ENVIRONMENTAL PROTECTION AGENCY
Office of Enforcement
EPA-330/2-77-024
CARBON MONOXIDE EMISSION TESTS
COMMERCIAL ENAMELING COMPANY
Huntington Park, California
(September 12-13, 1977)
December 1977
National Enforcement Investigations Center - Denver
and
Region IX - San Francisco
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CONTENTS
I INTRODUCTION 1
II SUMMARY AND CONCLUSIONS 2
III PROCESS DESCRIPTION 4
IV TEST PROCEDURES 6
SAMPLING LOCATION 6
SAMPLING PROCEDURES 6
PROCESS OBSERVATION PROCEDURES 10
V TEST RESULTS 11
FIGURES
1 Cupola Pollution Control Equipment 7
2 CO Monitoring System 9
3 CO Emissions at Cupola Startup 14
4 CO Emissions from Opened Charge Door 15
5 CO Emissions during Tuyere Cleaning 16
6 CO Emissions after Tuyere Cleaning 17
7 CO Emissions 18
8 CO Emissions at Cupola Shutdown 19
TABLE
1 15-Minute Average CO Concentrations 12
APPENDICES
A Presurvey Inspection
B CO Absorption Calculation
C Equipment Calibration and Quality Control
D One-Minute Average - CO Concentration Data
E Process Monitoring Data
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I. INTRODUCTION
Commercial Enameling Company operates a grey iron foundry and
enameling plant in Huntington Park, California. On February 11, 1976,
a source test performed by the Los Angeles Air Pollution Control District
(LAAPCD)*, determined that the cupola emissions contained 4,280 parts
per million by volume (ppmv) carbon monoxide (CO), twice the allowable
concentration (per LAAPCD Rule 71) of 2,000 ppmv.** LAAPCD cited the
source for violating Rule 71 and required upgrading of the cupola.
Region IX of the Environmental Protection Agency (EPA) asked the
National Enforcement Investigations Center (NEIC) to conduct a source
test following the upgrading of the cupola. On July 19, 1977, NEIC
conducted a presurvey inspection of Commercial Enameling Company to
evaluate sampling locations and obtain process information [Appendix A].
On September 12, 1977, NEIC personnel set up a CO analyzer at Commercial
Enameling, and from 6:00 a.m. to 2:30 p.m. on September 13 they con-
tinuously monitored the cupola CO emissions. The CO concentration data
was summarized in 15-minute averages** and compared with LAAPCD Rule 71
requi rements.
A consultant, Mr. Eddie Ong of Hunt Combustion Engineers, was
present during the sampling and assisted with the cupola operations.
* The Agency title has since been changed to Metropolitan Zone3 South
Coast Air Quality Management District; however3 EPA has not yet
approved all State Implementation Plan revisions. The LAAPCD
regulations are considered applicable by EPA.
** No time averaging period is specified in the LAAPCD Regulation.
Mr. Larry Zimmerman3 Air Resource Boards State of Californias
indicated (by telephone conversation) that 15-minute averages were
normally used.
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II. SUMMARY AND CONCLUSIONS
1. On September 13, 1977, from 6:00 a.m. to 2:30 p.m., NEIC
measured the CO emissions from the cupola of the Commercial Enameling
Company to determine compliance with LAAPCD Rule 71 which allows an
emission concentration of 2,000 ppmv. The emissions were continuously
monitored by a Bendix CO analyzer and the eight and one-half hours of CO
concentration data was initially summarized in 510 one-minute averages,
and then in 34 fifteen-minute averages.
2. The CO emissions averaged 100 ppmv over the operating day and
only once did a fifteen-minute average exceed 1,000 ppmv. The fifteen-
minute averages never exceeded the 2,000 ppmv limit and thus the cupola
CO emissions are in compliance.
3. The cupola furnace was operating at normal production rates
during the sampling. Process observations determined that the cupola
was being charged at a rate of 30 m. tons/day or 95% of capacity. The
afterburner control, however, was operated at a higher temperature
(980°C) than had occurred in the presurvey inspection (760°C).
