------
    TABLE 6
HYDROCARBON ANALYSIS
DATE:  8/11/75
TEST:  STAG #1
COMPOUND
Ethane
Propane
Isobutane
1-Butene
n-Butane
Isopentane
1-Pentene
n-Pentane
2-methyl Pentane
2-methyl, 1-Pentene
1-Hexene
n-Hexane
3,3-dimethyl, 1-Pentene
2,4-dimethyl Pentane & Benzene
1 methylcyclopentene & 2M C3 Hexene
Cyclohexane
2-methyl Hexane
3-methyl Hexane
1-Heptene
n-Heptane
Toluene
2,2,5-trimethyl Hexane
1-Octene
n-Octane
Ethyl benzene
meta, para Xylene
Orthoxylene
n-Nonane
N-Propylbenzene
1,3,4 Trimethyl Benzene
        -172-
 TIME:
 CONCENTRATION ppb)
 76.6
 57.3
 46.5
 29.2
 28.2
  4.9
  2.5
  5.4
  3.4
  2.8
 38.3
115.1
 22.9
 34.4
 10.4
  4.9
  1.8
  2.9
  8.6
 12.2
 49.9
  3.4
  6.8
  3.6
 37.3
 72.2
 18.9
  6.3
  4.7
  3.5

-------
       APPENDIX A



PARTIGULATE CALCULATIONS
           -173-

-------
                         PARTICIPATE CALCULATIONS


Volume of dry gas sampled at standard conditions - 70°  F,  29.92  "Hg


Vmsta .(SLH^lfJsw  |  B  0 plus   orifice

     pressure, AH, in. Hg.

Pstd = Standard pressure, 29.92 in.  Hg.

Tstd » Standard temperature, 530° R or 70° F

Tm = Meter temperature, 530° R for compensated meter

CFm = Meter correction factor
Volume of water vapor at standard conditions
               .      Tstd        1b.          =  0.0474
       cMH20     Pstd  1     454 gm.
         \     /  \       /                           ^
Vw = Volume of water vapor at standard  conditions, ft

Vi  = Volume of liquid collected in impingers and silica gel, ml

pHgO = Density of water, Ig/ml.

M H£0 - Molecular weight of water, 18 Ib/lb mol
R = Ideal gas constant, 21.83 in. Hg.  - cu.  ft./lb-mol   - °R


% Moisture in Stack Gas
                       Vw std
        % M = 100 x
                    Vmstd + Vwstd
                                -174-

-------
Average molecular weight of dr  stack gas
-Molecular weight of stack gas
 Stack  velocity at stack conditions
 v   -   85 48 x C   /Ts x AP avg. \  I
 V   -   8b.4b x L   I  ps  x  M
 V  =  stack velocity, fps.
 85.48 -  pitot  constant,    -              . OR   '/
 C  =  pitot coefficient, dimension! ess
 T  =  average  stack temperature, °R
 P  =  stack pressure, barometric pressure plus static pressure,  in.  Hg
 AP  Avg  = average differential pressure, in. fr^O
Stack gas volume at standard  conditions
nc - ^finn/i   %M \ \i   fl
Qs - 36001 1-      V   A
                         /Tstd
                          -
Qs = stack gas volume flow rate, SCF/hr
                          i rate, S
                                  2
 A  =  stack cross sectional area, ft
 3600 = seconds per hour
 Qs'  = Qs 7 60 = SCFM
                                    -175-

-------
 Per cent isokinetlc sampling
   = 1.667|(0.00267)   Vlc   +   Jfe  (PB
 I = per cent isokinetic sampling
 1.667 = minutes per second, X 100
 0.00267 =   ^O   X  R  X      b'
                             454 gm.
 9 = sampling  time, min.
 An = cross  sectional area of sampling nozzle, ft2

 Particulate emission
 Cc = 2.205  X  10
                      Vmstd(
 C  = particulate emission, Ib/scf
 2.205 X 10~6 = pounds per mg.
 Mn = total mass of particulate collected, mg.
C.. = CL X Qc « Ib/hr
 n    o    j>
CE = particulate emission per hour
CH = CE • H
CH = particulate emission, Ib. per million BTU
H = heat input, million BTU per hour
                                  -176-

-------
Excess air at sample point
% EA =       100 X % Q2
        (0.266 X % N2) -
% EA = excess air at sample point, %

0.266 = ratio of oxygen to nitrogen in air by volume
                                   -177-

-------
                   PARTICULATE SAMPLING CALCULATIONS
           Test ;S "buy -  &o'« ler4*/           Date:
Material collected  (mg)
Filter Catch           =  /C, 3. 2
Dry Catch
Acetone Wash           = JS&1, o
TOTAL

Gas Volume    Vm.^j = 0.0334/V,
                              m
0.0334
Volume of water vapor       Vw = 0,0474 X  Vic
0.0474 ( ;6>3   ml)  =    l,ll(>      SCF
% Moisture     %M  =  100  X Vwstd
                         Vmstd + Vwstd
100 X ( 7/7^4) _ .
Molecular Weight of dry stack gas
      MWD = %C02 X 0.44 + %02 X 0.32 +  %N2  X 0.28
   ( IO.S  X 0.44) + (/O.y X 0.32)  + (79,  / X 0.28) =
Molecular Weight  of  stack gas
MWw = 100 - %M X  MWn   +  %M  X 18
          100     u     100

100 - 8.^
     100
               X  30, 1      1 + 1      ^^         X 18 =
                             J  L       Too            J
                                  -178-

-------
                   PARTICULATE SAMPLING CALCULATIONS
     Test:
Stack Velocity   Vs  =  85.48 x C   pTs x P avgl  1/2
                                                        Date:
                                  [Ts x P avgl
                                  PsxMww  J
85.48 x
                    7??>7 x   0,C->t  1
                    2
      I   (o.
1.667    (0.00267)     (
                                        6 Vs  Ps  An


                                     530   \  	13.6
                                                                 7, 7
Excess Air at Sample  Point
                                           % EA =  100 x  %
                                                  (0.266 x % N2)  - % 02
                                                  100. (
                                                  (0.266
                                  -179-

-------
                                STOICHIOMETRIC
                             FLOWRATE CALCULATIONS

                               Boiler #1   8/12/75

Coal Composition
  Peabody-River King               Mols/100#                   Mols  02 required

                                  * 32         x 1            =       0.102
                                  f 18 =  0.716
                                    12         x 1             =       5.136
                                    2 = 2.185  x .5           =       1.093
                                    28 = 0.028
                                    32         x -1           =      -0.277
s
7/15/75 "2°
Btu
C
H
5/27/67 |J2
°2
3.25%
12.89
10.98
10856 Btu/lb
6163
4.37
0.77
8.86
                                               Theoretical  02         6.054

@ 97.7 % Excess air                                           =       5.915
                                                                     11.969

No = 3.76 x 09                                                =      45.003
             £
                                                                     56.972
 Mols Flue Gas = 5.136 + 0.102 + 5.915 + 45.003 + 0.028 = 56.184 mols
                      ft3
       56.184 x 386.7 IL-  = 21726.4 SCF/100# coal 9 70°F, latm.
                      mol

8/12/75    31.775 x 103 #/hr steam    @ 82.5% boiler eff.
           1193.8  Btu/#  125 psig; sat. steam
            178.1  Btu/#  210°F water
           1015.7  But/#

31.775 x IP3 x 1015.7  = 3.91198 x 107 Btu/hr input
        .825


3.91198 x 107 * 10856 = 3603.5 #/hr coal

3603.5 XL x 21726.4 = 782909.1 SCFH, dry
                                 -180-

-------
                              NOV EMISSION DATA
                                «        *
                                                     Date.
Run No.
Time
yg N02
T.- Initial Flask Temp, °R
Tf- Final Flask Temp, °R
Vf - Flask Volume, ml.
P.- Initial Flask Pres, "Hg
Pf- Final Flask Pres, "Hg
Ib/scf N02 X/0~S
lb/106Btu N02
/
1200
£-32
90
!io
lOHl
ZM
2
-------
                              NO  EMISSION DATA
                                A
                                                                /
                                                            75
Run No.
Time
yg N02
T-- Initial Flask Temp, °R
Tf- Final Flask Temp, °R
V- - Flask Volume, ml.
P^ Initial Flask Pres, "Hg
Pf- Final Flask Pres, "Hg
Ib/scf N02 X/0-4T
1b/106Btu N02
1
\UZ
4o?
90
HO
2072
e.Gk
21, iO
1,53
£.31
?
v.
/£20
•y^^




dot.}




.hbt
0>]>l
3
ISIO
—











V
/5^S
jse




205^3




/,V7
o.il
51
/5JO
^V6




tow




Ml
0,11*
(*
/s.ib"
3V6




ao??




/^f
^2i
^
ISSO
w/




2cl
/O
isssr
V?a




^oxl


-
/.ffj
o.il
Vsc=
/17.71  ^R    \

\      in.  Hg/
(Vfc)
                                  Tf       Ti
                                                 .  scf
Vfc = Vf - 25
C = 6.2 x 10"5  Ib/scf

                ug/ml
                        N02 ^ = Ib/scf N02
                            Vsc
                                    -182-

-------
                   PARTICIPATE SAMPLING CALCULATIONS
                               w.«s  I, *, 3
           Jest: Siot  - Bo'tlffr * |              Date:   #//.$
Material collected (mg)
Filter Catch            =
Dry Catch
Acetone Wash                
-------
                  PARTICULATE SAMPLING CALCULATIONS
     Test:  Boiler*!  -k*eltrtf>Hi   l,2,a
                                                       Date:
 Stack Velocity   Vs = 85.48 x C   fls x P
 85.48 x (0.%(s> )
                   /O257?x
          fls x P  avgl
          Lps * Mww  J

               -]'"
                                             1/2
 Stack Gas Volume  Qs = 3600/1- XM "\ (Vs)(A)/Tstd\ / Ps \
                          \  TOO"/        \jr~7 \Pstd/
3600   l-
fl
L
               100
(22.^7?)
                                           539  (2^.37)
                                                 29.92
                                                          -  /, 3 7 3.9* 6  SCFH
                 , EDS
Stack Emission Rate   Cs =  2.205 x IP"6/ Mn   \

                                            r"
2.205 x 10~6
?


CE = Cs x QS =


CH - CE * H  =



Isokinetic Variations
                                                 Ib/scf
                                                             Ib/hr
                      1 = 1.667   ((0.00267)  V,   +  Vm  /   + AH  \]
                                 [	'c     Ti  \PB  TI^/jTs
 .667    (0.
                                       8 V5  Ps  An
            00267)
                                   530
                                                   13.6
                    (ZZ.SW
Excess  Air at Sample Point
                                           EA =
                                                100 x X 0?
                                                (0.266 x %
                                                          N2) - % 02
                                                100


-------
Test: $-fA
-------
APPENDIX B



FIELD DATA
 -186-

-------
           SUPPLEMENTARY PROCESS DATA FOR POWER PLANTS
Date
Net Unit Load - MW
Average Steam Load - 10 Ib/hr
Boiler Heat Input
Fuel Burning Rate - Ib/hr
Fuel Heating Value - BTU/lb
Fuel Sulfur Content - %
Fuel Ash Content - %
Fuel Moisture Content %
sln-z/iz




/ O 8 STfc,
3.2S
I0,
-------
                       ORSAT  FIELD DATA
Location




Date  8-
          tSVa
Tine
Operator

rc
                   Comments:
Test
///£
/^V<9
/SJS

SUA •
<1




•
(co2)
Reading 1
/6.&
/?.o
9.o

IQ>$






CO)
Readirtg 2
W2//3.Z
30. (/ 8.£
/
^/.^//^^
-y
/0,y






(CO)
Reading 3
^y:^
3c.£
J/.3
\
0,0







                          -188-

-------
                       ossAT FIELD'DATA
Location i-? off




     _£
                                           Comments:
Tine
Operator
Test
soVS
/30Q

av*\,
w
-," t-





(CO )
Reading 1
//,£
/o.8

//a







CO)
Reaaing 2
^.^/4^
304/9.1
/ \
i
f,a







(CO)
Reading 3
3o. -g
3G.O

o.t>







                           -189-

-------
UD
O
                         re
       Run No.
                                          PARTICULATE  FIELD  DATA         I Ambient Temp °F
                                    VERY- IMPORTANT ;~ FILL IN ALL  BLANKS  !
Location /cw
                 cwcr
; Read and record at the start of each
 test point.
                                                                          Bar. Press. "Hg   3% 3C
                               Assumed Moisture "'.
       Datc 
-------
 Point j   Clock  Dry Gas -'  Pitot
      ;   Time   Meter CF :  In. H?0
i
10
                               Desired
     .i-jjjL..
Counts
                        o, c 7
                          • -/
                           -AAy..
                           -&J3JL.
  c.aB...
....4,0.? —
  0,0 f
                         &.Q.J..
                                      Or if ice AH
                                      In. H20
                                       /.% Ij^ooJ   
-------
                         PARTICULATE CLEANUP SHEET
Date:
7 '•
i *>
Run Number:
Operator:  6?ru''/vv  /A/PI

Sample Box No. 	
Plant:
                        rw
Location Of Sample Port:  ^ /  A>l

Impinger Prefilled With 30G ml

Volume Collected     HI     ml
Silica Gel
Weight After
                                  _g
Weight Before  3OO,C>  g

Moisture Weight 3*3,0   Moisture Total
Dry Probe and Cyclone Catch:
Container No.

Extra No.
                                                        Weight Results
Probe, Cyclone, Flask
And Front Of Filter
Acetone Wash:
Container No.

Extra No.
                                                           Weight Results  .
Filter Papers and Dry Filter Particulate

Filter No.   Container No.   Filter No.   Container No.
                                                            Filter Particulate
                                                            Weight
                                                            Total  Particulate
                                                            Weight
% Moisture By Volume
                                     -192-

-------
                           OXIDES OF NITROGEN FIELD DATA
Date
            *////
Plant
          S-U
Sample Collected  By
Field Data
Clock Time
Flask number
Volume of flask (ml)
Pressure before sampling in. Hg.
Pressure after sampling, in. Hg.
Flask temperature, °F
1260
1
Zo'll
2,U
Mil*
IZO
IZIG
a
^oM


...

l^fS
3
totf


- —
— —
/V2o
Y
2ott


.... .
_„. . .
/V2£
6~
Z02S



. ... . ___
/yjo
d
20 SZ
	
.„..,













* Flask + valve -  25 ml. for absorbing solution
                                       -193-

-------
                            OXIDES OF NITROGEN  FIELD DATA
Date
              tint
76"
Plant
Sample Collected By.
Field Data
Clock Time
Flask number
Volume of flask (ml)
Pressure before sampling in. Hg.
Pressure after sampling, in. Hg.
Flask temperature, °F
HIS"
1
Zom
Z.i*<*
2?,30
no
/MO
2.
Z039





/52o
3
^






/S2&
f
1MB


... -


/^"Jo
S
2^>^£
	




/53J
31
	


._...
* Flask + valve - 25 ml.  for absorbing solution
                                        -194-

-------
       Plant
vo
en
PARTICULATH FIELD  DATA          Ambient Temp °t!
- --3- - ^-
Run \o. Mhd &.?•£ ftv\ '
Location I Boi'ltv- S4t3if£.
Dr-te */U/7r
n <- f ', /I/I '
Operator ^riSCtn*\ //
C Factor
' VERY IMPORTANT - FILL tN ALL BLANKS'

; Read and record at the start of each
test point.



^^ || »
> T J



Bar. Press. "i!g 2*}, oO
Assumed Moisture ?« jOt^>
Heater Box Setting °F
// •'
Probe Tip Dia., In. /%
Probe Length £ ff, a (ASS
Probe Heater Setting
Avg . A P <9,<9(y Avg . .6. H // 7

| Point
. 3-3


|-^j-


.

;
;

i
;
;• 	 	 —
ClOCk :
tO'.S'O
. . ',£2

_j.i££
"S$

Dry Gas
Meter, CF
1 1 ££>, /£*£
{lbl'%
~
ts,o
fcjl
[{(*%• 3&2<

8 A 3.7 f l

\
	




	



|
Pitot
in H20
AP
O.08
O,G&
£>,o%

o>&*... .

l









Orifice AH
in H20
Desired } Actual
/ */ ! ^y
1 V ' i */
Iff '• It 1
1 eJ \ t fJ
(f7 ! Ill

^/y L ii*t
\
;
, - .,.!., ,.,,,.,1 .,.!., },..,,,. ,,.... ,11

Impinger Pump Box
°F Temp. Vacuum ' Temp
In. Hg., °F
Inlet
ISO
JJS_
:OutletGauSc i
: SS 12.5 [305
TO \3t$
'•
;
2iO\ JQ \ \33S
%*JO

'

,. _ _ . ; 	 1 „
,...!. j
_, .
i (
: 1
- • i \
\ |
I

i i ;
i ••" !" " ;
-^-4 	 r1^-
! !
1 1
i . _i

i
1 •'
j .
1 t
i i
._,.J 	 _L
. ! . . ..I
Probe Stack : Stack
Temp Press. •' Temp.
°F .! In. Hg... °F
; i
Z2O I SfO ;
3J£ l 5&O J
i ;
.MO .








L
'•53 O
\S*JO ;
'.££_£
i

'•
* i
t
I
;
i i
i
i
       to;
                             ,**

-------
                                                           c!«
Plant
                             PARTICIPATE FIELD DATA         I Ambient Temp °F
                            IMPORTANT - FILL IN ALL BLANKS^ :'••"        '
                                                          •  . .Bar. Press. "Hg
Location

Date
JJQI I
                  tf.y
Read and record at the start of each
test point.
Assumed Moisture %
                     /£?,
Operator
Sample  Bex No.

Meter Box No.

Meter A H'g   I

C Factor
                               c>V£*\ 4  p/A"feJ

Heater Box Setting °F

Probe Tip Dia., In. 	

