PB 198 350
SYSTEMS ANALYSIS OF EMISSIONS AND EMISSIONS CON-
TROL IN THE IRON FOUNDRY INDUSTRY. VOLUME III.
APPENDIX
A. T. Kearney and Company
Chicago, Illinois
February 1971
NATIONAL 'ECHNICAL INFORMATION SERVICE
Distributed ... 'to foster, serve
and promote the nation's
economic development
and technological
advancement.'
• •
U.S. DEPARTMENT OF COMMERCE
This document has been approved lor public release and sale.
-------
l£&£ r&38
NATIONAL TECHNICAL
INFORMATION SERVICE
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BIBLIOGRAPHIC DATA
SNHf
1. Repon No.
APTD-0646
3. Recipient's Accession No.
I, Title and Subtitle
Systems Analysis of Emissions ard Emissions Control 1n the
Iron Foundry Industry Volume III - Appendix
*• Report Uate
February 1971
6.
'. Author(s)
6. Performing Organization Kept.
No.
Performing Organisation Name and Address
A. T. Kearney & Company, Inc.
100 South Wacker Drive
Chicago, Illinois 60606
10. Project/Taak/Vork Unit No.
11. Contract/Grant No.
CPA 22-69-106
12. Sponsoring Organization Name and Address
EPA, A1r Pollution Control Office
Technical Center, Box 12055
Research Triangle Park, N. C. 27709
13. Type of Repon 8t Period
Covered
14.
15. Supplementary Notes
the volume o--o£r a study which was conducted for the purpose of defining the
air pollution problems of the iron foundry industry and of setting priorities for
research and development activities that will lead to improved emission control
capabilities at reduced cost.',; Jfcigi-ualwae. consists of the following appendices:
Bibliography, Data bank, material and heat balance of foundry melting furnajnces,
Detail Economic Cost Curves, Emission Test Procedure, and Glossary of terms/"
Volume I contains the text, and Volume II contains exhibits.
A
17. Key words and Document Analysis. 17o. Descriptors
Foundries
Foundry Core making
Foundry sands
Airborne wastes
Air pollution control equipment
Cost analysis
17k. Identifiers/Open-Ended Terms
17* COSATI Field/Group 13/B
It. Avail ability. Statement
Unlimited
19.. Security Class (This
Report)
UNCLASSIFIEt
frSSIFIED
"lass (Thi:
20. Security Class (This
'^CLASSIFIED
21. "NbTof P
2Z
FORM MTla-SS-OO.70)
use OK* DC 40»a»-P7i,
-------
This report was furnished to the
Air Pollution Control Office by
the A. T. Kearney Company in ful-
fillment of Contract No. CPA 22-69-106.
-------
SYSTEMS ANALYSIS OF EMISSIONS
AND EMISSIONS CONTROL IN THE
IRON FOUNDRY INDUSTRY
VOLUME III - APPENDIX
FEBRUARY, 1971
For
Division of Process Control Engineering
Air Pollution Control Office
Environmental Protection Agency
Contract No. CPA 22-69-106
Prepared by
A. T. Kearney & Company, Inc.
Chicago, Illinois
-------
AIR POLLUTION CONTROL OFFICE
SYSTEMS ANALYSIS OF EMISSIONS
AND EMISSIONS CONTROL IN THE
IRON FOUNDRY INDUSTRY
VOLUME III - APPENDIX
FEBRUARY. 1971
Appendix
A
B
C
D
E
F
TABLE OF CONTENTS
Title
Bibliography
Sources of Information
Associations and Government
Technical Centers
Published Bibliographies
Indexes
List of Serials
Data Bank
Material and Heat Balance
Detail Economic Cost Curves
Emission Test Procedures
Glossary of Terms
Page
A 1
A60
A60
A61
A61
A62
B 1
C 1
D 1
E 1
F 1
-------
- 2 -
TABLE OF APPENDIX EXHIBITS
Exhibit
Appendix Number Title
B 1 Data Bank
2 Format for Data Bank
C 1 Cupola Material and Heat Balance Model
2 Material and Heat Balance Program
3 Material and Heat Balances for Various
Cupola Classifications
D 1 Total Annual Costs for Low Energy Wet Scrubber
for Lined Cupola, 4,000-Hour Year
2 Total Annual Costs for Low Energy Wet Scrubber
For Unlined Cupola, 4,000-Hour Year
3 Total Annual Costs for High Energy Wet Scrubber
for Lined Cupola, 4,000-Hour Year
4 Total Annual Costs for High Energy Wet Scrubber
for Unlined Cupola, 4,000-Hour Year
5 Total Annual Costs for Fabric Filter for Lined
Cupola, 4,000-Hour Year
6 Total Annual Costs for Fabric Filter for Unlined
Cupola, 4,000-Hour Year
7 Total Annual Costs for Low Energy Wet Scrubber
on Lined Cupola, 2,000-Hour Year
8 Total Annual Costs for Low Energy Wet Scrubber
on Unlined Cupola, 2,000-Hour Year
9, Total Annual Costs for High Energy Wet Scrubber
on Lined Cupola, 2,000-Hour Year
10 Total Annual Costs for High Energy Wet Scrubber
on Unlined Cupola, 2,000-Hour Year
11 Total Annual Costs for Fabric Filter on Lined
Cupola, 2,000-Hour Year
-------
- 3 -
Exhibit
Appendix Number Title
D 12 Total Annual Costs for Fabric Filter on Unlined
Cupola, 2,000-Hour Year
13 Total Annual Costs for Low Energy Wet Scrubber
on Lined Cupola, 1,000-Hour Year
14 Total Annual Costs for Low Energy Wet Scrubber
on Unlined Cupola, 1,000-Hour Year
15 Total Annual Costs for High Energy Wet Scrubber
on £ined Cupola, 1,000-Hour Year
16 Total Annual Costs for High Energy Wet Scrubber on
Unlined Cupola, 1,000-Hour Year
17 Total Annual Costs for Fabric Filter on Lined
Cupola, 1,000-Hour Year
18 Total Annual Costs for Fabric Filter on Unlined
Cupola, 1,000-Hour Year
19 Cost per Ton of Melt for Low Energy Wet Scrubber
on Lined Cupola, 4,000-Hour Year
20 Cost per Ton of Melt for Low Energy Wet Scrubber
on Unlined Cupola, 4,000-Hour Year
21 Cost per Ton of Melt for High Energy Wet Scrubber
on Lined Cupola, 4,000-Hour Year
22 Cost per Ton of Melt for High Energy Wet Scrubber
on Unlined Cupola, 4,000-Hour Year
23 Cost per Ton of Melt for Fabric Filter on Lined
Cupola, 4,000-Hour Year
24 Cost per Ton of Melt for Fabric Filter on
Unlined Cupola, 4,000-Hour Year
25 Cost per Ton of Melt for Low Energy Wet Scrubber
on Lined Cupola, 2,000-Hour Year
26 Cost Per Ton of Melt for Low Energy Wet Scrubber
on Unlined Cupola, 2,000-Hour Year
27 Cost per Ton of Melt for High Energy Wet Scrubber
on LJ.ned Cupola, 2,000-Hour Yeajr
A. T. KEARNEY & COMPANY. INC.
-------
- 4 -
Exhibit
Appendix Number Title
28 Cost per Ton of Melt for High Energy Wet Scrubber
on Unlined Cupola, 2,000-Hour Year
29 Cost per Ton of Melt for Fabric Filter on Lined
Cupola, 2,000-Hour Year
30 Cost per Ton of Melt for Fabric Filter on
Unlined Cupola, 2,000-Hour Year
31 Cost per Ton of Melt for Low Energy Wet Scrubber
on Cupola, 1,000-Hour Year
32 Cost per Ton of Melt for High Energy Wet Scrubber
on Cupola, 1,000-Hour Year
33 Cost per Ton of Melt for Fabric Filter on Lined
Cupola, 1,000-Hour Year
34 Cost per Ton of Melt for Fabric Filter on
Unlined Cupola, 1,000-Hour Year
35 Total Annual Costs for High Energy Wet Scrubber
on Cupola for Different Pressure Drops, 4,000-
Hour Year
36 Total Annual Costs for High Energy Wet Scrubber
on Cupola for Different Pressure Drops, 2,000-
Hour Year
37 Total Annual Costs for High Energy Wet Scrubber
on Cupola for Different Pressure Drops, 1,000-
Hour Year
38 Total Annual Costs for High Energy Wet Scrubber
on Cupola for Different Pressure Drops, 500-
Hour Year
39 Equipment Requirements-Cupola, Cold Blast, No
Holding Furnance, Fabric Filter Emission Control
40 Equipment Requirements-Cupola, Hot Blast, Water-
Cooled, Channel Induction Holding Furnance,
Wet Scrubber Emission Control
41 Equipment Requirements-Electric Arc Furnace,
Channel Induction Holding Furnace, Fabric Filter
Emission Control
-------
- 5 -
Exhibit
Appendix Number Title
42 Equipment Requirements- Cor eless Induction
Furnaces, with Preheafcer, No Holding
Furnace, Afterburner on Preheater
43 Direct Material Cost
44 Summary of Conversion Costs -Cupola, Cold Blast,
No Holding Furnace, Fabric Filter Emission Control
45 Summary of Conversion Costs-Cupola, Hot Blast,
Water-Cooled, Channel Induction Holding Furnace,
High Energy Wet Scrubber Emission Control
46 Summary of Conversion Costs -Electric Arc Furnace
With Channel Induction Holding Furnace, Fabric
Emission Control
47 Summary of Conversion Costs-Coreless Induction
Furnace with Charge Preheater, No Holding
Furnace, Afterburner on Preheater
48 Annual Operating Costs for Emission Control
Equipment Systems
1 AFS/GDIFS Recommended Practice
2 Sampling and Analytical Techniques
A.T.KEARNEY 8t COMPANY, INC.
-------
APPENDIX A
BIBLIOGRAPHY
Prepared By
A. T. Kearney & Company, Inc
Kathryn Sheehan
Corporate Librarian
A.T.KEARNEY & COMPANY. IN c.
-------
APPENDIX A
BIBLIOGRAPHY
1920
Standard Method for Gap Sampling, Dust and Solid Fume
Determination. Technical Bulletin No.3-A, Research Corp.,
Trenton, New Jersey (.Rev. March 1, JLV2U).
1931
Roller, P. S., "Separation and Size Distribution of Micro-
scopic Particles", Technical Paper 490. U.S. Bureau of Mines,
1931.
1932
"Catches Dirt at Top of Cupola", Foundry. 60. 64 (November 1932).
1938
"Catch Cupola Smoke", Foundry. 66. 32, 86 (August 1938).
1939
"Spark Collector", Foundry. 67,, 92, 94 (August 1939).
1941
A.S.M.E. Power Test Code No. 21 for Dust-Separating Apparatus.
American Society of Mechanical Engineers, New York, N. Y., 1941.
Symposium on New Methods for Particle Size Determination in the
Subseive Range. A.S.T.M.; March 4, 1941.
1943
Moffat, 0. G., "Electrostatic Air Cleaners", Canadian
Refrigeration Journal. 14 (5), 17 (1943).
1944
Kane, J. M., "The Application of Local Exhaust Ventilation to
Electric Melting Furnaces", Paper presented at a Safety and
Hygiene Session of the 48th Annual Meeting, American Foundrymen's
Society, Buffalo, New York, April 27, 1944; AFS Transactions.
52., 1351-1356 (1944).
A.T.KEARNEY & COMPANY, INC.
-------
APPENDIX A
Page 2
Bibliography. . . (continued)
Dunbeck, N. J., "Gas Developed in Molds", Foundry. 72. 85+
(September 1944) .
1945
Allen, A. H., "Collectors on Cupolas Clean Waste-Gases",
Foundry. H, 88-90, 199-200 (November 1945).
1946
"Cupola Ash Collector", Foundry. 74. 240 (December 1946).
1947
List, J. H., "Spark Arresters, Interesting New Design for
Two-Cupola Operation", Iron and Steel. 20. 314 (June 1947).
1948
Smog Committee Report: Technical Subcommittee, Gray Iron
Founders' Smog Committee, Industrial Air Control Associates,
December 16, 1948.
Postman, B., "Adequate Dust Control for Foundries", Heating
and Ventilating. 12. 65-70 (December 1948) .
1949
"Characteristics of Emissions from Gray Iron Foundry Cupolas",
Technical Sub -Commit tee, Gray Iron Foundry Smog Committee,
Los Angeles, California, 1949.
Collier, R. I., "Cupola Dust Suppression; a survey report",
Gray Iron Founders' Society, Cleveland, Ohio, 1949.
Grindle, A. J., "Prevention of Smoke Fumes and Solids from
Cupola Operations", Smoke Prevention Association of America
Proceedings. 42. 39-43 (1949) .
Gustavsson, K. A., "Centrifugal Dust Classifier for Analysis
of Grain Size", A. B. Enkopings Verstader, Bahco, August, 1949,
"Handbook of Cupola Operation", American Foundrymen's Society,
Des Plaines, Illinois, 1949.
Witheridge, W. N., "Foundry Cupola Dust Collection; a Biblio-
graphy", Prepared for presentation at the Regional Conference
of the American Foundrymen's Society, East Lansing, Michigan,
October 28, 1949.
A. T. KEARNEY & COMPANY. INC.
-------
APPENDIX A
Page 3
Bibliography... (continued)
AFS Cupola Res. Committee, "This Problem of Air Pollution",
American Foundryman. 16. 22-24 (December 1949).
Church, P. E., "Dilution of Waste Stack Gases in the ATM",
Industrial and Engineering Chemistry. 41. 2753-2756 (December
1949).
Drake, J. F., et al., "Control of Cupola Stack Emissions",
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McCabe, L. C., et al., "Dust and Fume Standards", Industrial
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Witheridge, W. N., "Foundry Cupola Dust Collection", Heating
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1950
Dalla Villa, J., "Principles of Design, Application and
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May, 1950.
Locke, C., and Ashbrook, R. L., "Nature of Mold Cavity Gases",
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Foundryman. 18, 52 (August 1950).
A.T.KEARNEY & COMPANY. INC.
-------
APPENDIX A
Page 4
Bibliography... (continaed)
Harsell, T. L., Jr., "Los Angeles Foundrymen Test Air Pollution
Control Equipment", Western Metals. 8_, 25-27 (March 1950).
Howells, W. H., "Installs New Cupola Dust-Collector", Foundry.'
78, 242, 244 (May 1950).
I'Anson, J. E., et al., "Gray Iron Foundries Take the Stand",
Western Metals. 8_, 23 (March 1950).
Kane, J. M., and Sloan, R. V., "Fume Control-Electric Melting
Furnaces", American Foundryman. 18. 33-35 (November 1950).
Kane, J. M., "Removing Fine Particles from High Temperature
Industrial Stack Emissions", Industrial Heating. 17, 1160+
(July 1950).
Kennard, T. G., and Drake, J. F., "Closed Top System in Cupola
Stack Emission Control", American Foundryman, 17, 55 (February
1950). ~~
Molcohy, B. D., "The Cupola - Its Raw Materials and Operation",
Foundry. 7JJ, 75-76 (March 1950).
Morton, H. R., "Dust and Fume Removal", Industrial Heating
Engineer. 17., 101-102 (March 1950).
Witheridge, W. N., "Cupola Dust Collection", Foundry. 78, 84-85,
198-202, 204-205, 208 (February 1950); 18, 88-91, 220-279
(March 1950).
1951
Cupola Research Committee Reports, American Foundrymen1s Society,
Des Plaines, Illinois, 1951.
Roberts, L. M., and Beaver, C. E., "Application of Electrical
Precipitation Equipment for the Reduction of Atmospheric
Pollution", Proceedings, APCA, 1951, pp.50-59.
Anonymous, "West Coast Installation Passes Test1, American
Foundryman. 19. 59 (February 1951).
Chvetien-Horand, W., "Composition and Utilization of Waste
Gases of a Small Cupola", Giesserei. 38. 275-276 (June 14, 1951).
Ekman, F. 0., and Johnstone, M. F., "Collection of Aerosols in
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Grindle, A. J., "Dust, Fume and Smoke Suppression", Iron and
Steel Engineer. 28. 87-94; Discussion, 94-96 (July 1951).
A. T. KEARNEY & COMPANY. INC.
-------
APPENDIX A
Page 5
Bibliography... (continued)
Harsell, T. L., Jr., "Foundry Joins in Developing Cupola
Emission Control Unit", American Foundryman. 20. 42-44
(August 1951).
Holt, P. F., "The Study of Dusts in Industrial Atmospheres",
Metallurgia. 43., 151-152 (March 1951).
Kane, J. M., "What to Do About Air Pollution? Foundry Dust
Control Problems", American Foundryman. 19, 34-38 (February
1951). ~~
"Methods and Equipment for Control of Atmospheric Pollution",
Industrial Heating. 18. 1000 (June 1951).
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Precipitators - Effects of Moisture and Temperature",
Industrial and Engineering Chemistry. 43. 1350-1358 (June 1951).
Tubich, G. E., "Air Pollution Testing Procedures and Equipment",
American Foundryman. 19. 53-56 (March 1951).
1952
Allan, J. R., "AFS Safety, Hygiene, and Air Pollution Program",
AFS Transactions. 6£, 279 (1952).
Allen, G. L., et al., "Control of Metallurgical and Mineral
Dusts and Fumes in Los Angeles County, California", Information
Circular 7627. U.S. Bureau of Mines, 1952.
Cottrell Electrical Precipitators, Western Precipitation Corp.,
Los Angeles, California, 1952.
Holton, W. C., and Schulz, E. J., "Some Notes on Dust-Sampling
Equipment and Technique", Presented at A.S.M.E. Annual Meeting,
New York, N. Y., December 1, 1952 (Battelle Memorial Institute).
Keyser, N. H., and Mvmger, H. P., "The Foundryman Looks at Air
Pollution", AFS Transactions. 60, 364 (1952).
Lishow, J. G., "Elimination of Dust and Fumes from Electric
Furnaces", Electric Furnace Steel Conference Div., AIME.,
Pittsburgh, Pennsylvania, December, 1952.
Pring, R. T., "Bag-Type Cloth Dust and Fume Collectors",
McGraw-Hill Book Co., Inc., New York, N. Y., 1952.
Magill, Paul L., "Sampling Procedures and Measuring Equipment",
Chapter 6 in: "Air Pollution Abatement Manual", Manufacturing
Chemists' Association, Washington, D. C., 1952, 39pp.
A.T.KEARNEY & C OM T> \N Y, I v c.
-------
Page 6
Bibliography. . . (continued)
Radcliffe, J. C., and Delhey, W. F., "Air Pollution and the
Cupola", AFS Transactions. 60, 714 (1952).
Smith, K. M. , "How to Maintain Foundry Ventilation and Dust
Collecting Systems", AFS Transactions. 60. 485 (1952).
Tubich, G. E. , "Problems of Core Making and Molding",
(Chapter) Health Protection in Foundry Practice, American
Foundrymen's Society, Des Plaines, Illinois, 1952.
Weber, H. J., "Ventilation at Non-Ferrous Melting and Pouring
Operations", AFS Transactions. 60. 563 (1952).
Buchanan, W. Y., "Some Experiences With Cupola Spark and Dust
Arresters", British Cast Iron Research Association Journal of
Research and""Development. 4. 272-282 (February 1952).
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(July 1952) (French).
Dennis R.t et al., "How Dust Collectors Perform", Chemical
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(August 1952).
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in Combustion Processes in Cupolas and Their Results",
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Gases from Gray Iron Foundries" , Industrial and Engineering
Chemistry. 44, 103A-106A (June 1952); 45. 109A-110A. T.12A
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A.T.KEARNEY & COMPANY. INC.
-------
APPENDIX A
Page 7
Bibliography... (continued)
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1952) (French).
Upmalis, A., "Cupola Dust on Heating Surfaces of Heat
Exchanger", Brennstoff-Warme-Kraft. 4, 159-161 (May 1952)
(German).
1953
Caplan, K. J., "Trends in Dust Control—Past, Present and
Future", AFS Transactions. 61. 394 (1953).
Erickson, E. 0., "Dust Control of Electric Foundries in
Los Angeles Area", AIMS Electric Furnace Steel Proceedings.
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Operations in the Foundry Industry", AFS Transactions. 61, 467
(1953). ~~
Schmidt, C. D., "Application of Bag Filters to Metallurgical
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A.T.KEARNEY & COMPANY, IKC.
-------
Page 8
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Melting-Cleaner Air'1, American Foundryman. 23, 41-43 (February
1953).
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1954
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A.T.KEARNEY Sc COMPANY. INC.
-------
APPENDIX A
Page 9
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Electric Furnaces", Iron Age. 173. 107-110 (January 14, 1954).
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A.T.KEARNEY & COMPANY, INC.
-------
APPENDIX A
Page 10
Bibliography... (continued)
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A.T.KEARNEY & COMPANY. INC.
-------
APPENDIX A
Page 11
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A. T. KEARNEY & COMPANY, INC.
-------
APPENDIX A
Page 12
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A.T.KEARNEY & COMPANY, INC.
-------
APPENDIX A
Page 13
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A.T.KEARNEY & COMPANY. INC.
-------
APPENDIX A
Page 14
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A.T.KEARNEY & COMPANY, INC.
-------
APPENDIX A
Page 15
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1958
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A. T. KEARNEY & COMPANY. INC.
-------
Page 16
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A.T.KEARNEY & COMPANY, INC.
-------
APPENDIX A
Page 17
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1960
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A.T.KEARNEV & COMPANY, INC.
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Page 18
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A.T.KEARNEY & COMPANY. INC.
-------
APPENDIX A
Page 19
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A. T. KEARNEY & COMPANY. INC.
-------
APPENDIX A
Page 20
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A.T.KEARNEY & COMPANY, INC,
-------
APPENDIX A
Page 21
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Page 22
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A.T.KEARNEV & COMPANY, INC.
-------
APPENDIX A
Page 23
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Page 24
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A.T.KEARNEY & COMPANY, INC.
-------
APPENDIX A
Page 25
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Page 26
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A.T.KEARNEY & COMPANY, INC.
-------
APPENDIX A
Page 27
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A.T.KEARNEY & COMPANY. INC.
-------
APPENDIX A
Page 28
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A.T.KEARNEY 5c COMPANY, INC.
-------
APPENDIX A
Page 29
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A.T.KEARNEY & COMPANY. INC.
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APPENDIX A
Page 30
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A. T. KEARNEY" & COMPANY, INC.
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APPENDIX A
Page 31
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A.T.KEARNEV & COMPANY. INC.
-------
APPENDIX A
Page 32
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APPENDIX A
Page 33
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APPENDIX A
Page 34
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APPENDIX A
Page 35
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APPENDIX A
Page 36
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Afi'ttWUlA A
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Page 38
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-------
APPENDIX A
Page 40
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-------
APPENDIX A
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-------
APPENDIX A
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APPENDIX A
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APPENDIX A
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APPENDIX A
Page 45
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APPENDIX A
Page 46
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APPENDIX A
Page 47
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APPENDIX A
Page 48
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-------
APPENDIX A
Page 49
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APPENDIX A
Page 50
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"Eight Case Histories on Pollution Control", Metal Progress.
95, 90-97 (May 1969).
"Electric Furnace Conference, 26th, Cleveland, December 4-5;
Casting Session; Abstracts of Papers", Foundry. 97, 152+
"Emission Controls Surveyed", Gray and Ductile Iron News, no.7,
10-11 (July-August 1969).
Engels, G., "The Nature and Characteristics of Cupola Emissions",
Gray and Ductile Iron News, no.2, 88 (February 1969).
Geschelin, J., "Chevy's Foundry: Pattern for the Future",
Automotive Industries. 140. 77-81 (January 15, 1969).
Greenberg, S., "New Gas Burners Cut Air Pollution", Modern
Casting. 56. 59 (September 1969).
"HEW Authorizes Study of Iron Foundry Air Pollution", Foundry.
£7, 137 (September 1969).
Haecker, C. F., "Iron Melting and Pollution Control: an
Opportunity to Progress", Foundry. 97. 56-59 (August 1969).
A.T.KEARNEY Sc COMPANY. INC.
-------
APPENDIX A
Page 51
Bibliography... (continued)
Handley, J., and Stutterheim, N., "Air Pollution and the
Foundry Industry", Founding Welding. Production Engineering
Journal. £. 13-42 (January 1969).
Hanson, D. N., and Wilke, C. R., "Electrostatic Precipitator
Analysis", Industrial and Engineering Chemistry; Process
Design and Development. 8. 337-364 (July 1969).
Hawkins, G., "Scrubber Licks Tough Fume Problem", Plant
Engineering. 23. 70 (June 26, 1969).
Herrmann, R. H., "Computer Monitors Automatic Foundry",
Foundry. 97. 52-60 (January 1969).
"Isolating Electrostatic Precipitators for On-Load Maintenance",
Engineer. 227. 195 (February 7, 1969).
Jones, D. W., "Dust Collection at Moss No.3", Mining Congress
Journal. 5J5, 53-56 (July 1969).
Kalika, P. W.f "How Water Recirculation and Steam Plumes
Influence Scrubber Design", Chemical Engineering. 76, 133-138
(July 28, 1969).
Killman, T., "Dust and Fume Control for Electric Furnace",
Modern Casting. 55, 53 (May 1969).
Land, G. W., "Sulfur Dioxide Removal from Industrial Stacks;
Where We Stand; Abstract", Combustion. 40. 17 (June 1969).
Lund, H. F., "Industrial Air Pollution Control Equipment Survey;
Operating Costs and Procedures", Journal of the Air Pollution
Control Association. !£, 315-321 (May 1969).
Mcllvaine, R. W., "New Accuracy Should Eliminate Guesswork About
AP Control Equipment", Modern Casting. 56. 51-52 (October 1969).
McManus, G. J., "Technology and Pollution Vex Maintenance
Engineers", Iron Age. 203. 60 (May 22, 1969).
Miguel, T., "What Foundrymen Should Know About Air Pollution
Codes", Foundry. 97., 38-41 (March 1969).
A.T.KEARNEY Sc COMPANY. INC.
-------
APPENDIX A
Page 52
Bibliography... (continued)
"New Dust Collector Provides High Yield", Foundry Trade Journal.
126. 259 (February 13, 1969).
"Operating Experience With the First Full Scale System for
Removal of SO? and Dust from Stack Gases: Abstract", Combustion.
40, 21-23 (June 1969).
Penney, G. W., "Some Problems in the Application of the Deutsch
Equation to Industrial Electrostatic Precipitation", Journal of
the Air Pollution Control Association. 19. 596-600 (August 1969),
"Pollution: Causes, Costs, Control; Special Report", Chemical
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"Pollution Control", Science and Technology, no.90, June, 1969,
64pp. (entire issue).
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84 (September 4, 1969).
"Pollution Control: GM1 s Central Foundry Div. Sets Precedent
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"Precipitator Design Helps Maintain High Collection Efficiency",
Power. 113. 116 (August 1969).
"Product Guide/1970; Manufacturers of Emission Control Equipment
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Abstract", Combustion. 40. 19-20 (June 1969).
Rohr, F. W., "Suppressing Scrubber Steam Plume", Pollution
Engineering. I, 20-22 (October-November 1969).
Rose, H. E., and Duckworth, R. A., "Transport of Solid Particles
in Liquids and Gases", Engineer. 227, 392-396, 430-433, 478-483
(March 14-28, 1969).
Rossi, G., and Perin, A., "Brown Fume Powders", Iron and Steel
Institute Journal. 207. 1365-1368 (October 1969).
A. T. KEARNEY & COMPANY, INC.
-------
APPENDIX A
Page 53
Bibliography... (continued)
Row, G. R., "Baghouse Filter Controls Fine Dust Particles",
Plant Engineering. £3, 70 (July 10, 1969).
Sargent, G. D., "Dust Collection Equipment", Chemical Engineering.
76,, 130-150 (January 27, 1969).
"Scrubber's Throat-Twists Whisk Away Dusts", Chemical Engineering.
26, 66 (February 24, 1969).
Searle, V. C., "Technical Information Resources in the Air
Pollution Field", Journal of the Air Pollution Control Association.
12, 137-141 (March 1969).
"Selecting Pollution Control Methods & Equipment", Plant Engineer-
ing. £3, 70-78 (September 4, 1969).
Semrou, W. R., "Medium-Energy Scrubber Controls Cupola Emissions",
Foundry. 97. 161-162+ (November 1969).
Skinner, C. F., "New Use for Baghouse Filter; Handling Hot
Effluent", Plant Engineering. 2.3, 57-59 (June 26, 1969).
"Special Booth Reduces Metallic Dust Hazard", Safety Maintenance.
137. 43-44 (January 1969).
"Special Precipitator System Helps Maintain High Collection
Efficiency", Electrical World. 172. 37+ (August 18, 1969).
Swift, P., "Automatic Dust Filter With Integral Fan", Chemical
and Process Engineering. 50. 69+ (December 1969).
"System Filters Three Million CFM of Makeup Air", Foundry. 97.
194 (April 1969).
Taheri, M., and Haines, G. F., "Optimization of Factors Affecting
Scrubber Performance", Journal of the Air Pollution Control
Association. _19. 427-431 (June 1969) .
"Three Ways to Cleaner Air", Chemical Engineering. 76. 84
(September 8, 1969).
"A Total Approach", Metal Progress. £5, 98-99 (May 1969).
A.T.KEARNEY Sc COMPANY. INC.
-------
APPENDIX A
Page 54
Bibliography... (continued)
"Two-Phase Filter Keeps Vapors and Contaminants Out and Has
Long Life", Product Engineering. 40. 157 (January 27, 1969).
Turk, A., "Industrial Odor Control and Its Problems", Chemical
Engineering. 76. 70-78 (November 3, 1969).
Venendaal, R., and Davis, J. A., "Equipping for Natural-Gas
Cupola Injection", Foundry. 97_, 128-132 (July 1969).
Wertzler, J. E.t "Thermal Destruction of Fumes", Abstract,
Combustion. 41. 29 (December 1969).
Wiedemann, C. R., "A Discussion of Some Cupola Dust Collection
Systems", Modern Casting. 56. 71-73 (September 1969); 56. 66-68
(October 1969).
Wohlers, H. C., et al., "Rapid Emission Survey Procedure for
Industrial Air Pollutants", Journal of the Air Pollution Control
Association. 1.9, 309-314 (May 1969).
Zentgraf, K. M., "Present State of Flue Gas Desulphurization",
Combustion. 41, 6-11 (November 1969).
1970
Chi, M. M. S., and Ekman, F. , "The Nature of Measurement of
Cupola Effluent", AFS Transactions. 78., 450-452 (1970).
Cowen, P. S., "Cupola Collection Systems", Proceedings,
Session III, American Foundrymen's Society Total Environmental
Control Conference, Chrysler Center for Continuing Education,
University of Michigan, Ann Arbor, Michigan, November 16-19,
1970.
Culhane, F., "Dry Collectors for Effluent Control", Proceedings,
Session III, American Foundrymen's Society Total Environmental
Control Conference, Chrysler Center for Continuing Education,
University of Michigan, Ann Arbor, Michigan, November 16-19, 1970,
Fogel, M. E., et al., "Comprehensive Economic Cost Study of Air
Pollution Control Costs for Selected Industries and Selected
Regions", Research Triangle Institute, Durham, North Carolina,
February, 1970, 382pp., available from the National Technical
Information Service, Springfield, Virginia (PB-191 954).
A. T. KEARNEY & COMPANY. INC.
-------
APPENDIX A
Page 55
Bibliography... (continued)
Giever, P. M., "Characteristics of Foundry Effluents",
Proceedings, Session III, American Foundrymen's Society Total
Environmental Control Conference, Chrysler Center for Continuing
Education, University of Michigan, Ann Arbor, Michigan,
November 16-19, 1970.
Jacoby, M. R., "Charging a Production Cupola With a Vibrating
Feeder Reduces Cost of Air Pollution Control Equipment", AFS
Transactions. 78, 461-463 (1970).
Kane, J. M., "Wet Particulate Collectors for Effluent Control",
Proceedings, Session III, American Foundrymen1s Society Total
Environmental Control Conference, Chrysler Center for Continuing
Education, University of Michigan, Ann Arbor, Michigan,
November 16-19, 1970.
"Penton's Foundry List 1970-1971", Penton Publishing Co.,
Cleveland, Ohio, 1970.
Shaver, R. G., "Study of Cost of Sulphur Oxide and Particulate
Control Using Refined Coal", General Technologies Corporation,
Reston, Virginia, April, 1970, available from the National
Technical Information Service, Springfield, Virginia (PB 193 420)
Stern, A. C., "Principles of Separation and Collection",
Proceedings, Session III, American Foundrymen's Society Total
Environmental Control Conference, Chrysler Center for Continuing
Education, University of Michigan, Ann Arbor, Michigan,
November 16-19, 1970.
Uzhov, V. N., "Dust Collecting", Foreign Technology Div., Wright-
Patterson AFB Ohio, March 11, 1970, 21pp. Edited machine trans-
lation of Vsesoyuznoe Khimicheskoe Obshchestva, Zhurnal (USSR).
14, 432-437 (1969), by Ray E. Zarza, available from the National
Technical Information Service, Springfield, Virginia (AD-7Q6 206),
Wiedemann, C. R., "A Case History of Collection Equipment",
Proceedings, Session IV, American Foundrymen1s Society Total
Environmental Control Conference, Chrysler Center for Continuing
Education, University of Michigan, Ann Arbor, Michigan, November
16-19, 1970.
A.T.KEARNEY 8- COMPANY. INC.
-------
APPENDIX A
Page 56
Bibliography... (continued)
"Air Pollution Control...the Metalcaster and His Community",
Modern Casting. 57., 62-63 (June 1970).
Amala, R. S., and Walker, J. B., "Continuous Induction Iron
Melting - a Process Report on the Operation of an Experimental
Unit", Modern Casting. 57., 113-124 (May 1970).
"Average Increase of At-Spout Costs Per Ton of Metal Resulting
from Air Pollution Control", Modern Casting. 57, 139 (March
1970).
Bennett, K. W., "Pollution Control: Murkier and Murkier",
Iron Age. 206. 49-54 (July 9, 1970).
Butler, T. J., and Kutny, I. J., "A New Approach for Cupola
Emission Control", Modern Casting, 57. 55-57 (June 1970).
Celenza, G. J., "Controlling Air Pollution from Foundries",
Pollution Engineering. 2, 28-29 (March-April 1970).
"Cupola Pollution Control at Unicast", Foundry. 98, 240-242
(April 1970).
"Dust-and Soundproof Stone-Crushing Plant Protects Workers and
Environment", Pit and Quarry. 62. 134 (February 1970).
"Equipment on Parade; Dust Collection and Treatment", Rock
Products. 73. 67-68 (January 1970).
Gassmann, R., "Rationalization of Cupola Charging Installations
Through the Use of Vibrating Trough Conveyors", Giesserei. 57,
57-59 (January 29, 1970), Translation by Henry Brutcher (#8T72).
"High-Throughput Dust Collection Process", Chemical and Process
Engineering. 51. 99 (February 1970).
"How to Be a Good Neighbor", Foundry. 98. 115-116 (February 1970)
Huelsen, W. B., "Air Pollution Legislation: Fact and Fancy",
Modern Casting. 57, 63-64+ (May 1970).
Huelsen, W. B., and Weber, H. J., "Factors Affecting Control of
Metallurgical Fume Emission from Electric Furnace Operations",
Modern Casting. 57, 71 (April 1970).
A.T.KEARNEV & COMPANY, IKC.
-------
APPENDIX A
Page 57
Bibliography... (continued)
"In Defense of the Cupola", Modern Casting. 57, 47-48 (April
1970). ~~
Likens, W. H., "Don't Lose Perspective in Selecting Pollution
Control Equipment", Modern Casting. 57. 39-40 (June 1970).
Miske, J. C.t "Environment Control at Dayton Foundry", Foundry.
98, 68-71 (May 1970).
"National Castings Division's New Pollution Control System",
Modern Casting. 57., 101 (June 1970).
Peterson, W. A., "Removing Particulate Matter from Small Foundry
Cupolas", Foundry. 98, 171-172 (June 1970).
"Pumpless Scrubber Cleans Dusty Air With Sump Water", Chemical
Engineering. 77. 66 (February 23, 1970).
Schweisheimer, W., "How You Can Prevent Metal Fume Fever",
Foundry. 98, 162 (March 1970).
"Second Generation Emission Controls", Gray and Ductile Iron
News, no.l, 12-14 (January 1970).
Skinner, C. F., "Odor Determination Evaluation and Control",
Plant Engineering. 24. 66-68 (January 22, 1970).
Weber, H. J., "Impact of Air Pollution Laws on the Small Foundry"
Journal of the Air Pollution Control Association. 20. 67-71
(February 1970).
Wiedemann, C. R., "A Discussion of Some Cupola Dust Collection
Systems—Part 3", Modern Casting. 57. 73-74 (January 1970).
Woodcock, K. R., and Barrett, L. B., "Economic Indicators of the
Impact of Air Pollution Control - Gray Iron Foundries: a Case
Study", Journal of the Air Pollution Control Association, 20.
72-77 (February 1970) .
A.T.KEARNEY 8r COMPANY, INC.
-------
APPENDIX A
Page 58
Bibliography... (cor.tinued)
No Date
"Air Pollution Control - Cupola Melting (Present and Future)",
Industrial Science Corporation, Development & Engineering
Division, Huntington, West Virginia [n.d.J
"Air Pollution Control - Electric Melting (Present and Future)",
Industrial Science Corporation, Development & Engineering
Division, Huntington, West Virginia [n.d.]
"Clean Air and the Foundry Industry", American Coke and Coal
Chemicals Institute, Washington, D. C. 13pp. [n.d.]
"Elements of Air Quality Management", U.S. Department of Health,
Education and Welfare, Public Health Service - Robert A. Taft
Sanitary Engineering Center, Cincinnati, Ohio [n.d.]
"Foundry Dust Control", Bulletin No. 510, Malleable Founders'
Society, Cleveland, Ohio [n.d.]
Haines, G. F., Jr., and Hemeon, W. C. L., "Report on Solids
Discharge from Cupola Equipped With Dust Collector", Industrial
Hygiene Foundation of America, Pittsburgh, Pennsylvania [n.d.]
"Methods of Determination of Velocity, Volume, Dust and Mist
Content of Gases", Bulletin WP-50, Western Precipitation Corp.,
Los Angeles, California [n.d.]
"The New Way of Life - the Foundryman and Clean Air", American
Coke and Coal Chemicals Institute, Washington, D. C. [n.d.]
Tailor, J. P., "The Study of the CVX Wet Gas Scrubber in Its
Applications on Power Stations, Foundries, and Iron Ore Mills",
Tailor & Company, Inc., Bettendorf, Iowa [n.d.]
Tomany, J., "A Guide to the Selection of Air Pollution Control
Equipment", (Unpublished manuscript) [n.d.]
Study of the Foundry Industry by the Department of Commerce and
the Department of Health, Education and Welfare, Washington, D. C.,
(Unpublished) [n.d.]
A.T.KEARNEY 8s. C OM PAN Y, I N c.
-------
APPENDIX A
Page 59
Bibliography... (continued)
"Basic Continuous-Operation Hot-Blast Cupola Furnaces As
Premelting Units in Steelworks", Demag News. 170-17004 [n.d.J
"California Foundry Solves Smog Problems, Gets Higher Quality
Castings", Ajax Magnethermic News Digest [n.d.J
Massari, S. C., "Combustion Control in Cupola Operation",
The Hays Corporation, Michigan City, Indiana (Publication
No. 39-386) [Reprinted from Foundry. n.d.J
Butler, T. J., and Kutny, I. J. Butler Kutny Air Pollution
Control System. U.S. Patent No. 3.209.484 [n.d.J
Schmieg, J. D., and Schmieg Industries, Inc. Cupola Dust
Arrester. U.S. Patent No. 2.630.880 [n.d.J
A.T.KEARNEY & COMPANY, INC.
-------
Page 60
NAP(.A-DPCE LITERATURE SEARCH
Sources of Information
ASSOCIATIONS AND GOVERNMENT TECHNICAL CENTERS
Air Pollution Control Association
Air Pollution Technical Information Center
American Association for the Advancement of Science
American Conference of Governmental Industrial Hygienists
American Foundrymen's Society
American Coke and Coal Chemicals Institute
American Industrial Hygiene Association
American Institute of Mining, Metallurgical, and Petroleum
Engineers
American Iron and Steel Institute
American Petroleum Institute
American Society of Mechanical Engineers
American Society for Testing and Materials
American Society of Civil Engineers
Battelle Memorial Institute
Bay Area Air Pollution Control District, San Francisco
British Cast Iron Research Association
Center for Air Environmental Studies - Pennsylvania State Univ.
Graphic Arts Technical Foundation - Pittsburgh
Gray and Ductile Iron Founders' Society
Industrial Gas Cleaning Institute
Iron and Steel Institute
Los Angeles County Air Pollution Control District
Malleable Founders' Society
Manufacturing Chemists' Association
National Air Pollution Control Association
National Pollution Control Foundation
National Technical Information Service (formerly: Clearinghouse
for Federal Scientific and Technical Information)
Research-Cottrell, Inc.
U.S. Bureau of Mines
A.T.KEARNEY & COMPANY. INC.
-------
APPENDIX A
Page 61
NAPCA-DPCE LITERATURE SEARCH
Sources of Information
PUBLISHED BIBLIOGRAPHIES
Air Pollution Publications, 1955-1963
1963-1966
1966-1968
(U.S. Department of Health, Education and Welfare,
Public Health Service)
Bibliography from American Foundrymen1s Society -
Current Awareness Service
Bibliography from Air Pollution Technical Information Center
INDEXES
Applied Science and Technology Index
ASM Review of Metals Literature
Engineering Index
Environmental Health Series
Index to Air Pollution Research... Center for Air
Environmental Studies, Pennsylvania State University
Pollution Control Manual and Directory
U.S. Government Research & Development Reports Index
A.T.KEARNEY 8c COMPANY, INC.
-------
Page 62
NAPCA-DPCE LITERATURE SEARCH
Sources of Information
LIST OF SERIALS
AFS Transactions
A.M.A. Archives of Industrial Health
APCA Abstracts
ASHRAE Journal
Actual Specifying Engineer
Air Conditioning, Heating and Ventilating
Air Engineering
Air Pollution Control Association.
Journal
Air Pollution Control Association.
Proceedings
Air Repair
American Foundryman
American Industrial Hygiene Association.
Journal
American Institute of Mining, Metallurgical and Petroleum
Engineers. Proceedings
American Journal of Public Health
American Petroleum Institute.
Proceedings
American Society of Civil Engineers.
Proceedings
Archiv fur das Eisenhlittenwesen
Australian Chemical Processing
Automotive Industries
Bergbautechnik (German)
Blast Furnace and Steel Plant
Brennstoff-warme-Kraft BWK (German)
British Cast Iron Research Association.
Journal of Research and Development
A.T.KEARNHY & COMPANY. INC.
-------
APPENDIX A
Page 63
NAPCA-DPCE LITERATURE SEARCH
Sources of Information
LIST OF SERIALS (continued)
British Foundryman
Building Research
Canadian Mining and Metallurgical Bulletin
Canadian Refrigeration Journal
Chemical and Engineering News
Chemical and Process Engineering
Chemical Engineering
Chemical Engineering Progress
Chemical Processing
Chemistry and Industry
Clean Air (Tokyo)
Combustion
Electrical World
Engineer
Engineering
Factory
Factory Management
Fonderia (Italian)
Fonderia Italiana
Fonderie (French)
Fonderie Beige (French)
Founding, Welding, Production Engineering Journal
Foundry
Foundry Facts for Iron Foundrymen
Foundry Trade Journal
Fuel Engineering
Giesserei. Technisch-Wissenschaftliche Beihefte:
Metallkunde und Giessereiwesen (German)
A.T.KEARNEY 8e COMPANY, INC.
-------
APPENDIX A
Page 64
NAPCA-DPCE LITERATURE SEARCH
Sources of Information
LIST OF SERIALS (continued)
Giessereipraxis (German)
Giessereitechnik (German)
Gieterijcentrumberichten (Swedish)
Gigiyena i Sanitariya (Russian)
Gjuteriet (Swedish)
Gray and Ductile Iron News
Heating and Ventilating
Heating, Piping and Air Conditioning
IEEE Transactions on Industry and General Applications
Imono/Japan Foundrymen's Society
Journal
Industrial and Engineering Chemistry
Indus trial Chemi s t
Industrial Heating
Industrial Heating Engineer
Industrial Wastes
Iron Age
Iron and Steel (Eng)
Iron and Steel Engineer
Iron and Steel Institute (London)
Journal
Journal d1Informations Techniques des Industries de la
Fonderie (French)
Journal of Metals
Journal of The Institute of Fuel
Kohaszati Lapok (Hungarian)
Liteinoe Proizvodstvo (Russian)
A. T. KEARNEV & COMPANY, INC.
-------
APPENDIX A
Page 65
NAPCA-DPCE LITERATURE SEARCH
Sources of Information
LIST OF SERIALS (continued)
Machine Design
Machinery
Manufacturing Chemist
Maschinenmarkt (German)
Mechanical Engineering
Mechanical World and Engineering Record
Metal Finishing
Metal Industry (London)
Metal Progress
Metallurgia
Metals (London)
Metalworking News
Mill and Factory
Mining Congress Journal
Mitteilungen der Vereinigung der Grosskesselbesitzer (German)
Modern Casting
Modern Materials Handling
Modern Plant Operation and Maintenance
NAPCA Abstract Bulletin
Neue Huette (German)
Pit and Quarry
Plant Engineering
Pollution Atmospherique (French)
Pollution Engineering
Pollution Equipment News
Power
Power Engineering
Przeglad Odlewnictwa (Polish)
Product Engineering
A.T.KEARNEY Sc COMPANY. INC.
-------
APPENDIX A
Page 66
NAPCA-DPCE LITERATURE SEARCH
Sources of Information
LIST OF SERIALS (continued)
Production Engineer
Radex Rundschau (German)
Roads and Streets
Rock Products
Russian Castings Production (English Translation of
Liteinoe Froizvodstvo)
Safety Maintenance
Sangyo Kogai (Japanese)
Science and Technology
Smoke Prevention Association of America
Proceedings
Smokeless Air
Soviet Powder Metallurgy and Metal Ceramics
Stahl und Eisen (German)
Staub (German)
Steam Engineer (London)
Steel
TAPPI
Tetsu-to-Hagane/Iron and Steel Institute of Japan
Journal
33/The Magazine of Metals Producing
U.S.S.R. Literature on Air Pollution and Related
Occupational Diseases
Wasser Luft und Betrieb (German)
Welding Engineer
Western Metals
Zeitschrift des Nereins Deutscher Ingenieure (German)
Zentralblatt fur Arbeitsmedizin und Arbeitsschlitz (Darmstadt)
(German)
A.T.KEARNHY & COMPANY, INC.
-------
APPENDIX B
DATA BANK
All the data compiled on the foundries are contained
in the data bank which is a part of this appendix. The
actual listing of the data is given in Exhibit 1 of this
appendix.
Exhibit I is divided into six sections with each section
dealing with a different aspect of the foundry data. Each
section begins with the foundry identification number and this
number, therefore, provides the key between sections when
obtaining additional data listed for that foundry number.
If a foundry number is omitted in a section it can be
assumed that the data was not available or did not apply as
the case may be.
The headings for each section which describe the data
fields are, for the most part, abbreviations. A listing of
the abbreviations and the appropriate descriptions are given in
the Format for the Data Bank, Exhibit II of this appendix.
The format for the data bank is arranged in sections which
correspond to the sections of the data bank, Exhibit I.
In several cases the data is provided as coded input.
The explanation of the code is given after the appropriate
description of the abbreviated heading in Exhibit II.
A.T.KEARNEY 6e COMPANY, INC.
-------
GENERAL FOUNDRY DATA
FORY C5 IOC SET PEUEST CAST TON/MONTH MELT SU INO WT PRO NOD ALLOY ADDITIONS TO LADLE CUP TYP VENT EFF VENT EFF VISITED BY
NO. TY ZST GI II DI GI MI DI CLA CLA RG CST T LB T LB T LB 1 LB 2 LB REP FCE TAP SOLD EERP ATK
0001 01 362 1 100 030 000 00000 00000 43 20
0002 01 902 1 100 030 000 00000 00000 3320 1
0003 01 782 1 100 000 000 00000 00000 3 0 1
0004 01 492 2 300 100 000 00000 19000 00000 4 12 5 00 00 0 00 0 00 3.10 00 I 1 1 3 2 2 1
0005 01 918 1 100 030 000 375 00000 00000 3650 1
0006 01 212 1 100 030 000 3 0
0007 01 606 1 100 030 000 3200 00000 00000 3 72 4 00000000000000 0 0 1 2 1 2 1 1
0008 01 802 1 100 330 000 950 00000 00000 2 72 4 00000000000000 0 0 1 2 1 2 1 1
0009 01 074 1 100 030 000 3300 00000 00000 4 0 1
0010 01 641 1 100 000 000 00000 00000 3 0
0011 01 917 1 100 030 000 1500 00000 00000 3 0 1
0012 01 352 5 60 030 40 18000 00000 12000 4 362 13 90 4 54 5 90 1 001 31 3 I 1
0013 01 482 1 100 030 000 00000 00000 3 0 1
0014 01 070 1 100 030 000 00000 00000 0
0015 01 441 1 100 000 000 210 00000 00000 350 11
0016 01 130 1 100 030 000 3000 00000 00000 3 0 1
0017 01 948 5 030 00000 4331
0018 01 631 5 033 00000 3453 1
0019 01 534 2 000 100 000 00000 00000 4 0
0020 01 138 1 100 000 000 00000 00000 2 0 I
0021 01 532 5 20 000 80 1500 00000 5000 33281436 48 1 111321 1
0022 01 541 1 100 030 000 00000 00000 45460 1 $x I
0023 01 029 1 100 000 000 00000 00000 3 0
0024 01 482 1 100 000 000 00000 00000 4 0 ZL x
0025 01 492 1 100 030 000 00000 00000 345 0
O
M
-------
FORY CD
NO. TV
0026 01
0027 01
U028 01
0029 01
0030 01
0031 01
0032 01
0033 01
0034 01
0035 01
0036 01
0037 01
0038 01
0039 01
00*0 01
0041 01
0042 01
0043 01
0044 01
0045 01
0046 01
0047 01
0048 01
0049 01
0050 01
LO:
070
494
802
489
631
282
606
432
462
452
900
902
606
374
016
902
465
467
520
507
612
465
017
503
195
•4ET
:sr
i
i
i
i
i
i
2
5
1
5
1
1
1
1
1
5
7
1
1
5
5
5
1
1
1
PEUE-U
Gl 11
100 030
100 030
100 030
100 030
100 000
103 030
000 100
90 030
100 000
92 030
100 030
100 030
100 090
100 030
100 030
030
74 21
100 030
100 030
000
21 030
000
100 030
100 030
100 000
CAST
DI
000
000
000
000
000
000
000
10
000
8
000
000
000
000
000
3
000
000
79
000
000
000
TON/MONTH MELT
Gl HI 01
1500
2000
4000
00000
1900
120
160
4400
500
1600
900
00000
00000
00000
00000
00000
00000
2500
00000
00000
00000
00000
00000
00000
00000
00000
00000
1200
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
160
00000
00000
00000
00000
00000
200
00000
00000
6000
00000
00000
00000
su
CLA
3
3
2
4
4
4
4
4
4
2
2
4
4
3
3
4
3
4
4
4
3
2
2
3
IND Ml
CLA RG
6 6
1 3
1 6
3
6 6
1
1
4 6
5
5
5
6 6
4 2
2
2
2 6
5
6 6
PRO NOD ALLOY ADDITIONS TO LADLE CUP TYP VENT EFF VENT EFF
CST T LB T LB T LB 1 LB 2 LB REP FCE TAP 10LD
9 0730 00 0 00 0 00 0 00 0 0 1 1
0 0 30 0 00 0 00 0 00 0 00 0 0 1 3 2 3
1 0 4 30 0 00 0 00 0 00 0 00 0 0 1 2 1 2
0
0 0 00 0 00 0 00 0 00 0
4 00 00 0 00 0 00 239 00 0 0 1 2 1 3
5 1
5 0
51112245 0000 001 21 2
0
0 00
6 0
6 0
0
1
14272 111313
30 001212
7 0
7 1
713846 141221
I
3 00 00 0 00 0 00 23260 0 2 2 1 2
0
0
VISITED 8
EERP ATK
I
1
1
1
1
1
1
1
1 1
I
1
1
I
1
1
1
.1
1
1 1
-------
FDRY C3
NO. TY
0051 01
0052 01
0053 01
0054 01
0055 01
0056 01
0057 01
0058 01
0059 01
0060 01
0061 01
0062 01
0063 01
0064 01
0065 01
0066 01
0067 01
0068 01
0069 01
0070 01
0071 01
0072 01
0073 01
0074 01
0075 01
LO: '
622
487
801
624
150
071
212
440
481
481
441
441
165
801
485
618
435
486
486
486
142
480
454
150
146
;sr
i
i
i
i
i
i
5
1
5
5
5
5
2
1
1
4
7
2
1
5
1
1
1
1
1
PE<:E^T CAST
GI 11 01
100 000 000
100 030 000
103 030 000
100 000 000
100 030 000
100 030 000
030
103 030 000
030
030
89 030 11
030
000 100 000
100 030 000
100 030 000
000
65 5 30
000 100 000
103 000 000
030
100 000 000
100 030 000
100 000 000
100 030 000
100 000 000
TON/MONTH MELT
GI MI DI
5500 00000
6300 00000
00000
00000
00000
00000
00000
00000
00000
00000
3200 00000
00000
00000
00000
00000
47000 4000
00000 43000
60000 00000
00000
00000
30000 00000
8000 00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
40
00000
00000
00000
00000
21000
00000
00000
00000
00000
00000
00000
00000
su
CLA
4
4
3
3
3
4
4
4
4
4
3
4
4
4
4
4
4
4
4
4
3
IND
CLA
1
5
1
1
1
5
5
4
1
1
1
1
1
1
1
1
1
WT
RG
4
2
5
5
3
4
2
4
6
6
4
4
6
3
PRO
CST
5
6
5
5
5
5
3
5
5
5
5
5
5
5
5
5
NOD ALLOY ADDITIONS TO LADLE CUP TYP VENT
T LB T LB T LB 1 LB 2 LB REP FCE TAP
0
0 0 00 0 00 0 00 0 00 0 1 1 2
0
0
0
0
I
0
1
1
1 8 0 00 9 00 0 0 1
I
0
0
0 0 00 0 00 0 00 0 00 0
0
1 001
0 131
0 112
1
0 112
0 111
0
0
0
EFF VENT EFF VISITED
HOLD EERP AT
112 1
I
4
I
1
21211
1
1
222 1
222 1
222 1
1
222 I
1
312 1
-------
GENERAL FOUNDRY DATA
PA3E
FDRY
VQ.