4. Thirteen one-minute averages exceeded 1,000 ppmv; of these,
two averages exceeded 2,000 ppmv. These high concentrations were
directly related to one of the following cupola operations:
a. cupola startup
b. checking of furnace bed height by opening charge door
c. cleaning of cupola tuyeres
d. Cupola shutdown
The high CO concentrations caused by opening the charge door (5-minute
average of 800 ppmv) and shutting down the cupola (7-minute average of
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3
+1,000 ppmv) can be corrected by modifying the process operating con-
ditions. A sharp reduction in CO concentrations was noted immediately
after cleaning the tuyeres and for six hours afterward; this reduction
in the average CO emissions compensated for the short term high CO
concentrations (2 minutes of +2,000 ppmv) during tuyere cleaning.
5. The following operating procedures will minimize the cupola
furnace CO emissions, if implemented by Commercial Enameling Company:
a. check the bed height of cupola only during an actual
charge
b. clean the furnace tuyeres daily
c. operate the air pollution control system for five or
ten minutes after cupola shutdown
d. operate the afterburner at 980°C
In addition, it is expected that the startup CO emissions would be
reduced if the afterburner is turned on five or ten minutes before
cupola startup.
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III. PROCESS DESCRIPTION
Commercial Enameling Company produces porcelain sinks and tubs by
enameling iron castings. The weights of these finished products range
from 4.5 to 91 kg (10 to 200 lb) and average 23 kg (50 lb).
Scrap iron is melted and refined in a cupola furnace, and poured in
sand molds to form castings. The cupola is a particulate and carbon
monoxide (CO) emission source which is controlled by an afterburner -
quench chamber - baghouse system.
From 6:00 a.m. to 2:00 p.m., Monday through Friday, the Whiting
cupola furnace melts about 32 m. tons (35 tons)/day of material to
produce 27 m. tons (30 tons)/day of iron. Sustaining this production
rate requires about eight-five 380 kg (830 lb) charges during the daily
8-hour operation. Each charge is made up of the following material:
Raw Material kg lb
scrap iron 318 700
coke 41 90
limestone 16 35
ferrocarbon 2 5
ferrosilicon 2 4
A thermocouple monitors the furnace combustion gas temperature.
The cupola is charged whenever the thermocouple indicates a temperature
of 760°C (1,400°F). After the charge, the gas temperature drops to
about 650°C (1,200°F) and slowly rises as the iron melts.
The molten iron is tapped from the furnace into a ladle which
carries the metal to the pouring area where it is poured into molds.
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5
From the opposite side of the cupola, slag is tapped onto the ground and
when cooled is hauled away.
The molds are assembled from two mold sections (top and bottom) and
sometimes a core.** Three molding stations form green* sand into the
two sections. A 77 m. tons (85 tons)/day sand system supplies the green
sand to the molding stations.
Cores are formed from oil-sand mixed at the plant from sand, water
and lineseed oil. Once formed, the oil-sand cores are cured in a
natural gas-fired oven to give them strength. After cooling, the cores
are ready to be assembled in the mold.
After the molten iron is poured into the molds, the castings are
allowed to cool before being taken to the shakeout area. In the shake-
out area a vibrating screen separates the casting from the mold and core
sands. The sands are combined, processed and stored for reuse. The
castings are further cleaned in a shot machine which uses small metal
pellets to remove the remaining sand. Imperfections are removed by
grinding before the casting goes to the enameling department.
A vibrator is used to uniformly spread a fine glass powder over the
surface to be enameled. Most of the powdered glass is purchased, but
some glass is ground into powder at the plant. On contact with the hot
casting, the glass powder melts. The coated casting is then fired in
one of two natural gas-fired furnaces to improve the porcelain finish.
A second coat of powdered glass is then applied and fired. The final
products have a 0.9 mm (35-40 mil) porcelain thickness.
* The color of the sand gives it its name.
** The core is the inside of the complete molds causing the casting to
be hollow.
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IV. TEST PROCEDURES
SAMPLING LOCATIONS
A single 5 cm (2 in) port is located in a 76 cm (30 in) duct about
30 m (100 ft) downstream of the afterburner, just before the quencher
[Figure 1]. Here the cupola gas temperature and velocity are about
590°C (1,100°F) and 12 m (40 ft)/sec, respectively. At this point, the
gases should be well mixed because of upstream flow disturbances. This
2 2
sampling port and 1.5 m (16 ft ) sampling platform are 3.0 m (10 ft)
and 1.5 m (5 ft) above the ground, respectively.