Probe Length  ^ -Pr <
                                                             Probe Heater Setting
                                                             Avg. /:. P
                                                                                        Avg..,n
i Point
J&A

. 	
-••
_.ftJX-


i
\ 	

i 	 <
': 	
i Clock ; Dry Gas ' Pitot
1 Meter, CF- in H20
• I AP
: i
//'•V# \\l(*$t£83L '• O.O8
'5~o : \noti j &iO&
J_sr^ __;. j u it _i 	 : OtS>£
LSk i U1 i j^ o t^
1 yV ' ^ -M- Ok
/.y '^j^ '. 10 ; 35^
J ' ...j ..;._ _: . !
i i
. _ ._! 	 	 ! . .L ...J 	

• ' i • '
! ' ; i
* f
* f
3.V6




	 	
~~~ 	 ^$SO~'~
; j$£&
J

!
i
	 j — ....;
' J ' ! i ;
; i ! i i
~ t i i | !
i 1 i 1 !
t i
	 ! 	 i- - :
	 !._ 	 	 <
i ! 1 • j i ;
	 \ 	 ": 'f 	 ' : 	 ~ '" i i '"' I '
. _ 	 l...- 	 ( 	 	 • _.! 	 _ 	 i. __j 	 . ..! 	 	 _ ,L 	

-------
       Plant
--J:
I
PARTICULATE FIELD DATA          Ambient Teinp °
J
Ru'i No Zl /»/ ta
Location # f ]^\\f>r
Date £//3 /7S
Operator Gjriitryw
Sample Box Xo.
Meter Box No.
Meter A H :? \»O3^(^
C Factor

tf J VERY IMPORTANT - FILL IN ALL BLANKS
.3
Read and record at the start of each
&TACK • test point.
^ •
^le'^ ! 	 - 	 - 	 - 	 —
[\v\0(fr$g*i. {K^ G \f£#( pl-7 l&l <*>ITlv
> 1




Bar. Press. MHg <^/3^
Assumed Moisture ?5 /£), ,5
Heater Box Setting °F
Probe Tip Din., In. '/£
Probe Length 5 TI, 4/&SS
Probe Heater Setting
Avg . 4 P Avg . . K


I Point
3-3
•
;

,
. cf.£ 	
i 	
Clock j Dry Gas j Pitot
1 Meter, CF; in H20
! AP
_k_o$ U7(*>£*/o j £,08
;O7 '. iiT$t3 *• dOS
iOf '' i[8&»& \ &tO%
!/( MSI'I &,&&
J /J // f 3y -^ i £<£>#
yi/^ ':ll#StQS2, ; ^•fi'^
.

: ;
; i
! i i i
; ! ! i
' i '• '
	 	
	 --
: i i
> i
; j :. . 	
: , !
f
s
i ,
Orifice AH • Impinger
in H20 - '. °F Temp.
Desired i Actual : Inlet: Outlet

1
if
J»t
/^ 33 ^
X*?' iJ|AO i i^t y3'5f S3JT
/^ jr j t\ 3 ^j i (9 -^ ^/ *» ^
) ;
i i
i i
j

i ' i
( ;
! i -
! l
-r -f - , ' 	
; >
1 ;
_. ^ 	 — .; 	 	 .' 	 	 	

; ;









. 	 .











3>5iS" i •• £jO '
3CfO £?O
370 j i ^ff&
i
'•

i ;•
i
t ' ^
' ; '
• ,
! i :
• <
(
... i 	 i 	
i
. . . - < 	 „. : 	 .. ;
i
I i
	 _ 	 i-_. ..!.-.._! 	 i 	 _._L_ i 	 :_:.! .." "i 	 ;
      1:13-

-------
Date:
8/13 /:
                         PARTICULATE CLEANUP SHEET


                                           O;
Run Number:
Operator: G>rUtcryv\ /\L\f\ >

Sample Box No. 	
                                   Plant:
                                              ^
                             3     Location Of Sample Port:  **•/
                                   Barometric Pressure:

                                   Ambient Temperature
                                                   ,3o
 Impinger H20

Volume After Sampling

 Impinger Prefilled With JQQ ml

Volume Collected     5Q> 2   ml
                                   Silica Gel

                                   Weight After   J 10.

                                   Weight Before  ^~>£.<.
                         Moisture Weight
                                                          Moisture Total  (01. 0\
Dry Probe and Cyclone Catch:
                                   Container No.	

                                   Extra No. 	Weight Results
Probe, Cyclone, Flask
And Front Of Filter
Acetone Wash:
                                   Container No.  	

                                   Extra No. 	Weight Results  */?/ (* g
Filter Papers and Dry Filter Particulate

Filter No.   Container No.   Filter No.   Container No.
                                                            Filter Particulate
                                                            Weight  J?y.?,
-------
                  PARTICULATE SAMPLING  CALCULATIONS
          Test: S4*a  -B»f!er*(          Date:   IO//(0/7S
Material collected (mg)
Filter Catch
Dry Catch
Acetone Wash
TOTAL
Gas Volume    Vmstd = 0.0334/V    \/p
                           v*rAB
0.0334 (X*rt(tfiCfl    +        0,SI(0    j  ,  yy,35r
                                   13.6
Volume of water vapor      Vw = 0.0474  X Vic
0.0474 (  5-6   ml)      2,64~V    SCF
% Moisture     %M = 100 X Vwstd
                        Vmstd + Vwstd
100 X ( 2
Molecular Weight of dry  stack gas
      MWD = %C02 X 0.44  + %02 X 0.32 +  %N2 X 0.28

   ( S",C,  X 0.44) + (11.2 X 0.32)  + (7f,4  X 0.28)  =   2<1,
Molecular Weight of stack gas
MWw = 100 - %M X MWn    +  %n  X 18
         100      u     100

100 -
     100
                             \ + \      */>&(*        X  18 =
                             j  I      100            J
                                 -199-

-------
                   PARTICIPATE SAMPLING CALCULATIONS


     Test:   S-U*   -  &o\\er  * I                        Date:

 Stack Velocity   Vs =  85.48 x Cn  fTs x P avgl  1/2
                                  PsxMw
                                        _avg_l
                                        "w  J

85.48 x (0.56 )   fW.2  x 0,o^(a   "1  1/2 =

                  L   :'                 J


Stack Gas Volume   Qs = 3600(l-
                                                           fps
                            "I- %M \ (Vs)(A)/Tstd\ / Ps \
                              1W/        \TT~7 \Pstdj
 3600   [l-   (^C.C> )1(/V.6o)   (3570)    530  (e?,
-------
                                STOICHIOMETRIC
                             FLOWRATE CALCULATIONS

                               Boiler #1   10/15/75

Coal  Composition                       mols/100#              mols 0? required
C         65.00%                  * 12         x 1                  L 5.417
S         1.04                    * 32         x 1            =       0.033
Ho        4.50                    *• 2  = 2.25  X 0.5          =       1.125
4        1-0                     * 28 = 0.036
Oo        7.94                    * 32 = 0.248 x-1            =      -0.248
Ash       8.34
Moist     12.18                   * 18 = 0.677
Btu       10.390 Btu/lb                                             _______
                                  Theoretical Oo              =       6.327 mols
Excess air = 103.3%               excess 02                   =       6.536
                                  Total 02                    =      12.863

N2 = 3.76 x 02                                                =      48.364
Mols  Flue Gas = CO? + S00 + N? + 09 + N9
               = 5.417 + 6.033 + 0.836 +^6.536 + 48.364 = 60.386 mols

Flue Gas = 60.386 x 386.7 fi3-  = 23,351.3 SCF/100#

@ 29.5 x 103 Ib/hr steam  =  29.5 x IP3 x 1015.7   = 36.319 x 106 BTU/hr
                                   0.825

36.319 x 106 T 10390 = 3495.6 Ib/hr coal

3495.6 x-J-x 23,351.3 = 816267 SCFH
        1Q0            = 13604 SCFM
                                          -201-

-------
                        H2S04 MIST  and S02 EMISSION DATA
Date
Run No.
Vmc -Meter Volume, Ft3
Vmstd-Meter Volume, Std. Cond.
PB-Barometric Pressure, "Hg
AH-Avg. Orifice Pres. Drop, "H20
Vt-Vol . of Titrant, ml.
Vtb-Vol . of Titrant for Blank, ml.
Vsoln~Vo1- of Solution, ml.
Va-Vol . of Aliquot, Titrated, ml.
Ib/scf H2SD4 xfo" k
'1b/lo6BtuH2S04
Tb-scf S02 X/o"^
lb/106 Btu S02
10//S
I
Kr,S8$
\(*,ni
2f,V8.
0,1
t.n
*;i
aro
\,<*


|,Q8/
2,V














10/iO
1
itKS
U.6>53
2M
0,1
3*6
«.'/
loo
10
J.Sifc
0>oll


I olio
/




».47
Kfl
2ST>
».o


|,207
2,3
\&ko
2
it.W/
\i.1&
2%SI
O.I
4,2
rv,'/
loo
20
/,*/£
0,0 s y


/^/?0
2




^08
H.'/
^^D
/-o


I.?*/
2,y
Vmstd = 0.0334 (Vm)   /PR + AH
               TFT   I      T3J
        CFm = Meter correction  factor
CH.2S04 = /1.08 x TO"4 lb-1  \  (Vt -  Vtb)   (N)
        \            9-ml  /
                                              /VsnlnV Ib/scf
                                              V Va  /
                                              N.= 0.01  Normal
                                                  Barium
                                                  Perchlorate
                                 Vmstd
CS02 =
x 10"5 lb
b-1 }
-rril /
                           (V  -
                                        (N)
                                                       = lb/scf
                                 Vmstd
                                       -202-

-------
            SUPPLEMENTARY PROCESS DATA  FOR POWER PLANTS
Da,te
Net Unit Load - MW
Average Steam Load - 10 Ib/hr
Boiler Heat Input lO^flfciAr
Fuel Burning Rate - Ib/hr
Fuel Heating Value - BTU/lb
Fuel Sulfur Content - %
Fuel Ash Content - %
Fuel Moisture Content %
/e//r

Z1.S
36.3
3

/V.ff3
2a /
/733
10390
\.otj
V.3¥
: ii.tS
^0/50 -/

3
-------
                       ORSAT FIELD DATA
Location




Date




Time
                    ' £»/
                           er
                       7/6,
Operator
                                           Coi-ments:
Test
/6//T
1316
I3SV

ie/tu
/3^a
1136

la/LO
lit*
II3S



(CO )
Reading 1
9,2
^,y

5",d,
.5,8

/AS*
;/,fe



Reading 2
l/.o
JO, (e

11*8
9,o

*.f
^,r



(CO)
Reading 3
0.0
0,0

0.0
4, 0

0.0
0.0



                            -204-

-------
Plant.
Run No..
Location.
           1 o //6>
       Operator	!

       Meter  AH@,

       C Factor 	
                                                 PARTICULATE  FIELD DATA

                                           VERY IMPORTANT-FILL  IN ALL  BLANKS
                Read and  record  at the start of

                each test point.
                                                  Ambient Temp °F    7O
                                                                                               a
                                                                              Bar. Press "Hg__JLiiAL
                                                                                      Moisture %    Q
                                                                       Probe Tip Dia., In..
                                                                                             '/«
                                                t*»i
                            '•ft
                                      No *a 
-------
           Point
            -2
           -v
         Clock
                   1 1 \ .v
                                                                                  33O
                                                               O
                                                                               2/j
                                        0,0
,I7S*
  O,Cl
                                                                                   335"
                                                                               240
il
                                                        A
        COMMENTS:
                                          aoz fr

-------
                         PARTICULATE CLEANUP SHEET1
Date:
Run Number:
Operator:   Gr'i.s/.cw

Sample Box No.
        Plant:
        Location Of Sample Port:   Bo 11 en-  T

        Barometric Pressure:   2$, (g /

        Ambient Temperature 	
ml
Impinger H20

Volume After Sampling 2

Impinger Prefilled With

Volume Collected      *j \     ml
        Silica Gel
Weight After    SI S.
        Weight Before
        Moisture Weight  JS  g Moisture Total
Dry Probe and Cyclone Catch:
        Container No.

        Extra No.
                                                        Weight Results
                                               _g
Probe, Cyclone, Flask
And Front Of Filter
Acetone Wash:
        Container No.

        Extra No.
                                                           Weight Results
Filter. Papers and Dry Filter Particulate

Filter No.   Container No.   Filter No.   Container No.

    II      .	   	  	
                                 Filter Particulate
                                 Weight  0,0 81 ^   g
                                                            Total Particulate
                                                            weight
% Moisture By Volume
                                      -207-

-------
                      GAS SAMPLING FIELD DATA
 Material  Sampled For




 Date    /0//5-/7.T
                               4
 Plant
s-f,
                                  Location
Bar. Pressure



Ambient Temp _



Run No       /
                   "Hg
Comments :
                                                  .Vff JA, ft*,
                 7ST
 Power Stat Setting



 Filter Used:   Yes



 Operator 	<£,
                            No
Clock
Time
U-.fs
bos
\,IS

U3S"
h3 t / *%
I \jp *f V
I6K8

1 700, ^S
/7d>3,/^
/ 7o^,7 Vff



Pitot
in. H20
A?
(2103
ao*/
0,0 y
O.oS"
^).oy
aoz




Orifice
in H20
AH
O.I
0,1
O.I
0,1
O.I
0,\




Temperatures Op
Stack
5"Vo
SSO
S(*S
SC.S
S^o
SVO




Probe
^r
£7*
276'
Z7S
375
27^




-Coil-
OVCA
/^
83
/*«
170
178
170




Impinger
In
/OS
U5
30
*y
/3o
/24




Out
70
6,1
6,3
4,3
i
6.6




Comments:
                                                   7-3
                                    Ar
               *u
                                   -208-

-------
                      GAS  SAMPLING FIELD DATA
Material Sampled For




Date     \0/IG/7S



Plant
                                S£3
                                 Location  60 tier
Bar. Pressure



Ambient Temp



Run No
                                 Comments :   2 9» STO S" j K ,
                 75
Power Stat Setting



Filter Used:   Yes



Operator   G>r \
                            No
                           e I
Clock
Time
li;/o-
11:20
/mo
)/;*>
i
| i a too
/Z.'JO



Meter
(Ft.3)
i7*3,
-------
                      GAS SAMPLING FIELD DATA
Material Sampled For




Date 	lO/ZO



Plant
 Bar.  Pressure



 Ambient Temp



 Run No        ;
                           'Hg
Location



Comments
                                               I   po< ler
 Power  Stat Setting



 Filter Used:  Yes
                            No
 Operator    O»r<.styw\
Clock
Time
I2JAS
ie;^
IliJSS
i ;as
HtS
I
.



Meter
(Ft.3)
I7*>.3*(.
nw,f
/*00. 7
jjo3,i
IMS'* I
/«D7,3
.1*61,186



Pitot
in. H20
AP
O,O I
o.of
0,032"
0,0 3 S
O.o«
0,03




Orifice
in H20
AH
O.I
O.I
O.I
O.I
O.I
OJ




Temperatures °F
Stack
SOS
S70
5^0
$&
$10
S(*6




Probe
^74r
£73
210
£10
29S"
3o$




Coil

ISO
ISS



ISS




Impinger
In
/to
/zs*
130
its
ILO
iZO




Out
<»1
(*S
<*s
(.S
LS
LI




Comments:
                                    -210-

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       SOURCE TEST REPORT
GENERAL MOTORS ASSEMBLY DIVISION
       ST. LOUIS, MISSOURI

           BOILER NO. 2
                                TESTED BY:  ROCKWELL INTERNATIONAL
                                            R.W. Griscorn
                                            O.C. Klein
                                            F.E. Littman
               -211-

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                           TABLE OF CONTENTS

                                                                    PAGE
1.0  SUMMARY                                                         215
2.0  INTRODUCTION                                                    216
3.0  PROCESS DESCRIPTION                                             217
4.0  PROCESS OPERATION                                               218
5.0  SOURCE TEST DESCRIPTION                                         219
6.0  SAMPLING AND ANALYTICAL PROCEDURES                              222
     6.1  PARTICULATE MATTER                                         222
     6.2  NITROGEN OXIDE                                             225
     6.3  SULFURIC ACID MIST AND SULFUR DIOXIDE                      225
     6.4  PARTICLE SIZE                                              228
7.0  RESULTS                                                         231
8.0  DISCUSSION                                                      236
     APPENDIX A: PARTICULATE CALCULATIONS                            239
     APPENDIX B: FIELD DATA                                          252
                                     -212-

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                                TABLES





                                                                PAGE



TABLE 1  SUMMARY OF RESULTS                                      232



TABLE 2  PARTICLE SIZE,DISTRIBUTION                              233



TABLE 3  HYDROCARBON ANALYSIS                                    235



TABLE 4  COMPARISON OF FLOW RATE DETERMINATIONS                  237
                                     -213-

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                                FIGURES
                                                                    PAGE
FIGURE 1    SAMPLING LOCATION FOR BOILER NO.  2
220
FIGURE 2    OPERATOR POSITIONING SAMPLING UNIT AT TEST LOCATION      221
FIGURE 3    SUPPORTING STRUCTURE FOR SAMPLING EQUIPMENT
221
FIGURE 4    OPERATOR DETERMINING STACK GAS COMPOSITION WITH
            ORSAT APPARATUS
223
FIGURE 5    PARTICULATE SAMPLING TRAIN
224
FIGURE 6    OPERATOR EVACUATING FLASK FOR NITROGEN OXIDES TESTING    226
FIGURE 7    OPERATOR FILLING EVACUATED FLASK WITH STACK GAS SAMPLE   226
FIGURE 8    SULFURIC ACID MIST SAMPLING TRAIN
FIGURE 9    SAMPLING UNIT WITH ANDERSEN SAMPLER IN  OVEN
227


229
FIGURE 10   ANDERSEN STACK SAMPLER
 230
FIGURE 11   PARTICLE SIZE DISTRIBUTION/BOILER 2
 234
                                     -214-

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                             1.0  SUMMARY

     In conjunction with the RAPS project, a limited stack testing pro-
gram is being conducted.  This report details the results obtained on
boiler no. 2 at the General Motors Assembly Plant in St. Louis, Missouri.
     The stack testing included the following pollutants: S02 (sulfur dioxide),
particulates, NOX (nitrogen oxides), h^SO^ (sulfuric acid mist) and hydro-
carbons.  Orsat analysis for COg (carbon monoxide), and CL (oxygen) were also
performed.  Results of these tests are included in this report.  Although
these tests were not conducted to ascertain compliance with St. Louis stan-
dards, it is of interest that the particulate emissions are within the lim-
its.  The SOp emissions standards are not applicable for this time of the
year, nor for an individual boiler in an installation.
     We acknowledge and appreciate the excellent cooperation we obtained from
the engineering department and the power plant personnel at General Motors.
                                      -215-

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                           2.0  INTRODUCTION

     The current stack testing program is being conducted in conjunction
with the emission inventory work for the St. Louis RAPS project.  The
emission inventory is being compiled using published emission factors.
The -stack testing is being conducted to evaluate the emission factors and
to gather information for additional emission factors.
     This stack test was conducted at the General Motors Assembly Plant
in St. Louis, Missouri.  Testing was performed on boiler no. 2 on 8,9 and 10
September 1975.
     Boiler no. 2 is a coal-fired, 80,000 pounds per hour steam generating
unit.  The unit is equipped with a cyclone, mechanical precipitator.  This
boiler was sampled for total particulates, particle size, N0», S02, H2SO,
C02 and 02-
                                     -216-

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                       3.0  PROCESS DESCRIPTION

     Boiler no.  2 was built by Union Iron Works  and was installed in
November 1952.  It is equipped with a gravity fed spreader stoker.
Steam pressure is maintained at approximately 165 psi.   The firing
                                          ;
rate is controlled to match the demands of the assembly plant.   At
shift changes the load drops off 20-25% for an hour or two.  The ca-
pacity of this boiler is rated at 80,000 pounds  of steam per hour.
     This boiler is equipped with a Western Precipitation Multi-cyclone
mechanical precipitator rated at 98% efficiency. Boiler no. 2 is an
induced draft unit and uses a common stack with boilers 1, 3, and 4.
The stack is of brick construction and is 225 feet tall and 13 feet
inside diameter at the top.
     This boiler and no. 4 boiler are equipped with caustic scrubbers
for removing SOp.  These scrubbing units are in operation from October
through March for compliance with the local St.  Louis standards.
                                    -217-

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                       4.0  PROCESS OPERATION