0076
0077
0078
0080
0081
0032
0083
0084
0085
0036
0087
0088
0089
0090
0091
0092
0093
0094
0095
0096
0097
0098
0099
0100
0101
o
TY
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
10:
191
472
131
917
917
6)1
303
515
175
917
619
088
606
462
402
531
601
352
53*
488
083
482
611
176
075
1ET
:ST
1
1
1
1
1
1
1
1
1
1
1
1
1
2
5
5
1
1
1
1
1
2
1
PEUEMT
GI Ml
100
100
100
100
100
100
100
100
100
100
100
100
100
003
50
85
100
100
100
100
100
000
100
000
030
000
030
030
030
030
030
030
000
030
000
000
100
000
030
000
000
030
000
030
100
030
CAST
01
QUO
000
000
000
000
000
000
000
000
000
000
000
000
000
50
15
000
000
000
000
000
000
000
TON/MONTH MELT
Gl MI 01
00000
3300 00000
00000
00000
400 00000
00000
2350 00000
00000
500 00000
00000
00000
11200 00000
10500 00000
00000
1850 00000
6800 00000
00000
125 00000
00000
00000
5000 00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
1850
1200
00000
00000
00000
00000
00000
00000
00000
SI I
CLA
2
3
3
3
3
4
2
4
4
4
3
4
4
2
2
4
4
4
IND WT PRO N3D ALLOY ADDITIONS TO LAOLE CUP TYP VENT EFF VENT EFF
CLA RG CST T L8 T L8 T L8 1 LB 2 LB REP FCE TAP MOLD
0
6530
0
0
4430
0
0
0
66 00000000000000 0 0 1 3 I 3
4530
2 70
1650 1619002121
26 7 0425 10 110212001 22 2
2 70
35 2 16 99 4 13 8 30 1 13 0 0 2 2 1 3
54614 50 6 1 002313
0
0
0
1 0
14 1 0 0 00 0 00 0 00 0 00 0 00 1 1 I 2 1
0
0
VISITED
EERP AT
1
1
I
1
I
1
1
1
1
1
1
1
1
1
1
1
1
-------
NO.
0102
0103
C104
0105
0106
0107
0108
0109
0110
0111
0112
0113
0114
0115
0116
0117
0118
0119
0120
0121
0122
0123
0124
0125
0126
CO
TY
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
LO:
024
631
900
191
331
496
947
850
469
761
458
601
481
374
532
606
549
351
028
532
07*
900
8*6
085
•1ET
csr
1
1
5
1
1
5
5
1
2
1
1
2
1
1
2
5
1
2
5
1
1
5
5
GI
100
100
100
100
95
000
100
100
000
103
100
000
100
000
100
100
75
HI
030
000
030
000
000
030
000
030
100
030
000
100
030
000
100
030
030
100
030
030
030
000
000
CAST
01
000
000
000
000
5
000
000
000
000
000
000
000
000
000
000
000
000
25
TON/MONTH MELT
GI HI 01
500 00000
00000
00000
00000
00000
570 00000
00000
00000
00000
00000
630 00000
00000 2015
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
7500 00000
00000
00000
00000
00000
30
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
2500
SIZ INO WT PRO
CLA CLA RG CST
3 52
3
3643
3
2
3
3653
3
3
365
4 6 1
3
*
4 5
3
*
3 6
2
2
4
3352
NOD Al
T
0
0
1 5
0
0
I 9
1
0
0
0
0
0 0
c
0
0
1
0
0
1
0
0
1
1 6
GENERAL FOUNDRY DATA PAGE 5
SIZ INO WT PRO NOD ALLOY ADDITIONS TO LADLE CUP TYP VENT EFF VEST EFF VISITED ^r
T LB T L8 T L8 1 L8 2 LB REP FCE TAP
0 00 9 00 1
MOLD
EERP ATK
0 00 0 00 0 00 3
0 00 0
0 00 0 00 0 00 0 00 0
2 I
-------
FDRY
NO.
0127
0128
0129
0130
0131
0132
0133
0134
0135
0136
0137
0138
0139
QUO
0141
0142
0143
0144
0145
0146
0147
0148
0149
0150
0151
C3
TV
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
LO: IET
csr
900
452
917
900
945
083
631
088
535
194
352
473
441
112
196
691
761
195
331
080
352
374
374
945
604
1
1
1
1
1
1
1
1
4
4
1
3
1
1
1
1
1
1
5
5
1
1
5
1
PEUE^I
GI HI
100
100
100
100
100
100
100
100
11
100
100
100
100
100
100
100
60
103
100
73
100
030
000
000
090
030
000
030
000
3)
030
030
030
030
000
000
030
030
030
030
030
030
030
030
CAST
01
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
40
000
000
22
000
TON/MONTH MELT
GI HI 01
00000
260 00000
350 00000
00000
00000
00000
600 00000
00000
500 4000
700 00000
00000
525 00000
00000
350 00000
00000
400 00000
00000
16000 00000
00000
00000
00000
4500 00000
00000
00000
00000
00000
00000
00000
00000
00000
oooco
00000
00000
00000
00000
00000
00000
00000
00000
00000
12800
00000
00000
1250
00000
SIZ
CIA
2
3
3
3
2
3
4
2
4
4
3
3
3
4
3
3
2
4
4
4
4
3
3
1NO WT PRO NOD ALLOY ADDITIONS TO LA
CLA RG CST T LB T LB T L8 1 LB 2
0
0
5560
0
6530
3 20
6560
0
5 1 6 0 0 00 0 00 0 00 0 00 0
5 60
4580
6531
5 0
0
6530
0
6480
0
35216 4
4531
0
0
35 2 1 6 45 4 40 141
0
HOLD
EERP ATK
1
1
1
1
1
1
-------
GENERAL FOUNDRY DATA
PA3F
FDRY CO LO: 1EF PGUEVT CAST TON/NONTH KELT
NO. TY
0153 01 625
0154 01 61*
0155 01 982
0156 01 463
0157 01 950
0158 01 757
0159 01 494
0160 01 374
016 101 191
0162 01 070
0163 01 070
0165 01 523
0166 01 OT1
0167 01 081
0168 01 625
SIZ IND HT PRO NOO ALLOY ADDITIONS TO LADLE CUP TYP VENT EFF VENT EFF VISITED
ST
1
4
1
1
1
1
1
1
1
1
1
1
5
1
1
Gi
100
100
100
100
100
100
100
109
100
100
100
85
100
100
11
000
000
000
000
030
030
000
030
000
000
030
000
000
030
DI
000
000
000
000
000
000
000
000
000
000
000
000
15
000
000
GI HI
00000
00000
00000
00000
200 00000
7300 00000
375 00000
24000 00000
DOOOO
00000
00000
850 00000
3000 00000
435 00000
DI
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
00000
150
00000
00000
CLA CLA RG CST
4
4
3
2
3
3
4
343
4161
3
4
3566
265
0
0
0
0
0
0
0
0
0
0
0
0
1
0
0
T LB T LB T L8 1 LB 2 L B REP FCE TAP
0 00 0 00 0 00 0 00 0 0 0 2
49 9 00 0 0 2
0 30 0 00 0 00 0 00 0 00
1 1
HOLD
EERP
-------
FURNACE DATA
******»***FURNACE CLASSIFICATION*********
FDRY
NO.
C001
0001
0001
0001
0002
0002
0003
0004
0004
0004
i004
0004
0006
0007
0008
0009
0009
0009
0010
0011
0012
0012
0012
0012
CO
TY
10
10
10
10
10
10
10
10
10
10
10
10
I rt
1 u
10
10
13
10
13
10
10
10
10
10
10
10
FCE
NO
1
2
3
*
1
2
1
1
2
3
4
5
1
I
1
1
2
3
1
1
1
2
3
4
FCE
TYP
1
1
1
1
1
1
1
2
3
4
4
4
I
1
1
1
1
1
1
1
1
1
1
1
LI*
TVP
1
I
1
1
I
1
1
1
1
1
1
1
1
2
1
1
1
1
1
I
2
I
2
BLT
OES
3
3
3
3
3
3
0
3
3
0
0
3
3
2
2
3
3
1
1
2
3
BLT
HTG
1
1
1
1
1
1
0
0
0
0
0
1
1
3
3
1
1
3
3
3
1
TOP
C/0
1
1
1
1
1
0
0
0
0
0
I
1
1
1
1
1
2
2
2
2
CHG
2
2
2
2
2
2
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
GAS
T-0
2
2
1
1
0
0
3
3
3
2
1
1
1
1
1
8
a
8
8
AFT
0
0
0
0
0
2
1
2
2
2
2
0
0
0
0
CHG
OR
1
1
1
1
2
2
0
0
0
0
0
1
1
1
I
1
1
1
1
1
1
FL
IN
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
ox
EN
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
0
FCE
USE
1
1
1
1
1
I
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
FCE
OIA
66
78
48
48
54
54
300
000
120
120
120
A t
42
72
60
66
66
56
84
114
114
43
48
*
HLO
CAP
000
000
000
000
000
000
000
100
18
20
100
100
n c\f\
OUO
000
000
000
000
000
000
000
000
000
000
000
000
HLT
RAT
15
15
8
8
9
9
7
00
6
13
13
13
9
20
11
18
18
11
9
10
45
35
14
6
HT PR OT
UT UT UT
00 24 00
24 24 00
24 24 00
24 24 00
24 24 00
8 00
8 8 00
14 00
18 00 00
24 00 00
18 00 00
6 00 00
»*****BLAST»***
VOLUH PRES
8600
8600
4500
4500
6000
6000
00000 00
00000 00
00000 00
00000 00
00000 00
5500 20
5000 14
10500
10500
4550
r.200
19000
26000
8500
6000
TEHP
OOOi)
0000
0000
0000
0000
750
750
1100
800
450
SUE
CH OR
52
52
43
43
45
45
00
00
00
00
00
ft
I O
51
23
52
52
52
54
84
84
54
54
HT CHG AFT AFT 01 S POWR
OR PRE SIZE LOC AFT SPLY
0000
0000
0000
0000
0000
0000
0000
00 0 0000 0 000 1400
00 0 0000 0 000 3600
00 0 3000 0 000 1400
00 0 0000 0 000 1400
00 0 3000 0 000 1400
m nn
\j j \j\j
0000
35 0 3700 3 40 0000
19 0 3300 1 252 0000
4000 0000
4000 0000
4000 0000
0000
0000
27 0 0000 0 000 0000
27 0 0000 0 000 0000
26 0 0000 0 000 0000
26 0 0000 0 000 0300
CTL
SYS
1
1
1
I
1
I
0
0
1
1
1
1
1
1
1
1
2
1
1
w
f
t-
t c
K
0 ^
m >
X 13
X T5
h-H M
CO "Z.
l-l O
H M
X
1-1
CD
-------
FURNACE DAT*
PAGE
»**»**»*»»FURNACE ClASSIFICATION*********
FOR* CD FCE
NO. It NO
0012 10
0019 10
0013 10
0014 10
0014 10
0015 10
0016 10
0016 10
0017 10
0017 10
0018 10
0018 10
0019 10
0019 10
0019 10
0019 10
0020 10
0020 10
0021 10
0021 10
0022 10
0022 10
0022 10
0022 10
0023 10
5
1
2
1
2
1
1
2
1
2
1
2
1
2
3
4
1
2
1
2
1
2
3
4
1
FCE
TYP
1
1
1
1
1
1
1
1
1
1
1
1
1
1
6
6
2
2
1
1
3
3
3
3
1
LIV
TYi>
1
1
1
I
1
1
1
I
1
1
2
2
1
1
0
0
6
6
4
4
1
1
1
1
1
8LT
OES
2
3
3
3
3
3
3
3
3
0
0
0
0
2
1
0
0
0
0
3
BIT
HTG
3
1
1
1
I
1
1
1
1
0
0
0
0
3
3
5
5
5
5
I
TOP
C/0
2
I
1
1
1
2
2
1
1
2
2
2
2
0
0
0
0
1
1
0
0
0
0
1
CMC
2
2
2
2
2
2
2
2
2
2
2
0
0
0
0
2
2
0
0
0
0
2
GAS
T-0
a
i
i
a
8
a
8
a
a
0
0
0
0
i
i
0
0
0
0
1
AFT
0
0
I
0
0
0
0
0
0
0
0
0
0
0
0
CHG FL OX
OR IN EN
1
1
1
2
1
1
1
1
1
1
0
0
0
0
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
0
0
0
0
FCE FCE HLO NLT MT PR OT *»*«**BLAST**»* SIZE HT CHG AFT AFT OIS POHR
USE OIA CAP RAT UT UT UT VOLUM PRES TEMP CH. OR OR PRE SIZE LOG AFT SPIV
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
3
I
1
1
1
1
1
1
1
1
30 000 3
72 000 18
000 10
54 000 10
54 000 10
42 000 6
52 000 11
52 000 11
37 000
000
43 000 8
48 000 8
43 000 18
43 000 18
300 30 00
000 30 00
000 13 .5
000 13 .5
68 000 18
63 000 13
000 9 5
000 9 5
000 9 5
000 9 5
76 000
8 00 00 3500
2 5000
2
3600
5000
5000
2400
4500
4500
00 00000 00
00 03000 00
00000 00
00000 00
22 22 00 9000 36
22 22 00 9000 36
00000 00
00000 00
00000 00
00000 00
6000
400 18
30
10
44
44
0000 11
0000 11
28
28
0000 00
0000 00
0000 00
0000 00
1000 80
1000 80
0000 00
0000 00
0000 00
0000 00
18 0 0000 0 000 0000
0000 0 000 0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000 0 000 0000
0000 0 000 0000
00 0 0000 0 000 0000
00 0 0000 0 000 0000
00 0 0000 0 000
00 0 0000 0 000 0000
38 0 0000 0 000 0000
38 0 0000 0 000 0000
00 3 0000 0 000 1750
00 3 0000 0 000 1750
00 3 0000 0 000 1750
00 3 0000 0 000 1750
0000
CTL
SYS
0
1
1
1
1
1
2
1
I
1
2
1
2
I
1
I
-------
FURNACE DATA
PAGE
»******»*»FURNACE CLASS IFICATION*«*******
FDRY CO FCE
NO. TY N3
0024 10 1
00? «. 10 2
0025 10
0026 10
0026 10
0027 10
0023 10
0028 10
0029 10
0029 10
0029 10
0029 10
0030 10
0030 10
0030 10
0031 19
0031 10
0032 10
0032 10
0033 10
0033 10
0033 10
0033 10
0033 13
0033 10
1
1
2
1
1
2
1
2
3
4
1
2
3
1
I
I
2
1
2
3
4
5
6
FCE
TYP
1
1
1
1
1
1
1
3
1
4
4
4
4
4
*
1
1
1
6
1
1
2
2
2
2
UM
TV?
4
4
4
1
1
1
1
1
4
1
1
1
1
1
1
*
4
1
0
4
4
7
7
7
7
BLT
DES
2
2
3
3
3
3
3
2
0
0
0
3
0
0
2
2
3
0
1
1
0
0
0
0
BLT
HTG
3
3
1
1
1
1
5
3
0
0
0
0
0
0
3
3
1
0
3
3
0
0
0
0
TOP
C/0
1
1
2
1
1
2
0
1
0
0
0
0
0
0
1
1
2
0
1
1
0
0
0
0
CHG
2
2
2
2
2
2
0
2
2
2
2
2
2
2
0'
2
2
0
0
0
0
GAS
T-0
1
1
a
i
i
8
0
1
8
8
8
1
I
8
0
1
1
0
0
0
0
AFT
2
2
2
0
0
6
0
0
0
0
0
0
0
0
2
0
2
2
0
0
0
0
CHG
OR
1
1
1
1
1
1
0
1
0
0
0
0
0
0
1
1
1
0
1
1
0
0
0
0
FL OX
IN EN
0 0
0 0
0
0
0
1
0
0
0
0
0
0
0
0
0
0
1
0
0
0
0
0
0
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
FCE
USE
1
1
1
1
1
1
1
1
1
3
3
3
1
1
I
1
1
1
3
1
1
1
1
1
2
FCE HLD MLT
DIA CAP RAT
86 000 32
86 000 32
84 000 20
54 000 10
54 000 10
72 000 14
000 4
ooo .a
78 000 15
72 6 00
72 6 00
60 6 00
.5
2
4
96 000 35
96 000 35
56 000 16
20 00
108 000 50
103 000 50
000 137 10
000 137 10
000 137 10
000 137 00
MT PR OT *****«BLAST**»*
UT UT UT VOLUM PKES TENP
22000 750
22000 750
13 11000
10 00 5400
10 00 5400
8 8000
00000
14 12000
16 00000
16 00000
16 00000
00000
00000
00000
15000
15000
7 5400
00 10 5 00000
25000
25000
00000
00000
00000
00 00000
19
19
>.4
00
20
00
00
00
00
00
00
15
00
00
00
00
00
cooo
750
0000
0000
0000
0000
0000
0000
750
750
0000
1400
1400
0000
0000
0000
0000
SIZE HT
CH OR OR
70
58
58
68
00
50
00
00
00
00
00
00
60
60
60
00
99
99
00
00
00
00
33
00
00
00
00
00
00
00
26
00
00
00
00
00
CHG
PRE
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
AFT
SIZE
8000
8000
0000
3000
1780
0000
0000
0000
0000
0000
0000
0000
0000
1000
0000
0000
0000
0000
0000
AFT
LOC
4
2
2
0
0
1
0
0
0
0
0
0
0
0
2
0
0
0
0
0
OIS
AFT
720
720
000
000
276
000
000
000
000
000
000
000
000
31
000
000
000
000
000
POWR
SPLY
0000
0000
0000
0000
0000
0000
0000
0000
1000
1000
1000
0000
0000
0000
0000
0000
0000'
4400
4400
4400
2200
CTL
SYS
1
1
1
1
1
1
1
0
0
0
1
1
1
0
1
2
-------
FURNACE DATA
PAGE
****«*****FURNACE CLASSIFICATION******«*»
FORY CO FCE
NO. TY NO
0033 10
003s 10
0034 10
0035 10
0035 10
0035 10
0035 10
0036 10
0037 10
003B 10
0040 10
0040 10
0040 10
0040 10
0041 10
0041 10
0041 10
0041 10
0042 10
0042 10
0042 10
0043 10
0044 10
0044 10
0044 10
7
1
2
1
2
3
4
1
1
1
1
2
3
4
1
2
3
4
1
2
3
1
1
2
3
FCE
TYP
2
i
2
1
1
1
2
1
1
1
1
1
1
4
1
2
2
2
1
2
2
1
1
1
2
LM
TV?
7
4
6
4
2
2
7
1
1
4
4
5
5
I
4
4
6
BUT
OES
0
1
0
2
3
3
0
3
3
1
0
0
3
0
1
0
0
3
I
1
0
BIT
HTC
0
3
5
3
1
1
0
1
1
3
3
0
0
1
3
3
TOP
C/0
0
1
0
1
2
2
0
1
1
1
0
1
0
0
0
2
0
0
2
2
2
0
CHG
0
2
0
2
2
2
0
2
2
2
2
0
0
0
2
0
0
2
2
2
0
GAS
T-0
0
2
0
1
8
a
0
i
i
i
0
0
0
B
0
0
1
8
a
0
AFT
0
0
0
2
0
0
0
2
2
0
0
0
0
0
2
0
0
2
0
CHG FL OX
OR IN EN
0
1
0
1
1
1
0
1
1
1
0
0
0
0
I
0
0
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0
FCE FCE HLD NLT HT
USE 01 A CAP RAT UT
2
1
5
1
1
1
3
1
1
1
1
1
1
1
1
2
2
1
1
1
3
000 137 00 00
108 000 50
000 100 10 00
54 000 13 9
48 000 8 9
48 000 8 9
000 14 00 00
42 000 4
34 000 4 2
78 000 23
000 6
000 6
000 6
000 4
000 .75
000 .25
000 .20
72 000 25 16
000 9 00 00
000 9 00 00
54 000 11 5
72 000 20
72 000 20
000 30 00 00
PR OT *»***»BLAST**»*
UT UT VOLUM PRES TEMP
00000
25000
00000
9 00 5500
9 00 4500
9 00 4500
9 00 00000
2500
2000
00000
00000
00000
00000
12000
24 00000
24 00000
5300
00000
00
00
25
00
00
00
00
00
64
00
00
00
0000
1000
0000
600
0000
1000
0000
0000
0000
0000
1000
0000
0000
1400
1400
3000
SUE HT CHG AFT
CH OR OR PRE SIZE
00
99
00
55
55
55
00
5
4
95
00
00
00
00
16
00
00
50
00
00 0 0000
0000
00 0000
0
0 0000
0 0000
00 0 0000
0000
00 0000
00 0000
00 0000
00 0000
46 0 2100
00 0 0000
00 0 0000
0 4500
00 0 0000
AFT
LOC
0
0
0
0
0
0
0
0
0
0
0
1
0
0
2
0
OtS POUR CTL
AFT SPLY SYS
000 2200
000 0000
000 4000
0000
000 0000
000 0000
000 420
0000
0000
000 0000
0000
0000
0000
000
0000
000
000
000
480 0000
000 600
000 600 '
0000
0000
0000
000 750
1
1
2
3
1
1
1
1
1
0
0
1
-------
FURNACE DATA
PA3E
»*********FURNACE CLASSIFICATION*********
FORY
NO.
0044
OT, j
0045
0045
0045
0045
0045
0045
0045
0046
0046
0046
0046
0046
0046
0046
0047
0047
0048
0048
0048
0048
0049
0050
0051
CD FC«=.
1 Y N3
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
4
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
1
2
1
2
3
4
1
1
1
FCE
TYP
2
1
1
1
1
1
1
1
1
4
4
4
4
2
2
2
1
1
4
2
2
2
1
1
1
LIS
TYI>
6
4
4
4
4
4
4
4
4
1
1
1
1
&
6
6
1
1
1
7
7
7
I
i
BIT
DES
0
1
1
1
1
1
1
1
1
0
3
0
0
0
0
0
2
2
0
0
0
0
3
3
BUT
HTG
3
3
3
3
3
3
3
3
0
0
0
0
0
0
0
3
3
0
0
0
0
1
1
TOP
C/0
0
2
2
2
2
2
2
1
1
0
0
0
0
0
0
0
1
1
0
0
0
0
1
1
1
CHG
0
2
2
2
2
2
2
2
2
1
1
1
1
0
0
0
2
2
1
0
0
0
2
2
2
CAS
T-0
0
8
8
8
8
a
8
1
I
3
3
3
3
0
0
0
1
1
4
0
0
0
1
1
1
AFT
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
2
2
0
0
0
0
0
CHG
OR
0
I
1
I
1
1
I
1
I
0
0
0
0
0
0
0
1
I
0
0
0
0
2
1
1
FL
IN
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
ox
EN
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
FCE
USE
3
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
I
1
1
2
2
2
1
1
1
FCE
DIA
000
84
84
84
84
84
84
96
96
103
103
103
103
000
300
000
54
54
103
000
000
000
72
66
48
HLO
CAP
30
000
000
000
000
000
000
000
000
15
15
15
15
83
83
83
000
000
20
22
22
22
000
000
000
HLT
RAT
00
18
18
18
18
18
18
26
26
13
13
13
13
00
00
00
10
10
8
00
00
00
5
17
10
HT PR OT **«***BLAST*»**
UT UT UT VOLUH PRES TEMP
00 00000
10000
10000
9500
9500
9500
9500
12000
12000
16 00000
16 00000
16 00000
16 00000
00 15 00000
00 15 00000
00 00000
7000
7000
8 00 00000
00 2 22 00000
00 2 22 00000
00 2 22 00000
3500
6000
6000
00
00
00
00
00
00
00
00
00
00
00
00
0000
1400
1400
1400
1400
1400
t400
1400
i400
0000
0000
0000
0000
0000
0000
0000
500
500
0000
0000
0000
0000
SIZE HT CHG AFT
CH DR OR PRE SIZE
00
88
88
72
72
84
84
70
70
00
00
00
00
00
00
00
35
35
00
00
00
00
55
00 0 0000
0000
0000
0000
0000
0000
0000
0000
0000
00 0 0000
00 0 0000
00 0 0000
00 0 0000
00 0 0000
00 0 0000
00 0 0000
00 0 0000
00 0 0000
00 0 0000
00 0 0000
0000
AFT
LOC
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
OIS
AFT
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
P3WR
SPLY
750
0000
0000
0000
0000
0000
0000
0000
0000
9100
9100
9100
9100
1400
1400
0000
0000
6000
300
800 '
300
0000
0000
0000
CTL
SYS
1
1
1
1
2
2
0
0
0
1
1
1
1
I
I
-------
FURNACE DATA
PAGE
»«»*»«**»»FURNACE CLASS IFICATION*********
FOHY CD FCE
MO. T'' NO
0051 10
005? "0
0052 10
0052 10
0052 10
0053 10
0054 10
0055 10
0055 10
0056 10
0057 10
0058 10
0058 10
0058 10
0058 10
0058 10
0058 10
0058 10
0058 10
0059 10
0059 10
0059 10
0059 10
0059 10
0059 10
2
1
2
3
4
1
1
1
2
1
1
1
2
3
4
5
6
7
8
1
2
3
4
5
6
FCE
rvf>
i
i
i
i
i
4
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
LH
TV?
I
1
1
1
1
1
1
4
*
4
4
4
4
1
*
4
*
4
4
4
air
OES
3
2
2
2
3
0
3
J
1
1
1
1
1
1
0
1
1
1
1
I
1
BIT
HTG
1
3
3
3
1
0
I
1
3
3
3
3
3
3
0
3
3
3
3
3
3
TOP
C/0
1
2
2
2
2
0
1
1
1
1
1
1
1
1
0
1
1
1
1
1
1
CMC
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
GAS
T-0
1
8
a
8
8
1
1
1
1
1
1
1
1
1
1
1
1
1
AFT
0
0
0
0
4
0
0
2
2
2
2
2
2
0
CHG FL OX
OR IN EN
1 0 0
1 0 I
1 0 1
1 0 1
1 0 0
000
1 0 0
100
1 0 0
1 0 0
100
100
1 0 0
000
1
1
1
1
1
1
FCE
USE
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
FCE HID MLT
01 A CAP RAT
48 000 10
60 000 16
60 000 16
60 000 16
48 000 8
60 000 15
000 2
000 5
54 000 9
ooo a
96 000 30
96 000 30
96 000 35
96 000 35
96 000 35
96 000 35
96 000 35
12
96 000 25
96 000 25
96 000 25
96 000 25
96 000 35
96 000 35
MT
UT
16
16
16
8
PR OT ******BLAST**»*
UT UT V3LUM P*ES TEMP
6000
5900 18 450
5900 18 450
5900 18 450
3500 16
00000 00 0000
8800
SIZE HT CHG AFT AFT OIS P3WK CTL
CH OR OR PRE SIZE LOC AFT SPLY SYS
55
60
60
60
60
00
00
1000
1000
1000
1000
1000
1000
00000 00 0000 00 00
1000
1000
1000
1000
1000
1000
0000 0 000 0000
0 0000 0 000 0000
0 0000 0 000 0000
0 0000 0 000 0000
0 1000 4 480 0000
0000 0 000
0000 0 000 0000
ooou
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000 0 000
0000
0000
0000
0000
0000
0000
0000
1
0
1
0
2
I
1
1
2
3
4
5
6
1
'2
3
4
5
6
-------
FURNACE DATA
PAGE
»********»FURNACE CLASSIHICA1ION*********
FORY r.o
NO. TY
0059 10
OOS- 10
0059 10
0059 10
0059 10
0059 10
0060 10
0060 10
0060 10
0060 10
0060 10
0060 10
0060 10
0060 10
0060 10
0060 10
0060 10
0060 10
0061 10
0061 10
0062 10
0062 10
0063 10
0063 10
0064 10
FCE
NO
7
8
9
10
11
12
1
2
3
4
5
6
7
a
9
10
ii
12
1
2
1
2
1
2
1
FCE
TVP
i
i
i
4
2
2
1
1
1
1
1
1
4
4
4
4
4
1
2
1
1
4
4
1
LM
TYP
4
4
4
1
6
f>
4
4
4
4
4
4
2
2
2
2
2
1
1
1
1
1
1
BUT
OES
1
1
1
0
0
0
I
1
1
I
1
1
0
0
0
3
0
3
1
0
1
1
0
0
BLT
HTG
3
3
3
0
0
0
3
3
3
3
0
0
0
0
0
3
0
3
3
0
0
TOP
C/0
1
1
1
0
0
0
1
1
1
1
0
0
0
0
0
0
1
0
I
1
0
0
CMC
2
2
2
0
0
2
2
2
2
0
2
0
2
2
I
1
GAS
T-0
1
I
1
3
0
0
1
1
1
1
I
I
0
1
0
1
1
3
3
AFT
0
0
0
0
0
0
0
0
0
2
0
2
2
0
0
CHG
OR
1
1
I
0
0
0
1
1
1
1
1
1
0
0
0
0
0
0
1
0
1
1
0
0
FL
IN
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
ox
EN
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
FCE
USE
1
1
1
2
2
2
1
1
1
1
1
1
2
2
2
2
2
1
1
1
1
1
1
1
FCE
OIA
96
96
96
120
000
300
84
84
90
90
90
90
000
65
000
66
66
132
103
HLO
CAP
000
000
000
20
14
14
000
000
000
000
000
000
1
1
I
4
4
<*
000
1.5
000
000
000
MLT MT
RAT UT
35
35
35
00 00
00 00
00 00
15
15
22
22
22
22
00 00
00 00
00 00
00 00
00 00
20 8
1 8
14
14
12
4
8
PR OT *«****8LAST**»*
UT UT VOLUM PRES TEHP
1000
1000
00000
00000
00000
00000
00000
00000
00000
00000
00000
8 00 10000
8 00 00000
8000
BOOO
00000
00000
00
00
00
00
00
on
00
00
00
24
00
00
00
1000
JOOO
0000
0000
1000
1000
1000
1000
1000
1000
0000
')000
-------
FURNACE DATA
PA3E
•*****»**»FURNACE CLASSIFICATION*********
FDRY CD FCE
NO. ft NO
0064 10
OOC' 10
0065 13
0065 10
0065 10
0065 10
0065 10
0065 10
0066 10
0066 10
0066 10
0066 10
0066 10
0066 10
0066 10
0067 10
0067 10
0067 10
0067 10
0067 10
0067 10
0067 10
0067 10
0068 10
0068 10
2
I
2
3
4
5
6
7
1
2
3
4
5
7
8
1
2
3
4
5
6
7
8
1
2
FCE
ryp
l
i
i
l
i
l
l
4
1
1
1
1
1
4
2
1
1
1
3
2
2
4
4
1
1
LH
TYP
1
4
4
4
1
1
1
1
1
1
4
4
1
6
4
4
4
3
7
7
3
3
1
I
8LT
QES
1
1
1
2
2
2
0
1
1
0
0
I
1
1
0
0
0
0
0
2
2
8LT
HTC
3
3
3
3
3
3
0
3
3
0
0
3
3
3
5
5
5
0
0
3
3
TOP
C/0
1
1
1
2
2
2
0
2
1
0
0
1
1
2
0
0
0
0
0
2
2
CHG
2
2
2
2
2
2
2
2
1
0
2
2
2
1
1
1
1
\
2
2
GAS
T-0
1
1
1
8
8
8
8
2
0
1
1
8
0
0
0
0
0
a
a
AFT
2
2
2
0
0
0
0
0
1
I
0
0
0
0
0
0
0
0
CMC FL OX
OR IN EN
1 0
1 0
1 0
1 0
1 0
1 0
0 0
1 0
1 0
0 0
0 0
1 0
1 0
1 0
0 0
0 0
0 0
0 0
0 0
1 0
1 0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
FCE FCE HLO MLT
USE OIA CAP RAT
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
2
2
2
2
1
*
000 21
84 000 35
84 000 35
102 000 40
103 000 25
108 000 25
108 000 25
10
000 35
000 35
000 35
108 000 35
108 000 40
96 15 00
300 00
114 000 45
114 000 50
102 000 45
33 10
60 00
60 00
30 00
4 00
102 000 45
102 000 45
MT PR OT ******BLAST**»*
UT UT UT VOLUM PHES TEHP
16000
16000
16000
16000
16000
16000
00000
25000
25000
00 00000
00 00000
16 00 25000
16 00 25000
8 00 25000
10 2 4 00000
00 16 00 00000
00 16 00 00000
00 8 00 00000
00 8 00 00000
16 00 00 20000
16 00 00 20000
00
30
00
00
72
72
72
00
00
00
00
00
35
35
1600
1600
1000
750
750
750
0000
1000
1000
0000
0000
1200
1400
1200
0000
3000
0000
0000
0000
350
350
SI7E HT CHG AFT
CH DR OR PRE SIZE
96
96
00
97
00
00
99
51
57
00
00
00
00
00
85
85
0 1500
0 1500
00 0000
0000
0000
00 0 0000
00 0 0000
46 0 6000
35 0 9999
37 0 0000
00 2 0000
00 0 0000
00 0 0000
00 0 0000
00 0 0000
30 0 0000
30 0 100
AFT DIS
LOC AFT
1
1
0
0
0
0
0
2
1
0
0
0
0
0
0
0
I
600
600
000
000
000
000
000
000
000
000
000
000
000
000
POUR
SPLY
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
1300
1100
1100 '
3500
3500
0000
0000
CTU
SYS
1
2
3
4
5
6
1
1
2
3
0
0
0
0
0
1
2
-------
FURNACE OAT*
PAGE
*****«**»»(:URNACE CLASS IF ICAT ION*********
FDRY CD
NO. TY
0068 10
oo f- a 10
0068 10
0068 10
0068 10
0068 10
0068 10
0069 10
0069 10
0069 10
0069 10
0069 10
0069 10
0069 10
0069 10
0069 10
0069 10
0069 10
0069 10
0069 10
0069 10
0069 10
0069 10
0069 10
0069 10
FCE
NO
3
4
5
6
7
8
9
1
2
3
4
5
6
7
a
9
10
11
12
13
14
15
16
17
18
FC?
TYP
1
1
3
3
4
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
LiM
TY?
1
1
1
1
1
1
1
1
1
I
1
1
1
1
1
1
1
1
1
1
1
1
I
BLT
OES
2
2
0
0
0
0
0
1
1
I
1
1
1
3
3
3
3
3
3
3
3
3
3
0
0
BLT
HTG
3
3
0
0
0
0
0
3
3
3
2
2
2
1
1
1
1
1
1
1
1
1
1
0
0
TOP
c/o
2
2
0
0
0
0
0
I
1
I
1
1
2
2
2
2
2
2
2
2
2
2
2
0
0
CHG
2
2
0
0
0
0
0
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
0
0
GAS
T-0
a
8
0
0
0
0
0
2
2
2
2
2
2
8
8
a
8
8
8
8
8
8
8
0
0
AFT
0
0
I
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
CHG
DR
1
1
0
0
0
0
0
I
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
FL
IN
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
ox
EN
0
0
0
0
0
0
0
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
FCE
USE
1
1
1
3
3
3
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
FCE
OIA
102
102
72
60
108
108
108
114
114
108
108
102
102
72
72
72
72
72
72
72
72
72
72
96
108
HLD
CAP
000
000
65
33
18
18
18
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
17
18
NLT
RAT
45
45
40
10
3
3
3
55
55
45
45
35
35
20
20
20
20
20
20
20
20
20
20
00
3
MT PR
UT UT
16 00
00
16 16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
00 IS
8 16
Of ****»*BLAST»»»* SIZE HT
UT VOLUM PRES TE1P CH OR DR
00 20000
00 20000
00 03000
00000
00000
00000
00000
28000
28000
20000
22000
20000
20000
15000
15000
15000
15000
15000
15000
15000
15000
15000
15000
00000
00 00000
35 350 85
35 350 85
00 0000 00
00 COOO 00
00 0000 00
00 COOO 00
oo o-r.;? QJ
80 1030
80 1000
56 1000
72 1000
56 1000
56 1000
40
40
40
40
40
40
40
40
40
40
00 0000 00
00 0000 00
30
30
00
00
00
00
00
51
51
58
58
46
46
25
25
25
25
25
25
25
25
25
25
00
00
CHG
PRE
0
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
AFT
SIZE
100
100
5000
0000
0000
0000
0000
0000
0000
oqoo
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
AFT
LOC
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
DIS
AFT
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
P3WR
SPLY
0000
0000
1700
470
350
350
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
3500
6250
CTL
SYS
3
4
5
5
6
3
4
1
2
-------
r.-.;
NO. IT
0069 10
0069 10
0069 10
0069 10
0070 10
0070 10
( *.0070 10
30070 10
.,0070 10
COO 70 10
30070 10
50070 10
1:0071 10
0071 10
0071 10
0071 10
0071 10
0071 10
0071 10
0071 10
1
-0071 10
0071 10
0072 10
0072 10
0072 10
NO
19
23
21
22
1
2
3
*
5
6
7
a
i
2
3
*
5
6
7
a
9
10
1
2
3
•• -it -.-
rCe
TYP
4
2
2
4
1
1
1
1
1
4
4
2
1
1
1
1
2
2
2
2
2
2
1
1
1
rr>
i
7
7
I
4
4
4
*
*
2
2
6
4
4
4
4
7
7
.7
7
7
7
4
4
4
5«
0
0
0
0
1
1
1
1
1
0
0
0
1
1
1
1
0
0
6
0
0
0
2
2
1
. , s ._ ,1 r
SLT
HTG
0
0
0
0
3
3
3
3
2
0
0
0
3
3
3
3
0
0
0
0
0
0
3
3
3
>. I!.
TOP
c/o
0
0
0
0
1
1
1
1
1
0
0
.0
1
1
1
1
0
0
0
0
0
0
2
2
2
<;ii!
CHG
0
0
0
0
2
2
2
2
2
0
2
2
2
2
0
0
0
0
0
0
2
2
2
G4S
T-0
0
0
0
0
2
2
2
2
2
0
2
2
2
2
0
0
0
0
0
0
8
8
8
•" ' '_!>
AT r
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
CMC-
DR
0
0
0
0
1
1
1
1
1
0
.0
0
1
1
1
1
0
0
0
0
0
0
1
1
1
ri.
IN
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
r>.-
EN
0
0
0
0
0
0
0
0
0
0
,0
0
1
1
1
1
0
0
0
0
0.
0
0
0
0
FC£
USE
1
3
3
3
1
1
1
1
1
3
3
3
1
1
1
1
2
2
2
2
2
2
1
1
1 -
rCE HLO ML I
OIA CAP RAT
60 3 1
72 33 00
72 33 00
67 6 00
102 000 50
102 000 50
102 000 50
102 000 50
102 000 50
40
40
000 40
96 000 40
96 000 40
96 000 40
108 000 50
000 26 00
000 26 00
.OQO 26 00
000 26 00
000 26 00
000 54 00
96 000 30
96 000 30
96 000 30
Mf P«
UT UT
8 00
00 16
01 60
00 16
16 16
16 16
46 16
16 16
00 16
00 16
00 16
00 16
00 16
00 16
16 16
16 16
16 16
JT VOLUH
00 00000
00 00000
00 00000
00 00000
22500
22500
22500
22500
22500
00000
00000
00000
17500
17500
17500
17500
24 00000
24 00000
24 00000
24 00000
24 00000
24 00000
00 15000
00 15000
00 15000
PRES
00
00
00
00
00
00
00
80
80
80
96
00
00
00
00
00
00
30
30
30
7 «»»•••
TEMP
0000
0000
0000
0000
1000
1000
1000
1000
1000
0000
0000
0000
1100
1100
1100
1100
0000
0000
0000
0000
0000
0000
700
700
900
SJ^-:
CM DR
00
00
00
00
00
00
00
00
00
00
£00
00
00
88
88
88
r' "
Oft
00
00
00
00
00
00
00
51
51
51
57
00
00
00
00
00
00
30
30
39
PRF
0
0
0
0
0
0
0
0
0
0
0
0
0
0
4
4
4
SIZE
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
a; '
LUC
0
0
0
0
0
•o
0
0
0
0
0
0
0
0
0
0
-o
0
0
0
0
0
0
0
0
Oi i
AFT
000
000
000
000
000
000
:ooo
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
3PL*
1100
1100
1100
1600
0000
0000
-.0000
ooOO
0000
0000
0000
0000
0000
i
0000
0000
0000
'• r
h. •
SY
1
2
3
4
1
2
3
0
0
0
0
0
0
1
2
3
-------
FURNACE DAM
PASE
11
****»*****FURNACE CLASSIFICATION*********
FOKY CO
NO. T»
0072 10
0072 10
0072 10
0072 10
0072 10
0072 10
0072 10
0073 10
0073 10
0074 10
0075 10
0076 10
0076 10
0076 10
0076 10
0077 10
0077 10
0077 10
0077 10
0078 10
0080 10
0081 10
0082 10
0082 10
0083 10
FCE
NO
4
5
6
7
a
9
1J
1
2
1
1
1
2
3
*
1
2
3
4
1
1
1
1
2
1
FCE
TYP
1
1
1
4
4
4
4
1
1
1
4
1
1
1
1
1
1
4
1
1
1
I
LM
TVP
4
4
4
1
1
1
1
4
4
1
1
1
1
1
1
1
2
1
1
1
8LT
DES
1
3
3
0
0
0
0
1
1
0
0
0
0
1
1
1
1
0
3
3
3
BLT
HTG
3
1
1
0
0
0
0
3
3
0
3
3
3
3
0
1
1
1
TOP
c/o
2
2
2
0
0
0
0
1
I
2
0
0
0
0
1
1
I
1
0
1
2
2
7.
CHG
2
2
2
0
0
0
1
2
2
2
1
0
0
0
2
2
2
2
1
2
2
2
2
GAS
T-0
8
a
a
0
0
0
3
1
1
8
3
0
0
0
1
1
1
1
4
1
B
8
a
AFT
0
0
0
0
0
0
0
2
2
0
0
0
0
2
2
2
2
0
0
0
0
CHG
OR
1
1
1
0
0
0
0
1
1
1
0
2
0
0
0
1
1
1
1
0
1
1
1
1
FL OX
IN EN
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
FCE
USE
1
1
3
3
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
FCE
DIA
96
92
84
105
105
105
178
102
102
48
108
36
000
000
000
48
48
78
78
36
68
*8
42
HLO MLT
CAP RAT
000 30
000 24
000 21
15 00
15 00
15 00
65 00
000 45
000 45
000 10
8 4
000 3
1
I
1
000 10
000 10
000 20
000 20
000 22
4
000 4
000 20
000 20
000 8
NT PR OT ******BLAST****
UT UT UT VOLUM PRES TEMP
16 16 00 15000
16 16 00 12000
16 16 00 12000
00 16 00000
00 lf> 00000
00 16 00000
L3 16 00000
18000
18000
4000
00000
5600
00000
00000
00000
17500
17500
00000
2200
5000
30 900
30
30
00 0000
00 0000
30 0000
<» _H.-i0
1200
1200
00 0000
00 0000
00 0000
00 0000
1000
1000
1000
1000
00 0000
SIZE HT CHG AFT AFT
CH DR OR PRE SIZE LDC
88
88
88
00
00
00
00
15
00
33
00
00
00
00
12
22
39 4 0000 0
30 4 0000 0
30 4 0000 0
00 0 0000 0
00 0 0000 0
00 0 0000 0
00 4 0000 0
3000
3000
00 0000 0
00 0000 0
00 0000 0
00 0000 0
00 0000 0
0000 0
0000 0
0000 0
01 S POUR
AFT SPLY
000 0000
000 0000
000 0000
000 3500
000 3500
000 6500
000 2000
0000
0000
0000
000 5000
0000
000
000
000
0000
0000
0000
0000
0000
000
000 0000
000 0000
000 0000
0000
CTL
SYS
4
5
6
7
1
1
1
1
1
1
1
2
2
1
1
1
-------
FURNACE DATA
PASE
12
******»»**FU*NA:E CLASS IF ICAT ION«*»*»*•**
FORY CD
NO. IV
0083 10
OC8-. 10
0085 10
0086 10
0087 10
0088 10
0088 10
0089 10
0090 10
0090 10
0090 10
0090 10
0090 10
0090 10
0091 10
0091 10
0091 10
0091 10
0091 10
0091 10
0092 10
0092 10
0092 10
0092 10
0093 10
FCE
N3
2
1
1
1
1
1
2
1
1
2
3
4
5
6
1
2
3
4
5
6
1
2
4
5
1
FCE
TVP
1
1
1
1
1
I
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
3
3
1
LIN
TVP
I
4
1
I
1
1
1
1
I
1
7
7
1
1
1
1
1
1
1
1
1
BIT
DES
1
2
3
3
3
3
1
2
2
2
2
0
0
2
2
2
2
2
2
0
0
2
BIT
HTG
3
3
1
1
I
2
3
3
3
3
0
0
2
2
2
2
2
2
5
5
3
TOP
C/0
1
1
2
0
1
2
2
2
1
I
1
I
0
0
1
1
1
1
1
1
1
0
0
2
CHG
2
2
2
0
2
2
2
2
2
2
2
2
0
0
2
2
2
2
2
2
2
0
0
2
GAS
T-0
1
8
0
1
8
8
8
1
1
1
1
0
0
1
1
1
1
1
I
0
0
8
AFT
2
0
0
0
3
3
3
3
0
0
1
1
I
1
1
1
0
0
2
CHG FL ox
OR IN EN
1
1 0 0
1 0 0
0
1
1
I
1
1
1
1
1
0
0
2
2
2
2
2
2
0
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
FCE FCE HLD HLT
USE OIA CAP RAT
1 42 000 8
1 96 000 35
1 84 000 24
1
I
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
000 3
48 000 8
64 000 17
64 000 17
000 3
72 000 25
72 300 25
72 000 25
72 000 25
00
00
54 000 22
54 000 22
54 000 22
54 000 22
54 000 22
54 000 22
66 000 15
000 15
000 22
000 22
72 000 22
HT
UT
16
3
16
16
16
16
00
00
16
16
16
16
16
1.6
8
PR OT ******BLAST**»*
UT UT VOLUM PRES TEMP
5000
12000 1000
8000 500
00000
2 00 4250
7500
7500
13600
13600
13600
13600
00 24 00000
00 24 00000
16 10800
16 10800
16 10800
16 10800
16 10800
16 10800
7500
00000
00000
00 00 12000
00
32
22
22
22
22
00
00
32
32
32
32
32
32
00
00
16
0000
400
400
400
400
0000
0000
350
350
350
350
350
350
3000
0000
730
SIZE HT
CH OR OR
22
83
52
00
31
72
72
72
72
72
72
00
00
57
57
57
57
57
67
50
00
00
93
00
35
35
35
35
00
00
37
37
37
37
37
37
00
00
32
CHG AFT
PRE SUE
0 3500
0000
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0000
0000
80
80
80
80
0000
0000
1000
1000
1000
1000
1000
1000
0000
0000
6000
AFT OIS POWR
LOC AFT SPLV
0000
0000
0 000 0000
0
0
2
0
0
0
0
0
2
2
2
2
2
2
0
0
I
000
000 0000
0000
0300
0000
660 0000
660 0000
660 0000
660 0000
000 600
000 720
648 0000
648 0000
648 0000
643 0000
648 0000
643 0000
0000 '
0300
000
000 3350
0300
CTL
SYS
2
I
1
1
2
1
1
1
2
2
1
1
2
2
3
3
1
I
-------
FURNACE OAT*
PAGE
***«•*»»**FURNACE CLASSIFICATION*********
FDRY
NO.
0093
0093
0093
0094
0094
0094
0095
0095
0095
0095
0096
0097
0098
0098
0098
0098
0098
0099
0099
0099
0100
0101
0101
0102
0103
CD FCE
TY NO
13
15
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
2
3
4
1
2
3
1
2
3
4
1
1
I
2
3
4
5
1
2
3
1
1
2
1
1
FCE
TYP
1
3
3
1
1
4
1
1
1
1
1
1
1
1
4
3
3
1
1
2
6
1
1
1
1
LH
TYP
1
4
4
1
1
I
1
1
1
1
4
4
1
1
1
4
4
0
2
2
BLT
DES
z
0
0
I
1
3
3
3
3
3
3
1
1
0
0
3
1
I
0
0
BLT
HTC
3
0
0
3
3
0
1
1
1
1
1
3
3
0
5
5
3
3
0
0
TOP
C/0
2
0
0
1
1
0
1
1
1
1
1
1
0
0
0
1
1
0
0
1
1
CHG
2
0
0
2
2
1
2
2
2
2
2
2
2
2
0
0
0
2
2
0
0
2
2
GAS
T-0
3
0
0
2
2
4
1
1
1
1
1
1
0
0
2
2
0
0
1
AFT
2
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
CHG
OR
I
0
0
1
1
0
1
1
2
1
1
1
0
0
0
I
1
0
0
FL UX
IN EN
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
FCE
USE
1
3
3
1
1
1
1
1
I
1
I
1
1
1
2
1
I
1
1
3
1
1
1
I
1
FCE
OIA
72
000
000
112
112
96
102
102
102
102
102
28
102
102
240
000
000
54
54
000
000
60
60
72
HLO
CAP
000
14
14
000
000
8
000
000
000
000
000
000
000
000
60
23
23
000
000
20
80
000
000
000
000
MIT
RAT
22
00
00
30
30
4
25
25
25
25
15
.4
40
40
12
12
14
14
10
10
MT PR OT ******BLAST***»
UT UT UT VOLUM PRES TEHP
8 00 00 12000
00 00 8 00000
00 00 8 00000
17 17 12000
17 17 12000
9 8 00000
13000
13000
2700
1725
20000
20000
00000
00000
00000
20 6200
20 6200
00000
00000
8700
8700
4000
16
00
00
30
30
00
00
00
00
64
64
00
00
730
0000
0000
900
900
0000
800
800
0000
0000
0000
1000
1000
0000
0000
SIZE HT CHG AFT
CH OR OR PRE SIZE
93
00
00
99
99
00
55
55
8
3
90
90
00
00
00
69
69
00
00
14
14
32 0 6000
00 0 0000
00 0 0000
43 0000
43 0000
00 0 0000
0 3000
0 0000
0000
00 0 0000
00 0000
00 0000
0 0000
0 0000
00 0 0000
00 0000
AFT
LOC
I
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
OIS
AFT
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
POWR
SPLY
0000
1825
1825
0000
0000
3000
0000
0000
0000
0000
0000
0000
0000
0000
8000
3200
3200
0000
0000
0000
0000
0000
0000
CTl
SYS
2
0
0
1
1
2
1
1
1
1
1
1
I
I
!
1
I
1
-------
FURNACE DATA
PAGE
******«»»«FURNACE CLASSIFICATION**»******
FDRV CD FCE
NO. TV NO
0103 10 2
0103 10 3
0103 10
0104 10
0105 10
0105 10
0105 10
0105 10
0106 10
0107 10
o'toa 10
0108 10
0103 10
0109 10
0109 10
0109 10
0109 10
0110 10
0110 10
0110 10
0110 10
0111 10
0112 10
0113 10
0113 10
4
1
1
I
3
4
1
1
1
I
3
1
2
3
4
1
2
3
4
1
1
1
2
FCE LIY BLT
TYP TYP OES
1
4 I 0
4 1 0
I 1 3
1
1
3 0
3 0
1 1
1 1 3
1 2
1 1
3 0
1
1
1
4 1 0
1 1 3
113
60 0
600
1
1 1
1 1 2
1 1 2
BLT TOP
HTG C/0
0 0
0 0
1 1
1
I
0
0
2
1 2
1
1
0
I
I
1
0 0
1 I
1 1
0 0
0 0
2
3 2
3 2
CHS GAS
T-0
2 1
2
2
0 0
0 0
2 8
2 8
2
2
0 0
2
2
2
2 1
2 1
0 0
0 0
2 8
2 8
2 8
AFT CHG FL OX
OR IN EN
0000
0000
2200
0 000
0 000
1
0 100
1
0 000
1
1
1
0000
0 100
0 100
0000
0000
1
0101
0101
FCE FCE HLO
USE OIA CAP
I 000
3
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
I
1
.6
54 000
54 000
54 000
000 .5
000 .5
42 000
48 4
000
000
000
36 000
36 000
36 000
36
84 000
84 000
000 50
000 50
000
54 000
36 000
36 000
HLT MT
RAT UT
12
9 3
8
8
a
8 4
8
7
5
5
5
5
5
18
18
00 00
00 00
12
10
10 10
10 10
PR OT ******BLAST**«* SIZE HT CHG AFT AFT OIS POUR
UT UT VOLUM PRES TEMP CH OR OR PRE SIZE LOC AFT SPLY
0000
00000 00 0000 00 00 0000 0 000
00000 00
4700 20
6000
00000 00
00000 00
4 00 7000 21
3800
3700
00000 00
4000
4000
4000
00000 00
9500
9500
00000 00
00000 00
4600
9 3950 16
9 3950 16
0000 00
0000 00
0000 00
5
27
10
10
0000 00
12
12
12
0000 00
0000 00
0000 00
55
600 18
600 18
00 0000 0 000
35 2 360 0000
0000
0000
00 0000 0 000
00 0000 0 000
0000
8 0 0000 0 000 0000
0000
0000
00 0000 0 000
0000
0000
0000
00 0000 0 000
0000 0 000 0300
0000 0 000 0000
00 0 0000 0 000
00 0 0000 0 000
0000
0000
2T 0 0000 0 000 0000
27 0 0000 0 000 0000
CTt
SYS
I
1
1
1
1
1
2
2
3
1
1
1
1
1
2
-------
FURNACE DATA
PASE
15
»*»•*•*»»»FURNACE CLASSIFICATION**»•***•*
FDRV CD FCE
NU. TY N3
0113 10
0'. U 10
0114 10
0114 10
0115 10
0115 10
0115 10
0115 10
0116 10
0116 10
0117 10
0117 10
0117 10
0117 10
0118 10
0118 10
0118 10
0118 10
0118 10
0119 10
0119 10
0120 10
0120 10
0120 10
0120 10
3
4
1
2
1
2
3
4
1
2
1
2
3
4
1
2
3
4
5
1
2
1
2
3
4
FCE
r YP
6
2
1
1
1
2
2
1
1
1
1
1
6
6
1
1
1
1
1
1
1
1
1
6
7
'.IM
TYf»
0
6
1
1
2
2
2
2
4
4
1
1
0
0
4
4
1
1
4
1
1
0
BIT
OES
0
0
2
2
2
2
0
0
2
2
2
2
2
3
3
0
3
BLT
HTG
0
0
3
3
3
3
0
0
3
3
3
i
3
1
1
0
TOP
C/0
0
0
1
1
2
2
1
1
0
0
2
2
2
2
2
1
1
1
0
0
CHG
0
0
2
2
2
2
2
2
0
0
2
2
2
2
2
2
2
2
0
0
GAS
T-0
0
0
I
1
8
8
1
1
0
0
8
8
8
8
8
1
1
0
AFT
0
0
0
0
3
3
2
2
0
0
0
0
0
0
0
CHG FL
OR IN
0
0
1
1
1
1
1
1
1
1
0
0
1
I
I
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
;
0*
EN
0
0
0
0
0
0
0
0
0
J
3
0
1
J
J
0
FCE
USE
3
2
1
1
1
1
1
1
1
1
1
1
3
3
1
1
1
1
1
1
1
1
1
3
FCE HLD
DIA CAP
000 12
000 25
60 000
60 000
36 000
36 000
000
000
50 000
50 000
000
000
000 34
000 34
54 000
61 000
66 000
66 000
60 000
000
78 000
32 000
32 000
000 6
.5
MLT MT PR OT ******BL AST****
RAT UT UT UT VOLUM PRES TEMP
00
00 10 18
18
18
5
5
9 9
9 9
32
32
00 00
00 00
12
14
16
16
14
7
10
6
6
00 00
00000 00
00000 00
18500
18500
2800
2800
4400
4400
00000 00
00000 00
6000
6500
8000
8000
6500
00000 00
00000 00
0000
0000
750
750
750
750
0000
0000
0000
0000
SIZE HT CHG AFT AFT DIS POUR
CH OR OR PRE SJZE LOC AFT SPLY
00
00
80
80
31
31
54
54
00
00
48
46
61
61
55
00
00
00 0 0000 0 000 0300
00 0 0000 0 000 600
0 0000 0 000 0000
0 0000 0 000 0000
0000
0000
0000
0000
30 0 1050 1 0000
30 0 1050 1 0000
0000
0000
00 0 0000 0 000
00 0 0000 0 000
0000 0 000 0000
0000 0 000 0000
0000
0000
0000 0 000 0000
0000
0000'
0000
0000
00 0 0000 0 000
00 0000 0 000
CTL
SYS
0
0
1
1
1
2
1
2
1
I
2
2
3
1
1
1
-------
FURNACE DATA
PACE
16
**********FURNACE CLASSIFICATION*********
FORT CO FCE
NO. TY N3
0121 10
0121 10
0121 10
0121 10
0122 10
0123 10
0124 10
0125 10
0425 10
0125 10
0125 10
0125 10
0125 10
0126 10
0126 10
0126 10
0126 10
0126 10
0127 10
0128 10
0129 10
0130 10
0132 10
0132 10
0133 10
1
2
3
4
1
1
1
1
2
3
4
5
6
1
2
3
4
5
1
1
1
1
1
2
1
FCE
TYP
1
1
1
4
1
1
1
1
1
1
1
1
1
1
3
3
3
3
1
1
1
1
1
1
1
UN air
TYJ DES
1 3
1 3
I 3
1 3
1 3
1
2
4 1
4 1
4 1
0
0
0
0
1
1
2
1
1
1 3
BLT TOP
HTG C/0
1 2
I 2
1 2
0 0
1 1
1
1
3 1
3 I
3 1
0 0
0 0
0 0
0; 0
I
I
1
1
1
1
1 2
CHG GAS
T-0
2 8
2 8
2 8
2 1
2
2
2 1
2 1
2 1
0 0
0 0
0 0
0 0
2
2
2
2 1
2 1
2 1
2 8
AFT CHG FL OX
OR IN EN
1 0 0
1 0 0
100
0000
1 100
1
1
2 100
2 100
0 100
0000
0 000
0 000
0 000
1
1
2
1
1
0 100
FCE FCE HLO
USE DIA CAP
I
1
I
I
1
I
1
1
1
1
I
1
1
2
2
2
2
1
1
1
1
1
1
I
72 000
60 000
000
48 000
36 000
36 000
108 000
108 000
000
000
000
000
102 000
000 23
000 23
000 23
000 23
40 000
36 000
000
45 000
78 000
60 000
42 000
MCT Mr PR OT ******BLAST***» SIZE HT CHG AFT AFT ois POWR
RAT UT UT UT V3LUM P3ES TEMP CH OR OR PRE SIZE IOC AFT SPLY
12
12
6
3
8
6
4
35
35
20
20
12
40
6
5
9
9
12
12
7
7500
7500
00000 00
3800
9 15500
9 15500
17 00 20000 42
00 00 17 00000 00
00 00 17 00000 00
00 00 17 00000 00
00 00 17 00000 00
1600
4000
8 7500
8 7500
53
45
3000 00
22
7
8
1000 92
1000 92
1200 99
0000 00
0000 00
0000 00
0000 00
8
5
30
30
35
35
0000
0000
0000
00 0000 0 000
1 0000
0000
0000
4 5250 I 484 w«v>0
4 5250 1 484 0000
0000
0000
0000
0000
0 0000 0 000 0000
00 0 0000 0 000 1500
00 0 0000 0 000 1500
00 0 0000 0 000 1500
00 0 0000 0 000 1500
0000
0000
0000 '
0000
0000
0000
0000 0 000 0000
CTL
SYS
1
2
1
1
I
1
1
1
0
0
0
0
1
1
1
1
1
1
-------
FURNACE DATA
PA3E
17
******»»»»FURNACE CLASSIFICATION*********
FORY CD FCE
NO. TY NO
0133 10 2
Oil3 ID
0134 10
0134 10
0135 10
0136 10
0136 10
0136 10
0137 10
0137 10
0137 10
0137 10
0138 10
0138 13
0139 10
0140 10
QUO 10
0141 10
0141 10
0141 10
0141 10
0141 10
0141 10
0141 10
0142 10
3
1
2
1
1
2
3
1
2
3
4
1
2
1
1
2
1
2
3
4
5
6
7
1
FCE
TYP
1
7
1
1
1
1
1
6
1
1
1
1
1
1
1
1
1
1
1
4
3
3
3
3
1
in
TY?