The single sampling port, just before the quencher, is convenient
for a test. However, to assure that CO emissions at this point could be
considered representative of the CO emissions following the control
system, a calculation was made to determine whether the quench water
might absorb carbon monoxide. The maximum calculated change in carbon
monoxide concentration, assuming a CO concentration of 2,000 ppmv in the
gas stream to the quencher, would be 1.1 ppmv or 0.06% [Appendix B]. The
baghouse has no effect on the CO emissions.
SAMPLING PROCEDURES
The cupola CO emissions were continuously monitored following the
procedures specified in EPA Method 101. To meet these specifications, a
Bendix NDIR* CO analyzer capable of directly measuring concentrations
up to 1,000 ppmv was equipped with an air dilution and drying system to
1 Code of Federal Regulations3 Title 40, Part 60 - Standards of Per-
formance for New Stationary Sources, Appendix A - Reference Methods3
August 18, 1977.
* NDIR-Nondispersive Infrared
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Afterburner
Charge
door
Quencher
Cupola
Blower
VVVVV
Baghouse
Figure 1. Commercial Enameling Company, Huntington Park
Cupola Pollution Control Equipment
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8
enable measurements up to 10,000 ppmv [Figure 2]. The analyzer and
dilution system was assembled on-site, along with calibration and zero
gas cylinders, to sample the cupola CO emissions.
The gas sample was extracted from the duct center through a 1 m
(3.3 ft) stainless-steel-lined probe (no nozzle was used). A flexible
Teflon* probe carried the gas sample to two empty modified Greenburg-
Smith glass impingers which collected condensed water and some parti-
culate. From the impingers, stainless steel tubing, about 3 m (10 ft)
long and 0.6 cm (0.25 in) in diameter, carried the sample to the instrument.
At this point the sample passed through a trap containing glass wool, to
further remove moisture and particulates, before passing into a small
refrigeration unit. After the refrigeration unit, the sample passed
through an in-line glass wool filter and then through a rotameter cali-
brated in the range from 50 to 750 ml/min. A second rotameter cali-
brated in the range from 300 to 4,000 ml/min was used to supply dry
dilution air. The two flows combined at a stainless steel "T" and then
were pumped, by a stainless steel chambered pump, into a glass mixing
bulb equipped with a thermometer. A sample was then drawn from the
manifold into the NDIR, measured and recorded on a chart recorder.
Whenever the CO concentration was within the range of the analyzer the
rotameters were removed from the system to allow undiluted sample to
pass directly through the system.
The Bendix CO analyzer was checked for zero and span drift daily
for seven days prior to sampling the cupola emissions. When the in-
strument was on-site, similar drift checks were conducted hourly the day
before actual sampling to document instrument stability. Line voltage
was checked before and during sampling to ensure changes in CO con-
centration were not due to voltage fluctuations to the analyzer.
* Brand name
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Duct
Mixing
Stainless steel bulb
probe
Pump
Drying
tube
Flexible
teflon
probe
Rotameters
Manifold
Coarse
Bendix
NDIR
Calibration gases
Refrigerator
Impingers
Recorder
CD
Coarse
filter
M
Figure 2. Commercial Enameling - Huntington Park, California
CO Monitoring System
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10
Calibration gases were used before, twice during, and immediately after
sampling to validate calibration. Soap bubble flow meters were used to
verify rotameter calibrations on-site [Appendix C]. A calibration gas
was put through the entire sample train to verify that no concentration
change was produced. Before sampling began, leak checks were performed
on-site by pressurizing the system (^5 psia) and watching for any change
in pressure in one-minute's time; a change of 1 psia was considered
acceptable. All instrument settings were documented and NEIC personnel
were on-site to verify that none were changed during sampling. Periodic
cross-checks between the instrument's meter and the strip chart recorder
were also made. The equipment calibration and quality control techniques
used are discussed in Appendix C.
PROCESS OBSERVATION PROCEDURES
Cupola process operations were observed to determine whether normal
operating conditions occurred during the sampling period. The frequency
of charging, slagging and tapping was monitored, along with the after-
burner operating temperature. By counting the number of charges made to
the cupola during a time period, the process weight was calculated and
compared to the design production capacity of the cupola. The comparison
determined whether the cupola was operating at normal capacity during
sampling. The afterburner operating temperature was used as a general
indicator of auxiliary fuel (natural gas) use, which is independent of
the cupola process operations and directly related to the afterburner
control efficiency.