     Boiler no. 2 was tested 8 September to 10 September.  During the
testing period the boiler load remained fairly constant.   Because of
shift change, the load started to decrease between 2 and 2:30 PM.  Test-
ing was generally completed prior to 2 PM.  Ashes were pulled on the boiler
at approximately 11:30 AM and 1:30 PM each day.
                                    -218-

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                      5.0  SOURCE TEST DESCRIPTION

     Boiler no. 2 was tested in the ductwork between the boiler and  the
stack and ahead of the takeoff for the SOp scrubber.  The sampling lo-
cation and testing arrangement are illustrated in Figures 1,  2, and  3.
     The duct at this point is 49 inches wide by 5 feet high.   This  lo-
cation was between four and five diameters from the last bend  in the
duct.  In accordance with EPA Standard Method 1, thirty-two sampling
points were chosen, eight at each of four sampling ports.  General
Motors already had four, 3-inch pipe couplings installed for use as
sampling ports.
                                   -219-

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                                                                              PLAN VIEW
           FROM
           BOILER 1
                            SULPHUR DIOXIDE
                            SCRUBBER
FROM
BOILER 4

                                                                              ELEVATION
o
o
o
o
                       	_~	v	I	5P91
                                BOILER 3
                                                                              FAN
                   BOILER 2

              AND PRECIPITATOR
                            FIGURE 1  SAMPLING LOCATION FOR BOILER 2
                                            -220-

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                    FIGURE 2



OPERATOR POSITIONING SAMPLING UNIT AT TEST LOCATION
                    FIGURE 3



    SUPPORTING STRUCTURE  FOR SAMPLING EQUIPMENT












                      -221-



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               6.0  SAMPLING AND ANALYTICAL PROCEDURES

     All testing was performed with sampling equipment from Joy Manu-
facturing, designed for isokinetic sampling to enable testing by EPA
standard methods.
     Gas flow rates were calculated using the observed gas temperature,
molecular weight, pressure and velocity, and the flow area.  The gas
velocity was calculated from gas velocity head measurements made with
an S-type pi tot tube and a magnehelic pressure gauge, using standard
method 2.
     Moisture contents were determined by passing a measured amount of
gas through chilled impingers containing a known volume of deionized
water, measuring the increase in volume of the impingers liquid and the
increase in weight of silica gel used to finally dry the gas, and cal-
culating the amount of water vapor in the sample from this increase and
the measured amount of gas.
                                                                           f
     The stack gas concentrations of COp, oxygen, CO, and nitrogen by dif-
ference were measured with a standard Orsat apparatus.  This method is shown
in Figure 4.  These concentrations and the moisture content were used to de-
termine molecular weight of the stack gas.
5.1  PARTICULATE MATTER
     Standard method 5 was used for determining particulate emissions with
the exception that the probe and oven were operated at 300-350° °F. Measured
stack gas samples were taken under isokinetic conditions.  The samples were
passed through a cyclone, fiberglass filter, impingers, pump, a meter  and an
orifice as shown in Figure 5.
     The total particulate matter collected in each test was  the  sum of  the
filter catch plus material collected ahead of the filter  in the  sampling train.
The amount of filter catch is determined  by the difference in the weight of
the filter before and after the test, after dessicating.   The particulate mat-
ter from other portions of the train was  determined  by rinsing  the probe,
cyclone and all glassware ahead of the filter with acetone,  evaporating  to
dryness and weighing.
                                     -222-

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                       •x  "5~'tf
                        V^J    --.     ^

                FIGURE 4

OPERATOR DETERMINING STACK GAS COMPOSITION

          WITH ORSAT APPARATUS
                 -223-

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              STACK
              WALL
FILTER
HOLDER
REVERSE-
TYPE
PITOT TUBE
                  ORIFICE
                  GAUGE
                                                                                  CHECK
                                                                                  VALVE
                HEATED
                PROBE
                  VELOCITY
                  PRESSURE
                  GAUGE
                                                   FINE CONTROL
                                                     VALVE
                                             VACUUM
                                             LINE
                                      FIGURE 5

                             PARTICULATE SAMPLING TRAIN
                                           -224-

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6.2  NITROGEN OXIDE
     Using method 7, gas samples were withdrawn from the stack into evac-
uated 2-liter flasks containing a dilute solution of hydrogen peroxide and
sulfuric acid.  The hydrogen peroxide oxidizes the lower oxides of nitrogen
(except nitrous oxide) to nitric acid.  The resultant solution is evaporated
to dryness and treated with ohenol disulfonic acid reagent and ammonium hy-
droxide.  The yellow trialkali salt of 6-nitro-l-phenol-2, 4-disulfonic acid
is formed, which is measured colorimetrically.  The field procedure is shown
in Figures 6 and 7.
6.3  SULFURIC ACID MIST AND SULFUR DIOXIDE
     The Shell method was chosen for this determination due to uncertainties
which exist about the validity of the results using method 8>  A gas sam-
ple is drawn from the stack using a heated probe and passed through a water-
cooled, coil condenser maintained below the dew point of sulfuric acid at
140°-194°F, followed by a fritted glass plate and then passed through a chilled
impinger train with two impingers containing an isopropanol and hydrogen
peroxide mixture and followed by an impinger containing silica gel for drying.
This setup is shown in Figure 8.                            \
     The condensed sulfuric acid mist in the coil condenser is water washed
from the condenser.  The final determination is made by titrating the solu-
tion with barium chloride, using a thorin indicator.  Isopropanol must be
added to the solution to be titrated to improve the rapidity with which the
barium sulfate precipitates during titration.
     Sulfur dioxide in the gas sample is oxidized to sulfur trioxide  in the
impingers containing the hydrogen peroxide.  Sulfur dioxide is then determined
by titrating the hydrogen peroxide solution with  barium chloride,  using a
thorin indicator.

*Lisle, E.S. and J.D. Sensenbaugh, "The Determination of  Sulfur Trioxide and
Acid Dew Point in Flue Gases," Combustion, Jan.1965.
Goksoyr, H. and K. Ross, "The Determination of Sulfur Trioxide  in Flue Gases,"
J. Inst. Fuel, No. 35, 177, (1962)
                                      -225-

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                      FIGURE 6



OPERATOR EVACUATING FLASK FOR NITROGEN OXIDES TESTING
                      FIGURE 7



OPERATOR FILLING EVACUATED FLASK WITH STACK GAS SAMPLE
                        -226-

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STACK
 WALL
                                                                     CHECK
                                                                     VALVE
REVERSE-
TYPE
PITOT TUBE
      VELOCITY
      PRESSURE
      GAUGE
                                     FINE CONTROL
                                        VALVE
                                                                         VACUUM
                                                                         LINE
     ORIFICE
      GAUGE
                          FIGURE 8

              SULFURIC ACID MIST SAMPLING TRAIN
                              -227-

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6.4  PARTICLE SIZE
     An Andersen fractionating inertia!  impactor is used for the deter-
mination of particle size in the range of approximately 0.5 to 10.0 mi-
crons.  The sampling head is placed in the oven after the heated sampling
probe and a sample of stack gas is drawn isokinetically through the sam-
pler.  The particulate matter is fractionated and collected on the plates
inside the sample head and a determination is made by the difference in
weight of the plates before and after testing.  Results are expressed
for particles of unit density.  The sampling arrangement is shown in Fig-
ure 9.  The sampling head assembly is shown in Figure 10.
6.5  HYDROCARBONS
     Gas samples were withdrawn from the stack using a vacuum pump to fill
Tedlar bags.  The composition of the hydrocarbons was determined by gas
chromatograph.
                                     -228-

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                 FIGURE 9



SAMPLING UNIT WITH ANDERSEN SAMPLER IN OVEN
                   -229-

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AIR FLOW
                         FIGURE 10
                  ANDERSEN STACK SAMPLER
                            -230-

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                              7.0  RESULTS

     The results obtained from this test are summarized in Table 1 .   As
explained in the following discussion, the pollutant emissions are based
on calculated, rather than measured, flow rates. Although these tests
were performed for research purposes and not as part of compliance pro-
cedures, standard EPA methods were used.  Due to the seasonal nature of
the local SCL regulations the only applicable standard is for particulates.
It is of interest to note that this boiler is within the standard:  0.28 lb/
106 Btu compared to the standard of 0.40 lb/106 Btu.
     In addition to measuring particulate loadings, a particle size analy-
sis was made using an Andersen impactor.  The results are shown in Table 2
and Figure 11.
     The results of two samples taken on 8 September for hydrocarbons were:
          Carbon Monoxide:                '          26.80 and 23.04 ppm
          Methane:                                   0.23 and  0.25 ppm
    •\      Total Hydrocarbons, as CH4:                1.31 and  2.30 ppm

     The major components of several hydrocarbon samples taken on 8 and 9
September are given in Table 3.
                                     -231-

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                              TABLE  1



                        SUMMARY  OF   RESULTS
Date
Stack Flow Rate - SCFM * dry
% Water Vapor - % Vol .
% C02 - Vol % dry
% 0 - Vol % dry
% Excess air @ sampling point
S02 Emissions - lbs/106 Btu
NOX Emissions - lbs/106 Btu
H2S04 Mist - lbs/106 Btu
Participates
Probe, Cyclone, & Filter Catch
Ibs./hr.
lbs/106 Btu
Total Catch

Ibs./nr.
lbs/106 Btu
% Isokinetic Sampling
9/8
27,041
8.34
11.16
8.37
64.2

0.49

20.41
0.25



119.3
9/9
26,633
7.38
10.65
9.25
76.72
5.81
0.48
0.19
20.03
0.24



110.8
9/10
26,633




6.14

0.16





















r













,
*70° F, 29.92" Hg
                                     -232-

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                                TABLE 2

                     PARTICLE SIZE DISTRIBUTION
Test:  GM-Andersen #1
       Oven Temperature = 300 F
                                Date:  9/10
Plate
1
2
3
4
5
6
7
8
Backup
Total
Test:
Plate
1
2
3
4
5
6
7
8
Backup
Filter Net (mg)
1.1
1.7
3.5
4.7
4.6
4.6
3.5
5.3
Filter 48.0
77.0
GM-Andersen #2
Oven Temperature = 370. 9°F
Filter Net (mg)
1.2
: 1.4
3.3
5.3
4.8
4.5
3.2
3.8
Filter 22.8
% Of Total
1.43
2.21
4.55
6.10
5.97
5.97
4.55
6.88
62.34
100.00
Date:
% Of Total
2.39
2.78
6.56
10.54
9.54
8.95
6.36
7.55
45.33
ECD (Microns)
16.8
10.7
7.1
4.9
3.1
1.6
0.99
0.66
<0.66

9/11
ECD (Microns)
17.3
10.9
7.3
5.0
3.2
1.7
1.0
0.68
<0.68
Total
50.3
100.00
                                     -233-

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of total
         60
Run 1
Run 2
         50
         40
         30
         20
         10
              18  17 16  15 14  13  12  11  10 9  8  76  54  3  ?  1  0
                                                                         ECD(Microns)
                                      FIGURE 11
                              PARTICLE SIZE DISTRIBUTION
                                   GENERAL MOTORS
                                      BOILER 2
                                        -234-

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                                 TABLE 3
                          HYDROCARBON ANALYSIS
                    (Concentrations in ppb as Carbon)

Compound
                                            9/8      9/8      9/9      9/9
Ethane-Ethylene                            51.7     70.7      48.0    70.3
Acetylene                                  15.8     29.7      33.7    25.1
Propylene                                  ' 3.1      7.1               1.7
Propane                                    29.3     20.2      22.1    33.7
Isobutane                                  20.3               14.8    25.6
1-Butene & Isobutylene                              52.1              29.9
Butane                                     62.4     72.0      16.9    21.5
Pentane                                     2.1      9.1       7.4    22.3
Isopentane                                  6.7      9.2       4.3    21.5
Hexane                                     52.1     31.7     136.7    95.2
Benzene & 2,4-Dimethyl Pentane             66.3     53.5      14.6    18.7
1-Methylcyclopentane & 2M-C3-Hexane        21.2     37.9
Toluene                                    143.4     62.6      76.5   115.3
Ethyl Benzene                              58.7     65.2      83.1   100.1
Meta, Para-Xylene                  -        130.3    141.8     182.6   180.4
Ortho-Xylene                               29.3     30.4      38.4    40.9
                                     -235-

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                             3.0  DISCUSSION

     Flow determinations were made in accordance with EPA Standard Method
2, using an S-type pi tot tube.  This method gives correct results as long
as the pitot tube is positioned normally to the flow of gases.  This is
no problem as long as the flow of gases is laminar and parallel to the
walls of the duct.  However, if the flow is turbulent or vortex-type, the
readings obtained are incorrect, with a positive bias (too high).  The ex-
istence of a turbulent condition can be ascertained by turning the pitot
tube 90° on its axis.  A zero reading should then result.  If no zero read-
ing is obtained, the results are open to question.
     In the duct being tested, the existence of turbulence was evident by
the fact that a zero reading was not obtained with a 90° rotation of the
probe.
     Under conditions when satisfactory flow measurements cannot be obtained,
a stoichiometric calculation of flow rates can be made, based on fuel consump-
tion, fuel composition, combustion rate and excess air.  As a check on the cor-
rectness of the assumption, the mass flow of SO* can be calculated based on gas
flow and SO^ concentration on one hand, and fuel consumption and sulfur analy-
sis on the other.  The conversion of sulfur in coal to S0« is straightforward
and occurs with 95% efficiency.
     To determine the amount of coal consumed and Btu input, coal scale
readings were checked against the actual steam production.  This ratio was
also compared with a ratio determined by power plant supervision over  sev-
eral previous months.  On 10 September the coal scale readings averaged
7314 Ibs/hour and the steam flow averaged 66,910 pounds of steam per hour.
This gives a ratio of 9.15 pounds of steam per pound of coal.  The  ratio
used by plant supervision is 9.3. Since these two ratios are  so  close,  the
ratio of 9.3 determined by plant supervision was the one used  for all  de-
terminations of coal consumption during the test.
     Table 4 shows the comparison of the results obtained by  the two methods.
                                     -236-

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                              TABLE 4



               COMPARISON OF FLOW RATE DETERMINATIONS
Date
9/8
9/9
9/10
FLOW RATE, SCFH
Measured Calculated
1,622,490
1,598,005

1,403,921
1,434,847
1,396,329
S00 (Ibs/hr) Based On
L. ' "" - "- - • "~ 	 """'" 	 """'" 	 —-——•»— 	 •
AP-42* Calculated
Flow

478.5
480.0

472.0
501.3
Avg. Measured
Flow

545.9
578.1
	 	 	 	 -j
Compilation of Air Pollutant Emission Factors, EPA Publ.  No. AP-42
                                  -237-

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                             STOICHIOMETRIC
                          FLOWRATE CALCULATIONS
                                BOILER #2

 Coal Composition
 Moisture 7.71%
 Ash      10.895
 S         3.465 T 32 = 0.108 x 1 = 0.108
 C        62.0   T 12 = 5.167 x 1 = 5.167
 H2        5.0   T  2 = 2.500 x 5 = 1.25
 N2        1.0   v 28 = 0.036
 02        9.9   T 32 = 0.309 x-1 =-0.309
                                   6.216
 @ 70.46% Excess Air                4.380
                                  10.596
N2 = 3.76 x 02                  = 39.840
Mols  Flue Gas = C02 + S02 + N2 + EA + N2 =
 5.167 + 0.108 + 0.036 + 4.38 + 39.84 = 49.53  mols/100#
 On  9/9 7268.8 Ib/hr coal during S02 test 49.53 x 386.7 x 72.688 =
 1,392,211.5 SCFH
 On  9/9 7491.4 Ib/hr coal during particulate test 49.53 x 386.7 x 74.914
 1,434,846.6 SCFH
 9/8 7329.9 Ib/hr  1,403,921.1 SCFH
 9/9 1,434,846.6 SCFH Part.
    1,392,211.5 SCFH S02
 9/10 1,396,329.4 SCFH S02
     1,363,385.8 SCFH Andersen
                                     -238-

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       APPENDIX A
PARTICIPATE CALCULATIONS
              -239-

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                         PARTICIPATE CALCULATIONS

 Volume of dry gas sampled at standard conditions -  70° F.  29.92 "Hg
Vrast°
    \  /          \
 Vm.Wpp    AH   \
1.021)1      13.6  /
     A          /
Vmstd = Volume of dry gas sampled at standard conditions,  ft
                             3
Vm = Meter volume sampled, ft
1 .021 = Meter correction factor
Pm = Meter pressure, barometric pressure, PB> plus   orifice
     pressure, AH, in. Hg.
Pstd - Standard pressure, 29.92 in. Hg.
Tstd = Standard temperature, 530° R or 70° F
Tm = Meter temperature, 530° R for compensated meter
CFm = Meter correction factor
Volume of water vapor at standard conditions
Vw=Vi  / £lJ20\ A Tstd\       1b.         .  0.0474
vw   V]c I  MH£0 )(  Pstd  I     454 gm.
          \
                                                     **
Vw = Volume of water vapor at standard conditions, ft
VT  = Volume of liquid collected in impingers and silica gel, ml
pH20 = Density of water, Ig/ml.
M H20 = Molecular weight of water, 18 Ib/lb mol
R = Ideal gas constant, 21.83 in. Hg. - cu. ft./lb-mol  - °R
% Moisture in Stack Gas
                       Vw std
        % M = 100 x
                            Vwstd
                                   -240-

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Average molecular weight of dry  stack gas
Molecular weight of stack gas
                                      *   »'
Stack velocity at stack conditions
v   -   85 48 x C  /Ts x AP avg.  \  I/
    -   bb.4B x L  i                  /
V  = stack velocity, fps.
85.48 - pitot constant,
                                1b.      . oR
C  = pitot coefficient, dimension! ess
T  = average stack temperature,  °R
P  = stack pressure, barometric  pressure  plus static pressure, in. Hg.
AP Avg = average differential  pressure, in. ^0
Stack gas  volume at standard  conditions
                          Tstd.   Ps  \
n    ocnnT   %M \M
Qs = 3600^1- TW)V
Q  = stack gas volume flow rate,  SCF/hr
                                  2