1
0
4
4
2
1
1
0
1
1
1
1
1
1
1
1
I
1
BLT
OES
3
0
1
1
2
2
0
1
1
1
1
3
3
3
3
1
1
0
0
3
0
0
BLT
HTG
1
0
3
3
3
3
0
3
3
3
3
1
1
1
1
0
TOP
C/0
2
0
1
1
1
1
1
0
2
2
1
1
1
1
1
I
0
0
0
0
0
CMC GAS
T-0
2 8
0 0
2 1
2 1
2
2 1
2 1
0
2 a
2 8
2
2
2 1
2 1
2
2
0 0
0 0
0 0
0 0
AFT CHG FL
OR IN
0 I 0
000
1 0
1 0
0 1 0
0 1 0
000
1 0
1 0
1 (
1
1
1
0 0 '
0 0
0 0
0 0
0 0
ox
EN
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
FCE
USE
I
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
FCE
OIA
42
84
84
52
63
63
300
72
72
60
60
54
54
54
54
000
000
000
000
HLD
CAP
000
.5
000
000
000
000
000
30
000
000
000
000
000
000
000
000
000
000
000
000
MLT
RAT
7
60
60
4
16
16
14
18
18
25
25
10
6
16
7
7
12
12
5
MT PR OT ******BLAST**»*
UT UT UT VOLUH PHES TEHP
00000
16 15000
16 15000
3000
18 00 5500
18 00 5500
00 16 00 00000
10700
10700
3600
6400
5300
5300
6000
6000
00000
00000
00000
oooco
00000
00 0000
1000
1000
14 700
14 700
00 3000
1000
1000
1000
1000
00 0000
00 0000
00 0000
00 0000
00 0000
SIZE HT CHG AFT AFT OlS P3WR
CH OR OR PRE SIZE LOC AFT SPLY
0000 0 000 0000
00
45
45
00
69
69
17
50
37
37
40
40
00
00
00
00
00
00 0000 0 000
0000
0000
0000
0 0000 0 000 0000
0 0000 0 000 0000
00 0 3000 0 000 0000
0000
0000
0000
0000
0300
0000
0000
0000
0000
0000
0000
00 3000 0 030
00 0000 0 000
00 0000 0 000
00 0000 0 000
00 0000 0 000
0000
CTL
SYS
1
1
1
1
I
0
1
2
1
1
1
1
I
1
1
-------
FURNACE DATA
PAGE
18
CLASS IFJCAT ION»********
FORY CD FCE
NO. TV NO
0143 10 1
0:44 10 i
0145 10
0146 10
0146 10
0147 10
0147 10
0147 10
0147 10
0147 10
0148 10
0148 10
0149 10
0149 10
0150 10
0150 10
0151 10
0152 10
0152 10
0153 10
0153 10
0153 10
0153 10
0153 10
0153 10
1
1
2
1
2
3
4
5
1
2
1
2
1
2
1
1
2
1
2
3
t
5
6
FCE
TYP
i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
6
6
3
3
LM BIT
TYP OES
3
1
1 3
1 3
1
1
1
1
1
1
1
1 2
1 2
4 I
I 3
1 3
1 2
1 2
0 0
0 3
0
0
BLT TOP
HTG C/0
I
1 I
I
1 1
1 1
2
2
2
2
2
2 1
2 2
3 1
1 1
1 1
3 2
3 2
0 0
0 0
0
0
CHG
2
2
2
2
2
1
1
1
1
1
1
1
2
2
2
2
2
0
0
0
0
GAS
T-0
1
1
1
8
8
8
8
a
2
2
1
1
1
8
8
0
0
0
0
AFT
0
0
0
0
0
0
0
3
3
0
0
0
0
0
0
0
CHG FL OX
OR IN EN
1
2
2
0
0
0
0
0
2
2
1
1
1
I
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
0
0
0
0
0
1
1
0
0
0
0
0
0
0
0
0
FCE
USE
1
1
1
1
1
I
1
1
1
1
1
1
1
1
1
1
1
1
I
1
1
3
3
FCE HLD HUT MT P* OT ******BLAST***» SIZE HT CHG AFT
01 A CAP RAT UT UT UT VOLUM PRES TEMP CH OR OR PRE SIZE
000 8
43 000 9 4800 8
48 000 5 4200 21
108 000 55 16 00 00 16500 40 91
108 000 55 16 00 00 16500 40 91
70 000 20
70 000 20
70 000 55
70 000 55
70 000 55
000 35
000 35
000 13
000 13
78 000 38 9 11000 40 700
78 000 38 9 11000 40 700
96 000 25 12500 24 1000 60
60 000 22 10500
60 000 22 10500
SO 000 22 700
50 000 22 700
000 35 00000 00 0000 00
000 35 00000 00 0000 00
000 9 3 00000 00 0000 00
000 9 3 00000 00 0000 00
38 0 0000
38 0 0000
0000
0000
0000
0000
0000
21 0 4250
21 0 4250
0000
0000
0000
00 0000
00 0000
00 3000
00 0000
AFT OIS POUR
LOC AFT SPLY
0000
0000
0
0
0
0
0
0
0
1
1
0
0
0
0
0
0
0
0000
000 0000
000 0000
000 0000
000 0000
000 0000
000 0000
000 0000
0000
0000
0000
0000
150 0000
150 0000
000 0000
0000
0000
000 0000
000 0000
000
000
000 1600
000 1600
CTL
SYS
1
1
1
1
1
1
1
1
1
1
-------
FURNACE DATA
PAGE
19
*******»**FURNACE CLASSIFICATION*********
FDRY CO FCE
NO. TV NO
015* 10 1
G. 54 10 2
015* 10 3
0155 10
0156 10
0157 10
0158 10
0159 10
0160 10
0160 10
0160 10
0160 10
0160 10
0160 10
0160 10
0160 10
0160 10
0161 10
0161 10
0161 10
0162 10
0163 10
0163 10
0165 13
0165 10
1
1
1
1
1
1
2
3
4
5
6
7
8
9
1
2
3
1
1
2
1
2
FCE
TYP
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
1
1
7
1
1
1
4
4
LIV
TV?
1
1
1
1
1
1
4
4
1
1
1
1
5
5
5
1
1
1
1
1
BLT
3ES
3
3
3
2
3
3
3
3
1
0
3
0
0
0
3
3
J
0
BLT
HTG
1
1
1
3
1
1
1
1
0
0
0
1
1
0
0
TOP
c/o
2
2
2
2
1
2
1
1
1
2
2
2
2
0
0
0
1
0
1
1
1
0
0
CHG
2
2
2
2
2
2
2
2
2
2
2
2
2
0
0
0
2
0
2
2
2
1
1
GAS
T-0
8
8
8
8
8
1
1
8
8
a
8
0
0
0
1
1
3
3
AFT
0
0
0
2
0
0
0
0
0
0
0
0
0
0
0
0
0
CHG FL OX
OR IN EN
100
100
1 0 0
1
2
1
1
1
1
1
1
1
0
0
0
0
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
FCE
USE
1
1
1
1
1
1
1
1
1
1
1
1
1
I
2
2
2
1
1
1
1
1
1
1
FCE HLO MLT
OIA CAP RAT
48 000 6
60 000 15
60 000
000 5
66 000 23
37 000 4
88 000 21
42 000 6
90 000 34
90 000 34
68 000 23
68 000 23
68 000 23
68 000 23
000 35 00
000 30 00
000 25 00
54 000 4
54 000 4
.5
000
54 000 15
54 000 15
96 5
96 5
MT PR OT ******BLAST**»* ilZE HT CHG AFT AFT OIS P3WR
UT UT UT V3LUH P»ES TEHP CH OR OR PRE SIZE LOC AFT SPtY
0000 0 000 0000
0000 0 000 0000
0000 0 000 0000
2700
15000
3400
16 16 00 14000 54
16 16 00 14000 54
16 16 00 35
16 16 00 35
16 16 00 00000 35
16 16 00 00000 35
00 16 24 00000 00
00 16 24 00000 00
00 16 24 00000 00
6000
00000 00
3500
9000
9000
8 00000 00
a ooooo oo
750
20
60
14
99
99
60
60
0000 60
0000 60
0000 00
0000 00
0000 00
0000 00
0000 00
0000 00
0000
0000
0000
0000
0000
0 0000 0 000 0000
0 0000 0 000 0000
0 0000 0 000 0000
0 0000 0 000 0000
0 0000 0 000 0000
0 0000 0 000 0000
00 0 0000 0 000 600
00 0 0000 0 000 600
00 0 0000 0 000 600
0000
0000
00 0000 0 000
0000 0 000 0000
0000
0000
00 0 3000 0 000 4500
00 0 0000 0 000 4500
CTL
SYS
1
1
1
I
1
1
0
0
0
0
0
0
0
1
1
1
1
I
1
-------
FJRNACE DATA
PAGE 20
**«***»*«*FURNACE CLASSIFICATION*********
FDRV CO FCE FCE LH BLT SLT TOP CHG GAS AFT CMG FL OX FCE FCE MLO MLT HT PR OT ***»**BLAST**** SUE HT CHG AFT AFT OIS P9MR CTL
IN EN USE OlA CAP RAT UT UT UT VOLUM PRES TEMP CH OR OR PRE. SIZE LOC AFT SPLY SYS
B 16 00000 00 0000 00
8 16 00000 00 0000 00
00000 00 0000 00
10000 550 40
10000 550 40
6 00 00 3500 35 90 0000 0 QOO 0000 1
NO.
0165
0165
0166
0167
0167
0168
TV
10
10
10
10
10
10
NO
3
4
1
1
2
1
TYP
2
2
6
1
1
1
TYP
6
6
6
i
i
i
DES
0
0
0
2
2
3
HTG
0
0
0
3
3
I
C/0
0
0
0
2
2
1
0
0
0
2
2
2
T-0
0
0
0
8
8
1
0
0
1
1
0
OR
0
0
0
1
1
1
IN
0
0
0
0
0
0
EN
0
0
0
0
0
0
USE
2
2
1
1
1
1
OIA CAP RA
000 20 00
000 20 00
48 10
70 000 22
70 000 22
40 000 7
00
00
00
0 0000 0
0 0000 0
1
1
000 500
000 500
0000
0000 *
0000
0
0
I
1
2
-------
FORY
NO.
0001
0001
0001
0001
0002
0002
0004
0004
0004
0004
0005
0007
0008
0009
0009
0011
0012
0012
0012
0012
0012
0013
0014
0014
0015
CO FCE
Tf N3
20 1
20 2
iO 3
20 4
20 1
20
21
21
21
21
20
20
20
20
20
20
20
22
20
22
20
20
20
20
20
2
2
3
4
5
1
1
I
1
2
1
1
2
3
4
5
1
I
2
1
TOTAL
1TL CH
6000
39600
39600
39600
2500
4000
22000
22000
7000
5400
2500
1500
200
2000
2000
6300
21600
21600
21SOO
500
1500
8360
8360
1300
700
OOOOO
00300
60
OOOOO
OOOOO
PIG
IkON
0000
0000
0000
0000
0000
0000
1000
700
900
600
0000
687
687
PURCH
CST I
0000
0000
0000
0000
1500
2200
4500
0000
0000
0000
0000
1250
1250
PURCH BRIO
STEEL
OOOOO 000
16000 000
16000
16000
500 000
300 000
500 000
4000 000
800 800
900 000
140 000
OOOOO *63
OOOOO *63
PUN/
TURN
0000
2000
2000
2000
0000
0000
0000
000(
OOOi
000'
000
000
000
CING OPERATION
OOLO SOOA FLOU OTH
MITE ASH SPAR ER
l 000 00 00 00
200 00 00 00
200
0 000 00 00 00
5 000 00 00 00
:0 000 00 00 00
0 000 00 00 00
J 000 00 00 00
i 000 00 30 00
' 000 00 00 00
CARS FE-
COKE SIL
000
000
000
000
000
000
000 000
450 500
450 500
450 500
000
000 000
000 000
000 150
000 150
000
000 000
000 000
000 35
000 45
000 12
000
000
000
000
HN AODIT
T IBS
00 0 000
00 0 000
00 0 000
00 0 000
00 0 000
00 0 000
20 0 000
00 0 000
15 0 000
00 2 550
00 1 1
ME/CO SUL 0 Q C S LtTE-UP CO C02
RATIO CON A S M P TIME METrt
8
8
7
7
9
9
00 00 0 4 0 0 000 0 00 00
00 00 0 2 6 0 000 0 00 00
00 00 0 2 6 0 000 0 00 00
00 00 0 2 6 0 000 0 00 00
8
9 .6 0 3 2 0 30 2
7 .6 0320100 2
10 32 1
10 32 I
8
12 .6 2 2 3 3 120 5
9 .6 2133120 6
8 .60133 120 6
5 .6 0 1 3 3 120 6
6 .60133 120 C>
18
7 .7
7 .7
12
N2
00
00
00
00
10 14
16 12
18 It
65
68
63
HM
M oa
O n
ZH
rrf
-------
MELTING OPERATION
PAGt
FU*Y CO
MU. TY
0016 iJ
0016 20
ooio .-:"•
0018 £")
0021 20
0021 J2
0021 20
0021 22
0022 20
0022 73
0022 20
00,22 20
00-25 20
0026 23
0026 23
0027 20
0029 20
0031 23
0031 20
0032 21
0033 23
'0033 20
0034 20
0035 23
0035 20
r T c
NT
1
2
1
2
1
1
2
i
1
2
3
4
1
1
2
1
I
1
2
1
1
2
1
1
2
TOTAL
1030
1300
2275
2275
2500
2500
2500
2500
4000
2000
2000
4000
3000
4000
4JOJ
1935
1800
1300
1E1ELT
SOO
iOO
1330
1000
1000
1330
1000
1330
400
200
200
1630
750
1300
1JUO
900
400
550
PIG
0000
0000
75
75
100
100
100
.100
0000
0000
0000
800
•62
1000
1000
0000
900
230
230
PUUH
CST I
0003
0000
'JO 00
0000
0000
0000
0000
0000
0000
1500
1500
0000
1050
2000
2000
0000
3600
200
200
PURCH
ST8EL
400
400
1200
1200
1400
1400
1400
1400
2000
300
300
1500
450
1135
4500
00000
00000
BKI'J
000
000
000
000
000
000
000
000
000
000
000
100
750
030
750
600
PUN/ LIM
TURN STN
0000 40
0000 40
0000
0000 120
0000 120
0000
0000
0000
0000
0000 125
0000 75
0000 75
0000 130
0000
80
80
0000 60
200
200 120
200 90
OOLO SODA
HI re ASH
030 00
000 00
000 00
030 00
000 00
000 00
000 00
000 00
125
000 00
000 00
030 5
000 00
000 00
FLGU OTH
SPAR ER
00 00
00 00
30 00
30 00
00 00
2 00
2 00
00 00
25
00 00
03 00
00 00
5 00
3 00
CARD
COKE
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
FF- MN AOOIT
SIL T LBS
000 00 3 2
000 00 3 2
000 00 0 000
000 3 5
000 00 0 000
000 3 5
000 00 0 300
12 0 000
12 3 000
0 000
000 00 0 300
000 00 0 000
65
40 4 0 000
40 2 0 000
HE/CO SUL
RATIO CON
10
10
6
6
10 .6
7 .6
10 .6
7 .6
00 00
00 00
00 00
00 00
6
8 1.
8 1.
7 .6
6
10
10
12 .6
7
7
8
8 .6
8 .6
0 0 C S
A S M P
0420
0420
0420
0420
0 1
0 1
0 1
0 I
3
0330
0330
22 0
0330
0
0
0120
0333
0333
LITE-UP CO C02 N2
TIME METH
20 6
20 6
20 6
20 6
00 00 00
00 00 00
00 00 00
00 00 00
16 3 78
120 1
120 1
30 2 8
60 6
60 1
5
5
-------
MELTING OPERATION
PAGE
FORY C) FCE TOTAL *E1ELT PIG PLWCH PURCH BRIO PUN/ LIM DOLO
NO. Tf N3 MTU CH IRON CST I STEEL TURN STN MITE
0035 20
0036 ZO
0037 20
0042 20
0043 20
0045 20
0045 20
0045 20
0045 20
0045 20
0045 20
0045 20
0045 20
0046 22
0046 22
0046 22
0046 22
0047 20
0047 20
0048 20
0049 20
0052 20
0052 20
0052 20
0052 20
3 1800 550 230 200 00000 600 200 90 000
1
1
1 4000 1200 0000 0000 800 0000 000 12
1 1500 430 475 500 00000 125 0000 80 000
1
2
3
4
5
6
7
8
1 30000 15300 0000 0000 15000 000 0000 000 000
2 30000 15300 0000 0000 15000 000 0000 000 000
3 30000 15000 0000 0000 15000 000 0000 000 000
4 30000 15300 0000 0000 15000 000 0000 000 000
1
2
1 32000 liOOO 0000 5000 10000 000 1000 000 000
1
1 4000 1S30 1600 800 00000 *75 0000 60 000
2 4003 IS30 1600 800 00000 *75 0000 60 000
3 4000 1SOO 1600 800 00000 *75 0000 60 000
4 4000 1400 1600 800 00000 *75 0000 60 000
SODA FLQU OTH CARB
ASH SPAR ER COKE
00 3 00 000
000
000
00 00 00 000
00 00 00 000
000
000
000
000
000
000
000
000
00 00 00 600
00 00 00 600
00 00 00 600
00 00 00 600
000
000
00 00 00 550
000
00 00 00 000
00 00 00 000
00 00 00 000
00 00 00 000
FE- MN AODIT ME/CO SUL DOCS LITE-UP CO C32 N2
SIL T LBS RATIO CON A S M P THE METH
40 2 0 000 8 .60333
6
6 90
136 4 0 000 8 0 3 5 0 90
6 00 0 000 6 0 3 2 0 60
9
9
9
9
9
9
9
9
000 00 0 000 00 00 430 000
000 00 0 000 00 00 430 000
000 00 0 000 00 00 430 000
000 00 0 000 00 00 430 000
10
10
250 25 00 00 330 000
3
000 00 0 000 10 .6 2 2 0 90
000 00 0 000 10 .622 0 90
000 00 0 000 10 .622 0 90
000 00 0 300 10 .622 0 90
5
1
2
1
0 00 OO 00
0 00 00 00
0 03 00 00
0 00 OO 00
0 00 00 00
2 12 14 74
? 12 14 74
2 12 1* 74
2
-------
MELTING OPERATION
PAGb
FOR* CO FCE
NO. Tf N3
0061 20
0062 20
0062 20
0065 20
0065 20
0066 20
0067 20
0067 20
• V*
0067 20
0070 20
00.7.0 20
0070 20
007,0 20
00 W 20
0072 20
0072 20
0072 20
0072 20
0072 20
0072 20
0074 20
-------
MELTING OPERATION
P»GE 5
FDRY
NO.
0084
0085
0087
0088
0088
0090
0090
0090
0090
0091
0091
0091
0091
0091
0091
0092
0093
0093
0093
0093
0093
0093
0093
0093
009*
CO FCE
Tf ND
20 1
20
20
20
20
20
20
20
20
20
20
20
20
20
20
21
20
22
20
22
20
22
20
22
20
1
1
1
2
1
2
3
4
1
2
3
4
S
&
1
1
1
2
2
3
3
it
4
1
TOTAL
MTL CH
4000
2953
1000
2000
4200
4200
4200
4200
4000
4000
4000
4000
4000
4000
5500
6000
5500
6000
00000
00000
00000
00000
6500
ilEIELT
00000
1330
450
00000
14*5
U95
1495
1495
1400
1400
1400
1400
1400
1400
1100
1200
1100
1200
00000
00300
00000
00300
1400
PIG
IRON
0000
900
275
*250
1200
1200
1200
1200
900
900
900
900
900
900
0000
0000
0000
0000
0000
0000
0000
0000
0000
PURCH
CST I
400
0000
0000
150
260
260
260
260
500
500
500
500
500
500
1650
0000
1650
0000
0000
0000
0000
0000
2500
PURCH
STEEL
3600
1050
275
1600
600
600
600
600
1000
1000
1000
1000
1000
1000
2750
4800
2750
4800
00000
00000
00000
00000
2600
BRIO
000
000
000
000
500
500
500
500
200
200
200
200
200
200
000
000
000
000
000
000
000
000
000
PUN/
TURN
0000
0000
0000
0000
*125
*125
•125
• 125
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
LIH
STN
300
120
26
70
125
125
125
125
110
110
no
110
110
110
70
90
70
90
000
000
000
000
000
OOLO
MITE
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
100
SODA
ASH
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
FLOU
SPAR
30
00
00
4
00
00
00
00
00
00
00
00
00
00
00
30
00
00
00
00
00
30
00
OTH
ER
00
00
00
00
00
00
00
00
00
00
00
00
00
00
5
00
5
13
8
13
8
00
CARB
COKE
000
000
000
000
000
000
000
000
000
000
000
000
000
300
000
000
000
000
000
000
000
000
000
300
000
FE-
SIL
150
50
5
a
000
000
000
000
26
26
26
26
26
26
75
100
75
100
000
000
000
000
35
HN AOOIT
T LBS
00 4 10
00 0
3 0
12 0
00 0
00 0
00 0
00 0
20 5
20 5
20 5
20 5
20 5
20 5
00 0
00 0
00 0
00 0
00 3
00 3
00 3
00 3
00 0
000
000
000
000
000
000
000
30
30
30
30
30
30
000
000
000
000
11
13
11
13
000
^E/CO SUL
RATIO CON
7 .6
11
8
8
a
11
11
u
11
11
11
11
11
11
11
9
8
18
8
8
00
00
00
00
9
.5
.6
.6
.6
.6
.6
.6
.6
.6
.6
.6
.6
.6
.6
.6
00
00
00
00
.6
D 0
A S
0 4
0 3
0 3
0 3
0 3
0 3
0 3
0 3
0 3
0 3
0 3
2 1
2 4
2 1
2 4
0 0
0 0
0 0
0 0
2 3
C S
M P
1 1
3 0
3 0
3 0
3 0
3 0
3 0
3 0
3 0
3 0
3 0
3 0
3 0
3 0
3 0
0 0
0 0
0 0
0 0
3 0
LITE-UP CO C02 N2
TIME METH
11 13 76
90
45
45
45
45
45
90
90
90
90
90
90
120
120
120
000
000
000
000
240
6
1
1
1
1
1
1
1
1
1
1
2
2
2
2
0
0
0
0
2
3 13 82
13
13
00 00 00
1
00 00 00
00 00 00
00 00 00
16 13 71
-------
MELTING OPERATION
D/\Gr
FORY CO FCE TOTAL
MO. Tf N3 MTL CH
0094 22
0094 20
0094 22
0094 20
0095 20
0095 20
0096 20
-..I*1
0097 23
ty-^
0098 20
•W*
0098 20
0099 20
009^9 20
0102 20
0104 20
0106 20
9107 20
0108 20
0108 20
0109 20
0109 20
0109 20
QUO 21
0110 21
0113 21
0113 21
1 5000
2 6500
2 5000
3 7200
1
2
1
1 800
1
2
1 1100
2 1100
1
1 2000
1
1 1200
1
2
1
2
3
1 2945
2 2945
1 1000
2 1000
*E1ELT PIG PURCH
IRON CST I
750 0000 0000
1400 0000 2500
750 0000 0000
1550 1550 0000
00300 400 0000
200 0000 700
200 0000 700
800 400 200
600 0000 0000
1800 0000 0000
1800 0000 0000
580 «80 0000
580 *80 0000
PURCH BRIO PUN/ LIM OOLO SODA FLOU OTH
STEEL TURN STN MITE ASH SPAR ER
4250 000 0000 000 80 00 00 00
2600 000 0000 000 100 00 00 00
4250 000 0000 000 80 00 00 00
4100 000 0000 000 000 00 00 00
CARB ft- MN AOOIT HE/CO SUL 0 0 C S L1TE-IJP CO C32 N2
400 000 0000
00000 200 0000 60 000 00 00 00
OOOOQ 200 0000 60 000 00 00 00
600
60 000 00 00 00
600 000 0000 12 .5
1145 000 0000 60 000 00 00 00
1145 000 0000 60 000 00 00 00
340 000 0000 20 000 .5 00 00
340 000 0000 20 000 .5 00 00
COKE SIL T LBS
000 40 00 0 000
000 35 00 0 000
000 40 00 0 000
000 00 0 000
000
000
000
000
000
000
000 000 00 0 000
000 000 00 0 000
000
000
000
000 840 000
000
000
000
000
000
000 55 00 6 4
000 55 00 S 4
000 .75 .3 7 .5
000 .75 .3 7 .5
RATIO CON A
6 .62
9.62
6.62
00 00 0
a
7
7
6 0
6 0
6.63
8
8 55 3
9
9
10
10
10
10
10
11 .70
11 .7 0
S M o TIME METH
230 240 2 16 13
3 3 0 240 2 16 13
2 3 0 240 2 16 13
030 000 0 00 00
3
3
330 2 32
330 2 32
3
420 2
4 20 1
3
3
4 1 0 60 2
4 1 0 60 2
71
71
71
00
80
80
-------
HELTING OPERATION
pact
FDRY C3 FCE TOTAL
NO. Tf NO 1TL ;H
0114 20
0114 20
01:5 20
0115 20
0116 20
0116 20
0122 20
0123 20
0124 20
0125 20
0125 20
0126 20
0126 22
0127 20
0128 20
0130 23
0132 20
0132 20
0136 23
0136 21
0136 23
0136 21
0137 20
0137 20
0141 20
1 2000
2 2000
1
2
1 1*30
2 1430
1 1280
1
1
1
2
1 10000
1 1 0000
1
1
1
1 1933
2 1933
1 2500
1 2500
2 2500
2 2500
1
2
1
-------
MELTING OPERATION
PAGI-:
FOR* C3 FCE
NO. TY N3
0141 20 2
0145 20
0146 23
0146 22
0146 20
0146 22
0150 20
0150 22
0150 20
0150 22
0151 20
0157 20
0158 20
0160 20
0160 20
0160 23
0160 20
0160 23
0160 20
0162 20
0163 20
0163 20
0165 20
0165 22
0165 20
1
1
1
2
2
1
1
2
2
1
1
1
1
2
3
4
5
6
I
1
2
1
1
2
TOTAL
HTL CH
8000
8000
8000
8000
6000
5000
6000
5000
7060
5000
5000
3764
3764
3764
3764
1000
2025
2025
10000
10000
10000
IE«LT
560
300
560
300
900
500
900
500
5250
2300
2330
1700
1700
1700
1700
200
3400
4)90
3600
PIG
IRON
1760
3200
1760
3200
1500
2250
1500
2250
1050
600
600
500
500
500
500
300
1000
2000
1000
PURCH
GST I
3630
0000
3680
0000
2700
0000
2700
0000
700
0000
0000
0000
0000
0000
0000
200
1700
0000
1700
PURCH
STE€L
2000
4000
2000
4000
900
2250
900
2250
00000
1900
1900
1500
1500
1500
1500
300
3000
3000
3000
9ft 10
000
000
000
000
000
000
000
000
000
500
500
64
64
64
64
000
000
000
000
PUN/
TURN
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
700
700
700
LIM OOLO
STN MITE
160 000
160 000
160 000
160 000
130 000
130 000
130 000
130 000
200 000
150 000
150 000
90 000
90 000
90 000
90 000
000 400
70
70
000 000
000 000
000 000
SOOA
ASH
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
FLOU OTH CA«0
SPAR ER CflKE
000
30
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
100
100
100
FE- MN
SIL
25 00
25 00
25 00
25 00
000 00
20 00
000 00
20 00
60 00
99
99
30
30
30
30
000 00
120 00
120 00
120 00
AODIT
T LBS
0 000
0 000
0 000
0 000
7 20
7 000
7 20
7 000
0 000
0 000
0 000
0 000
0 000
9 30
8 20
8 30
ME/CO SUL 0 0 C S LITE-Uf
RATIO CON ASM" TIME ME 1
7
10
9
8
9
8
11
10
11
10
9
E
9
8
8
9
9
9
9
a
8
00
00
00
4
.6 3 4 2 3 120
.6 3 4 2 J 120
.6 3 4 2 3 120
.6 3 4 2 3 120
.6 2110
.6 2410
.6 2110
.6 2410
.6 2
0130
0130
0130
0130
0130
0130
00 3 4 3 0 000
00 3430 000
00 3430 000
2
2
2
2
6
6;.
6
6
2
2
2
2
2
2
0
0
0
8 17 76
8 17 76
-------
MELTING OPERATION
PAGE
Fi«r Ci) FCE TOTAL 1E1ELT PIG PURCH PURCH BRIO PUN/ LIM OOLO SODA FLOU OTH CARB FE- MN AOOIT HE/CO SUL 0 0 C S LITE-UP SO C02 N2
NO. TV NO MTL CH IRON CST I STEEL TURN STN MITE ASH SPAR ER COKE SIL T LBS RATIO CON A S H P TIME METH
0165
0166
0167
0167
0168
'Z
20
20
20
20
2
1
1
2
1
10000
14000
2400
2400
660
4)00 2000 0000
6300 5600 0000
2250 0000 0000
2250 0000 0000
660 00300 0000 255
3000 000 700 000 000 00
1600 LBP ERHR
150 000 0000 120 000 00
150 000 0000 120 000 00
405 000 0000 6 000 00
oo oo 100 120 oo a 20 oo
CO AL 100 OLB PE R TON
00 00 000 17 00 0 000 8
00 00 000 17 00 0 000 8
00 00 000 000 00 0 000 8
00 3430 000 0
4 3
43 3
43 3
3 2 0 120 1
-------
CONTROL SYSTEM
F3RY
NJ.
0001
0002
000"
0005
0006
0007
0008
0009
0009
0010
0011
0012
0013
0014
0015
0016
0016
0017
0018
0018
0019
0019
0021
0023
0024
C3 CTL
TY SYS
3C
30
30
30
30
30
30
33
30
33
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
1
1
2
1
2
1
1
1
SYS
TYP
4
27
4
26
6
26
26
24
24
6
26
4
25
4
5
23
23
6
3
3
3
3
35
4
5
F;ES
C3NT
123
12
345
1
1
1
1
12
3
1
1
12
1
12
1
1
2
12
1
2
1
2
12
1
12
YEAK
INST
58
54
51
68
67
67
67
67
69
65
55
63
68
67
58
58
56
56
66
59
67
GAS
VOLUME
104000
45300
200000
11500
54000
33000
84000
84000
46000
101000
34000
48000
11000
16500
32050
32050
24000
36000
3AS PKES HEIGHT
TEMP DROP EXH STK
400 8
550 4
120 9
200 4
500 6
500 7
450
450
450 6
500 6
163 12
400
1500 15
00
00
500
1435 00
1435 00
500
87
46
13
83
46
125
125
82
60
125
61
61
45
45
76
AFTBURN
SIZE
0000
9999
0000
250
0000
7400
3300
8000
8000
0000
7800
0000
500
0000
3300
3300
0000
0000
0000
0000
0000
*ATER CONSUMPTION
OUST GAS RECIRC
72
25
0000 000 0000
0000 30 30
0000 20 20
0000 000 0000
0000 000 0000
20
200
140
0000 000 0000
2200
175
175
20
20
175 250 0000
NOISE
CDNTR
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
F1L AI!l/CLOTH INLET OUT CATCH COLL MLT
MED RATIO CONC CONC EFF RTE
0
0
3
3
3
3
3
0
0
3
3
0
0
0
0
0
0
3
0
0
0
0
0
0
0
3
2
2
2
0
0
2
0
0
0
0
0
0
2
0
0
0
0
c
.28 80 15
.039 90 12
6 99
.008 99 7
.86 26 99 20
.69 11 99 12
.65 .13 11 80
.678 .163 13 75 13
.5 .075 85 40
18
.311 .153 51 6
.25 80 6
1.06 .159 35 6
.269 b 18
FIX "a
!X T»
iM
X
I
w
-------
CONTROL SYSTEM
PAGE
FDRV CO
MO. TY
0025 30
0026 30
0027 30
0029 30
0031 30
0032 30
0033 30
0033 30
003* 30
0035 30
0035 30
0035 30
0036 30
0037 30
0038 30
0039 36
0041 30
0042 30
0043 30
0045 30
0046 30
0046 30
0047 30
0048 30
0049 30
CTL SYS
SYS TYP
1
1
1
1
1
1
1
2
1
1
2
3
1
1
1
1
1
1
1
1
1
2
1
1
1
3
24
3
235
35
23
25
25
5
25
3
3
6
6
4
5
6
23
7
5
f,
6
6
24
6
5
F;ES
C3NT
i
12
1
1
12
1
1
2
1
1
2
3
1
1
1
1
1
1
1
78
12
34
12
I
1
YEAR
iNsr
67
68
68
69
69
58
66
66
65
64
47
47
51
50
58
70
57
69
70
63
6*8
68
58
65
67
GAS
VOLUME
46500
82000
19500
96000
96000
34500
25000
20000
20000
13200
13500
84000
50000
20000
50000
100000
1 00000
60000
32000
GAS-
TEMP
389
300
150
1000
130
120
122
140
450
425
500
2000
410
155
250
250
500
250
PRES HEIGHT
DROP EXH STK
8
00
40
45
00
58
3
70
35
00
00
6
6
9
4
14
13
13
6
4
6
125
76
125
100
70
107
107
124
175
71
99
50
70
35
35
90
27
AFTBURN WATER CONSUMPTION
SIZE OUST GAS RECUC
8000 0000
0000 200 000 180
150 000 0000
0000 1100 200 1150
2000 350 000 320
4240 3000
3000
300
450 400
0000 70 000 0000
0000 70 000 0000
60 12
4200 360 20
9000 0000 42 20
418 150
0000 0000 000 0000
0000 0000 000 0000
100
0000 0000 000 0000
NOISE FIL AIR/CLOTH INLET OUT CATCH C3LL MLT
CONTR MED RATIO CONC CONC E*F RTE
2
i
2
1
2
2
2
2
2
2
2
2
2
2
2
2
2
0
0
0
0
0
0
0
0
0
0
0
3
3
0
0
3
0
0
0
2
2
0
2
0
0
0
0
0
0
0
0
0
0
0
0
2
6
0
0
0
0
3
3
0
2
0
.314 20
.46 .174 19 55 10
1.06 .12 17 93 16
.177 30
.37 20 90 16
.016
.05 95 50
2.26 .13 95 12
.6 99 4
2.0 .029 38. 98 9
1.24 50 26
.85 99
.85 99
18 7
-------
CONTROL SYSTEM
P4GE
0050 30
0051 30
0052 30 1
0052 30
0054 30 1
0056 30 1
0058 30
0058 30
0061 30
0062 30
0063 30
0065 30
0065 30
0065 30
0065 30 4
0065 30
0066 30 1
0067 30
0067 30
0067 JO
0068 30 1
0068 30
0068 30
0068 30
0068 30
YS
1
1
1
2
1
1
1
2
1
I
1
1
2
3
4
5
1
1
2
3
1
2
3
4
5
TYP
5
6
3
23
5
4
4
4
*
'+
6
25
25
3
3
3
5
125
125
3
3
23
23
23
2
CDNT
1
12
2
4
1
1
1
2
12
12
12
1
2
3
4
6
5
1
2
3
1
2
3
4
5
INST
68
69
69
69
69
57
57
69
66
67
69
69
66
69
55
64
64
64
64
69
VOLUME TEMP DROP EXH STK
27500 50
26000 450 00 8t>
24000 2200 00 98
85000 500 80
72000 500 4 85
52000
80000 185 80
80000 185 80
27000 600 53 120
50000 1900 53 98
98
30000 800 100
30000 800 100
30000 800 95
30000 800
35000 1200
SIZE OUST GAS RECHC CONTR MED
0
0000 150 000 0000 2 0
0000 520 000 0000 2 0
0
0
0
0
750 0000 70 20
750 40 2 0
3000 1600 400 1800 0
3000 1600 400 1800 0
0
0
0
0
6000 999 785 1 0
9999 2200 1 0
600 0
0000 600 2 0
600 2 0
2 0
2 0
2 0
RATIO
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
CONC CONC EFF RTF.
1.09 .034 97
. 165 8
.15
.15
22 81 20
.227 80 17
.047 30
.035 30
12.9 .079 99 45
5.83 50
-------
CONTROL SYSTEM
PAGE
FORY CO
NO. TY
0064 30
0069 33
0069 30
0069 30
0069 30
0069 30
0070 30
0070 30
0070 30
0070 30
0071 30
0071 30
0071 30
0071 30
0072 30
0072 30
0072 30
0072 30
0072 30
0072 30
0072 30
0073 30
0074 30
0075 30
0076 30
CTL
SYS
1
2
3
4
5
6
1
2
3
4
1
2
3
4
1
2
3
4
5
6
7
1
1
1
1
SYS
TYP
236
236
35
35
15
35
5
5
5
5
5
5
5
5
J
3
3
3
3
3
6
*
3
6
26
F;ES
C3NT
5
6
3
4
1
2
1
2
3
*
1
2
3
4
1
2
3
4
5
6
10
12
1
1
1
YEAR
INST
70
70
69
68
68
70
66
67
67
68
65
65
65
70
68
64
57
52
GAS
VOLUME
35500
35600
22400
26600
29000
29000
027000
027000
027000
27000
110000
126000
12500
GAS PRES
TEMP DROP
500 18
500 18
170 72
170 72
170 72
170 72
110 80
110 80
110 80
110 80
265 12
500
00
450 6
HEIGHT
EXH STK
35
85
120
120
120
120
129
129
129
150
81
81
81
81
81
81
107
50
AKTBURS
SIZE
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000.
0000
0000
50
500
OUST
40
60
300
300
450
350
1000
1000
1000
800
750
750
750
750
750
750
0000
CONSUMPTION
GAS RECIRC
23 850
2) 850
30 800
30 1000
2700
2700
2700
2500
200
3
NOISE
CONTR
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
FIL
MEO
3
3
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
2
0
0
3
AIR/CLOTH INLET Ol'T
RATIO CONC CONC
2 4.0 .02
2 4.0 .02
0 4.0 .05
0 4.0 .05
0 4.0 .05
0 4.0 .05
0 .05
0 .05
0 .05
0 .05
0 6.67 .075
0 8.8 .051
0 .05
0
0
0
0
0
0
0
3
0
0
2 .6
CATCH COLL
EFF
15. 99
15. 99
15. 99
15. 99
15. 99
15. 99
99
"9
99
99
99
99
MLT
RTE
40
35
45
-------
CONTROL SVSTEM
PAGE
FORY
NO.
0077
0077
0080
0081
0083
0083
0084
0085
0087
0088
0088
0089
0090
0090
0091
0091
0091
0092
0093
0093
0094
0094
0095
0096
0097
CO
TY
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
CTL
SYS
1
2
I
1
1
2
1
1
1
2
1
1
2
1
2
3
1
1
2
L
2
1
1
1
SYS
TYP
4
4
6
6
23
4
6
5
3
3
3
24
24
24
24
24
4
23
23
5
5
25
26
5
F;ES
C3NT
12
34
I
1
1
2
1
I
1
2
1
12
34
12
3V
54
1
1
2
12
3
12
1
1
YEAR
INST
57
57
52
57
57
69
57
57
61
61
59
60
61
58
60
67
55
66
64
68
GAS
VOLUME
84000
32000
40000
21100
69000
69000
96000
96000
84000
84000
84000
60000
33000
16600
36000
16000
7200
GAC
TEMP
500
500
175
1500
300
300
500
500
400
400
400
500
300
900
130
540
110
PRES HEIGHT
DROP EXH STK
6
00
25
25
00
5
5
6
6
6
11
6
26
7
20
60
60
52
93
93
100
100
94
94
94
96
96
84
70
40
AFTBURN WATER CONSUMPTION
SIZE OUST GAS RECIRC
2000 35
2300 400
2300 400
7000 0000 000 0000
0000 420 395
2400 0000 000 0000
2400 0000 000 0000
1000 0000 220 0000
1000 0000 220 0000
1000 0000 220 0000
200 0000
200 0000
68 000 68
500 450
3000
0000
NOISE
CONTR
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
FIL AIR/CLOTH INLET OUT CATCH COLL ML1
MED RATIO CONC CONC EFF RTI
0 0
0 0
3
0
0
2
0
0
0
0
0
0
0
0
0
0
0
0
3
0
2
0
0
2
0
0
0
0
0
0
0
0
0
0
0
0
0
4.0 .8 35 80 30
8.35 .154 23 24
.144 17
.144 17
1.98 .83 6.8 Si 17
1.98 .83 6.8 61 17
.27 36 21
.30 94 21
.17 88 21
.97 .16 84
.7
.16 20
.148 20
.110
-------
CONTROL SYSTEM
PAGE
FDRY CO
NO. TV
0098 30
0099 JO
0101 30
0102 30
0104 30
0105 30
0106 30
0108 30
0109 30
0109 30
0109 30
0110 30
0112 30
0113 30
0113 30
011
-------
CONTROL SYSTEM
PAf.E
FOR*
NO.
0121
0121
0122
0123
0124
0125
0126
0127
0128
0129
0130
0132
0134
0135
0136
0137
0137
0138
0139
0140
0141
0143
0144
0145
0146
CO CTL
Tr SYS
JO
30
30
30
30
30
30
30
30
30
30
30
30
30
33
30
30
30
30
30
30
30
30
30
30
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
SYS
TVf-
3
3
5
6
26
5
5
26
26
6
26
25
5
5
5
23
23
5
24
5
24
7
5
5
5
F;ES
CDNT
1
2
1
1
1
12
1
1
1
1
1
12
12
1
12
1
2
1
1
12
12
1
1
1
12
YEAR
INST
64
64
70
51
66
67
70
51
50
60
60
68
67
69
69
53
53
68
67
69
67
69
67
69
GAS
VOLUME
16600
13000
33000
43800
10800
12550
28000
30000
60000
30000
18600
72000
26000
60000
20000
27000
40000
CAS
TEMP
158
500
500
80
150
440
450
500
165
250
1400
350
867
155
PRES HEIGHT
DROP EXH STK
00
00
25 81
20
3
88 78
26 114
4
3
6 49
45 62
50
7 150
00 77
00 77
7 85
35
a 125
25
6 50
20
AFTbURN rfATER CONSUMPTION NOISE FIL 4
SUE OUST GAS RECIRC CONTR MED
250 0
250 0
330 000 300 2 0
2 1
2 3
9999 750 750 0
0000 450 350 550 2 0
80 23
2000 15 2 3
3
3000 20 2 3
1200 60 2 0
0
0
0000 150 75 0000 2 0
640 450 2 0
640 450 2 0
0
0
0
1500 30 2 0
0
0
115 2 0
0000 1300 400 2 0
IR/CLOTH INLET OUT CATCH COLL ML'
RATIO CONC CONC EFF RTI
0
0
0
0
0
2
0
0
0
0
0
0
0
0
0
0
0
0
0
0
.024 8
6
4
.05 24 99 35
90 9
5.0 .038 99 10
2.43 .068 97
.114
.183 33 16
1.84 .83 20 52
-------
CONTROL SYSTEM
PAGE 8
FURY CO CTL SYS FCES YEAR GAS &AS PRES HEIGHT AFTBURN WATER CONSUMPTION NOISE FIL AIR/CLOTH INLET OUT CATCH C3LL *LT
• b»r» t w f
NO. TY
0150 30
0151 30
0152 30
0156 30
01!57 30
0158 30
oi59 30
0160 30
0161 30
Oil. 2 30
Oil?63 30
diVs 30
0166 30
0167 30
0167 30
0168 30
«« > v
SYS
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
•f • •*
TYP
26
5
5
3
26
3
5
5
4
5
5
6
2
3
3
5
C3NT
12
1
12
1
1
1
1
12
1
1
12
12
1
1
2
1
INST
61
70
70
62
65
70
68
57
68
69
69
VOLUME
48500
20000
42000
15000
35000.
11800
35000
18000
20000
50700
34700
TEMP
500
1200
480
800
150
500
160
171
120
DROP
- 9
50
50
15
00
25
5
16
30
EXH SU
32
80
120
50
82
50
97
79
79
45
SUE OUST GAS RECIRC
0000 10 0000
0000
3000 20
600
0000 300
0000 70 30
0000 0000 000 0000
300
300
0000 25
CONTR
2
2
2
2
2
2
2
2
2
2
2
MED
3
0
0
3
0
0
0
0
0
0
2
0
0
0
0
RATIO
2
0
0
3
0
0
0
0
0
0.
3
0
p
0
0
CONC CONC EFF RTE
2.04 18 99 37
1,09 .054 97 23
1.19 .033 97
2.16 .257 34 38 16
1.14 .25 78
.074
20
15.2 IBP ER HR
1.43 22
1.43 22
-------
ANALYSIS
FDRV CD
MO. TY
OOC9 40
0009 40
0014 4G
0018 40
0021 40
0025 40
0026 40
0032 40
0035 40
0046 40
0046 40
0061 40
0067 40
0067 40
0084 40
0099 40
0113 40
0113 40
0116 40
0116 40
0122 40
0125 40
0146 40
0151 40
0162 40
CTL S*.S ANALYSIS 1
SYS CO C02 02 N2 H2
1
2
1
1 .2 9 10 77
1 2 7 12 75
I 00 U 12 76
1
1 2 4 7 86
1
1
2
1
1 12 10 3
2 3 16 1
1 .2 10 11
1 1 3 17 75 3
1
2
I
2
1
1 00 14 7
1 00 13 7 80 00
1
1
PARTICLE PROP. PERCENT :LESS THAN
2 5 10 20 50 100 200 500 1000
65 92 98 99
30 50 65 82 90 99
64 82 98 99
2 12 34 92 99 99
13 28 45 55 60
54 86 98 99 99 99
99
99 99
99 99
14 15 15 21 99
19 25 99
64 90 97 99 99
64 90 97 99 99
5 25 53
5 25 53
82
99 99
.6 2 3 8 99 99
CATCH PROP. PERCENT :LESS THAN
2 5 10 20 50 100 200 500
74 90 95 98 99 99
8 16 23 31 "9 99
16 99
PI:
PI
o!
HM
M» :
Pi
HM
w
84
o
PI
-------
ANALYSIS
PAGE
*DRY C3 CTL
NO. TY SYS
0163 40 1
0166 40 1
0167 40 1
0167 40 2
GAS ANALYSIS PERCENT
CO C02 02 N2 H2 S02 H20
00
00
00
9
9
14 81
12 79
12 79
PARTICLE PROP. PERCENT :LESS THAN
2 5 10 20 50 100 200 500 1000
86
CATCH PROP. PERCENT :LESS THAN
2 5 10 20 50 100 200 500
-------
ANALYSIS AND COSTS
FORY CD CTL, CHEMICAL ANALYSIS COM BASIC AUX ENS 1MST TOT OP ER MAINT OEPR 0V 6
NO. IV SYS SI02 CA3 AL203 MGO FEOfFE MNO PBO ZNO SNO SOX BUS EQUIP EQUIP COST COST COST COST COST HE*
0001 50 1
0002 SO 1
0003 SO 1
0004 50 I 153 21 000 7 181 14
0005 SO 1
0007 50 1
0008 50 1 33 000 8 8 49 10
0009 SO 1
0009 SO 2
0011 SO 1
0012 50 1
0013 50 1
0015 50 1
0016 50 1
OOlb SO 2
0020 50
0021 50 1
0026 50 1 150 50 25 50 275 2 I 28
0027 50 1
0028 50 1
0029 50 1 284 31 85 610 63 5 50
0030 50
0031 50 1
0032 50 1
0034 50 1
153
33
302
150
60
284
80
26
150
375
21 000 7 181
60
420
000 8 8 49
384
384
358
999
44
70
45
45
200
108 410
50 25 50 275
20 5 15 100
100
31 85 610
35
160
6 2 5 39
500
-------
FDRY CO CFL
NO. TY SYS
0001 50 1
0002 50 1
0003 50 1
0004 50 1
0005 50 1
0007 53 1
0008 50 1
0009 50 1
0009 50 2
0011 50 1
0012 50 1
0013 50 1
0015 50 1
0016 50 1
0016 50 2
0020- 50
0021 50 1
0026 50 1
0027 50 I
0028 50 I
0029 50 1
00)0 SO
0031 50 1
0032 50 1
003* 50 1
SIQ2
CHEMICAL ANALYSIS
CA3 AL203 HGO FEO.FE MNU P30 ZNO
ANALYSIS AND COSTS
COM BASIC AUX
EN:
INST TOT OPER MAINT DEPR OVER
HEAD
SNO SOX BOS EQUIP EQUIP COST COST COST
150
375
P
153 21 000 7 181
60
420
33 000 8 8 49
384
384
358
999
44
70
45
45
200
302 103 410
150 50 25 50 275
60 20 5 15 100
IOC
284 31 85 610
35
80 160
26 6 2 5 39
COST COST
10 1
2 1
63 5
1 3
EQUIP TOT
CHANG ANN
500
14
00
28
50
58
00
00
50
50
34
176
t/;
i
^
t_<
O
z
a-
m
£S
— t
DC
I— i
r-3
t— t
^
"0
m
•z
o
I— i
X
03
-o
o
m
-------
ANALYSIS AND COSTS "AGE 2
FOR* CD CTL CHEMICAL ANALYSIS COM BASIC iUX tNG INST TOT OPER MAINT DCPR OVER EQUIP TOT
NO. TV SfS SI02 :<0 AL203 MGO FEO,*E UNO P30 ZNO SNO° S3X BUS EQUIP EQUIP COST COST COST COST COST HEAD CHANG ANN
0035 50 1 95. 45 56 10 10 121 12 10
0035 50 2
003b 50 3
0036 50 1
0037 53 1
0038 50 1
0040 50
0042 50 1
0043 50 1
0 no
-------
ANALYSIS ANO COSTS P»GE J
FDRY C3 CTL CHEMICAL ANALYSIS COM 3ASIC AUX tNC
-------
ANALYSIS MO COSTS PAGE *
FDKY CD CTL CHEMICAL ANALYSIS COM BASIC AUX ENb INST TOT OPER MAI NT OEPP. OVER:EQUIP TOf
NO. TV SYS SI02 CA3 AL203 MCO FEOtFE MNO PBO 2ND SNO SOX BUS EQUIP EQUIP COST COST COST COST COST HEAD CHANG ANN
0112 SO
0113 SO
0113 SO
0 .15 SO
0115 50
0116 50
0116 SO
0118 50
0118 50
01 18 50
6121 50
0121 50
0122 50
0121 30
012* 50
012S 90
0126 50
0127 50
0128 50
0129 50
0130 50
0131 50
0132 50
0136 50
0137 50
1
1 31.8 3.1 .05 8.6 3.7
2 31.8 J.I .05 8.6 3.7
1
2
1 10. 3. 5. 5. 10. 10. 1.
2 10. 3. 5. 5. 10. 10. I.