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V. TEST RESULTS
From 6:00 a.m. to 2:30 p.m., on September 13, 1977, the cupola CO
emissions were continuously measured and recorded. The data was sum-
marized first in one-minute averages [Appendix D] and then in discrete
fifteen-minute averages [Table 1]. No fifteen-minute average exceeded
2,000 ppmv and only one such average exceeded 1,000 ppmv. The average
CO concentration for the entire 8.5-hour period was 100 ppmv. Thus, the
cupola CO emissions averaged 5% of the allowed 2,000 ppmv.
The process monitoring data [Appendix E] verifies that the cupola
was charging, tapping and slagging at regular intervals, and maintained
normal charging rate (30 m. tons/day). The afterburner temperature
averaged 980°C (1,800°F) during the test period, which is much higher
than the temperature observed during the presurvey inspection (650-
760°C). Based on afterburner design criteria, the increased operating
temperature (^200°C) would increase the CO control efficiency.
All high CO concentrations were related to specific cupola operations
[Table 1]. The startup of the cupola furnace at 6:00 a.m. caused high
CO concentrations (+540 ppmv for five minutes) because the afterburner
startup was concurrent with the cupola startup [Figure 3].
Between 7:00 and 7:15 a.m., Company personnel pushed the cupola
charge door open with a stick to check the height of the furnace bed
[Figure 4]. The resultant high CO concentrations (+1,000 ppmv for one
minute), indicated incomplete combustion; according to Company personnel,
the open door shuts off the combustion air needed by the afterburner.
Company personnel also indicated that if the bed height is checked
immediately following a charge, before the charging door is closed, high
CO concentrations would not occur.
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12
Table 1
15-MINUTE AVERAGE CO CONCENTRATIONS
COMMERCIAL ENAMELING
HUNTINGTON PARK3 CALIFORNIA
September 13 s 1977
Sampling Period 15-Minute Average Sampling Period 15-Minute Average
(hours) Concentration (hours) Concentration
(ppmv) (ppmv)
0600-0615
3411
1015-
1030
36
0615-0630
113
1030-
1045
52
0630-0645
99
1045-
1100
34
0645-0700
122
1100-
1115
34
0700-0715
2512
1115-
1130
32
0715-0730
10103
1130-
1145
25
0730-0745
91
1145-
1200
18
0745-0800
28
1200-
1215
28
0800-0815
35
1215-
1230
52
0815-0830
18
1230-
1245
41
0830-0845
12
1245-
1300
34
0845-0900
31
1300-
1315
30
0900-0915
44
1315-
1330
28
0915-0930
38
1330-
1345
52
0930-0945
35
1345-
1400
51
0945-1000
12
1400-
1415
73
1000-1015
29
1415-
1430
4004
1 Cupola Startup
2 Charging Door Opened Manually
3 Cupola Tuyeres Cleaned
4 Cupola Shutdown
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13
During the first hour of monitoring, the CO concentration fluctuated
from 100 to 300 ppmv after each charge [Figure 4]. Upon seeing the
fluctuations, the Company personnel cleaned the furnace tuyeres (0715-
0730 hours). This cleaning caused high CO concentrations (>2,000 ppmv
for two minutes) [Figure 5] for fifteen minutes, but the average CO
concentrations were much lower afterward without any of the previous
fluctuations [Figure 6]. The emissions remained low for six hours.
Therefore, cleaning of the tuyeres will reduce the cupola CO emissions.
Near the end of the operating day (1:00 p.m.), fluctuations in CO
concentrations caused by charging were again evident [Figure 7] indicating
the tuyeres required cleaning.
The shutdown of the cupola [Figure 8] caused high CO concentrations
(+1,000 ppmv for five minutes). At approximately 2:25 p.m. the Company
restarted the blower for the control equipment and within five minutes
CO concentrations had already been reduced 70% [Figure 8]. CO monitoring
was then stopped. If the pollution control system had remained in
operation for five minutes after cupola shutdown, the CO concentrations
would have been reduced. Based on these shutdown monitoring data, it is
projected that the startup CO emissions would also be reduced if the
afterburner startup occurred five to ten minutes before the cupola
startup.