A = stack cross sectional  area, ft
3600 = seconds per hour
QS> = Q  i 60 = SCFM
                                   -241-

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Per cent isokinetic  sampling
I =
   = 1.667 [(0.00267)   Vlc   +   ^£  /Pg  +  AH\| T
           I	           'm   \	i j. o yj
                                9 Vs  Ps  An
 I = per cent isokinetic sampling
 1.667 = minutes per second,  X 100
 0.00267 .         „  „  x
 © = sampling  time, min.
 A^ = cross  sectional area of sampling nozzle, ft

 Particulate emission
 Cs = 2.205  X  10"6
 C  = particulate emission, Ib/scf
 2.205 X 10   = pounds per mg.
 Mn  = total mass of particulate collected, mg.
 CE  = C$ X Qs = Ib/hr
 Cr  = particulate emission per hour
CH = CE 7 H
CH = particulate emission, Ib.  per million BTU
H = heat input, million BTU per hour
                                    -242-

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Excess air at sample point


% EA =       TOO X % 02
        (0.266 X % N) - %
% EA = excess air at sample point, %

0.266 = ratio of oxygen to nitrogen in air by volume
                                     -243-

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                    PARTICULATE SAMPLING CALCULATIONS


            Test:  3/r, 2  - R"-" I           Date:  
-------
                   PARTICIPATE SAMPLING CALCULATIONS
     Test:'   Blr. 2  -Run I

Stack Velocity    Vs = 85.48 x C   ["is x P avg]   1/2
                                                        Date:  9/S/75
85.48 x (0,9-ST )
                                 ["is x P avg]
                                 LPs * M\  J

                                       1   i
                                       J
Stack Gas  Volume  Qs = 36001- XM \ (Vs)(A)/Tstd\ /
                              100/        \jr~7 ^
3600
               100
                           \

                       (3*847)
                                                   Ps  \
                                             530  (30. 13)   = /, ^^
                                                   29.92
Stack Emission Rate   Cs  =  2.205 x 10~6/  Mn
                                        VMstd/,
2.205 x 10-6    (
                                                   Ib/scf
CE = Cs  x  QS  =


CH = CE  v  H   =
                                                               Ib/hr
                                                       Btu
Isokinetic Variations   I =  1.667
                                  (0.00267)  Vn   +  Vm  /   +
                                             1c     T¥  \PB
                                                              AH
1.667
                                        e vs  PS  An
         (0.00267)     (8S.8  )  +
                                    530
                                                     13.6
                                   (30.13)
                                          % EA = 100 x % 02
                                                 (0.266 x % N2) - % 02
v..
                                                 100 (
                                                 10.266x34^7) - (^

-------
                   PARTICIPATE SAMPLING  CALCULATIONS


           Test:  Blr. 2   -"Run 2             Date:    ?/?/7S"

 Material collected  (mg)

 Filter Catch           =  /3O. 3
 Dry Catch              =
 Acetone Wash           =  138» 9

 TOTAL                  = 26?»/


 Gas Volume    Vmstd = 0.0334/Vm   yp   +
                            I 7r—'* ^
                            \ ^
 Volume of water vapor       Vw = 0.0474 X Vic

 0.0474 ( ?/,V  ml)  =     3,38£    SCF

 % Moisture     %M -  100 X Vwstd
                         Vmstd + Vwstd

 100 X ( 3,3£S)	    a    "73S        «
Molecular Weight  of dry stack gas

      MWD = %C02  X 0.44 + %02 X 0.32 +  %N2 X 0.28
             0.44) + (f.2^X 0.32)   +  (80.1 X 0.28) =   30,07
Mlecul ar Weight of stack gas
MWw = 100 -  %M X MWn    +  XH  X 18
          100      u      100


                                                   X 18
     100                               100
                                     -246-
                                                       ]
                                                       1

-------
                   PARTICULATE SAMPLING  CALCULATIONS
     Test:   B\t%2  -
Stack Velocity   Vs  = 85.48 x C_   Ts x P
                                                         Date:
                                 fTs x P avgl
                                 |_PsxMww  J
                                               1/2
 85.48 x  (O.8S" )
                    36.1

                                            /2 =
 Stack Gas Volume  Qs = 36001- %M   (Vs)(A)/Tstd\ / Ps \
                           \   100/        \Ts  ) \Pstd/
3600    l-
       fl
       L
               100
                                             530
                                                   29.92
 Stack Emission Rate   Cs = 2.205 x IP"6/  Mn
          '6
2.205 x ID
CE = Cs  x Qs  =
               (g&fJ)
               c^.^-// )
                                   •    \ VMstd

                                 J,3%X/0~S     Ib/scf
CH = CE v  H   =  (  2Q«03) =      O.2*/
                                                lb/106 Btu
                                                               ib/hr
Isokinetic Variations  I  =  1.667
                                  (0.
                                     00267)  V^   +  Vrn  /   + AH  \]
                                              c     Tm  \PB   13.6/jT
 .667 I   (0.
      L
                                        6 VS  Ps  An
            00267)
                                    ^/WfjO./^ +  Q^0\ \( 8T6
                                     530   V          13.6 /J
Excess  Air at Sample  Point
                                             EA = 100 x % 02
                                                 (0.266 x % N2) - % 02
                                                 100

-------
                              STOICIOMETRIC
                         FLOWRATE CALCULATIONS

                                Boiler #2
Coal Composition                    Mols/100#         Mols  02 required
  Moisture       7.71%
  Ash            10.895
  S              3.465
  C              62.0
  H9             5.0
  ^             1.0
  Oo             9.9
T 32 =
* 12 =
* 2 =
* 28 =
* 32 =




0.108 x 1
5.167 x 1
2.500 x .5
0.036
0.309 x -1




= 0.108
= 5.167
= 1.25

= -0.309
6.216
4.380
10.596
= 39.840
  @ 70.46% Excess air


  N2 = 3.76 x 02

  Mols Flue Gas = COo + SO- + N0 + EA + N2 =
                  5.T67 + 6.108H- 0.036 + 4.38 + 39.84 = 49.53 mols/100#

  on 9/9  7268.8 Ib/hr coal during S02 test

  49.53 x 386.7 x 72.688 = 1,392,211.5 SCFH

  on 9/9  7491.4 Ib/hr coal during particulate test

  49.53 X 386.7 x 74.914 = 1,434,846.6 SCFH
                                     -248-

-------
                             NO  EMISSION DATA
                               /\
                                                    Date.
                                                           Ms
Run No.
Time
ug N02
T.- Initial Flask Temp, °F
T-- Final Flask Temp, °F
V- - Flask Volume, ml.
Pr Initial Flask Pres, "Hg
Pf- Final Flask Pres, "Hg
Ib/scf N02 XJO"5'
lb/106Btu N02
/
I/SO
*b£
10
95-
2O^1
2,S
30. H*
2m
•O/ST
2
IZCQ
8LS
<)o

o,W




















Vsc=  17.71
            in.  Hg,
(Vfc)     [JjL  -   A.) =  scf


           Tf       Ti
Vfc - Vf - 25
C = 6.2 x 10"5  Ib/scf

                yg/ml
     N02 \  =  Ib/scf
                            Vsc
                                     -249-

-------
                              NO  EMISSION DATA
                                A
                                                    Date.
Run No.
Time
V9 N02
Tr Initial Flask Temp, °F
Tf- Final Flask Temp, °F
Vf - Flask Volume, ml.
P^ Initial Flask Pres, "Hg
Pf- Final Flask Pres, "Hg
lb/scfN02 x|0-«
lb/106Btu N02
/
09/0
?7o
90
15
ZOH1
l.S
30,l(*
3.&
O.St
2
0%
7/o
to
<&
263?
2.S
30. /(c
2.V5
^.^2
-/
/^)/0
7^^)
^
^^
2o2S>
2.S
3O./6,
2,^3
0,*/ff
5
/oyo
760
^0
^5
20&S
23
30.11*
l.M
0.1S
&
IQ
760
f 0
f^
2osi
2.S
30.11,
2,<*o
0,13
8
WS
760
to
is
2C&
I.S-
J6.lt.
Z.(,o-
5*Vi".
Vsc=
/17.71 ^R    \

\      in. Hg/
(Vfc)
                                                 =  scf
Vfc - Vf - 25
            "5
C - 6.2 x 10"   Ib/scf    yg N02 \ - Ib/scf N02
                                     -250-

-------
                H2S04 MIST and S02  EMISSION  DATA
Date
Run No.
Vmc-Meter Volume, Ft3
Vmstd-Meter Volume, Std. Cond.
PB-Barometric Pressure, "Hg
AH-Avg. Orifice Pres. Drop, "1^0
Vt-Vol . of Titrant, ml.
Vtb -Vol. of Titrant for Blank, ml.
Vsoln-Vol. of Solution, ml.
Va-Vol. of Aliquot, Titrated, ml.
Ib/scf H2S04 •*IQ~(f>
1b/106 Btu H2S04
Ib-SCf S02 , y|Q-*
lb/106 Btu S02
?/?
i
r$i3
7,S(*5
30, It
0,1
*4
K\l
loo
10
11,00
O.il


9/?
,2.
(*,*)
K.'l
100
10
1,li
O.llf


4/1
1*1
H.13(*
)H,S3(*
30,11
O.I
nw
»;/
2 so
/


3,3?
&€l
1/i '0
1
10, 33^
ID,27(*
308
n.1/
too
la
10. 20
o,n


9//o
2
w?
2.131
30,^
0,1
fr,g
m'/
too
to
2,21
o.ii
3,5^
b,l4
9//o
/^_
n.iss
11,207
30,61
0,1
*1.&
n//
230
/


i
f
ii

Vmstd =  0.0334  (Vm)
              /PB + AH  \
              V     13.6/
CFm = Meter correction factor
CH2S04  =/1.08  x  10-4  lb-1
•('•
                         - vtb)  (1)
                                              fVsolnV lb/scf
                                              \ Va  /
N.= 0.01  Normal
    Barium
    Perch!orate
                          Vmstd
CS02 =(7.05 x 10"5 lb-1  \  (Vt - Vtb)    (II)
                                               = lb/scf
                         Vmstd
                               -251-

-------
APPENDIX B
FIELD DATA
     -252-

-------
      SUPPLEMENTARY PROCESS DATA FOR  POWER PLANTS
Date
Net Unit Load - MW
Average Steam Load - 10 Ib/hr
Boiler Heat Input xiO^QlU/b
Fuel Burning Rate - Ib/hr
Fuel Heating Value - BTU/lb
Fuel Sulfur Content - %
Fuel Ash Content - %
Fuel Moisture Content %
1/8
•f

S2.o
1
11187
3MS
/& W
7,7!
9/9

•
«4,*/»/*3





9/10


*/' <• /n u














  £2,0
       70
       70
\\'.
       70
xill87: W« 8
            9,'30
            to\ao
            10', 30
                                           I,
                                       l',00
70
7l
43
                                                                   >t*. /-
                     k?
                                or
             Z',00
                    6V
                           -253-

-------
                       ORSAT FIELD DATA
Location




Date	




Time	
              t*er*
Operator
Test

-------

Plant <3MA£>
Run No.
Location
Date
Operator
1
*2 Bon.64
°il?hs
•

PARTICULATE FIELD DATA
VERY IMPORTANT - FILL IN ALL BLANKS
Read and record at the start of each
test point ,

Sample Box No.
Meter Box No.
Meter A H@ I»O2JL

-
tn

& .v

C Factor
Point
M
hi

i~y
j-^S
1-4
*-7
I-*
o£C
2-1

2^
i~H
Z-S
?-(o
•\ ">
2 I


Clock
fo',3 7
/0,**/0
/I I/O
//'•'3
ji;/6
N:tf
lint
II'. IS
iutt

.Jim. 	
i/,vtf

u;oo
p;oi
. -n •/}£,
Dry Gas
Meter, CF
/2/1?, Vfo
U22

12? fr
/U7.S
Htft'l
li^>o, &
/2iZ. ^

/2J3»^
/23S.Q
Ii31,y
Il3i
&•*/
Q'&l
9'S
o,s



@*2S
VI JS 	
a.tf
O./V
0, if
0.12
	 Vi3J


Orifice AH
in H20
Desired

/•V
O.y<£
0«>£S
Ot£S
JT\ Ajff
QtfaS
0,<>$

0/2^
jffi A f V
a i

O./4
O'*i&
&>&?
Actual
/•/I
/,?
7o
65^
^S"
6,6
4,^
^^) ^j

^p ^0
75"
1 72
72.
72
73
72
72

Pump
Vacuum
In. Hg.
Gauge


V.0












6^
Box
Temp
°F
310
3JS
130
3/S"
^-330
3S<9
3\so
36~o

3VO
330
33S
^>35"
3fO
3Y6
3Y-5"
36"0

Probe
Temp
Op
310
MO
3>OO .-•
33O
33-T
370
3^0
3/o

3/S
32O
335"
33-ST
3VJ
3-y^r ••--
36.5"
3.S-0
Stack
Press.
In. Hg-
-o.V









^^-*^^ fc 1 III^^^N^^^^^





Stack
Temp.
op
3fc
*/20
ti^O
yyo
Wo
4^35"
*f/O
44o

-3/O
yzo
*J3O
430
*J4O
tfi/O
V3S-

-------
I
ro
en
    : Point
    l_3dL_I
         Clock ! Dry Gas
                Meter. CF
     3-J   :  I2:
    "      "  "
!_i-.4_ J JU381
i...3-7__j_J.t;i/L_
._3-8_  i  12^1 _
; o||	L-iiiy.7_.
    i 4*2
             /JO?
     4-4   ;  /!/(.
    j_S#_Uli*£__
      _!_._.
                 !&(*.!
                        , S
                              Pitot
In. 1120  j  In. H20
         OrificeAH  I   Impingcr °F i  Pump
                                                    Temp
                                     Desired
                                                             Vacuum
                                                             In. Hg
                                        Actual! Inlet Outlet  j  Gauge
                                             "0"  |   Probe
                                             Teiiip j   Temp
                                             op   I   op
                                 !   Stack I  Stack
                                 j   Press.i  Temp
                                                            In. Hg
                                                                                                 op
Jfiji
                          &*.*_


                           (9,3 "
                              *!T /„*• J _ J _
        0, 3
                                                 _i^70_l
J_10_..

     J	i     	J	
	^35;   \_2jo T     _  ! Jto
	M5j_lii_j	ll^
    J_3J
                                   Of I
                                       O.I
                     	!   20,_
                   .J^LP_.L2.o__
              j5iL_i	 4___
               ^L'_270 _!
               a751 ! 2?o i
                                     ~"
                                _			|	
                   .L. 2.°P_!
               O.V5   2.70 T
               ^'^":       j

              roii£Ti7jL.ri^
                                                          7i
                                                                             ™.t-
                                                                         33 ST
                   :                  i
                   1	L
                                                                     33ST
                                                                               —
                                                  ._3.2£	
                                          _3sSO._

                                           M 	 ,_   I  ^h
                                                                                      _J_
                                                                       -t—

                                                                       .J_

    Conmcnts
                    »
                                                                           '

-------
 I
ro
Plant G>MAD
Run No.
Location
Date
Operator
2
2 So/*sg/t
9 /7 ITS

Sample Box No.
Meter Box No.
Meter A H@ J, o l(* _
C Factor
Point
H
l-l
M
j.y
1-5
\-L

\-%
Off
2-1
L'i
2-i
7> £/ b
9:tf9
9;S2
Q * C"~i^"
$'.$8
lOiOJi
•-:*?
Dry Gas
Meter, CF
\Z^,270
/^6>i"^
/ fc. ^> V>« / S-5
- / *c (^ Q * 1
11(05. tf
72.70,7
Hi*'2*
/o?7/
1 3.1 S, 55
inx,&£
/37C.7
/3 7g
/379
/3§0. /
/28 /. G
xf^rfz

PARTICULATE FIELD DATA
VERY IMPORTANT - FILL IN ALL BLANKS
Read and record at the start of each
test point.

Ambient: Temp °F
Bar. Press. "Hg
Assumed
S-S
ic.H
Moisture % d>S
Heater Box Setting °F
Probe Tip Dia.,
In, ^V
Probe Length .5" IT, &lats
•i
Probe Heater Setting
Avg . A P Avg . A H

Pitot
in H20
AP


c ^
o. ?y
o. -?4~
o. ?y
c.34
0.3
o. y
0.5
tf


o. 3 £
*'-?
o./
0. /
0. /

5


c./S

o. £ $
-, f : •'.' ' '•' "t /3 
Orifice AH
in H20
Desired
0,38
o. 33
c, 3£
0,33
c.33

-------
Ol
00
I
Paint;::  Clock i Dry Gas
                                Pitot
Or if ice AH
Time • j Meter. CF   In. H20  !   In. H20
                '  A P
                                       \
                                       '
                                       Desired Actual Inlet jOutlet
Inipinger °F;  .Pump
Temp       i  Vacuum
             In. Hg
             Gauge
Box
Temp
op
                                           ^_.*.^L/£ftj__jzf_
Probe !
                                                                                  Stack
                                                                                       Temp  l   Press.
                                                                                       oF
                                                       In. Hg
Stack
Temp
op
    Comincnts

-------
                         PARTICULATE CLEANUP SHEET
Date:
            °l 11/7$
Run Number:

Operator: _
Sample Box No.
Plant:    GM/\I)
                                   Location Of Sample Port:

                                   Barometric Pressure:

                                   Ambient  Temperature 	
Impinger H20

Volume After Sampling 272

Impinger Prefilled With

Volume Collected
                                   Silica Gel
                                   Weight After
                                   g
                                   Weight Before
                             ml
Moisture Weight /3»ffg Moisture Total  £S> gg
Dry Probe and Cyclone Catch:
                                   Container No.

                                   Extra No.
                                                        Weight  Results
Probe, Cyclone, Flask
And Front Of Filter
Acetone Wash:
                                   Container No.

                                   Extra No.
                                                           Weight Results 0-/VfV g
Filter Papers and Dry Filter Particulate

Filter No.   Container No.   Filter No.   Container No.
                                                            Filter Particulate
                                                            Weight  Q./VSV    g
                                                            Total Particulate
                                                            weight a
% Moisture By Volume
                                       -259-

-------
                         PARTICULATE CLEANUP SHEET
Date:
             9/9/75T
Run Number:

Operator: _
Sample Box No.
Plant: _

Location Of Sample Port:  *

Baromefric Pressure:     3O> 17

Ambient Temperature
 Impinger H20

 Volume After Sampling £6»Q ml

 Impinger Prefilled With 2.00 ml

 Volume Collected      (»O    ml
                                  Silica Gel
                                  Weight After
                                  _g
                                  Weight Before _ 5/9.Q  g

                                  Moisture Weight   % g Moisture Total
Dry Probe and Cyclone Catch:
                                  Container No.

                                  Extra NO. 	
                                                        Weight  Results
Probe, Cyclone, Flask
And Front Of Filter
Acetone Wash:
                                  Container No.

                                  Extra  o.
                                                           Weight Results Q.
Filter Papers and Dry Filter Particulate

Filter No.   Container No.   Filter No.   Container No.
                                                            Filter Particulate
                                                            Weight  Q, I $03    g
                                                            Total Particulate
                                                            Weight Q.16?/  g
% Moisture By Volume
                                      -260-

-------
                            OXIDES OF NITROGEN  FIELD  DATA
Date
Plant
Sample Collected By.
Field Data
Clock Time
Flask number
Volume of flask (ml)
Pressure before sampling in. Hg.
Pressure after sampling, in. Hg.
Flask temperature, °F
//so
/
20¥7
LA
3&K*
t(e
10
/Wo-
6
•2o ft
2-T
34. Ho
30












* Flask + valve - 25 ml. for absorbing solution
                                        -261-

-------
                            OXIDES OF NITROGEN FIELD DATA
Date
Plant
Sample Collected By,
Field-Data
Clock Time
Flask number
Volume of flask (ml)
Pressure before sampling in. Hg.
Pressure after sampling, in. Hg.
Flask temperature, °F
0110
t
10<41
1,5
20^
1t>
*$H
r
£
1038
t.S
3a^£
2'S
&./?•
10
HMl
&>
2W
e.s
ja/y
1C
/Mo
7
Zosi
2,$
30, If
?o
IW$
e
I0$(c
e.s~
v3
-------
                      GAS SAMPLING FIELD DATA
Material Sampled For     SQg. 4



        9/9/75*
Date
Plant    GMAb
                                  Location
Bar. Pressure



Ambient Temp



Run No
                           "Hg    Conunents :   Point
              1
Power Stat Setting



Filter Used:  Yes