1
2
3
1
2
1
1
1
1
1
1
1
1
1
1
1
1
38
13.9 27
13,9 27
25
25
5
5
997
997
997
175
175
45
15
30
72 13* 27 430
120 113 23 296
40
30
23
100
90
110 170
110 45 20 35 210
85
6
10 6 14 00 36
-------
FDRV CO
NO. TY
0137 50
,i39 50
OUl 50
0144 50
0145 50
0146 50
0150 50
0151 50
0155 50
0157 50
0158 50
0160 50
0162 50
0163 SO
0165 50
0166 SO
CTL
SYS
2
1
1
1
1
1
1
1
1
I
1
1
1
1
I
ANALYSIS AND COSTS
CHEMICAL ANALYSIS CON BASIC AUX ENS INST TOT OPER MAI NT
$102 :A3 AL203 MGO FEO.FE MNO PBO ZNO SNO SOX BUS EQUIP EQUIP COST COST COST COST COST
85
94
220
90
52
20.0 1.0 33.0 1.0 5.0 38.0 2.0 80 490 100 999 30 20
30.1 1.1 1.4 .99 11.6 5.5 20. 14.7 300 25 25 500 25 10
250 389
140
40
71
45 105 50 200 24 10
150
367
60 5 5 30 100 5 1
3. 8 5 13
PftGE 5
OEPR OVER EQUIP TOT
HEAD CHANG ANN
10
99 99 380
00 34
15
20
5 5 .5 1*
1*
-------
Appendix B
Exhibit IT
Section I. page 1
FORMAT FOR DATA BANK
SECTION I GENERAL FOUNDRY DATA
CONTENT
Abbreviation Description
FDRY NO. Foundry No.
CD TY Card Type
LOG Location (1st 3 Digits of Zip Code)
MET CST Type Metal Cast
(Code)
1 Gray Iron
2 Malleable Iron
3 Ductile Iron
4 Gray and Malleable
5 Gray and Ductile
6 Malleable and Ductile
7 All Three
Percent Cast
GI Grey Iron
MI Malleable Iron
DI Ductile Iron
Ton/Mo. Melt
GI Grey Iron
MI Malleable Iron
DI Ductile Iron
SIZ CLA Size Classification
(Code)
1 Under 10
2 10-49
3 50 - 249
4 Over 250
A.T.KEARNEY Sc COMPANY. I j$ c.
-------
Appendix B
Exhibit IT
Section I. page 2
Abbreviation Description
IND CLA Industry Classification
(Code)
1 Automotive
2 Agricultural
3 Cast Iron Pipe
4 Industrial and Electrical
Equipment
5 Valves and Fittings, Refrigeration
6 Jobbing
7 Railroad
WT RG Weight Range of Castings
(Code)
1 Under 10 Ibs
2 10-49
3 50-99
4 100 - 500
5 Over 500
6 Several of above
PRO CST Basic Product Cast
(Code)
1 Brake Drums
2 Pipe
3 Machinery and Machine Tools
4 Railroad Products
5 Automotive
6 Valves and Fittings
7 Agricultural Parts
8 Motors, Hardware, Appliances,
Tools
9 Municipal items (sewer covers,
grates, etc.)
NOD Nodularization
(Code)
0 None or does not apply
1 Yes
& COMPANY. INC.
-------
Appendix B
Exhibit II
Section I. page
Abbreviation Description
Alloy Additions to the Ladle
T Alloys Type
(Code)
0 None or does not apply
1 Caloy
2 Calcium Carbide
3 Mag-Coke
4 FeSi
5 FeCr
6 Mg Fe Si
7 Inoculoy 63
8 Ce
9 Noduloy 5C
LB Addition, Ibs.
T Alloys Type (Code)
(See Above)
LB Additions, Ibs.
T Alloys Type (Code)
(See Above)
LB Additions, Ibs.
1 #1 Other Additions
(Code)
0 None
1 Graphite
2 SmZ
3 Bi
LB Additions, Ibs.
2 #2 Other Additions
(Code)
0 None
1 Fe Si
2 Fe Mo
3 Al
9 See Questionnaire
LB Additions, Ibs.
A.T.KEARNEY Sc C OM " AN Y, I N c.
-------
ExnlEItTTT
Section I, page 4
Abbreviation
CUP REP
Description
Cupola Replaced last 10 yrs?
(Codef
0 No
1 Yes
TYP FCE
If Yes. Type of Furnace
(Co'de)
C Does not apply
1 Cupola
2 Channel induction
3 Coreless induction
4 Direct Arc
5 Indirect Arc
6 Air Furnace
7 Other, see Questionnaire
VENT TAP
Ventilation During Fee. Tapping
(Code)
1 General
2 Local
EFF
Effectiveness
(Code)
1 Excellent
2 Good
3 Fair
VENT MOLD
Ventilation During Mold Pouring
(Code)
1 General
2 Local
EFF
Effectiveness
(Code)
1 Excellent
2 Good
3 Fair
EERP
ATK
Foundries Visited by EERP/OLPA
Foundries Visited by A. T. Kearney
& Company, Inc.
A. T. KEARNEY
COMPANY, INC.
-------
SECTION 2 FURNACE DATA
CONTENT
Appendix B
Exhibit II
Section 2, page 1
Abbreviation
FDRY NO.
CD TY
FCE NO.
FCE TYP
Description
Foundry No.
Card Type
Furnace No.
Furnace Type
(Code) P
1 Cupola
2 Channel Induction
3 Coreless Induction
4 Direct Arc
5 Indirect Arc
6 Air Furnace
7 Other
LIN TYP
Lining Type or Coil Type
(Code)
0 Does Not Apply
1 Acid
2 Basic
3 Neutral
4 Unlined
5 Single Channel Open
6 Single Channel Closed
7 Double Channel
BLT DES
Blast Description
(Code)
0 Does Not Apply
1 Hot Blast >800*F
2 Warm Blast
3 Cold Blast
A.T.KEARNEY & C OM "AN Y. I NT c.
-------
Appendix B
Exhibit II
Section 2, page 2
Abbreviation Description
BLT HTG Blast Heating or Frequency
(Code)
0 Does Not Apply
1 No Blast Heating
2 Recuperative Heating
3 Externally Fired
4 Recup. and Ext. Fired
5 Line Frequency
5 Medium Frequency
7 High Frequency
TOP C/0 Cupola Top - Closed or Open
(Code)
0 Does not Apply
1 Closed Top
2 Open Top
CHG Top or Side Charged
(Code)
0 Does Not Apply
1 Top
2 Side
GAS T-O Gas Take-Off
(Code)
0 Does Not Apply
1 Above Charging Door
2 Below Charging Door
3 Gas Take-Off into Side Draft Hood
4 Gas Take-Off into Full Roof Hood
5 Gas Take-Off into Canopy Hood
6 Gas Take-Off into Snorkel
7 Direct Shell Evacuation
8 No Gas Take-Off
AFT Afterburners
(Code)
0 Does Not Apply or None
No. Indicates Use tind Quantity
of Burners
CHG DR Charging Door - Open or Closed
(Code)
0 Does Not Apply
1 Door Open
2 Door Closed
A. T. KEARNEY 6f COMPANY. lW.
-------
AjpenQix tt
Exhibit IT
Section 2, page 3
Abbreviation
FL IN
Description
Fuel Injection
(Code)
0 Does Not Apply or Without
Fuel Injection
1 With Fuel Injection
OX EN
Oxygen Enrichment
(Code)
0 Does Not Apply or Without
Oxygen Enrichment
1 With Oxygen
FCE USE
Furnace Use
(Code)
1 Melting
2 Holding
3 Duplexing
FCE DIA
HLD CAP
MLT RAT
MT UT
PR UT
OT UT
VOLUME
PRES
TEMP
SIZE CH DR
HT DR
CHG PRE
SIZE AFT
AFT LOC
DIS AFT
POWR SPLY
CTL SYS
Furnace Dia., Inches
Holding Cap., Tons
Melt Rate, Tons/Hours
Melting Utilization, Hour/Day
Pouring Utilization, Hour/Day
Other Utilization, Hour/Day
Blast Volume, SCFM
Blast Pressure, Oz H20
Blast Temperature, °F
Size of Charge Door, Sq. Ft.
Height Charge Door Sill Above Floor, Ft.
Charge Preheated and/or Dried
(Code)
0 No or Does Not Apply
1 Preheated
2 Dried
3 Both
3
Afterburner Size, BUT/Hr x 10
Afterburner Location
(Code)
0 Does Not Apply
1 Above Charge Door
2 Below Charge Door
3 In Gas Take-Off
4 Above and Below DDor
Distance Afterburner to las Take-Off, Inch,
Power Supply, KW or KVA
Control System No.
A. T. KEARNEY & C OM PAN Y. I N c.
-------
Appendix B
Exhibit TT
Secticn 3. page 1
SECTION 3 MILTING OPERATION
CONTENT
Abbreviation
FDRY NO.
CD TY
FCE NO
TOTAL MIL CH
PURCH CST I
PURCH STEEL
BRIO
PUN/TURN
LIM STN
FLOU SPAR
FE-SIL
MN
T
Description
Fourdry No.
Card Type
(Code)
20 Grey Iron
21 Malleable Iron
22 Ductile Iron
Furnace No.
Total Metallic Charge, 3bs.
Remelt, Ibs.
Pig Iron, Ibs. (With *, Silvery Pig)
Purchased Cast Iron, Ibs
Purchased Steel, Ibs.
Briquettes, Ibs.
Punchings and/or Turnings, Ibs.
Limestone, Ibs.
Dolomite, Ibs.
Soda Ash, Ibs.
Flourspar, Ibs.
Other, Ibs.
Carbo-Coke, Lbs .
Ferrosilican, Ibs.
Manganese, FeMn, SiMn. Ibs.
Additive, Type
(Code)
0 None
Copper
Silvery Iron
Silicon
Calcium Carbide
Silicon Carbide
1
2
3
4
5
6
7
8
Carnell (CoF2)
Ferrophosphorous
Graphite
LB
ME/CO RATIO
SUL CON
D A
Additive, Ibs.
Metal to Coke Ratio
Sulphur Content of Coke, %
Desulphurizing Agents
(Code)
0 Does Not Apply or None
1 Caustic Soda NaOH
2 Soda Ash Na7C03
3 Calcium Carbide
A. T.KEAKNtY & C OMCP'AN V. .1 -N
-------
Appendix B
Exhibit IT
S3Ction 3, page 2
Abbreviation
Description
Quality of Scrap
(Code)
0 Does Not Apply
1 Rusty
2 Dirty
3 Oily
4 Clean
C M
Charging Method
(Code)
0 Does Not Apply
1 Skip Hoist Side Discharge Bucket
2 Skip Hoist Bottom Discharge
Bucket
3 Crane Type Charger
4 Belt Conveyor
5 Vibrating Feeder
6 Magnet
7 Manual
S P
Scrap Preparation
(Code)
0 Does Not Apply or None
1 Shot Blast
2 Degreasing
3 Cut to Size
TIME
METH
Average Length of "Light-Up", Min. Per Day
Method of light-up
(Code)
0 Does Not Apply
1 Wood
2 Gas
3 Oil
4 Electric
5 Other
6 More than one of above
CO
C02
No
Carbon Monoxide,
Carbon Dioxide, ?4
Nitrogen, %
•'• .' • - -' I1./ i.: !,' .;. - - .•
A.T.KEARNEY & C OM PAN Y, 1 N c.
-------
Aopendix B
Appe
Exhl
Exhibit II
Section 4
SECTION 4 CONTROL SYSTEM
CONTENT
Abbreviation
FDRY NO.
CD TY
CTL SYS
SYS TYP
Description
Foundry No.
Card Type
Control System No.
Control System Type
(Code)
0 No Control System
1 Fly Ash and Spark Arrester
2 Afterburner
3 Wet Cap
4 Mechanical Collector
5 Wet Scrubber
6 Fabric Filter
7 Electrostatic Precipitator
FCES CONT
YEAR INST
GAS VOLUME
GAS TEMP
PRES DROP
HEIGHT EXH STK
AFTBURN SIZE
DUST
GAS
RECIRC
NOISE CONTR
FIL MED
Furnaces Controlled
Year Installed
Rated Gas Volume at Exh. Inlet, CFM
Gas Temperature at Exh. Inlet, °F
Pressure Drop, in H20
Height Exhaust Stack, Ft. „
Afterburner Size, BTU.Hr. x 10 J
Water Consumption, Dust Collector, GPM
Water Consumption, Gas Cooling, GPM
Water Consumption, Recirculated, GPM
Noise Control
TCode)
I Yes
Filter Media
(Code)
0 Does Not Apply
1 Natural Fibre
2 Synthetic Fibre
3 Glass Fibre
INLET CONG
OUT CONG
COLL EFF
MLT RTE
Air to Cloth Ratio
Inlet Concentration, GR/SCF
Outlet Concentration, GR/SCF
Catch, Ib. Dust/Ton Melt
Collection Efficiency, %
Melt Rate at Which Test was Made, TPH
A. T. KEARNEY & COM.PA N Y,> T N c.
-------
Exhibit I
Section 5
SECTION 5 ANALYSIS
CONTENT
Abbreviation
FDRY NO.
CD TY
CTL SYS
Description
Foundry No.
Card Type
Control System No.
Gas Analysis 7» CO
Cas Analysis 7<> C02
Gas Analysis % QI
Gas Analysis "L N2
Gas Analysis % Ho
Gas Analysis 7, 862
Gas Analysis 70
Particle Prop.
Less Than
Less Than
Less Than
Less Than
Less Than
Less Than
Less Than
Less Than
Less Than
2 Microns
5 Microns
10 Microns
20 Microns
50 Microns
100 Microns
200 Microns
500 Microns
1,000 Microns
Catch Prop., %
Less Than
Less Than
Less Than
Less Than
Less Than
Less Than
Less Than
Less Than
2 Microns
5 Microns
10 Microns
20 Microns
50 Microns
100 Microns
200 Microns
500 Microns
A.T.KEARNEY & COMPANY, INC.
-------
Appendix B
Exhibit II
Section 6
SECTION 6 ANALYSIS AND COSTS
CONTENT
Abbreviation
FDRY NO.
CD TY
CTL SYS
Description
Foundry No.
Card Type
Control System No,
Chemical Analysis
COMBUS
BASIC EQUIP
AUX EQUIP
ENG COST
INST COST
TOT COST
OPER COST
MAINT COST
DEPR
EQUIP CHANG
TOT ANN
SiOo
CaO
A1203
MgO
FeO, Fe2()3, Fe
MnO, Mn30/
PbO *
ZnO
SnO
SOX
Combustibles
Basic Equipment Costs
Aux. Equipment Costs
Engineering Costs
Installation Costs
Total Cost
Operating Cost
Maintenance Cost
Depreciation
Overhead
Process and Equipment Changes
Total Annual Costs
$
$
$
$
$
$
$
$
$
x 10:
x 10=
x 10
x 10
x 10
x 10
x 10
x
10:
10^
10J
A.T.KEARNEY 8c COMPANY, INC.
-------
APPENDIX C
MATERIAL AND HEAT BALANCE
Appendix C consists of three exhibits, each of which
deals with material and heat balances of foundry melting fur-
naces. The first exhibit of this appendix is the Cupola
Material and Heat Balance Model. This exhibit discusses the
development of the mathematical model and the nature of input
required. A sample of the material balance and heat balance
outputs and the chemical reactions considered in the model are given,
Exhibit 2 of this appendix is a listing of the FORTRAN IV
computer program version of the material and heat balance.
The final exhibit of Appendix C is a series of material
and heat balances for cupolas and electric furnaces. A material
and heat balance is given for different furnace classifications.
Each classification, as discussed earlier in this report,
represents a unique furnace type and operating characteristics
found in practice.
• ' •. . , i. i1" .>; , r •
A. T. KEARNEY & COMPANY. INC.
-------
APPENDIX U
EXHIBIT 1
Page 1
CUPOLA MATERIAL AND HEAT BALANCE MODEL
Because the major single source of air emissions from the
foundry is the cupola, a material and heat balance model has been
developed to compute (for given operating conditions) the esti-
mated emissions generated by the cupola,,
The model requires the following general inputs:
lo Size and certain design characteristics of the
cupola.
2. The type and hourly melting rate of iron being
produced.
3. The makeup of the charge, including metal lies, fuel,
flux and additives.
40 The rate and temperature of the blast air including
any oxygen enrichment.
5. The temperature of the top gases immediately above
the burden.
Using these inputs, the computerized version of the model
will calculate a material and heat balance for the cupola and
print out a summary report showing these results. An example
of the output report is shown in a later section of this
appendix.
The approach taken in constructing the model has been to con-
centrate on those aspects of cupola design and operation which
will influence the emissions characteristics of the top gases.
Those aspects which relate to such matters as detailed metallurgical
characteristics of the tapped iron but do not influence
emissions have not been included in the model.
A.T.KEARNEY & COKPANY. INC.
-------
APPENDIX C
EXHIBIT 1
Page 2
A search of the literature and previous research was under-
taken to collect the known physical and chemical relationships
in the cupola that influence emissions characteristics in terms
of composition and quantity.
Most of the relationships included in the model are based
on known chemical and physical laws and their accuracy with regard
to the computed results is limited only by the accuracy of the
input data0 It has been necessary, however, to include in the
model several empirical relationships cited in the literature to
permit the calculation of estimated quantities in the top gases
of particulate matter and sulfur dioxide „ Furthermore, in order
to simplify the task of specifying the input values and to limit
the required data to figures commonly available in foundry opera-
tion, the average or typical composition of charge materials has
been incorporated into the model. For example, when specifying
for the model that the tapped iron is gray iron, the model uses
an average composition for gray iron in its calculations. This
has been done to avoid having to specify the actual chemical com-
position of charging materials and tapped iron in order to use
the model. In practice, the slight variations in the actual
composition of materials from the averages used in the model will
have very little effect on the results calculated by the model as
far as emissions are concerned.
The average compositions for materials used in the model
have been taken from the literature and are shown in the
following table. It will be noted that the chemical compositions
used are not rigorously complete and only those components which
can significantly affect the calculated emissions are included.
A. T.^KEA^-NEY ,£c .QpJ^PAJST.Y- IN/:.
-------
APPENDIX C
EXHIBIT 1
Page 3
The balance of the documentation of the model included in
the report consists of a description of the chemical and physical
relationships incorporated in the model. A listing of the FOR-
TRAN IV computer program version of the model is given in
Exhibit 2 of this appendix.
Average Composition of Materials
Used in the Cupola Model
(Figures
Given Are Weight Percentages)
A. Metallics
Gray Iron
C
3.2%
Malleable Iron 2.5
Ductile Iron
Pig Iron
Silvery Pig
Iron Scrap
Steel Scrap
Ferrosilicon
B. Fluxes
Limestone &
Dolomite
Fluorspar
Fdry Carbide
Soda Ash
3.8
3.5
2.5
3.3
0.4
0.05
Si02
1.0%
2.0
3.0
Si
2.0%
1.2
2.4
0.6
10.0
2.1
0.2
50.0
(Ca, Mg)0
54 . 0%
8.0
14.0
Mn
0.6%
0.6
0.6
1.5
0.7
0.6
0.6
0.0
CaF2 C
-
84.0
s
0.12%
0.12
.03
.05
.05
.12
.05
0.00
C02
JaC2 Na20 (asC03)
45.0%
6.0
70.0 - 11.0
57.0 43.0
C. Foundry Coke Ash
D. Cupola
Acid
Basic
Si02
50.0%
Refractory
Si02
60.0%
20.0
A12°3
35.0%
Linings
A1203
30.0%
20.0
Fe203
8.0%
MgO
_
60.0
(Ca, Mg)0 Misc.
3.0% 4.0%
MiscO)
10 . 0%
-
A1203
2.0
Note: (1) Miscellaneous category includes various other metallic
oxides and trace elements not listed.
r ' , • 1 ,; •'• ! ' ; > I 3- '!' ' . ( •; '
A. T. KEARNEY & COMPANY. INC.
-------
APPENDIX C
EXHIBIT 1
Page 4
SPECIFIC INPUTS
REQUIRED FOR THE MODEL
Nature of Cupola and Metal Produced
1. Diameter of the cupola in inches
2. Type of lining
a. Ac i d
b. Basic
c. None (water cooled)
3. Type of iron being produced
a. Gray
b. Malleable
c. Ductile
4. Rate of molten iron produced in tons per hour
5. Temperature of the tapped iron in degrees Fahrenheit
Characteristics of Charge
1. Metallics (fraction or relative weight of each)
a. Pig iron
b. Silvery pig
c. Scrap
1) Steel
2) Iron
d. Foundry returns
1) Gray
2) Malleable
3) Ductile
e. Ferrosilicon (50%)
A. T. KEARNEY & COMPANY. INC.
-------
APPENDIX U
EXHIBIT 1
Page 5
2. Fuel
a. Metal to coke ratio
b. Coke analysis
1) Fixed carbon (fraction)
2) Ash content (percent)
3) Sulfur content (percent)
c. Other fuels (if any)
1) Natural gas (SCFM)
2) Fuel oil (gallons/mine)
3o Flux (percent to metal of each)
a. Limestone and/or dolomite
b. Flourspar
c. Foundry carbide
d. Soda ash
Characteristics of the Blast
1. Air
a. Quantity of air (SCFM)
b. Inlet air temperature ( F)
c. Relative humidity of air (fraction)
2. Oxygen enrichment (SCFM)
o
3. Blast temperature ( F)
Characteristics of Exhaust Gases
o
lc Top gas temperature (top of burden- F)
20 Stack gas above charge door
a. Volume of stack gas (CFM)
b. Temperature of stackgas for volume given ( F)
c. Carbon monoxide in stack gas (70/vol.)
A.T.KEARNEY & COMPANY, INC.
-------
APPENDIX C
EXHIBIT 1
Page 6
CHEMICAL REACTIONS ,
CONSIDERED IN THE MODEL
Oxidation Zone
1. C (coke) +02 -» C02
2. CH4 (natural gas) + 2-02 -* C02 + 2-H20
3. 4-C5H1;L (fuel oil*) + 31'02 -* 20'C02 + 22-H20
*The composition shown for fuel oil represents
the average total ratio of carbon to hydrogen for
the sum of the many hydrocarbon compounds which
comprise a typical fuel oil used in cupola oper-
ations .
4. Si + 02 -> Si02
5. 2-(Fe, Mn) +02 -> 2'(Fe, Mn)0
6. 2-CaC2 (foundry carbide) +5-02 -» 2-CaO + 4'C02
Reduction Zone
7. C (coke) + C02 -» 2-CO
8. C (coke) + H20 -^ CO + H
Preheating Zone
9. (Ca, Mg)C03 -> (Ca, Mg)0 + C02
10. Na2C03 -* Na20 + C02
11. S + Fe -* FeS
Slagging Reactions
12. (Ca, Mg, Fe, Mn)0 + Si02 -> (Ca, Mg, Fe, Mn)Si03
13. CaO + FeS -> CaS + FeO
14. CaS + FeSi03 + 2-MnO -> CaSiOa + Fe + 2-Mn + S02
.T. KEARNtY & COM PAN Y, I%-c.
-------
APPENDIX C
EXHIBIT 1
Page 7
MATERIAL BALANCE
RELATIONSHIPS CONSIDERED
IN THE MODEL
The material balance relationships employed in the model
use the input quantities (specified on the preceding pages)
of materials and the average compositions of materials shown
earlier in this exhibit. The source of empirical relationships
used are shown for reference. The quantities are all computed
to a base of 2,000 pounds of tapped iron.
1. Silicon Oxidized = Net Silicon Loss from Metalics
Net Silicon Loss From Metalics = Weight of Silicon in Metalic
Charge - Weight of Silicon
in Tapped Iron
2. Manganese Oxidized (same approach as for silicon above)
3. Carbon From Coke Into Iron = Net Carbon Gain of Tapped Iron
Net Carbon Gain = Weight of Carbon in Tapped Iron - Weight
of Carbon in Charged Metalics
4. Oxygen Input = Weight of Oxygen in Blast Air + Oxygen
Enrichment
5. Water Input = Water Content of Blast Air as a Function of
Temperature and Relative Humidity
6. Oxygen Available For Fuel Combustion = Oxygen Input - Oxygen
Used to Oxidize Silicon,
Manganese and Foundry
Carbide
7. Oxygen Available to Burn Coke = Oxygen Available For Fuel
Combustion - Oxygen Consumed
to Burn Natural Gas and/or
' ''! • 'li!l' • $ ''"Fuel Oil
A.T.KEARNEY & COMPANY, INC.
-------
APPENDIX C
EXHIBIT 1
Page 8
8. Coke Consumed in Complete Burning
*• Carbon Required to Combine with Available Oxygen
/Carbon Content of Coke
9. Total Water to React With Coke
• Water Input in Air + Water Generated in Combustion
of Natural Gas and Fuel Oil
10. Coke Available to Reduce Carbon Dioxide
= Total Coke Input - Coke Consumed in Complete Burning
- Coke Required to Reduce Total Water
11. Resulting Carbon Dioxide
• C0« from Complete Combustion of Coke
- C0£ Reduced by Remaining Coke
+ C02 from Calcining of Carbonates
12. Resulting Carbon Monoxide
«• CO from Water Reduction + CO from C02 Reduction
13. Resulting Hydrogen » Weight of Hydrogen in Total Water
14. Silica From Cupola Lining = Weight of Lining Melted as a
function of Cupola Diameter*
x Silica Content of Lining
15. Magnesium Oxide From Cupola Lining (same approach as for silica)
16. Total Silica For Slag • Silica From Coke Ash + Silica
Fluxes + Silica From Cupola Lining
17. Total Calcium and Magnesium Oxide for Slag
= (Ca, Mg)0 from Fluxes, Cupola Lining, and Coke Ash
18. Slag Basicity Ratio • Total (Ca, Mg)0/Si02
*The Cupola and Its Operation (third edition; Des Plaines,
Illinois: American Foundrymen's Society, 1965), p. 233.
A.T.KEARNEY & COM PAPTT, I N c.
-------
APPENDIX C
EXHIBIT 1
Page 9
19. Sulfur in Slag = Function of the Basicity Ratio* of the Slag
20. Sulfur To Top Gas (S02) - Total Sulfur Input in Coke and
Metalics - Sulfur Output in Tapped
Iron - Sulfur Output in the Slag
21. Oxidation of Iron To Slag = Assumption that Slag Contains
Two Percent FeO Derived from
Oxidation of Iron*
*Note: No method could be found in the literature to
predict the amount of iron oxidized and going into
the slag. Typical compositions suggest that two
percent is a good average value.
22. Particulate Matter in Top Gases = Empirical Function**of:
a) Blast Volume
b) Coke Ratio
c) Melting Rate
23. Total Slag Output = Weight of Slag Forming Constituents
in Coke Ash and Fluxes
+ Si02, MnO, and FeO from Metalics
+ Cupola Lining Melted
- Emissions Dust
24. Total Metallic Inputs = Tapped Iron Weight
+ Si, Mn, Fe Loss From Metallic Charge
- C and S Gain in Tapped Iron
*The Cupola and Its Operation, p. 236
**Eneels and Weber,Cupola Emission Control, trans. (Cleve-
land, Ohio: Gray and Durtile Iron Founders' Society, 1969, Ori-
ginal, 1967), pp. 52-54.
A.T.KEARNEV 8: COMPANY. INC.
-------
APPENDIX C
EXHIBIT 1
Page 10
HEAT BALANCE RELATIONSHIPS
CONSIDERED IN THE MODEL
The heat balance relationships are calculated in B.T.U.'s
per hour of cupola operation.
Heat Inputs
1. Potential Heat of Fuels = Heat of Total Combustion for
Weight of Carbon in Coke plus
Natural Gas and Fuel Oil Combustion,
2. Heat of Oxidation of Metallics
= Heats of Oxidation for Weight of
Iron, Silicon, Manganese, and
Carbide Oxidized per Hour
3. Sensible Heat of Air Blast
= Temperature x Specific Heat
x Weight of Air Blast Per Hour
Heat Outputs
1. Heat Content of Tapped Iron
= Temperature x Specific Heat
x Weight of Molten Iron Tapped
Per Hour
2. Heat for Calcining Carbonates
- Heat of Reaction for Calcining
x Weight of Carbonate
Fluxes Per Hour
3. Heat of Slagging = Heat of Reaction of Calcium and
Magnesium Oxides with Silica To
Form Silicates in the Slag
A.T.KEARNEY 6e COMPANY, INC.
-------
C
EXHIBIT 1
Page 11
4. Heat Content of Slag = Temperature x Specific Heat
x Weight of Slag - Heat of
Slagging Reactions
5. Heat of Water Decomposition
= Heat of Reaction with Carbon to
Reduce Water to Hydrogen and
Carbon Monoxide
6. Sensible Heat of Top Gas
= Temperature x Specific Heat
x Weight of Top Gases
7 . Latent Heat of Top Gas = Potential Heat of Combustion of
Carbon Monixide x Weight of Carbon
Monoxide in the Top Gas Per Hour
8. Heat Radiation From the Cupola
= Sum of Heat Inputs
- Sum of Heat Outputs (above)
A.T.KEARNEY & r ^M PAN Y, I v c.
-------
SAMPLE OUTPUT
MATERIAL BALANCE
INPUTS
METAL CHARGE
PIG IRON
RETURNS
STEEL SCRAP
IRON SCRAP
FERROALLOYS
COKE
NATURAL GAS
FUEL OIL
POUNDS
2015
288.
959.
672.
0.
96.
208.
0.
0.
PERCENT
51.50
7.36
24.52
17.17
OoOO
2.45
5.33
0.00
0.00
FLUX AND ADDITIVES 27.
AIR
OXYGEN
1641.
0.
CUPOLA LINING 20.
TOTAL INPUT MTLS 3912.
0.68
41.95
0.01
0.52
100.00
OUTPUTS
MOLTEN IRON
SLAG
EMISSIONS DUST
TOP GASES
NITROGEN
CARBON DIOXIDE
CARBON MONOXIDE
HYDROGEN
SULFUR DIOXIDE
2000.
64.
16.
1833.
1254.
375.
201.
1.
2.
51.13
1.62
0.40
46.85
68.41
20.44
10.99
0.07
0.09
APPENDIX C
EXHIBIT 1
Page 12
A.T.KEARNEY Sc COMPANY. INC.
-------
APPENDIX C
EXHIBIT 1
Page 13
SAMPLE OUTPUT
HEAT BALANCE
INPUT HEAT
POTENTIAL HEAT
OF FUEL
SENSIBLE HEAT
OF THE BLAST
HEAT FROM OXIDATION
OF MN, FE, SI
TOTAL INPUT HEAT
OUTPUT HEAT
HEATING AND MELTING
OF IRON
HEAT CONTENT
OF THE SLAG
CALCINING OF
LIMESTONE
DECOMPOSITION
OF WATER
TOP GASES
-SENSIBLE HEAT
-LATENT HEAT
HEAT RADIATION FROM
THE CUPOLA
VOLUME OF TOP GAS (MCF)
ACTUAL 1280.
STANDARD 508.
STOP
B.T.U.'s
(000/HR.)
56208.
2554.
2664.
61426.
7717.
PERCENT
91.51
4.16
4.34
100.00
24212.
1085.
419.
713.
8112.
19168.
39.42
1.77
0.68
1.16
13.21
31.20
12.56
A. T. KEARNEY 8c COMPANY, INC.
-------
APPENDIX C
EXHIBIT 2
Page 1
MATERIAL AND HEAT BALANCE
5 KEAL I,I1,I2,I3,IM,I5,I6, 17,10, I9,J,M1,M2,M3,M4,M5,M8
6 KEAL K,Kl,K2,K3,K4,K5,K6,K7,Kb,K9,Ll,L2,L3,L4,L5,N2,N3
15 KEAU (1,16)0, LI, L2, 17, 16, 19
16 16 FORMAT (10F10.0)
20 READ (1,16)M1,T4, II, I2,R3, 13,1
25 KEAL) (1,16)14, 15, I6,K1,K2,K7,K8,G1,G2
30 REAU (1,16)F1,F2,F3,F4,A1,T1,H3,02,T2,T3
32 REAU (1,16) V3,T5,COP
J5 J=I1+I2+ I3+I4+I5+I6+I+R3
40 I1=I1/J
45 I2=I2/J
50 I3=I3/J
60
65
ro
75
00
05
90
92
95
100
105
110
115
120
125
130
135
140
14|p
150
155
160
165
170
175
ibo
I5=I5/J
I6=16/J
I = I/J
i<3=R3/ j
S9=( . 006
"1
S9=M1-2000
59=59-2000
IF (59. LT.
C0 = . 032::
cb=(cb-.
Cb=2000.
Mb=2000.
01=(.209
03=01-20
H4=0.631
K3=(o3-(
C2=1.30-
Hl=5.72-
K4 = .667::
H= . 111-H
K5=2000.
K6=K5-K3
C3=4.66::
C2=C2-3.
Cl=lo5::
C4=100.0
17
1+ .
.0-
.0"
2.::
+ . 0
035::I
0-
0-
Ml-
Ml-
1:J
S9
Ml
I
**
(
Ml)
25
1-
Cb
(.
J J
•
I
+ .
0
0
.02-
59=
0-f
,
025"
00
-Al+02)".
.0
-Ml
"EXP(
10
03
.03
-.06
9::
Od
"F
I
2
0
I
I
•
3
:: 1 3+ . 49::R3+ . 02 1:: 1 + . 02:: 14 + . 012" I
7+.012-IO+. 024-19)
0-M1
8-19
2-. 004 -1 3-. 033" I -.032- 1 4 -.025" 1 5
1+
47-
3-1
.03590-
-Gl
Gl+519.
0
)-l'l
T
.002"(1.0-I1))
60.0
.14S9-.41-M8
1)"H3".0763::A1"60. 0/7 000.0
50
.0::G2)/(2.66"K2)
-G2+H4
H1/K2
1
0-
-K
K6
66
HI
-c
Ml/
"K2
-K6
Kl
b/
K
2
-K2
2/(C3+C2)
-.038::l6)
190 C2=C2+C5
200 N2=3.52»A1
205 L4 = (Ml"20.0"465.0/(D/2.0)::"1.75)"(Ll-»-L2)
210 S5
211 S5
215 M5=.0003"K7::K5+L4»( . 6::L2) + 20. 0::M1«( . 54"F1+ . 08-F2+ . 75XF3)
220 B1=M5/S5
22p Sl = Kd-"Ki)/100.0+.0076;:Gl+l. 3^"G2
230 S2 = 2000.0::M1»(.0005"'CI1+I2+I3+I6)+.0012::(I4+I5.|.I))
235 S2 = S^-2000.0::Ml»(.0012::(l7-»-lb)+.0003"I9)
240 SO = L4+K7::K5/100.0
245 Sb = Sb*20.0::Ml»( ,55::Fl+.945JF2*.b"F3+.57::F4
2JO 50=1.02-50
255 S3=(.0000659;;(B1"1.00.0):::!2.65)!CS8/10000.0
260 50 = 50 + 53 ' ' ' ' " '•'•.'''••'••
-------
APPENDIX C
EXHIBIT 2
Page 2
MATERIAL AND HEAT BALANCE
265 S4=2.0::CS1+S2-S3)
270 Kl=. 02-S8-. 76
2/5 M2=Ml"«i005.0-C8+S9+M8+Rl+S2
200 B3=(Al+02+Gi;>/(CD/24.0)::::2::3.l4l6)
2o5 t>3=.0625::(4.0+CB3/32.8-7.o;>;>
290 u4=2o_0.0/Kl-l6.0
29^ U5=56.0-29.2"M1/(CD/24.C»":;2"3.14)
;SOO Vl=CN2/28.0+C2/44.0+Cl/28.0+H/2.0+S4/64.o:)::.01073::CT3+460.0)/l4.7
305 V2=520.0::Vl/(T3+M60.o:)
310 i>6=U3::V2/Ml
320
325
330
335
340
350
355 06=02-5. Od/Ml
360 K=K5/M1
365 G4=2.54"G1/M1
370 G5=446.0::G2/M1
375
305
390 S6=SOYM1
39^ N3=N2/M1
400 C6=C2/H1
405 C7=Cl/i'll
410 H7=H/.-11
415 S7=S4/M1
420
42^> W6=W2/100.0
430
435 W^=W1-W3
440 Sb=S6+W4
445 W1=W1/100.0
450 R5=C I4-H5-H6)-M3
460 Q4 = CT4-60.0)::.2086::2.0::M1
465 Q5=2.16::.750::CC5-20.0::M1::F3:J.95)
470 CS=S5::(l.-OIM(l./(6l.:cM5/52./S5^))
472 Q6=.o2"M5-.44»CS
475 Q7=CT4-60.0)::.321::S6::M1/1000.0
400 Q7=Q7-Q6
4d5 QO=2.d9b"Hl
490 Q9=(T3-60.0)::C .254::N2+. 24 3»C2-i-. 256-C 1+3. 466:JH+.226::U7"M1)/1300 .0
495 P1=4.346::C1
500 Q=Q1*Q2*Q3
50S P2=Q-Q4-Q5-Q7-Q8-Q9-P1
510 Z=Q/100.0
700 KM32=M3/W1
705 KI11=I1::M3
710 RI12=RI11/W1
715 R52=R5/W1 .
720 RI31=I3::M3
-------
APPENDIX C
EXHIBIT 2
Page 3
MATERIAL AND HEAT BALANCE
725 KI32=RI31/W1
730 KI01=I::M3
735 RI02=RI01/W1
7^0 K62=R6/W1
7^5 RK02=K/W1
750 G^2=G4/W1
755 G52=G5/W1
760 F52=F5/W1
765 A52=A5/W1
770 u62=06/Wl
775 KL52=L5/W1
700 W11=100.::W1
705 W12=W11/W1
790 RM42=M4/W1
795 S62=S6/W1
dOO U72=L>7/W1
005 W2 H72=H7/w6
030 S72=S7/w6
035 Q12=Q1/Z
= Q3/Z
Q02 = Q/Z
055 Q42 = Q'4/Z
060 Q72=Q7/Z
065 Q5^=Q5/Z
070 Q02=QO/Z
075 Q9<^=Q9/Z
000 P12=P1/Z
605 P22=P2/Z
090 WRITE (9/30)
09b 30 FORMAT (5X16HMATERIAL BALANCE//6H INPUTS/20X17HPOUNDS PERCENT
900 WRITE (9,40;>M3,RM32
905 HO FORMAT (12HMETAL CHARGE8X, F7 . 0, F9 . 2)
910 WRITE (9,50)RI11/RI12
915 50 FORMAT (8HPIG IRON12X, F7 . 0, F9 .2)
920 WRITE (9,60)R5,R52
925 60 FORMAT (7HRETURNS13X/F7.0/F9.2)
930 WRITE C9,70)RI31,RI32
935 70 FORMAT (11HSTEEL SCRAP9X, F7 . 0, F9 . 2)
9^0 WRITE (9/00)RI01/RI02
945 00 FORMAT C10HIRON SCRAP10X, F7 . 0, F9 .2)
950 WRITE C9,90)R6,R62
955 90 FORMAT C11HFERROALLOYS9X/F7.0/F9.2)
960 WRITE (9/100)K/RK02
965 100 FORMAT (/^HCOKE16X/F7.0/F9.2)
970 WRITE (9,110;)G4,G42
975 110 FORMAT C11HNATURAL GAS9X, F7 . 0, F9 . 2)
900 WRITE (9/120)G5/G52
9t>i> 120 FORMAT (8HFUEL OIL12X, F7 .0, F9.2)
990 WRITE C9/130)F5,F52
995 130 FORMAT (/18HFLUX AND ADDIT I VES2X, F7 . 0, F9 . 2)
1000 WRITE C9/1^0)A5/A52 . , . , ,
-------
EXHIBIT 2
Page 4
MATERIAL AND HEAT BALANCE
10G5 140 FORMAT (/jHAIR17X,F7* 0,F9.2)
1010 WRITE 09,150)06,062
1015 150 FORMAT (6HOXYGEN14X,F7.0,F9.2)
1020 WRITE (9,160)L5,RL52
1025 160 FORMAT (/13HCUPOLA LINING7X,F?.0,F9.2)
1030 WRITE (9,170)W11,W12
1035 170 FORMAT C/16HTOTAL INPUT MTLS4X,F7.0,F9.2)
1040 WRITE (9,lbO)M4,RM42
1045 100 FORMAT (//7HOUTPUTS//11HMOLTEN IRON9X,F7.0, F9 . 2)
1050 WRITE (9,190)56,562
1055 190 FORMAT (/4HSLAG16X,F7.0,F9.2)
1060 WRITE (9,200)D7,D72
1065 200 FORMAT (/14HEMISSIONS DUST6X,F7.0,F9.2)
1070 WRITE (9,210)W2,W22
1075 210 FORMAT C/9HTOP GASES11X,F7.0,F9.2)
10dO WRITE (9,220)N3,RN32
1035 220 FORMAT (&HNITROGEN12X,F7.0,F9.2)
1090 WRITE (9,230)C6,C62
1095 230 FORMAT (14HCARBON DIOXIUE6X,F7.0,F9.2)
1100 WRITE (9,240)C7,C72
1105 240 FORMAT C15HCARBON MONOXIDE5X,F7.0,F9.2)
1110 WRITE (9,250)H7,H72
1115 250 FORMAT C6HHYDROGEN12X,F7.0,F9.2)
1120 WRITE (9,260)57,572
1125 260 FORMAT (14HSULFUR DIOXIDE6X,F7.0,F9.2)
1130 WRITE C9,265)
1135 265 FORMAT (///5X12HHEAT BALANCE//.10H INPUT HEAT10X7HB,
1140 WRITE C9,270)
1145 270 FORMAT (20X20HCOOO/HR.) PERCENT)
1150 WRITE (9,2bO)Ql,Q12
1155 200 FORMAT (/14HPOTENTIAL HEAT/10H OF FUEL10X,F7.0,F9
1160 WRITE C9,290)Q3,Q32
1165 290 FORMAT C/13HSENSIBLE HEAT/15H OF THE BLAST5X,F7.0,F9.2)
1170 WRITE (9,300)Q2,Q22
1175 300 FORMAT (/19HHEAT FROM OXIDATION/16H
1160 WRITE (9,310)Q,Q02
1105 310 FORMAT C/19H TOTAL INPUT HEATX,F7.0,F9.2)
1190 WRITE (9,320)
1195 32,0 FORMAT (//11HOUTPUT HEAT)
1200 WHITE (9,330)Q4,Q42
1205 330 FORMAT (/19HHEATING AND MELTING/10H
1210 WRITE (9,340)Q7,Q72
1215 340 FORMAT (/12HHEAT CONTENT/14H OF THE SLAG6X,F7.0, F9 . 2)
1220 WRITE (9,350)Q5,Q52
1225 360 FORMAT (/I3HDECOMPOSITION/11H OF WATER9X,F7.0,F9.2)
1230 WRITE (9,360)QO,Qd2
1235 350 FORMAT (/12HCALCINING OF/12H LIMESTONE&X,F7.0,F9.2)
1240 WRITE (9,370)Q9,Q92
1245 370 FORMAT (/9HTOP GASES/16H -SENSIBLE HEAT4X,F7.0,F9.2)
1250 WRITE (9,380)P1,P12
12^5 300 FORMAT (l4h -LATENT HEAT6X,F7.0,F9.2)
1260 WRITE (9,390)P2,P22
1265 390 FORMAT (/19HHEAT RADIATION FROM/13H
1270 WRITE (9,400)V1,V2
1275 ^00 FORMAT (//23HVOLUME OF TOP GAS (MCF)/6HACTUAL4x, F?.O/
1200 + OHSTANDARU2X,F7.0)
1960 Stop
1970 End
.T.U.S)
,2)
OF MN, FE, SI4X,F7.0,F9
OF IRON10X/F7.0,F9.2)
THE CUPOLA7X,F7.0,F9.2)
-------
Insufficient Data for
Heat: and Material
Balance Calculations
Cold Blast Air
Molten Iron
Spark Arrester
No Afterburner
Charge
Door Open
Unlined Water
Cooled Shell
No Fuel Injection
No 02 Enrichment
Slag
CUPOLA CLASSIFICATION - 1
IMI
oi
Ml
n
-------
HEAT BALANCE
INPUT HEAT
POTENTIAL HEAT
0F FUEL
SENSIBLE HEAT
9F THE BLAST
HEAT FR0M 0XIDATI0N
0F MN. FE. SI
TBTAL INPUT HEAT
B.T.U.S
(000/HR.)
100823.
. 158.
1537.
102518.
PERCENT
98.35
0.15
1.50
100.00
MATERIAL
INPUTS
METAL CHARGE
PIG 1R0N
RETURNS
STEEL SCRAP
IR0N SCRAP
FERH0ALL0Y3
C0KE
NATURAL GAS
FUEL 0IL
BALANCE
P0UNDS
1992.
233.
996.
739.
0.
23.
253.
0.
0.
PERCENT
47.42
S.S6
23.71
1 7. 60
0.00
0.56
6.03
0.00
0.00
BUTPUT HEAT
KEATING AND MELTING
0F IR0N 38157. 37.22
HEAT C0NTENT
0F THE SLAG
CALCINING 0F
LIMEST0NE
DEC0MP0SITI0N
0F WATER
T0P GASES
-SENSIBLE HEAT
-LATENT HEAT
HEAT RADIATI0N FR0M
THE CUP0LA 13714. 13.38
V0LUME 0F T0P GAS (MCF)
ACTUAL 2309.
STANDARD 917.
598.
1438.
1388.
14714.
32509.
0.58
1 .40
1.35
14.35
31 .71
FLUX AND ADDITIVES 58. 1.38
AIR 1898. 45.18
OXYGEN 0. 0.00
CUP0LA LINING 0. 0.00
T0TAL INPUT MTLS 4201. 100.00
0UTPUTS
M0LTEN IR0N 2000. 47.60
SLAG 44. 1.04
EMISSIONS DUST 19. 0.45
T0P GASES 2139. 50.90
NITR0GEN 1449. 67.77
CARB0N DI0XIDE 468. 21.87
CARB0N M0N0XIDE 220. 10.29
HYDR0GEN 2. 0.07
SULFUR DI3XIDE -0. -0.00
Gas Take-Off
Cold Blase Air
Molten Iron
Closed Top
No Afterburner
Charging
Door Open
Unllned Water
Cooled Shell
No Fuel Injection
No 0 Enrichment
Slag
CUPOLA CLASSIFICATION - 2
I
-------
Insufficient Data for
'Heat and Material
"- Balance Calculations
Warm Blast Air
Molten Iron
Spark Arrestor
No Afterburner
Charge
Door Open
Unlined Water
Cooled Shell
No Fuel Injection
No 02 Enrichment
Slag
CUPOLA CLASSIFICATION - 3
1
u>
-------
HEAT BALANCE
INPUT HEAT B.T.U.S
<000/HR.) PERCENT
MATERIAL BALANCE
INPUTS
POTENTIAL HEAT POUNDS
8K FUEL
SENSIBLE HEAT
OF THE BLAST
HEAT FROM OXIDATION
OF- MM. FE. SI
TOTAL INPUT HEAT
OUTPUT, HEAT
HEATING AND MELTING
OF IRON
HEAT C8NTENT
OF THE SLAG
CALCINING 0F
LIMEST0NE
DECOMPOSITION
OF WATER
TOP GASES
-SENSIBLE HEAT
-LATENT HEAT
HEAT RADIATION FROM
THE CUPOLA
56685. 85.19
9301. 13.96
556. 0.84
66S4I. 100.00
15432. 23.19
156. 0.23
984< 1 .48
680. 1.02
11973. 17.99
-15611. -23.46
52926. 79.54
VOLUME OF TOP GAS (MCF)
•>«.*., At 1 1Q1 _
METAL CHARGE
PIG IRON
RETURNS
STEEL SCRAP
IRON SCRAP
FERROALLOYS
COKE
NATURAL GAS
FUEL OIL
FLUX AND ADDITIVES
AIR
OXYGEN
CUPOLA LINING
TOTAL INPUT MTLS
OUTPUTS
MOLTEN IRON
SLAG
EMISSIONS DUST
TOP GASES
NITR0GEN
CARBON DIOXIDE
CARBON MONOXIDE
HYDK0GEN
SULFUR DIOXIDE
2004.
0.
982.
295.
687.
41.
333.
0.
0.
100.
4085.
0.
0.
6523.
2000.
56.
32.
4435.
3129.
1573.
-266.
2.
-3.
PERCENT
30.73
0.00
15.05
4.52
10.54
0.62
S.ll
0.00
0.00
1.54
62.63
0.00
0.00
100.00
30.66
0.86
0.49
67.99
70.55
35.46
-6.00
0.04
-0.06
ACTUAL
STANDARD 712
Gas Take-Off
Warm Air Blast
Molten Iron
Closed Top
Afterburner
Charging
Door Open
Unlined Water
Cooled Shell
No Fuel Injection
No 6 Enrichment
Slag
CUPOLA CLASSIFICATION - 4
-------
HEAT BALANCE
INPUT HEAT B.T.U.S
(000/HR. )
P0TCNTIAL HEAT
0F FUEL
SENSIBLE HEAT
8F THE BLAST
HEAT FROM 0XIDAT10N
0F MN. FE. SI
TOTAL INPUT HEAT
0UTPUT HEAT
HEATING AND MELTING
0F IR0N
HEAT CONTENT
0F THE SLAG
CALCINING 0F
LIMESTONE
DECOMPOSITION
OF WATER
TOP GASES
-SENSIBLE HEAT
-LATENT HEAT
HEAT RADIATION FROM
THE CUPOLA
40947.
3247.
3106.
47300.
14028.
806.
1221.
292.
5652.
10785.
14515.
MATERIAL BALANCE
PERCENT INPUTS
86.57
6.86
6.57
100.00
29.66
1.70
2. 58
0.62
11.95
22.80
30.69
VOLUME OF TOP GAS (MCF)
METAL CHARGE
PIG IRON
RETURNS
STEEL SCRAP
IRON SCRAP
FERROALLOYS
COKE
NATURAL GAS
FUEL OIL
FLUX AND ADDITIVES
AIR
OXYGEN
CUPOLA LINING
TOTAL INPUT MTLS
OUTPUTS
MOLTEN IRON
SLAG
EMISSIONS DUST
TOP GASES
NITROGEN
CARBON DIOXIDE
CARBON MONOXIDE
HYDROGEN
SULFUR DIOXIDE
POUNDS
2030.
256.
1507.
0.
223.
45.
250.
0.
0.
136.
1893.
81 .
0.
4390.
2000.
120.
19.
2251.
1450.
600.
199.
1.
1.
PERCENT
46.23
5.83
34.32
0.00
5.07
1.01
5.69
0.00
0.00
3.10
43.13
1 .85
0.00
100.00
45.55
2.74
0.44
51.27
64.43
26.65
8.82
0.04
0.06
ACTUAL 872.
STANDARD 346.
Gas Take Off
Warm Blast Air
to 1 ten Iron
Closed Top
Afterburner
Charging
Door Open
Unllned Water
Cooled Shell
No Fuel Injection
With 02 Enrichment
Slag
CUPOLA CLASSIFICATION - 5
ojcol
-------
HEAT BALANCE
INPUT HEAT
B.T.U.5
(000/HR.) PERCENT
INruii
POTENTIAL HEAT P0UNDS
0F FUEL
SENSIBLE HEAT
0F THE BLAST
HEAT FR0M 0X1 DAT I BN
0F MN. FE» SI
T0TAL INPUT HEAT
OUTPUT HEAT
HEATING AND MELTING
0F IRON
HEAT CONTENT
0F THE SLAG
CALCINING 0F
LtMEST0NE
DECOMPOSITION
0F WATER
T0P GASES
-SENSIBLE HEAT
-LATENT HEAT
44940. 89.05
4694. 9.30
834. I.6S
50468. 100.00
23343. 46.25
706. 1.40
326. 0.64
'1C 1 OO
O 1 J . 1 * f-C-
6892. 13.66
14898. 29.52
HEAT RADIATION FROM
THE CUPOLA 3688. 1.31
VOLUME OF TOP GAS
(MCF)
METAL CHARGE
PIG IRON
RETURNS
STEEL SCRAP
IR0N SCRAP
FERROALLOYS
COKE
NATURAL GAS
FUEL OIL
FLUX AND ADDITIVES
A f D
H 1 K
OXYGEN
CUPOLA LINING
TOTAL INPUT MTLS
OUTPUTS
MOLTEN IRON
SLAG
EMISSIONS DUST
TOP GASES
NITR0GEN
CARBON DIOXIDE
CARBON MONOXIDE
HYDROGEN
SULFUR DI0MDE
1981.
0.
869.
1043.
0.
70.
200.
•
0.
44.
1374.
0.
0.
3599.
2000.
45.
14.
1540.
1049.
324.
165.
1 .
1 .
PERCENT
S5.05
0.00
24.14
28.97
0.00
i
-------
Insufficient Data for
Heat and Material
Balance Calculations
Hot Air Blast
Molten Iron
Spark Arrester
Afterburner
Charge
Door Open
Unlined Water
Cooled Shell
No Fuel Injection
No $2 Enrichment
Slag
CUPOLA CLASSIFICATION - 7
mi
-------
HEAT BALANCE
INPUT HEAT B.T.li.S
lUUU/nr>*J rL^UC-iNI
POTENTIAL HEAT
0F FUEL 64255. 76.64
SENSIBLE HEAT
0F THE BLAST 12745. 15.20
HEAT T.K0M OXIDATION
0F SlN. FE. SI 6B40. b.16
TOTAL INPUT HEAT B3B40. 100.00
O'UTPUT HEAT
H FA-TINT, AND MELTING
OF IKHN 22H63. 27.27
HFAT 'COMTENT
OF THt: SLAG 1271 . 1 . 52
'C'A'LC'iN'lN'G OF
LIMESTONE «7i>. 1-04
DEC'JMPCJSITIHN
OF V.'ATF.K 1 1 90. 1 .42
Tfir GASES
-SENSIBLE HF.AT 12113. 14. 4b
-LATENT HEAT 356. 0.42
H£AT KADIATION FHOM
THE CUPOLA 45172. 53. HK
VOLUMF OF TOP GAS (KCF)
MATF.KIAL BALANCE
.INPUTS
POUNDS
METAL CHAKGE
PIG IH0N
KETIiKMS
STEEL SCKAP
IK0N SChAP
FEKKHALL3YS
COKE
NATUKAL GAS
FUEL OIL
FLbA AND ADDITIVES
A I K
OXYGF.N
CUPOLA LINING
TOTAL INPUT MTLS
OUTPUTS
MULTEN IKON
SLAG
EMISSIONS DUST
T0P GASES
NITK0GF.N
CAKBOM n I OX IDE
CAKBP)N MONOXIDE
HYUK01RF.M
<>'t FllK UIOAlljE
2023.
0.
5h V .
391 .
97h.
67.
267.
0.
O.
61.
2766.
0.
C.
51 1 7.
20UU.
W f.
O 1 •
26.
300H.
2112.
brl7.
4.
.
2.
PF.KCEN1
39.54
0.00
1 1 .47
7.65
19. 12
1*in
* JU
5.21
Onn
• \J U
0.00
1.19
54.06
11.00
0.00
100. UO
39.09
1 .63
0.50
5h. 7B
70.22
29. 4b
0 . 1 4
o.Ob
0.06
ACTUAL InbJ.
STANDARD 736.