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Figure 3
CO Emissions' at C
(^6:00 a.
.jpola Star tup
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4.— CO-Emissions-from Openec
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Figure 8
COiEmissions at C
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upola Shu
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APPENDIX A
PRESURVEY INSPECTION
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ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF ENFORCEMENT APPENDIX A A-l
NATIONAL FIELD INVESTIGATIONS CENTER-DENVER
BUILDING 53, BOX 23227, DENVER FEDERAL CENTER
DENVER, COLORADO 80225
to Chief, Field Operations Branch 0ATE August 10, 1977
P*
on Paul R. dePercin
isject. Presurvey Inspection of the Commercial Enamelling Company, Huntington
Park, California
On July 19, 1977, Messrs. Garoun Andranigian, Los Angeles Air
Pollution Control District (LA APCD), and the writer inspected the
Commercial Enamelling Company, Huntington Park, California, to obtain
information necessary to conduct a source test of the cupola furnace
emissions. This information included the cupola process description,
Air Pollution Control equipment configuration, source sampling feasi-
bility, and process and control equipment operating data availability.
Of particular interest were the available sampling locations and the
necessary modifications to these sampling locations in order to obtain
representative emission data. The plant representative contacted was Mr.
Mike Hurray, Vice President.
EPA Region IX requested NEIC to source sample the cupola carbon
monoxide (CO) emissions because a past source test performed on February
11, 1976 by the LA APCD determined a carbon monoxide concentration of
4280 ppmv (dry), twice the allowable concentration (LA APCD Rule 71) of
2000 ppmv. LA APCD cited the source for violating Rule 71 and required
upgrading of the cupola afterburner control system. NEIC source sampling
will determine if the afterburner modifications, which are now complete,
were sufficient to achieve compliance.
PROCESS DESCRIPTION
Commercial Enamelling produces porcelain sinks and tubs by enamelling
iron castings. The weights of these finished products range from 4.5 to
91 kg (10 to 200 lb) and average 23 kg (50 lb).
From 5 a.m. to 2 p.m., Monday through Friday, the Whiting* cupola furnace
melts about 32 m. tons (35 tons)/day of material to produce 27 m. tons
(30 tons)/day of iron. To sustain this production rate, it requires
about 85-380 kg (830 lb) charges during the daily eight operating hours.
Each charge is made up of the following material:
* Brand name
-------
A-2
Raw Material
hi
lb
scrap Iron
coke
limestone
.ferrocarbon
ferrosilicon
318
41
16
2
2
700
90
35
5
4
The cupola is charged whenever the thermocouple, which monitors the
furnace combustion gas temperature, indicates a temperature of 760°C
h,400°F). After the charge, the gas temperature drops to about 650°C
(i,200°F) and slowly rises as the iron melts.
The molten iron is tapped from the furnace into a ladle which
carries the metal to the pouring area. There, the iron is poured into
molds. Slag is tapped onto the ground from the opposite side of the
cupola and when cooled is hauled away.
The molds are assembled from two mold sections (top and bottom} and
sometimes a core. Three molding stations form green* sand into the two
sections. A 77 m. ton (85 ton)/day sand system supplies the green sand
to the molding stations.
Cores** are formed from oil sand mixed at the plant from sand,
water, and linseed oil. Once formed, the oil-sand cores are cured in a
natural gas-fired oven to give them strength. Then the cores are cooled
and ready to be assembled in the mold.
After the molten iron is poured into the molds, the castings are
allowed to cool before beir.g taken to the shakeout area. In the shakeout
area a vibrating screen separates the casting from the mold and core
sands. The sands are combined, processed and stored for reuse. The
castings are further cleaned in a shotmachine which uses small metal
pellets to remove the remaining sand. Imperfections are removed by
grinding before the casting goes to the enamelling department.
A vibrator is used to uniformly spread a fine glass powder over the
surface to be enamelled. Most of the powdered glass is purchased, but
some glass is ground into powder at the plant. On contact with the hot
casting, the glass powder melts. The coated casting is then fired in
one of two natural gas-fired furnaces to improve the porcelain finish.
A second coat of powdered glass is then applied and fired. The final
products have a 0.9 mm (35-40 mils) porcelain thickness.