Operator 	
                            No
Clock
Time
\:
\ JOS'
l:/o
ir/s
i.-zo
r.^
/Uo



Meter
(Ft.3)
rsezo^a
13 12. 1
\izq,b
132,0,1
1 332, 2
1 333. S1
1334.630



Pitot
in. H20
AP
Or/S"
o*/r
<9/^"
o»/s:
o./z
a. is-




Orifice
in H20
AH
O'l
O.I
O.I
o.i
O.I
o.i




Temperatures Op
Stack
4so
O

i

'
Comments:
             7,
                                 -263-

-------
                      GAS SAMPLING FIELD DATA
Material Sampled For   30 j  4 SO 3 _



Date    W.S£
t:oo
Z'.OS
&IO



Meter
(Ft.3)
|fe»U3A
»33Ml



Pitot
in. HzO
AP
6.15"
O.IS
0.11
0,12
O.J2
O.lff




Orifice
in H20
AH
O.I
(D>!
O.I
0.1
0.1
o./




Temperatures Op
Stack
Wo
110
^0
^30
130
43*




Probe
300
3^0
3*S-
32T
120
310




Coil

W
1^
l^V
170
170
165




Impinger
In
I/O
126
If/0
US
DO
125




Out
^
7V
7V
75
76
77




             C..992
                                 -264-

-------
                      GAS SAMPLING FIELD DATA
Material Sampled For



Date     9//O/7S
Plant    GfAAD
Bar. Pressure



Ambient Temp



Run No       I
_"Hg
Location



Comments
Power Stat Setting



Filter Used:  Yes



Operator 	
  No
Clock
Time
9 '.13
9:/8
T, &
K38
W9
9/5*




rnmrriPTTf <; !
Meter
(Ft.3)
1341. (030
1.3*2.?
13 VS.
i \ ^4 *7 ^r
im*
JJ.£"2.072




Pitot
in. H20
AP
O.j?
0,1
O.2
6.^
0,2





Orifice
in H20
AH
o./-
o.i
O.I
0.)
O.I





Temperatures Op
Stack
130
^30
130
435
430





Probe
270
30S
300
3/5-
330





Coil

I7S
no
\(oS

HoQ





Impinger
In
/JO
ISO
^^~
w
us





Out
*7
if
11
20
91



i

i0, 1 X"* . M..i._ rt / / ^— i J l»... ..^- - 5 y^,,-> «
                          Cc?o-l Co
-------
                      GAS SAMPLING FIELD  DATA
Material Sampled For     SO y




Date     W/0/76" _



Plant    GMAD _
                                 SO 3
Bar. Pressure




Ambient Temp _




Run No
                           "Hg
                                  Location



                                  Comments
Power Stat Setting



Filter Used:  Yes _



Operator 	
                            No
Clock
Time
IQ1/0
10'. IS
10', IS
)OMS*
lo'.i*
I0t£g




Meter
(Ft.3)
1352,072
I3S3JST
/AffST,?r
1357* a
;35fj
/36//O^o




Pitot
in. H20
AP
0.2
0./1
O.iS
0,1
o.z
0,1




Orifice
in H20
ZiH
o./
o./
o./
o./
o,/





Temperatures Op
Stack
MO
HtO
WO
440
WD



i

•"robe
£?0
2^0
330
3SS
3/S-





Coil

IVO

/6>6

/60





Impinger
In
;f<3
IbQ
ISO
120
I2S





Out
W
%s
W
^7
W





Comments:
                    T«
                                 -266-

-------
        Plant
i
ro
en
           GMA.D
       Run No>  I
Location

Dat®    ? /101 ?£
Operator
                                                PARTICULATE FIELD DATA
                                          VERY IMPORTANT - FILL IN ALL BLANKS
                                          Read and record at the start of each
                                          test point.
                                                                         Ambient Temp °F
                                                                         Bar. Press. "Hg   .30
                                                                         Assumed Moisture %   8,
                                           f»\  O
                                                       ven
       Sample Box No. 	

       Meter Box No. 	

       Meter A Hg   }
-------
 I
ro
o>
00
 I
Plant GMAD
Run No.
4 . A J :

Location ^2. &p)k£ft
Date
9//0/76*

Operator __
Sample Box No.
Meter Box No.
Meter A
C Factor
Point
I'l
















H@


Clock
I* ft
IV IS.
1'j 8
ml
\'>LH
1U7
II JO

h^(e
Vtf
)Wt






Dry Gas
Meter, CF
/37V. Z&3
IMStie
1377.0
|3T?,2#
/ 2> 5^/ 7
/ 3£Y. 0
/ j Si , 3
)3W*fc
/3Jj5StO
[3&b*l
lW,t,2Q







PARTICULATE FIELD DATA Ambient
VERY IMPORTANT - FILL IN ALL BLANKS
,- v; . • ••: •;•'••• • ;;; •.. - - .^
Read and record at the start of each
test point. A
H
jj
P
P
A
Pitot
in H20
AP


£.£9
0/2P
0,23
0/2?
^•i4/
tf»21
0,20


I
^,2^
0,2?







Orifice AH
in H20
Desired
o.y
ai j?
j G
0.3Z
^ ^
0.i3
O. V
(5,2^
CP.33
0.3^
(3.37







Actual
o.y

-------
                         PARTICULATE CLEANUP SHEET
Date:
Run Number:

Operator:
                          4- 2.
                                   Location Of Sample Port:
Sample Box No.
                                   Barometric Pressure:    J 0. OJ

                                   Ambient Temperature
Impinger H20

Volume After Sampling
                           ml
                                   Silica Gel
                                   Weight After
Impinger Prefilled With  2.QO ml

Volume Collected      ^i     ml
                                   Weight Before  $0&*Q   g

                                   Moisture Weight  ?,V g Moisture Total
Dry Probe and Cyclone Catch:
                                   Container No.

                                   Extra No.
                                                        Weight Results
                                                                                  _g
Probe, Cyclone, Flask
And Front Of Filter
Acetone Wash:
                                   Container No.

                                   Extra No.
                                                           Weight Results
Filter Papers and Dry Filter Particulate

Filter No.   Container No.   Filter No.   Container No.
                                                            Filter Particulate
                                                            Weight d. | 2 73     g


                                                            Total Particulate

                                                            Weight 0»} (o 1 f  g
% Moisture By Volume
                                       -269-

-------
     Test:  I

 Plate   Tare(g)
2

3

4

5

6

7

8
        O.HVf
       Q,
       0./V37
Filter
                    Particle Size Determination
                      ,--

                                         Date: ?//

                Final(g)   Net (nig)   Filter   Total
                                      Net
                 0,
                 aisi.7
                      Total
             S
                                         -
         77-0
                                                       % of
                                                      Total
                         5/f7
Cum %


 1,13
                                          BCD
                                        (Microns)
                                                                        to,;
                                                              37.O,

                                                              tOQ.o
                                                                        /.c.
                                           0.66
     Test:  9

Plate   Tare(g)    Final(g)
   2

   3

   4

   5

   6

   7

   8

Back Uf
Filter
                 0 •• f «J5 J
                     Total
              Date:
Net(mg)   Filter   Total   % of   Cum %   BCD
           Net            Total         (Microns)
                                       I.I
          5.3
                                                      zns
                                 -270-
                       tco.o
                                           J7/J
                                                              11.73     7.3
                                                                        3.2

-------
      SOURCE TEST REPORT
      AMOCO OIL REFINERY
     WOOD RIVER, ILLINOIS
   BOILER NO. 6 - POWERHOUSE
              AND
CATALYTIC CRACKER REGENERATOR
                                TESTED BY:  ROCKWELL INTERNATIONAL
                                           R.W. Griscorn
                                           O.C. Klein
                                           F.E. Littman
                -271-

-------
                           TABLE OF CONTENTS

                                                                          PAGE

1.0  SUMMARY                                                              275

2.0  INTRODUCTION                                                         276

3.0  PROCESS DESCRIPTION                                                  277

4.0  PROCESS OPERATION                                                    278

5,0  SOURCE TEST DESCRIPTION                                              279

6.0  SAMPLING AND ANALYTICAL PROCEDURES                                   283
     6.1  PARTICULATE WEIGHT                                              283
     6.2  NITROGEN OXIDE                                                  285
     6.3  SULFURIC ACID MIST AND SULFUR DIOXIDE                           285
     6.4  PARTICLE SIZE                                                   287
     6.5  HYDROCARBONS                                                    287

7.0  RESULTS                                                              289

     APPENDIX A:  PARTICULATE CALCULATIONS                                297

     APPENDIX B:  FIELD DATA                                              313
                                 -272-

-------
                                  TABLES






                                                                     PAGE





TABLE 1  SUMMARY OF RESULTS BOILER NO. 6                             290





TABLE 2  SUMMARY OF RESULTS CATALYTIC CRACKER REGENERATOR            291





TABLE 3  COMPARISON OF RESULTS                                       292





TABLE 4  PARTICLE SIZE DISTRIBUTION                                  293





TABLE 5  HYDROCARBON ANALYSIS BOILER NO. 6                           295





TABLE 6  HYDROCARBON ANALYSIS CATALYTIC CRACKER REGENERATOR          296
                                     -273-

-------
                                  FIGURES





                                                                      PAGE





FIGURE 1   SAMPLING EQUIPMENT SET UP AT SE PORT - BOILER NO. 6        280





FIGURE 2   SAMPLING EQUIPMENT SET UP AT SW PORT - BOILER NO. 6        280





FIGURE 3   CATALYTIC CRACKER REGENERATOR, PRECIPITATOR AND STACK      281





FIGURE 4   STACK, SAMPLING PLATFORM, AND CRANE FOR HOISTING           281





FIGURE 5   SAMPLING EQUIPMENT SUPPORT                                 282





FIGURE 6   SAMPLING EQUIPMENT SETUP FOR TESTING                       282





FIGURE 7   PARTICULATE SAMPLING TRAIN                                 284





FIGURE 8   SULFURIC ACID MIST SAMPLING TRAIN                          286





FIGURE 9   ANDERSEN STACK SAMPLER                                     288





FIGURE 10  PARTICLE SIZE DISTRIBUTION - BOILER NO. 6                  294
                                     -274-

-------
                             1.0  SUMMARY

     In conjunction with the RAPS project, a limited stack testing program
is being conducted.  This report details the results obtained on boiler no.
6 in the powerhouse and the stack for the catalytic ctfacker'-rsfenerator-'at
the Amoco Oil Refinery in Wood River, Illinois.
     The stack testing included the following pollutants: sulfur dioxide (S02),
particulates, nitrogen oxides (NOX), sulfuric acid mist  (H2S04), and hydrocar-
bons.  Orsat analysis is for carbon dioxide (C02), carbon monoxide (CO), and
oxygen (02) were also performed.  Results of these tests are included in this
report.  The tests oh boiler no. 6 were not conducted to ascertain compliance
with Illinois standards.  Amoco Oil may choose to use the test on the cataly-
tic cracker regenerator for demonstrating.compliance since the precipitator
on this unit was just recently installed.  Thus, it is of interest to note
that this unit is  in compliance with the regulations for particulates, S09
          ....      ._.__--------.                                    ^        £
and CO.
     The test on the catalytic cracker regenerator was witnessed by E. Sullivan,
R. Yoder, and J.C. Rhodes of Amoco and Dr. John Reed of  Illinois EPA Permit
Section and Mr. Fred Smith of Illinois EPA Testing Section.
     We acknowledge and appreciate the excellent cooperation we obtained from
the management and engineering personnel of the Amoco Oil Refinery.
                                    -275-

-------
                            2.6 "INTRODUCTION
     The current stack testing program is being conducted in conjunction with
the emission inventory work for the St. Louis RAPS project.  The emission inven-
tory is being compiled using published emission factors.  The stack testing is
being conducted to evaluate the emission factors and to gather information for
additional emission factors.
     This stack test was conducted at the Amoco Oil Refinery in Wood River,
Illinois.  Testing was performed on the No. 6 boiler at the powerhouse on 4, 5
and 6 November 1975 and on the Catalytic Cracker Regenerator on 12 and 17
November 1975.
     Boiler No. 6 is an oil and gas fired, 200,000 pounds per hour steam
generating unit.  There are no emission controls on this unit.  This boiler was
sampled for total particulates, particle size, nitrogen oxides, sulfur dioxide,
sulfuric acid mist, carbon dioxide, oxygen and hydrocarbons.
     The Catalytic Cracker Regenerator was recently equipped with an electrostatic
precipitator.  This stack test may be used as a compliance test on the newly in-
stalled precipitator.  This unit was sampled for total particulates, nitrogen
oxides, sulfur dioxide, sulfuric acid mist, carbon dioxide, oxygen, carbor
monoxide and hydrocarbons.
                                   -276-

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                        3.0  PROCESS DESCRIPTION

     Boiler no. 6 was built in 1954 by Babcock and Wilcox.  The boiler is
fired with a combination of plant oil and gas streams.  Steam pressure is
approximately 600 psi.  This boiler "swings" with the plant, that is,  it
picks up upsets or changes in plant operation or demands.  The capacity
of this boiler is rated at 200,000 pounds of steam per hour.  For environ-
mental concerns this boiler has been derated to less than 250 x 10  Btu/hr
input.
     There are no stack emission controls on this boiler.  Boiler no.  6 is
an induced draft unit and exhausts through a masonary lined, steel stack which
is 159 feet tall and 8.5 feet inside diameter.
     The Catalytic Cracker Regenerator has had an electrostatic precipitator
installed during 1975.  This precipitator was started up at the end of October
1975.  There is also a waste boiler being installed ahead of the precipitator
but this was not in operation at the time of testing.  The stack is of steel
construction and is 171 feet tall and 8  feet inside diameter.
                                    -277-

-------
                         4.0  PROCESS  OPERATION

     Boiler no. 6 was tested on 4,5 and 6 November 1975.  During the
testing the boiler load remained fairly constant even though it was pick-
ing up any changes in plant operation.  This boiler was fired on refin-
ery gas, fuel oil, and "slop" oil  during testing.   Since there are no
individual meters there was no way of  knowing how much of each fuel was
being burned.  There were no visible changes in  emissions during test-
ing.
     The Catalytic Cracker Regenerator was tested on 12 and 17 November
1975.  Since the startup of the precipitator during late October there
had been some problems with the precipitator.  During testing, the con-
veyors1 that remove the collected material from the precipitator were not
operating.  This did not seem to interfere with testing.  On 17 November,
however, there was a short in one of several compartments of the precipi-
tator and the precipitator was only kept in operation for our particulate
test.  The tests for sulfur dioxide, sulfuric acid mist, and nitrogen
oxides were run with the precipitator  by-passed.  Visible emissions at
this time increased significantly.
     Since the waste heat boiler was still being installed during testing,
water was being sprayed into the gas stream to drop the gas temperature
from 1,000°F to 600°F to prevent damage to the precipitator.  This con-
dition raised the flue gas moisture content to approximately 29%.
                                   -278-

-------
                       5.0  SOURCE  TEST DESCRIPTION

     Boiler no. 6 was tested in the stack.  The sampling location and test-
ing arrangement are shown in Figures 1 and 2.  Figure 2 illustrates how the
sampling equipment was somewhat obstructed.  In order to make a complete
traverse at this saniple port, a short  5 foot probe was used for the near
points and a longer 10 foot probe was  used for the far sample points..
     The stack is 8.5 foot  inside diameter.  The sampling .location  was  ap-r
proximately 36 feet from  the stack inlet which is perpendicular to the stack.
This means that the sample  ports are 4 diameters from the inlet.  In accor-
dance with EPA Standard Method 1, 36 sampling points were chosen, 18 on a
traverse.  A 3-inch pipe  coupling, pipe nipple, and reducing flange were
used to attach to an existing standard 4-inch flange on the sample ports.
     The Catalytic Cracker  Regenerator was tested in the stack after the pre-
cipitator.  Figure 3 illustrates the regenerator to the right followed by the
precipitator in the center  and the stack to the left.  Figure 4 shows the
stack and sampling platform and the crane used to hoist the sampling equip-
ment up to the platform.  The testing  arrangement is shown in Figures 5 and 6.
     The stack is 8; foot  inside diameter and the sampling location is approx-
imately 80 feet from the  stack inlet.   In accordance with EPA Standard Method
1, since the sampling location was  more th|n 8  diameters from the inlet, 12
sample points were chosen, 6 on a diameter.  A  3-inch pipe coupling, pipe re-
ducer, and a 4-inch flange were used to attach  to the existing 4-inch flanges
on the sample ports.
                                   -279-

-------
                     FIGURE 1
SAMPLING EQUIPMENT SET UP AT SE PORT - BOILER NO.  6
                     FIGURE 2
SAMPLING EQUIPMENT SET UP AT SW PORT -  BOILER NO.  6
                       -280-

-------
                       FIGURE 3

CATALYTIC CRACKER REGENERATOR, PRECIPITATOR, AND STACK
                       FIGURE 4

   STACK, SAMPLING PLATFORM, AND CRANE FOR HOISTING
                         -281-

-------
              FIGURE 5




     SAMPLING EQUIPMENT SUPPORT

              FIGURE 6



SAMPLING EQUIPMENT SET UP FOR TESTING






                -282-

-------
                 6.0  SAMPLING AND ANALYTICAL PROCEDURES

     All  testing was  performed  with  sampling equipment  from Joy Manufac-
turing, designed for  isokinetic sampling  to  enable  testing by EPA standard
methods.
     Gas  flow  rates were  calculated  using the observed  gas temperature,
molecular weight,  pressure  and  velocity,  and the flow area.  The gas ve-
locity was calculated from  gas  velocity head measurements made with an S-
type pitot tube and a magnehelic pressure gauge, using  standard method 2.
     Moisture  contents were determined by passing a measured amount of gas
          •i
through chilled impingers containing a known volume of  deionized water,
measuring the  increase in volume of  the impingers liquid and the increase
in weight of silica gel used to finally dry  the gas, and calculating the
amount of water vapor in  the sample  from  the increase and the measured
amount of gas.
     The  stack gas concentrations of carbon  dioxide, oxygen, carbon monox-
ide, and  nitrogen  by  difference were measured with a standard Orsat appa-
ratus.  These  concentrations and the moisture content were used to determine
molecular weight of the stack gas.

6.1  PARTICIPATE MATTER
     Standard  method  5 was  used for  determining particulate emissions with
the exception  that the probe and oven were operated at  300-350 °F. Measured
stack gas samples  were taken under isokinetic conditions.  The samples were
passed through a cyclone, fiberglass filter,  impingers, pump, a meter and an
orifice as shown in Figure  7.
     The  total particulate  matter collected  in each test was the sum of the
filter catch plus  material  collected ahead of the filter in the sampling train.
The amount of  filter  catch  is determined  by  the difference in the weight of
the filter before  and after the test, after  dessicating.  The particulate mat-
ter from  other portions of  the  train was  determined by  rinsing the probe,