Hot Blast Air
Molten Iron
Spark Arrester
No Afterburner
Charge
Door Open
Unlined Water
Cooled Shell
No Fuel Injection
No 02 Enrichment
Slag
CUPOLA CLASSIFICATION - 8
Ml 3
-------
Gas Take-Off
Insufficient Data for
Heat and Material
Balance Calculations
Hot Blast Air
Molten Iron
Closed Top
Afterburner
Charging
Door Open
Unlined Water
Cooled Shell
No Fuel Injection
No 02 Enrichment
Slag
CUPOLA CLASSIFICATION - 9
s>i
Oi
mi
-------
HEAT BALANCE
INPUT HEAT
POTENTIAL HEAT
OF FUEL
SENSIBLE HEAT
OF THE BLAST
HEAT FRBM OXIDATION
OF MN. Ft, SI
T0TAL INPUT HEAT
OUTPUT HEAT
HEATING AND MELTING
0F IKON
HEAT C0NTENT
0F THE SLAG
CALCINING 0F
LIMESTONE
DEC9HP0SJTION
0F WATER
T0H GASES
-SENSIBLE HEAT
-LATENT HEAT
HEAT HADIATI0N FH0M
THE CUPOLA
MATERIAL BALANCE
B.T.U.S
(000/HK.) PERCENT INPUTS
39360. 56. 01
6373. 9.07
24545. 34.93
70278. 100.00
11223. 15.97
4148. 5.90
795. 1.13
595. 0.85
5902. b.40
24225. 34.47
23390. 33.28
V0LUME 0F TOP GAS (MCF)
METAL CHAKGE
PIG IR0N
RETURNS
STEEL SCRAP
IR0N SCRAP
FERROALLOYS
C0KE
NATURAL GAS
FUEL UIL
FLUX AND ADDITIVES
AIR
0XYGEN
CUP0LA LINING
T0TAL INHUT MILS
OUTPUTS
M0LTEN IK0N
SLAG
EMISSIONS DUST
T0P GASES
N1TKUGEN
CAKB1N DI0XIDE
CARB0N MaNOXIDE
HYDRHGFN
SliLFUK DI0XIDE
POUNDS
2190.
0.
640.
0.
) 121.
429.
320.
0.
0.
I 19.
2766.
0.
29.
5425.
2000.
501.
27.
2897.
2112.
naa.
i57.
?..
3.
PERCENT
40.38
0.00
11.81
0.00
20.66
7.91
5.90
0.00
0.00
2.20
50.99
0.00
0.54
100.00
36. HI
9.24
0.49
53.40
72.91
7.67
19.24
0.08
0. 10
ACTUAL 971.
STANDARD 386.
Gas Take-Off
Hoc Blast Air
Molten Iron
Closed Top
No Afterburner
Charging
Door Open
Unllned Water
Cooled Shell
No Fuel Injection
No 0 Enrichment
Slag
CUPOLA CLASSIFICATION - 10
o
mca
-------
HEAT BALANCE
INPUT HEAT B.T.U.S
(000/HR.) PERCENT
POTENTIAL HEAT
0F FUEL 94371. 80.08
SENSIBLE HEAT
OF THE BLAST 11389. 10.63
HEAT FR0M OXIDATION
OF MN. FE. SI 1386. 1.29
TOTAL INPUT HEAT 107146. 100.00
BUT PUT HEAT
HEATING AND MELTING
0F IRON 39279. 36.66
HEAT C0NTENT
BF THE SLAG SOS. 0.47
CALCINING 0F
LIMESTONE 786. 0.73
DECOMPOSITION
0F UATEK 1190. 1.11
T0P GASES
-SENSIBLE HEAT 12693. 11.85
-LATENT HEAT 3903S. 36.43
HEAT RADIATION FR0K
THE CU1'0LA I36S8. 12.75
VOLUME JF TOI' f.Ao CHCf)
ACTUAL 2018.
CTAMPlAOn Of\\
MATERIAL BALANCE
INPUTS
METAL CHANGE
PIG IK0N
RETURNS
STEEL SCRAP
IR0N SCRAP
FERROALLOYS
C0KE
NATURAL GAS
FUEL 0IL
FLUX AND ADDITIVES
AIR
0XYGEN
CUP0LA LINING
T0TAL INPUT MTLS
OUTPUTS
MOLTEN IR0N
SLAG
EMISSIONS DUST
T0P GASES
NITK0GEN
CARB3N DIOXIDE
CARBON M0N0XIDF
HYDH0GEN
SULFUk DI0XIOE
POUNDS
1989.
0.
426.
791.
761.
1 1.
233.
0.
0.
31.
1 581 .
0.
0.
3833.
POOO.
27.
16.
1790.
1207.
324.
257.
1 .
1 .
PERCENT
SI. 90
0.00
11.12
20.65
19. US
0.28
6.07
C.OO
0.00
O.bO
41 .24
0.00
0.00
100.00
52. IB
0.70
0.42
46. 7O
67.43
18.09
14.34
0.07
0.08
Gas Take-Off
Hot Blast Air
Molten Iron
Closed Top
No Afterburner
Charging
Door Open
Unllned Water
Cooled Shell
No Fuel Injection
No 02 Enrichment
Slag
Ci:?OLA CLASSIFICATION - 11
-------
HEAT BALANCE
INPUT HEAT B.T.U.S
(000/HR.) PERCENT
P0TENTIAL HEAT
0F FUEL 29060. 86. 72
SENSIBLE HEAT
0F THE BLAST 61 > 0.18
HEAT FK0M 0XIDAT10N
OF MN. FE. SI 4390. 13.10
T0TAL INPUT HEAT 33511. 100.00
0UTPUT HEAT
HEATING AND MELTING
0F l!iflN 17623. 52.59
HEAT C0NTENT
0F 'iHE SLAG 274. O.b2
CALCINING 0F
LIMESTONE 756. 2.25
DEC0MP0SITI0N
0F WATER 3569. 10.65
TOP GASES
-SENSIBLE HEAT 6182. 18.45
-LATENT HEAT 6880. 20.53
HEAT RADIATI0N FROM
THE CUP0LA -1772. -5.29
VOLUME 0F T0H GAS (MCF)
A r>Tl 1 A 1 Q C O
MATERIAL BALANCE
INPUTS
METAL CHARGE
PIG IR0N
RETURNS
STEEL SCRAP
IR0N SCRAP
FERR0ALL0YS
C0KE
NATURAL GAS
FUEL 0IL
FLUX AND ADDITIVES
AIR
0XYGFN
CUP0LA LINING
T0TAL INPUT MTLS
0UTPUTS
M0LTEN IR0N
SLAG
EMISSIONS DUST
T0P GASES
NITR0GEN
CARB0N DI0XIDE
CARBON M0N0XIDE
HYDROGEN
SULFUK DIOXIDE
POUNDS
2004.
0.
802.
1 137.
0.
65.
167.
29.
0.
65.
1556.
0.
27.
3K48.
2000.
32.
14.
1802.
1 188.
507.
99.
9.
0.
PERCENT
52.08
0.00
20.83
29.56
0.00
1.69
4.33
0.75
0.00
1 .69
40.43
0.00
0. 71
100.00
51 .97
0.83
0.37
46. 84
65.91
28.10
5.49
0.47
0.02
Cold Blast Air
Molten Iron
Spark Arrestor
Acid Lining
Afterburner
Charge
Door Open
No Fuel Injection
No 0- Enrichment
Slag
CUPOLA CLASSIFICATION - 12
-------
HFAT BALANCE
MATERIAL BALANCE
INPiJT hEAT h.l .L'.S
(000/HK. )
I'HTF.NIIAL HEAT
f)F FijfiL bl 194.
.SENSIBLE HEAT
:>F THE HLAST 9O.
HEAT FKflM HXIDATMN
OF MN. FE. SI 691.
TOTAL INPUT HEAT b!976.
OUTPUT HEAT
HEATING AND KELTINIi
HF InUN Ib712.
HEAT CUNTE.NT
OF THE SLAG bl 1 .
CALCINING OF
LINF.aTa.NF. f>74.
DECOMPOSITION
OF WATEK 793.
TOP GASES
-SENSIBLE HEAT K'M>\ .
-LATENT HEAT 9439.
HEAT KADIATIUN F:•).!., 4
1.27
0.47
5b . 42
6K.59
25.99
5.29
0.07
O.Ob
Cold Blast Air
Molten Iron
Spark Arrestor
Acid Lining
No Afterburner
Charge
Door Open
No Fuel Injection
No 0, Enrichment
Slag
r
ACTUAL I2>;3.
-STANDAhD 509.
CUPOLA CLASSIFICATION - 13
_
O M
i-H
-------
HEAT BALANCE
MATEKIAL BALANCE
INPUT HEAT B.T.U.S INPUT'
(000/HK.) PEhCENT POUNDS
POTENTIAL HEAT
OF FUEL 3)164. 9b.54
SENSIBLE HEAT
0F THE BLAST 49. 0.16
HEAT FR0M 0X1DATI0N
0F MN> FE. SI 414. 1.31
T0TAL INPUT HEA1 31628. 1UO.OO
0UTPUT HEAT
HEATING AND MILTING
"Op IKON 11160. 35.29
HEAT CONTENT
"0F" THE SLAG 4b9. 1.45
CALCINING 9F
LIMESTONE 547. 1.73
DECOMPOSITION
OF WATEh 431 . 1 .36
TOP GASES
-SENSIBLE HEAT 45U1 . 14. 4B
-LATENT HEAT 9802. 30.99
HEAT RADIATION FK0M
THE CUPOLA 4647. 14.69
METAL CHANGE
PIG IRON
RETURNS
STEEL SCRAP
IKON SCRAP
FERROALLOYS
COKE
NATURAL GAS
FUEL OIL
FLUX AND ADDITIVES
AIM
OXYGEN
CUPOLA LINING
TOTAL INPUT MTLS
OUTPUTS
MOLTEN IKON
SLAG
EMISSIONS DUST
T0P GASES
NITROGEN
CAKB0N DIOXIDE
CARBON MONOXIDE
HYDROGEN
SULFUK DIOXIDE
2005.
0.
201.
301.
1504.
0.
250.
0.
0.
75.
2005.
0.
29.
4365.
2000.
77.
19.
2269.
1531 .
507.
226.
2.
4.
PERCENT
45.94
0.00
4.59
6.89
34.45
0.00
5.73
0.00
0.00
1 .73
45.94
0.00
0.67
100.00
45. b2
1.77
0.43
51 .99
67.47
22.34
9.94
0.07
o . ; a
VOLUME 0F TOP GAS (MCF)
ACTUAL 719
STANDAHO 285
Gas Take-Off
Cold Blast Air
Molten Iron
A
f
J
^r1^
t
Jj
^
\Z=5\
'
1
-J
5
\
•f
^=
1
i
fc^
HT
"
i
i
1
i
1
*i
Ft
• Ac id Lining
-. Charging
Door Open
• t rl 1 »
•• — • No Fuel Injection
No Q7 Enrichment
i
^
Slag
CUPOLA CLASSIFICATION - 14
n
pin
-------
HEAT BALANCE
INPUT HEAT B.T.U.S
(000/HR.) PERCENT
POTENTIAL HEAT
OF FUEL 35065. 98.73
SENSIBLE HEAT
OF THE BLAST 53. 0.15
HEAT FR3M OXIDATION
OF MN. FE. SI 399. 1.12
T0TAL INPUT HEAT 35518. 100.00
8UTPUT HtrtT
HFATING .1ND MELTING
0F IR0N ?312. 26.22
HEAT CONTENT
0F THE SLAG 420. 1.18
CALCINING OF
LIMEST0NE 350. 0.99
DECOMPOSITION
OF WATER 466. 1.31
TOP GASES
-SENSIBLE HEAT 4945. 13.92
-LATENT HEAT 12530. 35.28
HEAT RADIATION FROM
THE CUPOLA 7495. 21.10
V3LUME 0F THH GAS
-------
HEAT BALANCE
INPUT HEAT
POTENTIAL HEAT
8F FUEL
SENSIBLE HEAT
0F THE BLAST
HEAT FR0M 8XIDATI0N
11 8F MM, FE< SI
T8TAL INPUT HEAT
8UTPUT HEAT
'^'i
HEATING AND MELTING
"• 0F IR0N
HEAT C0NTENT
- 0F THE SLAG
CALCINING 0F
LIME3T0NC
DEC9HP0SITI0N
4(F MATER
T0P GASES
-SENSIBLE HEAT
-LATENT HEAT
HEAT RAOIATI0N FR0M
THE CUP0LA
B.T.U.S
(000/HR.l
25435.
48.
450.
25934.
9539.
485.
322.
421.
436S.
2615.
8186.
1 PERCENT
98.08
0.19
1.74
100.00
36.78
1.87
1.24
1.63
16.83
10.08
•
31.57
V0LUME 0F T0P GAS (MCF>
MATERIAL BALANCE
INPUTS
HETAL CHARGE
PIG IR0N
RETURNS
STEEL SCRAP
IR0N SCRAP
FERR0ALL0YS
C0KE
NATURAL GAS
FUEL 0IL
FLUX AND ADDITIVES
AIR
0XYGEN
CUP0LA LINING
T0TAL INPUT MTLS
0UTPUTS
M0LTEN IR0N
SLAG
EMISSIONS DUST
T0P GASES
NITR0GEN
CARB0N DI0XIDE
CAHB0N M0N0X1DE
HYDR0GEN
SULFUR DI0XIDE
P0UNDS
2002.
548.
896.
548.
0.
10.
250.
0.
0.
52.
2305.
0.
36.
4644.
2000.
76.
_
'21.
2547.
1760.
714.
71.
2.
I.
PERCENT
43.10
11.79
19.30
1 1.79
0.00
0.21
S.38
0.00
0.00
1.12
49.63
0.00
0.77
100.00
43.06
1.64
0.45
54.85
69.09
28.03
2.78
0.07
0.03
Closed Top
Gas Take-Off
Cold Blast Air
Molten Iron
s*~
J
—i
•^»"
ss
1
>,'
1
N
1
L
i
i
i
i
i n
A i f rl T I 1
AGIO Lining
Ho Afterburner
- Charging
Door Open
No Fuel Ini
No 02 Enrichment
Slag
CUPOU CLASSIFICATION - 16
ACTUAL 671.
STANDARD 266.
-------
HEAT BALANCE
INPUT HEAT
PBTENTIAL HEAT
8F FUEL
SENSIBLE HEAT
8F THE BLAST
HEAT FR0M 0XIDATI8N
8F HN. FE» SI
T9TAL INPUT HEAT
0UTPUT HEAT
HEATIN6 AND MELTING
8F IR0N
HEAT C8NTENT
0F THE SLAG
CALCINING 0F
LIMEST0NE
DEC0MP0SITI0N
0F «ATER
T0P BASES
-SENSIBLE HEAT
-LATENT HEAT
B.T.U.S
(000/HR.) PERCENT
144207. 97.67
194. 0.13
3240. 2.19
147641. 100.00
MATERIAL BAL
INPUTS
METAL CHARGE
PIG IR0N
RETURNS
STEEL SCRAP
IR8N SCRAP
FERR0ALL0YS
C0KE
NATURAL GAS
FUEL 0IL
.ANCF
P0UNDS
1984.
861 .
186.
931.
0.
6.
242.
.
0.
FLUX AND ADDITIVES «0.
62872. 42.SB
8849. 1.52
1604. 1.09
1636. |.||
18321. 12.41
49633. 33.62
HEAT RAOIATI0N FR0H
THE CUP0LA 11324. 7.6?
V8LUME BF T0P GAS
ACTUAL 8863.
STANDARD 1137.
AIR
8XYGEN
CUP0LA LINING
T8TAL INPUT MTLS
8UTPUTS
M8LTEN IR0N
SLAG
ENISSI0NS DUST
T0P GASES
NITR0GEN
CARB8N DI0XIDE
CARB8N M0N0XIDE
HYDR0GEN
SULFUR DI0XIDE
1383.
61.
12.
3722.
8000.
57.
IS.
1651.
1056.
382.
208.
1.
4.
PERCENT
53.30
23.13
5.00
25.01
0.00
0.16
6. Si
0.00
0.00
1.07
37.16
1.64
0.33
100.00
S3. 73
1.52
0.40
44.35
63.97
23.17
18.58
0.07
0.21
Gas Take- Off
Cold Blast Air
Molten Iron
Closed Top
Acid Lloing
No Afterburner
Charging
Door Closed
No Fuel Injection
02 Enrichment
Slag
CUPOLA CLASSIFICATION - 17
mil
-------
HEAT BALANCE
INPUT HEAT
POTENTIAL HEAT
0F FUEL
SENSIBLE HEAT
0F THE BLAST
HEAT FK0M 0XIDATION
0F MN, FE, SI
T0TAL INPUT HEAT
0UTPUT HEAT
HEATING AND MELTING
0F IKON
HEAT C0NTENT
0F THE SLAG
CALCINING 0F
LIMESTONE
DECOMPOSITION
OF WATER
T0P GASES
-SENSIBLE HEAT
-LATENT HEAT
HEAT KADIATI0N FROM
THE CUPOLA
B.T.U.S
(000/HK. )
53096.
62.
816.
53975.
22445.
885.
816.
545.
6038.
31804.
-8559.
MATFKIAL BALANCE
PEKCENT
96.37
0. 12
1.51
IOU.OU
41.59
1 .64
1.51
1 .01
11.19
58.92
-15.86
VOLUME OF TOP GAS (MCF)
ACTUAL 9b5.
INPUTS
METAL ChAHGF.
PIG IKON
KETUKNS
STEEL SCKAP
IK«»N SCKAP
FEKKOALLHYS
COKE
NATURAL GAS
FUEL OIL
FLUX AND ADDITIVES
A IK
OXYGEN
CUfJLA LINING
TOTAL INPUT MTLS
OUTPUTS
M0LTEN IKON
SLAG
EMISSIONS DUST
TOP GASES
N1TK0GEN
CAhBBN D10X1DE
CAhBBN M0.M9XIDE
HYDK0GEN
SULFUK DI0XIUE
POUNDS
2002.
0.
400.
400.
1201.
0.
222.
0.
0.
56.
1268.
0.
Ib.
3566.
2000.
68.
14.
1 484.
968.
147.
366.
1 .
2.
PERCENT
56.15
0.00
11.23
1 1 .23
33.69 G ft
0.00
-------
HEAT BALANCE
INPUT HEAT
POTENTIAL HEAT
OF FUEL
SENSIBLE HEAT
OF THE BLAST
HEAT FROM OXIDATION
OF MN, FE, SI
TOTAL INPUT HEAT
OUTPUT HEAT
HEATING AND MELTING
OF IRON
HEAT CONTENT
OF THE SLAG
CALCINING OF
LIMESTONE
DECOMPOSITION
OF MATER
TOP GASES
-SENSIBLE HEAT
-LATENT HEAT
B.T.U.S
COOO/HR. >
68407.
5504.
1434.
75345.
25332.
1103.
1604.
567.
I 1610.
17324.
PER
90.79
7.31
1.90
100.00
33.62
1.46
2.13
0.75
IS. 41
22.99
MATERIAL BALANCE
HEAT RADIATION FROM
THE CUPOLA
IT804.
23.63
INPUTS
METAL CHARGE
PIG IKON
RETURNS
STEEL SCRAP
IRON SCRAP
FERROALLOYS
COKE
NATURAL GAS
FUEL OIL
FLUX AND ADDITIVES
AIR
OXYGEN
CUPOLA LINING
TOTAL INPUT MTLS
OUTPUTS
MOLTEN IRON
VOLUME OF TOP GAS (MCF)
ACTUAL 1734.
STANDARD 644.
EMISSIONS DUST
TOP GASES
NITROGEN
CARBON DIOXIDE
CARBON MONOXIDE
HYDROGEN
SULFUR DIOXIDE
POUNDS
2010.
o.
1873.
125.
0.
13.
250.
0.
0.
101.
2089.
0.
18.
4468.
2000.
93.
20.
2355.
1600.
572.
181.
I.
I.
PERCENT
44.99
0.00
41 .91
2.79
0.00
0.29
5.59
0.00
0.00
2.25
46.75
0.00
0.41
100.00
44.76
2.Ob
0.46
52.70
67.94
24.27
7.69
0.04
0.05
Warm Blast Atr
Molten Iron
Spark Arrester
Acid Lining
Afterburner
Charging
Door Open
No Fuel Injection
With 02 Enrichment
Slag
CUPOLA CLASSIFICATION - 19
-------
HEAT BALANCE
JNPUT HEAT B.T.U.S
MATERIAL BALANCE
COOO/HR.) PERCENT IN'Pl'TS
POTENTIAL HEAT
MF FUEL 69898. 87.22
SENSIBLE HEAT
0F THE BLAST 9237. 1 1 . 53
-KEAT TK0M OXIDATION
0F MN. FE. SI 1004. 1.25
T0TAL INPUT HEAT 80140. 100.00
OUTPUT HEAT
HEATING AND MELTING
OF IRON 29100. 36.31
HEAT CONTENT
0F THE SLAG 695. 0.87
•CALCINING OF
LIMFSTONE 474. 0.59
DECOMPOSITION
OF MATER 1 190. 1 .48
TOP GASES
-SENSIBLE HEAT 12431. 15.51
-LATENT HEAT -3301. -4.12
HEAT RADIATION FROM
THE CUPULA 39552. 49.35
VOLUME OF TOP GAS CMCF)
METAL CHARGE
PIG I*0N
RETURNS
STEEL SCRAP
IRON SCRAP
FERROALLOYS
Cl'/KF
NATURAL GAS
FUEL HIL
FLUX AND ADDITIVES
AIR
OXYGEN
CLr-OLA LINING
TOTAL INPUT MTLS
OUTPUTS
MOLTEN IKON
SLAG
EMISSIONS DUST
TOP GASES
NITROGEN
CARBON DIOXIDE
CARBON MONOXIDE
HYDROGEN
SULFUR DIC-JXIDF
P0UNDS
1983.
0.
390.
974.
584.
35.
250.
0.
0.
26.
2213.
41 .
18.
4530.
2000.
36.
22.
2472.
1 690.
810.
-30.
P..
1 .
PERCENT
43.78
0.00
8.60
21.50
12.90
0. 78
5.52
U.OO
0.00
0.57
48. 85
0.90
0.39
100.00
44. 1 5
0. 79
0.48
54. 5«
68.34
32.76
-1 .23
0.07
n . n f.
ACTUAL
•STANDARD 746.
^mr
Warm Blast Air
Molten Iron
Spark Arrester
Acid Lining
Afterburner
Charging
Door Open
No Fuel Injection
With 02 Enrichment
Slag
CUPOLA CLASSIFICATION - 20
wta'
-------
HEAT BALANCF
INPUT HEAT p.T.i,_«j
(000/HR.) PERCENT
POTENTIAL HEAT
Of F"EL 9985. 79.64
SENSIBLE HEAT
OF THE BLAST I337. ,fli66
HEAT -FROM OXIDATION
OF MN* FE» SI 101*
ur 1111* rc.» .11 1216. 9.70
TOTAL INPUT HEAT ,351R. 100-00
OUTPUT HEAT
HEATING AND MELTING
0F IR0N 3367. 26- B5
HFAT CONTENT
0F THE SLAG 40, . ^^
CALCINING OF
LIMEST0NF n,n
unto iiarot 262. 2-09
DECOMPOSITION
OF WATER 19B. |>5R
TOP GASES
- SENSIBLE HEAT -,•>-,,
t"^*— ^" ••*."• O . J f 1 • O A PQ
- LATENT HEAT |30««. .,04.04
HEAT RADIATION FROM
THE CUPOLA |79Bf>. M3<4J,
VOLUME PF TOP GAS CMHF)
ACTUAL 487.
c;Ti.MnA--n
MATERIAL BALANCE
INPUTS
METAL CHARGE
PIG IRON
RETURNS
STEEL SCRAP
IR0N SCRAP
FERROALLOYS
COKE
NATURAL GAS
FUEL OIL
FLUX AND ADDITIVES
AIR
OXYGEN
CUPOLA LINING
TOTAL INPUT MTLS.
OUTPUTS
MOLTEN IRON
SLAG
EMISSIONS DUST
TOP GASSEP
NITROGEN
CARBON DIOXIDE
CARBON MONOXIDE
HYDROGEN
SULFUR DIOXIDE
POUNDS
2001 .
•
566-
1321 .
0.
1 13.
308 .
0.
0.
1 20.
5361 .
•
Rl .
7871 .
2000.
1 7R.
54.
5639.
4107.
2529.
-1000.
3.
1 .
PERCENT
25.42
o.oo
7.19
16.78
n . fln
U • WU
1 . 44
3*91
0.00
0 • 00
1 . S.9
1 * J C.
68. 12
0.00
1 .03
100.00
25.41
2O A
• tin
0.69
71 .64
72.82
44.85
-1 7.74
0.04
0.03
Warm Air Blast
Molten Iron
Spark Arrester
Acid Lining
No Afterburner
Charge
Door Open
With Fuel Injectic
No 02 Enrichment
Slag
19.-;.
CUPOLA CLASSIFICATION - 21
Moo
M
-------
HEAT BALANCE
INPUT HF.AT -B.T.U.S
(000/HK.) PEhCENT
POTENTIAL HEAT
MF FUEL 43B96. 92.59
SENSIBLE HEAT
OF THE BLAST 2600. 5.4S
HEAT Fh0M OXIDATION
0F MNj FE» SI 915. 1 .93
TOTAL INPUT HEAT 47411. 100.00
OUTPUT HEAT
HEATING AND MELTING
0F IKON 17956. 37.87
HEAT CONTENT
0F THE SLAG 718. 1 .bl
CALCINING .OF
llKFSTflMF* T»O« 0 . 7 44
i- i "tf. o l v rv c. o J v • \j • i *i
DtC«MK0SITI0N
0F WATEK 585. 1 .23
T0t; GASES
-SENSIBLE HEAT 6186. 13. Ob
-LATENT HEAT 15923. 33.59
HEAT RADIATION FK0M
THE CUPOLA 5693. 12.01
\ j rt 1 i i N- n nr T n LJ /• A
-------
HEAT BALANCE
INPUT HEAT
POTENTIAL HEAT
0F FUEL
SENSIBLE HEAT
HF THE BLAST
HEAT FKHM 0XIDATI0N
0F MM. FE» SI
T0TAL INPUT HEAT
0UTPUT HEAT
HEATING AND MELTING
0F IK0N
HEAT C0NTENT
0F THE SLAG
CALCINING 0F
LIMEST0NE
DECOMP0SITI0N
0F WATEK
T0P GASES
-SENSIBLE HEAT
-LATENT HEAT
HF.AT KADIATI0N FK0M
THE CUP0LA
B.T.U.S
(000/HK. )
33777.
3977.
2673.
40427.
18123.
I 157.
751.
545.
5668.
5977.
8205.
MATEK1AL BALANCE
PEhCENT
83.55
9.84
6.61
100.00
44.83
2.86
1 .86
l.3b
14.02
14.78
20.29
V0LUME 0F TBP GAS tPICF)
INPUTS
METAL CHAKGE
PIG IhHN
KETUhNS
STEEL SCKAH
IK0N JiCKAP
FEhhHALLBYS
C0KE
NATUKAL GAS
FUEL 0IL
FLUX AND ADDITIVES
AIK
0XYGEN
CUHflLA LINING
T0TAL INPUT MTLS
0UTPUTS
M0LTEN Ih0N
SLAG
EMISSIONS DUST
T0H GASES
NITK0GEN
CAKBUN DI0XIDE
CAKB0N M0N0XIDF
HYDhBGEN
SULFUh D10X1DE
P0UNDS
2024.
319.
996.
o>.
677.
32.
167.
0.
0.
68.
1 585.
0.
22.
3866.
2000.
95.
14.
1757.
1210.
459.
b6.
1.
1 .
PEkCENT
52.36
8.25
25.77
0.00
1 7.52
0.82
4.31
0.00
o.oo
1 .76
40.99
O.OC
0.57
100.00
51 .73
2.46
0.35
45.45
68.87
26.1 1
4.89
0.07
0.06
ACTUAL 878.
STANDARD 348.
Gas Take-0£f
Warm Blast Air
Molten Iron
Closed Top
Acid Lining
Afterburner
Charging
Door Open
No Fuel Injection
No Q Enrichment
Slag
CUPOLA CLASSIFICATION - 23
OM
fia
-------
HEAT BALANCE
INPUT HEAT
B.T.U.S
(OOO/HK.)
PERCENT
MATERIAL BALANCE
INPUTS
P0UNDS
POTENTIAL HEAT
0F FUEL
SENSIBLE HEAT
0F THE BLAST
HEAT FR0M 0X1DAT10N
0F MN» FE» SI
T0TAL INPUT HEAT
0UTPUT HEAT
HEATING AND MELTING
0F 1R0N
HEAT CONTENT
0F THE SLAG
CALCINING 0F
LIMEST0NE
DEC0MP0SITI0N
0F WATER
T0P GASES
-SENSIBLE HEAT
-LATENT HEAT
HEAT RADIATI0N FR0M
THE CUP0LA
85775.
8173.
1937.
95886.
03043.
1 450.
1219.
1091 .
1 1927.
23741 .
1341 5.
89.46
8.52
2.02
100.00
44.89
1 .51
1 .27
1.14
12.44
24.76
13.99
V0LIJME 0F T0P GAS CMCF)
METAL CHARGE
PIG IR0N
RETURNS
STEEL SCRAP
IR0N SCRAP
FERR0ALL0YS
C0KE
NATURAL GAS
FUEL 0IL
FLUX AND ADDITIVES
AIR
0XYGEN
CUP0LA LINING
T0TAL INPUT MTLS
0UTPUTS
M0LTEN IR0N
SLAG
EMISSIONS DUST
T0P GASES
NITR0GEN
CARB0N D10XIDE
CARB0N MBN0X1DE
HYDR0GCN
SULFUR DI3X1DE
2009.
502.
301 .
301 .
904.
0.
182.
0.
0.
44.
1335.
40.
IS.
3625.
2000.
56.
12.
1556.
1019.
391 .
144.
1 .
1 .
PERCENT
55.42
13.86
8.31
8.31
24.94
0.00
5.02
0.00
0.00
1 .22
36. b2
1.11
0.42
100.00
55.17
1 .56
0.34
42.92
65.49
25.1 4
9.24
0.07
0.06
1852
STANDARD 735.
Top Charged
Closed Top
Afterburner
Gas Take Off
Warm Blast Air
Molten Iron
CUPOLA CLASSIFICATION - 24
-------
HEAT BALANCE
INPUT HEAT
POTENTIAL HEAT
OF FUEL
SENSIBLE HEAT
0F THE BLAST
HEAT Fk0M OXIDATION
OF MN, FE* SI
TOTAL INPUT HEAT
OUTPUT HEAT
HEATING AND. MELTING
OF IKON
HEAT CONTENT
HE THE SLAG
CALCINING 0F
'- LIMESTONE
DECOMPOSITION
OF WATER •
T0P GASES
-SENSIBLE HEAT
-LATENT HEAT
HFAT KAPIATIMN FnWM
THE CUPOLA
B.T.U.S
COOO/Hk.)
54422.
5225.
1323.
60970.
28057.
797.
1 130.
1349.
I3S26.
-2951 1.
45622.
MATERIAL BALANCE
PEkCENT
B9.26
fa. 57
2.1 7
100. UO
46.02
1 .31
1 .85
2.21
22. 19
-48.40
74. B3
VOLUME HF TOP GAS (MCF)
INPUTS
KETAL CHAKGE
PIG IK0N
KETUKNS
STEEL SCRAP
Ih0N SCKAP
FERK0ALL0YS
C0KE
NATUhAL GAS
FUEL 0IL
FLUX AND ADDITIVES
AIK
OXYGEN
CUPOLA LINING
T0TAL INPUT MTLS
OUTPUTS
M0LTEN IKON
SLAG
EMISSI0NS DUST
T0P GASES
NITROGEN
CAHBON DIOXIDE
CAKB0N MONOXIDE
HYDROGEN
SULFUR DIOXIDE
POUNDS
8009.
574.
954.
287.
134.
60.
182.
0.
0.
62.
250b.
I).
IB.
4779.
2000.
5B.
21.
2699.
1915.
1054.
-272.
2.
0.
PEHCENT
42.04
12.01
19.97
6.01
2.80
1.25
3.80
0.00
0.00
1.30
52. 4B
0.00
0.37
100.00
41 .85
1 .22
0.45
56. 4B
70.95
39.04
-10.06
0.08
0.00
ACTUAL 2000.
STANDAkD 794.
Gas Take-Off
Warm Blast Air
Molten Iron
Closed Top
Acid Lining
Afterburner
Charging
Door Open
No Fuel Injection
No 02 Enrichment
Slag
CUPOLA CLASSIFICATION - 25
-------
HEAT BALANCE
MATERIAL BALANCE
INPUT HEAT B.T.U.S IMPHTC
tuuu/nn* 9 rLnui.nl pflUNDS
METAL CHARGE
POTENTIAL HEAT ---
OF FUEL
SENSIBLE HEAT
OF THE BLAST
HEAT FROM OXIDATION
OF MN. FE. SI
TOTAL INPUT HEAT
OUTPUT HEAT
HEATING AND MELTING
OF IRON
HEAT CONTENT
OF THE SLAG
CALCINING OF
LIMESTONE
DECOMPOSITION
OF HATER
TOP GASES
-SENSIBLE HEAT
-LATENT HEAT
HEAT RADIATION FROM
THE CUPOLA
48492. 91.27
3539. 6.66
1108. 2.07
53133. 100.00
24690. 46.47
949. 1.79
898. 1.69
1071. 2.02
10842. 20.41
-16022. -30.15
30705. 57.79
PIG IRON
RETURNS
STEEL SCRAP
IRON SCRAP
FERROALLOYS
COKE
NATURAL GAS
FUEL OIL
FLUX AND ADDITIVES
AIR
OXYGEN
CUPOLA LINING
TOTAL INPUT MTLS
OUTPUTS
MOLTEN IRON
SLAG
EMISSIONS DUST
TOP GASES
NITROGEN
CARBON DIOXIDE
CARBON MONOXIDE
HYDROGEN
SULFUR DIOXIDE
2001.
429.
698.
498.
343.
34.
190.
0.
•
56.
2263.
.
29.
4540.
2000.
65.
23.
2453.
1728.
890.
-168.
2.
1.
PERCENT
44.08
9. 44
15.37
10.98
7.55
0.75
4.20
0.00
0.00
1.23
49.85
0.00
0.64
100.00
44.05
1.43
0.50
54.02
70.46
36.28
-6.83
OflQ
• UO
0*03
VOLUME OF TOP GAS (MCF)
ACTUAL 1618.
STANDARD 642.
Gas Take-Off
Warm Blast Air
Molten Iron
Closed Top
s^
J
h
i
•
A
\
L
1
L Acid Lining
— InfirglUg
Door Closed
— 1 M- 1?.._1 TM«AA
Enrichment
Slag
CUPOLA CLASSIFICATION - 26
-------
HEAT BALANCE
MATEKIAL BALANCE
INPUT HEAT
POTENTIAL HEAT
0F FUEL
SENSIBLE HEAT
HF THE BLAST
HEAT FK0M 0X1DATIUN
OF MN. FE. SI
T0TAL INPUT HEAT
HUlPUT HEAT
HEATING AND MELTING
OF IK0N
HEAT CONTENT
0F THE SLAG
CALCINING 0F
LIMESTONE
DECOMPOSITION
0F WATEK
TOP GASES
-SENSIBLE HEAT
-LATENT HEAT
HEAT RADIATION FK0M
THE CUP0LA
B . T . U . S
(000/Hh. )
97700.
22327.
20b5.
1221 12.
51441 .
1 122.
Ib37.
1884.
19276.
-10714.
57267.
PERCENT
80.01
lb.2b
1 .71
100.00
42. 1J
0.92
1 .50
1.54
15.79
-b.77
46.90
INPUTS
METAL CHAhGE
PIG IK0N
kETUKNS
STEEL SCKAP
Ik0N SChAP
FEKH0ALL0YS
C0KE
NATUhAL GAS
FUEL 0IL
FLUX AND ADDITIVES
Alh
OXYGEN
CUP0LA LINING
T9TAL INPUT MTLS
OUTPUTS
MOLTEN IK0N
SLAG
EMISSIONS DUST
T0P GASES
NITK0GEN
CAhBUN D1HXIUE
CAKB0N MONOXIDE
HYDK0GEN
SULFUK DIOXIDE
POUNDS
2012.
2b7.
292.
143.
1290.
0.
174.
0.
0.
56.
1947.
0.
8.
4IV6.
2000.
49.
1 6.
2132.
I4b6.
696.
-5b.
2.
0.
PEKCENT
47.94
6.H3
6.97
3.41
30.73
0.00
4. 14
0.00
0.00
1 .34
46.38
0.00
0. 19
100.00
47.66
1.17
0.37
50. bO
69.72
32. 7b
-2.57
o.ob
0.02
VOLUME 0F T0P GAS
ACTUAL 2917.
STANDAKU 1156.
Hot Blast Air
Molten Iron
Spark Arrester
Acid Lining
Afterburner
Charge Door Open
No Fuel Injection
No 02 Enrichment
Slag
CUPOLA CLASSIFICATION - 27
-------
HEAT BALANCE
MATERIAL BALANCE
INPUT HEAT B.T.U.S
COOO/HK.) PERCENT INPUTS
POTENTIAL HEAT
0F FUEL 52620. 82.89
SENSIBLE HEAT
HF THE BLAST 9878. 15.56
HEAT FROM 0XIDATI0N
0F MN. FE. SI 9fal. 1.54
TflTAL INPUT HEAT 63478. 100.00
OUTPUT HEAT
HEATING AND MELTING
0F IRON 23029. 36.28
HEAT C0NTENT
OF THE SLAG 789. 1 .24
CALCINING OF
LIMF.ST0NE 583. 0.92
DECOMPOSITION
0F MATER 922. 1 .45
T0P GASES
-SENSIBLE HEAT 9487. 14.95
-LATENT HEAT 1458. 2.30
HEAT RADIATION FROM
THE CUPOLA 27209. 42.86
VBLUMF. OF TOP GAS
-------
Insufficient Data for
Heat and Material
Balance Calculations
Gas Take-Off
Hot Blast Air
Molten Iron
Closed Top
Acid Lining
No Afterburner
Charging
Door Open
No Fuel Injection
With 02 Enrichment
Slag
CUPOLA CLASSIFICATION - 29
£
o
w
fo
vO
M
ac
M
M
H
LO
>
2
w
z
o
M
X
0
-------
HEAT BALANCE
MATERIAL BALANCE
INPUT HEAT B.T.U.S
(000/HK.) PEKCENT INPUTS
POTENTIAL MEAT
OF FUEL 23751. 92.57
SENSIBLE HEAT
0F THE BLAST 37. 0.15
HEAT FK0M 0XIDATI0N
0F MiM. FE» SI Ib70. 7.29
TftTAL INPUT HEAT 25658. 100.00
WUTPU1 HEAT
HEADING AND MELTING
0.F. IKHN 6323. 32.44
HfAT CONTENT
OF, THE SLAG 5B«. 2.29
CALCINING 0F
"LIMPST0NE 547. 2.13
D,EC0MP0SITI0N
"0F WATEh 327. 1 .2b
T0P GASES
-SENSIBLE HEAT 346H. I3.S2
-LATENT HEAT 8626. 33.62
HEAT KADIATI0N FK0M
THE CUP0LA 3779. 14.73
VOLUME 0F TOP GAS (MCF1
METAL CHAhGF.
PIG Ih0N
KFIUK'NS
STEEL SChAP
IKBN SCKAH
FFKkMALLOYS
C0KF
NATUKAL GAS
FUEL '/)IL
FLUX AND ADDITIVES
A IK
0XYGFN
CUPULA LINliMH
T0TAL INPliT MTLS
HUT PUTS
MOLTFN Ih0N
SLAG
EMISSI0NS [JUST
T0P GASES
NITK0GEN
CAKB0N DI0XIDE
CAKB0N M0N0XIDE
HYDROGEN
SULFUK DIOXIDE
P9UNDS
2030.
256.
1506.
0.
223.
45.
247.
U.
().
102.
2U2H.
0.
36.
4443.
2000.
137.
19.
2266.
1549.
470.
265.
2.
1.
PFhCENT
45.69
5.77
33. VO
0.00
5.02
1 .00
5.56
0.00
0.00
2.29
45.66
0.00
O.hO
100.00
45. OH
3.09
0.42
51 .47
67.74
20.55
11.57
0.07
0.06
ACTUAL 547.
STANDARD 217.
Cold Blast Air
Molten Iron
Spark Arrestor
Basic
Lining
No Afterburner
Charge Door Open
No Fuel Injection
No 02 Enrichment
Slag
CUPOLA CLASSIF1CAT10N - 30
-------
HEAT BALANCE
INPUT HEAT B.T.ll.S
(000/HK. )
POTENTIAL HEAT
OF FUEL 39465.
SENSIBLE HEAT
0F THE BLAST 56.
HEAT FK0M OXIDATION
0F MM, FE> SI 462.
TOTAL INPUT HEAT 399b4.
OUTPUT HEAT
HEATING AND MELTING
0F IKON 126B6.
HEAT C0NTENT
OF THE SLAG 413.
CALCINING OF
LIMEST0NE 474.
DECOMPOSITION
0F WATER 496.
T0P GASES
-SENSIBLE HF.AT 11694.
-LATENT HEAT 16365.
HEAT RADIATION Fk0M
THE CUPOLA -2144.
urn IIMC nr TOP na<; fnnm
HEKCENT
98.70
0. 14
1.16
100. 00
31.73
1.03
I.IK
1.24
29.25
40.93
-5.36
MAItMAL HftLHNU
I M PI IT Q
I NrUl b
METAL CHAKGE
PIG IKON
KETUKNS
STEEL SCKAP
IKON SCKAP
FEKKOALL9YS
COKE
NATURAL GAS
FUEL OIL
FLUX AND ADDITIVES
A I L>
A I K
OXYGEN
CUPOLA LINING
TOTAL INPUT MTLS
OUTPUTS
M0LTF.N IKON
SLAG
EMISSIONS DUST
TOP GASES
NITK0GEN
CAKB0N DIOXIDE
CAhBON MONOXIDE
HYDKOGEN
SULFUk DIOXIDE
L
P0UNDS
2009.
0.
753.
151.
1 105.
0.
2b6.
0.
0.
58.
«3 rt t «•
£ ODO .
0.
24.
4436.
2000.
75.
20.
2340.
1 571 .
430.
336.
2.
2.
PEhCENT
45.30
0.00
16.99
3.4O
24.91
0.00
6.44
0.00
0.00
1 .31
Af* Jit\
•ID* **U
0.00
0.55
100.00
45.09
1 .69
0.46
52.77
67.14
IB. 35
1 4 . .1 7
0.07
0.07
ACTUAL 1455.
STANDARD 335.
Closed Top
Gas Take-Off
Cold Blast Air
Molten Iron
S^
J
-r1^
t
^
*— ^~"
h
i
i
-j
j-
^
j
i
i
A
~TJ
L
M
fi
Afterburner
Door Open
r- No Fuel Injection
No 02 Enrichment
X
Slag
CUPOLA CLASSIFICATION - 31
iL,
1
-------
HEAT BALANCE
MATEKIAL BALANCE
INPUT HEAT
POTENTIAL HEAT
0F FUEL
SENSIBLE HEAT
0F THE BLAST
HEAT FK0M 0XIDAT10N
0F MN. FE. SI
T0TAL INPUT HEAT
HUTPUT- HEAT
HEATING AND MELTING
OF -IRON
HEAT C0NTENT
OF THE SLAG
CALCINING OF
LIMEST0NE
DECOMPOSITION
0F WATEK
TOP GASES
-SENSIBLE HEAT
-LATENT HEAT
HEAT RADIATION FK0M
THE CUH0LA
B.T.U.S
(UOO/Hh. >
79902.
2161 1.
1634.
103147.
40009.
61 7.
2347.
1473.
25238.
-93602.
127064.
PERCENT
77.46
20.95
1 .5K
100.00
3b.79
0.60
2.28
1 .43
24.47
-90.75
123.19
INPUTS
MFTAL CHAKGE
PIG IK0N
hETUKNS
STEEL SCRAP
IR0N SCKAP
FEHKOALL0YS
CUKE
NATUKAL GAS
FUEL MIL
FLUX AND ADDITIVES
AIR
51XYGEN
CUPflLA LINING
THTAL INPUT MTLS
OUTPUTS
MOLTEN IKON
SLAG
EMISSIONS DUST
TOP GASES
NITROGEN
CAKBON DI0XIDE
CAKBON M0N0XIDE
HYDKflGEN
SULFUR DIOXIDE
H0LINDS
1963.
255.
255.
1454.
0.
0.
235.
0.
0.
90.
341 4.
0.
a.
571 1 .
2000.
64.
25.
3622.
2615.
1625.
-615.
2.
-4.
PEhCENT
34. 3B
4.46
4.46
f.5.47
0.00
0.00
4. 12
0.00
u.oo
1 .5b
59. 78
0.00
0. 14
100.00
35.02
1 . 12
0.44
63.42
72.20
44.86
-16.99
0.04
-0. 12
V/MLUME 0F TOP GAS (MCF)
ACTUAL 3651.
STANDARD 1449.
Hot Blast Air
Molten Iron
Spark Arrester
Basic
11 Lining
jj
j| No Afterburner
'Charge Door Open
No Fuel Injection
No 6 Enrichment
Slag
CUPOLA CLASSIFICATION - 32
-------
APPENDIX D
DETAIL ECONOMIC COST CURVES
This appendix contains the detail curves used to determine
the cost of pollution control equipment. Summaries of these
curves appear as exhibits in Section VIII of the report.
Following the economic cost curves are the detail data
for determining the melt shop costs for the model foundries.
A.T.KEARNEY 8e COMPANY, Ii!fc.
-------
TOTAL ANNUAL COSTS FOR
LOW ENERGY WET SCRUBBER
FOR LINED CUPOLA
4.000-HOUR YEAR
(FOR VARIOUS COKE RATES)
100
ABOVE CHARGE DOOR 1AKE-OFF
BELOW CHARGE DOOR TAKE-OFF
X
15 20 25
MELT RATE, TPH
-------
TOTAL ANNUAL COSTS FOR
LOW ENERGY WET-SCRUBBER
FOR UNLINED CUPOLA
4,000-HOUR YEAR
(FOR VARIOUS COKE RATES)
100
o
o
o
X
•CO-
M
OT
I
O
g
O
H
ABOVE CHARGE
DOOR TAKE-OFF
BELOW CHARGE DOOR TAKE-OFF
0
15 20 25
MELT RATE, TPH
-------
$250
0
0
TOTAL ANNUAL COSTS FOR HIGH ENERGY
WET SCRUBBER FOR LINED CUPOLA
4.OOP-HOUR YEAR
(FOR VARIOUS COKE RATES)
ABOVE CHARGE DOOR TAKE-OFF
20
MELT RATE,
-------
TOTAL ANNUAL COSTS FOR HIGH
.ENERGY. WET *SCRUBBER-
FOR UNLINED CUPOLA
4.OOP-HOUR YEAR
250
§ 200
150
100
50
(FOR VARIOUS COKE
ABOVE CHARGE DOOR
GAS TAKE-OFF
BELOW CHARGE DOOR
GAS TAKE-OFF
10
20 25
MELT RATE., JTPH
-------
300
TOTAL ANNUAL COSTS FOR
FABRIC FILTER FOR LINED
CUPOLA 4.000-HOUR YEAR
(FOR VARIOl]
COKE RATES)
ABOVE CHARGE DOOR
GAS TAKE-OFF
BELOW CHARGE DOOR
GAS TAKE-OFF
15 20 25
MELT RATE, TPH
-------
I I
TOTAL ANNUAL COST? FOR
FABRIC FILTER FOR UNLINED
CUPOLA 4,000-HOUR YEAR
(FOR VARIOUS COKE RATES)
ABOVE CHARGE DOOR
GAS TAKE-OFF
BELOW CHARGE DOOR
GAS TAKE-OFF
0
10
20 25
MELT RATE, TPH
-------
APPENDIX D
NUMBER 7
TOTAL ANNUAL COSTS FOR
LOW ENERGY WET SCRUBBER
ON LINED CUPOLA 2.OOP-HOUR YEAR
(FOR VARIOUS COKE RATES)
100'
80-
o
o
o
ABOVE CHARGE DOOR
GAS TAKE-OFF
60
OT
H
OT
O
O
12/1
H
O
H
0
0
BELOW CHARGE DOOR
GAS TAKE-OFF
10 15 20
MELT RATE, TPH
25
30
-------
APPENDIX D
NUMBER 8
TOTAL ANNUAL COSTS FOR
LOW ENERGY WET SCRUBBER
ON UNLINED CUPOLA
2.OOP-HOUR YEAR
(FOR VARIOUS COKE RATES)
100
80
o
o
o
60
40
20
0
ABOVE CHARGE DOOR
GAS TAKE-OFF
BELOW CHARGE DOOR
GAS TAKE-OFF
10 15 20
MELT RATE, TPH
-------
APPENDIX D
NUMBER 9
TOTAL ANNUAL COSTS FOR
HIGH ENERGY WET SCRUBBER
ON LINED CUPOLA
2.OOP-HOUR YEAR
(FOR VARIOUS COKE RATES)
200-
175-
ABOVE CHARGE DOOR
GAS TAKE-OFF
o
2 125-
0
12/1
BELOW CHARGE DOOR
GAS TAKE-OFF
0
10 15 20
MELT RATE, TPH
25
30
-------
APPENDIX D
NUMBER 10
TOTAL ANNUAL COSTS FOR
HIGH ENERGY WET SCRUBBER
ON UNLINED CUPOLA
2.OOP-HOUR YEAR
(FOR VARIOUS COKE RATES)
280-
240-
o
o
o
200
C/5
8 160
40
0
ABOVE CHARGE DOOR
GAS TAKE-OFF
5/1
BELOW CHARGE DOOR
GAG TAKE-OFF
0
10 15 20
MELT RATE, TPH
25
30
-------
TOTAL ANNUAL COSTS FOR FABRIC FILTER
ON LINED CUPOLA 2.OOP-HOUR YEAR
(FOR VARIOUS COKE RATES)
ABOVE CHARGE DOOR
GAS TAKE-OFF
BELOW CHARGE DOOR
GAS TAKE-OFF
0
20 25
MELT RATE, TPH
21
O
M
X
O
-------
300
250
§
x
CO-
S"
100
50
0
TOTAL ANNUAL COSTS FOR FABRIC FILTER
ON UNLINED CUPOLA 2.OOP-HOUR YEAR
(FOR VARIOUS COKE RATES)
ABOVE CHARGE DOOR
GAS TAKE - OFF
BELOW CHARGE DOOR
GAS TAKE-OFF
10/1
5/1
10/1
w
z:
15 20 25
MELT RATE, TPH
-------
APPENDIX D
NUMBER 13
TOTAL ANNUAL COSTS FOR
LOW ENERGY WET SCRUBBER
ON LINED CUPOLA
1.000-HOUR YEAR
(FOR VARIOUS COKE RATES)
60'
6/1
50-
8/1
ABOVE CHARGE
DOOR GAS
TAKE-OFF
10-
0-
12/1
J3ELOW CHARGE DOOR
GAS TAKE-OFF
10 15
MELT RATE, TPH
20
-------
APPRENDIX D
NUMBER 14
TOTAL ANNUAL COSTS FOR
LOW ENERGY WET SCRUBBER
ON UNLINED CUPOLA
1.000-HOUR YEAR
(FOR VARIOUS COKE RATES)
60-
50-
o
o
o
co
H
to
O
30-
ABOVE CHARGE DOOR
GAS TAKE-OFF
O
H
20-
10-
0
BELOW CHARGE DOOR
GAS TAKE-OFF
0
5 10 15
MELT RATE, TPH
20
-------
TOTAL ANNUAL COSTS FOR
HIGH ENERGY WET SCRUBBER
ON LINED CUPOLA
1.000-HOUR YEAR
(FOR VARIOUS COKE RATES)
APPENDIX D
NUMBER 15
175
150
125
o
o
o
X
•CO-
CO
H
g 100
o
-4
I
H
75
50
25
0
ABOVE CHARGE
DOOR GAS
TAKE-OFF
BELOW CHARGE DOOR
GAS TAKE-OFF
MELT RATE, TPH
-------
TOTAL ANNUAL COSTS FOR
HIGH ENERGY WET SCRUBBER
ON UNLINED CUPOLA
1.000-HOUR YEAR
(FOR VARIOUS COKE RATES)
APPENDIX D
NUMBER 16
175
150
o
o
o
125
g 100
75
s
50
25
0
10/1
ABOVE CHARGE DOOR
GAS TAKE-OFF
10/1
BELOW CHARGE DOOR
GAS TAKE- OFF
MELT RATE, TPH
-------
TOTAL ANNUAL COSTS FOR FABRIC FILTER
ON LINED CUPOLA 1.000-HOUR YEAR
(FOR VARIOUS COKE RATES)
200
§150
o
X
•CO-
£100
O
O
50
ABOVE CHARGE DOOR
GAS TAKE-OFF
BELOW CHARGE DOOR
GAS TAKE-OFF
15 20 25
MELT RATE, TPH
M
2:
X
-------
TOTAL ANNUAL COSTS FOR FABRIC FILTER
ON UNLINED CUPOLA 1.000-HOUR YEAR
(FOR VARIOUS COKE RATES)
250
200
o
o
o
150
O
O
52
2
100
ABOVE
DOOR GAS
TAKE-OFF
5/1
10/1
10/1
0
10
15 20
MELT RATE, TPH
25
BELOW CHARGE DOOR
GAS TAKE OFF
PI
30
35
40
oo
M
Z
O
M
X
-------
$2.50
•C/J-I
0
0
COST PER TON OF MELT FOR
LOW ENERGY WET SCRUBBER
ON LINED CUPOLA
4,000-HOUR YEAR
VARIOUS COKE RATES]
ABOVE CHARGE DOOR GAS TAKE-OFF
12/1
BELOW CHARGE DOOR GAS TAKE-OFF
50 75 100 125 150
ANNUAL PRODUCTION, TONS x 1,000
175
2S
O
M
X
o
200
-------
COST PER TON OF MELT FOR
LOW ENERGY WET SCRUBBER
ON UNLINED CUPOLA
4,000-HOUR YEAR
(FOR VARIOUS COKE RATES)
ABOVE- CHARGE-DOOR GAS TAKE-OFT
BELOW -CHARGE DOOR GAS
TAKE-OFF
75 100 125 150
ANNUAL PRODUCTION, TONS x 1,000
-------
$5.0
COST PER TON OF MELT FOR HIGH
ENERGY WET SCRUBBER
ON LINED CUPOLA
4.OOP-HOUR YEAR
(FCR VARIOUS COKE RATES
ABOVE CHARGE DOOR GAS TAKE-OFF
BELOW CHARGE DOOR GAS TAKE-OFF
75 100 125 150
ANNUAL PRODUCTION, TONS x 1,000
175
200
-------
COST PER TON OF MELT FOR HIGH ENERGY
WET SCRUBBER ON UNLINED CUPOLA
4.OOP-HOUR YEAR
(FOR VARIOUS COKE. RATES)
$2.50
O
2
w
PH
H
CO
O
CJ'
2.00
1.50
ABOVE-CHARGE DOOR
GAS TAKE-OFF
BELOW CHARGE DOOR GAS TAKEhOFF
1.00
0
25
50
75 100 125
ANNUAL PRODUCTION, TONS x 1,000
-------
COST PER TON OF MELT FOR FABRIC FILTER
ON LINED CUPOLA 4.OOP-HOUR YEAR
(FOR VARIOUS COKE RATES)
ABOVE CHARGE DOOR
GAS TAKE-OFF
0
0
DOOR
tn
23
75 100 125 150
ANNUAL PRODUCTION, TONS x 1,000
200
ro
X
-------
3.00
2.50
2.00
s
1-50
o
H
OS
w
CJ
1.00-
0.5
0
0
COST PER TON OF MELT FOR FABRIC FILTER
ON UNLINED CUPOLA 4,000-HOUR YEAR
(FOR VARIOUS COKE RATES)
ABOVE CHARGE DOOR
GAS TAKE-OFF
25
50
10/1
BELOW CHARGE POOR
GAS TAKE-OFF
I
PI
25
75 100 125 150
ANNUAL PRODUCTION, TONS x 1,000
175
200
-------
3.00
2.50
2.00
1.50
1.00
0-
0
COST PER TON OF MELT FOR LOW
ENERGY WET SCRUBBER ON
LINED CUPOLA 2.OOP-HOUR YEAR
(FOR VARIOUS COKE RATES)
ABOVE CHARGE DOOR
GAS TAKE-OFF
12/1
BELOW CHARGE DOOR
GAS TAKE-OFF
10
12/1
M
55
15 20 25 30
ANNUAL PRODUCTION, TONS x 1,000
35
N)
X
-------
COST PER TON OF MELT FOR
LOW ENERGY WET SCRUBBER
ON UNLINED CUPOLA
2.OOP-HOUR YEAR
(FOR VARIOUS COKE RATES)
2.50-
5/1 ABOVE CHARGE DOOR
GAS TAKE-OFF
BELOW CHARGE DOOR
GAS TAKE-OFF
0-
2S
O
20 30 40 50
ANNUAL PRODUCTION, TONS x 1,000
-------
6.0
5.0
•CO-
A
H
4.0
o 3.0
53
8
H 2.0
CO
O
CJ
1.0
0
COST PER TON OF MELT FOR
HIGH ENERGY WET SCRUBBER
ON LINED CUPOLA 2.000-HOUR YEAR
(FOR VARIOUS COKE RATES)
ABOVE CHARGE DOOR
GAS TAKE-OFF
BELOW CHARGE DOOR
GAS TAKE-OFF
10/1
30 40 50 60
ANNUAL PRODUCTION, TONS x 1,000
70
N>X
-------
5.0
0
COST PER TON OF MELT FOR
HIGH ENERGY WET SCRUBBER
ON UNLINED CUPOLA
2.OOP-HOUR YEAR
(FOR VARIOUS COKE RATES)
ABOVE CHARGE DOOR
GAS TAKE-OFF
BELOW CHARGE DOOR
GAS TAKE-OFF
20 30 40 50
ANNUAL PRODUCTION, TONS x 1,000
70
M
fO
oo
-------
COST PER TON OF MELT FOR
FABRIC FILTER ON LINED CUPOLA
2,000-HOUR TEAR
:OKE RATES.)