AIR POLLUTION CONTROL EQUIPMENT
The cupol$ is the major emission source at Commercial Enamelling
and thus has the most sophisticated air pollution control system [Figure
1], Cupola gases contain coke breeze, iron dust, carbon monoxide, and
* The color of the sand gives it its name
** The core is the inside of the complete mold, causing the casting to be
bnl.l.m,)
-------
'Ifterburner
gase:
Charge
Door
p < ?-5 cm Ports at 90° on roof
13.7 m (45 ft.)
Quencher
Cupola
Blower
1-5 cm port
vvvvv
Baghouse
Figure 1: Comnerlcal Enameling Company, Huntington Park
Cupola Pollution Control Equipment.
I
U>
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A-4
gaseous "com&u'stTon'products. A natural gas-fired afterburner, that
operates between 650-760°C (1,200-1,400°F), combusts the majority of the
coke breeze and carbon monoxide. These 650°C (1,200°F) gases are drawn
through a large duct into a Whiting* quencher by a 60 HP fan and then
blown into a baghouse at 150°C (300°F). A temperature monitor in
baghouse-adjusts-the-quencher water sprays to maintain the inlet baghouse
gas temperature below 175°C (350°F). The Whiting* baghouse has five
compartments with a total of 100 fiberglass bags (29 cm-O.by 6.8 m-H.
each). Pressure gauges measure the pressure drop across the five baghouse
compartments.
SOURCE SAMPLING FEASIBILITY
Sampling Locations
With the sampling locations presently available, the cupola carbon
monoxide emissions can be sampled. About 30 m (100 ft) downstream of
the afterburner, just before the quencher, a single 5 cm (2 in) sampling
port is located in the 76 cm (30 in) duct. Here the cupola gas temperature
and velocity are about 590°C (1,100°F) and 12 m (40 ft)/sec, respectively.
Because of the flow disturbances (more then four) and length of duct,
the gases are well mixed. This sampling port and a 1.5 m^ sampling
platform are 3.0 (10 ft) and 1.5 m (5 ft) above the ground, respectively.
There is a straight section of duct between the cupola and the
quencher which is 76 cm (30 in) in diameter and 25 m (80 ft) long. Two
5 cm (2 in) ports are located about 13.7 m (45 ft or 18 diameters) down-
stream from, and 11 m (36 ft or 14.4 diameters) upstream of 90° bends.
This location meets all requirements of EPA Method 1 and 2 (traverse
points and velocity determination) and thus is an excellent location to
perform velocity and temperature determinations. Little change in gas
temperature, velocity or static pressure between these ports and the
single sampling port is expected, but will be checked. The straight
section of duct is on the foundry roof, that has about a 15° slope. In
late July and early August 1977, the plant will be renovated, including
work on the roof. Presently, the roof near the sampling ports are of
questionable structural integrity, but will be shored.
The single sampling port, just before the quencher, is convient to
test, however it was necessary to assure that these CO emissions results
would be representative of the control system CO emissions. A calculation
was made whether actual CO emissions exhausted from the control system
would be less than those measured before the quencher because the quench
water might absorb carbon monoxide. The maximum calculated reduction in
the carbon monoxide concentration, assuming a gas concentration of 2000
ppmv, would be 6 ppmv or 0.3% which should not affect the compliance
determination.
During the presurvey inspection the company expressed the desire
that the EPA sampling be performed simultaneously with sampling by their
* Brand, name
-------
contractor. There is room near the first sampling port for a second
port, but the two ports should be separated so that the two test teams
do not interfere with each other. The velocity and temperature determination
of the two teams can be performed at the same two sampling ports.
Modifications
No modifications are needed to source sample the cupola carbon
monoxide emissions.
Miscellaneous
All equipment must be carried to the sample location (30 m), because
the NEIC air sampling van cannon be parked at or driven near the sampling
location. The Company must provide electric power (110 volt, 30 amp)
for the sampling. A shelter is needed to protect the CO analyzer from
the dust.
PROCESS AND CONTROL EQUIPMENT OBSERVATIONS
The cupola furnace operating conditions can easily be monitored by
observing the number of charges made and the furnace operating temperature.