cyclone and all glassware ahead of the filter with  acetone, evaporating  to
dryness and weighing.                 ~x
                                  "-283-

-------
              STACK
              WALL
                HEATED;
                PROBE .
   Li
REVERSE-
TYPE
PITOT TUBE
                  ORIFICE
                  GAUGE
FILTER
HOLDER
                                                                               CHECK
                                                                               VALVE
                 VELOCITY
                 PRESSURE
                 GAUGE
                                                 FINE CONTROL
                                                   VALVE
                                            VACUUM
                                            LINE
                                    FIGURE 7

                           PARTICULATE SAMPLING TRAIN
                                      -284-

-------
6.2   NITROGEN OXIDE
      Using method 7,  gas samples were withdrawn from the stack  into  evac-
uated 2-liter flasks  containing a dilute solution of hydrogen peroxide and
sulfuric acid.   The hydrogen peroxide oxidizes the lower oxides of nitrogen
(except nitrous oxide) to nitric acid.  The resultant solution  is evaporated
to dryness and treated with phenol disulfonic acid reagent  and  ammonium hy-
droxide.  The yellow trialkali salt of 6-nitro-l-phenol-2,  4-disulfonic
acid  is formed, which is measured colorimetrically.

'£T~ SULFURIC ACIDllTsTAN~DlULRJR DIOXIDE
      The Shell  method was chosen for this determination due to  uncertain-  .
                                                                  *
ties  which exist about the validity of the results using method 8.   A gas
sample is drawn from the stack using a heated probe and passed  through a
water-cooled coil  condenser maintained below  the dew point of sulfuric  acid
at  140°-194°F,  followed by a fritted glass plate and then passed through a
chilled impinger train with two impingers containing an isopropanol  and hy-
drogen peroxide mixture and followed by an impinger containing  silica gel
for drying.  This setup is shown in Figure 8.
      The condensed sulfuric acid mist in the coil condenser is  water washed
from  the condenser.  The final determination is made by titrating the solu-
tion  with barium chloride, using a thorin indicator.  Isopropanol must be
added to the solution to be titrated to improve the rapidity with which the
barium sulfate precipitates during titration.
 *     Lisle, E.S. and J.D. Sensenbaugh, "The Determination of Sulfur Trioxide
  and Acid Dew Point in Flue Gases," Combustion, Jan. 1965.
  Goksoyr, H. and K. Ross, "The Determination of Sulfur Trioxide in Flue Gases,"
  J.  Inst. Fuel, No. 35, 177, (1962)
                                    -285-

-------
STACK;
 WALL.
                                                                    CHtCK
                                                                    VALVE
                                     FINE  CONTROL
                                        VALVE
                                                                         VACUUM
                                                                         LINE
      GAUGE
                         FIGURE 8

             SULFURIC ACID MIST SAMPLING TRAIN
                             -286-

-------
     Sulfur dioxide  in the  gas  sample  is  oxidized  to  sulfur trioxide fn the
impingers containing the  hydrogen  peroxide.   Sulfur dioxide is then deter-
mined by titrating the hydrogen peroxide  solution  with  barium chloride,
using a thorin  indicator.

6.4  PARTICLE SIZE
     An Anderson  fractioning inertfal  impactpr is  used  for the deter-
mination of particle size in the range of approximately 0.5 to 12.0 microns.
The sampling head is placed in  the oven after the  heated  sampling probe and
a sample of stack gas  is  drawn  isokinetically through the sampler, ..The par-
ticulate matter is fractionated and collected on the  plates inside the sam-
ple head and a  determination is made by the difference  jn weight of the plates
before and after  testing.  Results are expressed for  particles of unit density.
The sampling head assembly is shown in Figure 9.
                                                   -7  .   "      _'    „.. ,
6.5  HYDROCARBONS       v/                                         ;
     Gas samples  were  withdrawn from the  stack using "a  vacuum pump" to.fill Ted-
lar bags.  The  composition of the hydrocarbons was determined by gas chromato-
gr»ph,uttll2i»*tra^B«ck»aB>:68000foci'Cev:CH|f .andgtot
Perkin Elmer 900  for the complete hydrocarbon breakdown.
                                    -287-

-------
AIR FLOW
                         FIGURE  9
                  ANDERSEN STACK SAMPLER
                          -288-

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                               7.0  RESULTS

      Results  obtained from the test on boiler no.  6  are  shown  in Table 1.
 Results  obtained from the test on the Catalytic  Cracker  Regenerator are
.shown in Table 2.   Although these tests were performed for research pur-
 poses,  standard EPA methods were used. Since the test on the Catalytic
 Cracker  Regenerator may be used for compliance,  it is of interest to com-
 pare  the results with the State of Illinois standards.   A comparison is
 shown in Table 3.                f
      In  addition, to measuring particulate loadings on boiler no. 6, a par-
 ticle size analysis was made using an Andersen impactor.  The  results are
 shown in Table 4 and Figure 10.
      The average results of hydrocarbon samples  taken on boiler no. 6 on
 4 and 5 November are:
      Carbon Monoxide:                 1.11 ppm
      Methane:                         1.07 ppm                            ..;
      Total Tfydrocarbons, as CH4       3.28 ppm                           '  ,
 The major hydrocarbon components of these samples are given in Table 5.
      The average results of hydrocarbon samples  taken on the Catalytic
 Cracker Regenerator on 10 and12Novemberrarei-
      Carbon Monoxide:                28.91 ppm
      Methane:                         0.13 ppm
      Total hydrocarbon results are not available due to  a malfunction of  the
 analyzer.  A complete analysis of the major components  indicates that the to-
 tal hydrocarbons are approximately 2-3 ppm.  The major components are given in
 Table 6.
                                   "-289-

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                                  TABLE 1



                    SUMMARY OF RESULTS - BOILER NO. 6
Date
Stack Flow Rate - SCFM * dry
% Water Vapor - % Vol ,
% C02 - . Vol % dry
% 0 2 - Vol % dry
% Excess air @ sampling point
S02 Emissions - lbs/106 Btu
NOX Emissions - lbs/106 Btu
H2S04 Mist - lbs/106 Btu
Particulates
Probe, Cyclone, & Filter Catch
Ibs./hr.
lbs/106 Btu
total Catch

Ibs./hr.
lbs/106 Btu
% Isokinetic Sampling
11/4
54,010
13.19
10,33
5.90
35.6

0.45




26.4
0.14
100.4
11/5
47,766
12.67
10.83
6.30
39.6

0.58
i



32.2
0.18
92.7
11/6
42,348




1.88

0.021
























••



.'••'".-•.
; . ..•






*70° F, 29.92" Hg
                                    -290-

-------
                                 TABLE 2
                  SUMMARY OF RESULTS - CATALYTIC CRACKER REGENERATOR
Date
Stack Flow Rate - SCFM * dry
% Water Vapor - % Vol. ' "
% COa - Vol % dry- "
1 0 2 - Vol % dry
% Excess air @ sampling point
S02 Emissions - PPM
NOX Emissions - PPM
H2S04 Mist - PPM
Participates :
.Probe, Cyclone, & Filter, Catch
Ibs./hr.
lbs/106 Btu 	
Total Catch

Ibs./hr.
lbs/105 Btu
% Isokinetic Sampling
11/12
87,367
27.98
16.5
"1.65
8.1

71.2

•
. .,,-,.-

18.7

116.3
11/17
84,642
• 29.9
17.2
1.4
6.8
• 419
: 362.7
3.4
•


27.4

100'. 26


. .. ,, ,-

i
•



f
-••'••- 	






- . ,. .,.,,, .,







.......... , ..





t
i
(






t
i
i
f

1


*70° F, 29.92" Hg
                                    -291-

-------
       TABLE 3
COMPARISON OF RESULTS
SOURCE
Boiler No. 6


Catalytic Cracker
Regenerator


POLLUTANT
Particulates
so2
CO

Particulates
so2
CO
ILLINOIS STATE
STANDARD
0.1 lb/105 Btu
1 lb/106 Btu
200 ppm

80.1 Ib/hr
2000 ppm
200 ppm
AMOUNT FOUND
0.16 lb/106 Btu
1.9 lb/106 Btu
1.1 ppm
••
23.1 Ib/hr
419.0 ppm
28.9 ppm
        -292-

-------
                                 TABLE 4  ,   ;



                       PARTICLE SIZE DETERMINATION
TEST: AMOCO - BOILER NO. 6
DATE:  11/4
Plate

1
2
3
4
5
6
7
8
Backup

TEST: AMOCO
Plate
1
2
3
4
5
6
7
8
Rackuo
LJVIV* INU l^
Filter
Net (mg)
0.0
0.0
4.0
4.7
6.9
9.8
11.7
15.1
59.9
112.1
- BOILER NO. 6
Filter
Net (mg)
1.7
4.6
1.4
2.6
2.7
5.1
,,6.1
8.9 '
28.7 -
61.8
% Of
Total
0.0
0.0
3.57
4.19
6.16
8.74
10.44
13.47
53.43
100.00

% Of
Total
2.75
7.44
2.27
4.21
4.37
8.25
9.87
14.40
46.44
100.00
ECD
(microns)
14.4 & above
9.1
6.1
4.3
2,6
1.4
0.84
0.56
<0.56

DATE: 11/6
ECD
(microns)
14.2 & above
9.0
6.0
4.3
2.6
1.4
0.83
0.55
<0.55

                                    -293-

-------
% OF
TOTAL
       30
        20
— ffl
                        .11/4
              11/6
IS   W    13   12   I'    10    f    8    7    6

                             FIGURE TOT  ""
                                                               V    3
                                                                     ECO (MICRONS)
                          PARTICLE SIZE_ DISTRIBUTION-BOILER NO.  6
                                      -294-

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                                 TABLE  5
                          HYDROCARBON ANALYSIS
                               BOILER NO.  6

COMPOUND                                         CONCENTRATION (ppb as C)
                                                          11/4        11/5
Ethane                                                     20.7        16.8
Ethyl ene                                                   36.3        27.8
n-Propane                                                  35.5        34.3
Acetylene                                                  35.0        32.8
n-Butane                                                   55.7        52.2
Isopentane                                                 11.1         7.5
n-Pentane~                                                  5.4         8.4
Hexane                                                     29.7        33.0
Benzene +2,4 DM-C5                                                    I8-5
Heptane                                                                15/1
2,5  dimethyl Hexane                                                    10-9
Toluene                                                    33-3        94-6
1, Octene                                                  38-9        128.5
Octane                                                      ^         9-]
Ethyl Benzene                                              24.3        56.7
InrFxyleKT                                              123-2        290'3
-o-Xylene    "                                              37-5        79.0
Nonane                                                      13'2        19A
 n-Propyl  Benzene                                            9-7        49'6
1,3,5 trimethyl fenzene                                     16-4
                                    -295-

-------
                              TABLE  6

                         HYDROCARBON  ANALYSIS
                       CAT  CRACKER REGENERATOR

 COMPOUND                    CONCENTRATION   (ppb  as  C)
                               11/10         11/12
 Ethane                                        19.5
 Ethylene                                      12.8
 n-Propane                                     51.3
 Acetylene                                      9.5
 Isobutane                                     16.7
 n-Butane                                       4.7
 Propylene                                      3.7
 Isopentane                                     1.4
 n-Pentane                                      5.1
 Hexane                         41.3
 Benzene + 2,4 DM Pentane       38.1
 Heptane                        27.6
 Toluene                        46.1
 1, Octene                      29.3
 Octane                          4.4
 Ethyl Benzene                  18.6
 m.p-Xylene                    111.2
 6-XyTehe                       33.1
Nonane                         10.4
                                  -296-

-------
       APPENDIX A
PARTICULATE CALCULATIONS
            -297-

-------
                         PARTICULATE CALCULATIONS

 Volume of dry gas sampled at standard conditions - 70° F, 29.92 "Hci
                                                            3
 Vmstd =  Volume of dry gas sampled at standard conditions, ft
                             3
 Vm = Meter volume sampled, ft
 1.021 =  Meter correction factor
 Pm = Meter pressure, barometric pressure, PB» plus  orifice
     pressure, AH, in. Hg.
 Pstd = Standard pressure, 29.92 in. Hg.
 Tstd = Standard temperature, 530° R or 70° F
 Tm - Meter temperature, 530° R for compensated meter
 CFm = Meter correction factor
Volume of water vapor at standard conditions
                                 1b-         =  0.0474 * Vic
 "™    MC I  MH20 M  Pstd  J     454 gm.
         \     /  \       /                           A
 Vw = Volume of water vapor at standard conditions, ft
 VTC = Volume of liquid collected in impingers and silica gel, ml
 pH£0 = Density of water, Ig/ml.
M H£0 = Molecular weight of water, 18 Ib/lb mol
 R = Ideal gas constant, 21.83 in. Hg. - cu. ft./lb-mol  - °R
% Moisture in Stack Gas
                       Vw
        % M = 100 x
                                 -298-

-------
Average molecular weight of dry stack gas
              v   44 V /„, „     32 \  i  .
Molecular weight of stack gas
Stack velocity at stack conditions
vs  •   85-<8 *      V xA
V  = stack velocity, fps.
 J
85.48 - p1t.t constant,
                                lb. H    . oR
C  = pitot coefficient, dimension! ess
T  = average stack temperature, °R
 5
P  B stack pressure, barometric pressure plus static pressure, in. Hg.
AP Avg = average differential pressure, in. HgO
Stack gas volume at standard conditions
n    ocnni       u              Ps
Qs - 3600  1-.) Vs
Qs = stack gas volume flow rate, SCF/hr
                                  2
A = stack cross sectiona] area, ft
3600 = seconds per hour
Qs'  = Qs T 60 = SCFM
                                  -299-

-------
Per cent isokinetic sampling

1 = 1.6671(0.00267)   VIG    +  5^  (PB
   - 1.667 [(0.
                                        An
 I = per cent isokinetic sampling
 1.667 = minutes per second,  X  100
 0.00267 =  jjjj^   X  R  X

 0 = sampling  time,  rain.
                                                2
 A  = cross  sectional area of sampling nozzle, ft

 Particulate emission
                  fi
 C  = 2.205  X  10~b
 s
 GS = particulate emission, Ib/scf
 2.205 X 10   • pounds per mg.
 Mn = total mass of particulate collected, mg.
C£ » Cs X Qs - Ib/hr
Cg = particulate emission per hour
CH = Cj £ H
                                             t
CH = particulate emission, Ib. per million BTU
H = heat input, million BTU pert hour
                                  -300-

-------
Excess air at sample point


% EA -       TOO X % 02
        (0.266 X % N) - %
% EA = excess air at sample point, %

0.266 = ratio of oxygen to nitrogen in air by volume
                                   -301-

-------
                   PARTICULATE SAMPLING CALCULATIONS


           Test: Arhoco  - Blr. (o  -/?«.* /    Date:

 Material collected (mg) =
 Filter Catch            =
 Dry Catch               =
 Acetone Wash            = Jrf, 7
 TOTAL                   = 2?7.o
 Gas Volume    Vm . .  = 0.0334 /Vm    D    .
                Slu          I   HI   II rn  T
 0.0334
Volume of water vapor       Vw =  0.0474 X Vic

0.0474 (zyoml) =   /// 3JC,        $CF
% Moisture     %M = 100 X Vwstd
                          Vmstd  + Vwstd

100 X (/
Molecular Weight of dry stack gas

      MWp = %CQ2 X 0.44 + %02 X 0.32 +  %N2 X 0.28


   ( 10,^3 X 0.44) + (S,f   X 0.32)  + (?3>77 X 0.28) =


Molecular Weight of stack gas

MWw = TOO - XM X MWn    +  %M X 18
          1QO      u      100
ioo- I         x  i%?l    +          ./         X 18
     100                                lo
                                   -302-
                                                        J

-------
                   PARTICIPATE SAMPLING CALCULATIONS
     Test;   Blr£  -   l?u.v\  I

Stack Velocity   Vs  =  85.48 x C   hs. x P avgl  1/2
                                                         pate:
 85.48 x
                  \ ffi6.
                  L W.b'/
                           x 18.321
                                  hs. x P avgl
                                  Lps x M\  J


                                       1   1
                                       J
                                                   30. /O  fps
Stack Gas Volume  Qs =
                       3600 fl- %M \ (Vs)(A)/Tstd\ ( Ps \
                           \   100/        \jr~7 \Pstd/
               100
                                             530
                                                     .92
Stack Emission Rate    Cs  = 2.205 x IP"6/  Mn
                                      V VMstd

2.205 x 10-6   (  277
               (  2     }
               t7V/^)
                                   gjj,
                                                   ib/scf
CE = Cs x Qs =


CH = CE T H  =
                                                               Ib/hr
                                                lb/106 Btu
Isokinetlc Variations  I = 1.667
                                  (0.00267)   Vi   +  Vm  /   + AH  \1
                                               c     Tm  \PB   13.6/jTs
 .667     (0.
                                        6 Vs  Ps  An
            00267)
                                    530
                                                    ^^
                                                     13.6 /J
                     (30.10)
Excess Air at Sample  Point
                                           %  EA = 100 x % 02
                                  -303-
                                                 CO.266 x  % N2) - % 02

                                                 100 (  >5Tf  )	
                                                 (0.266 x§£77)  -  (^f )"=

-------
                    PARTICULATE SAMPLING CALCULATIONS
            Test:  Amoco ~£lr.6»  -  tf"« 2   Date;   H/S/7S

  Material collected (mg)  =
  Filter Catch            =
  Dry Catch               =
  Acetone Wash            =   .fr?, 7
  TOTAL                   = 353, (e>



  Gas
  0.0334                                                           SCP
 Volume of water vapor      Vw = 0.0474 X Vic

 0.0474 U/ayml) =   °l,173	SCF

 % Moisture     XM = 100 X  Vwstd
                           Vmstd + Vwstd

 100 X (?.17J)	   _    M,-,
 Molecular Weight of dry stack gas

       MWD = %C02 X 0.44 + %02 X 0.32 +  %N2 X 0.28


    (/0^3 X 0.44) + (t.,3  X 0.32)  + (&8* X 0.28)  =
 Molecular Weight of stack gas

 MWw = 100 - %M X MWn   t  *M  X 18
           100      u     TW


FlOQ - ;^fe7    X  ^.$73   ] + [     /^g»7        X 18
[     100                     J L       TOO1            J
                                     -304-

-------
                   PARTICULATE SAMPLING CALCULATIONS
     Test:   Bk Ct - Run 2

 Stack Velocity   Vs = 85.48  x C   fls x P avgl   1/2
                                                        Date
                                                           ;  ///JT/7S
85.48 x (O.
                                 fls  x  P avg"l
                                  Pc  x  Mw
                                 L s     w  J

                  f lO&.qZ x 0J3*y  I   1/2 =
                  l_ "23,11  x  25V/.T&  J           2 7, 13  fps
Stack Gas  Volume  Qs



       [l-
       L
                       3600/1- %M \ (Vs)(A)/Tstd\ / Ps \
                           \  100/        \TT~7 \Pstdj
3600
               100
                      (27,73)
                                             530
7/1   = t,8tetl83 SCFH
                                                  29:92
Stack Emission  Rate   Cs = 2.205 x 1Q-6/ Mn   \