ABOVE CHARGE DOOR
GAS TAKE-OFF
BELOW CHARGE DOOR
GAS TAKE-OFF
20 30 40 50
ANNUAL PRODUCTION, TONS x 1,000
M
25
O
M
X
o
-------
COST PER TON OF MELT FOR FABRIC FILTER
ON UNLINED CUPOLA 2.OOP-HOUR:YEAR
(FOR VARIOUS COKE RATES)
ABOVE CHARGE DOOR
GAS TAKE-OFF
BELOW CHARGE DOOR
GAS TAKE-OFF
0
30 40 50
ANNUAL PRODUCTION, TONS
M
PO
u>
X
-------
6.0-,-
5.0 __
4.0 __
3.0 __
o
I
0 2.0 1
w
1.0 __
0
0
COST PER TON OF MELT FOR
LOW ENERGY WET SCRUBBER
ON CUPOLA 1.000-HOUR YEAR
(FOR VARIOUS COKE RATES)
UNLINED CUPOLA
ABOVE CHARGE DOOR
GAS TAKE-OFF
BELOW CHARGE DOOR
GAS TAKE-OFF
10
LINED CUPOLA
ABOVE CHARGE DOOR
GAS TAKE-OFF
BELOW CHARGE DOOR
GAS TAKE-OFF
15 20 0 5
ANNUAL PRODUCTION, TONS x 1,000
10
15
12/1
20
M
u>
PI
-------
5
§
fr.
CO
8
10 _.
8 --
6 --
4 --
2 "-
0
0
COST PER TON OF MELT FOR HIGH
ENERGY WET SCRUBBER ON CUPOLA
1.000-HOUR YEAR
(FOR VARIOUS COKE RATES)
UNLINED CUPOLA
ABOVE CHARGE DOOR
GAS TAKE-OFF
'10/1
BELOW CHARGE DOOR
GAS TAKE-OFF ,
10
LINED CUPOLA
6/1
ABOVE CHARGE
DOOR GAS TAKE
BELOW CHARGE
DOOR GAS
TAKE-OFF
15 20 0 5
ANNUAL PRODUCTION, TONS x 1,000
10
15
8/1
6/1
NJ
-------
§
w
H
CO
O
COST PER TON OF MELT FOR
FABRIC FILTER ON LINED CUPOLA
1,000-HOUR YEAR
(FOR VARIOUS COKE RATES)
ABOVE CHARGE DOOR
GAS TAKE-OFF
BELOW CHARGE DOOR
GAS TAKE-OFF
10/1
0
0
10 15 20 25
ANNUAL PRODUCTION, TONS x 1,000
M
Z
O
M
u>
-------
10"
H
•J
§
H.
w
O
0
COST PER TON OF MELT FOR FABRIC FILTER
ON UNLINED CUPOLA 1,000-HOUR YEAR
(FOR VARIOUS COKE RATES)
ABOVE CHA
GAS TAKE-
RGE DOOR
DFF
BELOW CHARGE DOOR
GAS TAKE-OFF
5/1
10/1
MS
10
15 20 25 30
ANNUAL PRODUCTION, TONS x 1,000
35
-------
360
320
280
240
o
o
o
200
C/3
H
W
8 160
S
<:
_!
120
80
40
0
TOTAL ANNUAL COSTS
FOR HIGH ENERGY WET
SCRUBBER ON CUPOLA
FOR DIFFERENT PRESSURE
DROPS 4,000-HOUR YEAR
APPENDIX D
NUMBER 35
80
70
80
GAS VO:,'iJME, ACFM x 1,000
100
-------
NUMBER' 36
TOTAL ANNUAL COSTS FOR
HIGH ENERGY WET SCRUBBER
ON CUPOLA FOR DIFFERENT
PRESSURE DROPS 2,000-HOUR
YEAR
320
280
240
o
o
o
200
C/5
H
CO
O
U
I
1
160
120
20 40 60 80
GAS VOLUME, ACFM x 1,000
100
-------
APPENDIX D
TOTAL ANNUAL COSTS FOR
HIGH ENERGY WET SCRUBBER
ON CUPOLA FOR DIFFERENT
PRESSURE DROPS 1.000-HOUR YEAR
280
0
20
40 60 80
GAS VOLUME, ACFM x 1,000
100
-------
APPENDIX D
38
TOTAL ANNUAL COSTS FOR
HIGH ENERGY WET SCRUBBER
ON CUPOLA FOR DIFFERENT
PRESSURE DROPS 500-HOUR YEAR
175
20 30 40
GAS VOLUME, ACFW x 1,000
50
60
-------
Buildings
c
FURNA
N
an
1. Cupola Building 500 & 1,000 Hours per Year, $25/Sq. Ft. 2,500
2. Cupola Auxiliary Building $10/Sq. Ft. 750
B. Scrapyard Equipment
1. Scrapyard Crane
2. Crane Runway
3. Metal Trim Platform S Weigh Hopper
4. Coke & Stone Weigh Hoppers & Feeders
5. Coke & Stone Bins
6. Coke & Stone Unloading Equipment
7. Magnet 1-45"
8. Platform Scale
C. Charging Equipment
1. Skip Charger
2. Charge Buckets
D. Melting Equipment
1. Cupolas ? 500 & 1,000 H/A
2. Blower & Motor (SCFM Basis)
3. Air Piping, Piping, Valves & Weight Control
4. Forehearth
5. Runners
6. Refractories for Cupola & Runners
7. Slag Buckets
8. Slag Disposal Equipment
9. Piping, Header, & Sewer Connections
E. Holding Equipment (Not Required)
Subtotal #1 (B + C + D -H E)
F. Spares & Freight (3V/» of B, C, D, E)
Subtotal #2 (S.T. #1 + A + F)
G. Engineering 5%
Subtotal
H. Conringencies 10%
Total
Cost/Ton
500 Hours
1,000 Hours
-------
EQUIPMENT REQUIREMENTS
per Year, $25/Sq. Ft.
Ft.
r
ers
ht Control
•ns
CUPOLA, COLD BLAST, NO HOLD INC
FURNACK, FABRIC FILTER EMISSION CON 1 KOI.
FOR 500 & 1.000 HOURS PER YEAR
5 FPH
Number
and Size
2 ,500 Sq. Ft.
750 Sq. Ft.
1-5T
12 ,500 Open
1-45"
-
1-56"
1-3,100
Cost
$ 63,000
8,000
60,000
19,000
20,000
15,000
10,000
6,000
10,000
24,000
14,000
26,000
25,000
5,000
3,000
10,000
5,000
10,000
$262.000
$ 9,000
$342.000
$ 17.000
$359.000
$ 36.000
$395.000
$158
79
15 TPH
Number
and Size Cost
4,000 Sq. Ft. $100,000 8,0'
1,800 Sq. Ft. 18", 000 3,0'
1-7VT 83,000 2-7;
16,000 Covered 128,000 24,
55,000
95,000
40,000
1-65" 8,000 2-6
1-15 TPH 134,000 2-1
1-90" 34,000 2-9'
1-9,200 36,000 2-9
40,000
6,000
4,000
29,000
21,000
20,000
$733.000
$ 25.000
$876.000
$ 44.000
$920.000
$ 92,000
$1,012,000
$67.47
-------
APPENDIX D
NUMBER 39
Page 1 of 2
'MENT REQUIREMENTS
;OLD BLAST, NO HOLDING
1IC FTLTER EMISSION CONIROL
1.000 HOURS PER YEAR
PH
TCost
$ 63,000
8,000
60,000
19,000
20,000
15,000
10,000
6,000
10,000
24,000
14,000
26,000
25,000
5,000
3,000
10,000
5 , 000
10,000
$262,000
$ 9.000
$342.000
J
$ 17.000
$359.000
$ 36.000
$395.000
$158
79
15 TPH
Number
and Size Cost
4,000 Sq. Ft. $100,000
1,800 Sq. Ft. 18,000
1-7J2T 83,000
16,000 Covered 128,000
55,000
95,000
40,000
1-65" 8,000
1-15 TPH 134,000
1-90" 34,000
1-9,200 36,000
40,000
6,000
4,000
. 29,000
21,000
20,000
$733.000
$ 25.000
$876.000
$ 44,000
$920.000
$ 92.000
$1.012.000
$67
30 TPH
Number
and Size
Cost
8.000 Sq. Ft. $200,000
3,000 Sq. Ft. 30,000
166,000
192,000
70,000
143,000
52,000
16,000
24,000 Covered
2-65"
2- 15 TPH
2-90"
2-9,200
67,000
72,000
50,000
12,000
6,000
58.000
27,000
25,000
$1.194.000
$ 42.000
$1.466.000
$ 73.000
$1.539.000
$ 154.000
$1.693.000
50 TPH
Number
and Size
10,000 Sq. Ft.
5,000 Sq. Ft.
2-10T
30,000 Covered
3-65"
Cost
238,000 2-30 TPH
2-108"
2-12,500
$250,000
50,000
200,000
240.000
90,000
240,000
75,000
24,000
330,000
80.000
175,000
72.000
15,000
8,000
70,000
36,000
30,000
$1.685.000
$ 59.000
$2.044.000
$ 102.000
$2.146.000
$ 215.000
$2.361.000
-------
Increase For
'.,000 & 4,0007
•jours per Year
BuiIdings
Cupola Building
Charging Equipment
Swivel Skip Charger
Melting Equipment
1. Cupolas
3. Air Piping & Valves
6. Runners
7. Refractories
9. Slag Disposal Equipment
5. Forehearth
Subtotal #1 (C + D)
Spares & Freight 3-1/2%
Subtotal (#1 + A + E)
Engineering 5%
Subtotal
Contingencies 107»
Subtotal
Total from 500 & 1,000 Hours Page 1.
Grand Total
Cost/Ton
2,000 Hours
4',000 Hours
80%
15%
100%
10
50
100
15
100
CUPOLA
FURN
FOR 2.0
Number
and Sizi
-------
EQUIPMENT REQUIREMENTS
Increase For
2,000 & 4,0007
Hours per Year
CUPOLA, C01D BLAST, NO HOLDING
FURNACE, SUPPLEMENTARY COSTS
FOR 2.000 &4.000 HOURS PER YEAR
5.TPI
Number '
and Size
Cost
15 TPH
Number
and Size
Cost
Numbe
and Si
80%
50,000
80,000
15%
3,000
20,000
100%
10
50
100
15
100
? 1.
14,000
3,000
2,000
10,000
1,000
5.000
$ 38.000
$ 1.000
$ 89.000
$ 4.000
$ 93.000
$ 9.000
$102.000
$395.000
$497.000
$
$
$
$
$
34,000
4,000
2,000
29,000
3,000
6.000
98.000
3.000
$ 181.000
$ 9.000
190.000
19.000
209.000
$] .012.000
$1.221.000
$49.70
$40.70
20.35
-------
IT REQUIREMENTS
) BLAST, NO HOLDING
1UPPLEMENTARY COSTS
t. 000 JrtOURS PER YEAR
Cost
$.50,000
3,000
14,000
3,000
2,000
10,000
1,000
5.000
$ 38.000
$ 1.000
$ 89.000
$ 4,000
$ 93.000
$ 9.000
$102.000
$395.000
$497.000
$49.70
15 TPH
Number
and Size Cost
$ 80,000
20,000
34,000
4,000
2,000
29,000
3,000
6.000
$ 98.000
$ 3.000
$ 181,000
$ 9.000
$ 190.000
$ 19.000
$ 209.000
$1.012.000
$1.221,000
$40.70
20.35
30 TPH
Number
and Size Cost
$ 160,000
36,000
67,000
5,000
3,000
58,000
4,000
12,000
$ 185,000
$ 6,000
$ 351.000
$ 18.000
$ 369,000
$ 37.000
$ 406.000
$1.693.000
$2.099,000
$34.98
17.49
APPENDIX D
NUMBER 39
Page 2 of 2
50 TPH
Number
and Size Cost
$ 200,000
50,000
80,000
7,000
4,000
70,000
5,000
15.000
$ 231,000
$ 9,000
$ 440,000
$ 22.000
$ 462.000
$ 46.000
$ 508.000
$2.361.000
$2.869,000
$28.69
14.35
-------
I
cu
A. Buildings
1. Melting Building 3 $*25/Sq. Ft. 2,00(
2. Cupola Auxiliary Building @ $10/Sq. Ft. 1,00(
B. Scrapyard Equipment
1. Scrapyard Crane 1-5T
1A. Crane Runway & Stockyard 12,5(
2. Metal Trim Platform & Weigh Hopper Lump
4. Coke & Stone Weigh Hoppers, Feeders, Scales & Bins
5. Coke & Stone Unloading Equipment Lump
6. Magnets ' 1-4V
7. Platform Scale Lump
C. Charging Equipment
1. Skip Charger-Swivel Type
2. Charge Buckets
D. Melting Equipment
1. Cupola-Unlined-Water Cooled 1-36'
2. Air Piping. Gates, Charge Indicator Lump
3. Blower & Mptor 2,301
4. Forehearth-i Lined 1
5. Runners Lump
6. Refractories for Runners Lump
7. Gas Piping & Meter Lump
8. Hot Blast Heater Lump
9. Piping, Headers, Sewer Connections Lump
10. Slag Disposal Equipment Lump
11. Water Cooling Tower & Pumps Lump
E. Holding Equipment
1. Channel Induction Furnace & Controls
1A. Spare Furnace Body
3. Refractories for Holding Furnaces
Subtotal #1 (B + C'+ D + E)
F. Spares & Freight (3^7, of B + C + D + E)
Subtotal #2 (St. #1 + A + F)
G. Engineering (5% of St. #2)
Subtotal #3 (G + Sr...
H. Contingencies (10% of St. #3)
Total (St. #3 + H)
Cost/Ton
?. ,000 Hours
4,000 Hours
A-
if'
-------
EQUIPMENT REQUIREMENTS
CUPOLt HOT ULAST, WATER- COOLED,
CHANNE1INDUCTION HOLDING FURNACE,
WET iCRUBBER EMISSION CONTROL
510/Sq. Ft.
topper
•"eeders , Scales & Bins
nent
licator
tions
Controls
aces
E)
D + E)
+ F)
5
tlumbr
and S?.e
2,000
1,000
1-5T
12,500 Oen
Lump S urn
Lump Sim
1-45"
Lump Sum
1-36"
Lump Sum
2,300 SOI
1
Lump Sum
Lump Sum
Lump Sum
Lump Sum
Lump Sum
Lump Sum
Lump SUIT.
TPH
Cost
$ 50,000
10,000
60,000
19,000
20,000
10,000
6,000
10,000
24,000
40,000
50,000
25,000
5,000
3,000
1,500
7,500
65,000
15,000
5,000
20,000
$366.000
$ 13,000
$439.000
$ 22.000
$461.000
$ 46,000
$507,000
,$50.
15 IPH
N'.mber
anJ Size
1-2,500 Sq. Ft.
1,500 Sq. Ft.
1-71? T-^O1
16,000 Sq. Ft.
Lump S urn
Lump Sum
Lump Sum
1-65"
1-15 TPH
1-66"
Lump S urn
7,700 SCFM
1
Lump Sum
Lump Sum
Lump Sum
Lump Sum
Lump Sum
Lump Sum
Lump Sum
1-13-VT 500KW
Lump Sum
Lump Sum
$1
$
$1
$
$1
$
$1
70
Cost
$ 63,000
15,000
83,000
128,000
55,000
95,000
40,000
8,000
134,000
80,000
66,000
30,000
6,000
3,000
2,000
10,000
75,000
20,000
21,000
30,000
100,000
30,000
20.000
.036.000
36.000
.150.000
58.000
.208.000
121.000
,129.000
$44.
22.
N
an
1-4,0
1-3,0
2-7%
25.0C
Lump
Lump
2 -65
1-30
1-901'
Lump
14 , 3C
1
Lump
Lump
Lump
Lump
Lump
Lump
Lump
1-20/
Lump
Lump
30
15
-------
APPENDIX D
NUMBER 40
EJ U1PMENT REQUIREMENTS
POI1 HOT BLAST, WATER-COOLED,
SNE1INDUCTION HOLDING FURNACE,
VET GRUBBER EMISSION CONTROL
.=• rpn
i tribe
ii Sri'
0 Oun
Sum
Slim
ijuir
3um
SO!
iunr
>UtT
iun
5un
>un
iun
Sun
Cost
$ 50,000
10,000
60,000
19,000
20,000
-
10,000
6,000
10,000
24,000
40,000
5C.OOO
25,000
5,000
3,000
1,500
7,500
65,000
15,000
5,000
20,000
-
-
$366.000
$ 13,000
$439.000
$ 22.000
$461.000
$ 46,000
$507.000
$50.
15 TP1I
Il'.nihor
anJ Size
1-2,500 Sq. Ft.
1,500 Sq. Ft.
1-7^ T-701
16,000 Sq. Ft.
Lump Sum
Lump S um
Lump S um
1-65"
1-15 Tt'H
1-66"
Lump Sum
7,700 SCFM
1
Lump Sum
Lump Sum
Lump Sum
Lump Sum
Lump Sum
Lump Sum
Lump Sum
1-13VT 500KW
Lump Sum
Lump Sum
$1
$
$1
$
$1
$
$1
70
Cost
$ 63,000
15,000
83,000
128,000
55,000
95,000
40,000
8,000
-
134,000
—
80,000
66,000
30,000
6,000
3,000
2,000
10,000
75,000
20,000
21,000
30,000
100,000
30,000
20.000
.036.000
36,000
.150.000
58.000
.208.000
121.000
.329.000
$44.
22.
30 TPh
Nutnbe r
and Size
1-4,000 Sq. Ft.
1-3,000 Sq. Ft.
2-7% T
25,000 Sq. Ft.
Lump Sum
Lump Sum
Sum
2 -65"
1-30 TPH
1-90"
Lump Sum
14,300 SCFM
1
Lump Sum
Lump Sum
Lump Sum
Lump Sum
Lump Sum
Lump Sum
Lump Sum
1-20^8 800KW
Lump Sum
Lump Sum
$1
$
$1
$
f $i
• $
$2
30
15
Cost
$100,000
30,000
166,000
192,000
70,000
143,000
52,000
16,000
. ~
165,000
-
180,000
84,000
52,000
12,000
4,500
3,000
12,000
112,000
25,000
27,000
40,000
200,000
80,000
45.000
,680,500
59,000
.869.500
93.000
.962.500
196.000
,158,500
$35.
17.
50 TPH
Number
and Size
1-5,000 Sq. Ft.
5,000 Sq. Ft.
2-10T
30,000 Sq. Ft.
Lump Sum
Lump Sum
Lump Sum
3-65"
1-50 TPH
1-108"
Lump Sum
20,600 SCFM
1
Lump Sum
Lump Sum
Lump Sum
Lump Sum
Lump Sum
Lump Sum
Lump Sum
1-60T 1.200KW
Lump Sum
Lump Sum
$2
$
$2
$
$2
$
/ $3
/ —
98
99
Cost
$125,000
50,000
200,000
240,000
90,000
240,000
75,0.)0
24,000
-
225,000
~
265,000
150,000
120,000
15,000
5,000
5,000
15,000
195,000
30,000
36,000
50,000
350,000
125,000
90.000
.545.000
89.000
.809.000
1
140.000
.949.000
295.000
JJ244JDOO
$32
16
c
I
.44
.22
-------
A. Buildings
Melting Building $13/Sq. Ft. 10,
Transformer Rooms $10/Sq. Ft. 1,2
B. Scrapyard Equipment
1. Scrapyard Crane 1-5
2. Crane Runway & Stockyard 1-3
. 3. Platform Scales
4. Magnets 1-4
C. Charging Equipment
1. Charge Bucket Transfer Cars 6< Trnck
2. Charge Buckets 2
3. Charging Crane
D. Melting Equipment
1. Arc Furnaces . 2-3'
2. Transformers 1-5
3. Furnace Refractories Lum;
4. Electrodes Lum]
5. Power Feeders, Piping Headers, Sewer Connections
6. Slag Buckets 1
E. Holding Equipment
1. Channel Induction Furnaces & Electrics None
2. Spare Furnace Body
3. Refractories for Holding Furnaces
Subtotal
F. Spares & Freight
Subtotal
G. Engineering.5%
Subtotal
H. Contingencies 10%
Total
Cost/Ton
500 Hours
1,000 Hours
2,000 Hours
1,000 Hours
2,000 Hours
4,000 Hours
-------
EQUIPMENT REQUIREMENTS
ELECTRIC ARC FURNACE, CHANNEL
INDUCTION HOLDING, FABRIC FILTER
EMISSION CONTROL
ack
ewer Connections
ctrics
•s
5 TPH
Number
and Size
10,000 Sq. Ft.
1,200 Sq. Ft.
1-5T
1-3T
1-45"
2
2-3T
1-5.000KVA
Lump
Lump
1
None
>
Cost
$ 130,000
12,000
60,000
19,000
15,000
6,000
10,000
10,000
410,000
Inc luded
in D- 1
9,000
2,000
10,000
3,000
-
$554,000
$ 19.000
$715.000
$ 36.000
$751.000
$ 75.000
$826,000
$330
165
82.
'
If:
Number
and Size
18,000
1,500 Sq. Ft
1-7^T-80'
1
1-65"
Lump S um
3
1-25/45
2- 11"- 1ST
2-7,500 KVA
Lump
Lump
Lump
2
1-30T 600 KW
1
Lump
50
TPH
Cost
$ 234,000
15,000
83,000
128,000
20,000
8,000
15,000
18,000
85,000
830,000
Included
in D-l
20,000
6,000
20,000
8,000
325,000
115,000
45,000
$1,726.000
$ 61.000
$2.036.000
$ 102,000
$2.138.000
$ 214.000
$2,352,000
$156.
78.
39.
a
25,0
2,10
2-7^
2-65
3
3"-l
3-10
Lump
Lump
3
2-40
1
Lump
80
40
20
-------
EQUIPMENT REQUIREMENTS
APPENDIX D
NUMBER 41
LECTRIC ARC FURNACE, CHANNEL
UCTION HOLDING, FABRIC FILTER
EMISSION CONTROL
5*.TPH
mber
Size Cost
b
Sq. Et. $ 130,000
3q. Ft. 12,000
60,000
19,000
15,000
6,000
10,000
10,000
410,000
)KVA Included
In D-l
9,000
2,000
10,000
3,000
-
$554.000
$ 19.000
$715.000
$ 36.000
«
$751.000
$ 75.000
• $826,000
$330
165
82.
15 TPH
Number
and Size Cost
18,000 $ 234,000
1,500 Sq. Ft. 15,000
l-7i;T-80' 83,000
128,000
1 20,000
1-65" 8,000
Lump Sum 15,000
3 18,000
1-25/45 85,000
2-ll"-15T 830,000
2-7,500 KVA Included
in D-l
Lump 20,000
Lump 6,000
Lump 20,000
2 8,000
1-30T 600 KW. 325,000
I 115,000
Lump 45,000
$1.726.000
$ 61,000
$2.036.000
$ 102.000
$2.138.000
$ 214.000
$2,352,000
50
$156.
78.
39.
30 Tl-n
Number
and Size Cost
25,000 Sq. Ft. $ 325,000
2,100 Sq. Ft. 21,000
2-7^T 166,000
192,000
30,000
2-65" 16,000
20,000
3 18,000
100,000
3"-15T 1,275,000
3-10,000 KVA Included
in D-l
Lump 30,000
Lump 9,000
25,000
3 9,000
2-40T 800 KW Ea . 700,000
1 125,000
Lump 90,000
$2.815.000
$ 99,000
$3.260.000
$ 163.000
$3.423,000
$ 342.000
$3,765.000
80
40 $62.
20 31.
50 TPH
Number
and Size Cost
30,000 Sq. Ft. $ 540,000
3,000 Sq. Ft. 30,000
2- 10T 200,000
3C;000 Sq. Ft. 240,000
2 50,000
3-65" 24,000
2 25,000
4 24,000
1 130,000
4-ll'-15T 1,816,000
4-L3,000 KVA Included
in D- 1
Lurp 40,000
Lunp 12,000
30.000
4 12,000
2- >OT 1200 KW Ea. 800, 000
1 145.000
LUMP 180,000
$3.778,000
$ 132,000
$4.480,000
$ 224.000
$4,704,000
$ 470,000
$5J,74L000
75 $51.74
38 25.87
-------
COREL!
PREHE/
Al
A. Buildings
Melting Building $17/Sq. Ft.
Transformer Building $10/Sq. Ft.
B. .'.ci'iipyard Equipment
1. Scrapyard Crane
2. Crane Runway
.5. Platform Scales
4. Magnets
5. Charge Bucket Transfer Cars & Track
C. Charging Equipment
Charging Monorail
D. Melting Equipment
1. Core less Induction Furnaces
3. Preheater with Charge Bucket
4. Slag Box
5. Piping, Headers, Sewer Connections
E. Holding Equipment - None Specified
Subtotal #1 (B + C + D + E)
F. Spares & Freight (3V/. of B, C, D, E)
Subtotal #2 (ST. #1 •*- A + F)
G. Engineering (5% of ST. #2)
Subtotal #3 (G + ST. #2)
H. Contingencies (10% of ST. #3)
Total (ST. #3 + H)
Cost/Ton
500
1,000
2,000
1,000
2,000
4,000
2,000
4,000
Nlllllln
. Ill
-------
EQUIPMENT REQUIREMENTS
CORELESS INDUCTION FURNACES, WITH
PREHEATERS, NO HOLDING FURNACES,
AFTERBURNER ON PREHEATER
5 TPH
Number
and Size
5,000 $
1,000 Sq. Ft.
1-5T
Open
1-45"
Cost
85,000
10,000
60,000
19,000
15,000
5,000
8,000
15 TPH
Number
and Size
9,000 Sq. Ft. $
1,200 Sq. Ft.
1-7^T-80' Span
Covered
1
1-65"
Lump
Cost
153,000
12,000
83,000
128,000
20,000
8,000
10,000
Nu
and
13,500
1,800
2-7i;T
Covere
2-65"
40,000
50,000
2-10 Ton ,
KW 2,100 Each
1
400,000
28,000
2,000
10,000
2-20 Ton
4,100 KW Each
2
850,000
64,000
5,000
20,000
3-25 T
6,250
3
$588.000
$ 21.000
$704.000
$ 35.000
$739.000
$ 74.000
$813.000
$1.238.000
$ 43.000
$1.446.000
$ 72.000
$1.518.000
$ 152.000
$1.670.000
$325
162.50
81.25
$111.33
55.67
27.84
-------
[JUIPMENT REQUIREMENTS
SS INDUCTION FURNACES, WITH
TERS, NO HOLDING FURNACES,
TERBURNER ON PREHEATER
5 TPH 15 TPH
r Number
ze Cost and Size
$ 85,000 9,000 Sq. Ft. $
Ft. 10,000 1,200 Sq. Ft.
60,000 1-7%T-80' Span
19,000 Covered
15,000 1
6,000 1-65"
8,000 Lump
40,000
400,000 2-20 Ton
Each 4,100 KW Each
28,000 2
2,000
10,000
$588.000 $1
$ 21,000 $
$704.000 $1
$ 35.000 $
$739.000 $1
$ 74,000 $
$813.000 $1
$325
162.50
81.25
Cost
153,000
12,000
83,000
128,000
20,000
8,000
10,000
50,000
850,000
64,000
5,000
20,000
.238,000
43.000
.446.000
72.000
.518.000
152.000
.670.000
$111.
55.
27.
30 TK»
Number
and Size Cost
13,500 Sq. Ft. $ 230,000
1,800 Sq. Ft. 18,000
2-7%T 166,000
Covered 192,000
30,000
2-65" 16,000
15,000
60,000
3-25 Ton 1,600,000
6,250 KW Each
3 129,000
7,000
25,000
$2.240.000
$ 78.000
$2.566.000
$ 128.000
$2.694.000
$ 269.000
$2.963.000
33
67
84
$ 49.
24.
APPENDIX D
NUMBER 42
50 TPH
Number
and Size Cost
20,000 Sq. Ft. $ 340,000
3,000 Sq. Ft. 30,000
:MOT 200,000
Covered 240,000
10,000 Sq. Ft.
:: r.o,ooo -
3 24,000
:'. 20,000
75,000
4-30 Ton 2,200,000
6,750 KW Each
4 172,000
4 10,000
30,000
$3.021.000
$ 106,000
$3.497.000
$ 175,000
$3.672,000
$ 367.000
$4,039,000
38 $ 40.39
69 20.20
-------
DIRECT M
Cost
Metallics
Pig Iron
#2 Heavy Melting Steel Scrap
iV'l Heavy Melting Steel Scrap
Borings-Briquettes
Borings-Loose
Iron Scrap-Retnelt
Iron, Cast Scrap
Sil Mn. Briquettes
Sil. Carb. Briquettes
Fe. Si. 85%
Fe. Si. 50%
Nonmetallics
Coke
Sil. Mn. Briquettes
Carbo-Graphite
Soda Ash
Limestone
Sil. Carb. Briquettes
Cost per Ton
Pound
$.03326
.01451
.01813
.01506
.00924
.02121
.02121
.1050
.075
.1945
.1530
Percent
5%
30
5
15
_
34
10
.40
.40
.20
-
Pounds
104
623
104
312
_
706
208
8
4
4
-
Cost
$3.46
9.04
1.89
4.70
14.97
4.41
.84
.60
.78
Perc
37
5
15
_
32
10
.
.
.
-
2,077
.02475
.1050
.04
.03
.00388
.075
360
1.5
8.5
2.5
60
9
$8.91
.16
.34
.08
.23
.68
$51.09
ft-
-------
DIRECT MATERIAL COST
Lined Cupola Water-Cooled Cupola Electric Furnace
i Pounds Cost Percent Pounds Cost Percent Pounds
104
623
104 1.89 5 104 1.89 50% 1,045
312
300
706 14.97 32 706 14.97 33 680'
208
8
4
4 .78 .20 4 .78 .4 8
1.4 30
$3.46
9.04
1.89
4.70
14.97
4.41
.84
.60
.78
37
5
15
—
32
10
.40
.40
.20
800
104
312
_
706
208
8
8
4
$11.61
1.89
4.70
14.97
4.41
.84
.60
.78
50%
_
15
33
_
.4
2,077 2,150 2,063
360 $8.91 250 $6.19
1.5 .16 1.5 .16
8.5 .34 - 60
2.5 .08 2.5 .08
60 .23 60 .23
9 .68 9 .68
$51.09 $47.14
-------
APPENDIX D
NUMBER 43
TERIAL COST
ater-
nt
0
0
0
2
Cooled
Pounds
800
104
312
_
706
208
8
8
4
_
,150
250
1.5
-
2.5
60
9
Cupola
Cost
$11.61
1.89
4.70
14.97
4.41
.84
.60
.78
$6.19
.16
.08
.23
.68
Electric Furnace
Percent Pounds Cost
50% 1,045 $18.95
_
15 300 2. 77
33 680 14.42
_ _
.4 8 1.56
1.4 30 4.59
2,063
60 $2.40
. Induction Furnace
Percent Pounds
27 550
15 302
_
34 686
22 445
.4 8
1.4 30
2,021
60
Cost
$ 9.97
4.55
14.55
9.44
1.56
4.59
$2.40
$47.14
$44.69
$47.06
-------
SUMMARY OF CC
CUPOLA, COLD BLAST
FABRIC FILTER
Melt Rate
5 Tons Per Hour
. Operating Hours Per Year
Costs Per Ton 5001.0002.000
Direct and Indirect Labor $18.00 $16.00 $14.00
Salaried Personnel 4.32 3.60 2.88
Depreciation 16.00 8.00 5.00
Capital Charges (Interest, Insurance, Taxes) 20.40 10.20 6.50
Electrical Power .07 ;05 .04
Gas .05 .05 .0:
Supplies and Maintenance Material 3.00 3.00 3.0C
Allocated Costs 4.00 4.00 4.PC
Total S65.84 $44.90 $35.21
-------
SUMMARY. OF CONVERSION COSTS
CUPOLA, COLD BLAST NO HOLDING FURNACE,
FABRIC FILTER EMISSION CONTROL
Melt Rate
5 Tons Per Hour
eratlng Hours Per Year
00
8.00
4.32
6.00
0.40
.07
.05
3.00
^.00
5.84
1.000
$16.00
3.60
8.00
10.20
.05
.05
3.00
4.00
$44.90
2.000
$14.00
2.88
5.00
6.50
.04
.05
3.00
4.00
$35.27
Melt Rate
15 Tons Per Hour
Operating Hours Per Year
1.000
$ 8.67
1.92
6.73
8.80
.05
.05
3.00
4.00
$33.22
2,000
$ 7.33
1.92
4.07
5.30
.03
.05
3.00
4.00
$25.70
4 . OOP
$ 6.36
1.44
2.03
2.65
.03
.05
3.00
4.00
$19.56
Melt Rate
30 Tons Per
Operating Hoi
2,000 t
$ 5.83 :
.96
3.50
4.55
.03
.05
3.00
4.00
$21.92 '<
-------
,.°PENDIX P
RSJON COSTS
NUMBER 44
HOLDING FURNACE,
SSION CONTROL
Melt Rate
15 Tons Per Hour
Operating Hours Per Year
1,000
$ 8.67
1.92
6.73
8.80
.05
.05
3.00
4.00
$33.22
2 , OOP
$ 7.33
1.92
4.07
5.30
.03
.05
3.00
4.00
$25.70
4 . 000
$ 6.36
1.44
2.03
2.65
.03
.05
3.00
4.00
$19.56
Melt Rate
30 Tons Per Hour
Operating
2.000
$ 5.83
.96
3.50
4.55
.03
.05
3.00
4.00
$21.92
Melt Rate
50 Tons Per Hour
Hours Per Year Operating
4.000
$ 4.58
.72
1.75
2.28
.02
.05
3.00
4.00
$16.40
2.000
$ 4.30
.58
2.87
3.73
.02
.05
3.00
4.00
$18.55
Hours Per Year
4.000
$ 3.35
.43
1.44
1.87
.02
.05
3.00
4.00
$14.16
-------
SUMMARY OF C(
CUPOLA, HOT BLAST, I,
CHANNEL INDUCTION t
ENERGY WET SCRUB1
Cost per Ton
Direct and Indirect Labor
Salaried Personnel
Depreciation
Capital Charges (Interest, Insurance, Taxes)
Electrical Power
Water
Gas
Supplies and Maintenance Material
Allocated Costs
Total
Melt Rate
5 Tons per Hour
Operating
2.000
$17.00
2.88
5.07
6.59
.05
.20
.25
2.00
4.00
Hours per Yeai
4.000
$15.00
2.16
2.54
3.29
.04
.20
.25
2.00
4.00
$38.04 $29.48
-------
SUMMARY OF CONVERSION COSTS
CUPOLA, HOT BLAST, WATER-COOLED, UNLINED,
CHANNEL INDUCTION HOLDING FURNACE, HIGH
ENERGY WET SCRUBBER EMISSION CONTROL
Melt Ra
5 Tons per
te
Hour
irating Hours per Year
2.000
$17.00
2.88
5.07
6.59
.05
.20
.25
2.00
4.00
$38.04
4.000
$15.00
2.16
2.54
3.29
.04
.20
.25
2.00
4.00
$29.48
Melt
15 Tons
Rate
per Hour
Operating Hours per Year
2,000
$ 7.33
1.92
4.43
5.76
.62
.20
.25
2.00
4.00
$26.51
4.000
$ 5.83
1.44
2.22
2.88
.40
.20
.25
2.00
4.00
$19.22
Melt Rate
30 Tons per
Operating Ho
2,000
$ 5.50
.96
3.60
4.68
.52
.20
.25
2.00
4.00
$21.71
-------
x.°PENDIX D
VERSION COSTS
TER-COOLED, UNLINED,
LDING FURNACE, HIGH
REMISSION CONTROL
Melt
15 Tons
Rate
per Hour
Operating Hours per Year
2.000
$ 7.33
1.92
4.43
5.76
.62
.20
.25
2.00
4.00
$26.51
4.000
$ 5.83
1.44
2.22
2.88
.40
.20
.25
2.00
4.00
$19.22
Melt Rate
30 Tons per
NUMBER
Hour
Operating Hours per Year
2,000
$ 5.50
.96
3.60
4.68
.52
.20
.25
2.00
4.00
$21.71
4.000
$ 4.41
.72
1.80
2.34
.33
.20
.25
2.00
4.00
$16.05
45
Melt
50 Tons
Ope ra tine
2,000
$ 3.90
.58
3.24
4.21
.45
.20
.25
2.00
4.00
$18.83
Rate
per Hour
Hours per Year
4.000
$ 3.10
.43
1.62
2.11
.29
.20
.25
2.00
4.00
$14.00
-------
SUMMARY OF i
ELECTRIC ARC FURNACE WITH C:
FABRIC FILTE:
Melt Rate
5 Tons Per Hour _
Operating Hours Per Year _0
Costs Per Ton ._5QO_ .1,000. Z.OOO L
Direct and Indirect Labor $18.00 $14.00 $12.00
Salaried Personnel 4.32 3.60 2.88
Depreciation 33.04 16.52 8.26
Capital Charges (Interest, Insurance, Taxes)42.95 21.48 10.74
Electrical Power 36.00 19.90 11.76
Water .05 .05 .05
Gas .05 .05 .05
Electrodes 2.85 2.85 2.85
Supplies and Maintenance Material 2.50 2.50 2.50
Allocated Costs 4.00 4.00 4.00
Total $143.76 $84.95 $55.09 $
-------
SUMMARY OF CONVERSION COSTS
ELECTRIC ARC
FURNACE WITH CHANNEL INDUCTION HOLDING FURNACE,
FABRIC FILTER EMISSION CONTROL
Melt Rate
5 Tons Per Hour
Operat
500
$18.00
4.32
33.04
-------
SUMMARY OF i
ELECTRIC ARC FURNACE WITH C!
FABRIC FILTE:
Melt Rate
5 Tons Per Hour _
Operating Hours Per Year 0
Costs Per Ton .__500._ i.OQQ. lxQO_n I
Direct and Indirect Labor $18.00 $14.00 $12.00
Salaried Personnel 4.32 3.60 2.88
Depreciation 33.04 16.52 8.26
Capital Charges (Interest, Insurance, Taxes)42.95 21.48 10.74
Electrical Power 36.00 19.90 11.76
Water .05 .05 .05
Gas .05 .05 .05
Electrodes 2.85 2.85 2.85
Supplies and Maintenance Material 2.50 2.50 2.50
Allocated Costs 4.00 4.00 4.00
Total $143.76 $84.95 $55.09
-------
SUMMARY OF CONVERSION COSTS
TRIG ARC
FURNACE WITH CHANNEL INDUCTION HOLDING FURNACE,
FABRIC FILTER EMISSION CONTROL
Rate
ns Per Hour
ng^ Hours
1 000
$14.00
3.60
16.52
21.48
19.90
.05
.05
2.85
2.50
4.00
$84.95
Per Year
2.000
$12.00
2.88
8.26
10.74
11.76
.05
.05
2.85
2.50
4.00
$55.09
Melt Rate
15 Tons Per Hour
Operating
1,000
$7.66
1.92
15.67
20.40
19.68
.05
.05
2.85
2.50
4.00
$74.78
Hours
2.000
$6.67
1.92
7.84
10.20
11.86
.05
.05
2.85
2.50
4.00
$47.94
Per Year
4J)00
$5.50
1.44
3.92
5.10
7.92
.05
.05
2.85
2.50
4.00
$33.33
Melt Rate
30 Tons Per Hour
Operating Hour 3
2 ,000 A,
$5.3J $
.96
6.28
8.17
11.25
.05
.05
2.85
2.50
4.00
$41.44 $2
-------
APPENDIX )
DNVERSION COSTS
NUMBER 4f>
\NNEET INDUCTION HOLDING FURNACE,
EMISSION CONTROL
Melt Rate
L5 Tons Per Hour
arat
000-
7.66
1.92
5.67
0.40
9.68
.05
.05
2.85
2.50
4.00
'4.78
ing Hours Per Year
2.000
$6.67
1.92
7.84
10.20
11.86
.05
.05
2.85
2.50
4.00
$47.94
4JHLQ
$5.50
1.44
3.92
5.10
7.92
.05
.05
2.85
2.50
4.00
$33.33
Melt Rate
30 Tons Per
Hour
Operating Hour 3 Per Year
2...QQ.Q
$5.33
.96
6.28
8.17
11.25
.05
.05
2.85
2.50
4.00
$41.44
/uQQO
$4.50
.72
3.14
4.09
7.57
.05
.05
2.85
2.50
4.00
$29.47
Melt Rate
50 Tons Per
Hour
Operating Hours P°r Year
2,000
34.10
.5?
5.17
6.73
11.11
.05
.05
2.8.1
2.50
4.00
$37.14
4 ,000
$3.45
.43
2.59
3.37
7.50
.05
.05
2.35
2.50
4.00
$26.79
-------
SUMMARY OF C<
CORELESS INDUCTION FURN;
NO HOLDING FURNACE, i
Melt Rate
5 Tons Per Hour _J
Operating Hours Per Year 0±
Costs Per Ton 500 I.OOP 2,000 I.
Direct and Indirect Labor $18.00 ?15.00 $14.00 $
Salaried Personnel 4.32 3.60 2.88
Depreciation 32.52 16.26 8.13 1
Capital Charges (Interest, Insurance, Taxes)42.27 21.14 10.57 1
Electrical Power 39.79 22.18 13.37 1
Water .05 .05 .05
Gas .30 .30 .30
Supplies and Maintenance Material 3.00 3.00 3.00
Allocated Costs 4.00 4.00 4.00 _
Total $144.25 $85.53
-------
SUMMARY OF CONVERSION COSTS
CORELESS INDUCTION FURNACE WITH CHARGE PREHEATER,
NO HOLDING FURNACE, AFTERBURNER ON PREHEATER
lelt
'ons
Rate
Per Hour
iting Hours Per
•0
;2
,2
7
9
'5
0
0
0
5_
1,000
$15.00
3.
16.
21.
22.
.
.
3.
4.
$85,
60
26
14
18
05
30
00
00
53
Year
2,000
$14
2
8
10
13
3
4
$16
.00
.88
.13
.57
.37
.05
.30
.00
.00
15
Melt
Tons
: Operating
1^000
$ 8.
1.
11.
14.
14.
.
.
3.
4.
00
92
13
47
86
05
30
00
00
Rate
Per
Hour
Hours Per Year
2.000
$7.00
1.
5.
7.
9.
.
.
3.
4.
92
57
24
40
05
30
00
00
.30 $57.73 $38.48
4.000
$ 6.36
1
2
3
6
3
4
$28
.44
.78
.62
.64
.05
.30
.00
.00
^12
Melt Rate
30 Tons Per Ho
Operating HouFs
2.OOP3
$ 4.84 $
.96
4.94
6.42
9.64
.05
.30
3.00
4.00
-------
APPENDIX D
JVERSION COSTS
:E WITH CHARGE PREHEATER,
•TERBURNER ON PREHEATER
Melt Rate
3 Tons Per Hour
! rat ing "Hours Per Year
7H5 2.000 4.000
3.00
1.92
1.13
'4.
4.86
.05
.30
3.00
4.00
$7.00
1.92
5.57
7.24
9.40
.05
.30
3.00
4.00
$ 6.36
1.44
2.78
3.62
6.64
.05
.30
3.00
4.00
$38.48 $28.19
NUMBER 47
Melt Rate Melt Rate
30 Tons Per Hour 50 Tons Per Hour
Operating Hours
2.000 4,
$ 4.84 $
.96
4.94
6.42
9.64
.05
.30
3.00
4.00
$34.15 $2
Per Year
000
4.16
.72
2.47
3.21
6.76
.05
.30
3.00
4.00
4.67
Operating Hours Per Year
2.000
$ 3.90
.58
4.04
5.25
8.68
.05
.30
3.00
4.00
$29.85
4.000
$ 3.40
.43
2.02
2.62
6.28
.05
.30
3.00
4.00
$22.10
-------
ANNUAL
FOR EMISSION CO
5 Tons/Hour
Fabric Filter on Cupola (Cold Blast)
Number Cupolas
ACFM Each
Annual Operating Cost
Annual Tons
Cost/Ton
Wet Scrubber on Cupola (Hot Blast)
ACFM
Annual Operating Cost
Annual Tons
Cost /Ton
Fabric Filter on Electric Arc
Furnace Diameter
Annual Operating Cost /System
Number Fabric Filter Systems
Total Annual Operating Cost
Annual Tons
Cost /Ton
Afterburner on Coreless Induction
Annual Operating Cost
Tons
Cost /Ton
500
1
9,200
$25,000
2,500
$10
7' 3"
$28,000
2
$56,000
2,500
$22.40
$1,150
2,500
$.46
1.000
1
9,200
$30,000
5,000
$6
7'3"
$31,000
2
$62,000
5,000
$12.40
$1,350
5,000
$.27
2,000
1
9,200
$35,000
10,000
$3.50
6,800
$35,000
10,000
$3.50-
7'3"
$37,500
2
$65,000
10,000
$6.50
$1,730
10,000
$.17
-------
ANNUAL OPERATING COSTS
FOR EMISSION CONTROL EQUIPMENT SYSTEMS
Zold Blast)
3t Blast)
Arc
/stem
stems
Cost
nduction
5 Tons /Hour
500
1
9,200
$25,000
2,500
$10
7' 3"
$28,000
2
$56,000
2,500
$22.40
$1,150
2,500
$.46
1,000
1
9,200
$30,000
5,000
$6
7'3"
$31,000
2
$62,000
5,000
$12.40
$1,350
5,000
$.27
2.000
1
9,200
$35,000
10,000
$3.50
6,800
$35,000
10,000
$3.50-
7'3"
$37,500
2
$65,000
10,000
$6.50
$1,730
10,000
$.17
15 Ton
4.000 1.000
1
27,300
$60,000
15,000
$4.00
6,800
$50,000
20,000
$2.50
11'
$41,000
2
$82,000
15,000
$5.47
$3,040
15,000
$.20
2.C
27,
$70,
30,
$2
22,
$60.
30 ;
$;
$49;
$98.
30.
$:
$4.
30.
d
s
-------
DERATING COSTS
'TROL EQUIPMENT SYSTEMS
APPENDIX D
NUMBER 48
,000
15 Tons/Hour
30 Tons/Hour
50 Tons/Hour
6,800
50,000
20,000
$2.50
1.000
1
27,300
$60,000
15,000
$4.00
11'
$41,000
2
$82,000
15,000
$5.47
$3,040
15,000
$.20
2,000
1
27,300
$70,000
30,000
$2.33
22,800
$60,000
30,000
$2.00
11'
$49,000
2
$98,000
30,000
$3.27
$4 , 150
30.000
$.14
4.000
1
27,300
$80,000
60,000
$1.33
22,800
$75,000
60,000
$1.25
11'
$64,000
2
$128,000
60,000
$2.13
$6,380
60,000
$.11
2.000
2
27,300
Each
$140,000
60,000
$2.33
43,000
$110,000
60,000
$1.83
11'
$49,000
3
$147,000
60,000
$2.45
$7,260
60.000
$.12
4.000
2
27,300
Each
$160,000
120,000
$1.33
43,000
$140,000
120,000
$1.17
11'
$64,000
3
$192,000
120,000
$1.60
$11,640
120,000
$.10
2,000
2
37,200
Each
$180,000
100,000
$1.80
62,000
$165,000
100,000
$1.65
11'
$49,000
4
$196,000
100,000
$1.96
$11,060
100,000
6 -i ^
$ . J.J.
4.000
2
37,200
Each
$200,000
200,000
$1.00
62,000
$195,000
200,000
$ .98
11'
$64,000
4
$256,000
200,000
$1.28
$18,280
200,000
$.09
-------
APPENDIX E
EMISSION TEST PROCEDURES
A standard recommended procedure for testing particulate
emissions from iron foundry cupolas did not exist until the
end of 1970. At that time the "Recommended Practice for Testing
Particulate Emissions from Iron Foundry Cupolas" was adopted by
the American Foundrymen's Society and the Gray and Ductile Iron
Founders' Society, Inc. This industry standard procedure,
broadly based on the American Society of Mechanical Engineers
Performance Test Codes 21-1941 and 27-1957, recognizes the
unique problems of cupola testing and recommends procedures
to deal with them in a satisfactory manner0 The recommended
practice is reproduced in Exhibit 1 of this appendix for in-
formation purposes only.
In a more specific manner, Exhibit 2 presents detailed
sampling and analytical techniques for individual components
of cupola emissionso These techniques are widely accepted
by chemical and testing laboratories and used in analytical
work. Techniques are included for identification and quantifi-
cation of particulate matter such as arsenic, beryllium,
cadmium, fluorides, lead, mercury, and zinc, and two gaseous
components, nitrogen oxides and sulfer dioxide.
A.T.KEARNEY & COMPANY, INC.
-------
APPENDIX E
EXHIBIT 1
RECOMMENDED PRACTICE FOR TESTING
PARTICULATE EMISSIONS
FROM
IRON FOUNDRY CUPOLAS
Edited by
A Joint Committee of
American Foundrymen's Society
and
The Gray & Ductile Iron Founders' Society, Inc.
The recommended procedure discussed in this
section has, as of this date, not been endorsed
by any bodies other than A.F.S. and G.D.I.F.S.
and is presented for information only.
-------
Appendix E
Exhibit 1
Page 2
INTRODUCTION
The iron foundry industry has had many air pollution studies con-
ducted on cupola emissions at their various plants. Of great concern to the
industry and to the individual firms that have conducted such testing are the many
varied and diverse test methods and test procedures used by the variety of independent
organizations conducting such tests. The diverse methods and equipment used in
performing such tests have made comparison and evaluation of results impractical
or a near impossibility. Many of the tests conducted have shown marked incon-
sistencies between individual test runs by the same test group and also in
comparing the results on the same system by different testing organizations.
A number of the procedures used in cupola testing suffer from
obvious inadequacies when they are carefully scrutinized. Consequently, it has
been deemed desirable and necessary that a recommended test procedure and testing
method be made available to assist the metalcasting industry in achieving the
maximum in emission control v/ith the minimum of wasted and misdirected effort
and expense. Since the industry is unique in the large, nonproductive investments
needed to gain compliance with air pollution control requirements, it is especially
significant that its emissions be evaluated by test methods and procedures able to
produce consistently reliable results detailing these emissions, but do not
unnecessarily and unfairly penalize the plant.
Particulate emission tests of cupola stack gases are done under
varied conditions and in several different locations, depending on the test objec-
tive. Both location and objective influence the test equipment employed although
the two usual purposes will be:
1) to determine nature and/or quantity of emissions released
in the raw cupola gases
2) to determine nature and/or quantity of emissions on the
cleaned gas side of a control unit.
-------
Appendix E
Exhibit 1
Page 3
Raw gas test locations:
a) In cupola stack, above charging door. This is the most
difficult location for testing. Gas flow is extremely
uneven and the flow rate is relatively low; gas temperature
is high - often 1200°-2200°F - and fluctuating; dust loading
is extremely uneven because of channeling caused by indraft
of much cold outside air drawn into the cupola stack through
the charge door. This test location is necessary where a
cupola has no control systems or has a wet cap type collector.
b) In inlet duct ahead of dust collector. This is an easier
location if a reasonably straight duct run is available.
Duct velocities and dust loadings are more uniform and confined
in a smaller cross section. Normally gases will be cooled to
500°F or lower at the sampling point from evaporation of
cooling water. The added volume of water vapor must be measured
and considered in gas density calculations and dust loadings
if reported in grains per standard cubic feet dry gas.
Inlet and outlet samples should be supplemented wherever
possible by using the catch as a check for the test data.
Catch can be more readily obtained from dry collector
types especially for a complete melting cycle.
c) Catch plus outlet loadings. Where dry collectors are employed,
the entire test procedure is simplified by actual weighing of
collected material. The higher the efficiency of the collecting
device the more nearly the catch will represent the raw
sample. Chances for error are diminished because of quantity
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Appendix E
Exhibit 1
Page 4
of collected material available although it will
be difficult to obtain accurate catch quantities
except for a complete melting cycle - thus providing
an averaging of the peaks and valleys of emission
concentrations.
See comments for outlet loading under "Cleaned Gas Locations".
Cleaned Gas Locations:
a) After dry collector. Conventional dust sampling tech-
niques will be satisfactory for such locations. Coarse
particles will be removed by a dust collector so the
importance of a large diameter sampling probe diminishes.
Water vapor content of the gas should cause no condensation
problems with 350° to 550°F gas temperatures. Collecting
device in sampler can be influenced by intended analysis -
gross weight, particle size distribution, chemical compo-
sition, particle count, etc.
b) After wet collector. Sampling problems are more complicated
than after dry collectors because gas stream is saturated or
nearly so. Close coupling of sampling components is essential
and heating of the sampled air often required.