The control equipment operating conditions, however, are difficult to
monitor. Only the pressure drop across the baghouse can be monitored as
an indication of the operating conditions. The process and control
equipment operating conditions are only needed to ensure steady-state
operating conditions, there is no process weight rate limitation of
carbon monoxide.
SUMMARY AND CONCLUSIONS
Commercial Enamelling can be sampled without duct or port modifications.
The single sampling port is in satisfactory position to obtain a representative
gas sample. Where the gas velocity and temperature are determined, the
ports are ideally located.
If a contractor is going to perform simultaneous sampling, a second
sample port will be necessary, separated from the first by at least 0.5
m (1.5 ft). All that is required from the Company is electrical power
(110 volt, 30 amp).
-------
APPENDIX B
CO ABSORPTION CALCULATION
-------
APPENDIX B
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B-2
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-------
APPENDIX C
EQUIPMENT CALIBRATION AND QUALITY CONTROL
-------
Appendix C
Quality Control and Pre-Survey Calibrations
Calibration gases, with stated concentrations ±2%, were initially obtained
from two suppliers, Scientific Gas Products (SGP) and Scott Environmental
Associates with the intention of cross-checking the two suppliers rather
than relying solely on one. The stated concentrations supplied by SGP were
969, 601, and 324 ppmv; that supplied by Scott was 600 ppmv. When spanned
against the SGP 969 ppmv standard the other standards read as follows:
SGP 601 - 560 ppmv
SGP 324 - 280 ppmv
Scott 600 - 525 ppmv
Several techniques, including dilution of the calibration gases, were used
to elucidate the discrepancies. Prior to the survey it was concluded
from the testing that the SGP 969 Dpmv gas was significantly higher than
stated and since a more reasonable agreement existed between the remaining
calibration gases, the SGP 601 ppmv gas was chosen to be used on the sur-
vey as the span gas. When spanned against the SGP 601 ppmv qas, the other
gases read as follows:
SGP 324 - 303 (7% lower than expected)
Scott 600 - 560 (7% lower than exDected)
Within the time constraints of the pre-survey and survey, the SGP gases
could not be verified against NBS gases; however, all CO reference gases
were, prior to the survey, sent back to their respective manufacturers
for restandardization. The manufacturers sent back results which were
essentially the same as before.
Some two months after the actual survey, results were received pertaining
to calibrations of the SGP 601 ppmv and 969 ppmv gases. This work was
done by QAB/EMSL, MD-77, Research Triangle Park and referenced against
NBS Standards. Their results were as follows:
SGP 969 - 1,049 ppmv {8.3% higher than stated concentration)
SGP 601 - 624 ppmv (4% higher than stated concentration)
The most reasonable conclusion to draw from all calibration data collected
to this point is that the SGP 324 and Scott 600 ppmv gases were close to
being correct and that the SGP 601 v/as actually 4 to 7% higher than stated.
Since the data reported is based Drincipally on the SGP 601 ppmv standard,
the survey data reported mav be approximately 4% low. Even this conclu-
sion is not concrete though since some commercial reference gas suppliers
insist that inconsistencies and inaccuracies have been found with NBS
gases too.
-------
C-2
Other considerations investigated in connection with the sampling train
were the effect of the CaSCL in-line drying tube on CO concentrations
and C0? interference at the detector. The in-line dryer was evaluated
by spanning the instrument both with and without the filter in place
over a period of 15 minutes. No appreciable effect (less than 0.5%
change) was observed with the CaSO- tube so it was left in-line to
remove final traces of HLO (which does affect the readings). The effect
of C0? was evaluated by Bleeding percentages of C02 into the instrument
up to and including 100% CO^. The C0~ was found to have no appreciable
effect on the CO measurement (less than 1% of full scale change with
100% C0p). The ascarite trap utilized in Method 10* was therefore
dropped from the system. Checks were also made by bleeding span gas at
the inlet point of the first glass wool filter (Figure 2 of this report)
to insure that the system as a whole functioned properly.
* Code of Federal Regulations, Title 40, Part 60 Standards of Performance
for New Stationary Sources, Appendix A, Reference Methods, August 18,
1977. '
-------
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-------
APPENDIX D
ONE-MINUTE AVERAGE--CO CONCENTRATION DATA
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-------
APPENDIX E
PROCESS MONITORING DATA
-------
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