2.205 x TO'6    (3S6,&>)    =      l,IZ£x/Q~      Ib/scf
               C 3S£>. (e \
               (68,7 W
CE = Cs  x  Qs  =
                                           = ^2,2 2 f
                                                               Ib/hr
                                               lb/106 Btu
                /77,^


Isokinetic Variations  I = 1.667
                                 f(0.00267)   Vi   +  Vm  /   + AH   \
                                 [            C     Ti  \PB   T3^j_
                                                                   Ts
1.667
      I   (0.
      L
                                        8  Vs  Ps  An
            00267)
                                    530   \
                                                    ^tt  «W
                                                    13.6  /J _
                     (21.12)     (tf.ll)     (7.t7*/o'  }
Excess Air at  Sample Point
                                          %  EA = 100 x % 02
                                                (0.266 x % N2)
                                                               - % C2
                                -305-
                                                 100  (
                                                (0.266
                                                        ,3  )
                                                       WM) -

-------
                            NO  EMISSION DATA
                                                 Date.
                                                             7S
 Run No.
 Time
                           gpM

                          /OHS
                   z
                   ^••
                  lass
 3
Itlo
                                                                   2
 U9
                                                 314
                                        /ooo
                             lots
  ^ Initial Flask Temp,  R
                          SIS
                  S2S
     Fimal Flask Temp,  R
                                     SIS
 \lf - Flask Volume,  ml.
                          let?
                                                   lost,
  ^ Initial Flask Pres* "Hg
                           t.
                  2/5
z.s
t.s
2,5
2.5
z.s
   - Final Flask Pres, "Hg
 Ib/scf N0
                          l.M
                                   1,27
                       3JQ
                 3.S8
 lb/10Btu
                                     o.os
                            O.lLe
                       0,67
Vsc= M7.
71  !R    \
   in. Hg/
(Vfc)    / Pf   -   Pi
                                         '1
                                              =  scf
Vfc - Vf - 25
C = 6.2  x 10"5  Ib/scf
               yg/ml
               ryg NO,  \  - Ib/scf NO,
                          Vsc
                                 -306-

-------
                            N0¥ EMISSION DATA
                              J\
Boil
          er
                 .  (f>
                                                   Date.
/*/
                                                                75"
Run No.
Time
ug N02
Tj- Initial Flask Temp, °F
Tf- Final Flask Temp, °F
Vf - Flask Volume, ml.
P- Initial Flask Pres, "Hg
Pf- Final Flask Pres, "Hg
Ib/scf N02 x/cfS
lb/106Btu N02
/
ono

-------
               H2S04 MIST and S02 EMISSION' DATA
                                                         Boiler No.
Date
Run No.
Vmc -Meter Volume, Ft3
Vmstd-Meter Volume, Std. Cond.
PB-Barometric Pressure, "Hg
AH-Avg. Orifice Pres. Drop, "^0
Vt-Vol. of Titrant, ml.
Vtb'Vol. of Titrant for Blank, ml.
Vsoln'Vol- of Solution, ml.
Va-Vol. of Aliquot, Titrated, ml.
Ib/scf H2S04 XIO'**
lb/1°G Btu H2S04
Ib-scf S02 w~*
Ib/lO6 Btu S02
It/t
/
&.OS-7
S.182
tf.si
O.I
1.*
nil
S£0 *
5


i.tsi
1,12

/




/,£

loo
ts
I.IS4
o.on


"/(a
Z
7,2&
7.7t>2
Zt.f'f
O.I
/S.05
*,'/
500
5


!>$(*(,
2&/

I




3.CS

IOO
^s
I.(*U
O.OIS



















,

':







.
Vmstd = 0.0334  (Vm)
                   AH
CFm = Meter  correction factor
CH2S04 =1.08 x
        /1.
        \
                    lb-1
                    9-ml
                    (Vt - Vtb)  (H
                         Vmstd
                                      v
i= Ib/scf    N. = 0.01 Norma!
'                Bari urn
                Perchlorate
C$02 Bf'
       7.05 x
                   (Vt - Vtb)   (H)
                                                Ib/scf
                        Vmstd
                              -308-

-------
                    PARTICULATE SAMPLING CALCULATIONS
            I§st.: Amofo  ' Caf Cra^/cer       Date:    H/IZ/7S
 Material collected (mq) =
 Filter Catch            = £3,o
 Dry Catch
 Acetone Wash            =32.1
 TOTAL

 Gas Volume    Vm .. = 0.0334/V
                 Stu         { _J

 0.0334
   . .  B       13.6,
m
 Volume of water vapor       Vw = 0.0474 X Vic
 0.0474 (3^2. ml) =      }(»,&(     SCF
 % Moisture     %M = 100 X Vwstd
                           Vmstd + Vwstd
 100 X ( 1C.ail )	
 Molecular Weight of dry stack gas
       MWQ = %C02 X 0.44 -H %02 X 0.32 +  %H2 X 0.28
            X 0.44)  + ( \.UST X 0.32)  + (*I*$^X  0.28) =
 Molecular Weight of stack gas
 MWw * 100 - %M X MWn    + JM_ X 18
           Too"     u     100
flOO - 21, 1U   X  30,70G    1 + T    2.7*176      x 18 =
[ - TOO                      J L      100            J
                                                                  SCF
                                      -309-

-------
                  PARTICULATE SAMPLING CALCULATIONS

     Test:   (^f  Cracker                          Date:  II/II/7S
Stack Velocity   Vs = 85.48  x Cn  fTs x P avgl  1/2
                             P  LPs * Mww  J

85.48 x (0. fo )  \IOIl.l   x  0,1 rf   1   1/2  =
                 |_2*,3fr/   x  27.AS7  J         -2f
                                                           fps
 Stack Gas Volume  Qs  = 3600/1- %M V(Vs)(A)/Tstd\ / PS \
                           \  100/        \Ts  y \Pstdy
       fl-
       L
 3600    l-   U7.te)   (7^.2      (4TA265*)    530  (Ifrj^fl   = S.M/     SCFH
               100                        /, N  29.92
 Stack Emission Rate   Cs = 2.205 x 10"6/ Mn   \
                                      V VMstd /
 2.205 xlO'6   ( ^5.9  )    =      3, Vg**/0"^    Ib/scf
 CE = Cs x QS = (3,V£2x/<        (sr,&l,9) =  />?	Ib/hr

 CH = CE T H  = (        ) =  	^15/106 Btu
 Isokinetic Variations   1 = 1.667  [(0.00267)  Vlr  +  Vm  (   + AH  \\
                                 L            c     Tm  \PB   T3T6"/JTs
                          —         evs  Ps  An
 1.667    (0.00267)     ( 3*J2   )  +  *M&(}0M> +
                                    530   \          13.6  /
Excess Air at  Sample Point
                                          % EA = 100 x  %  0?
                                                 CO.266 x  %  N2)  -  % 02
                                                 100

-------
                    PARTICULATE SAMPLING CALCULATIONS


            Test:  Amoco  - Gd  Cracker      Date:     ////7/7$*

 Material  collected  (mq) =

 Filter  Catch            =   32,?
 Dry  Catch
 Acetone Wash            =

 TOTAL                   =
 Gas  Volume    Vmst(j = 0.0334/Vm   \/p   +

                                      B       13T6,
 0.0334                      .
                                                                  SCF
 Volume of water vapor       Vw = 0.0474 X Vic

 0.0474 (3l/.5-ml)      K76S'      SCF
% Moisture     XM = 100 X Vwstd
                          Vmstd + Vwstd

100 X (  )g)
Molecular Weight of dry stack gas

      MWQ = %C02 X 0.44 + %02 X 0.32 +  %N2 X 0.28


   ( H. 7  X 0.44) + (/^  X 0.32)   •»• (g/,7 X 0.28) =
Molecular Weight of stack gas

MWw = 100 - %M X MWn    +  %M  X 18
          Too"            100
                                    -311-

-------
                   PARTICULATE SAMPLING CALCULATIONS


      Test:   /(moc.0  "  CA^  Cracker               Date:
Stack
85.48
Stack
3600
Velocity
Gas Volume
fi- (£'
Vs = 85.48 x
[i03% 3 x
2^,£?/y x
Qs = 3600/1-
?,?)] (7?,3t
c_ [~TS
P IPs
0,)     (AT^7^,^/0 =   27*VQ	Ib/hr
  t.    ^                           /    /        ^^"^•"^•^•^"•^^•""•""^^•^i »•	«	—•••»—^•



 CH = CE T H  =  (	) -	^lb/106 Btu
  ||    •«•        "J™ "'"J-i" rr i__  —       L  -IIII.TI_L-. jj	 - -i -i ir« . -i  |   I   "W
 Isokinetic Variations  1=1.667   F(°-00267)  Vi   +  Vm  /   + AH
                                   [	lc     Tin  \PB   U

                                         evs  PS  An
 1.667     (0.00267)     (3H.S    )
                                     530   \13.6
Excess Air at Sample Point
                                            % EA = 100 x % 0?	
                                                   CO.266 x X: N2)  - % 02
                                                   100 (   hi
                                 -312-             (0.266

-------
APPENDIX B
FIELD DATA
   -313-

-------
                             NO  EMISSION DATA
                               A
Cotf. Cracker
Run No.
Time
yg N02
T.J- Initial Flask Temp, °R
T.p- Final Flask Temp, °R
Vf - Flask Volume, ml.
P.- Initial Flask Pres, "Hg
Pf- Final Flask Pres, "Hg
Ib/scf N02 XJ0-S
lb/106Btu N02
H/12
/
las
M
SIC
S3 0
OX/7
Z.S
2*5*
Q-33

2
ills'
2U
S/O
£36
2028
t.s
2Wl
0.&

0
3
12/0
tooo
S3Q
SSO
Z6&
z.s
2U/
1.SO

^ nut. */////
n/i 7
y
U2S
I2C*
SJO
ss-o
202$
2,5
2M
V.2^

S
1305
II8&
£&
S-SO
2o2S
2*S
21.&I
4.IS

(e
fSOO
/Soo
S30
sso
2o$2
2.S
*1.U
*/.*4

7
IS3Q
hio
530
SSO
2QSI
2.5
nu
v,s*


8
We
Itio
$30
^s-c
20^6
2.5
2UI

-------
                       H2S04 MIST and S02 EMISSION1 DATA
                                                              Cc\i
                                                                     k
                                                                            er
Date
Run No.
Vmc-Meter Volume, Ft3
Vmstd-Meter Volume, Std. Cond.
Pg-Barometric Pressure, "Hg
AH-Avg. Orifice Pres. Drop, "1^0
VfVol . of Titrant, ml.
Vtb-Vol • of Titrant for Blank, ml.
Vsoln~V°' • ,of Solution, ml.
V -Vol . of Aliquot, Titrated, ml.
Ib/scf H2S04 XJO-U
lb/106 Btu H2S04 ItAr
Ib-scf S02 x/o'5
lb/106 Btu S02 lU/^r
11/17
1
!,$&
1.3o(,S
M-C,I
0,\
1.1
ml
s&o
s


6.W/
3S3,r






^3
KU'I
100
so
Q.OZf
Q,*\(o


11/17
2
HJtt
W.WC*
2^.t/
O.I

*;/




L,8$(*
3S3.8






2,7$
n.'l
100
so
131*
8.ZS






























Vmstd = 0.0334


        CFm = Meter correction factor
          m
CH2S04 =/1.08 x TO"4 lb-1  \  (Vt - Vtb)   (H)   /VsoW
CS02 "/
      \
"7.05 x
                                                i= Ib/scf    N. =  0.01 Normal
                                                '                Barium
                                                                Perch!orate
lb-1
   ,
g-ml
                                  Vmstd
                           (Vt-Vtb)    (N)
                                 Vmstd
                                                      = Ib/scf
                                        -315-

-------
                SUPPLEMENTARY PROCESS DATA FOR POWER PLANTS
                                         Boiler  Nlo.
Date
Net Unit Load - MW
Average Steam Load - 10 Ib/hr
Boiler Heat Input
Fuel Burning Rate - Ib/hr
Fuel Heating Value - BTU/lb
Fuel Sulfur Content - %
Fuel Ash Content - %
Fuel Moisture Content %
nli

sec






ills

b e ( ou-»






II /(ff

















 II
Part.
NOX
    Part
ii A
                  Checked,  over
                           r  -  /8S.9
                                  180,0
                                  /77.6
                                      , 3
                                             o-f
                                                          /Ik
                                  -316-

-------
                       ORSAT FIELD DATA
Location
                                          Comments:
Time
Operator
Jtlai
Test
n/y
J0I&'
1030
/(e>00

ll/f
)3&o
I43o
0*110

II/C*


(CO )
Reading 1
/0,6
/o.y
lo.c

11,0
10*7
taf


-------
Plant.
Run No..
            I
Location-
natA    lt/?
                                                                  Assumed Moisture  % .

                                                                  Probe Tip Dia., In.
                                                                  Probe length   IP

                                                                  Avg.  AP	Avg.  AH.
I
CO

00
  Point
           Clock
                    Dry Gas
                    Meter,
                    CF
                             Pi tot
                             in HoO
                              AP
Orifice  AH
in H20
                                       Desired
                                              Actual
Impinger
°F Temp.
                                                     Inlet
                                                        Outlet
                                                                       Pump
                                                                       Vacuum
                                                                       In. Hg.
                                                                       Gauge
Box
Temp-
°F
Probe
Temp
°F
Stack
Press
In.
Stack
Temp.
°F
          /O : 
                                                                                           V^ro
  1-13
                  /-?//, s"
                              a. &>

                                                                                           4CTO
                  I VIS
                              Q>1*
                                               1. IS
                                                                             gfo
                                        1,1*
                                                                 1,0
                                                                       3VJT
                  /?/*'$
                                              Ids.
                                                           £>*,
  HJ_
                                                                       1VJ1
I-//
                              0,1*1
                                                                       3VS
                                                                               3e>o

-------
I
CO
                                                                            Pump
                                                                            Vacuum
                                                                            In.  Hg
                                                                            Gauge
Stack
Press.
In. Hg
 Impinger
.°F Temp. '

-------
                         PARTICULATE CLEANUP SHEET
     :  X/yV/7/
Run Number:

Operator:
Sample Box No.
Plant:  AMOCO
      Location Of Sample Port:

      Barometric Pressure:

      Ambient Temperature

                                    -S»
 Impinger H20

 Volume After Sampling j'fe  ml

 Impinger Prefilled With

 Volume Collected      / g    ml
Silica Gel
Weight After
                                        _g
ml    Weight Before
                        g
      Moisture Weight
                       Moisture To
Dry Probe and Cyclone Catch:
Container No.

Extra No.
                                                        Weight Results
Probe, Cyclone, Flask
And Front Of Filter
Acetone Wash:
Container No.

Extra No/
                                                           Weight Results
Filter Papers and Dry Filter Particulate

Filter No.   Container No.   Filter No.   Container No.
                                                            Filter Particulate
                                                            Weight &. 3/73   g
                                                            Total Particulate
                                                            Weight  d. <
% Moisture By Volume
                                     -320-

-------
Run No.    c	

InraHnn  ** &>  B\f.

Date	!
Operator,
Meter  AH@

C Factor 	
            /*QZ.Ce>
                                      PARTICULATE FIELD DATA

                                 VERY  IMPORTANT-FILL IN ALL BLANKS
                                  Read  and record at the start of
                                  each  test point.
                                                 Ambient Temp °F
                                                           "Hg_
                                                                 %	UL
                                                 Probe Tip Dia., In —

                                                 Probe i pngth  ^ 4+  4. /O-fi

                                                 Avg.  AP  <^./7  Ax/g   AH	
   Point
         Clock
Dry Gas
Meter,
CF  '
Pi tot
in HoO
 AP
                                                 Orifice  AH
                                                 in H20
                                        Desired
                                             Actual
                                 Inlet
      Pump
      Vacuum
      In. Hg
Outlet! Gauge
Impinger
°F Temp.
Box
Temp
°F
Probe
Temp
°F
Stack
Press.
In.  Hf»
Stack
Temp .
°F
CO
ro
   e-/
                                                     HO
                                        76
                                                                3/0
                        '. O
                                                                         J/0
                                                                                             VJTO
   e-v
   i-7
                      , 7
           Otlt

                       2(0
            ISO

                  iolV.o
   2-
                                                           7  /
                                                    3/o
                                                 / to
            .1/1.
                             P»*3
                                                           JA±
   JLdJ
         J2L
                    ^*
                                                 ^oo
                       it.
                                                            wr
                                          LC
                                                 1.0
Jill
                                                0*11
                                                                           VJP

-------
           Point
           1-2
         Clock
Dry GQS
Meter,
CF
Pi tot
in HoO
 AP ^
                             J2*.
           0.IZ,
Orifice AH
in fO
                                                 Desired
                                                  0,7 ,(
-------
                         PARTICULATE CLEANUP SHEET
Date:  //
         kh
                                   Plant:
Run Number:

Operator:
Sample Box No.
                                   Location Of Sample Port:

                                   Barometric Pressure:

                                   Ambient Temperature
                                                                &l i? ,
                                                                :-. .- i1
Impinger H20

Volume After Sampling
                          3mi
                                   Silica Gel
                                   Weight After'
Impinger Prefilled With £ ^ ml

Volume Collected _ /f3  ml
                                   Weight Before  *T(f> g
% Moisture By Volume
                                     -323-

-------
                            OXIDES OF NITROGEN  FIELD  DATA
Date
Plant
Sarr.ple Collected By.
Field Data
Clock Time
Flask number
Volume of flask (ml)
Pressure before sampling in. Hg.
Pressure after sampling, in. Hg.
Flask temperature, °F
/o-.4S
/
£w/
J.S
3t.fi
If
Sfi'.fT
A
lotf
J.£
—
—
tl',3*
Z
*otf
3.?
-
-
xj?;3o
¥
3*3<£
3.f
-
-
/J?/cf5
5
Jojf
A.S
-
-
/r:uf
L
fa*
3. r
-
-
tfl !f
7
2o$A
3.?
-
~
1C ,' fo
'/
^ojC,
3.f
-
-
* Flask + valve - 25 ml. for absorbing solution
                                        -324-

-------
                            OXIDES OF NITROGEN FIELD DATA
Date
Plant    Amoto   - filt*  ^4



Sample Collected Ry
Field Data
Clock Time
Flask number
Volume of flask (ml)
Pressure before sampling in. Hg.
Pressure after sampling, in. Hg.
Flask temperature, F
0^30
1
Wl
2.S
;?,zr
%
)oe>o
Z
&&%
2.$
&xr
10
/03d
3
103<}
i<$
&7S
<*o
1200
¥
Z&28
2^
21,7 S
£}Q
tf*o
S
^o2s
^>s
&>?s
90
lios
<*
2GS2
2*S
Zi'tt
90


>