Exception: Wet cap type of collectors have too short a
contact time to bring gas stream close to saturated con-
ditions. Sampling after the collector will be questionable
value unless gases are gathered in a discharge stack of
several diameter lengths.
In recognition of these differences in purpose and location for
testing emissions the following procedure is divided into three sections.
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Page 5
Section I deals exclusively with sampling raw particulate emissions
in the cupola stack.
Section II deals exclusively with sampling raw particulate emissions
in the inlet duct connecting the cupola to the dust collector.
Section III deals exclusively with sampling cupola gases after they
have been cleaned.
REASONS FOR SAMPLING A CUPOLA
Basically sampling is done for three reasons:
1) to determine 1f a collecting device is of a high enough
efficiency so that its effluent does not exceed a pre-
determined level.
2) to meet regulatory requirements that specify a minimum
efficiency of removal of particulate from the gas stream,
expressed as a percentage of uncontrolled emission.
3) to obtain information regarding particulate emission
which will be used for designing gas cleaning devices.
Officials of local, regional or state regulatory bodies should
be consulted prior to testing except when the testing is being done for purely
informational data for the cupola owner or operator.
If source testing is being done to determine compliance with legal
requirements the appropriate control officials should be consulted. If the
control body has experience and is equipped to perform cupola testing, they
may wish to perform their own tests to determine compliance.
Generally control bodies will not accept the results of tests
performed by the owners, operators or vendors of collection devices unless
standard procedures were followed and test data and reports show evidence
that experienced personnel conducted the tests.
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Page b
In most cases it will be necessary for the owner or operator of a
cupola to employ the services of an organization capable of performing these tests.
When this is done the control authorities should have given prior approval of the
testing organizations capabilities and acceptability of their test.results. In
any event, it is advisable to notify the proper authorities in advance so that
they may have on site observers present if they so desire.
The foundryman should select a testing organization with proven
capability, a good reputation and in whom he has complete confidence. As test
data can have major economic consequences and as the foundryman usually cannot
check the quality of the testing procedures confidence in the organization is a pre-
requisite.
The next step is consultation with the appropriate control author-
ities. The foundryman along with the testing organization must involve them-
selves in this because regulations are sometimes not easily understood, and fre-
quently interpretation is modified by political and community attitudes. Authori-
ties will be aware of changes in enforcement policies, or pending changes in
legislation, and the foundryman cannot expect outside testing organizations to
be cognizant of these considerations.
The number and type of tests to be taken must be agreed on in
advance by all parties concerned. Frequently, meeting the specifications of the
pertinent code dictate the number and kind of samples to be run. At other times
the purchase agreement between vendor and foundryman specifies testing methods.
If discretion can be used the use of several short tests is recommended over one
longer one. When several results can be compared, any large differences are
evident. If these differences are not as a result of operational changes or
adjustments they may indicate error in the test procedure or malfunction of the
test equipment. One test of long duration gives only one answer with no basis
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Appendix E
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Page 7
for comparison. Accuracy and precision of testing is controlled as much by the
care exercised and quality of the testing personnel as it is by the test procedure.
Errors In each manipulation such as weighing, measuring gas volume,
and calculating results must not exceed 1 percent and should be kept under that
if possible. In this way cumulative errors can be held to little more than 1
percent.
CUPOLA OPERATING AND TEST CONDITIONS
Due to the various possible modes of operation of cupolas and
cupola systems, it 1s recommended that cupola emissions be evaluated under con-
ditions that characterize normal or average cupola operations at any particular
plant.
Particulate matter emitted via raw cupola stack gases consists
principally of iron oxides and silica from the charge metal and impurities adhering
to the charge metal plus combustible matter. Secondary combustion in the upper
portion of a cupola stack will tend to reduce the combustible portion of the
particulate emissions to ash if temperature and retention time are sufficient.
Cupola stack gas will also contain some vapor from substances which
reaches the melting zone and is volatilized. These substances include silicon,
zinc and silica (sand). The degree of volatilization will depend on melting zone
temperature which is influenced by changes in the fuel (coke and/or gas) ratio,
preheating of the blast air or scrap and enrichment of the blast air with oxygen.
Consequently, it is of utmost importance that the factors affecting melt zone
temperature be normal before testing begins. Equally as important, materials that
can cause fuming, such as galvanized iron, sand, and silicon, for example, be added
in normal amounts during the test period. Changes from normal melt process can
result in emissions which are markedly better or worse than will be obtained
during everyday operation. Either result will be unsatisfactory.
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The particulate matter emanating from a cupola has a wide range
of particle size distribution which influences the correct choice of stack testing
method. For many cupolas, peaks in particle sizes can be found on distribution
curves at three ranges. These are in the 200 to 500 micron range, the 20 to 50
micron range and the 5 micron and below range.
Many factors influence the particul ate emission rates of a cupola
system. These include the rate of cupola operation, the character, cleanliness
and method of introduction of the charge, material, the type, size and amount of
the coke used, the frequency, length of time and number of periods when tuyere
blast air is operative or inoperative during any period, the type of metal being
melted, the method and type of alloy introduction, and other diverse factors.
It is necessary, therefore, that each cupola and cupola system be
individually analyzed to determine conditions under which stack or source
emission tests are needed to define the full range and character of its emissions.
One of the factors having a most profound effect in cupola emis-
sions is the rate of cupola melting; as cupola blast air and coke input is
increased to accommodate higher melting rates, cupola emissions increase signifi-
cantly. It is important, therefore, that cupola source-emission tests be conducted
at melting rates approaching the normal expected rate of cupola operation if the
results are expected to characterize emissions for the system. Often times it is
not practical to operate at maximum melting rates since melting rates must
reflect current production and pouring schedules. It should be appreciated,
however, that cupola charging and melting rates have a profound influence on
cupola emissions.
If for any reason tests during either start-up or burn down periods
are made such tests should be kept and evaluated separately f;*om each other as
well as all others.
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If various metals are produced at various times from the same
cupola (such as gray and cutile iron) it is desirable that the emissions be
evaluated for each type produced if there is a difference in melting conditions.
The melting conditions that would tend to require evaluation in terms of
differences in emissions would be reflected by variations in blast air rates,
coke rates and charge metal characteristics.
Prior to any field test period the testing firm should be con-
sulted for recommendations as to the number of days and number of test runs to
be conducted to define the full range of cupola emissions consistent with cupola
operating practices and other pertinent considerations. It is important that the
plant's full range of operations be evaluated consistent with the stated objec-
tives of the emission test program.
OBTAINING MEANINGFUL TEST DATA
For short run jobbing cupolas, it is recommended that a minimum of
three dustloading test determinations be conducted of cupola emissions as part
of any emission study. A volumetric determination should be conducted for each
of the three test periods. To make the emission data be the most meaningful it is
necessary and desirable that detailed records be kept of cupola operating con-
ditions concurrent with the emission studies.
The emission test program can usually be conducted in one to three
days of field sampling by an experienced testing organization. The following
minimum information is considered necessary in establishing and fixing cupola
operating conditions. It is necessary that these cupola operating data be
secured concurrently with stack emission studies:
1) Nature, weight and constituents of all cupola charges.
2) Number and time of all cupola charges made on the test
date(s).
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Appendix E
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3) Cupola blast air record showing volume changes during
test. Verify that records indicate volume introduced
but not quantities diverted as a means of throttling.
4} Presence of, type, number, capacity and location of
afterburners.
5) Existence of gas ignition in the stack.
Ample precedents exist for evaluating the emission performance of
only one cupola in a bank of two cupolas that are operated on alternate days.
This situation is particularly valid if both cupolas are of the same size,
oerate from the same tuyere blast air supply, are used in the production of
similar types of iron and are operated at the same approximate rates.
If there are marked variations or changes in the operation of a
2-bank cupola system, particularly with respect to the factors outlined above,
it is recommended that each cupola be evaluated individually for its emission
potential. The design of a single emission control system serving a dual bank
of cupolas must be predicated on achieving conformance with regulations for the
most severe conditions of cupola operation during the normal production part of
the melt cycle. For the larger job-shop cupola-operators and for the production
foundry it is recommended that a minimum of two days field testing of cupola
emissions be conducted. This type of test program will permit the operation
and evaluation of both cupolas in a two unit bank.
The cupolas themselves should be operated at normal melting rates
during the test period. Test dates should be selected when foundry pouring
schedules will permit normal operation.
It is not necessary to obtain a gas analysis to determine gas
density from the cupola because the difference in weight between air and the
combustion gases is insignificant for exhaust volume calculation purposes.
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Exhibit 1
Page 11
SAMPLING PROCEDURES AND EQUIPMENT
A major problem in sampling and analysis is that high accuracy
and precision must be obtained in a working foundry, where conditions are
not conducive to laboratory-type manipulations. To achieve effective installation
and operation of a sampling train in a foundry requires someone who is not
overly worried with minute detail. On the other hand, when the critical ana-
lytical measurements and manipulations are made, the greatest attention to
cleanliness, accuracy, and detail is required.
The sampling equipment required for this work must fit the same
pattern. It must be simple, rugged, and yet capable of high accuracy. In general,
it must be highly portable. Reliable equipment is available from several vendors,
and all qualified testing groups have their own.
a. Filtering Media
A good filtering medium is a prerequisite to accurate
sampling. Efficiency of collection must be at least 99
percent for all particulates encountered. An ideal filter
medium should be very light so that accurate weight dif-
ferences can be obtained from small samples. The filter
should also be strong and resistant to both heat and moisture.
No medium available has all these properties so a
compromise must be made. Readily available media and some
of their characteristics are listed below. Reliable
suppliers will give the characteristics of their products
on demand.
FILTER PAPER
Conventional filter paper, made from cellulose, comes
in hundreds of grades; most of them are not suited to fine
particulate filtration, but some are specially designed for
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Appendix E
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Page 12
this service. They have good mechanical strength, good
resistance to moisture, and reasonable heat resistance.
Conventional paper must be dried and desiccated before
each weighing, and must weighed on a balance from which
moisture can be excluded. Ideally the paper should be
allowed to reach equilibrium in a constant-humidity room,
and should be weighed there.
GLASS FIBER FILTER PAPER
Glass fiber filter paper will withstand higher temperature
than conventional paper, but it should be remembered that
a plastic binder is used in the manufacture of most of this
paper and that the binder lowers temperature resistance.
Some paper is made without binder and this is much more resistant
to temperature. However, this material lacks mechanical strength,
and the unbonded variety is particularly weak. Glass fiber filter
paper has the great advantage that it is not sensitive to humidity
and so can be used where a dessicator is not available.
THIMBLES
The Soxhlet thimble has been used widely in the past. The
thimbles are made of two materials, paper and ceramics. The
paper thimbles have the same strengths and weaknesses as ordinary
paper, and the same precautions apply. The ceramic ones come
in a variety of porosities. If the pores are small enough for
this work, rates of filtration will be extremely small. In
addition, ceramic thimbles are very heavy so that large samples
must be weighed to obtain accuracy. Thimbles of any type are
not recommended for this work.
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Page 13
A variety of cloth materials are used for filtering
participates. Usually efficient filtration results
only after a coating of particulate has been built upon
the cloth. This buildup occurs most rapidly when the
sampled gases contain large amounts of particulate,
hence sampling error is minimized.
When particulate loading is low, such as when sampling
cleaned gas, significant error can be Introduced unless
the fabric is 99 percent efficient on the first material
that deposits.
b. Weighing
The first steps in sampling is weighing the filter paper,
or other medium. Each paper should be marked with a number
before weighing. The common practice of writing the weight
on the paper after it has been obtained creates an error
equal to the weight of the ink used. Much larger errors can
result from the handling required to write on the paper.
Lastly, and most importantly, the practice is poor technique,
and, if allowed, will encourage other slovenly practices.
The atmosphere in an ordinary analytical balance can be dried
to some extent if a small beaker of concentrated sulfuric
acid or container of silica gel is placed inside and the
doors are kept closed.
If filter papers are weighed on one balance initially,
and on a second when loaded, the second balance should be
checked for consistency with the first. This can best be
done by checking the weight of pre-weighed paper, and
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Appendix E
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Page 14
applying a correction if required. Accuracy on the total
weight is not vital, but the difference between initial
and final weights, which represents the weight of the sample,
is critical.
c. Flow Measuring
Volume flow rate measuring devices must be preceded by
system components to minimize the surging or pulsating effects
normal in cupola operation and sampling. The use of flow
rate measuring devices in testing effluents from a dynamic
system, such as a cupola, requires that frequent readings
be taken (2 or 3 minutes reading cycle should be the maximum
time period between readings) and that all readings must
be conducted on a stopwatch timed basis.
It is recommended that sampling volume flow rate measure-
ments be taken using two different flow measuring mechanisms
in any high volume sampling train. The average of the two
sampling volume rate measurements and computed sampling volumes
should then be used in the subsequent dustloading calculations.
d. Flushing the Sampling Train
At the end of each dustloading test run it is imperative
that the sampling train (nozzle, connecting tube or hose and
sampler) be thoroughly cleaned and flushed. Distilled water
should be used and introduced into the nozzle at high veloci-
ties to aid in scrubbing the sampling train.
The particulates flushed from the sampling train should be
handled, weighed and separately determined. Significant
quantities of particulates are deposited in any sampling train,
so it is important that this material be included with the
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Appendix E
.Exhibit 1
Page ib
sampled catch when computing the dustloading test results.
e. Velocity-Volumetric Tests
An S-type pi tot tube is preferred to a regular pi tot tube
because it is not as prone to plugging. Stainless steel, Iconel
or other high temperature resistant material should be used
.in the pi tot tube construction. A ruggedly constructed inclined
draft gage is recommended for use in the velocity and dustloading
tests. The pi tot tube should be checked and calibrated according
to the manufacturers recommendations at regular intervals to
establish the proper correction factor to be used in the volu-
metric calculations.
f. Sampling Trains and Sampling Equipment
Few emission sources offer the trying field test conditions
attendant to sampling as do cupola systems. The need also
cannot be emphasized enough for rugged field sampling equipment
for this testing. A schematic diagram of sampling apparatus
for the static balanced tube method of sampling, incorporating
recommendations for cupola effluent source emission sampling
is presented in Fig. 1.
A possible commercial source for various components of the
sampling train is indicated in Table 2. This is not to be
construed as an endorsement of any particular manufacturer
but is illustrative only of the rugged type of test equipment
recommended for cupola source sampling.
When assembling sampling equipment, joint sealing materials
should not be exposed to the sampled gas stream where adherence
of the particulate could occur. Long-radius bends should be used
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Appendix E
Page 16
instead of elbows to facilitate cleaning. The probe should
be just long enough for the task at hand. The rest of the train
should be assembled and tested for leaks. If the meter is a dry
gas meter, it is to be calibrated before each use. If an orifice
meter, or flow-meter type, is used it must also be calibrated
each time, and it must, in addition, have enough sensitivity
so that readings can be read to less than 1 percent. Finally,
if volume is obtained by multiplying an instantaneous reading
by the time of operation, fluctuations must be kept to 1 percent.
The vacuum pump or compound air ejector must be the last
element of the sampling train unless it can be proved that there
is no leakage through the packing, etc., under the worst con-
ditions that can be visualized.
g. Analysis of Captured Particulate
It is recommended that the procedure for weighing and
determining size distribution of the captured particulate
be used as stated in the ASME PTC 27-1957 Section 4 Paragraphs
75-79 (see Appendix).
Fine particulate matter should be sized and analyzed
within 24 hours after the sample is taken to minimize agglome-
ration and a possible change in character. It is most
desirable if the sample is dried immediately after the test
has been run to prevent degradation.
The minus 44 micron fraction of the collected particulate
must be carefully handled and analyzed because of the strong
tendency to agglomerate.
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Page l/
SECTION I - SAMPLING RAW PARTICULATE EMISSIONS IN THE CUPOLA STACK
Recommended Test Method and Procedures
A thorough and complete review of the available test methods and
procedures used in the conduct of source emission studies has resulted in the
recommendation of the following basic requirements as essential to an acceptable
evaluation of the test methods:
1) In order to obtain a truly representative sample of coarse
particulates from the gas stream a large volume sampling
train should be used. The sampling nozzle should be
constructed of stainless steel having a minimum inside
diameter of 3/4 inches, since raw cupola emissions cover
a broad range of particle sizes, with individual particles
not uncommonly ranging up to 3/8 inch diameter or larger.
2) Particulate matter is defined consistent with the definition
accepted by the dust collection industry and as adopted
in the American Society of Mechanical Engineers Performance
Test Code 21-1941, Dust Separating Apparatus and Performance
Test Code 27-1957, Determining the Dust Concentration in
a Gas Stream. See item 1 in the Appendix. In essence, this
defines particulate matter as all filterable solids present
at standard temperature in an effluent gas stream.
3) It is necessary that a truly "isokinetic" sample of gases
and solids be secured by the sampling system. This requirement
is a practical consideration dictated by the wide range of
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Appendix E
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Fuge 18
particle sizes involved and, therefore, the special
need for securing a truly isokinetic sample of the
effluent solids.
4) When sampling in the cupola stack, water-cooled
corrosion-resistant, sampling probes and sampling nozzles
are required. This is a practical requirement since
cupola temperatures in excess of 1200°F are common, and
sample contamination by corrosion products formed in the
nozzles and probes of the sampling system must be prevented.
Water-cooling also serves to preserve the sampling probes
from deterioration and distortion.
5) The American Society of Mechanical Engineers Performance
Test Code 27-1957, Determining Dust Concentration in a
Gas Stream, with modifications as outlined below offers the
best and most practical test method and test procedures
for the conduct of source emission studies from cupolas.
The following are additional important considerations in
the sampling of cupolas and cupola systems when utilizing as
a broad base the test procedures and techniques embodied in
ASME PTC 27-1957, Determining Dust Concentration in a Gas
Stream. See item 2 in the Appendix. The criteria supplement
the methods and procedures contained in ASME PTC 27, when
applied to cupola source emission testing:
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Page iy
a. Test Location and Test Openings
A test location in a cupola stack must at best be a
compromise. The location should be as far above the top
of the charge door opening as practical but be at least
one equivalent cupola inside daimeter below the top of the
cupola stack. This location will require that protective
shelter be provided since test personnel and equipment may
be subjected to possible fallout of particles.
Test ports should consist of two six inch pipe nipples
(schedule 40) installed radially in the cupola shell and
cupola lining at 90 degrees to each other. Both 90 degree
test ports must be accessible from the sheltered test plat-
form. Six-in test ports are usually required to accommodate
high volume sampling nozzles. An acceptable test platform
can usually be constructed using temporary steel scaffolding.
Corrugated metal sheeting can be used for the roof of the test
platform. The six-inch pipe nipple test ports should protrude
out a few inches from the cupola shell and should be flush with
the inside of the cupola lining. The test port nipples should
be fillet-welded to the cupola shell. The threads of the pipe
nipples should be graphited and six-inch pipe caps installed
hand tight so that they can be readily removed during the test
period.
b. >Method of Subdividing Cupola Stack
The cupola stack cross-sectional area should be measured
at the test elevation. Due to refractory erosion and/or the
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Appendix E
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Page 20
buildup of slagged deposits which affect the cupola cross
section, it is important that the cupola cross section and
cross sectional area be determined at the test elevation.
The ASf€ PTC 27 test code prescribed procedure (see item 2
in Appendix) should be followed in determining the location
of the test points to be used in both the volumetric or
pi tot tube traverses and during the test runs.
A minimum of 12 points should be used as sampling
locations in traversing a cupola stack in the dustloading
test runs. Additional sampling points should be used when
the maximum to minimum velocity variation in the velocity
profile approaches, or exceeds, a 2 to 1 figure.
It is important that dust sampling be conducted at each
test point and that the dustloading test-data sheet reflects
the sampling conditions at each test point in traverse of the
cupola from each test port. The practice of using a much
\
smaller number of test points during the dustloading test
runs, as compared to a large number of points used in the
velocity checks, is almost certain to bias the test results
and cause the results to be of a questionable nature with
respect to securing a representative cupola sample.
c. Number and Duration of Test Runs
Test runs shall consist of a minimum of 60 minutes
actual dust sampling. Based upon a minimum of 12 points of
dust sampling of the cupola cross section from the two 90
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Appendix E
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Page 21
degree test ports, an acceptable minimum sampling schedule
would consist of sampling for 5 minutes at each of the
12 points. The field test data sheets and the test report
must clearly reflect the location and the time of sampling
at each of the sampling points used. A minimum of three
sets of flow, temperature and pressure readings should be
taken at each sampling point. The field data shall be logged
and should reflect the dynamic conditions of cupola flows and
sampling rates at each test point.
Readings of sampling flow rates, temperatures, pressures,
gas analyses and other pertinent test data which are part
of each dustloading test run should be taken on a 2 (maximum
3) minute cycle at each sampling point during each dustloading
test run. The total sampling program should be conducted under
stopwatch timing precision.
Three dustloading test runs and 3 velocity-volumetric test
runs should be conducted in a single day of field sampling,
as previously mentioned.
d. Sampling Probes
Sampling probes used in the dustloading test runs of raw
gas should be of water-cooled, stainless steel construc-
tion. The sampling probes should be a minimum of 3/4 inch inside
diameter, and preferably of larger inside diameter for tests
conducted on raw gas emissions. Conventional smaller diameter
test probes are suitable for use on the downstream side of
dust collectors, but should not be used in raw gas sampling.
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Either a standard or null type probe may be used for
sampling raw cupola gases. Whichever probe is employed, a
truly 1sbk1net1c sample must be taken at all test points
during all test runs.
A null sampling probe of either the balanced static
pressure type or balanced impact pressure type can be used.
Null type probes are prone to introduce minimum error as
their diameters increase and as the velocity of the flow
system increases.
A null sampling probe must be calibrated and of such
a size as to give the minimum sampling error (deviation from
isokinetic) for the expected sampling velocity range.
Either type probe presents certain shortcomings which
must be compensated for under the adverse, dynamic and widely
varying flow conditions attendant to normal cupola operation.
Cupola velocities can be expected to range from 600 to
2400 ft/min. depending upon the size of the cupola and the
rate of cupola operation. Normal operating velocity ranges
can be expected to be 1000 to 1800 ft/min.
Fixed rate sampling trains, based upon an occasional
velocity determination made at some fixed time, are unaccept-
able for cupola source sampling since such methods completely
ignore the dynamic nature of the cupola melting process.
e. Filter Media
Due to the need for a large diameter sample probe and the
necessity of isokinetically sampling the gas stream, a high
volume sampling train is mandatory. The filtering media used
for removing'particulate from the gas stream must be of
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Appendix E
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Page 23
sufficient size to maintain the sampling rates necessary
without imposing undue pressure drop restrictions on the
sampling train.
The advantages and disadvantages of some of the various
filtering media that can be used in removing the particulates
from the sampled gas stream are stated in ASf€ PTC 27
Section 4 Paragraph 59 (See Appendix).
FOOTNOTE: Cloth is often used as the filtering media because of its high
collection efficiency, good flow permeability, ability to be
shaped or adapted to any sampler configuration, and freedom
from plugging or excessive pressure buildup under minimum
condensation conditions.
In the event that a cotton sateen fabric is selected it
must be thoroughly washed and rinsed prior to use to be free
of starch and sizing materials. This filter medium has as
its most serious limitation a humidity or moisture pickup
tendency. This problem can be adequately dealt with by
proper and skilled weighing and handling techniques using
an enclosed single pan desiccated analytical balance.
Sampler units housing the filter medium should be made
or lined with corrosion resistant material and must permit
ready and free insertion and removal of the filter medium.
Sampler units must consist of airtight enclosures to ensure
that all sampled gases pass through the filter medium, be
capable of easy field cleaning and of conserving the sampled
dusts with a minimum of sample loss in filter handling.
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Page 24
To facilitate transfer of collected material and prevent
the possibility of incandescent particles from contacting
the final filter medium it may be desirable to incorporate a
small stainless steel cyclonic collector ahead of the ultimate
filter medium. Such cyclones tend to remove the larger
particulates and prolong the sampling period before the pressure
buildup on the filter medium restricts isokinetic sampling,
due to reduced sampling flow rate capability.
Such cyclones offer the additional advantage of providing
a convenient method of measuring the gas sampling flow rate.
This can be accomplished by calibrating the pressure drop across
the cyclone collector unit entailing the measurement of the
pressure differential across the cyclone, the temperature and
the static pressure at that location.
FOOTNOTE: Scrubber (impinger) or condensing systems are considered unsatis-
factory for particulate filtration in cupola sampling trains. Such
systems promote and cause the formation of reaction products which
were not present in the cupola gas stream. Since most available
impinger or wet collecting apparatus, are associated with low
volume sampling rates (not to exceed 1.0 cfm), it can be seen
that they do not lend themselves well to high volume rate
sampling without the use of multiple, parallel units.
While it may be of interest in some instances to determine if
condensible material is present in cupola effluents such deter-
minations are beyond the scope of this recommended practice for
particulate.
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Page 25
When a gas analysis is desired it is recommended that a con-
tinuous carbon dioxide and/or a continuous oxygen analyzer be
used to measure these gas constituents. Periodic checks can
also be made using an Orsat gas analyzer to verify the performance
of the continuous gas analyzer or to check on the total gas
composition (C02, 02, CO, Np). The continuous gas analyzer
should be read on a two or three minute cycle throughout each
test run and the time noted. Results of each Orsat gas analysis
conducted should be clearly indicated on the field data sheets
and in the test report.
Sulfur oxide emissions from cupola systems are of such a low
order that it is usually unnecessary to measure them in light
of present day standards.
f. Sampling Volume Flow Rate
The need for a high volume sampling system to secure repre-
sentative samples from cupola raw gas effluents often mitigates
against the use of an integrating gas meter for measuring the
sample gas volume although such are available to handle the
flow ranges covered by 3/4 to 2 inch inside diameter dust
sampling nozzles. However, portability requirements for
such meters leave much to be desired and adverse field
conditions in cupola sampling often preclude the use of
such meters.
Sampling volume flow rate measurements can be made by
flowrator systems, calibrated pressure drop mechanisms such
as orifices, Venturis or other similar flow measuring devices.
-------
Appendix E
Exhibit 1
Page 26
SECTION II - RAW GAS TEST LOCATION IN DUCT AHEAD OF COLLECTOR
Tests are often conducted to determine performance of collectors
Installed for cupola gas cleaning. Often a sample location in the connecting duct
will have advantages over that of a cupola stack location because -
1. Gases will be cooled, usually by evaporation of water,
to temperatures below 500°F.
2. Location more accessible.
3. Dustloadings and gas velocity more uniform thru cross
section of sampling area.
(Duct velocities usually in teh 3000 - 5000 fpm range.)
In such locations:
a. Number of sample points can correspond to ASME PTC 27
and need not be the minimum of 12 recommended for the
cupola stack.
b. Gas volume will include substantial proportion of
water vapor and influence gas density.
c. Some dust, especially of the coarser fractions, can
bypass the sample area if there is substantial run-
off of cooling water or for dust fallout in cooling
towers, external combustion chambers, etc.
Whenever possible, catch from collector should be obtained and checked
against calculated collected quantity from inlet and outlet samples. It is often
difficult to get a sample covering only the test period, but often feasible to
obtain quantity collected during a complete melting cycle. In the latter case,
daily average data can be compared to short test runs of the sampling equipment.
Comparison of coarse fraction in the catch with the quantities re-
ported by sampling will also give an indication of effectiveness of the sampling
technique of such fractions. When indicated, catch from the collector needs to be
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Appendix E
Exhibit 1
Page 21
augmented by inclusion of fallout in preceding system elements as noted in Item c.
SECTION III - SAMPLING CLEANED CUPOLA GASES
General
Sampling behind a gas cleaner alleviates some of the problems
experienced when sampling raw cupola gases. Extremely large particles are no
longer present permitting the use of conventional 1/4" or 3/8" diameter sampling
probes and lower sampling volumes. The violent velocity fluctuations experienced
in a cupola stack have been moderated; and the high temperatures of raw cupola
gases have been reduced. On the other hand, a different problem is accentuated.
Gas cleaning equipment is expensive, and is usually sold to meet a specified
emission standard. Since performance curves for emissions become asymptotic,
s^ail changes in performance can cause large expenditures in equipment alteration,
therefore accuracy of testing becomes more critical.
Because the gas sampled is hot and humid, the probe :or filter
holder must be heated to stop condensation on the walls of the apparatus from
occuring. Such condensate will interfere with the filtration of particulate.
Cupola off-gases are almost always cooled by direct contact with
water, so it can be a-sumed that they are humid after they have passed through a
cleaning device, whether a wet scrubber or not. Consequently, a condenser must
be inserted in the filtering train. This serves two purposes. First, it
rer.oves excess water which may condense and damage the gas meter. Secondly,
and of vital importance, a condenser gives assurance that the gas passing
through the train is saturated at an identifiable point. This provides the
basis for exact calculation of the volume of dry gas metered, converted
to standard conditions.
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Appendix E
Exhibit 1
Page 28
An acceptable procedure for testing is "Determining Dust
Concentration in a Gas Stream", PTC 27-1957, published by the American
Society of Mechanical Engineers.
While isokinetic sampling is not as critical for cleaned gases
because of the small particle sizes involved, its use is recommended, following
the sama procedure of test locations, sample time, pitot traverse and data
log recommended in Section I and II.
-------
WET AND DRY BULB
THERMOMETE
ORIFICE
SURGE
DRUM
PRESS.
DROP
"H20
SCHEMATIC DIAGRAM OF SAMPLING APPARATUS
STATIC BALANCED TUBE METHOD OF SAMPLING
CYCLONE
PRESSURE DROP
"H20
SAMPLER
STACK
CYCLONE
THERMOMETER
WATER JACKETED
S.S. PROBE
INCLINED
DRAFT GAUGE
PYROMETER
GAS FLOW
00
n
n
M M
ORSAT
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TABLE 2 - REPRESENTATIVE SOURCES OF
COMMERCIALLY MANUFACTURED COMPONENTS
Component
1. Stainless steel, water-cooled
static balanced, tube sampling
nozzle-3/4 in. minimum ID.
2. Inclined draft gage and holder,
pitot tube.
3. Stainless steel cyclone
4. Sampler
5. Manometer
6. Thermometer
7. Industrial exhauster
8. Continuous gas analyzer
9. Orsat gas analyzer
10. Pyrometer and thermocouple
Source
Individually designed and constructed
to meet nozzle diameter and probe
length needs. Fitted with 6 in. pipe
cap and pipe sleeve. Nozzles are to
be calibrated to effect isokinetic
sampling with minimum sampling error
at the optimum velocity range for each
different probe diameter. An acceptable
nozzlehead design is schematically .il-
lustrated in ASME PTC 27 (Fig. 2).
Industrial Engineering Instrument
Co., Allentown, Pennsylvania
UOP Air Corrections Division
Darien, Connecticut
Fabricate to meet filter media con-
finement and handling requirements.
The Meriam Instrument Co.,
Cleveland, Ohio
Weston Electrical Instrument Corp.,
Newark, New Jersey
Clements Manufacturing Co.,
Chicago, Illinois
Thermco Instrument Corp.,
LaPorte, Indiana
Hayes Corp.,
Michigan City, Indiana
Alnor Instrument Co.,
Division 111. Testing Laboratories, Inc.
Chicago, Illinois
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APPENDIX E
EXHIBIT 2
Page 1
SAMPLING AND ANALYTICAL TECHNIQUES
INTRODUCTION
Sampling and analytical techniques for the determination
of emission rates from industrial processes have been stan-
dardized for many specific particulate and gaseous materials.
The techniques described in the following paragraphs are those
most widely used in the testing of iron foundry emissions
testing. The format and wording for most procedures correspond
to the source indicated for each procedure.
SAMPLING TECHNIQUE
Scope
The primary objective of stack testing is to determine
the nature and/or quantity of emissions being released into
the atmosphere. Sampling procedures that follow are applicable
to the cleaned gas side of the control unit,,
Apparatus
The accuracy of emission testing results is dependent
upon qualified personnel conducting the test and the use of
the proper apparatus for the material to be collected. Figure
1 illustrates information on sampling locations and apparatus
most commonly involved in stack testing.
Sampling Principles
The location and number of sampling points are based on
size and shape of the duct, uniformity of gas flow in the duct,
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APPENDIX E
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availability of an adequate sampling port, and the space re-
quired to set up the equipment. Unfortunately, ideal condi-
tions are seldom found in field testing and agreement on these
factors must be reached before conducting the test0
To insure constancy of test conditions and results, com-
plete information must be developed as to continuous or cyclic
operation; nature, weight and composition of materials; gas
volume and fluctuations; pressure; temperature and humidity;
presence of other devices such as afterburners; and related
conditions affecting the operation and equipment. These
factors will regulate the time, number and duration of test
runs.
Stack Gas Velocity
To determine particulate concentration in an exhaust
stack, isokinetic source sampling must be used. This is the
condition that exists when the velocity in the nozzle of the
sampling tube is exactly the same as that in the stack,,
Isokinetic sampling is not mandatory when only gaseous sub-
stances are to be assayed.
In isokinetic sampling, the traverse area of the duct
must be divided into equal areas and a pitot traverse taken.
The use of the S-type pitot is recommended where particulates
are involved to avoid any possibility of partial plugging
and faulty readings. The velocity at each point must be
calculated, and the volume of flow required to maintain that
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APPENDIX E
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velocity in the sampling tip should volume fluctuate. Provi-
sions must be made so that the volume can be recalculated im-
mediately each time the pressure changes at the meter. However,
when sampling is downstream from a gas cleaner, the volume is
controlled by the system's fan and remains relatively constant
and this procedure may not be necessary„
Detailed procedures on conducting velocity measurements
are given in Bulletin WP-50 of the Western Precipitation
Company, ASME Performance Test Code 27-1957 and the Industrial
Ventilation Manual of the American Conference of Governmental
Industrial Hygienists.
Concurrent with conducting the pitot traverse, it is es-
sential to determine the temperature of the stack gas. The
measuring device will be dependent on the temperatures involved.
Sample Probe
In assembling the sampling probe, teflon tape should al-
ways be used instead of pipe dope to prevent adherences of
particulates. Long radius bends should be used instead of el-
bows to facilitate cleaning. The probe should be just long
enough for the task at hand. The rest of the train should be
assembled and tested for leaks„
Temperature and Humidity
If the gas sampled is hot and humid, condensation may
occur in the probe or in the .-filter holder „ The probe or
filter holder must be heated to stop condensation from occurring
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APPENDIX E
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because the water formed will trap water on the walls of the
apparatus and will interfere with the filtration of particulates,
Temperature control baths may be required for gas absorbers.
In some cases the probe can be provided with a water cooling
jacket.
Condensation
A condenser in the sampling train is required if the gas
is humid. This serves two purposes„ First, it removes excess
water which may condense and damage the gas meter„ Second,
and of vital importance, a condenser gives assurance that the
gas passing through the train is saturated at an identifiable
point. This provides the basis for exact calculations of the
volume of dried gas metered and conversion to standard condi-
tions „
Collection Devices
The characteristics of the material in the stack will
determine the collection method required. Dry filter mediums,
of a variety of types, are most commonly used for particulate
mattero Although in some cases the wet impingement method
followed by a thimble is used0 Gases are collected in ab-
sorbers with a proper absorbing solution. Grab sample units
are available for spot sampling„
Flow Meters
If a dry gas meter is used, it must be calibrated before
each use. If an orifice meter, or flow-type meter, is used
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APPENDIX E
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it must also be calibrated each time, and it must have enough
sensitivity so that readings can be obtained to less than one
percent. Finally, if volume is obtained by multiplying an
instantaneous reading by the time of the operation, fluctuations
must be kept to one percent.
Vacuum Source
A vacuum source is required to draw the sample from the
stack through the sampling train, A variety of pumps or ejec-
tors are available for this purpose. Their capacity must be
sufficient to draw the gas through the sample train at the re-
quired volume„ The range is from one liter to several cubic
feet per minute.
Sampling time will be dependent upon the factor of ob-
taining a representative sample of the operation. It may vary
from several long continuous integrated samples of 30 to 60
minutes or a number of short samples of 5-10 minutes,
ANALYTICAL PROCEDURES
Introduction
Analytical procedures for a number of materials are given
in the sections that follow., All calculations must be accord-
ing to standard procedures and the standard conditions of tem-
perature at 70 degrees Fahrenheit and an atmospheric pressure
of 29.92 inches of mercury.
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APPENDIX E
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Particulate Matter
(a) Scope
The definition of particulate matter "accepted by the dust
collection industry is given in the ASME Performance Test Codes
21-1941 and 27-1957. In essence, this defines particulate mat-
ter as all filterable solids present at standard temperature in
an effluent gas stream.
(b) Auxiliary
Apparatus
- Filter Media - Efficiency of collection must be
at least 997<> for all particulates
encountered and must be resistant
to both heat and moisture.
- Balance - Macro analytical balance or
equivalent.
- Drying Oven - Suitable for drying filters for
about 5 hours at 105° C0
- Desiccation - To retain dried filters before
weighing.
(c) Sampling
Procedure
The first step in sampling is to prepare the filtering
mediunio An identification number should be provided for each
filter and recorded on a separate data sheet. Prior to weigh-
ing, the filter should be dried for about 5 hours at about 105°
C and then weighed immediately. This weight should be recorded
on the data sheets and not on the filter. In order to keep
weighing errors at a minimum, careful handling of the filters
is required,,
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APPENDIX E
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Preferably the pitot traverse, temperature and humidity
readings should be taken not more than one-half hour before
sampling is begun. Assemble the sampling train as shown in
Figure 1 and proceed with the sampling by inserting the probe
into the test stack. Continual observation of the sampling
train during the entire sampling period is required to record
any changes in pressure, temperature and airflow. This infor-
mation, along with barometric pressure, sampling time and rate,
is recorded on the sampling data sheet. Complete information
on the process should also be noted on the sampling data sheet0
Length of the sampling time, at any specific point in the
stack, will be contingent upon changes, if any, in the process
or fluctuations of air volume„ The sampling time should at
least cover a complete cycle and will vary from 30-60 minutes.
If airflow is not uniform in the stack, 5- to 10- minute samples
at each of the traverse points should be obtained. Samples
taken during start-up and burn-down periods should, as a rule,
be considered separately from those taken during the production
cycle of the cupola.
After a run is completed the probe must be cleaned of
retained particulate matter,, An acceptable procedure is to
brush with a long flexible brush while the sample train is
pulling in clean air. For other contaminants, follow pro-
cedures, if any, indicated for the specific material.
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APPENDIX E
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(d) Sample
Preparation
Collected samples should be dried and placed in a desic-
cator to reach equilibrium before weighing. The difference
between the original weight and final weight is the total
amount of particulate matter collected.
(e) Calculations
The total particulate matter collected is expressed in
grams. From this value, calculations can be made to express
the findings in grains/SCF, pounds/hour, or pounds/1,000 pounds
of gas, using the following constants:
One (1) gram =•? 15.43 grains
One (1) pound = 7,000 grains
One (1) gram = 00002205 pounds
One (1) standard cubic foot of air = 00075 pounds
1. Grains/SCF
Grains/SCF = (Grams) (15 .,43)
Total SCF sampled
2. Pounds/Hour
Pounds/hour = 60 (grains/SCF) (total gas volume to atmosphere - SCFM)
7,000
3. Pounds/I,OOP Pounds Gas
Pounds/1,000 Pounds gas = (grams) (2.205)
(0.075) (total SCF sampled)
Arsenic
Source: American Conference of Governmental Industrial
Hygienists.
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APPENDIX E
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(a) Scope
Stack sampling for arsenic is based on the reaction of
arsine with silver diethyldithiocarbamate. The amount of
arsenic, in the air sample, is read directly from the calibra-
tion curve.
(b) Auxiliary
Apparatus
Greenberg-Smith Impinger,
Beckman DU Spectrophotometer with photomultiplier
or equivalent
- Arsine Generator (See Figure 2)
(c) Reagents
Silver Diethyldithiocarbamate - a cooled solution of
silver nitrate (107 g in 100 ml distilled water) is added to
a cooled solution of sodium diethyldithiocarbamate (2.25 g in
100 ml distilled water). The lemon yellow precipitate is
filtered off, washed thoroughly with distilled water and dried
in a vacuum desiccator below 20° C0
Pyridine - Mallinckrodt reagent grade pyridine is passed
through an alumina column 1 inch in diameter and 6 inches in
depth, at the rate of approximately 150 ml per hour. This
process may remove a considerable quantity of colored material.
Arsine Absorbing Solution - Dissolve 1 g of silver
diethyldithiocarbamate in 200 ml of chromatographed pyridine
and filter the solution,,
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APPENDIX E
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Hydrochloric acid - Baker's analyzed, specific gravity
1.19.
Potassium Iodide Solution - Dissolve 15 g reagent grade
potassium iodide in 100 ml distilled water. -
Stannous Chloride Solution - Dissolve 40 g stannous
chloride dihydrate in 100 ml hydrochloric acid.
Zinc - Baker's analyzed; granular 20 mesh.
Lead Acetate - Dissolve 10 g reagent grade lead acetate
in 100 ml distilled water.
Arsenic Standard Stock Solution - Dissolve 10320 g arsenic
trioxide in 10 ml of 4070 sodium hydroxide and diluted to 1
liter with distilled water. (Various strengths of standard
solutions are prepared by further diluting this stock solution
with suitable volumes of water, triple distilled in glass.)
Nonag - Stopcock grease, Fischer Scientific Co,
(d) Sampling Procedure
Assemble sampling train of probe, impinger with 100 ml of
distilled water, flow meter and vacuum pump. Sampling rate is
at 1 CFM for a period long enough to provide a minimum of 30
cubic feet at standard conditions»
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APPENDIX E
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(e) Analytical Procedure
Calibration curve - known microgram amounts of arsenic
(1-15 micrograms) in the form of standard arsenic solution
are pipetted into 125 ml Erlenmeyer flasks. Distilled water
is added to make the total volume 35 ml. To the flasks are
added 5 ml hydrochloric acid, 2 ml 1570 potassium iodide
solution, and 8 drops of stannous chloride solution. The
flasks are swirled and allowed to stand for 15 minutes.
Three ml of the pyridine solution of silver diethyldi-
thiocarbatnate are placed in the absorbing tube, which is
attached to the scrubber containing glass wool impregnated
with lead acetate. (See Figure 2.)
The ground joints are lubricated with "Nonag" stopcock
grease, 3 g of granulated zinc are added to the solution in
the flask, and the receiving tube is -inserted immediately,,
Arsine evolution is completed in about 30 minutes.
At the end of this time, the absorbing solution is
transferred to a 1 cm square cell and the absorbance measured
at 560 millimicrons in the Beckman spectrophotometer. Plotting
measured absorbances against micrograms of arsenic taken pro-
duces the standard curve„
Air samples, after the previously described preparation
treatment, are treated in the same manner as the standards,,
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APPENDIX E
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(f) Calculations
Arsenic, in the form of arsine, displaces an equivalent
amount of silver from silver diethyldithiocarbamate.
mg
As/M3 = VY
1,000-vVa
Where v = aliquot (ml)
V = total sample (ml)
Y = micrograms in v
Va = gas sample volume, in cubic meters,
at standard conditions
Beryllium
Source: Michigan Department of Public Health.
(a) Scope
This method describes a procedure for determining
beryllium in stack gases-
(b) Auxiliary
Apparatus
Millipore filters and holder,
Bausch & Lomb Large Littrow Emission Spectrograph
or equivalento
(c) Reagents
Platinum Internal Stock Solution - Purchase directly from
Jarrell-Ash Company a 1070 platinic chloride solution,, This
calculates out to be 57088 mg platinum in 1 ml solution.,
Platinum Internal Standard Working Solution - Pipette 1 ml
of platinum stock solution containing 57.88 mg Pt per ml into a
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APPENDIX E
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25 ml volumetric flask, take to volume with water giving a
solution containing 116 micrograms platinum/.05 ml.
Standard Beryllium Solutions:
1. Beryllium stock solution. Dissolve ,0982 g of
BeS04'4H20 in 10 ml of redistilled 1:1 hydrochloric acid
and dilute to 100 ml with distilled water. Solution contains
5.0 mg beryllium per 100 ml or 2.5 micrograms Be/.05 ml.
2. Working beryllium standard solutions. These
should be prepared from the stock solution just before use,
Suggested concentrations are from .003 to .5 microgram Be/.05
ml.
Nitric Acid - To clean all laboratory glassware.
(d) Sampling
Procedure
Assemble sampling train of probe, millipore filter and
holder, flow meter and vacuum pump,, Sampling rate at 1 CFM
for a period long enough to provide a minimum of 10 CF at
standard conditions.
(e) Analytical
Procedure
The millipore filter containing the sample is transferred
to a chemically clean 125 ml beaker. The filter and sample are
wet ashed with nitric acid» The residue is then dissolved in
3 ml of concentrated nitric acid and 1-2 ml of distilled water.
Transfer to a graduated centrifuge tube, rinse the beaker with
water and add the rinsing to the sample solution. Evaporate to
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APPENDIX E
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a volume of 002 ml and if an appreciable amount of salt is
present, a volume of more than 0.2 ml may be required.
The standard curve is plotted on log-log paper and
micrograms Be per 005 ml is plotted versus the intensity
ratio of Be 2348.6 line over Pt 2357.1 line. The standard
curve is usually set up in the range of .003 microgram Be/.05
ml to .5 microgram Be/.05 ml. Six beryllium concentrations
used to establish the working curve are prepared as follows:
For the first 3 concentrations, the stock solution
containing 50 micrograms Be/ml is diluted 1 ml to 100 in
distilled water giving a working solution of 05 microgram
Be/ml.
!«, c003 microgram Be/«05 m!0 Pipette 1.2 ml of
working standard beryllium solution (.5 microgram Be/ml) into
a 10 ml volumetric flask and take to volume with water„
20 o005 microgram Be/.05 m!0 Pipette 2 ml of
working standard beryllium solution (.5 microgram Be/ml) into
a 10 ml volumetric flask and take to volume with water,
3o oOl microgram Be/.05 ml. Pipette 4 ml of
working standard beryllium solution (.5 microgram Be/ml) into
a 10 ml volumetric flask and take to volume with water„
4. 005 microgram Be/.05 ml0 Pipette .2 ml of stock
beryllium solution (50 micrograms Be/ml) into a 10 ml volumetric
flask and take to volume with water,
A. T. KEARKEY & COMPANV, INC.
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APPENDIX E
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5. .1 microgram Be/.05 m!0 Pipette .4 ml of stock
beryllium solution (50 micrograms Be/ml) into a 10 ml volumetric
flask and take to volume with water„
6. .5 microgram Be/.05 ml. Pipette 2 ml of stock
beryllium solution (50 micrograms Be/ml) into a 10 ml volumetric
flask and take to volume with water.
Spectrographic apparatus, materials and exposure conditions
are as follows:
10 Optical conditions - 10 micron slit is used in
the spectrograph.
20 Densitometer - Non-recording National Spectro-
graph Spec Readero
3o Electrodes - Upper Electrode (cathode) United
Carbon Products Company, 3/16" diameter, sharpened to a point
in a regular de-leaded pencil sharpener. Lower Electrode
(anode). United Carbon Products Electrode, catalog No, 100-L,
1/4" diameter, crater is 3/16" diameter and 5/32" deep.
4. Exposure conditions - 220 volts DC arc, operating
at 7.5 amperes with a constant gap of 5 mm maintained between
the anode and cathode, exposure time is until burn-out of
lithium chloride buffer.
5» Photographic - Eastman Kodak Spectrum Analysis
No. 1 Plate, developed 305 minutes in Eastman D-19 Developer
at 68 F and fixed for 8 minutes in Eastman Koda Fixer (National
Spectrographic Developing machine)„ Emulsion is calibrated by
use of the two-step filter in front of the slit. The density of
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APPENDIX E
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the filter section is given by Bausch and Lomb Company, makers
of the filter.
60 Nitrogen - AirCo dry nitrogen, flow rate regu-
lated by F. W. Dwyer Manufacturing Company flow meter, maximum
flow rate 6 liters per minute, regulator 3,000 pounds. The
nitrogen flow around the electrode is between 3-4 liters per
minute.
Preparation of the electrodes for both standard curve and
sample analysis is as follows: A 1/4" diameter electrode is
waterproofed by immersion in Dow Corning silicone solution
(2% in acetone), and air dried for at least 30 minutes. A 10
mg charge of lithium chloride-graphite buffer is placed in the
electrode and packed by tapping gently on the table top.
Into the electrodes prepared as described above is pipetted
.05 ml of the platinum internal standard working solution (116
micrograms/.05 ml). The electrodes are placed in a 60° C oven
and allowed to dry. Upon removal from the oven, 005 ml of the
standard beryllium solution is pipetted into the appropriate
electrodes. From the centrifuge tubes, where the samples have
been evaporated down, is pipetted .05 ml into the appropriate
electrodeso The electrodes are then returned to the 60° C oven
and maintained at that temperature until dry. The temperature
is then brought up to 105° C and maintained at that temperature
for 1 hour» The electrodes are now removed from the oven and
are ready for analysis„ After the spectrograph and power
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APPENDIX E
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supply have been set as previously described, the electrodes
are placed in the respective electrode holders. The nitrogen
flow is turned on and set at a rate of between 3-4 liters per
minute around the lower electrode. With the shutter open during
the entire exposure the arc is lit and allowed to run until
burn-out of the lithium chloride buffer which is indicated by
a vanishing of the red lithium color.
After the plate has been developed and dried as described
previously, it is placed on the densitometer and the percent
transmission set to 100 on a clear portion of the plate. The
percent transmittance value of Be 2348.6 and the background
adjacent to this line is read. The percent transmittance
value of Pt 2357.I line is also read. Through the use of the
gamma curve the percent transmission values of the bismuth line
and the background adjacent to it and the Pt line are trans-
formed to I values and a ratio taken of I value Be 2348.6 over
I value Pt 2357.1 made. Each one of the varying concentrations
of beryllium standard curve and of the sample is run in tripli-
cate and an average of these taken for the final calculation.
The amount of beryllium per 005 ml sample is read from the
standard curve.
(f) Calculation
micrograms Be/M3 = V-Y
v.Va
where v = aliquot (ml)
V = total sample (ml)
Y = micrograms in v
Va = gas sample volume, in cubic meters,
at standard conditions
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Cadmium
Source: Michigan Department of Public Health.
(a) Scope
Stack testing for cadmium can be accomplished by the
polarograph method using a dropping-mercury electrode with
the sample as the electrolyte.
(b) Auxiliary
Apparatus
Sargent Polarograph - Model XXI, recording type or
equivalent.
(c) Reagents
Standard Lead Solution - Dissolve approximately 25 grams
of C.P. Pb(N03>2 in minimum of hot water and cool with stir-
ring. Filter with suction on small Buchner funnel. Repeat
recrystallization0 Dry crystals at 100°-110° C to constant
weight, cool in desiccator and store in tightly stoppered pyrex
bottle. The product has no water of crystallization and is not
appreciably hygroscopic. Weigh exactly 0.1599 grams of recry-
stallized C.P» Pb(N03)2, put into 500-ml volumetric flask, and
take to volume with 0»1 N HC1. This gives a standard lead
solution containing 200 micrograms Pb/ml with 0.1 N HC1 as the
electrolyte. The 0.1 N HC1 should be prepared from constant
boiling hydrochloric acid.
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APPENDIX E
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Standard Cadmium Solution - Weigh exactly 0.2744 grams of
into a 500-ml volumetric flask and take to
volume with 0.1 N HC1. This gives a standard cadmium solution
containing 200 micrograms cadmium per ml with 0.1 NHC1 as the
electrolyte. As in the lead solution the 0.1 N HC1 should be
prepared from constant boiling hydrochloric acid.
Oxygen Absorbent for Purification of Nitrogen - Pass
nitrogen through a first scrubbing flask (a midget impinger)
containing concentrated NlfyOH and copper turnings„ Caution:
Make certain hole in impinger is not plugged before turning
nitrogen under pressure on. Then pass nitrogen through a
second scrubbing flask containing concentrated sulfuric acid,
again making certain this is not plugged before applying
pressure.
0.2 N hydrochloric acid - Prepare this from constant
boiling hydrochloric acid according to outline in Lange's
Handbook.
Clean, Dry Mercury - Purchase from Eberback & Son
(d) Sampling
Procedure
Assemble sampling train of probe, impinger with 100 ml
of 57o nitric acrid, flow meter and vacuum pump. Sample at
rate of 1 CFM for a period long enough to provide a minimum of
30 cubic feet at standard conditions.
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APPENDIX E
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(e) Analytical
Procedure
Sample Preparation - Transfer the collecting solution
from the impinger into a 250 ml beaker, wash out impinger with
hot 5% nitric acid and all taken down to dryness on a hot plate.
Cool and add 25 ml of 002 N HC1. Heat just to boiling and
transfer to a 50 ml volumetric flask,, Dilute to volume with
distilled water which will dilute the 0,2 N HC1 to 0.1 N HC1
which is the electrolyte.
Transfer a 10-ml aliquot from the 50-ml volumetric flask
into the polarographic cell, add 1 ml of 200 micrograms Pb per
ml solution, and remove oxygen from the cell by bubbling
nitrogen, which is being purified as described under reagents,
through for three to five minutes. The initial voltmeter is
set at .3 volts, the span voltmeter is set at .6 volts, there-
by giving a range from -.3 volts to -.9 volts. This is suffi-
cient as lead "comes off" at approximately -.44 volts and
cadmium at approximately -.66 volts. The sensitivity setting
might have to be found by trial and error; 0.020 suffices for
most samples although if the cadmium is low the sensitivity will
have to be increased (decreasing the number of microamperes/mm.) ,
If there is a possibility that Pb is present in the sample
an aliquot of the sample should be run in the polarographic cell
first, without any internal standard added. If there is Pb
present in the sample, this must be taken into account when Pb,
the internal standard, is added„
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Standard Curve - Into the polarographic cell is introduced
1 ml of 200 micrograms Pb per ml solution, 1 ml of 200 micro-
grams Cd per ml solution and 9 ml of 0.1 N HC1. This gives a
total amount of solution in the cell of 11 ml, thereby enabling
a later removal of 10 ml of the sample and 1 ml of 200 micro-
grams Pb per ml internal standard solution. Also, there is
an electrolyte in the cell of 0.1 N HC1. Both the volume of
liquid in the cell and the electrolyte for standard curve and
sample are critical for a proper analysis,
On the standard curve the heights of the Pb and Cd curves
are measured in mm0 The Cd to Pb ratio is found, which is
divided by the number of micrograms of Cd used giving a factor
for 1 microgram Cd versus 200 micrograms Pb0 It is suggested
that 200 micrograms Pb be used as an internal standard in each
sample for Cd thereby simplifying the calculations» The factor
for 1 microgram Cd versus 200 microgram Pb, found at the be-
ginning of the series of samples being analyzed, will be used
for the calculations throughout this series„
(e) Calculations
For the sample "polarogram" the heights of the Pb and
Cd curves are measured in mm0 and the Cd to Pb ratio found in
the same manner as the standard curve. The ratio found here
is divided by the factor found in the standard curve for 1
microgram Cd versus 200 micrograms Pb giving the number of
micrograms of Cd in the aliquot put into the polarographic cell
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mg Cd/M3 = V-Y
1,000-vrVa
Where v = aliquot (ml)
V = total sample (ml)
Y = micrograms in v
Va = gas sample volume, in cubic meters,
at standard conditions
Fluoride
Source: Talvitie method modified by Michigan Department
of Public Health.