* Flask + valve - 25 ml. for absorbing solution
                                         -325-

-------
                       GAS SAMPLING FIELD DATA
 Material Sampled For

 Date  /I
 Plant  AMOCO
                                  Location
                                           -^3<
Bar. Pressure

Ambient Temp

Run No     /
                           "Hg
                                  Comments :
 Power Stat Setting 	

 Filter Used:  Yes 	

 Operator J^=*g/.sconi   Mej
                             No
 Clock
 Time
          Meter
          (Ft.3)
                       Pitot
                       in. H20
 Orifice
 in H20
AH
   Temperatures Op
Stack
robe
Coil
Impinger
                                                                In   Out
                          6.1
                                                               /Lo
                          &•/'
                                            ¥¥»
II'
Comment s :
             • //
                                    -326-

-------
                       GAS SAMPLING FIELD DATA
Material Sampled For

Date   I/ / C> / 7f

Plant  /
                                   Location
 Bar. Pressure  *?
-------
       Plant.
Run No-- Andet-^
                         ei\
       Inrat.inn.    ** Co
       DatP    11/4/73"
       Operator.
       Meter A HO,
       C Factor 	
      PARTICULATE  FIELD DATA
VERY IMPORTANT-FILL  IN ALL BLANKS
                                     Read and record at the start of
                                     each test point.
Ambient Temp Of
Bar. Press "Hg_
                                                                       Probe Tip
                                                                       Probe Length
                                                                       Avg.  AP	
                                                   In	~
                                                    s-ti
                                                  .Avg.  AH.
Point
^-?




O-M












Clock
3 ''03
;/3
\+3
''}5
;V3
J5-3










.
•
Dry Gas
Meter,
CF
/?<&£. ^f J-'
^6^//
/f76.o
/Igt.SS1
}
O,/l
o,/70
- 3<&&
3&J-
36,0













Stack
Press.
In. Hg.


















Stack
Temp.
°F
/60
V6o
Vfeo
Y6a
V60











'. ^

ro
00

-------
      Plant.
 A
M.OCO
      Run No..
A A A* vse.K
       Location.
                II /sr/7Jr
       Operator
       Meter AH@
       C Factor
                             PARTICULATE FIELD DATA
                        VERY  IMPORTANT-FILL  IN ALL BLANKS
                           Read and record at the start of
                           each test point.
Ambient Temp OF
Bar. Press "Hg
                                                           Assumed Moisture
                                                              Probe Tip Dia.,  In.	
                                                              Probe Length.	
                                                              Avg.   AP	Avg.  AH.
Point
hi

















Clock
/ /' £/S"
'. fO
', $£
r? ' 4?^
i&*$
i/0
', AT
:*o
z:^s









Dry Gas
Meter ,
-CF
3.0TH.M.Q
AC 76 . ?
,&?7?/7
A«5o
^^"
101
_Jo__
70
7C
7/
7Z.










Pump
Vacuum
In. Hg.
Gauge
7,-T

&•*/

S.S













Box
Temp
°F
36-0
3>ST
363
3?o
37S~
3 eg
?>?&
3f£










Probe
Temp
°F
3£>S~
$!Q
3/O
32-8
32 $
3*c
2>3o
33$


•







Stack
Press.
In. Hg.


















Stack
Temp.
oF
i7c
*n&
V7S
ye$
ygc
y
-------
       Plant.
       Run No.,
Location.
                  *<*  g\r.
       Operator
       Meter A HO
       C Factor
                                          PARTICIPATE FIELD DATA
                                    VERY IMPORTANT-FILL IN ALL BLANKS
                                            Read and record at the  start of
                                            each test point.
Ambient Temp °F
Bar. Press "Hg_
Assumed Moisture %	
Probe Tip Dia., In —
Probe Length ____*£_£
Avg.  AP	Avg.
                                                                                             AH.
Point
i*$

















Clock
^', /£
I ?.o
*, l£
:±Q
t 3S
rye
fjyf











Dry Gas
Meter,
CF
&!&(*, 170
Z/o% 7
ZII3.0
A//6, 3
1//9>S
2/&£> t»
MAS'. 8$?











Pi tot
in H?0
AP
0,/i
O> ll
A. It
Ott*
0,/A
Ctl-i










.

Orifice AH
in H20
Desired
0.7?


0.7S
0,75
0.7S












Actual
OSS'
0*75"
0,75
/>, 74-
^,7^
0,7?












Impinger
°F Temp.
Inlet
too
l*jS
J.7&'
23 £
3/o
3/5"












Outlet
76"
6A
fc(e
fat
70
73.










~

Pump
Vacuum
In. Hg.
Gauge
9,0
?>«2
/0'P
lQ>*>
fO*&0
39o
3&£










.••

Probe
Temp
°F
3/0
2>A.0
"b3o
32>£
340
3^5"












Stack
Press.
In. Hg.


















Stack
Temp.
°F
V^iP
vj^-
VJ«T
VJ^'
vyo
y^5
-------
Test:
Particle Size Determination




                        :   I//V/7S"
     . 6>
                       Date:
	 „ 0.^.1.= \y / rj.acix^y^ iNet imy;
1 0.153* G»KS37
2 CM W 0>IW8
\
3 O. I £"70 CP. /6.IO
4 O.lffOCp 0-ISS3
5 O. lASTO O.J6.C?
6 0. \1& Q.lSZb
7 OJ5-JO 0,/C.Vl
8 O.IS-00 0,/Wf
Is'1 •
Back Up £ , £ , ,273^ CPJ^C6
4 O.JV4?? (P./S"4»/
5 O»/WV O,\SOt
e o.msq Oiibii
7 0, /V£V Of|«r^3
8 O. M2fc 0,/£'
6,3 ^.61 V^o
&.? 5^V 2^£>
/3,0 ///75 1.3(0
\t, 9 //^5" 0,^3
;t,7 /^^ o/^s-
^^,f V-^08- 
-------
    Test:

Plate  Tare(g)
     Particle Size Determination

    Sir. (e>               Date:  11
Final (g)   Net (nig)    Filter   Total   % of   Cum %   BCD
                     Net           Total         (Microns).
0,15-21     o,IS3ff
   1

   2

   3

   4

   5



   7   0.H3I

   8   0, j.^^J

 Back Up _ 3151
 Filter ^'^  '



      Test:

 Plate  Tare(g)


   1

   2

   3

   4

   5

   6

   7

   8

Back Up
Filter
o.mi
O.M1Z
                    Total
                 Final (g)   Net (mg)
 i.i

 i.v
 z,(*
 2,7
 sr.l
6,i
 SM
                                                    2,75"
                                                 /V/23
                                                    9, $7
                                   100,00
                                        Date:
                    Filter
                    Net
                                      Total   % of
                                             Total
                      Cum %   BCD
                            (Microns)
                   Total
                                      -332-

-------
            SUPPLEMENTARY PROCESS DATA FOR POWER PLANTS
Date
Net Unit Load - MW
Average Steam Load - 10 Ib/hr
Boiler Heat Input
Fuel Burning Rate.- Ib/hr
Fuel Heating Value - BTU/lb
Fuel Sulfur Content - %
Fuel Ash Content - %
Fuel Moisture Content %




































                                             Co,-/  Cracker-
             Frtsk
/
I//7
                                                     #35"
                                                     7/6
                                            0!'
                                -333-

-------
                       ORSAT  FIELD DATA
Date




Tina
II/I
Z   4  II
                       /J7
Operatbr
                                            Comments:
Test
H//2
/00&
/loo

n /n
1/36
I5ZO






(CO )
Reading 1
/6,-/
/&.L

/&>.%
17,2






CO)
Reading 2
*,0
t,3

Z,7L
1,4






(CO)
Reading 3
O.O
0.0

^) 00
0,6






                           -334-

-------
Plant.
      A
Run No	L
I nrat-inn  Ca.j

Date.   M//Z.
Operator

Meter  A

C  Factor
                                      PARTICULATE FIELD DATA

                                VERY IMPORTANT-FILL IN ALL BLANKS
                                 Read and record at the start of
                                 each test point.
                                                 Ambient Temp °F _
                                                 Bar. Press "Hg	
                                                 Assumed Moisture

                                                 Probe Tip Dia., in.    */f

                                                 Probe tpngth   loft

                                                 Avg.  A P  &' & . Avg. AH_
   Point
        Clock
 Dry Gas
 Meter ,
 CF
                             Pi tot
                             in  H?0
                             AP
                                               Orifice AH
                                               in H20
                                        Desired
                                             Actual
Impinger
°F Temp-.
                                  Inlet
                                                        Outlet
Pump
Vacuum
In.  Hg
Gauge
Box
Temp
OF
Probe
Temp
°F
Stack
Press.
In.-ttfr
Stack
Temp.
°F
CO
co
en
           /O.' 30
                                             Q.12
                                   IZto
                                                                10.0
   /-sr
                                             O.&L
                                        y
                                                                                 2 oo
                    Ziso
                                                         . 6
           l/to
-------
                         PARTICULATE CLEANUP SHEET
Date:
Run Number:   * f

Operator: 	
Sample Box No.
                                   Plant:

                                   Location Of Sample Port:

                                   Barometric Pressure:   £f. rf2-

                                   Ambient Temperature
Impinger H20

Volume After Sampling

Impinger Prefilled With

Volume Collected
                           mi
      Silica Gel

      Weight After
$•/
ml    Weight Before
                                                           g
ml    Moisture Weight
                                                          Moisture Total -
Dry Probe and Cyclone Catch:
                                   Container No.

                                   Extra No.
                                                        Weight Results
                                                                                  _g
Probe, Cyclone, Flask
And Front Of Filter
Acetone Wash:
                                   Container No.

                                   Extra No.
                                                           Weight Results
Filter Papers and Dry Filter Particulate

Filter No.   Container No.   Filter No.   Container No.
                                                            Filter Particulate
                                                            Weight  <0.a33Q
                                                            Total Particulate
                                                            Weight  6- 0 d> 5f g
% Moisture By Volume
                                      -336-

-------
Plant A*W>CO -•
Rim Nn 2

Date t'/)7
Operator Cs>trt4eo*\ . Kl.t?lt\ ,
Meter A HO l»02 2
PARTI CULATE FIELD DATA
VERY IMPORTANT-FILL IN ALL BLANKS
Read and record at the start of
each test point.
£*' 14., ""»*•<£"
                                                                                         3O
C Fartnr      0, 3
                                                                          •Ambient Temp  °F _

                                                                           Bar.  Press  "Hg___

                                                                           Assumed Moisture

                                                                           Probe Tip Dia., Tn.   VV

                                                                           Probe I ength      /# ^

                                                                           Avg.  AP	Avg.  AH_
  Point
                 Clock
 Dry Gas
 Meter,
 CF
Pi tot
in HoO
 AP
Orifice  AH
in H20
                                       Desired
                                                     Actual
Impinger
°F Temp.
                                  Inlet
                           Outlet
Pump
Vacuum
In.  Hg
Gauge
Box
Temp
°F
Probe
Temp
°F
Stack
Press
In.
Stack
Temp.
°F
I
co
co
                                                                  1.0
  J^L.
                                                                 (e,C>
                                                                               3*10
  2-2
                                               0,12
  Z'f
                                                     &&&
                                                                           5% a
                                                     no
                                                                        7.0
eaoc.
                                                                  7.0
                                                                               303
                                                                  7,0
                                               6.J1
                                                                               3Vo
   I-/
                                     a?
                                               «*•<>
                                         2LSL
  _Q££
                 Llia.

-------
                         PARTICULATE CLEANUP SHEET
Date:  //
 Run  Number:   <*-

 Operator: 	
 Sample  Box No.
                                   Plant:
Location Of Sample Port:  (

Barometric Pressure:

Ambient Temperature
                                                             f~
                                                             F
                                                                      nc>6$'*?    g
Probe, Cyclone, Flask
And Front Of Filter
Acetone Wash:
                                   Container No.

                                   Extra No.
                                                           Weight Results
                                                                                _g
Filter Papers and Dry Filter Particulate

Filter No.   Container No.   Filter No.   Container No.
                                                            Filter Particulate
                                                            Weight  6-63^*    g
                                                            Total Particulate
                                                            Weight
                                                                             g
% Moisture By Volume
                                       -338-!

-------
Date -
Plant
                 OXIDES OF NITROGEN FIELD DATA
 11/12     4  t,/i7	
Ti o c Q   -   Car  Crack
Sample Collected  By
Field Data
                               II
Clock Time
Flask number
Volume of flask (ml)
Pressure before sampling in. Hg.
Pressure after sampling, in. Hg.
Flask temperature, °F
•lots
1
2011
2,S
^^v4AAHaHM^HB
an
10
///S
2
Z038

OMvftBHIItMMIIIW
2W
70
ll/o
3
2029

•••••••••v^b
2UI
90
1*3$-
y
&28

•WV««0>M»>~
tf,6l
90
13 os
5"
202 S

" 1 •*,• 1 • 1
21.61
9o
/£oo
t,
Zosz

^I^V^I^P^^I^^I^
#,6/
V«VV^HM«<«VI
M.bl
90
/syc
2
^ost,

•••••VBWVHi
2f-6/
9o
//,
* Flask + valve -  25 ml. for absorbing solution
                                        -339-

-------
                       GAS  SAMPLING  FIELD DATA
Material Sampled For




Date



Plant
                               -3o
                                   Location
&
 Bar.  Pressure ^ lf,



 Ambient  Temp



 Run No      /
                           "Hg
Comments :
          */
 Power Stat  Setting



 Filter Used:   Yes



 Operator
                            No
1 x
Clock
Time
z:*f
-2- Jo
A' ^

*' D -?
*"^ £*t f*-. °*> • *~J
*) *J *7 3 /
j*\ «*N^C ^/» ys»
^-? -iy f

5 J?-2 7. 3
/



Pitot
in. H20
&P
^-f
^-7

0.*^
/
^.f




Orifice
in H20
AH
*/
&•/
6./
. /

o-l




Temperatures Op
Stack
sff
^
fff
£
-------
Material  Sampled For

Date  /l//7/7l'

Plant
Bar. Pressure

Ambient Temp

Run No
GAS SAMPLING FIELD DATA

       /  ^
      •y     ^-	_



      _     Location

            Comments : r^CC
                                                       \ teener #!
'Hg
                                                    "'/*
                                                        ?  A/6r 6 /••<
Power Stat Setting

Filter Used:  Yes

Operator  C
                             No
Clock
Time
          Meter
          CFt.3)
Pitot
in. H20
AP
            Orifice
            in H20
            AH
                           O-S
                    Temperatures Op
                                             Stack
                       Probe
Coil
Impinger
                                                                In  Out
Comments:  /3. •  .rfi> j-
                                   -341-

-------
                                   TECHNICAL REPORT DATA
                            (Please read Instructions on the reverse before completing)
 i. REPORT NO.
   EPA-600/4-77-014
                                                          3. RECIPIENT'S ACCESSIOWNO.
 4/TITLE AND SUBTITLE
   REGIONAL AIR POLLUTION STUDY
   Point  Source Emission Inventory
                                                          5. REPORT DATE
                                                            March  1977
                                                          6. PERFORMING ORGANIZATION CODE
 7. AUTHOR(S)
    Fred E.  Littman, Robert W. Griscom,  and Otto Klein
                                                            8. PERFORMING ORGANIZATION REPORT NO.
                                                            10. PROGRAM ELEMENT NO.

                                                                  1AA603
9. PERFORMING ORGANIZATION NAME AND ADDRESS
  Rockwell International
  Air Monitoring Center
  11650  Administration Drive
  Creve  Coeur,  MO 63141	
                                                            11. CONTRACT/GRANT NO.
                                                                  68-02-1081
                                                                  Task Order 55
 12. SPONSORING AGENCY NAME AND ADDRESS
   Environmental Sciences Research  Laboratory- RTP.NC
   Office of Research and Development
   U.S.  Environmental Protection Agency
   Research Triangle Park. N.C. 27711	
                                                           13. TYPE OF REPORT AND PERIOD COVERED
                                                           	Final	•  •
                                                           14. SPONSORING AGENCY CODE
                                                             EPA/600/09
 15. SUPPLEMENTARY NOTES
 16. ABSTRACT
         Emission data from stationary point sources in the St.  Louis Interstate Air
   Quality Control Region were  gathered during 1975.  Data for  "criteria" pollutants
   were obtained on an hourly basis.   Emissions from large sources were based on
   hourly, measured values of pertinent operating parameters. Those from smaller
   sources, between 10 and 1000 tons  per year, were based on  annual data modified
   by a detailed operating pattern.   Examples of the data are presented in the
   report.  The full set of data are  available from the RAPS  Data Bank.

         An emission factor verification program was initiated by testing typical
   sources using standard EPA methods.  Results indicate good agreement for S0_
   values.  Data for NO  and particulates originating from combustion sources
   indicate that the existing factors are too high by variable  but substantial      ;
   amounts.
 7.
                                KEY WORDS AND DOCUMENT ANALYSIS
                  DESCRIPTORS
                                             b.lDENTIFIERS/OPEN ENDED TERMS
                                                                            COSATI Field/Group
   *Air pollution
   *Emission
   *Data
   Collection
                                                 St. Louis,  MO
                                                 Stationary  point
                                                       sources
13B
 8. DISTRIBUTION STATEMENT
   RELEASE TO  PUBLIC
                                               19. S
                                                                         21. NO. OF PAGES
                                                                            350
                                               20. SECURITY CLASS (Thispage)
                                                  UNCLASSIFIED
                                                                         22. PRICE
EPA Form 2220-1 (9-73)
                                       342

-------