(a) Scope
This method describes a procedure for determining fluoride
in stack gases„
(b) Auxiliary
Apparatus
Standard impinger with fritted glass bubbler.
250 ml Claissen flasks.
100 ml Nessler Tubes.
(c) Reagents
Standard Sodium Fluoride - Make a solution containing 1 mg
of fluoride per ml (2.21 g of sodium fluoride to 1 liter).
Take 10 mis of this solution and dilute to 1 liter; 1 ml of
this dilution contains .01 mg fluoride„
Color Forming Reagent - Dissolve 36,99 g of sodium sulfate
in about 500 ml of hot distilled water and 17.7 g of sodium
formate in about 200 ml of hot distilled water. Mix together
and when cooled, add 001436 g thorium nitrate tetrahydrate and
11 ml of 90% formic acid.
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APPENDIX E
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Alizarin monosodium sulfonate indicator 128.25 mg dissolved
in 1 liter of distilled water.
Nitric Acid - About 5 ml concentrated acid, diluted to a
liter with distilled water.
Sodium Hydroxide - .5 N. (20 g dissolved in 1 liter of
water).
Silver Sulfate.
Concentrated Sulfuric Acid.
(e) Sampling
Procedure
Assemble sampling train of probe, impinger with fritted
glass bubbler containing 100 ml of a 2% sodium hydroxide
solution, flow meter and vacuum pump. Sample at a rate of
1 CFM for a period long enough to provide a minimum of 15
cubic feet at standard conditions.
(f) Analytical
Procedure
Sample Preparation - Transfer the collecting solution from
the impinger into a Claissen flask. Slowly add 35 ml of con-
centrated sulfuric acid (using small long stem funnel) to
content, submerging and swirling flask in cool-cold water
while adding the acid--this offsets the loss of HF0 Add
boiling chips and silver sulfate (to cover the end of a spatula)
Close the flask with a two-hole rubber stopper, through which
passes a thermometer and a 6 mm O.D. glass tube drawn to
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APPENDIX E
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capillary size and extends down into the solution. Connect
tube to a separatory funnel containing water. This is to
slowly add water to both cool the flask and to replenish the
water boiled off due to distillation in the Claissen flask.
The distillation flask should be placed on a pad of
transite or asbestos, or on a plate of aluminum with a hole
about 2 inches in diameter made to fit the flask perfectly.
Regulate the heat under the steam distillation flask so
that the distillate being collected remains coolo Adjust the
application of heat to the still so that a temperature of 165°
C is maintainedo Collect the distillate in a 250-ml volumetric
flask or in a 250-ml beaker, and then make up to exactly 250 ml
in a volumetric flask. Stopper the flask and mix. Pipette 25
ml into a 100-ml-long form Nessler tube. Add 5.0 ml of alizarin
indicator. Titrate carefully with a .5 N sodium hydroxide un-
til the solution changes from yellow to a decided pink. Back
titrate with the dilute nitric acid until the solution changes
to a pure yellow. Dilute to about 90 ml, add 3 ml of thorium
reagent, make up to exactly 100 ml and mix well. After 30
minutes, compare with the standards„ If the same is beyond
the range of the standards, use a smaller aliquot. If it is
too close to the standard containing no fluorine, double or
treble the aliquot.
A blank must be carried through all the steps of the pro-
cedure, using the same amounts of reagents as are used in the
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EXHIBIT 2
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samples. An aliquot of 75 ml is usually necessary to determine
the amount of fluorine present in the blank.
(f) Calculations
Calculate the total amount of fluorine present in the
blank and subtract this from the total fluorine found in each
sample.
mg F/M3 = V-Y
1,000-vVa
where v = aliquot (ml)
V = total sample (ml)
Y = micrograms in v
Va = gas sample volume, in cubic meters,
at standard conditions
Lead
Source: Michigan Department of Public Health.
(a) Scope
Stack testing for cadmium can be accomplished by the
polarograph method using a dropping-mercury electrode with
the sample as the electrolyte.
(b) Auxiliary
Apparatus
Sargent Polarograph - Model XXI, recording type, or
equivalent.
(c) Reagents
Standard Lead Solution - Dissolve approximately 25 grams
of CoPo Pb (1*103)2 i-n minimum of hot water and cool with stir-
ring. Filter with suction on small Buchner funnel„ Repeat
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APPENDIX E
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recrystallization. Dry crystals at 100°-110° C to constant
weight, cool in desiccator and store in tightly stoppered pyrex
bottle. The product has no water of crystallization and is not
appreciably hygroscopic. Weight exactly 0..1599 grams of recry-
stallized C.P« Pb(N03)2, put into 500-ml volumetric flask, and
take to volume with 0.1 N HC1. This gives a standard lead
solution containing 200 micrograms Pb/ml with 0.1 N HC1 as the
electrolyte. The 0.1 N HC1 should be prepared from constant
boiling hydrochloric acid.
Standard Cadmium Solution - Weight exactly 0.2744 grams
of Cd(N03)2*4H20 into a 500-ml volumetric flask and take to
volume with 0»1 N HC1. This gives a standard cadmium solution
containing 200 micrograms cadmium per ml with 0«1 N HC1 as the
electrolyte. As in the lead solution, the 001 N HC1 should be
prepared from constant boiling hydrochloric acid.
Oxygen Absorbent for Purification of Nitrogen - Pass
nitrogen through a first scrubbing flask (a midget impinger)
containing concentrated NH^OH and copper turnings. Caution:
Make certain hole in impinger is not plugged before turning
nitrogen under pressure on0 Then pass nitrogen through a
second scrubbing flask containing concentrated sulfuric acid,
again making certain this is not plugged before applying
pressure.
0.2 No Hydrochloric Acid - Prepare this from constant
boiling hydrochloric acid according to outline in Lange's
Handbook.
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Clean, Dry Mercury - Purchase from Eberbach and Son.
(d) Sampling
Procedure
Assemble sampling train of probe, impinger with 100 ml 5%
nitric acid solution, flow meter and vacuum pump0 Sample at
rate of 1 CFM for a period long enough to provide a minimum
of 30 cubic feet at standard conditions.
(e) Analytical
Procedure
Sample Preparation - Transfer the collecting solution to
a 250-ml beaker, wash out impinger with 5% hot nitric acid and
all taken down to dryness on a hot plate. Cool and add 25 ml
of 002 N HClc Heat just to boiling and transfer to a 50-ml
volumetric flask. Dilute to volume with distilled water which
will dilute the 0.2 N HC1 to 0,1 N HC1 which is the electrolyte.
Transfer a 10-ml aliquot from the 50-ml volumetric flask
into the polarographic cell, add 1 ml of 200 micrograms Cd per
ml solution, and remove oxygen from the cell by bubbling nitro-
gen which is being purified as described under reagents, through
for three to five minutes. The instrument used is a Sargent
Polarograph - Model XXI and the settings are as follows: A.C.
switch down (on), D.MoE, - up (negative), Damping - down (off),
Initial E.M.F0 - up (additive), D.C. E.M.F. - down (1.5 V
span), Chart drive - up (on), Operation - up (E.M.F. Increasing).
The initial voltmeter is set at .3 volts, the span voltmeter is
set at .6 volts, thereby giving a range from -03 volts to -.9
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APPENDIX E
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volts. This is sufficient as lead "comes off" at approximately
-.44 volts and cadmium at approximately -.66 volts. The sen-
sitivity setting might have to be found by trial and error,
0.020 suffices for most samples although if the lead is low
the sensitivity will have to be increased (decreasing the
number of microamperes/mm) .
If there is a possibility that Cd is present in the sample,
an aliquot of the sample should be run in the polarographic
cell first, without any internal standard added,, If there is
CD present in the sample this must be taken into account when
Cd, the internal standard, is added.
Standard Curve - Into the polarographic cell is introduced
1 ml of 200 micrograms Pb per ml solution, 1 ml of 200 micro-
grams Cd per ml solution and 9 ml of 0.1 N HC1. This gives a
total amount of solution in the cell of 11 ml thereby enabling
a later removal of 10 ml of the sample and 1 ml of 200 micro-
grams Cd per ml internal standard solution. Also, there is an
electrolyte in the cell of 0.1 N HC1. Both the volume of liquid
in the cell and the electrolyte for standard curve and sample
are critical for a proper analysis.
On the standard curve the heights of the Pb and Cd curves
are measured in mm0 The Pb to Cd ratio is found, which is
divided by the number of micrograms of Pb used giving a factor
for 1 microgram Pb versus 200 micrograms Cd. It is suggested
that 200 micrograms Cd be used as an internal standard in each
sample for Pb thereby simplifying the calculations. The factor
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APPENDIX E
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for 1 microgram Pb versus 200 microgratns Cd, found at the
beginning of the series of samples being analyzed, will be
used for the calculations through this series.
(f) Calculations
For the sample "polarogram" the heights of the Pb and
Cd curves are measured in mm and the Pb to Cd ratio found in
the same manner as the standard curve. The ratio found here
is divided by the factor found in the standard curve for 1
microgram Pb versus 200 micrograms Cd giving the number of
micrograms of Pb in the aliquot put into the polarographic
cell.
mg Pb/M3 = V'Y
1,000-vVa
where v = aliquot (ml)
V = total sample (ml)
Y = micrograms in v
Va = gas sample volume, in cubic meters,
at standard conditions.
Mercury
Source: American Conference of Governmental Industrial
Hygienists.
(a) Scope
Divalent mercury forms an orange-yellow complex with
dithizone in dilute acid solution which can be extracted by
chloroform. An additional extraction in the presence of
chloride and bromide ions eliminates the interference of other
metalso
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APPENDIX E
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(b) Auxiliary
Apparatus
Beckman DU Spectrophotometer or equ:.valent.
Squibb separator funnels <,
Cuvettes.
(c) Reagents
HC1-0.1 N.
Meta Cresol Purple Indicator - Dissolve 0.05 g of the
power in 6 ml of 0.05 N NaOH; then dilute to 100 ml with dis-
tilled water.
Buffer Solution - Dissolve 300 g anhydrous Na2HP04 and
75 g K2C03 in distilled water to make 2 liters of solution
(Macllvaine's Buffer Solutions)„
Treated Chloroform - Chloroform treated with hydroxylamine
hydrochloride as per the method of Hubbard, Industrial Engi-
neering Chemistry, Anal, Ed., 9, 493 (1937).
Dithizone Solutions - Make up a stock solution containing
0.5 mg dithizone per ml of chloroform. Other strength dithizone
solutions can be made up as needed,, It is advisable to allow
the dithizone solutions to stabilize overnight before use.
Potassium Bromide Solution - 4070 KBr in distilled water.
Ammonium Citrate - 40%o Mix 40 g citric acid, monohydrate,
«
with about 20 ml distilled water. Add sufficient ammonium
hydroxide slowly with constant stirring to make solution
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alkaline to phenol red and make to volume with water. Purify
by shaking with dithizone in chloroform and clear with pure
chloroform.
Mercury Standard Solutions - Dissolve 0.1354 g mercuric
chloride, C.P., special reagent grade in 1 N HC1 and make up
to 100 ml with the acid0 This solution contains 1 mg Hg per
ml and is quite stable„ If any cloud or sediment develops,
it should be discarded. Other strength solutions can be made
by dilution with distilled water as the need arises.
Hydroxylamine Hydrochloride - 20% solution in distilled
water.
(d) Sampling
Procedure
Assemble sampling train of probe, impinger with 100 ml of
0.25% iodine in a 370 aqueous solution of potassium iodide.
Sampling rate of 1 CFM for a period long enought to provide a
minimum of 30 cubic feet at standard conditions„
(e) Analytical
Procedure
Sample Preparation - The contents of the impinger flask
and washings are made up to a known volume with distilled
water. A proper aliquot is taken to place the mercury con-
centration within range of the method„ Add 5 ml of ammonium
citrate, 1 ml hydroxylamine hydrochloride and shake. Add 2
drops of phenol red indicator„ (Always add the hydroxylamine
hydrochloride before the phenol redo) Titrate with ammonium
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APPENDIX E
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hydroxide to the full color end point pH of 8.5. Extract with
5 ml portions of 20 rag/liter dithizone solution, withdrawing the
chloroform layers into another 250 ml Squibb separatory funnel,
into which has been placed 50 ml of 0.1 N HC1. Continue to
extract with and withdraw 5-ml portions until the dithizone in
the chloroform layer does not change color.
Shake the above dithizone extract with 50 ml 0.1 N HC1
for 2 minutesc Draw off the chloroform into a clean separatory
funnelo Wash the aqueous phase with two, 3-5 ml portions of
treated chloroform and add to the extracts. Discard the aqueous
phase. To the chloroform extracts, add 50 ml of 001 N HC1 and
10 ml of the 40% KBr reagent. Shake for 2 minutes. The Hg
goes into the aqueous phase as H2HgBr4 while the Cu and Bi
remains in the dithizone which is discarded. Wash the aqueous
phase with a few ml of treated chloroform,. Let the phases
separate well and discard completely all chloroform droplets.
An aliquot of the stripping solution may be taken if necessary
so that the amount of Hg will fall on the standard curve. If
an aliquot is taken, make up to 50 ml volume with 0»1 N HC1.
Add 10 ml buffer solution to bring the pH to 6, and 10 ml
of 10 mg/liter dithizone solution. Shake well for 2 minutes.
Avoid any exposure to direct sunlight or exceedingly bright
artificial light.
NOTE: If the separatory funnel was not washed thoroughly with
distilled water, the dithizone may be oxidized,,
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By means of a cotton swab on an applicator stick, remove
any traces of moisture from the stem of the funnel after the
stopcock has been opened for a second to allow the chloroform
to fill the bore. Loosely insert a small cotton plug in the
stem of the funnel. Rinse a cuvette twice with 1-2 ml portions
of the chloroform layer and draw off the remaining dithizone
into the cuvette. Place in the spectrophotometer and read at
point of maximum light absorption (485 millimicron) against
distilled chloroform. A blank on reagents should be carried
through the entire procedure and this blank subtracted from
the final result.
Standard curve - Suitable concentrations of mercury to
give coverage over the entire range are used to establish a
particular curve. Three or four points are sufficient.
Place 5 ml of the 4070 KBr reagent, 10 ml of the buffer
solution and the proper amount of standard mercury solution in
a 125 ml Squibb separatory funnel„ Add enought 0.1 N HC1 to
make the final volume 65 ml. Then add 10 ml of 10 mg/liter
dithizone solution and shake for 2 minutes. Flush the stem of
the separatory funnel and remove moisture by means of a cotton
swab, withdraw the chloroform layer and read in the spectro-
photometer as described above.
The 10 mg/liter dithizone solution is of sufficient
strength to cover the range from 0 to 15 micrograms of mercury„
By using 20 ml instead of the standard 10 ml of this reagent,
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APPENDIX E
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the concentration range covered can be doubled,, It is not re-
commended to add more than 20 ml of 10 mg/liter dithizone to
any sample.
For only an occasional mercury analysis, it is better to
bracket the sample with standard amounts rather than prepare
an entire curve.
(f) Calculation
mg Hg/M3 = y.Y
1,000.v-Va
where v = aliquot (ml)
V = total sample (ml)
Y = micrograms in v
Va = gas sample volume, in cubic meters,
at standard conditions
Zinc
Source: Michigan Department of Public Health,,
(a) Scope
Stack testing for zinc can be accomplished by the polaro-
graph method using a dropping-mercury electrode with the sample
as the electrolyte.
(b) Auxiliary
Apparatus
Sargent Polarograph - Model XXI, recording type, or
equivalent.
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(c) Reagents
Stock Zinc Solution - Weigh exactly 5.0 grains of dry
reagent zinc (30 mesh or finer) into a 500-tnl volumetric
flask and add a minimum amount of constant boiling hydrochloric
acid to get the zinc in solution. Boil until solution is
complete and make up to volume with distilled water. The
solution contains 10.0 mg zinc per ml.
Working Standard Zinc Solution - Pipette 5.0 ml of stock
zinc solution (10cO mg zinc per ml) into 500~ml volumetric
/
flask and take to volume with 0,2 M KC10 The solution contains
100 micrograms zinc per ml with 0»2 M KC1 as the electrolyte.
0.2 M KC1 Solution - Weigh 14„9 grams reagent grade KC1
into 1 liter volumetric flask and take to volume with distilled
water„
Standard Cadmium Solution - Weigh exactly 0»2744 grams
of Cd(NC>3)2*4H20 into a 500-ml volumetric flask and take to
volume with 002 M KC1» The solution contains 200 micrograms
Cd per ml with 0.2 M KC1 as electrolyte.
Oxygen Absorbent for Purification of Nitrogen - Pass
nitrogen through a first scrubbing flask (midget impinger)
containing concentrated NH4.0H and copper turnings. Caution:
Make certain hole in impinger is not plugged before turning
nitrogen on under pressure. Then pass nitrogen through a
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APPENDIX E
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second scrubbing flask containing concentrated sulfuric acid,
again making certain this is not plugged before applying
pressure.
Clean, Dry Mercury - Purchase from Eberbach & Son.
(d) Sampling
Procedure
Assemble sampling train of probe, impinger with 100 ml
5% nitric acid solution, flow meter and vacuum pump. Sample
at rate of 1 CFM for a period long enough to provide a minimum
of 30 cubic feet at standard conditions.
(e) Analytical
Procedure
Sample Preparation - Transfer the collecting solution
from the impinger into a 250 ml beaker, wash out impinger
with 570 hot nitric acid and all taken down to dryness on a
hot plate. Add 2 ml concentrated nitric acid, wetting the
sample thoroughly0 Add 6 drops perchloric acid and swirl to
mix., Evaporate to dryness on a hot plate at 350°-400° C.
Repeat the acid treatment to obtain complete digestion,, Cool
and add 10 ml of 0.2 M potassium chloride solution,, Loosen
the solids with a rubber policeman, rinse policeman and beaker
walls with 3-5 ml of 0.2 M potassium chloride solution. Cover
with a watch glass and boil 2-3 minutes. Filter the solution
into a 50-ml volumetric flask washing the filter with 002 M KC1.
Dilute to volume with 0.2 M KC1 giving the sample in 50 ml with
0.2 M KC1 as the electrolyte.
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Transfer 10 ml aliquot into polarographic cell, add 1 ml
of 200 micrograms Cd per ml solution, and remove oxygen from
cell by bubbling nitrogen through for three to five minutes.
The initial voltmeter is set at .4 volts, the span voltmeter is
set at 1 volt, thereby giving a range from -.4 volts to -1,4
volts. This is sufficient as cadmium "comes off" at approxi-
mately -066 volts and zinc at approximately -1.05 volts„ The
sensitivity setting will vary depending on the amount of zinc
present„ The setting used for the standard curve is 0,02
microamperes/mm.
If there is a possibility that Cd is present in the sample
an aliquot of the sample should be run in the polarographic cell
first, without any internal standard added,, If there is Cd
present in the sample this must be taken into account when CD,
the internal standard, is added.
Standard curve - Into the polarographic cell is introduced
1 ml of 100 micrograms Zn per ml solution, 1 ml of 200 micro-
grams Cd per ml solution, and 9 ml of 002 M KC1 solution. This
gives a total amount of solution in the cell of 11 ml thereby
enabling a later removal of 10 ml of the sample and 1 ml of
200 micrograms Cd per ml internal standard solution. Also,
there is an electrolyte in the cell of 0,2 M KC1. Both the
volume of liquid in the cell and the electrolyte for standard
curve and sample are critical for a proper analysis0
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On the standard curve the heights of the Zn and Cd curves
are measured in mm. The Zn to Cd ratio is found which is
divided by the number of micrograms of Zn used giving a factor
for 1 tnicrogram Zn versus 200 micrograms Cd. It is suggested
that 200 micrograms Cd be used as an internal standard in each
sample for Zn thereby simplifying the calculations„ The factor
for 1 microgram Zn versus 200 micrograms Cd, found at the
beginning of the series of samples being analyzed, will be used
for the calculations through this series.
(f) Calculations
For the sample "polarogram" the heights of the Zn and Cd
curves are measured in mm and the Zn to Cd ratio found in the
same manner as the standard curve. The ratio found here is
divided by the factor found in the standard curve for 1 micro-
gram Zn versus 200 micrograms Cd giving the number of micro-
grams of Zn in the aliquot put into the polarographic cell.
mg Zn/M3 = V-Y
1,000-vVa
where v = aliquot (ml)
V = total sample (ml)
Y = micrograms in v
Va = gas sample volume, in cubic meters,
at standard conditions
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Nitr9gen Oxides, Phenoldisulfonic
Acid Method
Source: Public Health Service.
(a) Scope
When sulfur dioxide, ammonia, iron or other compounds
that interfere with the hydrogen peroxide method are present
in the gas to be sampled and/or the concentration of the
nitrogen oxides is below about 100 ppm, this method is usedo
Accuracy below 5 ppm is questionable. This test is unsuitable
for atmospheric sampling.
(b) Apparatus
Sampling Probe
Stainless steel (type 304 or
316) or glass tubing of suit-
able size (1/4-inch-OD, 6-foot-
long stainless steel tubing has
been used)„
Collection Flask -
Orifice Assembly -
Adapter with
Stopcock
Three-way Stopcock.
A 2-liter round-bottom flask
with an outer 24/40 joint for
integrated samples or a 250-
ml MSA sampling tube for grab
samples.
The size of the glass capillary
tubing depends on the desired
sampling period (flow rates of
about 1 liter per minute have
been used). Use of this orifice
is not mandatory.
Adapter for connecting col-
lection flask to sampling "T"
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Manometer - A 36 -inch Hg manometer or
accurate vacuum gage0
Spectrophotometer - Beckman Model "B" or
equivalent.
(c) Reagents
Thirty Percent Hydrogen Peroxide - (reagent grade) .
Three Percent Hydrogen Peroxide - Dilute 30% H202 with
water at 1:10 ratio. Prepare fresh daily.
Concentrated Sulfuric Acid.
Ool N (approximate) Sulfuric Acid - Dilute 2.8 ml con-
centrated H2SO^ to 1 liter with water.
Absorbing Solution - Add 12 drops 3% H202 to each 100 ml
0.1 N H2S04. Make enough for required number of tests.
1 N (approximate) Sodium Hydroximde - Dissolve 40 gm NaOH
pellets in water and dilute to 1 liter.
Concentrated Ammonium Hydroxide.
Fuming Sulfuric Acid - 15 to 18 weight percent free
sulfuric anhydride (oleum) „
Phenol (reagent grade) .
Phenoldisulfonic Acid Solution - Dissolve 25 grams of
pure white phenol in 150 ml concentrated H2S04 on a steam bath.
Cool and add 75 ml fuming sulfuric acid. Heat to 100° C for 2
A.T.KEARNEY & COMPANY, IN c.
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APPENDIX E
EXHIBIT 2
Page 41
hours. Store in a dark stoppered bottle. This solution should
be colorless if prepared with quality reagents.
Potassium Nitrate (reagent grade).
Standard Potassium Nitrate Solution - Solution A:
Dissolve 005495 gram KNOo and dilute to 1 liter in a volumetric
tj
flaskc Solution B: Dilute 100 ml of Solution A to 1 liter.
One ml of Solution A contains the equivalent of 0.250 mg N02
and of Solution B, 0.0250 rag N02.
(d) Sampling
Procedure
Integrated Grab Sample - Add 25 ml freshly prepared ab-
sorbing solution into the flask. Record the exact volume of
absorbing solution used.
Set up the apparatus as shown in Figure 3, attach the
selected orifice. Purge the probe and orifice assembly with the
gas to be tested before sampling begins by applying suction to
it. Evacuate the system to the vapor pressure of the solution:
this pressure is reached when the solution begins to boil.
Record the pressure in the flask and the ambient temperature.
Open the valve to the sampling probe to collect the sample0
Constant flow will be maintained until the pressure reaches
0«53 of the atmospheric pressure. Stop before this point is
reached. During sampling, check the rate of fall of the
mercury in one leg of the manometer in case clogging, especially
of the orifice, occurs. At the end of the sampling period,
record the pressure, temperature, and barometric pressure.
A.T.KEARNEY 8e COMPANY. INC.
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APPENDIX E
EXHIBIT 2
Page 42*
An extended period of sampling can be obtained by following
this procedure. Open the valve only a few seconds at regular
intervals. For example: Open the valve for 10 seconds and
close it for 50 seconds; repeat every 60 seconds.
Grab Sample - Set up the apparatus as shown in Figure 4
for high concentrations (200-3000 ppm) or the apparatus as shown
in Figure 4 for low concentrations (0-200 ppm) but delete the
orifice assembly. The same procedure is followed as in the
integrated method except that the valve is opened at the source
for about 10 seconds and no orifice is used.
Calibration curves are made to cover different ranges of
concentrations. Using a microburette for the first two lower
ranges and a 50-ml burette for the next two higher ranges,
transfer the following into separate 150-ml beakers (or 200-ml
casseroles)»
!„ 0-100 ppm: 0.0 (blank), 200, 4009 6.00, 8.0,
10.0, 12.0, 16.0, 20.0 ml of KN03 Solution B.
2. 50-500 ppm: 0.0 (blank), 1.0, 1.5, 2.0, 3.0,
400, 6.0, 8.0, 10.0 ml of KN03 Solution A.
3» 500-1500 ppm: 0.0 (blank), 5.0, 10.0, 15.0,
20oO, 25.0, 30.0 ml of KN03 Solution A.
4. 1500-3000 ppm: 0.0 (blank), 15.0, 3000, 35.0,
4000, 45.0., 5000, 55.0, 60.0ml KN03 Solution A,
Add 25.0 ml absorbing solution to each beaker. Follow as
directed in the Analytical Procedure section starting with the
addition of 1 N NaOH.
A.T.KEARNEY 8e COMPANY, INC.
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APPENDIX E
EXHIBIT 2
Page 43
After the yellow color has developed, make dilutions for
the following ranges: 50 to 500 ppm (1:10); 500 to 1,400 ppm
(1:20); and 1,500 to 3,000 ppm (1:50). Read the absorbance of
each solution at 420 millimicron.
Plot concentrations against absorbance on rectangular
graph paper. A new calibration curve should be m.ade with each
new batch of phenoldisulfonic acid solution or every few weeks.
(e) Analytical
Procedure
Shake the flask for 15 minutes and allow to stand over
night.
Transfer the contents of the collection flask to a beaker.
Wash the flask three times with 15-ml portions of 1^0 and add
the washings to the solution in the beaker. For a blank add
25 ml absorbing solution and 45 ml H20 to a beaker. Proceed
as follows for the bank and samples0
Add 1 N NaOH to the beaker until the solution is just
alkaline to litmus paper. Evaporate the solution to dryness
on a water bath and allow to coo!0 Carefully add 2 ml
phenoldisulfonic acid solution to the dried residue and
triturate thoroughly with a glass rod, making sure that all
the residue comes into contact with the solution. Add 1 ml
H20 and four drops concentrated I^SO^. Heat the solution on
the water bath for 3 minutes, stirring occasionally.
A.T.KEARNEY & COMPANY, INC.
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APPENDIX E
EXHIBIT 2
Page 44
Allow to cool and add 20 ml 1^0, mix well by stirring,
and add 10 ml concentrated NH^OH, dropwise, stirring constantly.
Transfer the solution to a 50-ml volumetric flask, washing the
beaker three times with 4- to 5-ml portions of 1^0. Dilute to
mark with water and mix thoroughly. Transfer a portion of the
solution to a dry, clean centrifuge tube and centrifuge, or
filter a portion of the solution.
Read the absorbance of each sample at 420 millimicron. If
the absorbance is higher than 0.6, make a suitable dilution of
both the sample and blank and read the absorbance again,
(f) Calculations
ppm NO? = (5,24 x 105) (C)
VS
Where C = concentration of NC>2, mg (from calibration
chart)
Vs= gas sample volume at 70° F and 29.92 in
Hg, ml.
Sulfur Dioxide and Sulfur Trioxide,
Shell Development Company Method
Source: National Air Pollution Control Administration
Publication 999-AP-13.
(a) Scope
This method describes a procedure for determining sulfur
dioxide and sulfur trioxide in stack gases.
A.T.KEARNEY & COMPANY, INC.
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APPENDIX E
EXHIBIT 2
Page 45
(b) Apparatus
- Sampling Probe
- Filter
- Adapter
- Heating Tape
- Dry Gas Meter
Vacuum pump,,
Thermometers
Manometer
Absorbers
Glass tubing (preferably boro-
silicate or quartz) of suitable
size with a ball joint at one
end and a removable filter at
the other (a 1/2-inch-OD, 6-
foot-long tube has been used.)
A filter is needed to remove
particulate matter, which may
contain metal sulfates and
cause interference during
analysis. Borosilicate glass
wool, Kaolin wool, or silica
wool are suitable filters for
removing particulate matter.
Six plug-type connecting tubes
T 24/40, one with a 90° bend
and a socket joint.
An insulated heating tape with
a powerstat to prevent con-
densation in exposed portion
of probe and adapter. Alter-
native: glass wool or other
suitable insulators.
A Ool-cubic-foot-per-revolution
dry gas meter equipped with a
fitting for a thermometer and a
manometer. Alternately, a
calibrated tank or a rotameter
calibrated at the operating
pressure may be used.
- One 10°-50° C, + 1° C; and
one 0°-300° C + 5° C are
suitable.
A 36-inch-Hg manometer
- Two U-shaped ASTM D 1266 lamp
sulfur absorbers with coarse-
sintered plates.
A.T.KEARNEY & COMPANY, INC.
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APPENDIX E
EXHIBIT 2
Page 46
- Filter Tube - One 40-mm-diameter Corning
medium-sintered plate.
- Scrubber for - An ASTM D 1266 lamp sulfur
Purifying Air absorber with coarse-sintered
plate.
- Teflon Tubing - Teflon tubing, 1/4-inch ID,
for connecting absorbers.
Alternative: 8-mm pyrex tubing
with butt-to-butt connections
held together with Tygon.
(c) Reagents
Water - Distilled water that has been deionized.
Isopropanol, Anhydrous.
Eighty Percent Isopropyl Alcohl - Dilute isopropanol with
water at a ratio of 4 to 1.
Thirty Percent Hydrogen Peroxide - (reagent grade).
Three Percent Hydrogen Peroxide - Dilute 30% hydrogen
peroxide with water at a ratio of 10 to 1. Prepare fresh
daily.
Barium Chloride - (BaCl2*2H20, reagent grade).
0.0100 N Alcoholic Barium Chloride - Dissolve 1.2216 grams
BaCl2'2H20 in 200 ml of water and dilute to 1 liter with
isopropanol„ Standardize this solution with 0.01 N alcoholic
sulfuric acid solution.
A.T.KEARNEY & COMPANY, INC.
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APPENDIX E
EXHIBIT 2
Page 47
(As an alternate titrating solution to 0.01 N alcoholic
barium chloride, in American Petroleum Institute Study Group
uses 0.01 N alcoholic barium perchlorate because they believe
that it gives a sharper end point during titration.)
Thorin Indicator - 1-(0-arsonophenylazo)-2 naphthol-3,
6-disulfonic acid, disodium salt.
0.2 Percent Thorin Indicator - Dissolve 0.2 gram thorin
indicator in 100 ml water. Store in polyethylene bottle.
(d) Sampling
Procedure
Set up the apparatus as shown in Figure 5. Place 30 ml
of 8070 isopropyl alcohol in the first absorber and 10 ml in
the filter tube0 The add 50 ml of 37» hydrogen peroxide to the
second absorber,, A light film of silicone grease on the upper
parts of the joints may be used to prevent leakage. Wind the
heating tape in a uniform single layer around the exposed
portion of the probe and adapter and cover the heating tape
with asbestos tape wound in the opposite direction. Place a
thermometer between the heating tape and asbestos as near the
adapter joint as possible. Connect the heating tape to a
powerstat, switch on the current, and maintain the probe and
adapter at a temperature at which no condensation will occur
(about 250° C). Sample at 0»075 cubic foot per minute until
2 cubic feet or a suitable volume of gas has been sampled,,
Record the meter readings, temperatures and pressures at
A.T.KEARNEY & COMPANY, INC.
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APPENDIX E
EXHIBIT 2
Page 48
10-minute intervals. Note the barometric pressure. Do not
sample at a vacuum of more than 8 inches Hg.
Disconnect the asbestos tape, heating tape, probe, and
adapter and allow them to cool. Connect the scrubber for
purifying air to the inlet of the isopropyl alcohol absorber
and add 50 ml of 3% hydrogen peroxide. Replace the water in
the ice bath with tap water„ Draw air through the system for
15 minutes to transfer residual sulfur dioxide to the hydrogen
peroxide absorber. Disconnect the purifying air scrubber.
(Although the use of air for removal of sulfur dioxide from
isopropyl alcohol should not result in oxidation of sulfur
dioxide to sulfur trioxide, the American Petroleum Institute
Joint Study Group uses 99% nitrogen to preclude any possibility
of oxidation.) Remove the filter and wash the probe and
adapter with 80% isopropyl alcohol. Place the washings in the
isopropyl alcohol absorber„
Disconnect the hydrogen peroxide absorber and transfer
the contents and the water washings to a 250-ml volumetric
flask. Dilute the water to the mark. Analyze for sulfur
dioxide.
Stopper the isopropyl alcohol absorber and apply suction
to the filter end. Remove the suction line and allow the
partial vacuum in the absorber to draw the solution from the
filter. Rinse the filter tube with 80% isopropyl alcohol be-
fore the suction is lost. Transfer the contents of the isopropyl
A.T.KEARNEY & COMPANV, INC.
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APPENDIX E
EXHIBIT 2
Page 49
alcohol absorber and its washings to a 250-ml volumetric flask
and dilute to the mark with 80% isopropyl alcohol„ Analyze for
sulfur trioxide,,
(e) Analytical
Procedure
Sulfur Trioxide - Pipette a suitable aliquot to a flask
and dilute to 100 ml with 80% isopropyl alcohol. Add a few
drops of thorin indicator (enough to give a yellow color)„
Titrate with 0,01 N BaCl2 to the pink end point. Make a blank
determination in parallel.
Sulfur Dioxide - Transfer a suitable aliquot to a flask
and add 4 times this volume of isopropyl alcohol„ Dilute to
100 ml with 80% isopropyl alcohol, add enough thorin indicator
to give a yellow color, an titrate with standard 0*01 N BaCl2
to the pink end point. Run a blank determination in parallel*
(f) Calculations
ppm S02 or S03 by volume = 24(A-B) (N) (F) (T)
(V0) (P)
Where A = 0001N BaCl2 used for titration of sample
B = ml OoOlN BaCl2 used for titration of blank
N = exact normality of BaCl2
F = dilution factor
T = average meter temperature, °R
V0 = observed volume of gas sample, cu ft
P = average absolute meter pressure, in0 Hg
A.T.KEARNEY & COMPANY, INC.
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WIND
3 - D
MINIMUM
SAMPLE PORT
10 D PREFERRED
6 D MINIMUM
BREECHING
WHERE REQUIRED, PLACE IN
HEATED ENCLOSURE TO
PREVENT CONDENSATION
O
CONDENSER IF REQUIRED
(BEFORE OR AFTER COLLECTING UNIT)
STAINLESS STEEL
(30^3.6-
NULL OR INTERCHANGEABLE
OR SINGLE SIZE NOZZLE
^^
S - TYPE
PITOT TUBE
INCLINED
DRAFT GUAGE
TEMPERATURE
MEASURING
STACK
PARTICULATE - FABRIC, PAPER,
GLASS, MEMBRANE, CERAMIC,
OR METAL FILTER MEDIA
PARTICULATE OR
G.S ABSORPTIO,
~ms^
FREEZE - OUT TRAP
ADSORPTION
ACTIVATED CARBON,
SILICA GEL,
ALUMINA, ETC.
GAS - INTEGRATED GRAB SAMPLE
GAS - GRAB SAMPLE
FIG. 1 SAMPLING LOCATION & TRAIN COMPONENTS
PUMP
TT
COMPRESSED AIR
-t-
AP T2
(M
ORIFICIAL FLOWHETER
CRITICAL ORIFICE
r
J
ROTAMETER
GAS METER
-------
APPENDIX E
EXHIBIT 2
FIGURE 2
I
A GENERATOR
125 ml Erlenmeyer
B 19/38
C SCRUBBER
lead acetate on pyrex wool
D 12/2 ball joint
E ABSORBER
12 ml heavy wall
centrifuge tube
FIGURE 2
Arsine Generator
-------
APPENDIX E
EXHIBIT 2
FIGURES 3 6e 4
PROBE
12 5
12 5
.- TO VACUUM
./ PUMP
DETAIL A
FIGURE 3
APPARATUS FOR INTEGRATED GRAB SAMPLES
TO VACUUM
PUMP
7
250-ML FLASK
MERCURY MANOMETER
FIGURE 4
APPARATUS FOR GRAB SAMPLES
-------
APPENDIX E
EXHIBIT 2
FIGURE 5
Filter Tube
Sample
Probe
Glass
Wool
Ball &
Socket
Joint
Adapter
Ice Bath
S03 S02
Absorbers
FIGURE 5
Sulfur dioxide - sulfur trioxide sampling train.
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APPENDIX F
Page 1
GLOSSARY OF TERMS
ACFM -
Acid Lining -
Additive -
Aerosol -
Afterburner -
Agglome rat ion
Air Cleaner -
Air Filter -
Air Furnace -
Air
Pollution -
Anneal -
Actual cubic feet per minute; refers to the
volume of gas at the prevailing temperature
and pressure.
A refractory furnace lining essentially of
silica.
A substance added to another in relatively
small amounts to impart or improve desirable
qualities, or suppress undesirable qualities.
As additives to molding sand, for example,
cereal, sea coal, etc.
Small particles, liquid or solid, suspended in
the air. The diameters vary from 100 microns
down to 0.01 microns or less; for example,
dust, fog, smoke.
A device for burning combustible materials that
were not oxidized in an initial burning process.
Gathering together of small particles into
larger particles.
A device designed for the purpose of removing
atmospheric airborne impurities such as dusts,
gases, vapors, fumes and smokes.
Any method used to remove gases and particulates
from the environment and stack emission; it may
be of cloth, fibers, liquid spray, electrostatic,
etc.
A reverberatory-type furnace in which metal is
melted by heat from fuel burning at one end of
the hearth, passing over the bath toward the
stack at the other end.
The presence in the outdoor atmosphere of one
or more air contaminants or combinations thereof
in such quantities and of such duration that
they are or may tend to be injurious to human,
plant or animal life, or property, or that
interfere with the comfortable enjoyment of
life or property or the conduct of business.
A heat treatment which usually involves a slow
cooling for the purpose of altering mechanical
or physical properties of the metal, particularly
to reduce hardness.
A.T.KEARNEY 8c COMPANY. INC.
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APPENDIX F
Page 2
Baghouse -
Baked Core -
Balanced
Blast -
Basic Lining -
Bed -
Blast -
Blast Volume
Briquette -
Burden -
Burned Sand -
Canopy Hood -
A large chamber for holding bags used in the
filtration of gases from a furnace to recover
metal oxides and other solids suspended in the
gases. It's a form of dust collector and the
bags may be constructed of natural, synthetic,
or glass fibers.
A core which has been heated through sufficient
time and temperature to produce the desired
physical properties attainable from its
oxidizing or thermal setting binders.
Arrangement of tuyeres in a cupola which pro-
vides for distributing or balancing the blast
as required between upper and lower levels of
the melting zone.
In a melting furnace, the inner lining and
bottom composed of materials that have a basic
reaction in the melting process, usually either
crushed burned dolomite, magnesite, magnesite
bricks or basic slag.
Initial charge of fuel in a cupola upon which
the melting is started.
Air driven into the cupola furnace for combustion
of fuel.
The volume of air introduced into the cupola for
the burning of fuel. This volume governs the
melting rate of the cupola and approximately
30,000 cubic feet of air is required per ton of
metal melted.
Compact cylindrical or other shaped block formed
of finely divided materials by incorporation
of a binder, by pressure, or both. Materials
may be ferroalloys, metal borings or chips,
silicon carbide, coke breeze, etc.
A collective term of the component
parts of the metal charge for a cupola
melt.
Sand in which the binder or bond has
been removed or impaired by contact with
molten metal.
A metal hood over a furnace for collecting
gases being exhausted into the atmosphere
surrounding the furnace.
A.T.KEARNEY fie COMPANY. INC.
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APPENDIX F
Page 3
Cantilever
Hood -
Cast Iron -
Catalytic
Combustion
Centrifuging -
Cereal
Binder -
Charge -
Charging
Door -
Coke -
Coke Breeze
Convection •
Cope -
Core -
A counterbalanced hood over a furnace that can
be folded out of the way for charging and
pouring the furnace.
Essentially an alloy of iron, carbon and silicon
in which the carbon is present in excess of the
amount which can be retained in solid solution
in austenite at the eutectic temperature.
A device for burning combustible gases, vapors,
aerosols and odorous substances, reducing them
to water vapor and carbon dioxide.
A method of casting, employing a core and
depending on centrifugal force to make the metal
more dense and strong in the outer portion of
the casting. The mold cavities are usually
spaced symmetrically about a central sprue, and
the whole assembly is rotated about that axis
during pouring and solidification.
A binder used in core mixtures and molding
sands, derived principally from corn flour.
The total ore, ingot, metal, pig iron, scrap,
limestone, etc. introduced into a melting fur-
nace for the production of a single heat.
An opening in the cupola or furnace through
which the charges are introduced.
A porous gray infusible product resulting from
the dry distillation of bituminous coal, which
is used as a fuel in cupola melting.
These are fines from coke screenings.
The motion resulting in a fluid from the differ-
ences in density and the action of gravity due
to temperature differences in one part of the
fluid and another. The motion of the fluid
results in a transfer of heat from one part to
the other.
The upper or topmost section of a flask, mold,
or pattern.
A separate part of the mold which forms cavities
and openings in castings which are not possible
with a pattern alone. Cores are usually made
of a different sand from that used in the mold
and are generally baked or set by a combination
of resins.
A. T. KEARNEY 8c COMPANY. INC.
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APPENDIX F
Page 4
Core Binder -
Core Blower -
Core Oven -
Core Sand -
Crucible -
Cupola -
Cupola, Hot
Blast -
Cupola Stack -
Cyclone -
(centrifugal
collector)
Cyclonic
Scrubber -
Density -
Desulfurizing
Direct Arc
Furnace •
Drag -
Any material used to hold the grains of core
sand together.
A machine for making cores by blowing sand into
the core box by means of compressed air.
Specially heated chambers for the drying of
cores at low temperatures.
Sand for making cores to which a binding material
has been added to obtain good cohesion and
porosity after drying.
A vessel or pot made of a refractory such as
graphite or silicon carbide with a high melt-
ing point and used for melting metals.
A cylindrical straight shaft furnace usually
lined with refractories, for melting metal in
direct contact with coke by forcing air under
pressure through openings near its base.
A cupola supplied with a preheated air blast.
The overall top column of the cupola from the
charging floor to the spark arrester.
A device with a control descending vortex
created to spiral objectionable gases and dusts
to the bottom of a collector cone for the purpose
of collecting particulate matter from process
gases.
Radial liquid (usually water) sprays introduced
into cyclones to facilitate collection of
particulates.
Ratio of the weight of gas to the volume, nor-
mally expressed as pounds per cubic foot.
The removal of sulfur from molten metal by the
addition of suitable compounds.
An electric arc furnace in which the metal being
melted is one of the poles.
The lower or bottom section of the mold, flask
or pattern.
A.T.KEARNEY & COMPANY. INC.
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APPENDIX F
Page 5
Ductile Iron -
Duplexing -
Dust -
Dust
Collector
Dust Loading -
Efficiency -
Iron of a normally gray cast type that has been
suitably treated with a nodularizing agent so
that all or the major portion of its graphitic
carbon has a nodular or spherulitic form as
cast.
A method of producing molten metal of desired
analysis. The metal being melted in one furnace
and refined in a second.
Small solid particles created by the breaking
up of larger particles by processes such as
crushing, grinding, drilling, explosion, etc.
An air cleaning device to remove heavy particu-
late loadings from exhaust systems before dis-
charge to outdoors.
The concentration of dust in the gas entering
or leaving the collector, usually expressed
as pounds of particulate per 1,000 pounds of
dry gas or grains per standard cubic foot.
With regard to dust collectors, it is the ratio
of the weight of dust trapped in the collector to
the weight of dust entering the collector. This
is expressed as a percent. __. _
Effluent -
Electrostatic
Precipitator-
Elutriation -
emission -
Endotherraic
Reaction -
Equivalent
Opacity -
The discharge entering the atmosphere from
the process.
A dust collector utilizing a high voltage
electrostatic field formed by negative and
positive electrodes; the positive, uncharged
electrode attracts and collects the gas-borne
particles.
The sizing or classifying of particulate matter
by suspension in a fluid (liquid or gas), the
larger particulates tending to separate by
sinking.
The total pollutants emitted into the atmosphere
usually expressed as weight per unit of time
such as pounds per hour.
Designating, or pertaining to a reaction which
occurs with the absorption of heat from the
surroundings.
The determination of smoke density by comparing
the apparent density of smoke as it issues from
a stack with a Rinselmann chart. In effect, it
is a measure of the light obscurity capacity
of the plume.
A.. T. KEARNEY ? C OM PAN Y, I N-c.
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APPENDIX F
Page 6
Exothermic
Reaction
Fabric
Filter -
Facing Sand -
Fines -
Flask -
Flux -
Fly Ash -
Forehearth -
Foundry
Effluent -
Fourth Hole
Ventilation
(Direct Tap)
Fume -
Chemical reactions involving the liberation
of heat; such as burning of fuel and deoxidizing
of iron with aluminum.
A dust collector using filters made of synthetic,
natural or glass fibers within a baghouse for
removing solid particulate matter from the air
or gas stream.
Specially prepared molding sand mixture used
in the mold adjacent to the pattern to produce
a smooth casting surface.
A term the exact meaning of which varies.
1. Those sand grains that are
substantially smaller than
the predominating grain size.
2. That portion of sieved material
that passes through the mesh.
Metal or wood frame without top or without
fixed bottom used to retain the sand in which
a mold is formed; usually consists of two
parts, cope and drag.
Material or mixture of materials which causes
other compounds with which it comes in contact
to fuse at a temperature lower than their nor-
mal fusion temperature.
A finely divided siliceous material, usually
oxides, formed as a product of combustion of
coke. A common effluent from the cupola.
Brick lined reservoir in front of and connected
to the cupola or other melting furnaces for
receiving and holding the melted metal.
Waste material in water or air that is discharged
from a foundry.
In air pollution control, using a fourth hole
in the roof of an electric furnace to exhaust
fumes.
A term applied to fine solid particles dispersed
in air or gases and formed by condensation, sub-
limation, or chemical reaction.
A.T.KEARNEY Sc COMPANY. INC.
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APPENDIX F
Page 7
Gas »
Gate -
Gray Iron -
Green Sand -
Griffin
System -
Heat Balance -
Heat
Treatment
Heel -
Holding
Furnace -
Hood -
Hot Blast -
Indirect Arc
Furnace -
Induction
Furnace -
Inlet
Volume -
Formless fluids which tend to occupy entire
space uniformly at ordinary temperatures and
pressures.
The portion of the runner in a mold through
which molten metal enters the mold cavity.
Cast iron which contains a relatively large
percentage of its carbon in the form of graphite
and substantially all of the remainder of the
carbon in the form of eutectoid carbide.
A naturally bonded sand or a compounded molding
sand mixture which has been tempered with water
and additives for use while still in a damp or
wet condition.
A method operating in two stages, to recoup and
preheat air by using the latent heat of cupola
gases.
A determination of the sources of heat input and
the subsequent flow of heat usually expressed in
equation form so that heat input equals heat output.
A combination of heating and cleaning operations
timed and applied to a metal or alloy in the
solid state in a manner which will produce
desired properties.
Metal left in ladle after pouring has been com-
pleted. Metal kept in induction furnaces during
standby periods.
A furnace for maintaining molten metal, from a
larger melting furnace, at the proper casting
temperature.
Projecting cover above a furnace or other equip-
ment for purpose of collecting smoke, fume or
dust.
Blast which has been heated prior to entering
into the combustion reaction of a cupola.
An electric arc furnace in which the metal
bath is not one of the poles of the arc.
A melting furnace which utilizes the heat gen-
erated by electrical induction to nfelt a metal
charge.
The qmantity of gas entering the collector from
the system it serves (in cubic feet per minute
at a specified temperature).
A.T.KEARNEY (x COMPANY. INC.
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APPENDIX F
Page 8
Inoculant -
Inoculation -
Ladle
Addition -
Latent Heat -
Lining -
Magnesium
Treatment
Malleable
Iron -
Material
Balance -
Melting Rate
Micron -
Mist -
Mold -
Muller -
Material which when added to molten metal modi-
fies the structure changing the physical and
mechanical properties of the metal.
The addition to molten metal substances designed
to form nuclei for crystallization.
The addition of alloying elements to the molten
metal in the ladle.
Thermal energy absorbed or released when a sub-
stance changes state; that is, from one solid
phase to another, or from solid to liquid or
the like.
Inside refractory layer of firebrick, clay,
sand or other material in a furnace or ladle.
The addition of magnesium to molten metal to
form nodular iron.
A mixture of iron and carbon, including smaller
amounts of silicon, manganese, sulfur and
phosphorous, which, after being cast as white
iron, is converted structurally by heat treat-
ment into a matrix of ferrite containing nodules
of temper carbon, and substantially free of all
combined carbon.
A determination of the material input to the
cupola and the output to fully account for
all material.
The tonnage of metal melted per unit of time,
generally tons per hour.
A unit of measurement which is 1/25,000 Of an
inch or a millionth of a meter. Often desig-
nated by the Greek letter mu.
Visible emission usually formed by a condensa-
tion process or vapor-phase reaction, the liquid
particles being sufficiently large to fall of
their own weight.
The form, usually made of sand, which contains
the cavity into which molten metal is poured
tb produce a casting of definite shape and
outline.
A type of foundry sand mixing machine.
A.T.KEARNEY & C OMPAN Y. In c.
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Nodular Cast
I ron -
Opacity -
Outlet Volume -
Oxidizing
Atmosphere
Oxidation
Losses -
Particulate
Matter -
Parting
Compound -
Pattern -
Plume -
Pollutant -
Preheater -
Process
Weight -
Recuperator -
Reducing
Atmosphere
Page 9
(See Ductile Iron)
The state of a substance which renders it partially
or wholly impervious to rays of light. Opacity as
used in an ordinance refers to the obscuration of
an observer's view.
Quantity of gas exhausting from the collector
(in cubic feet per minute at a specified
temperature).
An atmosphere resulting from the combustion of
fuels in an atmosphere where excess oxygen is
present, and with no unburned fuel lost in the
products of combustion.
Reduction in amount of metal or alloy through
oxidation. Such losses usually are the largest
factor in melting loss.
Solid or liquid particles, except water, visible
with or without a microscope, that make up the
obvious portion of an exhaust gas or smoke.
A material dusted, brushed or sprayed on patterns
or mold halves to prevent adherence of sand and
to promote easy separation of cope and drag
parting surfaces when cope is lifted from drag.
A form made of wood, metal or other materials
around which molding material is placed to make
a mold for casting metals.
A visible, elongated, vertical (horizontal when
windblown) column of mixed gases and gas-borne
particulates emitted from a smoke stack.
Any foreign substance in the air or water in
sufficient quantities and of such characteristics
and duration as to be injurious to human, plant,
or animal life or property, or which unreasonably
interferes with the enjoyment of life and property.
A device used to preheat the charge before it
is charged into the furnace.
The total weight of raw materials, except air,
introduced into any specific process, possibly
causing discharge into the atmosphere.
Equipment for transferring heat from hot gases
for the preheating of incoming fuel or air.
An atmosphere resulting from the incomplete
combustion of fuels.
A.T.KEARNEY *- COMPANY. INC.
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APPENDIX F
Page 10
Refractory -
Reverberatory
Furnace -
Ringelmann's
Scale -
(chart)
Riser -
Rotary
Furnace -
SCFM -
Sea Coal -
Sensible Heat
Shakeout -
Shell Molding
Shotblasting
Slag -
Heat resistant material, usually nonmetallic,
used for furnace linings, etc.
A large quantity furnace with a vaulted ceiling
that reflects flame and heat toward the hearth
or the surface of the charge to be melted.
A system of optical charts reading from all
clear to solid black for. grading the density
of smoke emissions.
An opening in the top of a mold which acts as
a reservoir for molten metal and connected
to the casting to provide additional metal to
the casting as it contracts on solidification.
A furnace using pulverized coal, gas or oil;
of cylindrical shape with conical ends, mounted
so as to be tipped at either end to facilitate
charging, pouring and slagging.
Units standing for Standard Cubic Feet per Minute.
The volume of gas measured at standard conditions,
one atmosphere of pressure and 70° F.
A term applied to finely ground coal which is
mixed with foundry sands.
That portion of the heat which changes only
the temperature, but does not cause a phase
change.
The operation of removing castings from a
sand mold.
A process for forming a mold from thermosetting
resin bonded sand mixtures brought in contact
with preheated metal patterns, resulting in a
firm shell with a cavity corresponding to the
outline of the pattern.
Casting cleaning process employing a metal
abrasive propelled by centrifugal force.
Nonmetallic covering which forms on the molten
metal as a result of the flux action in com-
bining impurities contained in the original
charge, some ash from the fuel and silica
and clay eroded from the refractory lining.
A. T. KEARNEY A
. Inc.
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APPENDIX F
Page 11
Smoke -
Spark
Arrester -
Sprue -
Standard Air -
A type of emission resulting from incomplete com-
bustion and consisting predominantly of small
gas-borne particles of combustible material
present in sufficient quantity to be observable
independently of the presence of other solids
in the gas stream.
Device over the top of the cupola to prevent
the emission of sparks.
The channel, usually vertical, connecting the
pouring basin with the runner to the mold
cavity. In top pour casting the sprue may
also act as a riser.
Air with a density of .075 pounds per cubic
foot, generally equivalent to dry air at 70° F
and one atmosphere of pressure (14.7 psia).
Superheating - Heating of a metal to temperatures above the
melting point of the metal to obtain more com-
plete refining or greater fluidity.
Tapping -
Tuyere -
Vapor -
Ventilation
System -
Venturi
Scrubber
Wet Cap -
Removing molten metal from the melting furnace
by opening the tap hole and allowing the metal
to run into a ladle.
The nozzle openings in the cupola shell and
refractory lining through which the air blast
is forced.
The gaseous form of a substance normally in the
solid or liquid state and which can be returned
to these states either by increasing pressure
or decreasing temperature.
In the foundry, the exhaust ventilation and dust
control equipment for the health, safety, comfort
and good housekeeping of those who work there.
In air pollution control, a high velocity gas
stream directed into the throat of a venturi of
a wet scrubber to separate out particulates.
A device installed on a cupola stack that
collects emissions by forcing them through a
curtain of water. The device requires no
exhaust fan but depends upon the velocity
pressure of the effluent gases.
A. T. KEARNEY & COMPANY. IKC.
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APPENDIX F
Page 12
Wet In air pollution control, a liquid spray device,
Scrubber - usually water, for collecting pollutants in
escaping foundry gases.
Wind Box - The chamber surrounding a cupola through which
air is conducted under pressure to the tuyeres.
A.T.KEARNEY 8t COMPANY. Inc.
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